72965 12 1 B2

1 Part No. 72965 Rev B2 January 2007 Service Manual(from serial number GR-101 to GR05-4999)(from serial number GR-101 to GR05-4999)(from serial number GR-101 to GR05-4999)August 2005GR-8 GR-12 GR-15 Part No. 72965 ImportantRead, understand and obey the safety rules andoperating instructions in the appropriate Operator'sManual on your machine before attempting anymaintenance manual provides detailed scheduledmaintenance information for the machine ownerand user. It also provides troubleshooting andrepair procedures for qualified mechanical, hydraulic and electricalskills are required to perform most , several procedures require specializedskills, tools, lifting equipment and a suitableworkshop.

2 In these instances, we stronglyrecommend that maintenance and repair beperformed at an authorized Genie dealerservice PublicationsGenie Industries has endeavored to deliver thehighest degree of accuracy possible. However,continuous improvement of our products is a Geniepolicy. Therefore, product specificationsare subject to change without are encouraged to notify Genie of errorsand send in suggestions for improvement. Allcommunications will be carefully considered forfuture printings of this and all other 2001 by Genie Industries72965 Rev BAugust 2005 First Edition, Second Printing"Genie" is a registered trademark of GenieIndustries in the USA and many other countries.

3 "GR" is a trademark of Genie Industries. Printed on recycled paperPrinted in : 2005 Part No. 72965GR-8 GR-12 GR-15iiiSerial Number LegendGS30 05 A - 12345 ModelFacility code ()used only for models manufacturedin multiple facilitiesSequencenumberPN - 77055 Model:Model year:Manufacture date:Maximum allowable inclination of the chassis:Country of manufacture: USAThis machine complies with:Serial number:Rated work load (including occupants):Genie Industries18340 NE 76th StreetRedmond, WA 98052 USAE lectrical schematic number:Gradeability:Maximum allowable side force :Maximum number of platform occupants:Machine unladen weight.

4 ANSI ,714 lb / 1,231 kg500 lb / 227 kgN/AN/A100 lb / 445 kg22005 Model yearSerial Number LegendAugust 2005GR-8 GR-12 GR-15 Part No. 72965ivThis page intentionally left 2005 Part No. 72965GR-8 GR-12 GR-15 DangerFailure to obey the instructions and safety rulesin this manual and the appropriate Operator'sManual on your machine will result in death orserious of the hazards identified in theoperator s manual are also safety hazardswhen maintenance and repair proceduresare Not Perform MaintenanceUnless:You are trained and qualified to performmaintenance on this read, understand and obey.

5 - manufacturer s instructions and safety rules- employer s safety rules and worksiteregulations- applicable governmental regulationsYou have the appropriate tools, liftingequipment and a suitable 1 Safety RulesSafety RulesAugust 2005GR-8 GR-12 GR-15 Part No. 72965 SAFETY RULESP ersonal SafetyAny person working on or around a machine mustbe aware of all known safety hazards. Personalsafety and the continued safe operation of themachine should be your top each procedure thoroughly. Thismanual and the decals on the machine,use signal words to identify the following:Safety alert symbol used to alertpersonnel to potential personalinjury hazards.

6 Obey all safetymessages that follow this symbolto avoid possible injury or used to indicate thepresence of an imminentlyhazardous situation which, if notavoided, will result in death orserious used to indicate thepresence of a potentiallyhazardous situation which, if notavoided, could result in death orserious with safety alert symbol used to indicate the presence of apotentially hazardous situationwhich, if not avoided, may causeminor or moderate without safety alertsymbol used to indicate thepresence of a potentiallyhazardous situation which, if notavoided, may result in used to indicate operationor maintenance sure to wear protective eye wear andother protective clothing if the situationwarrants aware of potential crushing hazardssuch as moving parts, free swinging orunsecured components when lifting orplacing loads.

7 Always wear approved SafetyBe sure to keep sparks, flames andlighted tobacco away from flammable andcombustible materials like battery gasesand engine fuels. Always have an approved fireextinguisher within easy sure that all tools and working areasare properly maintained and ready foruse. Keep work surfaces clean and free ofdebris that could get into machine components andcause sure that your workshop or work areais properly ventilated and well sure any forklift, overhead crane orother lifting or supporting device is fullycapable of supporting and stabilizing theweight to be lifted.

8 Use only chains or straps thatare in good condition and of ample sure that fasteners intended for onetime use ( , cotter pins and self-lockingnuts) are not reused. These componentsmay fail if they are used a second sure to properly dispose of old oil orother fluids. Use an approved be environmentally safe .viSection 1 Safety RulesAugust 2005 Part No. 72965GR-8 GR-12 GR-15 Table of ContentsIntroductionImportant Information ..iiSerial Number 1 Safety RulesGeneral Safety Rules ..vSection 2 RevSpecificationsBMachine 2 - 1 BPerformance 2 - 2 BHydraulic 2 - 2 BManifold Component 2 - 3 BHydraulic Hose and Fitting Torque Specifications.

9 2 - 4 BSAE and Metric Fasteners Torque Charts .. 2 - 7 Section 3 RevScheduled Maintenance 3 - 1 Pre-delivery Preparation 3 - 3 Maintenance Inspection Report ..3 - 5 BChecklist A ProceduresA-1 Perform Pre-operation 3 - 6A-2 Perform Function 3 - 6A-3 Perform 30 Day 3 - 7A-4 Grease the Steer Yokes .. 3 - 7viiApril 2006GR-8 GR-12 GR-15 Part No. 72965 TABLE OF CONTENTSS ection 3 RevScheduled Maintenance Procedures, continuedBChecklist B ProceduresB-1 Inspect the 3 - 8B-2 Inspect the Electrical Wiring .. 3 - 9B-3 Inspect the Tires and Wheels (including castle nut torque).

10 3 - 10B-4 Check the Lifting Chain Adjustments ..3 - 10B-5 Clean and Lubricate the Columns .. 3 - 11B-6 Adjust the Sequencing Cables ..3 - 11B-7 Test the Emergency 3 - 12B-8 Test the Key 3 - 13B-9 Test the Automotive-style Horn (if equipped) .. 3 - 13B-10 Test the Drive Brakes ..3 - 14B-11 Test the Drive Speed - Stowed Position .. 3 - 14B-12 Test the Drive Speed - Raised 3 - 15B-13 Test the Flashing Beacon (if equipped) .. 3 - 15B-14 Test the Alarm Package (if equipped).. 3 - 16B-15 Perform Hydraulic Oil 3 - 17B-16 Inspect the Hydraulic Tank Cap Venting 3 - 17 CChecklist C ProceduresC-1 Replace the Hydraulic Tank Breather Cap - Models with Optional Hydraulic 3 - 18C-2 Grease the Platform Overload Mechanism (if equipped).