CWP Stockpicker: Service Manual

Technical
Publications
®CWPS UPER
ERIES
® StockPickerS UPER
ERIES
Service
Manual
First Edition, First Printing

Part No. 40460
Introduction Service Manual - First Edition
Important
Read, understand and obey the safety rules and
Genie North America
operating instructions in the Genie CWP Super Telephone (206) 881-1800
Series Operator’s Manual and the Toll Free 800 536-1800 in U.S.A.
Genie StockPicker Super Series Operator's Toll Free 800 426-8089 in Canada
Manual before attempting any maintenance or Sales Fax (206) 883-3475
repair procedure. Service Fax (206) 556-8649
This manual provides detailed scheduled
maintenance information for the machine owner Genie Europe
and user. It also provides troubleshooting and
Telephone (44) 01636-605030
repair procedures for qualified service
Fax (44) 01636-611090
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. Copyright © 1996 by Genie Industries
Genie Industries has endeavored to deliver the First Edition: First Printing, July 1996
highest degree of accuracy possible. However, Genie® is a registered trademark
continuous improvement of our products is a of Genie Industries. Registered 2009987
Genie policy. Therefore, product specifications
Printed on recycled paper
are subject to change without notice.
Printed in U.S.A.
Readers are encouraged to notify Genie Industries
This machine complies with
of any errors and send in suggestions for ANSI/SIA A92.3-1990.
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.
ii Genie CWP Super Series & 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

operator’s manuals are also safety hazards
when maintenance and repair procedures
are performed.
Do Not Perform Maintenance

Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
- manufacturer’s instructions and safety rules
- employer’s safety rules and worksite
regulations
- applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.
Part No. 40460 Genie CWP Super Series & Genie StockPicker Super Series iii
Introduction Service Manual - First Edition
SAFETY RULES
Personal Safety Workplace Safety

Any person working on or around a machine must Be sure to keep sparks, flames and
be aware of all known safety hazards. Personal lighted tobacco away from flammable and
safety and the continued safe operation of the combustible materials like battery gases.
machine should be your number one priority. Always have an approved fire extinguisher within
easy reach.
Read each procedure thoroughly. This

manual and the decals on the machine Be sure that all tools and working areas
use signal words to identify the following: are properly maintained and ready for
use. Keep work surfaces clean and free
Indicates the presence of
of debris that could get into machine components
a hazard that will cause
and cause damage.
death or serious injury.
a hazard that may cause Be sure that your workshop or work area
death or serious injury. is well ventilated and safely and
adequately illuminated.
a hazard that will or may
cause serious injury or
damage to the machine. Be sure any forklift, overhead crane or
other lifting or supporting device is fully
Indicates special capable of supporting and stabilizing the
operation or maintenance weight to be lifted. Use only chains or straps that
information. are in good condition and of ample load capacity.
Be sure to wear protective eye wear and Be sure that fasteners intended for
other protective clothing if the situation one-time use (i.e., cotter pins and
warrants it. self-locking nuts) are not reused. These
components may fail if they are used a second
time.
Be aware of potential crushing hazards
such as moving parts, free-swinging or
unsecured components when lifting or Be sure to properly dispose of old oil or
placing loads. Always wear approved steel-toed other fluids. Use an approved container.
shoes. Please be mindful of the environment.
iv Genie CWP Super Series & Genie StockPicker Super Series Part No. 40460
Service Manual - First Edition
Table of Contents
Introduction
Important Information ..................................................................................................... ii
Section One Safety Rules

General Safety Rules .................................................................................................... iii
Section Two Specifications

CWP Super Series Models ....................................................................................... 2 - 1
StockPicker Super Series Models ............................................................................ 2 - 2
Performance Specification ........................................................................................ 2 - 3
Bolt Torque Specification ......................................................................................... 2 - 4
Section Three Scheduled Maintenance Inspections

Introduction ............................................................................................................... 3 - 1
Table A ..................................................................................................................... 3 - 2
Table B ..................................................................................................................... 3 - 3
Table C ..................................................................................................................... 3 - 3
Maintenance Inspection Report ................................................................................ 3 - 4
Section Four Scheduled Maintenance Procedures

Introduction ............................................................................................................... 4 - 1
A-1 Inspect the Operator's and Responsibility Manuals ........................................ 4 - 2
A-2 Inspect the Decals and Placards .................................................................... 4 - 2
A-3 Inspect for Damage and Loose or Missing Parts ............................................ 4 - 3
A-4 Check for Hydraulic Leaks .............................................................................. 4 - 3
A-5 Test the Base Operation ................................................................................. 4 - 4
A-6 Check the Auxiliary Platform Lowering Operation ........................................... 4 - 4
A-7 Check the Manual Platform Lowering Operation ............................................ 4 - 4
A-8 Inspect the Battery and Battery Charger - DC Models ................................... 4 - 4
A-9 Inspect the Columns for Damage ................................................................... 4 - 5
A-10 Check the Sequencing Cables ........................................................................ 4 - 5
A-11 Check the Interlock System for Proper Operation .......................................... 4 - 5
Part No. 40460 Genie CWP Super Series & Genie StockPicker Super Series v
TABLE OF CONTENTS
Section Four Scheduled Maintenance Procedures, continued

A-12 Test the Power and Function Controls ........................................................... 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 ........................................................................... 4 - 8
B-2 Inspect All Welds ............................................................................................ 4 - 8
B-3 Check the Battery - DC Models ...................................................................... 4 - 9
B-4 Clean and Lubricate the Columns ................................................................... 4 - 9
B-5 Test the Lifting Capacity ............................................................................... 4 - 10
B-6 Test the Power To Platform Operation ......................................................... 4 - 10
B-7 Adjust the Sequencing Cables ...................................................................... 4 - 11
B-8 Check the Chain Adjustment - CWPS Models Equipped
with Platform Outreach Option ...................................................................... 4 - 12
C-1 Inspect and Lubricate the Wheels ................................................................ 4 - 13
C-2 Inspect the Mast Assembly for Wear ............................................................ 4 - 13
C-3 Lubricate the Lifting Chains .......................................................................... 4 - 15
C-4 Replace the Hydraulic Oil ............................................................................. 4 - 15
C-5 Replace the Auxiliary Platform Lowering Batteries ....................................... 4 - 16
Section Five Troubleshooting Flow Charts

Introduction ............................................................................................................... 5 - 1
1 Power Light Will Not Turn On - AC Models .................................................... 5 - 3
2 Power Light Will Not Turn On - DC Models .................................................... 5 - 5
3 Foot Pad Interlock Lights Will Not Turn On .................................................... 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 ................................................................ 5 - 13
7 Machine Will Not Lift, But Power Unit Will Operate - AC Models.................. 5 - 16
8 Machine Will Not Lift - DC Models ................................................................ 5 - 18
9 Machine Will Not Lift, But Power Unit Will Operate - DC Models ................. 5 - 21
10 Machine Will Not Lower - Up Function Operates .......................................... 5 - 23
11 Base Will Not Raise With Steer Handle ........................................................ 5 - 25
vi Genie CWP Super Series & Genie StockPicker Super Series Part No. 40460
TABLE OF CONTENTS
Section Five Troubleshooting Flow Charts, continued

12 Platform Will Not Hold In Up Position ........................................................... 5 - 26
13 Power Unit Will Not Lift Rated Load ............................................................. 5 - 27
14 Auxiliary Platform Lowering Will Not Operate ............................................... 5 - 28
15 Power Wheel Assist Will Not Operate -
Models with Power Wheel Assist Option ...................................................... 5 - 29
Section Six Schematics

Introduction ............................................................................................................... 6 - 1
Symbols Legend ....................................................................................................... 6 - 2
Electrical Schematic - CWP & StockPicker AC Models ........................................... 6 - 3
Electrical Schematic - CWP & StockPicker DC Models ........................................... 6 - 4
Electrical Schematic - CWP & StockPicker DC Models with Power Wheel Assist ... 6 - 5
Hydraulic Schematic - CWP & StockPicker Models ................................................. 6 - 6
Hydraulic Schematic - CWP & StockPicker Models with Power Wheel Assist ......... 6 - 7
Section Seven Repair Procedures

Introduction ............................................................................................................... 7 - 1
Base Assembly
1-1 Interlocks ........................................................................................................ 7 - 2
1-2 Base Components .......................................................................................... 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 How to Test the Transformer - AC Models ..................................................... 7 - 6
2-2 How to Test the AC Contactor - AC Models ................................................... 7 - 6
Hydraulic Power Units
3-1 Hydraulic Power Unit Components - AC Models ............................................ 7 - 8
3-2 Hydraulic Power Unit Components - DC Models .......................................... 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 ............................... 7 - 12
3-5 How to Remove the Hydraulic Pump ............................................................ 7 - 13
Part No. 40460 Genie CWP Super Series & Genie StockPicker Super Series vii
TABLE OF CONTENTS
Section Seven Repair Procedures, continued

3-6 How to Adjust the Pressure Relief Valve ...................................................... 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 ...................................... 7 - 15
Power Pack
4-1 How to Change a Power Pack ...................................................................... 7 - 16
Mast Assembly
Mast Illustrations ........................................................................................... 7 - 17
5-1 How to Remove the Lift Cylinder .................................................................. 7 - 18
5-2 How to Remove the Mast Assembly ............................................................. 7 - 19
5-3 How to Adjust the Lifting Chains ................................................................... 7 - 22
5-4 How to Adjust the Glide Pads ....................................................................... 7 - 22
5-5 How to Inspect the Lifting Chains ................................................................. 7 - 23
Platform
6-1 How to Remove the Platform ........................................................................ 7 - 25
6-2 How to Install a Fiberglass Platform ............................................................. 7 - 25
6-3 Platform Control Box ..................................................................................... 7 - 25
6-4 How to Adjust the Platform Outreach Chain
- CWPS Models ............................................................................................ 7 - 26
6-5 How to Replace the Outreach Chain - CWPS Models .................................. 7 - 26
viii Genie CWP Super Series & Genie StockPicker Super Series Part No. 40460
Service Manual - First Edition Section 2 - Specifications
Specifications
Specifications Platform dimensions

Height, working maximum Standard platform 27 x 26 x 443/4 in
CWP-8 13 ft 11 in 4.2 m (l x w x h) gated or sliding mid-rail 69 x 66 x 113.7 cm
CWP-12 17 ft 3 in 5.3 m
CWP-15 20 ft 8 in 6.3 m Gated ultra-narrow platform 22 x 18 x 443/4 in
(l x w x h) 56 x 46 x 117 cm
Height, platform maximum
CWP-8 7 ft 11 in 2.4 m Gated narrow platform 26 x 20 x 443/4 in
CWP-12 11 ft 3 in 3.4 m (l x w x h) 66 x 51 x 113.7 cm
CWP-15 14 ft 8 in 4.5 m
Standard fiber platform 29 x 261/2 x 431/2 in
Lift capacity (l x w x h) 74 x 67 x 110 cm
All models 350 lbs 159 kg
Narrow fiber platform 26 x 22 x 431/2 in
Lift capacity (l x w x h) 66 x 56 x 110 cm
with outreach option 300 lbs 136 kg
3-sided entry platform 30 x 28 x 431/2 in
Power source (l x w x h) 76 x 71 x 110 cm
DC models 12V
AC models 110V or 220V Extra large platform 30 x 28 x 431/2 in
(l x w x h) 76 x 71 x 110 cm
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
DC models 175A fuse, power unit
Part No. 40460 Genie CWP Super Series & Genie StockPicker Super Series 2-1
Section 2 - Specifications 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 135°F

SP-12 11 ft 3 in 3.4 m temperature -29°C to 57°C
SP-15 14 ft 8 in 4.5 m
Airborne noise emissions 80 dB
Machine lift capacity 500 lbs 227 kg Maximum sound level at normal operating workstations
Platform capacity 400 lbs 181 kg (A-weighted)
Material storage
compartment capacity 150 lbs 68 kg Current Protection Rating
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 lbs 386 / 427 kg
SP-15 930 / 1020 lbs 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 & Genie StockPicker Super Series Part No. 40460
Service Manual - First Edition Section 2 - Specifications
SPECIFICATIONS
Platform function speed, 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
Section 2 - Specifications Service Manual - First Edition
SPECIFICATIONS
Bolt Torque Specifications

Size Threads SAE Grade 5 Bolts 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 50 70
14 68 95
20 55 75 80 109
1/2 75 110
13 102 149
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
9 430 583 600 814
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.
Service Manual - First Edition Section 3 - Scheduled Maintenance Inspections
Scheduled Maintenance Inspections
About This Section Dealer

Tools are New parts service
required required suggested
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, the Maintenance Tables and
Observe and Obey: the Maintenance Inspection Report have been
divided into three subsections—A, B and C. Use
Maintenance inspections shall be completed by the following chart to determine which group(s) of
a person trained and qualified on the procedures are required to perform a scheduled
maintenance of this machine. inspection.
Scheduled maintenance inspections shall be
Inspection Table or Checklist
completed daily, quarterly and annually as
specified on the Maintenance Inspection Daily A
Report.
Quarterly (every 150 hours or three months) A+B
Failure to properly complete each
inspection when required may Annual A+B+C
result in death, serious injury or
substantial machine damage.
Maintenance Tables
Immediately tag and remove from service a
damaged or malfunctioning machine. The maintenance tables contained in this section
provide summary information on the specific
Repair any machine damage or malfunction physical requirements for each inspection.
before operating machine.
Complete step-by-step instructions for each
Keep records on all inspections for three years. scheduled maintenance procedure are provided in
section 4, Scheduled Maintenance Procedures.
Machines that have been out of service for a
period longer than 3 months must have a Maintenance Inspection Report
quarterly inspection.
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 & Genie Stock Picker Super Series 3-1
Section 3 - Scheduled Maintenance Inspections Service Manual - First Edition
Maintenance Tables
Table A Dealer
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
A-5 Test the Base Operation
A-6 Check the Auxiliary Platform Lowering Operation
A-7 Check the Manual 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 & Genie Stock Picker Super Series Part No. 40460
Service Manual - First Edition Section 3 - Scheduled Maintenance Inspections
MAINTENANCE TABLES
Table B Dealer
— Complete all procedures in Table A
B-1 Inspect the Electrical Wiring
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
— Complete all procedures in Table A and Table B
C-1 Inspect and Lubricate the Wheels
C-2 Inspect the Mast Assembly for Wear
C-3 Lubricate the Lifting Chains
C-4 Replace the Hydraulic Oil
C-5 Replace the Auxiliary Platform Lowering Batteries
Part No. 40460 Genie CWP Super Series & Genie Stock Picker Super Series 3-3
Section 3 - Scheduled Maintenance Inspections Service Manual - First Edition
Maintenance Inspection Report

Model Checklist A Y N R Checklist B Y Dealer
N R
Serial number Refer to Table A Refer required
to Table B required suggested
A-1 Operator's B-1 Electrical wiring

Date
and Responsibility
manuals B-2 Welds
Machine owner
A-2 Decals and placards B-3 Battery
Inspected by (print) B-4 Clean and lubricate
A-3 Damage, loose or
missing parts columns
Inspector signature
A-4 Hydraulic leaks B-5 Lifting capacity
Inspector title
A-5 Test base operation B-6 Power to platform
operation
Inspector company
A-6 Auxiliary lowering
operation B-7 Sequencing cables
Instructions B-8 Chain adjustment
A-7 Manual lowering
· Make copies of this page to use for operation - CWPS models
each inspection. with outreach
· Select the appropriate checklist(s) for A-8 Battery and charger
the type of inspection to be performed. - DC models
A-9 Columns Checklist C Y N R

Daily Inspection: A
A-10 Sequencing cables Refer to Table C
Quarterly Inspection: A+B
Annual Inspection: A+B+C A-11 Interlock system C-1 Casters and wheels
operation C-2 Mast assembly
· Place a check in the appropriate box
after each inspection procedure is A-12 Power and C-3 Lifting chains
completed. function controls
C-4 Hydraulic oil
· Use the maintenance tables in this A-13 Lifting chains
section and the step-by-step and idler wheels C-5 Auxiliary platform
procedures in section 4 to learn how to lowering batteries
perform these inspections. A-14 Breather cap
· 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
3-4 Genie CWP Super Series & Genie Stock Picker Super Series Part No. 40460
Service Manual - First Edition Section 4 - Scheduled Maintenance Procedures
Scheduled Maintenance Procedures
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.
Observe and Obey: Symbols Legend
Maintenance inspections shall be completed by Indicates the presence of a hazard
a person trained and qualified on the that will cause death or serious
maintenance of these machines. injury.
Scheduled maintenance inspections shall be Indicates the presence of a hazard
completed daily, frequently (every 3 months), that may cause death or serious
and annually as specified on the maintenance injury.
report.
Indicates the presence of a hazard
Failure to properly complete each that will or may cause serious
inspection when required may injury or damage to the machine.
result in death, serious injury or
substantial machine damage. Indicates special operation or
maintenance information.
damaged or malfunctioning machine. Indicates that a specific result is expected after
performing a series of steps.
Repair any machine damage or malfunction
before operating machine.
Keep records on all inspections for three years.
Section 4 - Scheduled Maintenance Procedures Service Manual - First Edition
Table A Procedures
A-1 A-2
Inspect the Operator’s and Inspect the Decals and Placards
Responsibility Manuals Maintaining all of the safety and instructional
Maintaining the operator’s and responsibility decals and placards in good condition is essential
manuals in good condition is essential to safe for safe machine operation. Decals alert operators
machine operation. Manuals are included with and personnel to the many possible hazards
each machine and should be stored in the associated with using a machine. They also
container provided at the platform. An illegible or provide users with operation and maintenance
missing manual will not provide safety and information. An illegible decal will fail to alert
operational information necessary for a safe personnel of a procedure or hazard and could
operating condition. result in unsafe operating conditions.
1 Check to be sure the storage container and lid 1 Refer to the Decals section in the Genie CWP
are present and in good condition. Super Series Operator's Manual or the Genie
StockPicker Super Series Operator’s Manual
2 Check to make sure that the operator’s and and use the decal list and illustrations to
responsibility manuals are present and determine that all decals and placards are in
complete in the storage container at the place.
platform.
2 Inspect all decals for legibility and damage.
3 Examine the pages of each manual to be sure Replace any damaged or illegible decal
that they are legible and in good condition. immediately.
4 Always return the manuals to the storage Contact your authorized Genie
container after use. distributor or Genie Industries if
replacement decals are needed.
Contact your authorized Genie
distributor or Genie Industries if
replacement manuals are needed.
TABLE A PROCEDURES
A-3 A-4
Inspect for Damage and Loose or Check for Hydraulic Leaks
Missing Parts Detecting hydraulic fluid leaks is essential to
Daily machine condition inspections are essential operational safety and good machine performance.
to safe machine operation and good machine Undiscovered leaks can develop into hazardous
performance. Failure to locate and repair damage, conditions, impair machine functions and damage
and discover loose or missing parts may result in machine components.
an unsafe operating condition. 1 Inspect for hydraulic oil puddles, dripping or
1 Inspect the entire machine for damage and residue on or around the following areas:
improperly installed or missing parts including: · hydraulic power unit—reservoir, valves,
· electrical cables and wiring fittings
· electrical cable anchors and pulleys · hydraulic cylinder
· hydraulic power unit, cylinder, hoses, fittings
· flow control valve
· sequencing cables and pulleys
· ground area under the machine
· lifting chains and idler wheels
· adjustable glide pads · all hydraulic hoses and fittings
· mast columns and counterweight(s) · hydraulic manifolds
· mast covers
If equipped: CWPS Models with Power Wheel
· nuts, bolts and other fasteners Assist Option
· platform entry mid-rail(s) and/ or gate · hydraulic motor and hoses
· 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-5 4 Reconnect the power and raise the platform

slightly.
Test the Base Operation
5 Disconnect the power from the machine.
Testing the base for proper operation is essential
for safe machine operation. An unsafe working 6 Push in the control activate button and rotate
condition exists if the base fails to operate the up/down switch in the down direction.
properly. The base should operate smoothly and Result: Platform should lower.
be free of hesitation, jerking and binding.
1 Lift the base with the steer handle.

Result: The foot pads should be 1/2 to 1 inch A-7
(1.5 to 2.54 cm) off the ground. Check the Manual Platform
2 Push the base steer handle to the stowed Lowering Operation
position.
Detection of a manual lowering malfunction is
Result: The base should lower, putting the two essential for safe machine operation. An unsafe
foot pads in firm contact with the ground. working condition exists if the manual lowering
3 Raise the platform slightly. function does not operate in the event of a main
and auxiliary power failure.
4 Attempt to raise the base with the steer handle.
1 Raise the platform slightly.
Result: The base should not raise.
2 Activate the manual lowering valve located at
the bottom of the hydraulic cylinder.
A-6 Result: Platform should lower.
Check the Auxiliary Platform

Lowering Operation
A-8
The auxiliary platform lowering is powered by a Inspect the Battery and Battery
secondary battery pack that is located in the
ground control box. The auxiliary platform lowering Charger - DC Models
can be activated from the ground or platform
Proper battery and charger condition is essential to
controls. Detection of an auxiliary lowering
good machine performance and operational safety.
malfunction is essential for safe machine
Improper fluid levels or damaged cables and
operation. An unsafe working condition exists if the
connections can result in component damage and
auxiliary platform lowering function does not
hazardous conditions.
operate in the event of a main power failure.
Batteries contain acid. Avoid
spilling or contacting battery acid.
2 Disconnect the power from the machine. Neutralize battery acid spills with
baking soda and water.
3 Activate the auxiliary platform lowering button at
the ground controls. 1 Put on protective clothing and eye wear.
Result: Platform should lower. 2 Be sure that the battery cable connections are
tight and free of corrosion.
TABLE A PROCEDURES
3 Check the battery acid level. If needed, A-10

replenish with distilled water to the bottom of
the battery fill tube. Do not overfill. Check the Sequencing Cables
4 Install the vent caps. Detection of damage to sequencing cables or
components is essential for safe machine
5 If equipped: Set the battery charger AC Selector operation. An unsafe working condition exists if the
switch to the proper voltage. sequencing components are damaged and do not
6 Set the power switch to the AUTO position. operate smoothly. A daily check of the sequencing
system allows the inspector to identify changes in
Result: The charger ammeter should be ON. the operating condition that might indicate damage.
1 Visually inspect the cables and components for

the following:
A-9
· frayed or broken wire strands
Inspect the Columns for Damage
· kinks in the cable
Detection of damage to columns is essential for
· corrosion
safe machine operation. An unsafe working
condition exists if the columns are damaged and · paint or foreign materials
do not operate smoothly, free of hesitation and
· broken or damaged pulleys
binding. A daily check of the columns allows the
inspector to identify changes in the operating · unusual or excessive pulley wear
condition of the column assembly that might
indicate damage. · split or cracked threaded swage ends
2 Check to be sure of the following:
1 Visually inspect each column for the following:
· dents, gouges, cracks or abrasions · cables are on the pulleys
· bends or warping · upper and lower cable ends are properly
· excessive wear secured
2 Raise and lower the platform through a · upper and lower mounting brackets are
complete cycle. properly secured
Result: Platform should raise and lower
smoothly, free of hesitation and binding.
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.
TABLE A PROCEDURES
Result: All four interlock display lights should be Result: Platform up and down functions should
off. operate smoothly.
4 Place a 1/2 inch (1.2 cm) block under one of the 4 Push in the Emergency Stop button at the
foot pads. platform controls to the OFF position and test up
and down functions.
5 Lower the base with the steer handle. Be sure
the steer handle is in the stowed position. Result: Up/down functions should not operate.
Result: The foot pad indicator lights and the 5 Twist to release the red Emergency Stop button
steer handle indicator light should be on. The at the platform controls.
level sensor light should be off because the
6 Push in the Emergency Stop button at the
machine is not level.
ground controls to the OFF position. Then test up
6 Twist to release the red Emergency Stop button and down functions.
at the platform controls.
Result: Up/down functions should not operate.
7 Push in the control activate button and rotate
the up/down switch to the up position, then the
down position.
A-13
Result: Platform up function should not operate.
Inspect the Lifting Chains and
8 Raise the base and remove the block. Lower
the base. Idler Wheels
Maintaining the lifting chains and idler wheels in
good condition is essential to safe machine
A-12 operation. Failure to find and replace damaged
Test the Power and chains or idler wheels could result in unsafe
operating conditions and may cause component
Function Controls damage.
Testing the machine functions and the Emergency 1 Raise the platform approximately 3 feet (1 m).
Stop buttons for malfunctions is essential for safe
machine operation. An unsafe working condition 2 Visually inspect the chains and idler wheels
exists if any function fails to operate properly or near the top of each column for the following:
either Emergency Stop button fails to stop all the · excessive wear, corrosion or damage
machine functions. Each function should operate
smoothly and be free of hesitation, jerking and · broken or missing chain leafs and pins
unusual noise. · tight or kinked joints in the chain
1 Turn the key switch to the ON position and pull · missing or damaged idler wheels and related
out the red Emergency Stop button to the ON components
position.
3 Inspect the chain terminations near the bottom
Result: The power light should be on. of each column to confirm that each termination
2 Twist to release the red Emergency Stop button has a lock nut.
at the platform controls.
3 Push in the control activate button and rotate to
the UP position, then the DOWN position.
TABLE A PROCEDURES
4 Inspect the chain terminations near the bottom A-14

of each column to confirm that the chain
tensioner bracket is centered in the inspection Inspect the Breather Cap
hole.
The hydraulic reservoir is a breathing-type
reservoir. The breather cap has an internal air filter
a 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
b
enter the hydraulic system and cause component
d damage.
c
1 Be sure the breather cap is installed on the
hydraulic power unit reservoir and is not
damaged. Do not remove it.
a chain tensioner bracket

b adjustment nut (hidden from view)
c termination rod (hidden from view)
d column
Table B Procedures
B-1 B-2
Inspect the Electrical Wiring Inspect All Welds
Maintaining electrical wiring in good condition is Weld inspections are essential to safe machine
essential to safe operation and good machine operation and good machine performance. Failure
performance. Failure to find and replace burnt, to locate and repair damage may result in an
chafed, corroded or pinched wires could result in unsafe operating condition.
unsafe operating conditions and may cause
component damage. 1 Visually inspect the welds in the following
locations:
Electrocution hazard. Contact with
· platform
hot or live circuits may cause
death or serious injury. Remove · base
all rings, watches and other
jewelry. · mast brace mounting brackets
1 Inspect the following areas for burnt, chafed, · foot pads

corroded and loose wires: · power wheel assist (if equipped)
· 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
TABLE B PROCEDURES
B-3 B-4
Check the Battery - DC Models Clean and Lubricate the Columns
Proper battery condition is essential to good Clean and properly lubricated columns are
machine performance and operational safety. essential to good machine performance and safe
Improper fluid levels or damaged cables and operation. Extremely dirty conditions may require
connections can result in component damage and that the columns be cleaned and lubricated more
hazardous conditions. often.
Batteries contain acid. Avoid 1 Raise the platform to the maximum height.
spilling or contacting battery acid.
2 Visually inspect the inner and outer channels of
Neutralize battery acid spills with
the columns for debris or foreign material. If
baking soda and water.
necessary, use a mild cleaning solvent to clean
1 Put on protective clothing and eye wear. the columns.
2 Remove the battery vent caps and check the This procedure will require the use
specific gravity with a hydrometer. of additional access equipment.
Do not place ladders or scaffold
3 Check the battery acid level. If needed,
on or against any part of the
replenish with distilled water to cover the
machine. Performing this
battery plates. Do not overfill.
procedure without the proper skills
4 Install the battery vent caps. and tools may result in death or
serious injury. Dealer service is
5 If equipped: Set the battery charger AC Selector strongly recommended.
switch to the proper voltage.
3 If needed, lubricate the inner and outer
6 Plug charger in and set timer to the AUTO channels of the columns with a dry silicone
position and observe charger ammeter after spray or silicone wax (Genie part no. 90337).
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-5 B-6
Test the Lifting Capacity Test the Power To Platform
Proper lifting capacity is essential to safe machine Operation
operation. Improper lifting capacity adjustment AC power to the platform is intended to be an
could allow machine to be overloaded and may extension cord to the platform for using hand tools.
cause death or serious injury.
1 Connect an appropriate extension cord to the
This procedure requires specific AC power supply cord at the base of the
repair skills, lifting equipment and machine.
a suitable workshop. Attempting
this procedure without these skills 2 In the platform, plug a power drill (or similar
and tools may result in death or tool) into the AC outlet.
serious injury and significant
Result: The tool should operate normally.
component damage. Dealer
service is strongly recommended. GFCI outlet may require that the
outlet be reset with the reset
1 Place the maximum load capacity in the
button.
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.
Result: The hydraulic power unit should raise
the platform.
3 Fully lower the platform.
4 Add an additional 30 pounds (14 kg) to the
platform. Secure the additional weight.
Result: The hydraulic power unit 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.
4 - 10 Genie CWP Super Series & Genie StockPicker Super Series Part No. 40460
TABLE B PROCEDURES
B-7 3 Hold the threaded swage end of the cable from

turning and adjust the tension nut to obtain
Adjust the Sequencing Cables correct tension (deflection). Turn the
adjustment nut clockwise to increase the
Maintaining proper adjustment of the sequencing
tension or counterclockwise to decrease the
cables is essential for safe machine operation. An
tension.
unsafe working condition exists if the sequencing
cables are improperly adjusted. A frequent check Component damage hazard. Do
of the sequencing cables allows the inspector to not exceed the recommended
identify changes in the operating condition that tension.
might indicate 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
6 Raise and lower the platform through three
and pulling the cable from one side then to the
complete cycles and re-check deflection.
other. Measure the total distance between the
two points (this is the maximum 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 & Genie StockPicker Super Series 4 - 11
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.

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 does not meet this

specification, see Repair
Platform Outreach Chain.
Table C Procedures
C-1 C-2
Inspect the Wheels Inspect the Mast Assembly
Extremely dirty conditions may require that the for Wear
casters and wheels be inspected more often. Detection of excessive or unusual wear in the mast
1 Visually inspect each wheel for cuts, cracks or assembly is essential for safe machine operation.
unusual wear. An unsafe working condition exists if the mast
assembly has excessive wear and/or does not
2 Move the machine on a flat smooth surface and operate smoothly, free of hesitation
check that the wheels roll smoothly. 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
Shim Pads.
4 Loosen but do not remove the adjustment nut
on the sequencing cable located at the top of
the first column.
TABLE C PROCEDURES
5 Raise the platform approximately 3 feet (1 m)

above the top of the base.
a
6 Place a jack stand on the top of the base,
centered under the platform. Adjust the jack b
stand to 24 inches (61 cm).
c
a idler wheel
b
b spacer
c lifting chain
If idler wheel inspection results in

c a measurement that is not within
specification, refer to Repair
procedure 5-2, How to Assemble
the Mast.
a platform
b jack stand
9 Raise the platform and remove the jack stand
c base and the support blocks. Then lower the
platform.
7 Lower the platform onto the jack stand just
enough to take the weight off the lifting chains. 10 Install the mast covers and adjust the
sequencing cable. See B-7, Adjust the
Crushing hazard. Keep away from Sequencing Cables.
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
TABLE C PROCEDURES
C-3 C-4
Lubricate the Lifting Chains Replace the Hydraulic Oil
Lubricated chains are essential to good machine Replacement of the hydraulic oil is essential for
performance and safe operation. Extremely dirty good machine performance and service life. Dirty
conditions may require that the chains be cleaned oil and a dirty suction strainer may cause the
and lubricated more often. machine to perform poorly and continued use may
cause component damage. Extremely dirty
1 Raise the platform to the maximum height. conditions may require oil changes to be
2 Lubricate each chain with a dry type spray performed more often.
lubricant.
This procedure will require the use
2 Remove the plastic cover from the power pack.
of additional access equipment.
Do not place ladders or scaffold 3 Remove the drain plug from the hydraulic
on or against any part of the reservoir and completely drain the reservoir into
machine. Performing this a container. Properly discard of oil.
procedure without the proper skills
4 Models with Power Wheel Assist Option:
and tools may result in death or
Remove the hose on the bottom of the reservoir
serious injury. Dealer service is
and drain oil into a suitable container.
strongly recommended.
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.
5 Remove the reservoir from the hydraulic 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.
TABLE C PROCEDURES
10 Replace the breather cap with a new one. C-5

11 Raise and lower the platform through three Replacing the Auxiliary Platform
complete cycles. Add hydraulic oil if needed to
allow platform to reach full height.
Lowering Batteries
Component Damage Hazard. Do 1 Turn the machine off and remove the key.
not allow the hydraulic reservoir to 2 Loosen the two ground control box cover
completely empty when raising the fasteners.
platform. Pressurized air in the
hydraulic system can damage 3 Open the base control box and locate the
hydraulic components. battery pack.
4 Remove the fasteners that hold the battery pack
Hydraulic System
in place.
Hydraulic fluid Dexron equivalent
5 Carefully slide the battery pack out of the
Hydraulic reservoir capacity holder.
AC models 3 quarts 2.8 liters
The wires connected to the battery
DC models 3 quarts 2.8 liters
pack are very small. Be careful not
Hydraulic System Capacity (includes reservoir) to damage the wires.
AC models 6 Remove the old batteries from the pack.
CWP-8S 3.1 quarts 2.9 liters 7 Insert new batteries into the pack.
CWP-12S 3.1 quarts 2.9 liters
Make sure the batteries are
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-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
Service Manual - First Edition Section 5 - Troubleshooting Flow Charts
Troubleshooting Flow Charts
Before Troubleshooting:
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: Be sure that all necessary tools and test
equipment are available and ready for use.
Troubleshooting and repair procedures shall be
completed by a person trained and qualified on Read each appropiate flow chart thoroughly.
the repair of this machine. Attempting shortcuts may produce hazardous
conditions.
damaged or malfunctioning machine. Be aware of the following hazards and follow
generally accepted safe workshop practices.
Repair any machine damage or malfunction
before operating the machine. Electrocution hazard. Contact with
electrically charged circuits may
result in death or serious injury.
Remove all rings, watches and
other jewelry.
or spray.
Perform all troubleshooting on a
firm level surface.
Two persons will be required to
safely perform some
troubleshooting procedures.
Section 5 - Troubleshooting Flow Charts Service Manual - First Edition
TROUBLESHOOTING FLOW CHARTS
About This Section General Repair Process
When a malfunction is discovered, the flow charts

in this section will help a service professional Malfunction Identify Troubleshoot
pinpoint the cause of the problem. To use this discovered symptoms
section, basic hand tools and certain pieces of test
equipment are required—voltmeter, ohmmeter,
pressure gauges. problem
still exists
The location of terminals mentioned in this section
can be found on the appropriate electrical or Return to Inspect Perform
hydraulic schematics provided in Section 6, service problem and test repair
Schematics. solved
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.
Chart 1
Power Light Will Check the power supply 0V AC Plug into a different
Not Turn On - with a voltage meter. power supply and
recheck the voltage.
AC Models 110V AC
Be sure the keyswitch is
Check the voltage at 0V AC Repair or replace the pig
in the appropriate terminal 3 on the key tail and/or the 12/3 cable.
position. switch. Put Pos. lead of
voltage meter on terminal
Be sure the Emergency 3 and Neg. lead on the
white wire from the pig
Stop buttons are pulled tail.
up to the ON position.
110V AC
Be sure the ground
control box PC board 0V AC
Check the voltage at Replace the key switch.
fuse is not blown. terminal 4 on the key
switch.
110V AC
Check the voltage at Trace the black wire from

terminal 1 on the 0V AC terminal 1 back to the
Emergency Stop button. key switch and repair
open in wire.
110V AC
Check the voltage at 0V AC Replace the Emergency

terminal 2 on the Stop button.
Emergency Stop button.
110V AC
Check the voltage at the Repair open in the yellow

black transformer wire 0V AC transformer wire between
where it connects to the the Emergency Stop
brown transformer wire. button and the
transformer OR replace
the transformer because
110V AC of a faulty thermal fuse.
Continued on the next

page.
CHART 1
Continued from the Check the voltage at 0V AC Repair the transformer

previous page. terminals 1 and 3 of 13 wires OR replace the
pole terminal strip (J1). transformer.
Put Pos. lead of voltage
meter on terminal 1 and
Neg. lead on terminal 3.
14 to 16V AC
Check the voltage on 12V DC

both sides of the 5amp on one
P.C. board fuse. Put side
Neg. lead of voltage Replace the 5amp fuse.
meter on terminal 10
(ground terminal) of 13
pole terminal strip (J1).
12V DC
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.
Chart 2
Power Light Will Check the battery pack 0V DC Charge the battery OR
voltage. check the battery
Not Turn On - condition and replace a
DC Models 12V DC bad battery.
Be sure the keyswitch is Check the voltage at Trace the black input wire
in the appropriate terminal 3 on the key 0V DC back to the motor start
position. switch. Put Pos. lead of solenoid and repair open
voltage meter on terminal in the wire.
3 and Neg. lead on
Be sure the Emergency terminal 10 of 13 pole
Stop buttons are pulled terminal strip (J1).
up to the ON position.
12V DC
Be sure the battery
cables are connected. Check the voltage at Trace the black wire from
0V DC terminal 3 back to the
terminal 3 on the key
Be sure the ground switch. fuse and check for
damage.
control box PC board
fuse is not blown. 12V DC
0V DC
Check the voltage at Replace the key switch
terminal 4 on the key contact block.
switch.
12V DC
Check the voltage at 0V DC Trace the black wire from

terminal 1 on the terminal 1 back to the
Emergency Stop button. key switch and repair
open in wire.
12V DC
Check the voltage at 0V DC Replace the Emergency

terminal 2 on the Stop button.
Emergency Stop button.
12V DC
Check the voltage at Trace the black wire from

terminal 3 (black wire) of 0V DC terminal 3 of the 3 pole
3 pole terminal strip (J2). terminal strip (J2) back to
the Emergency Stop
button and repair the
12V DC wire.

page.
CHART 2
Continued from the Check the voltage on 12V DC

previous page. both sides of the 5amp on one
P.C. board fuse. Put side
Neg. lead of voltage Replace the 5amp fuse.
meter on terminal 10
(ground terminal) of 13
pole terminal strip (J1).
12V DC
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.
Chart 3
Foot Pad Check the power light. light off Refer to either Chart 1 or
Interlock Chart 2.
light on
Lights Will
Not Turn On Check for power at
terminal 8 (black wire) on
Be sure the the 13 pole terminal strip
(J1). Put Pos. lead of 0V DC
keyswitch is in the voltage meter on terminal Replace the P.C. board.
appropriate 8 and Neg. lead on
position. terminal 10 (ground
terminal).
Be sure the
Emergency Stop 12V DC
buttons are pulled
Disconnect the power
up to the on supply. Unplug the 18/7
position. cable quick disconnect
(from base) under the bad Repair or replace
Be sure the power base control box and connectors.
inspect the male and
light is on. female connectors for
damage.
Be sure the steer
handle is locked in good
the up position.
Check for power at the
Be sure the unit is black wires located at the 0V DC Replace 18/7cable
set up according to base mounted 10 pole because of open in black
terminal strip. wire.
the operator's
manual.
12V DC
Remove the foot pad Repair open circuit in the

switch access covers on black wire (or replace 16/
the end of the base 0V DC 2 cable) from the base
weldment and check for mounted 10 pole terminal
power at the common strip to common terminal
terminal of each foot pad at S1 or S4.
switch.
12V DC

page.
CHART 3
no
While the footpad switch Remove the foot pad continuity Replace the footpad
Continued from the is being activated, check 0V DC switch and perform a switch.
previous page. for power at the N.O. continuity test.
terminal.
12 V DC
Check for power at the 0V DC Repair open in white wire

base mounted 10 pole or replace 18/7 cable.
terminal strip, white wire
from S1 or white wire
from S4.
12V DC
At the 13 pole terminal

strip (J1) check for power
at terminal 7 (red wire 0V DC
Repair open in wire.
from switch 4) and and
at terminal 4 (white wire
from switch 1).
12V DC
Replace P.C. board OR

consult Genie Industries
Service Department.
Chart 4
Steer Handle Check the power light. light off Refer to either Chart 1 or
Chart 2.
Interlock light on
Light Will
Check for 12 volts DC at
Not Turn On terminal 8 (black wire) on
the 13 pole terminal strip
Be sure the (J1). Put Pos. lead of 0V DC Replace the P.C. board.
keyswitch is in the voltage meter on terminal
8 and Neg. lead on
appropriate terminal 10 (ground
position. terminal).
Be sure the 12V DC

Emergency Stop
buttons are pulled Disconnect the power
cable quick disconnect
position. (from base) under the bad Repair or replace
base control box and connectors.
Be sure the power inspect the male and
damage.
Be sure the unit is
set up according to good
the operator's
manual. Check for power at the Replace 18/7 cable
black wires located at the 0V DC because of an open
base mounted 10 pole circuit in the black wire.
terminal strip.
12V DC
Remove the steering Repair open circuit in the

handle switch access black wire from the
cover on the top of the 0V DC 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.
12V DC

page.
CHART 4
While the steering handle Remove the steering no Replace steering handle
Continued from the
previous page. switch is being activated, 0V DC handle switch and continuity switch.
check for power at the perform a continuity test.
normally open terminal.
12 V DC
At the 13 pole terminal

strip (J1) located in the Replace 18/7 cable
base control box, check 0V DC because of an open
for power at terminal 6 circuit in blue wire.
(blue wire from switch 3).
12V DC

Service Department.
Chart 5
Level Sensor Check the power light. light off Refer to either Chart 1 or
Chart 2.
Interlock light on
Light Will
Check for 12 volts DC at
Not Turn On terminal 8 (black wire) on
the 13 pole terminal strip
Be sure the (J1). Put Pos. lead of 0V DC
voltage meter on terminal Replace the P.C. board.
keyswitch is in the
8 and Neg. lead on
appropriate terminal 10 (ground
position. terminal).
Be sure the 12V DC

Emergency Stop
buttons are pulled Disconnect the power
cable quick disconnect
position. (from base) under the bad Repair or replace
base control box and connectors.
Be sure the power inspect the male and
damage.
Be sure the unit is
set up according to good
the operator's
manual. Check for power at the Replace 18/7 cable
black wires located at the 0V DC because of open in black
base mounted 10 pole wire.
terminal strip.
12V DC
Pull apart the quick Relocate Neg. lead of

disconnect at the top of voltage meter at terminal
the level sensor and 10 which is a grounding
check for power at the 0V DC terminal (green/yellow
black wire (wire harness wire) of 13 pole terminal
side). Put Neg. lead of strip (J1) in the base
voltage meter on green control box.
wire (wire harness side).
12V DC
Repair open circuit in the

12V DC green grounding wire
(from 10 pole terminal
strip to level sensor) OR
replace 18/7 cable
because of open circuit in
Continued on the next the green wire.
page.
CHART 5
Reconnect the quick 0V DC Replace the defective

Continued from the
previous page. disconnect at the top of level sensor.
the level sensor and
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.
12V DC
Replace 18/7 cable
because of open circuit in
Check for power at orange wire OR repair
terminal 5 of the13 pole defective pins in the
terminal strip (J1). Put 0V DC
quick disconnect under
Neg. lead of voltage base control box OR
meter at terminal 10 tighten the orange wire at
(ground terminal). the 10 pole terminal strip
(base mounted).
12V DC

Service Department.
Chart 6
Machine Will Check for power at

terminal 9 (red wire) of 13
Not Lift - AC pole terminal strip(J1).
Put Neg. lead of voltage 0V DC Replace the P.C. board.
Models meter on terminal 10
(grounding terminal).
Be sure the
keyswitch is in the
appropriate 12V DC
position.
Check for power at
Be sure the terminal 1 of Emergency
Stop switch contact in Replace 16/6 cable
Emergency Stop
platform control box. Put because of open in red
buttons are pulled Neg. lead of voltage 0V DC wire OR repair open in
meter on terminal 10 quick disconnect under
up to the on base control box.
position. (green/yellow wire) of 13
pole terminal strip (J1) in
base control box.
Be sure the power
light and all 12V DC
interlock display
lights are on. Emergency Stop switch
should be pulled up for
Be sure the ground the contact to close. Replace Emergency Stop
Check for power at 0V DC switch N.C. contact
control box circuit
terminal 2 of Emergency block.
breaker has been Stop switch contact.
reset.
12V DC
Replace red wire
(because of open circuit)
Check for power at between Emergency
terminal 4 of control 0V DC
Stop switch contact
activate switch. block and control activate
switch contact block.
12V DC
While pushing in and

holding control activate 0V DC Replace control activate
switch, check for power switch N.O. contact
at terminal 3 of control block.
activate switch contact.
12V DC

page.
CHART 6
Continued from the While pushing in and Replace the red wire
previous page. holding the control 0V DC (because of open circuit)
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.
12V DC
While pushing in the

control activate switch
and activating the up
function, hold both 0V DC Replace up switch N.O.
switches and check for contact block.
power at terminal 3 of up
switch contact.
12V DC

and activating the up Replace 16/6 cable
function, hold both because of open in
switches and check for orange wire OR repair
power at terminal 13 0V DC
open in quick disconnect
(orange wire) of the 13 under base control box.
base control box.
12V DC

function, hold both 0V DC Replace P.C. board OR
switches and check for consult Genie Industries
power at terminal 11 (red Service Department.
wire) of the 13 pole
terminal strip (J1) in the
base control box.
12V DC

function, hold both Relocate Neg. lead of the
switches and check for 0V DC voltage meter at terminal 0V DC
power at the motor 10 (green/yellow wire) of Repair open circuit in red
contactor coil (terminal 1 the13 pole terminal strip wire.
red wire). Put Neg. lead (J1).
of the voltage meter on
terminal 0 green/yellow 12V DC
wire.
Repair open circuit in
12V DC green/yellow wire.

page.
CHART 6
Continued from the Perform a continuity test no

previous page. across the motor continuity Replace the motor
contactor coil (terminals 1 contactor.
and 0).
continuity
Check for 110 volts AC

at the common terminals 0V AC Replace faulty circuit
(white and black wires) of breaker.
the motor contactor.
110V AC

function, hold both 0V AC 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 7
Machine Will While pushing in the While pushing in the

Not Lift, But control activate switch control activate switch
and activating the up and activating the up
Power Unit function, hold both function, hold both
switches and check for 0V DC switches and check for 0V DC
Replace P.C. board.
Will Operate input voltage at the N.O. power at terminal 12
valve coil on the power (black wire) of the 13 pole
- AC Models unit. Wait 1 second terminal strip (J1). This is
before checking voltage. a 1 second ON time
Be sure the power Put Pos. lead of the delayed terminal.
voltage meter on the
unit reservoir is full black wire and Neg. lead
and the breather on the green/yellow 12V DC
cap has been grounding wire.
Replace or repair black
installed. wire because of an open
12V DC circuit.
Check the resistance of infinite

the N.O. valve coil. ohms Replace N.O. valve coil.
7 ohms
Tee in pressure gauge at Inspect the mast for a

pressure port (stamped mechanical bind such as
P) 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 and check for voltage at valve and inspect valve
fitting, leaving 3000 psi 1800 to the N.C. valve coil (down for contamination or
gauge teed in at the P 2000 psi valve coil white/black 0V DC 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
control box.
page.
CHART 7
Continued from the On the power unit,

previous page. remove and inspect the
N.O. valve for
contamination or damage.
Clean, repair or replace
valve and then perform
pressure test again.
less than 1800 psi
Adjust the pressure relief

valve. See Repair
procedure, How to Adjust
the Pressure Relief
Valve, and then perform
less than 1800 psi
Consult Genie Industries

Service Department.
Chart 8
Machine Will Check for power at

terminal 9 (red wire) of 13
Not Lift - DC pole terminal strip (J1). 0V DC
Put Neg. lead of voltage Replace the P.C. board.
Models meter on terminal 10
(ground terminal).
Be sure the
keyswitch is in the
appropriate position. 12V DC
Be sure the Check for power at

Emergency Stop terminal 1 of Emergency
buttons are pulled Stop switch contact in Replace 16/6 cable
platform control box. Put 0V DC because of open in red
up to the on Neg. lead of voltage wire OR repair open in
position. meter on terminal 10 quick disconnect under
(green/yellow wire) of 13 base control box.
Be sure the power pole terminal strip (J1) in
base control box.
light and all interlock
display lights are
12V DC
on.
Emergency Stop switch
should be pulled up for
the contact to close. 0V DC Replace Emergency Stop
Check for power at switch N.C. contact
terminal 2 of Emergency block.
Stop switch contact.
12V DC
Check for power at 0V DC Replace the red wire

terminal 4 of control (because of open circuit)
activate switch. between the Emergency
Stop switch contact
block and the control
12V DC activate switch contact
block.
While pushing in and
holding the control 0V DC
activate switch, check for Replace the control
power at terminal 3 of the activate switch N.O.
control activate switch contact block.
contact.
12V DC

page.
CHART 8
Continued from the While pushing in and Replace the red wire
previous page. holding the control (because of open cir cuit)
activate switch, check for 0V DC between the control
power at terminal 4 of the activate switch contact
up switch contact. block and the up switch
contact block.
12V DC

function, hold both 0V DC Replace the up switch
switches and check for N.O. contact block.
power at terminal 3 of the
up switch contact.
12V DC
While pushing in the Replace the 16/6 cable

control activate switch because of open in the
and activating the up orange wire OR repair
function, hold both 0V DC open in the quick
switches and check for disconnect under base
power at terminal 13 control box.
(orange wire) of the 13
the base control box.
12V DC
While pushing in the 0V DC 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
wire) of the 13 pole
terminal strip (J1) in the
base control box.
12V DC

page.
CHART 8
Continued from the While pushing in the Relocate the Neg. lead of 0V DC Repair open circuit in the
previous page. control activate switch the voltage meter at red wire.
and activating the up 0V DC terminal 10 (green/yellow
function, hold both wire) of the 13 pole
switches and check for terminal strip (J1) in the
power at the motor base control box.
contactor coil (positive
terminal red wire). Put
Neg. lead of the voltage 12V DC
meter on the negative
terminal (green/yellow Repair open circuit in the
wire). green/yellow wire.
12V DC
no
Perform a continuity test continuity
across the motor Replace the motor
contactor coil. contactor.
continuity

control activate switch Replace the motor
and activating the up 0V DC
contactor because of
function, hold both damaged contacts.
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 continuity
across the 12 volt motor. Replace the motor
brushes OR the 12 volt
DC motor.
continuity
Check the condition of

the battery OR consult
Genie Industries Service
Department.
Chart 9
Machine Will While pushing in the

Not Lift, But and activating the up
function, hold both Replace or repair the red
Power Unit switches and check for wire between the motor
Will Operate - input voltage at the N.O. 0V DC contactor coil and the
valve coil on the power N.O. valve coil because
DC Models unit. Put Pos. lead of the of an open circuit.
voltage meter on the red
wire and Neg. lead on the
Be sure the power green/yellow grounding
unit reservoir is full wire.
and the breather cap
has been installed. 12V DC
infinite
Check the resistance of ohms Replace the N.O. valve
the N.O. valve coil. coil.
7 ohms
Tee in a 3000 psi Inspect the mast for a

pressure gauge at the mechanical bind such as
pressure port fitting 1800 to the hold down bar not
(stamped P) of the power 2000 psi releasing properly or
unit. Push in the control foreign objects that could
activate switch, activate have fallen in between
the up function, hold both the columns.
switches and check the
pressure.
less tnan 1800 psi
On the power unit,

hose off of the T port
fitting and plug the hose Activate the up function Remove the N.C. down
fitting, leaving the 3000 1800 to and check for voltage at valve and inspect valve
psi gauge teed in at the P 2000 psi the N.C. valve coil (down 0V DC for contamination or
port fitting. Push in the valve coil white/black damage OR consult
control activate switch, wire) at the barrel end of Genie Industries Service
activate the up function, the lift cylinder. Department.
hold both switches and
check the pressure. 12V DC
Replace defective N.O.

less than 1800 psi contact block for down
function in the platform
control box.
page.
CHART 9
Continued from the On the power unit,

previous page. remove and inspect the
N.O. valve for
contamination or damage.
Clean, repair or replace
valve and then perform
less than 1800 psi
Adjust the pressure relief

valve. See Repair
procedure, How to Adjust
the Pressure Relief Valve
and then perform
less than 1800 psi

Service Department.
Chart 10
Machine Will While pushing in the Check the resistance of infinite Replace the N.C. valve
control activate switch 12V DC the N.C. down valve coil. ohms coil because of an open
Not Lower - and activating the down circuit.
function, hold both
Up Function switches and check for
voltage at the down valve 7 ohms
Operates solenoid at the barrel end
of the lift cylinder. Put Pull the manual lowering platform The N.C. down valve is
Pos. lead of the voltage knob (red knob) at the lowers damaged or possibly
meter on the white/black barrel end of the lift contaminated. Consult
wire and Neg. lead on the cylinder. Genie Industries Service
green/yellow grounding Department.
wire.
platform will not lower
The flow control valve at

the barrel end of the lift
cylinder is possibly
0V DC contaminated. Consult
Genie Industries Service
Department.
Repeat the test but Check for a loose

relocate the Neg. lead of connection at the
the voltage meter at the grounding stud in the
ground terminal 10 12V DC base control box OR
(green/yellow wire) of the check for a bad pin
13 pole terminal strip (J1) connection at the quick
in the base control box. disconnect under the
base control box OR
replace 16/6 cable
because of an open
circuit in the green/yellow
grounding wire.
0V DC
Check the voltage at

terminal 3 on the down Replace the red jumper
N.O. contact block 0V DC wire because of an open
located in the platform circuit.
control box.
12V DC

page.
CHART 10
Continued from the Activate the down

function and check the 0V DC Replace the N.O. down
previous page. contact block because of
voltage at terminal 4 (blue
wire) of the N.O. down an open circuit.
contact block.
12V DC
Check the voltage at Inspect pin 2 for a defect

terminal 2 on the N.O. in the quick disconnect
auxilary down contact 0V DC under the base control
block in the base control box OR replace the 16/6
box. cable because of an open
circuit in the blue wire.
12V DC
Inspect pin 5 for a defect

in the quick disconnect
under the base control
box OR replace the 16/6
cable because of an open
circuit.
Chart 11
Base Will Not Check the base lift Adjust the base lift
lockout release cable for incorrect lockout release cable.
Raise With proper adjustment. See Repair procedure,
Steer Handle How to Adjust the Base
lift lockout Release
correct Cable.
Be sure the platform
is fully lowered.
Remove the steering Adjust the base lift
Be sure to pump the handle switch (S3) lockout release cable.
mounting plate and check incorrect See Repair procedure,
foot pedal with slow, for proper cable How to Adjust the Base
even strokes. adjustment on the base lift lockout Release
lift lockout plate. Cable.
Chart 12
Platform Will Activate the platform up

function while platform
Not Hold In simultaneously activating holds up Inspect the hydraulic
Up Position the manual lowering system for
valve. Test the unit. contamination.
platform wont hold up
On the power unit,

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, yes Replace or repair check

is the motor spinning valve.
backwards?
no
Remove and rebuild the

hydraulic lift cylinder OR
contact Genie Industries
Service Department.
Chart 13
Power Unit Check the power source. Charge the battery OR

Note on DC models the low 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.
good
Check the pressure relief Adjust the pressure relief

valve setting. See incorrect valve. See Repair
Maintenance procedure, procedure, How to Adjust
Test the Lifting Capacity. the Pressure Relief
Valve.
correct

Service Department.
Chart 14
Auxiliary Check the low auxiliary

battery indicator (red on Replace the 8 -1.5V, AA
Platform LED) light. If on, it is size batteries.
showing a low voltage
Lowering condition.
Will Not
off
Operate
Check the auxiliary
lowering battery holder to no Install the 8 - 1.5V, AA
make sure that the size batteries.
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 0V 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 0V 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 bad
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 power 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).
Chart 15
Power Wheel
Remove the S3 steering
Assist Will handle switch access
cover on the top of the 0V DC Replace steering handle
Not Operate - base weldment and switch because of an
check for power at the open circuit.
Models with N.C. terminal of the
steering handle switch
Power Wheel (black wire).
Assist
12V DC
Be sure the base
foot pads are not Check for power at the 0V DC
function solenoid on the Repair open in the black
contacting the
power assist manifold. wire.
ground.
12V DC

common terminal (black 0V DC Repair open in the black
wire) of the backup wire.
switch on the handle.
12V DC
Check for power at the 0V DC Replace backup switch

N.C. terminal of the (SPDT) because of an
backup switch. open circuit.
12V DC

page.
CHART 15
Continued from the Check for power at the Repair wire between the
previous page. common terminals of the 0V DC backup switch and the
rocker switch (DPDT). rocker switch.
12V DC
Activate the rocker

switch for forward travel Replace the rocker
0V DC switch (DPDT) because
and check for power at
the white wire on the of an open circuit.
rocker switch (goes to
motor contactor).
12V DC
Check for power at the 0V DC Repair white wire or

motor contactor. replace 16/4 cable
because of an open
circuit.
12V DC

wire to the forward 0V DC Replace rocker switch
solenoid, at the rocker (DPDT) because of an
switch. open circuit.
12V DC
Check for power at the 0V DC Repair or wire or replace

forward solenoid at the 16/4 cable because of an
power assist manifold. open circuit.
12V DC
Remove foward,
reverse and function bad Repair or replace
valves from power assist damaged valve.
manifold and inspect for
damage.
good

Service Department.
Service Manual - First Edition Section 6 - Schematics
Schematics
About This Section

There are two groups of schematics in this section.
Electrical Schematics
Electrocution hazard. Contact with
electrically charged circuits may
Observe and Obey: result in death or serious injury.
Remove all rings, watches and
Troubleshooting and repair procedures shall be other jewelry.
completed by a person trained and qualified on
the repair of this machine. Hydraulic Schematics
Immediately tag and remove from service a Bodily injury hazard. Spraying
damaged or malfunctioning machine. hydraulic oil can penetrate and
Repair any machine damage or malfunction connections very slowly to allow
before operating the machine. the oil pressure to dissipate
Before Troubleshooting: or spray.
Read, understand and obey the safety rules General Repair Process
and operating instructions printed in the
Genie CWP Super Series Operator's Manual
and the Genie StockPicker Super Series
Operator's Manual.
Malfunction Identify Troubleshoot
Be sure that all necessary tools and test discovered symptoms
equipment are available and ready for use.
problem
still exists
Return to Inspect Perform

service problem and test repair
solved
Section 6 - Schematics Service Manual - First Edition
Symbols Legend
Electrical Symbols
ORG/BLK-1
TB20
L4 OP BLK #21 TB21
Wire color Terminal Light T-circuits connect T-circuits Connection

with cable at terminal connect no terminal
number
15AMP.
P1
Circuit breaker Solenoid or Circuits crossing Diode Battery Emergency Stop

relay coil no connection button
normally closed
1 2 3 4
CR4
CR4
6 R R 7 R 8
Relay contact Resistor Relay Contactor Relay Coil Transformer

normally open
Hydraulic Symbols
Cylinder Pressure gauge Filter Fixed displacement Check valve

pump
M
0.035
Relief valve Orifice with size Solenoid operated 2 pos., Solenoid operated Pump prime mover
3 way, directional valve dump valve (engine or motor)
Electrical Schematic -
CWP & StockPicker AC Models
CWP & StockPicker DC Models
CWP & StockPicker DC Models with Power Wheel Assist
Hydraulic Schematic -
CWP & StockPicker Models
Hydraulic Schematic -
CWP & StockPicker Models with Power Wheel Assist
This page intentionally left blank.
Service Manual - First Edition Section 7 - Repair Procedures
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.
Observe and Obey: Perform disassembly procedures to the point
where repairs can be completed. Then to
Repair procedures shall be completed by a
re-assemble, perform the disassembly steps in
person trained and qualified on the repair of this
reverse order.
machine.
General Repair Process
damaged or malfunctioning machine.
Repair any machine damage or malfunction Malfunction Identify Troubleshoot
before operating the machine. discovered symptoms
Before Repairs Start:

problem
Read, understand and obey the safety rules still exists
and operating instructions in the Genie CWP
Super Series Operator's Manual and the Return to Inspect Perform
Genie StockPicker Super Series Operator's service problem and test repair
Manual. solved
Be sure that all necessary tools and parts are Symbols Legend
available and ready for use.
Read each procedure completely and adhere to
that will cause death or serious
the instructions. Attempting shortcuts may
injury.
produce hazardous conditions.
that may cause death or serious
injury.
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.
Section 7 - Repair Procedures Service Manual - First Edition
Base Assembly
1-1 1-2
Interlocks Base Components
The base interlock switches indicate that the foot How to Adjust the Steer Handle
pads are in firm contact with the ground.
Interlock Cable
How to Remove a Base Interlock 1 Lower the base with the steer handle.
Switch 2 Remove the base cover to access the cable.
1 Fully lower the platform, turn the machine off 3 Check to be sure the cable is properly
and remove the key. connected to the latch plates.
2 Lower the base with the steer handle.
a b c b
3 Remove the foot pad switch holder fasteners.
4 Pull the foot pad switch holder out of the base
tube.
f e d
a steer handle cable

b lock nut
c measurement
d latch plate
e spring
f cable mounting plate
a b
4 Check to be sure the cable is attached to the
a switch holder fasteners cable mounting bracket with a lock nut on each
b switch holder cover
side. There should be 21/2 to 25/8 inches (6.6 to
5 Remove the wires from the switch. Take note of 6.8 cm) between the cable mounting plate and
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.
BASE ASSEMBLY
5 Locate the steer handle interlock cable 8 Slide the cable mounting bracket up, until the
mounting bracket on the bottom side of the top of the bracket is even with the reference
number 1 column. mark from step 7. Tighten the mounting
fasteners.
9 At the top of the cable mounting bracket, make
a a reference mark on the number 2 column
4 inches (10 cm) above the top of the cable
mounting bracket.
b
10 Slide the cable striker bracket down, until the
c top of the bracket is even with the reference
mark from step 9. The spring will need to be
d compressed with the slider bracket, when the
cable striker bracket is pulled down. Tighten the
mounting fasteners.
e 11 Raise the platform.
f
12 Pull the steer handle away from the machine to
be sure the steer handle remains in the locked
g
position. Re-adjust if necessary.
a number 1 column
b steer handle interlock cable
c cable striker bracket
d slider bracket
e spring
f lock nut
g cable mounting bracket
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
1-3
Hydraulic Manifold Components - CWPS Models with Power Wheel Assist
Index Schematic
No. Description Item Function Torque
1 Check valve ....................................... O ........... System pressure ............................... 25-35 ft-lbs / 34-41 Nm
2 2 position 3 way spool valve ............. L ........... Reverse ............................................. 25-35 ft-lbs / 34-41 Nm
3 2 position 3 way spool valve ............. K ........... Forward ............................................. 25-35 ft-lbs / 34-41 Nm
4 2 position 3 way spool valve ............. J ............ All functions ....................................... 25-35 ft-lbs / 34-41 Nm
4 3 2
Plug Torque Specifications

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
BASE ASSEMBLY
1-4
How to Check the Resistance
of a Valve Coil
1 Fully lower the platform, turn the machine off
and remove the key.
2 Connect the leads from an ohmmeter to the
valve coil terminals.
Valve coil specifications
Solenoid operated N.O. valve, 10V 6.5 to 7.2 Ω
Solenoid operated N.C. valve, 10V 7.8 to 9.5 Ω
Ground Control Box
2-1 2-2
How to Test the Transformer How to Test the AC Contactor
- AC Models - AC Models
1 Fully lower the platform, turn the key switch off 1 Fully lower the platform, turn the key switch off
and disconnect the power supply. and disconnect the power supply.
2 Open the ground control box and locate the 2 Open the ground control box and locate the AC
transformer. contactor.
3 Label and then disconnect all wiring from the 3 Label and then disconnect all wiring from the
transformer. contactor.
4 Connect the leads from an ohmmeter to the 4 Connect the leads from an ohmmeter to the
following terminal combinations and check the following terminal combinations and check the
resistance. continuity/resistance.
h g f a b c d
c b a
a yellow wire
b black wire
f e
c white wire
d brown wire
e blue wire a terminal no. 1
f red wire No. 1 b terminal no. 8
g red/yellow wire c terminal no. 6
h red wire No. 2 d terminal no. 2
e terminal no. 4
f terminal no. 0
Test Desired result
brown wire to blue wire 20 to 22 Ω Test Desired result
black wire to white wire 16 to 19 Ω terminal 0 to 1 80 to 85 Ω
yellow wire to white wire 16 to 19 Ω all other terminal combinations no continuity

(infinite Ω)
red/yellow wire to red wire #1 0.5 to 1.5 Ω
red/yellow wire to red wire #2 0.5 to 1.5 Ω
red wire #1 to red wire #2 0.5 to 1.5 Ω
yellow wire to black wire 0.5 to 1.5 Ω
all other wire combinations no continuity

(infinite Ω)
This page intentionally left blank.
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 Capacitor .......................................................... 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 10V DC coil ....................................................... Activates N.O. dump valve
6 Reservoir .......................................................... 3 quarts (2.8 liters)
7 Drain plug ......................................................... Drains reservoir
8 Sight gauge ...................................................... Hydraulic fluid level
9 Breather cap ..................................................... Reservoir vent
10 Pick-up filter ...................................................... Filters hydraulic fluid
11 O-ring ................................................................ Seals reservoir
12 Pump ................................................................ 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 ...................................................... One-way valve for pump output
14 Motor seal ......................................................... Seals motor from contaminants
15 Motor bearing ................................................... Aligns motor shaft into pump
HYDRAULIC POWER UNITS
3-2
Hydraulic Power Unit Components - DC Models
Index
No. Description Function
1 12V DC electric motor ...................................... 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 ......................................... Hydraulic relief valve adjustment
4 Solenoid operated N.O. dump valve ................ Diverts pump output back to reservoir during motor start up
5 10V DC coil ....................................................... Activates N.O. dump valve
6 Reservoir .......................................................... 3 quarts (2.8 liters)
7 Drain plug ......................................................... Drains reservoir
8 Sight gauge ...................................................... Hydraulic fluid level
9 Breather cap ..................................................... Reservoir vent
10 Pick-up filter ...................................................... Filters hydraulic fluid
11 O-ring ................................................................ Seals reservoir
12 Pump ................................................................ 0.7 to 1 gallons per minute at 2000 psi
2.6 to 3.76 liters per minute at 138 bar
13 Check valve ...................................................... One way valve for pump output
14 Motor seal ......................................................... Seals motor from contaminants
15 Motor bearing ................................................... Aligns motor shaft into pump
3-3 3-4
How to Remove the Hydraulic How to Remove the Hydraulic
Power Unit - AC Models Power Unit - DC Models
1 Fully lower the platform, turn the machine off, 1 Fully lower the platform, turn the machine off,
remove the key, and disconnect the power remove the key, and disconnect the power
supply. supply.
2 Lower the base with the steer handle. 2 Lower the base with the steer handle.
3 Remove the power unit cover. 3 Remove the power unit cover.
4 Tag, disconnect and plug the hydraulic hoses. 4 Tag, disconnect and plug the hydraulic hoses.
Cap the fittings on the power unit. Cap the fittings on the power unit.
Bodily injury hazard. Spraying Bodily injury hazard. Spraying
hydraulic oil can penetrate and hydraulic oil can penetrate and
burn skin. Loosen hydraulic burn skin. Loosen hydraulic
connections very slowly to allow connections very slowly to allow
the oil pressure to dissipate the oil pressure to dissipate
gradually. Do not allow oil to squirt gradually. Do not allow oil to squirt
or spray. or spray.
5 Tag and disconnect the electrical wiring from 5 Tag and disconnect the electrical wiring from
the valve coil. the valve coil.
6 Remove the cover from the junction box on the 6 Tag and disconnect the electrical wiring from
motor. Then tag and disconnect the electrical the motor start solenoid.
wiring in the junction box. Loosen the squeeze
7 Support the hydraulic power unit with a lifting
connector on the junction box and pull the
device.
wiring out through the squeeze connector.
8 Remove the power unit mounting fasteners,
7 Support the hydraulic power unit with a lifting
then remove the power unit from the machine.
device.
Crushing hazard. The power unit
8 Remove the power unit mounting fasteners,
will fall unless it is properly
then remove the power unit from the machine.
supported.
Crushing hazard. The power unit
If a new power unit is installed, the
pressure relief valve must be
supported.
properly adjusted. See 3-6, How to
If a new power unit is installed, the Adjust the Pressure Relief Valve.
pressure relief valve must be
properly adjusted. See 3-6, How to
Adjust the Pressure Relief Valve.
3-5
How to Remove the Hydraulic
Pump
and remove the key.
2 Lower the base with the steer handle.
3 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.
3-6 12 The power unit should not be able to lift the

platform. If the power unit lifts the platform, turn
How to Adjust the Pressure the relief valve counterclockwise until the
Relief Valve adjustment is correct.
1 Remove the power unit cover. 13 Hold the relief valve screw and tighten the lock
nut. Be sure the relief valve screw does not
2 Remove the breather cap from the reservoir.
turn.
3 Fill the reservoir up to the sight glass with
Dexron ATF hydraulic oil equivalent. 14 Bleed the hydraulic system by raising the
platform to full height. If the pump cavitates or
4 Install the breather cap. platform fails to reach full height, add hydraulic
5 Follow the appropriate operator's manual to set oil until the pump is functioning correctly. Do not
up the machine. overfill the hydraulic reservoir.
6 Place the maximum load capacity in the Component damage hazard. Do
platform. Refer to the operator's manual or the not continue to operate the
load capacity decal on the machine to machine if the hydraulic pump is
determine the maximum load capacity. Be sure cavitating.
the load is secure.
15 Install the breather cap and the power unit
7 Hold the relief valve screw and loosen the lock cover.
nut.
8 While activating the platform up function, turn
the relief valve screw clockwise, just until the
platform begins to raise.
10 Add an additional 30 pounds (14 kg) to the
platform. Secure the additional weight.
3-7 3-8
How to Check the Resistance How to Test the Motor Start
of a Valve Coil Solenoid - DC Models
1 Fully lower the platform, turn the machine off Electrocution hazard. Contact with
and remove the key. electrically charged circuits may
2 Connect the leads from an ohmmeter to the result in death or serious injury.
valve coil terminals. Remove all rings, watches and
other jewelry.
Electrocution hazard. Disconnect
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 Ω
2 large posts no continuity

(infinite Ω)
Small post to no continuity

Valve coil specifications
any large post (infinite Ω)
Solenoid operated N.O. valve, 10V 5.9 to 7.2 Ω
a b a
Lowering valve, 10V 7.8 to 9.5 Ω
(located at base of cylinder)
a high amp power contact terminal

(large post)
b solenoid activate coil terminal
(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 Ω)
Power Pack
4-1 9 Support the power unit assembly and remove

the mounting bolts.
How to Change a Power Pack
Crushing hazard. When mounting
1 Fully lower the platform and disconnect the bolts are removed, power unit
machine from the power source. assembly will become unbalanced
and may fall if not properly
2 Lower the base with the steer handle. supported.
3 Remove the power unit cover. 10 Remove the power unit assembly.
4 Separate both quick disconnect couplers from 11 Remove the ground control box assembly
the ground control box. mounting bolts. Remove the control box
5 Unplug the quick disconnects. assembly from the machine.
6 DC models: Disconnect the battery cables from
the motor.
7 Remove the breather cap from the hydraulic
power unit and install a pipe plug into the filler
Installation
hole. Reassemble in the reverse order of disassemble
8 Label, disconnect and plug the hydraulic hoses procedure.
from the power unit. Do not install the motor cover until
Bodily injury hazard. Spraying the relief valve adjustment is
hydraulic oil can penetrate and complete. Refer to 3-6, How to
burn skin. Loosen hydraulic Adjust the Pressure Relief Valve.
the oil pressure to dissipate Component damage hazard. Do
gradually. Do not allow oil to squirt not overtighten the hydraulic
or spray. fittings.
Mast Assembly
CWP-8 CWP-12S / SP-12S
CWP-15S / SP-15S
Mast Components
a carriage e number 3 column
b number 2 column f number 3 column idler wheel assembly
c number 1 column g number 4 column
d number 2 column idler wheel assembly h number 4 column idler wheel assembly
MAST ASSEMBLY
5-1 4 Remove the cylinder mounting fasteners from

the cylinder barrel end.
Lift Cylinder
5 Loosen the cylinder bracket mounting
fasteners.
How to Remove the Lift Cylinder
This procedure requires specific a
repair skills, lifting equipment and
this procedure without these skills
and tools may result in death or d
service is strongly recommended.
1 Remove the mast. See 5-2, How to Remove
the Mast Assembly.
c b
2 Remove the socket head retaining bolt from the
a bracket mounting fasteners
clevis block on the lift cylinder rod end. b cylinder mounting fasteners
c hydraulic cylinder
d cylinder mounting plate
a 6 Support the cylinder and carefully slide it out of

the bottom of the mast.
b
Crushing hazard. The lift cylinder
c supported.
a top of no. 1 column

b retaining bolt
c clevis block
3 Disconnect and plug the lift cylinder hydraulic

hoses. Cap the fittings on the lift cylinder.
or spray.
MAST ASSEMBLY
5-2 10 Remove the four base mounting fasteners.
How to Remove the Mast 11 Carefully lift the mast out of the base.
Assembly Crushing hazard. The mast will fall
unless it is properly supported.
This procedure requires specific
repair skills, lifting equipment and 12 Place two saw horses under the mast.
13 Lower the bottom of the mast onto one saw
this procedure without these skills
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.
service is strongly recommended. The level sensing system will not
operate correctly if the number 1
column is not perpendicular to the
and remove the key.
base (front to back and side to
2 Lower the base with the steer handle. side). Consult Genie Industries
Service Department.
3 Remove the platform. See 7-1, How to Remove
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.
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.
MAST ASSEMBLY
How to Disassemble the Mast bracket from the mast.
This procedure requires specific 10 Remove the adjustment nuts from all the
repair skills, lifting equipment and sequencing cables.
a suitable workshop. Attempting 11 Slide the carriage towards the top enough to
this procedure without these skills remove the tension on the lifting chain.
serious injury and significant 12 Slide the column that is under the carriage
component damage. Dealer towards the top about 6 inches (15.2 cm) to
service is strongly recommended. access the idler wheel mounting fasteners.
1 Remove the mast. See How to Remove the 13 Hold the idler wheel axle from turning by placing
Mast Assembly. a small screwdriver in the hole of the axle.
Remove the axle mounting fasteners, then
2 Remove the mounting fasteners from the remove the idler wheel assembly.
cylinder mounting plates.
When the idler wheel assemblies
3 Remove the retaining bolt from the clevis block are removed, be sure to label the
on the lift cylinder rod end. location of each idler wheel
assembly.
14 Remove the adjustment nuts from the chain
tension rocker on the carriage.
a
15 Slide the carriage out the bottom of the mast
b assembly.
16 Lay the chains out on the floor at the top of the
c
mast. Do not allow the chains to become
twisted or dirty.
17 Remove the adjustment nuts from the chain
a top of no. 1 column
tension rocker on the top column.
b retaining bolt
c clevis block 18 Slide the column out the bottom of the mast.
4 Support the cylinder and carefully slide it out of 19 Push the next column towards the top of the
the bottom of the mast. mast to access the idler wheel assembly
5 Carefully rotate the mast until it is resting on the mounting fasteners.
back of the number 1 column. 20 Hold the idler wheel axle from turning by placing
6 Remove the mast covers. a screwdriver in the hole of the axle. Remove
the axle mounting fasteners, then remove the
CWPS Models with Platform Outreach: idler wheel assembly.
Remove the outreach assembly from the
carriage. 21 Remove the adjustment nuts from the chain
tension rocker on the column.
7 Remove the cover from the platform control box
and AC outlet to access the mounting screws.
8 Remove the control box and AC outlet and set
aside.
9 Remove the steer handle interlock cable
MAST ASSEMBLY
22 Slide the column out the bottom of the mast. 11 Pick up the number 2 column chains and lay
them inside the number 3 column. Be sure not
23 Follow steps 19 through 22 for each remaining
to twist the chains.
column.
12 Follow steps 4 through 11 for each remaining
If the chains are removed, be sure
column and the carriage.
to mark the location and label
each chain before removal. 13 After all the columns are together the idler
wheel assemblies need to be installed.
How to Assemble the Mast
14 Rotate the mast over onto the carriage side.
This procedure requires specific
repair skills, lifting equipment and 15 Remove the tension from the lifting chains by
a suitable workshop. Attempting pushing the top column toward the bottom of
this procedure without these skills the mast.
and tools may result in death or 16 Install the idler wheel assembly into the top of
serious injury and significant the number 2 column. Tighten the mounting
component damage. Dealer fasteners. Push or pull the columns to increase
service is strongly recommended. the space for mounting the idler wheel
1 Thoroughly clean all columns. assembly.
2 Secure the number 1 column to the saw horses Be sure the removal hole in the
and lay the chains out on the floor at the top. idler wheel axle is accessible. Be
sure all idler wheels rotate with no
3 Apply a generous amount of Boe-lube wax excessive side to side movement
(Genie part number 90337) to the inside and and be sure that they do not rub
outside channels of each column. on the inside of the column.
Replace worn shims if necessary.
4 Slide the number 2 column into the number 1
column. Be sure not to damage the slide block. 17 Follow steps 15 and 16 for each remaining idler
wheel assembly.
5 Lay the number 2 column chains onto the floor.
Do not allow the chains to become twisted or 18 Be sure that all of the idler wheel axle mounting
dirty. fasteners are flush with the column.
6 Pick-up the number 1 column chains and lay Component damage hazard. The
them inside the number 2 column. Be sure not roller wheels will become
to twist the chains. damaged if the idler wheel axle
mounting fasteners are not flush
7 Slide the number 3 column into the number 2
with the column.
column. Be sure not to damage the slide block.
19 Reassemble the machine. Then adjust the lifting
8 When the column is almost all the way in, guide
chains. See 5-3, How to Adjust the Lifting
the number 1 column chains into the chain
Chains.
tension rocker on the number 3 column.
20 Adjust the steer handle interlock cable.
9 Install the adjustment nuts onto the number 1
See 1-2, How to Adjust the Steer Handle
column chains.
Interlock Cable.
10 Lay the number 3 column chains on the floor.
Do not allow the chains to become twisted or
dirty.
MAST ASSEMBLY
5-3 5-4
How to Adjust the Lifting Chains How to Adjust the Glide Pads
1 Fully lower the machine and check to see if all 1 Fully lower the platform, turn off the machine
the columns (except the carriage) are even at and remove the key.
the top. The chains are adjusted correctly if all
2 Locate the upper and lower glide pad bolts
the columns are even at the top.
below each top roller wheel bolt on both sides
To adjust column chains: of the columns.
2 Mark the column to be adjusted. 3 Hold each glide pad bolt and loosen the lock nut
on all the glide pads.
3 Raise the platform 6 feet (2 m).
4 Turn all the glide pad bolts clockwise until the
4 Turn the adjustment lock nuts evenly on both glide pads make contact with the column.
chain terminals clockwise to raise the column Adjust both sides of the mast. Be sure the sides
or counterclockwise to lower the column. of the columns are within 1/8 inch (3.175 mm) to
5 Fully lower the machine and recheck the even with each other.
alignment of the columns. Re-adjust if 5 Starting at the number 1 column, torque the
necessary. upper and lower glide pad bolts to 12 in-lbs
6 Check to make sure the chain terminals on (1.356 Nm). Hold the glide pad bolt and tighten
each column have equal tension and the lock the lock nut. Be sure the glide pad bolt does not
nuts are tight. turn.
7 Check to be sure the chain tension rockers are 6 Repeat step 5 for each remaining upper and
centered in the inspection hole of the column. lower glide pad bolt on one side of the mast.
Start at the number 1 column and adjust each
column, working toward the carriage.
7 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.
MAST ASSEMBLY
5-5
How to Inspect the Lifting Chains
Inspection Procedure Inspection Failure Inspection Remedy
Wear Count out 16 chain links When the length of the Replace both chains on
and measure pin to pin 16 links (pin to pin) that column section.
centerline dimension with measure more than 8.25 Replace entire chain. Do
a steel tape. inches for 1/2 inch chain not repair just the
or 10.31 inches for 5/8 affected portion of the
inch chain. chain.
Note: Be sure to
measure a section of
chain that moves over
the idler wheels.
Rust and Corrosion Visually inspect the Evidence of rust or Remove chain and
chains for rust and corrosion. inspect for cracked plates
corrosion. (see inspection of
cracked plates). If no
cracks are found,
lubricate chain with motor
oil (SAE 40) and re-install
chain.
Visually inspect the When external surfaces Lubricate chain with

chains for lubrication. are not protected with a motor oil (SAE 40).
layer of oil.
Tight Joints Inspect chain link joints Joints that do not flex If rust and corrosion is
for easy movement. freely or are bound up. 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.
MAST ASSEMBLY
Inspection Procedure Inspection Failure Inspection Remedy
Raised or Turned Pins Visually inspect for raised Raised pins. Replace both chains on
pins. that column section. Do
not repair just the
affected portion of the
chain.
Visually inspect for turned Misalignment of flats on Replace both chains on

pins by insuring all the all "V" heads. that column section. Do
flats on the "V" heads are not repair just the
aligned. affected portion of the
chain.
Chain Side Visually inspect for wear Wear on pin heads or Replace both chains on
patterns on heads of link noticeable wear in the that column section. Do
pins and outside link profile of the outside link not repair just the
plates where they contact plate. affected portion of the
the idler wheel. chain.
Check alignment of chain

anchors and idler wheels.
link plate wear
Chain Anchors Visually inspect chain Broken chain anchor Replace chain anchor.
anchors. fingers.
Bent or damaged anchor. Replace chain anchor.
Twisted or misaligned Re-align chain anchor to

chain anchor. ensure even loading of
chain threaded
rod chain.
anchors
Threaded rod not visible Replace chain anchor
in inspection hole. and threaded rod.
Idler Wheels Visually inspect chain idler Idler wheels have badly Replace idler wheel and
wheels. worn flanges. check chain alignment.
Idler wheels have Replace idler

idler grooves worn into chain wheel.
wheel
contact surface.
Cracked Link Plates Visually inspect chain link Cracks in any chain link Replace both chains on
plates for cracks. plate. that column section.
Replace entire chain. Do
not repair just the affected
portion of the chain.
Platform
6-1 6-3
How to Remove the Platform Platform Control Box
1 CWP Models: Place support blocks between
the platform and base. Then lower the platform How to Test the Contactors
onto the blocks. 1 Fully lower the platform, turn the key switch off
Crushing hazard. Keep away from and disconnect the power supply.
descending platform. 2 Loosen the platform control box lid fasteners
Stockpicker Super Series Models: Attach an and open the control box.
overhead crane or similar lifting device to the 3 Observe the markings on the contactor to be
platform. checked. The N.O. marking designates the
2 Remove the mounting fasteners from the switch as normally open and N.C. designates
platform. the switch as normally closed.
3 Pull the platform away from the mast and 4 Connect a continuity tester to the exposed
remove it from the machine. screw terminals.
If a platform is being replaced, be Result: Normally open contactors should have

sure that all appropriate safety and no continuity. Normally closed contactors
instructional decals are applied to should have full continuity.
the new platform. 5 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
6-2 should have no continuity.
How to Install a Fiberglass
Platform - CWPS Models
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.
PLATFORM
How to Test Power-to-Platform 6 Loosen but do not remove both sprocket

housing fasteners.
GFCI outlet
7 Push downward on the sprocket housing to
1 Fully lower the platform, turn the key switch off. remove any excess slack in the chain.
2 Be sure the AC power supply is properly 8 Tighten the sprocket housing fasteners.
connected.
9 Check the chain adjustment. Refer to
3 Connect an AC voltage tester or a small hand maintenance procedure B-8, Check the Chain
tool to the platform GFCI receptacle. Adjustment.
4 Test the voltage or test the hand tool operation. If chain cannot be adjusted to
specification, refer to 7-5, How to
Result: The voltage should be 115V AC nominal
Replace the Outreach Chain.
or the hand tool should operate normally.
5 Push the black TEST button on the GFCI
receptacle.
7-5
Result: The voltage should be 0V or the hand
tool should not operate.
How to Replace the Outreach
Chain - CWPS Models
6 Push the red RESET button on the GFCI
receptacle. 1 Fully lower the platform, turn the key switch off.
Result: The voltage should be 115V AC nominal 2 Fully lower the base and disconnect the power
or the hand tool should operate normally. supply.
the Platform.
7-4 4 Remove the fasteners on platform control box
How to Adjust the Platform cover to access the control box mounting
fasteners.
Outreach Chain - CWPS Models
5 Remove the platform control box mounting
1 Fully lower the platform. fasteners. Remove the platform control box
2 Turn the power off and remove the key. from the outreach and set it aside.
3 Fully extend the platform outreach and lock the 6 Extend the outreach approximately 14
handle into position. Be sure the handle is inches (36 cm) and lock the handle in position.
locked. Be sure the handle is locked.
4 Place a block of wood between the carriage and 7 Attach a overhead crane to the center brace
the platform outreach to prevent the outreach pivot pin on the outreach.
from collapsing when the fasteners are 8 Remove the fasteners that hold the outreach to
loosened. the carriage.
Crushing hazard. The platform
outreach will collapse if a suitable
block or brace is not used.
5 Locate the two fasteners which hold the lower
sprocket housing onto the outreach.
PLATFORM
Crushing hazard. When the 23 Thread the chain through the upper sprocket
mounting fasteners are removed, housing, around the sprocket and then back
the platform outreach will become through the housing.
unbalanced and may fall if it is not
24 Thread the chain through the lower sprocket
properly supported.
housing, around the sprocket and back through
9 Lay the outreach onto a work bench or table the housing. Make sure the chain does not
with the chain assembly facing up. Be sure the become twisted.
work bench or table is of ample capacity.
25 Connect the two ends of the chain together with
10 Place a block of wood under the inner frame a new master link. Do not re-use the old master
assembly to support it while removing the link.
chain.
26 Slide the platform mounting column onto the
Crushing hazard. The platform inner frame assembly.
outreach will collapse if a suitable
27 Install the column outreach locking bracket onto
block or brace is not used.
the platform mounting column.
11 Remove the lower sprocket housing mounting
28 Install the upper sprocket housing to the
fasteners. Do not allow the chains to become
column.
twisted.
When fasteners are installed, be
12 Remove the upper sprocket housing mounting
sure the center bolt is in between
fasteners. Do not allow the chains to become
the two chains inside the housing.
twisted.
29 Pull the slack out of the chain by pulling on the
13 Remove the fasteners from the column
lower sprocket housing.
outreach locking bracket.
30 Install the lower sprocket housing.
14 Slide the platform mounting column off of the
inner frame assembly and set it aside. 31 Adjust the chain. See 7-4, How to Adjust the
Outreach Chain.
15 Locate the two allen head screws in the chain
slider block. 32 Install the outreach back onto the machine.
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.
Genie North America
18340 NE 76th Street
P.O. Box 97030
Redmond, Washington
98073-9730
Distributed By:
Genie Europe
Brunel Drive
Newark
Nottinghamshire
NG24 2EG England

CWP Stockpicker: Service Manual

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CWP Stockpicker: Service Manual

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Technical

First Edition, First Printing

service center. Copyright © 1996 by Genie Industries

If you have any questions, please call

Many of the hazards identified in the

Do Not Perform Maintenance

Personal Safety Workplace Safety

Read each procedure thoroughly. This

Section One Safety Rules

Section Two Specifications

Section Three Scheduled Maintenance Inspections

Section Four Scheduled Maintenance Procedures

Section Four Scheduled Maintenance Procedures, continued

Section Five Troubleshooting Flow Charts

Section Five Troubleshooting Flow Charts, continued

Section Six Schematics

Section Seven Repair Procedures

Section Seven Repair Procedures, continued

Specifications Platform dimensions

Height, stowed 63 in 160 cm

Ambient operating -20°F to 135°F

Airborne noise emissions 80 dB

Current Protection Rating

Specifications Platform Specifications

Height, platform maximum Ambient operating -20°F to 135°F

Height, stowed 751/2 in 192 cm

Platform function speed, Platform function speed,

CWP-15S AC DC Maximum hydraulic pressure - All Models

Maximum hydraulic pressure - All Models

Bolt Torque Specifications

20 90 122 120 163

18 120 163 170 231

18 170 231 240 326

16 300 407 420 570

14 470 637 660 895

12 700 949 1000 1356

Scheduled Maintenance Inspections

About This Section Dealer

There are three types of maintenance inspections

Make copies of the Maintenance Inspection

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

A-5 Test the Base Operation

A-6 Check the Auxiliary Platform Lowering Operation

A-7 Check the Manual Platform Lowering Operation

A-8 Inspect the Battery and Battery Charger

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

— Complete all procedures in Table A

B-1 Inspect the Electrical Wiring

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