Terex Genie GR-12 Service Manual
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Terex Genie GR-12 Service Manual

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Service Manual
GR -12
GR -15
GR -20
QS-12R
QS-15R
QS-20R
QS-12W
QS-15W
QS-20W
Serial Number Range
from GR10-20000
from GR10-20000
from GR10-20000
from QS11-1000
from QS11-1000
from QS11-1000
from QS11-1000
from QS11-1000
from QS11-1000
Part No. T110280
Rev B1
November 2014

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Summary of Contents for Terex Genie GR-12

  • Page 1 Service Manual Serial Number Range GR -12 from GR10-20000 GR -15 from GR10-20000 GR -20 from GR10-20000 QS-12R from QS11-1000 QS-15R from QS11-1000 QS-20R from QS11-1000 QS-12W from QS11-1000 QS-15W from QS11-1000 Part No. T110280 QS-20W from QS11-1000 Rev B1 November 2014...

  • Page 2: Introduction

    Third Edition, Second Printing e-mail:awp.techpub@terex.com "Genie" is a registered trademark of Terex South Dakota in the USA and many other countries. "GR" is a trademark of Terex South Dakota, Inc. Printed on recycled paper Printed in U.S.A. GR • QSR • QSW...
  • Page 3 November 2014 Revision History Revision Date Section Procedure / Schematic Page / Description 4/2011 New release 10/2011 2 - Spec. 3 - Maint. 3-5, 3-27 6 - Schem. 6-2, 6-3, 6-4, 6-6, 6-10, 6-14, 6-18, 6-22, 6-26, 6-30, 6-34 11/2014 6 - Spec.
  • Page 4 November 2014 REVISION HISTORY, CONTINUED Revision Date Section Procedure / Schematic Page / Description REFERENCE EXAMPLES: Electronic Version Kubota Engine_Section 2_Specifications. A-6,B-3,C-7_Section 3_Maintenance Procedure. Click on any procedure or page number 3-2, 6-4, 9-1_Section 4_Repair Procedure. highlighted in blue to view the update. Fault Codes_Section 5.

  • Page 5: Serial Number Legend

    November 2014 INTRODUCTION Serial Number Legend Part No. T110280 GR • QSR • QSW...

  • Page 6: Safety Rules

    November 2014 Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the appropriate Operator's Manual on your machine will result in death or serious injury. Many of the hazards identified in the operator’s manual are also safety hazards when maintenance and repair procedures are performed.
  • Page 7 November 2014 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 top priority.

  • Page 8: Table Of Contents

    November 2014 Table of Contents Introduction Important Information ..................ii Serial Number Information ................. ii Serial Number Legend ..................iii Section 1 Safety Rules General Safety Rules ..................v Section 2 Specifications Machine Specifications ................2 - 1 Performance Specifications ................. 2 - 2 Hydraulic Specifications ................
  • Page 9 November 2014 TABLE OF CONTENTS Section 3 Scheduled Maintenance Procedures, continued Checklist B Procedures B-1 Inspect the Batteries ................. 3 - 11 B-2 Inspect the Electrical Wiring ............. 3 - 14 B-3 Inspect the Tires and Wheels (including castle nut torque) ....3 - 15 B-4 Check the Lifting Chain Adjustments ..........
  • Page 10 November 2014 TABLE OF CONTENTS Section 4 Repair Procedures Introduction ....................4 - 1 Platform Controls Circuit Board ..................4 - 3 Joystick ....................4 - 4 Platform Controls Alarm ..............4 - 4 Platform Emergency Stop Button ............4 - 5 Ground Controls Software Revision Level ..............
  • Page 11 November 2014 TABLE OF CONTENTS Section 4 Repair Procedures, continued Platform Components 10-1 Platform ................... 4 - 30 10-2 Platform Extension ................4 - 31 10-3 Work Tray ..................4 - 32 Mast Components 11-1 Mast ....................4 - 33 11-2 Glide Pads ..................
  • Page 12 November 2014 TABLE OF CONTENTS Section 6 Schematics Introduction ....................6 - 1 Electrical Component and Wire Color Legends ........... 6 - 2 Wiring Diagram - Ground and Platform Controls ......... 6 - 3 Electrical Symbols Legend ................6 - 4 Electrical Schematic - GR and QSW - ANSI and CSA Models (from GR10-20000 to GR11-20683 and from QS11-1000 to QS11-1015) ..

  • Page 13: Specifications

    November 2014 Section 2 • Specifications Specifications Machine Specifications Height, stowed maximum GR-12, GR-15, QS-12R , QS-15R Batteries, Standard QS-12W and QS-15W 62 in (ANSI and CSA) 1.57 m Voltage 6V DC GR-12, GR-15, QS-12R , QS-15R Group QS-12W and QS-15W 68.1 in Type T-105...

  • Page 14: Performance Specifications

    Section 2 • Specifications November 2014 SPECIFICATIONS Performance Specifications Rated work load at full height, maximum GR-12 and GR-15 Drive speed, maximum Standard Platform 500 lbs Platform stowed, fast 2.5 mph 227 kg 40 ft / 10.9 sec 4 km/h GR-20 12.2 m / 10.9 sec Standard Platform...

  • Page 15: Hydraulic Specifications

    November 2014 Section 2 • Specifications SPECIFICATIONS Hydraulic Specifications Function pump Type Gear Hydraulic Oil Specifications Displacement per revolution 0.244 cu in Hydraulic oil type Chevron Rando HD equivalent 4 cc Viscosity grade Multi-viscosity Viscosity index Flow rate @ 2500 psi / 172 bar 4 gpm 15 L/min Cleanliness level, minimum...

  • Page 16: Manifold Component Specifications

    Section 2 • Specifications November 2014 SPECIFICATIONS Manifold Component Valve Coil Resistance Specifications Note: The following coil resistance specifications are at an ambient temperature of 68°F / 20°C. As valve coil Plug torque resistance is sensitive to changes in air temperature, the coil resistance will typically increase or decrease by 4% SAE No.

  • Page 17: Hydraulic Hose And Fitting Torque Specifications

    November 2014 Section 2 • Specifications SPECIFICATIONS Hydraulic Hose and Fitting SAE O-ring Boss Port (tube fitting - installed into Aluminum) Torque Specifications (all types) Your machine is equipped with JIC 37° flared SAE Dash size Torque fittings and hose ends. Genie specifications require that fittings and hose ends be torqued to 14 ft-lbs / 19 Nm specification when they are removed and installed...
  • Page 18 Section 2 • Specifications November 2014 SPECIFICATIONS Torque Procedure Seal-Lok™ fittings 1 Replace the O-ring. The O-ring must be replaced anytime the seal has been broken. The O-ring cannot be re-used if the fitting or hose end has been tightened beyond finger tight.
  • Page 19 November 2014 Section 2 • Specifications SPECIFICATIONS SAE FASTENER TORQUE CHART • This chart is to be used as a guide only unless noted elsewhere in this manual • A574 High Strength Grade 5 Grade 8 SIZE THREAD Black Oxide Bolts LUBED LUBED LUBED...
  • Page 20 Section 2 • Specifications November 2014 This page intentionally left blank. 2 - 8 GR • QSR • QSW Part No. T110280...

  • Page 21: Scheduled Maintenance Procedures

    November 2014 Section 3 • 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 Safety alert symbol—used to alert by a person trained and qualified on the personnel to potential personal...

  • Page 22: Pre-Delivery Preparation Report

    Section 3 • Scheduled Maintenance Procedures November 2014 SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend Pre-delivery Preparation Report Note: The following symbols have been used in The pre-delivery preparation report contains this manual to help communicate the intent of the checklists for each type of scheduled inspection. instructions.
  • Page 23 500 Oak Wood Road The Maltings, Wharf Road PO Box 1150 Grantham, Lincolnshire Watertown, SD 57201-6150 NG31- 6BH England (605) 882-4000 (44) 1476-584333 Copyright © 2011 Terex Corporation. Genie® is a registered trademark of Terex South Dakota, Inc. 133192 Rev D...
  • Page 24 Section 3 • Scheduled Maintenance Procedures November 2014 This page intentionally left blank. 3 - 4 GR • QSR • QSW Part No. T110280...

  • Page 25: Maintenance Inspection Report

    November 2014 Section 3 • Scheduled Maintenance Procedures Maintenance Inspection Report Model Checklist A Y N R Checklist B Y N R A-1 Inspect the manuals B-1 Batteries Serial number and decals B-2 Electrical wiring A-2 Pre-operation B-3 Tires and wheels Date inspection B-4 Lifting chain...

  • Page 26: Checklist A Procedures

    Section 3 • Scheduled Maintenance Procedures November 2014 Checklist A Procedures 3 Open the operator's manual to the decals inspection section. Carefully and thoroughly Inspect the Manuals and Decals inspect all decals on the machine for legibility and damage. Maintaining the operator’s and safety manuals in good condition is essential to safe machine Result: The machine is equipped with all operation.

  • Page 27: Perform Pre-Operation Inspection

    November 2014 Section 3 • Scheduled Maintenance Procedures CHECKLIST A PROCEDURES Perform Pre-operation Inspection Perform Function Tests Completing a Pre-operation Inspection is essential Completing the function tests is essential to safe to safe machine operation. The Pre-operation machine operation. Function tests are designed to Inspection is a visual inspection performed by the discover any malfunctions before the machine is operator prior to each work shift.

  • Page 28: Test The Obstruction Sensing System (Qsr Models Only)

    Section 3 • Scheduled Maintenance Procedures November 2014 CHECKLIST A PROCEDURES 3 At the ground controls, attempt to lower the platform. Test the Obstruction Sensing Result: The obstruction sensing alarm sounds System (QSR models only) and the platform will not lower. The system is working properly.
  • Page 29 November 2014 Section 3 • Scheduled Maintenance Procedures CHECKLIST A PROCEDURES 4 Remove the weight from the pad. Push in the red Emergency Stop button to the off position at the ground controls, then pull out the red Emergency Stop button to the on position at the ground controls.

  • Page 30: Perform 30 Day Service

    Section 3 • Scheduled Maintenance Procedures November 2014 CHECKLIST A PROCEDURES Perform 30 Day Service Grease the Steer Yokes The 30 day maintenance procedure is a one time Genie specifications require that this procedure be procedure to be performed after the first 30 days performed every 100 hours of operation.

  • Page 31: Checklist B Procedures

    November 2014 Section 3 • Scheduled Maintenance Procedures Checklist B Procedures Inspect the Batteries Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper battery condition is essential to good machine performance and operational safety. Improper fluid levels or damaged cables and connections can result in component damage and hazardous conditions.
  • Page 32 Section 3 • Scheduled Maintenance Procedures November 2014 CHECKLIST B PROCEDURES Models without maintenance-free or sealed 13 Check the ambient air temperature and adjust batteries: the specific gravity reading for each cell as follows: 9 Remove the battery vent caps and check the •...
  • Page 33 November 2014 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES All models: 16 Check each battery pack and verify that the batteries are wired correctly. 17 Inspect the battery charger plug and pigtail for damage or excessive insulation wear. Replace as required.

  • Page 34: Inspect The Electrical Wiring

    Section 3 • Scheduled Maintenance Procedures November 2014 CHECKLIST B PROCEDURES 4 Inspect for a liberal coating of dielectric grease in all wiring connections between the ECM and Inspect the Electrical Wiring the platform controls, and level sensor wiring. 5 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform Genie specifications require that this procedure be...

  • Page 35: Inspect The Tires And Wheels (Including Castle Nut Torque)

    November 2014 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES Inspect the Tires and Wheels Check the Lifting Chain (including castle nut torque) Adjustments Genie specifications require that this procedure be Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever performed every 250 hours or quarterly, whichever comes first.

  • Page 36: Clean And Lubricate The Columns

    Section 3 • Scheduled Maintenance Procedures November 2014 CHECKLIST B PROCEDURES Clean and Lubricate the Columns Adjust the Sequencing Cables Genie specifications require that this procedure be Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever performed every 250 hours or quarterly, whichever comes first.

  • Page 37: Test The Emergency Stop

    November 2014 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES 3 Confirm proper tension of each sequencing cable by measuring the height of the spring Test the Emergency Stop between the nylock nut and the upper sequencing bracket. Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever Result: The measurement is within comes first.

  • Page 38: Test The Key Switch

    Section 3 • Scheduled Maintenance Procedures November 2014 CHECKLIST B PROCEDURES Test the Key Switch Test the Automotive-style Horn (if equipped) Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever Genie specifications require that this procedure be comes first.

  • Page 39: Inspect The Voltage Inverter (If Equipped)

    November 2014 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES B-10 3 Connect an appropriate power tool to the inverter. Activate the tool. Inspect the Voltage Inverter Result: The power tool should operate. There (if equipped) may be a brief (0.5 second) delay if the power tool has not been used in the previous 10 Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever...

  • Page 40: Test The Drive Brakes

    Section 3 • Scheduled Maintenance Procedures November 2014 CHECKLIST B PROCEDURES B-11 Test the Drive Brakes Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper brake action is essential to safe machine operation.

  • Page 41: Test The Drive Speed - Stowed Position

    November 2014 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES B-12 Test the Drive Speed - Stowed Position Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper drive functions are essential to safe machine operation.

  • Page 42: Test The Drive Speed - Raised Position

    Section 3 • Scheduled Maintenance Procedures November 2014 CHECKLIST B PROCEDURES B-13 Test the Drive Speed - Raised Position Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper drive functions are essential to safe machine operation.

  • Page 43: Test The Slow Drive Speed

    November 2014 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES B-14 Test the Slow Drive Speed Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper drive functions are essential to safe machine operation.

  • Page 44: Test The Motion Alarm (If Equipped)

    Section 3 • Scheduled Maintenance Procedures November 2014 CHECKLIST B PROCEDURES 6 Press and hold the low speed lift enable button. B-15 Test the Motion Alarm 7 Press the platform up button and raise the platform approximately 1 foot / 0.3 m. (if equipped) Result: The motion alarm should sound when Genie specifications require that this procedure be...

  • Page 45: Test The Flashing Beacons (If Equipped)

    November 2014 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES 17 Press and hold the low speed lift enable button. B-16 Test the Flashing Beacons 18 Press the platform down button and lower the platform to the stowed position. (if equipped) Result: The motion alarm should sound when Genie specifications require that this procedure be...

  • Page 46: Perform Hydraulic Oil Analysis

    Section 3 • Scheduled Maintenance Procedures November 2014 CHECKLIST B PROCEDURES B-17 B-18 Perform Hydraulic Oil Analysis Inspect the Breather Cap Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Genie specifications require that this procedure be A free-breathing hydraulic tank cap is essential for performed every 250 hours or quarterly, whichever good machine performance and service life.

  • Page 47: Inspect The Electrical Contactor

    November 2014 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES B-19 Inspect the Electrical Contactor Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first. Maintaining the electrical contactor in good condition is essential to safe machine operation. Failure to locate a worn or damaged contactor could result in an unsafe working condition and component damage.

  • Page 48: Checklist C Procedures

    Section 3 • Scheduled Maintenance Procedures November 2014 Checklist C Procedures Grease the Platform Overload Replace the Mechanism (if equipped) Hydraulic Tank Breather Cap - Models with Optional Hydraulic Oil Genie specifications require that this procedure be performed every 500 hours or 6 months, Genie specifications require that this procedure be whichever comes first.

  • Page 49: Test The Platform Overload System (If Equipped)

    November 2014 Section 3 • Scheduled Maintenance Procedures CHECKLIST C PROCEDURES 3 Using a suitable lifting device, place an appropriate test weight equal to the maximum Test the Platform Overload platform capacity in the center of the platform System (if equipped) floor.
  • Page 50 Section 3 • Scheduled Maintenance Procedures November 2014 CHECKLIST C PROCEDURES 4 Add an additional weight to the platform not to 9 Turn the key switch to ground control. exceed 20% of the maximum rated load. Refer Result: The LCD at the ground controls to the machine serial plate.

  • Page 51: Checklist D Procedures

    November 2014 Section 3 • Scheduled Maintenance Procedures Checklist D Procedures 2 Raise the platform until approximately 4 inches / 10 cm of each column is visible. Inspect the Mast Assembly 3 GR-12 and GR-15: Visually inspect the top of for Wear each column for clearance between the roller wheels and the adjacent column surface.

  • Page 52: Inspect And Lubricate The Lifting Chains

    Section 3 • Scheduled Maintenance Procedures November 2014 CHECKLIST D PROCEDURES 8 Inspect each idler wheel for the following: Inspect and Lubricate the • Excessive wear on the side flanges Lifting Chains • Unusual wear • Movement side to side in excess of 0.040 inch / 1 mm •...

  • Page 53: Replace The Hydraulic Tank Return Filter

    November 2014 Section 3 • Scheduled Maintenance Procedures CHECKLIST D PROCEDURES 4 Use a permanent ink marker to write the date and number of hours from the hour meter onto Replace the the filter. Hydraulic Tank Return Filter 5 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls.

  • Page 54: Checklist E Procedure

    Section 3 • Scheduled Maintenance Procedures November 2014 Checklist E Procedure 2 Open the power unit module tray. Test or Replace the Hydraulic Oil 3 Tag and disconnect the hydraulic tank return hard line from the hydraulic filter head and remove the hard line from the tank.
  • Page 55 November 2014 Section 3 • Scheduled Maintenance Procedures CHECKLIST E PROCEDURE 10 Install the hydraulic pump inlet hard line into the tank. Install the fitting onto the pump and torque to specification. Refer to Section 2, Specifications . 11 Install the hydraulic pump return hard line into the tank.
  • Page 56 Section 3 • Scheduled Maintenance Procedures November 2014 This page intentionally left blank. 3 - 36 GR • QSR • QSW Part No. T110280...
  • Page 57 November 2014 Section 4 • 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.

  • Page 58: Platform Controls

    Section 4 • Repair Procedures November 2014 Platform Controls The platform controls are used to operate the Operational Indicator Codes machine from the platform. These codes are generated by the electrical Activating a function button sends a signal to the system to indicate machine operating status.

  • Page 59: Circuit Board

    November 2014 Section 4 • Repair Procedures PLATFORM CONTROLS 9 Carefully remove the platform controls circuit board fasteners. Circuit Board 10 Carefully remove the platform controls circuit board from the platform control box. How to Remove the Platform 11 Remove the transparent caps from the platform Controls Circuit Board controls circuit board and save.

  • Page 60: Joystick

    Section 4 • Repair Procedures November 2014 PLATFORM CONTROLS Joystick Platform Controls Alarm How to Remove the Joystick How to Remove the Platform Controls Alarm 1 Push in the red Emergency Stop button to the off position at both the ground and platform 1 Push in the red Emergency Stop button to the controls.

  • Page 61: Platform Emergency Stop Button

    November 2014 Section 4 • Repair Procedures PLATFORM CONTROLS 6 Carefully remove the Emergency Stop base from the Emergency Stop button. Platform Emergency Stop Button 7 Carefully remove the retaining ring from the Emergency Stop button. How to Remove the Platform 8 Carefully remove the Emergency Stop button Controls Emergency Stop Button from the platform control box.

  • Page 62: Ground Controls

    Section 4 • Repair Procedures November 2014 Ground Controls The ground controls, used to operate the machine from the ground, can also be used to tune the performance of the machine. The ground controls consist of an Electronic Control Module (ECM), emergency stop button, key switch and circuit breaker.

  • Page 63: Software Revision Level

    November 2014 Section 4 • Repair Procedures GROUND CONTROLS 2 Press the ground controls scroll down button. Software Revision Level Result: The ground controls LCD display will indicate the software revision and hour meter information. After 5 seconds, the ground How to Determine the controls LCD display will display machine Software Revision Level...

  • Page 64: Machine Setup

    Section 4 • Repair Procedures November 2014 GROUND CONTROLS 1 Turn the key switch to the ground controls position and pull out the red Emergency Stop Machine Setup button to the on position at the platform controls. How to Setup the Machine from 2 Press and hold the ground controls scroll up Ground Controls and scroll down buttons.

  • Page 65: Level Sensor

    November 2014 Section 4 • Repair Procedures GROUND CONTROLS 3 Place the new level sensor onto the level sensor base with the "X" on the level sensor Level Sensor closest to the mast of the machine and the "Y" on the level sensor closest to the steer end of the machine.
  • Page 66 Section 4 • Repair Procedures November 2014 GROUND CONTROLS 4 Install the level sensor adjusting fasteners 7 Turn the key switch to ground control and pull through the level sensor and springs, and into out the red Emergency Stop button to the on the mount.
  • Page 67 November 2014 Section 4 • Repair Procedures GROUND CONTROLS 19 GR-12, GR-15, QS-12R, QS-15R, QS-12W 31 Raise the machine slightly. and QS-15W: Place a 0.79 x 6 x 6 inch / 2 x 15 32 Remove the blocks from under both wheels. x 15 cm thick steel block under both wheels at the tank side of the machine.

  • Page 68: Hydraulic Pump

    Section 4 • Repair Procedures November 2014 Hydraulic Pump 4 Activate the platform up function from the ground controls. Function Pump Result: If the pressure gauge reads 3200 psi / 221 bar, immediately stop. The The hydraulic pump is attached to the motor which pump is good.
  • Page 69 November 2014 Section 4 • Repair Procedures HYDRAULIC PUMP How to Remove the Hydraulic Pump Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation.

  • Page 70: Function Manifold

    Section 4 • Repair Procedures November 2014 Function Manifold Function Manifold Components The function manifold is mounted next to the hydraulic power unit. Index Schematic Description Item Function Torque — Coil nut (items E, F and H) ......................5 ft-lbs / 7 Nm Diagnostic nipple ........
  • Page 71 November 2014 Section 4 • Repair Procedures FUNCTION MANIFOLD Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic Note: 'alpha-numeric' callouts refer to corresponding notes on the electrical schematic Part No. T110280 GR • QSR • QSW 4 - 15...

  • Page 72: Valve Adjustments - Function Manifold

    Section 4 • Repair Procedures November 2014 FUNCTION MANIFOLD 3 Chock both sides of the wheels at the steer end of the machine. Valve Adjustments - 4 Remove the platform controls from the Function Manifold platform. Note: Perform this test from the ground with the How to Adjust the platform controls.
  • Page 73 November 2014 Section 4 • Repair Procedures FUNCTION MANIFOLD How to Adjust the 5 Turn the key switch to platform control and pull out the red Emergency Stop button to the on Platform Lift Relief Valve position at both the ground and platform controls.
  • Page 74 Section 4 • Repair Procedures November 2014 FUNCTION MANIFOLD 14 Hold the lift relief valve with a wrench and How to Adjust the Steer Relief remove the cap (hydraulic schematic item C). Valve 15 While activating the platform up function, adjust Note: Be sure that the hydraulic oil level is at the the internal hex socket clockwise, just until the mark on the hydraulic tank.
  • Page 75 November 2014 Section 4 • Repair Procedures FUNCTION MANIFOLD 4 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls. 5 Activate the function enable switch and press and hold the steer thumb rocker switch to the right.

  • Page 76: Valve Coils

    Section 4 • Repair Procedures November 2014 FUNCTION MANIFOLD Valve Coil Resistance Valve Coils Specification Note: The following coil resistance specifications How to Test a Coil are at an ambient temperature of 68°F / 20°C. As valve coil resistance is sensitive to changes in air A properly functioning coil provides an temperature, the coil resistance will typically electromagnetic force which operates the solenoid...
  • Page 77 November 2014 Section 4 • Repair Procedures FUNCTION MANIFOLD How to Test a Coil Diode Genie incorporates spike suppressing diodes in all of its coils. Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes. Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil.

  • Page 78: Brake Release Hand Pump Components

    Section 4 • Repair Procedures November 2014 Brake Release Hand Pump Components Brake Release Hand Pump Components The brake release hand pump manifold is mounted behind the hydraulic power unit. Index Schematic Description Item Function Torque Hand pump ........J ....Manual brake release ......30 ft-lbs / 41 Nm Needle valve, pilot operated .....

  • Page 79: Hydraulic Tank

    November 2014 Section 4 • Repair Procedures Hydraulic Tank 2 Tag, disconnect and plug the return hard line at the hydraulic filter. Cap the fitting on the filter. Hydraulic Tank Bodily injury hazard. Spraying hydraulic oil can penetrate and The primary functions of the hydraulic tank are to burn skin.

  • Page 80: Steer Axle Components

    Section 4 • Repair Procedures November 2014 Steer Axle Components 7 Tag, disconnect and plug the hydraulic hoses on the drive motor. Cap the fittings on the drive Yoke and Drive Motor motor. Bodily injury hazard. Spraying How to Remove the Yoke hydraulic oil can penetrate and and Drive Motor Assembly burn skin.
  • Page 81 November 2014 Section 4 • Repair Procedures STEER AXLE COMPONENTS How to Remove a Drive Motor 7 Tag, disconnect and plug the hydraulic hoses on the drive motor. Cap the fittings on the drive 1 Block the wheels at the non-steer end of the motor.

  • Page 82: Steer Cylinder

    Section 4 • Repair Procedures November 2014 STEER AXLE COMPONENTS Steer Cylinder Steer Bellcrank How to How to Remove the Steer Cylinder Remove the Steer Bellcrank Note: When removing a hose assembly or fitting, 1 Remove the steer cylinder. See 7-2, How to the O-ring on the fitting and/or hose end must be Remove the Steer Cylinder.

  • Page 83: Non-Steer Axle Components

    November 2014 Section 4 • Repair Procedures Non-steer Axle Components 7 Tag, disconnect and plug the hydraulic hose from the brake. Cap the fitting on the brake. Drive Brake Bodily injury hazard. Spraying hydraulic oil can penetrate and How to Remove a Drive Brake burn skin.

  • Page 84: Obstruction Sensing System

    Section 4 • Repair Procedures November 2014 Obstruction Sensing System How to Replace an Obstruction Obstruction Sensing Pads Sensing Pad (QSR models only) 1 GR-12: Raise the platform The function of the Obstruction Sensing System is approximately 3 feet / 1 m. to detect a person or an object standing on the GR-15 and GR-20: Raise the platform machine chassis.
  • Page 85 November 2014 Section 4 • Repair Procedures OBSTRUCTION SENSING PADS Hydraulic Tank Side Ground Controls Side 5 At the non-steer end of the machine, unlatch Non-steer End the covers and open the ground controls cover. 6 Working with the obstruction sensing pad to be replaced, locate the pad cables.

  • Page 86: Platform Components

    Section 4 • Repair Procedures November 2014 Platform Components 10-1 7 Remove the fasteners securing the junction box bracket to the mast. Set the bracket and Platform fasteners to the side. 3 Attach a lifting strap of suitable capacity from How to Remove the Platform an overhead crane and center it around the platform railing.

  • Page 87: Platform Extension

    November 2014 Section 4 • Repair Procedures PLATFORM COMPONENTS 10-2 5 Remove the fasteners securing the white slide blocks to the main deck. Set the slide blocks Platform Extension and the fasteners to the side. 6 Activate the foot release latch and slide the How to Remove the extension platform out of the platform.

  • Page 88: Work Tray

    Section 4 • Repair Procedures November 2014 PLATFORM COMPONENTS 10-3 Work Tray How to Remove the Work Tray (if equipped) 1 Turn the key switch to the off position. 2 Disconnect the battery pack from the machine. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury.

  • Page 89: Mast Components

    November 2014 Section 4 • Repair Procedures Mast Components 11-1 6 Remove the fasteners securing the lower rear access cover to the chassis and remove the Mast cover. Set the cover and the fasteners to the side. How to 7 Tag and disconnect the wire harness from the Remove the Mast Assembly platform down valve coil at the base of the lift cylinder.
  • Page 90 Section 4 • Repair Procedures November 2014 MAST COMPONENTS How to Disassemble the Mast 4 Remove the lift cylinder barrel end mounting fasteners. Bodily injury hazard. This procedure requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant...
  • Page 91 November 2014 Section 4 • Repair Procedures MAST COMPONENTS 7 Remove the cover from the top of each column. 15 Remove the adjustment nuts from the chain tension rocker on the column. 8 Remove the adjustment nuts from all of the sequencing cables.
  • Page 92 Section 4 • Repair Procedures November 2014 MAST COMPONENTS How to Assemble the Mast 10 Lay the number 3 column chains on the floor. Note: Do not allow the chains to become twisted Bodily injury hazard. This or dirty. procedure requires specific repair skills, lifting equipment and a 11 Lay the number 2 column chains inside the suitable workshop.

  • Page 93: Glide Pads

    November 2014 Section 4 • Repair Procedures MAST COMPONENTS 11-2 11-3 Glide Pads Lifting Chains Glide pads, used on the GR-12, GR-15, QS-12R, How to Adjust the Lifting Chains QS-15R, QS-12W and QS-15W, and wear pads 1 Mark the column to be adjusted. used on the GR-20, QS-20R and QS-20W, are used to provide a uniform fit between the columns 2 Raise the platform approximately 6 feet / 2 m.
  • Page 94 Section 4 • Repair Procedures November 2014 MAST COMPONENTS How to Inspect the Lifting Chains Inspection Procedure Inspection Failure Inspection Remedy Count out 16 chain links When the length of the Replace both chains Wear and measure pin to pin 16 links (pin to pin) on that column.
  • Page 95 November 2014 Section 4 • Repair Procedures MAST COMPONENTS Inspection Procedure Inspection Remedy Inspection Failure Replace both chains on Raised or Turned Pins Visually inspect for raised Raised pins. pins. that column section. Do not repair just the affected portion of the chain.

  • Page 96: Lift Cylinder

    Section 4 • Repair Procedures November 2014 MAST COMPONENTS 11-4 Lift Cylinder The lift cylinder is equipped with a normally closed solenoid valve to prevent movement in the event of a hydraulic line failure. How to Remove the Lift Cylinder Bodily injury hazard.

  • Page 97: Platform Overload Components

    November 2014 Section 4 • Repair Procedures Platform Overload Components 12-1 GR-12 and GR-15 Platform Overload System Standard Platform 500 lbs 227 kg Calibrate the Platform Overload GR-20 System (if equipped) Standard Platform 350 lbs Note: Perform this procedure with the machine on 159 kg a firm, level surface.
  • Page 98 Section 4 • Repair Procedures November 2014 PLATFORM OVERLOAD COMPONENTS Determine the limit switch trigger point: Confirm the setting: 6 Gently move the platform up and down by 10 Turn the key switch to platform control. hand, so it bounces 1 to 2 inches / 2.5 to 5 cm. 11 Lift the test weight off the platform floor using a 7 Check the continuity between the red and white suitable lifting device.

  • Page 99: Platform Overload Recovery Message

    November 2014 Section 4 • Repair Procedures PLATFORM OVERLOAD COMPONENTS 13 Add an additional weight to the platform not to 12-2 exceed 20% of the maximum rated load. Refer Platform Overload Recovery to the machine serial plate. Message Result: The LCD display at the ground controls will show "OL: Platform Overloaded"...
  • Page 100 Section 4 • Repair Procedures November 2014 PLATFORM OVERLOAD COMPONENTS 3 Pull out the red Emergency Stop button at the 7 Press and hold the scroll down button for 5 ground controls. seconds. Result: The ground control LCD display will Result: The ground control LCD display will show the following.
  • Page 101 November 2014 Section 5 • Diagnostics Diagnostics Before Troubleshooting: Read, understand and obey the safety rules and operating instructions in the appropriate operator's manual on your machine. Be sure that all necessary tools and test equipment are available and ready for use. Observe and Obey: Be aware of the following hazards and follow generally accepted safe workshop practices.
  • Page 102 Section 5 • Diagnostics November 2014 DIAGNOSTICS About This Section Definitions When a malfunction is discovered, the diagnostic GSDS - acronym for Genie SmartLink trouble code chart in this section will help a service Diagnostic System professional pinpoint the cause of the problem. To ECM - acronym for Electronic Control Module use this section, basic hand tools and certain pieces of test equipment are required—voltmeter,...
  • Page 103 November 2014 Section 5 • Diagnostics DIAGNOSTICS GCON LCD Diagnostic Readout Genie SmartLink Diagnostic System This machine is equipped with the Genie SmartLink Diagnostic System (GSDS). The GSDS indicates a machine malfunction has happened by displaying Operational Indicator The diagnostic readout displays alpha numeric Codes (OIC) and Diagnostic Trouble Codes codes that provide information about the (DTC).

  • Page 104: Gcon I/O Map Without Load Sense

    Section 5 • Diagnostics November 2014 DIAGNOSTICS GCON I/O MAP without LOAD SENSE Ground Wire Gauge I/O Type Controls Circuit Function and Color Pin Number J1 Connector - Gray J1-01 ECM Power Power Input 14 RD J1-02 PCON — E-Stop Power Power Output 18 RD J1-03...

  • Page 105: Gcon I/O Map With Load Sense

    November 2014 Section 5 • Diagnostics DIAGNOSTICS GCON I/O MAP with LOAD SENSE Ground Wire Gauge Controls Circuit Function I/O Type and Color Pin Number J1 Connector - Gray J1-01 ECM Power Power Input 14 RD J1-02 PCON — E-Stop Power Power Output 18 RD J1-03...

  • Page 106: Operational Indicator Codes

    Section 5 • Diagnostics November 2014 DIAGNOSTICS Operational Indicator Codes Diagnostic Trouble Codes (DTC) (OIC) These codes are generated by the system to indicate that a device or circuit malfunction has These codes are generated by the electrical been detected in the electrical system. system to indicate machine operating status The types of Diagnostic Trouble Codes that may such as Off-level, Overload Cutout, Chassis...

  • Page 107: Troubleshooting "Hxxx" And "Pxxx" Faults

    November 2014 Section 5 • Diagnostics DIAGNOSTICS Troubleshooting "HXXX" and "PXXX" Faults The procedure below illustrates typical steps for diagnosing and fixing faults of type "HXXX and PXXX". Diagnostic Chart No Good Check the fault device for a short or open circuit. Replace fauled device.

  • Page 108: Fault Inspection Procedure

    Section 5 • Diagnostics November 2014 DIAGNOSTICS Fault Inspection Procedure 5 - 8 GR • QSR • QSW Part No. T110280...
  • Page 109 November 2014 Section 5 • Diagnostics DIAGNOSTICS Part No. T110280 GR • QSR • QSW 5 - 9...

  • Page 110: Type "Hxxx" Faults

    Section 5 • Diagnostics November 2014 Type "HXXX" Faults Message on Problem Possible Failure Number GCON LCD Description Causes Mode • Short circuit in platform up #1 harness. H001:COILFAULT Short circuit of the platform up Platform up • Platform up #1 coil short circuit. H001 PLAT UP1:Bat- #1 circuit to battery negative.

  • Page 111: Type "Pxxx" Faults

    November 2014 Section 5 • Diagnostics Type "PXXX" Faults Message on Problem Possible Failure Number GCON LCD Description Causes Mode • Short circuit in switched power #1, down limit Short circuit of the switched P001:PWR FAULT All functions switch, pothole limit switch, digital tilt switch P001 power #1 circuit to battery SW PWR1:Bat-...

  • Page 112: Type "Uxxx" Faults

    Section 5 • Diagnostics November 2014 Type "UXXX" Faults Message on Problem Possible Failure Number GCON LCD Description Causes Mode Short circuit of the GCON main • Short circuit of the GCON main function U001:SWITCHFAULT All GCON functions function enable switch at enable switch.

  • Page 113: Type "Fxxx" Faults

    November 2014 Section 5 • Diagnostics Type "FXXX" Faults Message on Problem Possible Failure Number GCON LCD Description Causes Mode • Short circuit of the down limit switch circuit. All functions F003:SWITCHFAULT Short circuit of the down limit F003 • Down limit #1 switch short circuit. inhibited except DOWN LIMIT1:Bat+ #1 switch at system start up.

  • Page 114: Type "Cxxx" Faults

    Section 5 • Diagnostics November 2014 Type "CXXX" Faults Message on Problem Possible Failure Number GCON LCD Description Causes Mode C001:GCON ECM • Incorrect software file. All functions GCON ECM CRC check error. C001 FAULT TYPE 1 • GCON ECM internal failure. inhibited.
  • Page 115 November 2014 Section 6 • Schematics Schematics About This Section There are two groups of schematics in this section. An illustration legend precedes each group of drawings. Electrical Schematics Observe and Obey: Electrocution/burn hazard. Contact with electrically charged circuits Troubleshooting and repair procedures shall be could result in death or serious completed by a person trained and qualified on injury.

  • Page 116: Electrical Component And Wire Color Legends

    Section 6 • Schematics November 2014 Electrical Component and Wire Color Legends ELECTRICAL COMPONENT LEGEND ELECTRICAL COMPONENT LEGEND cont. Item Description Item Description Battery Resistor Circuit breaker, 7A R27 = Resistor 25 Ohm, 25W (QS retail) R30 = Resistor, 200 Ohm, 10W CON1 Contactor, Motor controller power, NOHC Diode...
  • Page 117 November 2014 Section 6 • Schematics Wiring Diagram Ground and Platform Controls Part No. T110280 GR • QSR • QSW 6 - 3...

  • Page 118: Electrical Symbols Legend

    Section 6 • Schematics November 2014 Electrical Symbols Legend Limit switch Key switch Motor controller Emergency Stop button Wire with description or color Motor Solenoid valve with diode Circuit breaker Circuits crossing no connection Fuse Level sensor Battery charger Diode Horn or alarm 6V DC battery Pressure switch...

  • Page 119: Electrical Schematic - Gr And Qsw - Ansi And Csa Models

    Section 6 • Schematics November 2014 Electrical Schematic GR and QSW • ANSI and CSA Models (from serial number GR10-20000 to GR11-20683 and serial number QS11-1000 to QS11-1015) 6 - 5...
  • Page 120 Section 6 • Schematics November 2014 Electrical Schematic GR and QSW • ANSI and CSA Models (from serial number GR10-20000 to GR11-20683 and serial number QS11-1000 to QS11-1015) 6 - 6 GR • QSR • QSW Part No. T110280...
  • Page 121 November 2014 Section 6 • Schematics Electrical Schematic GR and QSW • ANSI and CSA Models (from serial number GR10-20000 to GR11-20683 and serial number QS11-1000 to QS11-1015) Part No. T110280 GR • QSR • QSW 6 - 7...

  • Page 122: Electrical Schematic - Gr And Qsw - Ansi And Csa Models

    November 2014 Section 6 • Schematics Electrical Schematic GR and QSW • ANSI and CSA Models (from serial number GR10-20000 to GR11-2068 and serial number QS11-1000 to QS11-1015) 6 - 7 6 - 8...
  • Page 123 Section 6 • Schematics November 2014 Electrical Schematic GR and QSW • ANSI and CSA Models (from serial number GR11-20684 and serial number QS11-1016) 6 - 9 6 - 10...
  • Page 124 Section 6 • Schematics November 2014 Electrical Schematic GR and QSW • ANSI and CSA Models (from serial number GR11-20684 and serial number QS11-1016) 6 - 10 GR • QSR • QSW Part No. T110280...
  • Page 125 November 2014 Section 6 • Schematics Electrical Schematic GR and QSW • ANSI and CSA Models (from serial number GR11-20684 and serial number QS11-1016) Part No. T110280 GR • QSR • QSW 6 - 11...
  • Page 126 November 2014 Section 6 • Schematics Electrical Schematic GR and QSW • ANSI and CSA Models (from serial number GR11-20684 and serial number QS11-1016) 6 - 11 6 - 12...
  • Page 127 Section 6 • Schematics November 2014 Electrical Schematic • ANSI and CSA Models (from serial number QS11-1000 to QS11-1015) 6 - 13 6 - 14...

  • Page 128: Electrical Schematic - Qsr - Ansi And Csa Models

    Section 6 • Schematics November 2014 Electrical Schematic • ANSI and CSA Models (from serial number QS11-1000 to QS11-1015) 6 - 14 GR • QSR • QSW Part No. T110280...
  • Page 129 November 2014 Section 6 • Schematics Electrical Schematic • ANSI and CSA Models (from serial number QS11-1000 to QS11-1015) Part No. T110280 GR • QSR • QSW 6 - 15...

  • Page 130: Electrical Schematic - Qsr - Ansi And Csa Models

    November 2014 Section 6 • Schematics Electrical Schematic • ANSI and CSA Models (from serial number QS11-1000 to QS11-1015) 6 - 15 6 - 16...
  • Page 131 Section 6 • Schematics November 2014 Electrical Schematic • ANSI and CSA Models (from serial number QS11-1016) 6 - 17 6 - 18...
  • Page 132 Section 6 • Schematics November 2014 Electrical Schematic • ANSI and CSA Models (from serial number QS11-1016) 6 - 18 GR • QSR • QSW Part No. T110280...
  • Page 133 November 2014 Section 6 • Schematics Electrical Schematic • ANSI and CSA Models (from serial number QS11-1016) Part No. T110280 GR • QSR • QSW 6 - 19...
  • Page 134 November 2014 Section 6 • Schematics Electrical Schematic • ANSI and CSA Models (from serial number QS11-1016) 6 - 19 6 - 20...

  • Page 135: Electrical Schematic - Gr And Qsw - Ce And Aus Models

    Section 6 • Schematics November 2014 Electrical Schematic GR and QSW • CE and AUS Models (from serial number GR10-20000 to GR11-20683 and serial number QS11-1000 to QS11-1015) 6 - 21 6 - 22...
  • Page 136 Section 6 • Schematics November 2014 Electrical Schematic GR and QSW • CE and AUS Models (from serial number GR10-20000 to GR11-20683 and serial number QS11-1000 to QS11-1015) 6 - 22 GR • QSR • QSW Part No. T110280...
  • Page 137 November 2014 Section 6 • Schematics Electrical Schematic GR and QSW • CE and AUS Models (from serial number GR10-20000 to GR11-20683 and serial number QS11-1000 to QS11-1015) Part No. T110280 GR • QSR • QSW 6 - 23...

  • Page 138: Electrical Schematic - Gr And Qsw - Ce And Aus Models

    November 2014 Section 6 • Schematics Electrical Schematic GR and QSW • CE and AUS Models (from serial number GR10-20000 to GR11-20683 and serial number QS11-1000 to QS11-1015) 6 - 23 6 - 24...
  • Page 139 Section 6 • Schematics November 2014 Electrical Schematic GR and QSW • CE and AUS Models (from serial number GR11-20684 and serial number QS11-1016) 6 - 25 6 - 26...
  • Page 140 Section 6 • Schematics November 2014 Electrical Schematic GR and QSW • CE and AUS Models (from serial number GR11-20684 and serial number QS11-1016) 6 - 26 GR • QSR • QSW Part No. T110280...
  • Page 141 November 2014 Section 6 • Schematics Electrical Schematic GR and QSW • CE and AUS Models (from serial number GR11-20684 and serial number QS11-1016) Part No. T110280 GR • QSR • QSW 6 - 27...
  • Page 142 November 2014 Section 6 • Schematics Electrical Schematic GR and QSW • CE and AUS Models (from serial number GR11-20684 and serial number QS11-1016) 6 - 27 6 - 28...
  • Page 143 Section 6 • Schematics November 2014 Electrical Schematic • CE and AUS Models (from serial number QS11-1000 to QS11-1015) 6 - 29 6 - 30...
  • Page 144 Section 6 • Schematics November 2014 Electrical Schematic • CE and AUS Models (from serial number QS11-1000 to QS11-1015) 6 - 30 GR • QSR • QSW Part No. T110280...
  • Page 145 November 2014 Section 6 • Schematics Electrical Schematic • CE and AUS Models (from serial number QS11-1000 to QS11-1015) Part No. T110280 GR • QSR • QSW 6 - 31...
  • Page 146 November 2014 Section 6 • Schematics Electrical Schematic • CE and AUS Models (from serial number QS11-1000 to QS11-1015) 6 - 31 6 - 32...
  • Page 147 Section 6 • Schematics November 2014 Electrical Schematic • CE and AUS Models (from serial number QS11-1016) 6 - 33 6 - 34...
  • Page 148 Section 6 • Schematics November 2014 Electrical Schematic • CE and AUS Models (from serial number QS11-1016) 6 - 34 GR • QSR • QSW Part No. T110280...
  • Page 149 November 2014 Section 6 • Schematics Electrical Schematic • CE and AUS Models (from serial number QS11-1016) Part No. T110280 GR • QSR • QSW 6 - 35...
  • Page 150 November 2014 Section 6 • Schematics Electrical Schematic • CE and AUS Models (from serial number QS11-1016) 6 - 35 6 - 36...

  • Page 151: Hydraulic Component Reference And Symbols Legend

    November 2014 Section 6 • Schematics Hydraulic Component Reference and Symbols Legend Orifice Check valve Brake Variable speed motor Solenoid operated Fixed displacement pump Hydraulic cylinder 3 position 4 way directional valve Solenoid operated 2 position 4 way directional valve Bi-directional motor Solenoid operated 3 position 4 way...

  • Page 152: Hydraulic Schematic

    Section 6 • Schematics November 2014 Hydraulic Schematic (to GR12-24138 and QS12-1063) 6 - 38 GR • QSR • QSW Part No. T110280...
  • Page 153 November 2014 Section 6 • Schematics HYDRAULIC SCHEMATIC (from GR12-24139 and QS12-1064) Part No. T110280 GR • QSR • QSW 6 - 39...

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