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

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 GR05-5001
from GR05-5001
from GR05-5001
from QS09-101
from QS09-101
from QS09-101
from QS09-101
from QS09-101
from QS09-101
Part No. 84700
Rev C1
January 2011

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Summary of Contents for Terex Genie GR -12

  • Page 1 Service Manual Serial Number Range GR -12 from GR05-5001 GR -15 from GR05-5001 GR -20 from GR05-5001 QS-12R from QS09-101 QS-15R from QS09-101 QS-20R from QS09-101 QS-12W from QS09-101 QS-15W from QS09-101 QS-20W Part No. 84700 from QS09-101 Rev C1 January 2011...

  • Page 2: Introduction

    Copyright © 2001 by Genie Industries www.genieindustries.com 84700 Rev C September 2009 e-mail: techpub@terex.com Second Edition, Third Printing "Genie" is a registered trademark of Genie Industries in the USA and many other countries. "GR" is a trademark of Genie Industries.

  • Page 3: Serial Number Legend

    September 2009 INTRODUCTION Serial Number Legend MANUFACTURED BY/FABRIQUE PAR: Genie Industries 18340 NE 76th Street Redmond, WA 98052 USA Model: GR-15 Serial number: GR05-1234 Manufacture date: 4/14/08 Model year: 2008 Elec/Hydr Schematic: ES0126/HS0039 Power supply voltage/Pneumatic Pressure: 85-264 VAC, 60/50 Hz, 900 W Nominal Power: 8.3 Hp / 6.2 kW Machine unladen weight: 2,250 lbs / 1,021 kg Max Load: 500 lbs / 227 kg...
  • Page 4 September 2009 This page intentionally left blank. GR • QSR • QSW Part No. 84700...

  • Page 5: Safety Rules

    September 2009 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 6 September 2009 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 7: Table Of Contents

    September 2009 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 8 September 2009 TABLE OF CONTENTS Section 3 Scheduled Maintenance Procedures, continued Checklist B Procedures B-1 Inspect the Batteries ................. 3 - 10 B-2 Inspect the Electrical Wiring ............. 3 - 12 B-3 Inspect the Tires and Wheels (including castle nut torque) ....3 - 13 B-4 Check the Lifting Chain Adjustments ..........
  • Page 9 September 2009 TABLE OF CONTENTS Section 4 Repair Procedures Introduction ....................4 - 1 Platform Controls Circuit Boards ..................4 - 2 Controller Adjustments ............... 4 - 3 Software Configuration ............... 4 - 8 Platform Components Platform ................... 4 - 12 Platform Extension ................
  • Page 10 September 2009 TABLE OF CONTENTS Section 4 Repair Procedures, continued Non-steer Axle Components Drive Brake ..................4 - 40 Brake Release Hand Pump Components 10-1 Brake Release Hand Pump Components ......... 4 - 41 Platform Overload Components 11-1 Platform Overload System ............... 4 - 42 Obstruction Sensing System 11-1 Obstruction Sensing Pads (QSR models only) .........

  • Page 11: D Machine Specifications

    September 2009 Section 2 • Specifications Specifications REV D Machine Specifications Tires and wheels Tire size (solid rubber) 10 x 3 in Batteries, Standard 25.4 x 2.5 cm Voltage 6V DC Tire contact area 6.5 sq in 41.9 cm Group Castle nut torque, lubricated 150 ft-lbs Type...

  • Page 12: Performance Specifications

    Section 2 • Specifications September 2009 SPECIFICATIONS REV D 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...

  • Page 13: Hydraulic Specifications

    September 2009 Section 2 • Specifications REV D 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 14: Manifold Component Specifications

    Section 2 • Specifications September 2009 SPECIFICATIONS REV D 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 15: Hydraulic Hose And Fitting Torque Specifications

    September 2009 Section 2 • Specifications REV D SPECIFICATIONS Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with JIC 37° flared fittings and hose ends. Genie specifications require that fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed.
  • Page 16 Section 2 • Specifications September 2009 SPECIFICATIONS REV D Torque Procedure 3 Working clockwise on the body hex fitting, make a second mark with a permanent ink marker to JIC 37° fittings indicate the proper tightening position. Refer to Figure 2. 1 Align the tube flare (hex nut) against the nose of Use the JIC 37°...
  • Page 17 September 2009 Section 2 • Specifications REV D 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...
  • Page 18 Section 2 • Specifications September 2009 This page intentionally left blank. 2 - 8 GR • QSR • QSW Part No. 84700...

  • Page 19: Observe And Obey

    September 2008 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 20: Pre-Delivery Preparation Report

    Section 3 • Scheduled Maintenance Procedures September 2009 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 21 Pre-Deliver Pre-Deliver Pre-Deliver y Preparation y Preparation y Preparation y Preparation Pre-Deliver Pre-Deliver y Preparation September 2008 Section 3 • Scheduled Maintenance Procedures Fundamentals Instructions It is the responsibility of the dealer to perform the Use the operator’s manual on your machine. Pre-delivery Preparation.
  • Page 22 Section 3 • Scheduled Maintenance Procedures September 2009 This page intentionally left blank. 3 - 4 GR • QSR • QSW Part No. 84700...

  • Page 23: Maintenance Inspection Report

    September 2009 Section 3 • Scheduled Maintenance Procedures Maintenance Inspection Report Model Checklist A - Rev D Y N R Checklist B - Rev D 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...

  • Page 24: Checklist A Procedures

    Section 3 • Scheduled Maintenance Procedures September 2009 Checklist A Procedures REV D 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...

  • Page 25: Perform Pre-Operation Inspection

    September 2009 Section 3 • Scheduled Maintenance Procedures REV D 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 26: Test The Obstruction Sensing System (Qsr Models Only)

    Section 3 • Scheduled Maintenance Procedures September 2009 REV D Hydraulic Tank Ground Controls Side Side Test the Obstruction Sensing System (QSR models only) Place the15 lb / 6.8 kg weight 2 inches / 5.08 cm from the edge of the obstruction pad. Non-steer End Genie specifications require that this procedure be performed every 8 hours or daily, whichever...

  • Page 27: Perform 30 Day Service

    September 2009 Section 3 • Scheduled Maintenance Procedures REV D 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 or performed every 100 hours of operation.

  • Page 28: Checklist B Procedures

    Section 3 • Scheduled Maintenance Procedures September 2009 Checklist B Procedures REV D 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 275A Fuse...
  • Page 29 September 2009 Section 3 • Scheduled Maintenance Procedures REV D CHECKLIST B PROCEDURES 11 Check the ambient air temperature and adjust All models: the specific gravity reading for each cell as 17 Check each battery pack and verify that the follows: batteries are wired correctly.

  • Page 30: Inspect The Electrical Wiring

    Section 3 • Scheduled Maintenance Procedures September 2009 CHECKLIST B PROCEDURES REV D 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...

  • Page 31: Inspect The Tires And Wheels (Including Castle Nut Torque)

    September 2009 Section 3 • Scheduled Maintenance Procedures REV D 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 32: Clean And Lubricate The Columns

    Section 3 • Scheduled Maintenance Procedures September 2009 CHECKLIST B PROCEDURES REV D 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 33: Test The Emergency Stop

    September 2009 Section 3 • Scheduled Maintenance Procedures REV D 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...

  • Page 34: Test The Key Switch

    Section 3 • Scheduled Maintenance Procedures September 2009 CHECKLIST B PROCEDURES REV D 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 35: Inspect The Voltage Inverter (If Equipped)

    September 2009 Section 3 • Scheduled Maintenance Procedures REV D CHECKLIST B PROCEDURES 3 Connect an appropriate power tool to the B-10 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 Genie specifications require that this procedure be tool has not been used in the previous 10 performed every 250 hours or quarterly, whichever...

  • Page 36: Test The Drive Brakes

    Section 3 • Scheduled Maintenance Procedures September 2009 CHECKLIST B PROCEDURES REV D 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 37: Test The Drive Speed - Stowed Position

    September 2009 Section 3 • Scheduled Maintenance Procedures REV D 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 38: Test The Drive Speed - Raised Position

    Section 3 • Scheduled Maintenance Procedures September 2009 CHECKLIST B PROCEDURES REV D 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 39: Test The Slow Drive Speed

    September 2009 Section 3 • Scheduled Maintenance Procedures REV D 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 40: Test The Motion Alarm (If Equipped)

    Section 3 • Scheduled Maintenance Procedures September 2009 CHECKLIST B PROCEDURES REV D 4 Turn the key switch to platform controls. B-15 Test the Motion Alarm 5 Press the lift function select button. (if equipped) 6 Press and hold the function enable switch on the joystick.

  • Page 41: Test The Flashing Beacons (If Equipped)

    September 2009 Section 3 • Scheduled Maintenance Procedures REV D CHECKLIST B PROCEDURES B-16 B-17 Test the Flashing Beacons Perform Hydraulic Oil Analysis (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 42: Inspect The Breather Cap

    Section 3 • Scheduled Maintenance Procedures September 2009 CHECKLIST B PROCEDURES REV D B-18 Inspect the Breather Cap Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. A free-breathing hydraulic tank cap is essential for good machine performance and service life.

  • Page 43: Checklist C Procedures

    September 2009 Section 3 • Scheduled Maintenance Procedures Checklist C Procedures REV D 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, whichever Genie specifications require that this procedure be comes first.

  • Page 44: Test The Platform Overload System (If Equipped)

    Section 3 • Scheduled Maintenance Procedures September 2009 CHECKLIST C PROCEDURES REV D 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 45 September 2009 Section 3 • Scheduled Maintenance Procedures REV D CHECKLIST C PROCEDURES 6 Turn the key switch to ground control. 7 Test all machine functions from the ground controls. Result: All ground control functions should not operate. 8 Lift the test weight off the platform floor using a suitable lifting device.

  • Page 46: Checklist D Procedures

    Section 3 • Scheduled Maintenance Procedures September 2009 Checklist D Procedures REV D 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 47: Inspect And Lubricate The Lifting Chains

    September 2009 Section 3 • Scheduled Maintenance Procedures REV D 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 48: Replace The Hydraulic Tank Return Filter

    Section 3 • Scheduled Maintenance Procedures September 2009 CHECKLIST D PROCEDURES REV D 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...

  • Page 49: Checklist E Procedure

    September 2009 Section 3 • Scheduled Maintenance Procedures Checklist E Procedure REV B 3 Tag and disconnect the hydraulic tank return hard line from the hydraulic filter head and Test or Replace the Hydraulic Oil remove the hard line from the tank. Cap the fitting on the filter head.
  • Page 50 Section 3 • Scheduled Maintenance Procedures September 2009 CHECKLIST E PROCEDURE REV B 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 51 September 2009 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 52: Platform Controls

    Section 4 • Repair Procedures September 2009 Platform Controls REV E The platform controls, used to operate the machine from the platform or while standing on the ground, Circuit Boards can also be used to tune the performance of the machine.

  • Page 53: Controller Adjustments

    September 2009 Section 4 • Repair Procedures REV E PLATFORM CONTROLS How to Determine the Controller Adjustments Software Revision Level 1 Remove the platform controls from the platform. Platform lift speed, stowed drive speed, raised drive speed and slow drive speed are adjustable to 2 Place the platform controls close to the compensate for wear in the hydraulic pump and diagnostic display on the power unit side of the...
  • Page 54 Section 4 • Repair Procedures September 2009 PLATFORM CONTROLS REV E How to Adjust the Lift Speed Tip-over hazard. Do not adjust the lift and/or drive speed higher than specified in this procedure. Setting the function speeds greater than specifications could cause the machine to tip over resulting in death or serious injury.
  • Page 55 September 2009 Section 4 • Repair Procedures REV E PLATFORM CONTROLS How to Adjust the Stowed Drive Speed Tip-over hazard. Do not adjust the lift and/or drive speed higher than specified in this procedure. Setting the function speeds greater than specifications could cause the machine to tip over resulting in death or serious injury.
  • Page 56 Section 4 • Repair Procedures September 2009 PLATFORM CONTROLS REV E How to Adjust the Raised Drive Speed Tip-over hazard. Do not adjust the lift and/or drive speed higher than specified in this procedure. Setting the function speeds greater than specifications could cause the machine to tip over resulting in death or serious injury.
  • Page 57 September 2009 Section 4 • Repair Procedures REV E PLATFORM CONTROLS How to Adjust the Slow Drive Speed Tip-over hazard. Do not adjust the lift and/or drive speed higher than specified in this procedure. Setting the function speeds greater than specifications could cause the machine to tip over resulting in death or serious injury.

  • Page 58: Software Configuration

    Section 4 • Repair Procedures September 2009 PLATFORM CONTROLS REV E Software Configuration The Electronic Control Module (ECM) contains programming for all configurations of the Genie Runabout. The machine can be adjusted to a different configuration using the buttons at the platform controls.
  • Page 59 September 2009 Section 4 • Repair Procedures REV E PLATFORM CONTROLS How to Change the Software Configuration 1 Pull out the red Emergency Stop button to the on position at the ground controls. 2 Push in the red Emergency Stop button to the off position at the platform controls.
  • Page 60 Section 4 • Repair Procedures September 2009 PLATFORM CONTROLS REV E Machine Configuration Code Machine Configuration Code Chart (from serial number Chart (after serial number GR05-5001 to GR07-8706) GR07-8705 and from QS09-101) A mark in the four right columns indicates that the A mark in the four right columns indicates that the machine configuration, at left, includes this feature.
  • Page 61 September 2009 Section 4 • Repair Procedures REV E PLATFORM CONTROLS How to Activate the How to Battery Drain Alarm Option Determine the Battery Voltage 1 Pull out the red Emergency Stop button to the The diagnostic display on the platform controls is on position at the ground controls.

  • Page 62: Platform Components

    Section 4 • Repair Procedures September 2009 Platform Components REV C Platform Platform Extension How to Remove the Platform How to Remove the Platform Extension 1 Raise the platform approximately 1 foot / 30 cm. 1 Turn the key switch to the off position. 2 Place support blocks between the platform and the drive chassis.

  • Page 63: Work Tray

    September 2009 Section 4 • Repair Procedures REV C PLATFORM COMPONENTS 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 64: Mast Components

    Section 4 • Repair Procedures September 2009 Mast Components REV B 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...
  • Page 65 September 2009 Section 4 • Repair Procedures REV B 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 66 Section 4 • Repair Procedures September 2009 MAST COMPONENTS REV B 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 67 September 2009 Section 4 • Repair Procedures REV B 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 or Bodily injury hazard. This dirty.

  • Page 68: Glide Pads

    Section 4 • Repair Procedures September 2009 MAST COMPONENTS REV B 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 69 September 2009 Section 4 • Repair Procedures REV B MAST COMPONENTS How to Inspect the Lifting Chains Inspection Procedure Inspection Failure Inspection Remedy Count out 16 chain links When the length of the Wear Replace both chains and measure pin to pin 16 links (pin to pin) on that column.
  • Page 70 Section 4 • Repair Procedures September 2009 MAST COMPONENTS REV B Inspection Procedure Inspection Remedy Inspection Failure Visually inspect for raised Raised pins. Replace both chains on Raised or Turned Pins pins. that column section. Do not repair just the affected portion of the chain.

  • Page 71: Lift Cylinder

    September 2009 Section 4 • Repair Procedures REV B MAST COMPONENTS 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 72: Ground Controls

    Section 4 • Repair Procedures September 2009 Ground Controls REV B 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 Electronic Control Module (ECM) is the machine.
  • Page 73 September 2009 Section 4 • Repair Procedures REV B 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 74 Section 4 • Repair Procedures September 2009 GROUND CONTROLS REV B 18 Raise the machine approximately 29 Lower the machine onto the blocks. 2 inches / 5 cm. 30 Raise the platform approximately 1 foot / 30 cm. 19 GR-12, GR-15, QS-12R, QS-15R, QS-12W and Result: The level sensor alarm should not QS-15W: Place a 0.79 x 6 x 6 inch / 2 x 15 x 15 sound.

  • Page 75: Hydraulic Pump

    September 2009 Section 4 • Repair Procedures Hydraulic Pump REV A 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 pump The hydraulic pump is attached to the motor which is good.
  • Page 76 Section 4 • Repair Procedures September 2009 HYDRAULIC PUMP REV A 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 77 September 2009 Section 4 • Repair Procedures This page intentionally left blank. Part No. 84700 GR • QSR • QSW 4 - 27...

  • Page 78: Function Manifold

    Section 4 • Repair Procedures September 2009 Function Manifold REV B 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 79 September 2009 Section 4 • Repair Procedures REV B 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. 84700 GR • QSR • QSW 4 - 29...

  • Page 80: Valve Adjustments - Function Manifold

    Section 4 • Repair Procedures September 2009 FUNCTION MANIFOLD REV B 3 Chock both sides of the wheels at the steer end of the machine. Valve Adjustments - 4 Remove the platform controls from the platform. Function Manifold Note: Perform this test from the ground with the platform controls.
  • Page 81 September 2009 Section 4 • Repair Procedures REV B 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 82 Section 4 • Repair Procedures September 2009 FUNCTION MANIFOLD REV B 14 Hold the lift relief valve with a wrench and How to Adjust the Steer Relief remove the cap (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 83 September 2009 Section 4 • Repair Procedures REV B 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 84: Valve Coils

    Section 4 • Repair Procedures September 2009 FUNCTION MANIFOLD REV B 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 85 September 2009 Section 4 • Repair Procedures REV B FUNCTION MANIFOLD How to Test a Coil Diode Genie incorporates spike suppressing diodes in all COIL of its coils. Properly functioning coil diodes protect MULTI METER 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 86: Hydraulic Tank

    Section 4 • Repair Procedures September 2009 Hydraulic Tank REV A 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 87: Steer Axle Components

    September 2009 Section 4 • Repair Procedures Steer Axle Components REV A 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 88 Section 4 • Repair Procedures September 2009 STEER AXLE COMPONENTS REV A 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 89: Steer Cylinder

    September 2009 Section 4 • Repair Procedures REV A STEER AXLE COMPONENTS Steer Cylinder Steer Bellcrank How to How to Remove the Steer Cylinder Remove the Steer Bellcrank 1 Remove the steer cylinder. See 8-2, How to Note: When removing a hose assembly or fitting, Remove the Steer Cylinder.

  • Page 90: Non-Steer Axle Components

    Section 4 • Repair Procedures September 2009 Non-steer Axle Components REV A 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 91: Brake Release Hand Pump Components

    September 2009 Section 4 • Repair Procedures Brake Release Hand Pump Components REV A 10-1 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 92: Platform Overload Components

    Section 4 • Repair Procedures September 2009 Platform Overload Components REV B 11-1 Determine the limit switch trigger point: Platform Overload System 6 Gently move the platform up and down by hand, so it bounces 1 to 2 inches / 2.5 to 5 cm. Calibrate the Platform Overload 7 Check the continuity between the black and red System (if equipped)
  • Page 93 September 2009 Section 4 • Repair Procedures REV B PLATFORM OVERLOAD COMPONENTS Confirm the setting: 14 Test all machine functions from the platform controls. 10 Turn the key switch to platform control. Result: All platform control functions should not 11 Lift the test weight off the platform floor using a operate.

  • Page 94: Obstruction Sensing System

    Section 4 • Repair Procedures September 2009 Obstruction Sensing System REV A 12-1 5 Carefully pull the cables to identify the connector cable located at the ground controls, Obstruction Sensing Pads non-steer end of the machine. 6 After the connector cable has been identified, The function of the Obstruction Sensing System is tag and disconnect the cable from the to detect a person or an object standing on the...
  • Page 95 September 2009 Section 4 • Repair Procedures REV A OBSTRUCTOION SENSING PADS Hydraulic Tank Side Ground Controls Side Non-steer End Steer End Obstruction Sensing Pads cable connectors Deutsch connector battery box obstruction sensing pad ground controls side obstruction sensing pad steer end obstruction sensing pad hydraulic tank side...
  • Page 96 Section 4 • Repair Procedures September 2009 This page intentionally left blank. 4 - 46 GR • QSR • QSW Part No. 84700...

  • Page 97: Troubleshooting And Repair Procedures Shall Be Completed By A Person Trained And Qualified On The Repair Of This Machine

    September 2009 Section 5 • Fault Codes Fault Codes 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 98: Return To

    Section 5 • Fault Codes September 2009 FAULT CODES REV C About This Section LED Diagnostic Readout When a malfunction is discovered, the fault code chart in this section will help a service professional pinpoint the cause of the problem. To use this section, basic hand tools and certain pieces of test equipment are required—voltmeter, ohmmeter, pressure gauges.

  • Page 99: Fault Code Chart

    September 2009 Section 5 • Fault Codes Fault Code Chart REV C Fault Code Problem Possible Causes Solution Internal ECM error. EPROM not programmed. Replace ECM. Malfunctioning control cable Troubleshoot control cable ECM/Platform OR malfunctioning platform OR troubleshoot platform communication error. controls.
  • Page 100 Section 5 • Fault Codes September 2009 This page intentionally left blank. 5 - 4 GR • QSR • QSW Part No. 84700...
  • Page 101 September 2009 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 Troubleshooting and repair procedures shall be circuits could result in death or completed by a person trained and qualified on serious injury.

  • Page 102: Electrical Component And Wire Color Legends

    Section 6 • Schematics September 2009 Electrical Component and Wire Color Legends REV C ELECTRICAL COMPONENT LEGEND ELECTRICAL COMPONENT LEGEND Item Description Item Description Battery Power switch Button P1 = Emergency Stop button at ground controls BN5 = Horn P2 = Emergency Stop button at platform controls BN6 = High torque Quick disconnect BN8 = Drive enable...

  • Page 103: Ecm Pin-Out Legend

    September 2009 Section 6 • Schematics ECM Pin-out Legend REV B ECM PIN-OUT LEGEND Item Description Flashing beacon FB1 (output) Ground from platform controls (input) (White wire at platform controls) Plug Driver Power (input) Level sensor power S7 (output) Platform up coil Y8 (output) Drive reverse coil Y5 (output) Motor controller U6, terminal 1 Motor controller U6, terminal 3...

  • Page 104: Relay Layout

    Section 6 • Schematics September 2009 Relay Layout REV C Relay Layout - GR and QSW Relay Layout - QSR platform overload CR27A resistor 25 ohm/25 watt (motor cont) (option) obstruction sensing CR111A platform overload CR27B (QS retail) (load sense) (option) obstruction sensing alarm platform overload CR27C obstruction sensing CR111B...
  • Page 105 September 2009 Section 6 • Schematics Wiring Diagram REV B Ground and Platform Controls GROUND CONTROLS MOTOR CONTROLLER TERMINAL B+ 7A CIRCUIT KEY SWITCH BREAKER MOTOR CONTROLLER TERMINAL 1 6-PIN CONNECTOR PIN 1 ECM PIN B12 (UP) TS66 ECM PIN A12 PLATFORM UP/DOWN (DOWN) TOGGLE SWITCH...

  • Page 106: Electrical Symbols Legend

    Section 6 • Schematics September 2009 Electrical Symbols Legend REV B N.C. N.C.H.O. N.O. LEVEL SENSOR Limit switch CIRCUIT BOARD Motor controller LEVEL SENSOR Level sensor Button or switch Wire with description or color Motor Solenoid valve with diode Toggle switch Circuits crossing no connection Capacitor...
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  • Page 108: D Electrical Schematic - Gr And Qsw - Ce Models

    Section 6 • Schematics September 2009 Electrical Schematic - GR and QSW ANSI and CSA Models REV C Part 1 of 2 6 - 8 GR • QSR • QSW Part No. 84700...
  • Page 109 September 2009 Section 6 • Schematics Electrical Schematic - GR and QSW ANSI and CSA Models REV C Part 2 of 2 Part No. 84700 GR • QSR • QSW 6 - 9...
  • Page 110 Section 6 • Schematics September 2009 Electrical Schematic - GR and QSW CE Models REV D Part 1 of 3 6 - 10 GR • QSR • QSW Part No. 84700...
  • Page 111 September 2009 Section 6 • Schematics Electrical Schematic - GR and QSW CE Models REV D Part 2 of 3 Part No. 84700 GR • QSR • QSW 6 - 11...
  • Page 112 Section 6 • Schematics September 2009 Electrical Schematic - GR and QSW CE Models REV D Part 3 of 3 6 - 12 GR • QSR • QSW Part No. 84700...
  • Page 113 September 2009 Section 6 • Schematics This page intentionally left blank. Part No. 84700 GR • QSR • QSW 6 - 13...

  • Page 114: A Electrical Schematic - Qsr - Ansi And Csa Models

    Section 6 • Schematics September 2009 Electrical Schematic - QSR ANSI and CSA Models REV A Part 1 of 3 (QUICK DISCONNECT) EMERGENCY KEY SWITCH STOP PLATFORM CONTROL ALARM N.C.H.O. GROUND CONTROL POTHOLE TS66 GROUND GUARD PLATFORM SWITCH UP/DOWN CONTROLS N.C.H.O.
  • Page 115 September 2009 Section 6 • Schematics Electrical Schematic - QSR ANSI and CSA Models REV A Part 2 of 3 GN/YL QD4A OR/BK (JUNCTION BOX) CR48 POWER RELAY TO U5 (E-STOP) RD/BK WH/BK N.C. LEVEL SENSOR CIRCUIT BOARD - NOTE - MACHINE SHOWN LEVEL IN THE STOWED...
  • Page 116 Section 6 • Schematics September 2009 Electrical Schematic - QSR ANSI and CSA Models REV A Part 3 of 3 GN/YL OUTLET OUTLET EMERGENCY STOP RD/BK POWER TO PLATFORM POWER TO GROUND GROUND PIO3 PIO2 DATA LINK (HIGH) PIO4 DATA LINK (LOW) PIO5 24V DC 5V DC...
  • Page 117 September 2009 Section 6 • Schematics This page intentionally left blank. Part No. 84700 GR • QSR • QSW 6 - 17...
  • Page 118 Section 6 • Schematics September 2009 Electrical Schematic - QSR CE Models REV A Part 1 of 3 (QUICK DISCONNECT) EMERGENCY KEY SWITCH STOP PLATFORM CONTROL ALARM N.C.H.O. GROUND CONTROL POTHOLE TS66 GROUND GUARD PLATFORM SWITCH UP/DOWN CONTROLS N.C.H.O. CIRCUIT N.C.H.O.
  • Page 119 September 2009 Section 6 • Schematics Electrical Schematic - QSR CE Models REV A Part 2 of 3 GN/YL QD4A OR/BK (JUNCTION BOX) CR48 POWER RELAY TO U5 (E-STOP) BL/BK RD/BK WH/BK CR27A CR27B CR27C N.C. OVERLOAD OVERLOAD OVERLOAD (LOAD SENSE) (DOWN COIL) MOTOR CONT) LEVEL...
  • Page 120 Section 6 • Schematics September 2009 Electrical Schematic - QSR CE Models REV A Part 3 of 3 FOR UK PLUG OPTION, GN/YL GROUND GN/YL LS19 WIRE CONNECTS TO OUTLET BOX GROUND SCREW AND OUTLET PLUG LOAD OUTLET GROUND TERMINAL. N.O.
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  • Page 122: Hydraulic Component Reference And Symbols Legend

    Section 6 • Schematics September 2009 Hydraulic Component Reference and Symbols Legend REV A 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...

  • Page 123: Hydraulic Schematic

    September 2009 Section 6 • Schematics Hydraulic Schematic REV A LIFT CYLINDER STEER STEER LEFT RIGHT LEFT RIGHT LEFT RIGHT DRIVE DRIVE MOTOR MOTOR BRAKE MANUAL HAND RELEASE PUMP BRAKE 5 psi RELEASE 1 gpm 0.3 bar 3.8 L/min MANIFOLD 10 psi 0.7 bar 1500 psi...
  • Page 124 Section 6 • Schematics September 2009 This page intentionally left blank. 6 - 24 GR • QSR • QSW Part No. 84700...
  • Page 125 Genie North America Phone 425.881.1800 Toll Free USA and Canada 800.536.1800 Fax 425.883.3475 Genie Australia Pty Ltd. Phone +61 7 3375 1660 Fax +61 7 3375 1002 Genie Scandinavia Genie China Phone +46 31 575100 Fax + 46 31 579020 Phone +86 21 53852570 Fax +86 21 53852569 Genie France...
  • Page 126 Part No. 84700 Rev C1...

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