Genie QS-15W Service Manual

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Download this manual See also: Operator's Manual, Instruction and Installation Manual

Service Manual

-12

™

-15

™

-20

™

-12R

™

-15R

™

-20R

™

-12W

™

-15W

™

-20W

™

Serial Number Range

from GR10-20000

to GR16-40865

from GR16P-40866

to GR16P-44699

from GRP-44700

from GRR-101

from QS11-1000

to QS16-2429

from QS16P-2430

to QS16P-4499

from QSP-4500

Part No. 1275811GT

Rev A2

May 2018

Table of Contents

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Do you have a question about the QS-15W and is the answer not in the manual?

Questions and answers

Summarization of Contents

Serial Number Range

Introduction

Important Information

Safety and operating instructions are critical for maintenance.

Compliance

Machine classification and design life details.

Technical Publications

Information on accuracy, improvements, and feedback.

Contact information for Genie.

Find a Manual for this Model

Instructions to locate manuals on the website.

Revision History

Specifications

Machine Specifications

Details on batteries, motors, fluid capacities, and dimensions.

Performance Specifications

Drive speed, braking distance, gradeability, and function speeds.

Hydraulic Component Specifications

Details on hydraulic pump, manifold, and component specifications.

Hydraulic Oil Specifications

Requirements for hydraulic oils, optional fluids, and temperature ranges.

Hydraulic Hose and Fitting Torque Specifications

Torque specifications for Seal-Lok™ and JIC 37° fittings.

Safety Rules

Personal Safety

Awareness of hazards and top priority for safety.

Workplace Safety

Awareness of hazards and safe practices in the work area.

Scheduled Maintenance Procedures

Machine Configuration

Specifies machine setup for procedures.

Maintenance Schedule

Outlines maintenance intervals and types.

Commissioning

One-time procedures at 50 and 150 hours.

Quarterly and Annually

Procedures performed quarterly or annually.

Programmed

Procedures based on operating hours or pre-delivery.

Maintenance Inspection Report

Report checklists for scheduled inspections.

Instruction Examples

Examples of how to use the report and symbols.

Commissioning Procedures

C-1 Perform 50 Hour Service

First 50-hour maintenance tasks.

Quarterly Maintenance Procedures

Q-1 Check for Open Bulletins and Owner Registration

Verifies open bulletins and owner registration status.

Q-2 Battery Inspection

Inspects battery condition, levels, and connections.

Q-3 Inspect the Electrical Wiring

Checks wiring for damage, corrosion, or loose connections.

Q-4 Inspect the Electrical Contactor

Inspects contact points of the contactor for wear or damage.

Q-5 Inspect the Voltage Inverter (if equipped)

Checks voltage inverter operation and indicators.

Q-6 Test the Flashing Beacons (if equipped)

Tests the function of flashing beacons.

Q-7 Test the Alarm Package (if equipped)

Tests the machine's alarm system.

Q-8 Inspect the Tires and Wheels (including castle nut torque)

Checks tires and wheels for damage and proper torque.

Q-9 Check the Lifting Chain Adjustments

Checks and adjusts lifting chain tension.

Q-10 Clean and Lubricate the Columns

Cleans and lubricates mast columns.

Q-11 Adjust the Sequencing Cables

Adjusts sequencing cable tension.

Q-12 Visual Inspection of the Hydraulic Oil

Visually inspects hydraulic oil for clarity, color, and contamination.

Q-13 Test the Drive Brakes

Tests the functionality and stopping distance of drive brakes.

Q-14 Test the Drive Speed – Stowed Position

Tests drive speed in the stowed position.

Q-15 Test the Drive Speed - Raised Position

Tests drive speed in the raised position.

Annual Maintenance Procedures

A-1 Grease the Platform Overload Mechanism (if equipped)

Greases the platform overload mechanism.

A-2 Test the Platform Overload System (if equipped)

Tests the platform overload system.

Programmed Maintenance Procedures

P0-1 Grease the Steer Yokes

Greases the steer yokes.

P1-1 Inspect the Mast Assembly for Wear

Inspects mast assembly for wear.

P1-2 Inspect and Lubricate the Lifting Chains

Inspects and lubricates lifting chains.

P2-1 Replace the Hydraulic Return Filter

Replaces the hydraulic tank return filter.

P2-2 Test or Replace the Hydraulic Oil

Tests or replaces hydraulic oil.

Repair Procedures

Machine Configuration

Specifies machine setup for repair procedures.

10-4 How to Remove the Lift Cylinder

Steps to remove the lift cylinder.

Platform Controls

Operational Indicator Codes

Codes indicating machine operating status or faults.

1-1 Circuit Board

Instructions for removing the platform controls circuit board.

1-2 Joystick

Instructions for removing the joystick.

1-3 Platform Controls Alarm

Instructions for removing the platform controls alarm.

1-4 Platform Emergency Stop Button

Instructions for removing the emergency stop button.

Ground Controls

2-1 Software Revision Level

How to determine the machine's software revision level.

2-2 Machine Setup

How to set up machine parameters from ground controls.

2-3 Level Sensors

Information on level sensors and their function.

How to Install and Calibrate the Level Sensor - Procedure 1

Procedure for installing and calibrating level sensor type 1.

How to Install and Calibrate the Level Sensor - Procedure 2

Procedure for installing and calibrating level sensor type 2.

Hydraulic Pump

3-1 Function Pump

Information about the function pump.

How to Test the Hydraulic Pump

Steps to test the hydraulic pump's output pressure.

How to Remove the Hydraulic Pump

Steps to remove the hydraulic pump.

Function Manifold

4-1 Function Manifold Components

Lists components of the function manifold and their torque specs.

4-2 Valve Adjustments - Function Manifold

Adjustments for function manifold valves.

How to Adjust the System Relief Valve

Procedure to adjust the system relief valve pressure.

How to Adjust the Platform Lift Relief Valve

Procedure to adjust the platform lift relief valve.

How to Adjust the Steer Relief Valve

Procedure to adjust the steer relief valve pressure.

4-3 Valve Coils

Information on testing solenoid valve coils.

How to Test a Coil Diode

Procedure to test coil diodes for proper function.

Brake Release Hand Pump Components

5-1 Brake Release Hand Pump Components

Lists components of the brake release hand pump.

Hydraulic Tank

6-1 Hydraulic Tank

Details the functions and components of the hydraulic tank.

How to Remove the Hydraulic Tank

Steps to remove the hydraulic tank.

Non-Steer Axle Components

7-1 Drive Brake

Components related to the drive brake.

How to Remove the Drive Brake

Steps to remove the drive brake assembly.

Steer Axle Components

8-1 Yoke and Drive Motor

Components related to the yoke and drive motor.

How to Remove the Yoke and Drive Motor Assembly

Steps to remove the yoke and drive motor assembly.

8-2 Steer Cylinder

Components related to the steer cylinder.

How to Remove the Steer Cylinder

Steps to remove the steer cylinder.

8-3 Steer Bellcrank

Components related to the steer bellcrank.

How to Remove the Tie Rod

Steps to remove the tie rod.

Platform Components

9-1 Platform

Components related to the platform.

How to Remove the Platform

Steps to remove the platform assembly.

9-2 Platform Extension Deck

Components related to the platform extension deck.

How to Remove the Platform Extension Deck

Steps to remove the platform extension deck.

9-3 Work Tray

Components related to the work tray.

How to Remove the Work Tray (if equipped)

Steps to remove the work tray.

Mast Components

10-1 Mast

Components related to the mast assembly.

How to Remove the Mast Assembly

Steps to remove the mast assembly.

How to Disassemble the Mast

Steps to disassemble the mast assembly.

How to Assemble the Mast

Steps to assemble the mast assembly.

10-2 Glide Pads

Information about glide pads and their adjustment.

How to Adjust the Glide Pads

Procedure to adjust glide pads.

10-3 Lifting Chains

Information about lifting chains.

How to Adjust the Lifting Chains

Procedure to adjust lifting chains.

How to Inspect the Lifting Chains

Procedure to inspect lifting chains for wear, rust, or tight joints.

Platform Overload Components

11-1 Platform Overload System (if equipped)

Information on the platform overload system.

How to Calibrate the Platform Overload System

Steps to calibrate the platform overload system.

11-2 Platform Overload Recovery Message

Information on clearing overload recovery messages.

How to Clear the Platform Overload Recovery Message

Steps to clear the platform overload recovery message.

Obstruction Sensing System

12-1 Obstruction Sensing Pads

Function and indicators of the obstruction sensing system.

How to Replace an Obstruction Sensing Pad (QSR models)

Steps to replace an obstruction sensing pad.

Battery Charger

13-1 Battery Charger

Information on charger profiles and status indicators.

Selecting a Charge Profile

Steps to select the correct battery charger profile.

Batteries

14-1 How to Remove the Batteries

Steps to remove the machine's batteries.

Diagnostics

GCON LCD Diagnostic Readout

Explains diagnostic readouts and codes.

Genie® SmartLink™ Diagnostic System

Overview of the diagnostic system.

GCON ECM Connector Layout

Diagram of the GCON ECM connector.

GCON I/O Map without Load Sense

Pinout map for GCON without load sense.

GCON I/O Map with Load Sense

Pinout map for GCON with load sense.

Operational Indicator Codes (OIC)

Lists and explains operational indicator codes.

Diagnostic Trouble Codes (DTC)

Explains types of diagnostic trouble codes.

Troubleshooting "HXXX" and "PXXX" Faults

Steps for diagnosing H and P type faults.

Wiring Diagram

Illustrates wiring for H and P type faults.

Fault Inspection Procedure

Step-by-step procedure for fault inspection.

Type "HXXX" Faults

Details HXXX fault codes, causes, and failure modes.

Type "PXXX" Faults

Details PXXX fault codes, causes, and failure modes.

Type "UXXX" Faults

Details UXXX fault codes, causes, and failure modes.

Type "FXXX" Faults

Details FXXX fault codes, causes, and failure modes.

Type "CXXX" Faults

Details CXXX fault codes, causes, and failure modes.

Battery Charger

Explains charger fault and error codes.

Charger Fault Codes

Lists charger fault codes, descriptions, causes, and solutions.

Charger Error Codes

Lists charger error codes, conditions, and possible causes.

Schematics

Electrical Schematics – ANSI / CSA Models

Electrical schematics for ANSI/CSA models.

Electrical Schematic, GR • QSW, ANSI / CSA (from serial number GR10-20000 to GR11-20683 and QS11-1000 to QS11-1015)