Terex Genie QS-20W Service manual

Ser vice Manual

Serial Number Range

GR -12

GR -15

GR -20

QS-12R

QS-15R

QS-20R

QS-12W

QS-15W

QS-20W

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

November 2014

Introduction

ii

Important

Read, understand and obey the safety rules and operating instructions in the appropriate

Operator's Manual on your machine before attempting any maintenance procedure.

Basic mechanical, hydraulic and electrical skills are required to perform most procedures.

However, several procedures require specialized skills, tools, lifting equipment and a suitable workshop. In these instances, we strongly recommend that maintenance and repair be performed at an authorized Genie dealer service center.

Compliance

Machine Classification

Group A/Type 3 as defined by ISO 16368

Machine Design Life

Unrestricted with proper operation, inspection and scheduled maintenance.

Technical Publications

Genie has endeavored to deliver the highest degree of accuracy possible. However, continuous improvement of our products is a Genie policy.

Therefore, product specifications are subject to change without notice.

Readers are encouraged to notify Genie of errors and send in suggestions for improvement. All communications will be carefully considered for future printings of this and all other manuals.

Serial Number Information

Genie offers the following Service Manuals for these models:

Title Part No.

Genie Runabout Service Manual,

First Edition

(GR - before serial number 5001) ......................... 72965

Genie Runabout Service Manual,

Second Edition

(GR - from serial number 5001 to 19999)

(QS - from 101 to 999) .......................................... 84700

Contact Us:

www.genielift.com

e-mail:[email protected]

GR • QSR • QSW

Copyright © 2011 by Terex Corporation

T110280 Rev B October 2011

Third Edition, Second Printing

"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.

Part No. T110280

November 2014

Revision History

Revision Date

A 4/2011

B

B1

Section

10/2011 2 - Spec.

3 - Maint.

6 - Schem.

11/2014 6 - Spec.

4 - Repair

6 - Schem.

Procedure / Schematic Page / Description

New release

2-1

3-5, 3-27

6-2, 6-3, 6-4, 6-6, 6-10, 6-14, 6-18, 6-22, 6-26, 6-30, 6-34

2-5, 2-6

12-2

6-39

REFERENCE EXAMPLES:

Section 3_Maintenance, B-3.

Section 4_Repair Procedure, 4-2.

Section 5_Diagnostic Codes, All charts.

Section 6_Schematics, Legends diagrams and schematics.

Part No. T110280 GR • QSR • QSW

Electronic Version

Click on any procedure or page number highlighted in blue to view the update.

iii

November 2014

REVISION HISTORY,

CONTINUED

Revision Date Section Procedure / Schematic Page / Description

iv

REFERENCE EXAMPLES:

Kubota Engine_Section 2_Specifications.

A-6,B-3,C-7_Section 3_Maintenance Procedure.

3-2, 6-4, 9-1_Section 4_Repair Procedure.

Fault Codes_Section 5.

6-35, 6-56, 6-104_Section 6_Schematic Page #.

GR • QSR • QSW

Electronic Version

Click on any procedure or page number highlighted in blue to view the update.

Part No. T110280

November 2014

Serial Number Legend

INTRODUCTION

Part No. T110280 GR • QSR • QSW v

Safety Rules

November 2014

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.

Do Not Perform Maintenance

Unless:

You are trained and qualified to perform maintenance on this machine.

You read, understand and obey:

- manufacturer’s instructions and safety rules

- employer’s safety rules and worksite regulations

- applicable governmental regulations

You have the appropriate tools, lifting equipment and a suitable workshop.

vi GR • QSR • QSW Part No. T110280

November 2014

SAFETY RULES

Personal Safety

Any person working on or around a machine must be aware of all known safety hazards. Personal safety and the continued safe operation of the machine should be your top priority.

Read each procedure thoroughly. This manual and the decals on the machine, use signal words to identify the following:

Safety alert symbol—used to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, may cause minor or moderate injury.

Indicates a potentially hazardous situation which, if not avoided, may result in property damage.

Be sure to wear protective eye wear and other protective clothing if the situation warrants it.

Be aware of potential crushing hazards such as moving parts, free swinging or unsecured components when lifting or placing loads. Always wear approved steel-toed shoes.

Workplace Safety

Be sure to keep sparks, flames and lighted tobacco away from flammable and combustible materials like battery gases and engine fuels. Always have an approved fire extinguisher within easy reach.

Be sure that all tools and working areas are properly maintained and ready for use. Keep work surfaces clean and free of debris that could get into machine components and cause damage.

Be sure any forklift, overhead crane or other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted. Use only chains or straps that are in good condition and of ample capacity.

Be sure that fasteners intended for one time use (i.e., cotter pins and self-locking nuts) are not reused. These components may fail if they are used a second time.

Be sure to properly dispose of old oil or other fluids. Use an approved container.

Please be environmentally safe .

Be sure that your workshop or work area is properly ventilated and well lit.

Part No. T110280 GR • QSR • QSW vii

November 2014

Table of Contents

Introduction

Section 1

Section 2

Section 3

Important Information ........................................................................................ ii

Serial Number Information ................................................................................. ii

Serial Number Legend ..................................................................................... iii

Safety Rules

General Safety Rules ....................................................................................... v

Specifications

Machine Specifications ................................................................................ 2 - 1

Performance Specifications ......................................................................... 2 - 2

Hydraulic Specifications .............................................................................. 2 - 3

Manifold Component Specifications ............................................................ 2 - 4

Hydraulic Hose and Fitting Torque Specifications ....................................... 2 - 5

SAE and Metric Fasteners Torque Charts ................................................... 2 - 7

Scheduled Maintenance Procedures

Introduction .................................................................................................. 3 - 1

Pre-delivery Preparation Report .................................................................. 3 - 3

Maintenance Inspection Report ................................................................... 3 - 5

Checklist A Procedures

A-1 Inspect the Manuals and Decals ........................................................ 3 - 6

A-2 Perform Pre-operation Inspection ...................................................... 3 - 7

A-3 Perform Function Tests ...................................................................... 3 - 7

A-4 Test the Obstruction Sensing System (QSR models only) ................. 3 - 8

A-5 Perform 30 Day Service ................................................................... 3 - 10

A-6 Grease the Steer Yokes ................................................................... 3 - 10 viii

GR • QSR • QSW Part No. T110280

November 2014

Section 3

Part No. T110280

TABLE OF CONTENTS


, 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 ............................................... 3 - 15

B-5 Clean and Lubricate the Columns .................................................... 3 - 16

B-6 Adjust the Sequencing Cables ......................................................... 3 - 16

B-7 Test the Emergency Stop ................................................................. 3 - 17

B-8 Test the Key Switch .......................................................................... 3 - 18

B-9 Test the Automotive-style Horn (if equipped) ................................... 3 - 18

B-10 Inspect the Voltage Inverter (if equipped) ........................................ 3 - 19

B-11 Test the Drive Brakes ....................................................................... 3 - 20

B-12 Test the Drive Speed - Stowed Position ........................................... 3 - 21

B-13 Test the Drive Speed - Raised Position ............................................ 3 - 22

B-14 Test the Slow Drive Speed ............................................................... 3 - 23

B-15 Test the Motion Alarm (if equipped) ................................................. 3 - 24

B-16 Test the Flashing Beacons (if equipped) .......................................... 3 - 25

B-17 Perform Hydraulic Oil Analysis ......................................................... 3 - 26

B-18 Inspect the Breather Cap ................................................................. 3 - 26

B-19 Inspect the Electrical Contactor ........................................................ 3 - 27

Checklist C Procedures

C-1 Grease the Platform Overload Mechanism (if equipped) ................. 3 - 28

C-2 Replace the Hydraulic Tank Breather Cap -

Models with Optional Hydraulic Oil ................................................... 3 - 29

C-3 Test the Platform Overload System (if equipped) ............................. 3 - 29

Checklist D Procedures

D-1 Inspect the Mast Assembly for Wear ................................................ 3 - 31

D-2 Inspect and Lubricate the Lifting Chains .......................................... 3 - 32

D-3 Replace the Hydraulic Tank Return Filter ......................................... 3 - 33

Checklist E Procedure

E-1 Test or Replace the Hydraulic Oil ..................................................... 3 - 34

GR • QSR • QSW ix

November 2014

TABLE OF CONTENTS

Section 4 Repair Procedures

Introduction .................................................................................................. 4 - 1

Platform Controls

1-1 Circuit Board ...................................................................................... 4 - 3

1-2 Joystick .............................................................................................. 4 - 4

1-3 Platform Controls Alarm ..................................................................... 4 - 4

1-4 Platform Emergency Stop Button ....................................................... 4 - 5

Ground Controls

2-1 Software Revision Level .................................................................... 4 - 7

2-2 Machine Setup ................................................................................... 4 - 8

2-3 Level Sensor ...................................................................................... 4 - 9

Hydraulic Pump

3-1 Function Pump ................................................................................. 4 - 12

Function Manifold

4-1 Function Manifold Components ....................................................... 4 - 14

4-2 Valve Adjustments - Function Manifold ............................................ 4 - 16

4-3 Valve Coils ....................................................................................... 4 - 20

Brake Release Hand Pump Components

5-1 Brake Release Hand Pump Components ........................................ 4 - 22

Hydraulic Tank

6-1 Hydraulic Tank ................................................................................. 4 - 23

Steer Axle Components

7-1 Yoke and Drive Motor ...................................................................... 4 - 24

7-2 Steer Cylinder .................................................................................. 4 - 26

7-3 Steer Bellcrank ................................................................................ 4 - 26

Non-steer Axle Components

8-1 Drive Brake ...................................................................................... 4 - 27

Obstruction Sensing System

9-1 Obstruction Sensing Pads (QSR models only) ................................ 4 - 28 x


November 2014

Section 4

Section 5

TABLE OF CONTENTS

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 ....................................................................................... 4 - 37

11-3 Lifting Chains ................................................................................... 4 - 37

11-4 Lift Cylinder ...................................................................................... 4 - 40

Platform Overload Components

12-1 Platform Overload System ............................................................... 4 - 41

12-2 Platform Overload Recovery Message ............................................ 4 - 43

Diagnostics

Introduction .................................................................................................. 5 - 1

GCON I/O Map without Load Sense ............................................................ 5 - 4

GCON I/O Map with Load Sense ................................................................ 5 - 5

Operational Indicator Codes ........................................................................ 5 - 6

Diagnostic Trouble Codes ........................................................................... 5 - 6

Troubleshooting "HXXX" and "PXXX" Faults ............................................... 5 - 7

Fault Inspection Procedure .......................................................................... 5 - 8

Type "HXXX" Faults .................................................................................. 5 - 10

Type "PXXX" Faults ................................................................................... 5 - 11

Type "UXXX" Faults .................................................................................. 5 - 12

Type "FXXX" Faults ................................................................................... 5 - 13

Type "CXXX" Faults .................................................................................. 5 - 14

Part No. T110280 GR • QSR • QSW xi

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) .. 6 - 6

Electrical Schematic - GR and QSW - ANSI and CSA Models

(from GR11-20684 and from QS11-1016) ................................................. 6 - 10

Electrical Schematic - QSR - ANSI and CSA Models

(from QS11-1000 to QS11-1015) .............................................................. 6 - 14

Electrical Schematic - QSR - ANSI and CSA Models

(from QS11-1016) ..................................................................................... 6 - 18

Electrical Schematic - GR and QSW - CE and AUS models

(from GR10-20000 to GR11-20683 and from QS11-1000 to QS11-1015) 6 - 22

Electrical Schematic - GR and QSW - CE and AUS models

(from GR11-20684 and from QS11-1016) ................................................. 6 - 26

Electrical Schematic - QSR - CE and AUS models

(from QS11-1000 to QS11-1015) .............................................................. 6 - 30

Electrical Schematic - QSR - CE and AUS models

(from QS11-1016) ..................................................................................... 6 - 34

Hydraulic Component Reference and Symbols Legend ............................ 6 - 37

Hydraulic Schematic .................................................................................. 6 - 38 xii


November 2014 Section 2 • Specifications

Specifications

Machine Specifications

Batteries, Standard

Voltage

Group

Type

Quantity

Battery capacity, maximum

Reserve capacity @ 25A rate

Batteries, Maintenance-free (option)

Voltage

Group

Type

Quantity

Battery capacity, maximum

Reserve capacity @ 25A rate

DC Motor

Voltage

Horse Power

Kilowatts

Fluid capacities

Hydraulic tank

Hydraulic system

(including tank)

6V DC

GC2

T-105

4

C20 = 225AH

447 minutes

6V DC

GC2

6V-AGM

4

200AH

380 minutes

24 V

4.5 HP @ 2950 RPM

3.3 kW @ 2950 RPM

1.5 gallons

5.7 liters

2.2

gallons

8.3 liters

Height, stowed maximum

GR-12, GR-15, QS-12R , QS-15R

QS-12W and QS-15W

(ANSI and CSA)

GR-12, GR-15, QS-12R , QS-15R

QS-12W and QS-15W

(CE models and Australia models)

GR-20, QS-20R and QS-20W

(all models)

Tires and wheels

Tire size (solid rubber)

Tire contact area

Castle nut torque, lubricated

62 in

1.57 m

68.1 in

1.73 m

78 in

1.98 m

10 x 3 in

25.4 x 7.62 cm

6.5 sq in

41.9 cm

2

150 ft-lbs

203 Nm

Continuous improvement of our products is a

Genie policy. Product specifications are subject to change without notice.

For operational specifications, refer to the

Operator's Manual.

Part No. T110280 GR • QSR • QSW 2 - 1

Section 2 • Specifications November 2014

SPECIFICATIONS

Performance Specifications

Drive speed, maximum

Platform stowed, fast

Platform stowed, slow

Platform raised

2.5 mph

40 ft / 10.9 sec

4 km/h

12.2 m / 10.9 sec

1.1 mph

40 ft / 24.8 sec

1.8 km/h

12.2 m / 24.8 sec

0.5 mph

40 ft / 55 sec

0.8 km/h

12.2 m / 55 sec

Braking distance, maximum

High range on paved surface 19 in ± 6 in

48 cm ± 15 cm

30%

Gradeability

Airborne noise emissions

Sound pressure level at ground workstation < 70 dBA

Sound pressure level at platform workstation < 70 dBA

Maximum slope rating,

Function speed, maximum from platform controls

(with 1 person in platform)

GR-12, QS-12R and QS-12W

Platform up (fast mode)

Platform up (slow mode)

Platform down

GR-15, QS-15R and QS-15W



Platform down

GR-20, QS-20R and QS-20W



Platform down

19 to 21 seconds

30 to 32 seconds

17 to 19 seconds

20 to 22 seconds

31 to 33 seconds

18 to 20 seconds

23 to 25 seconds

32 to 34 seconds

20 to 22 seconds

Rated work load at full height, maximum

GR-12 and GR-15

Standard Platform

GR-20

Standard Platform

GR-12, GR-15 and GR-20

AWP Platform

QS-12R, QS-15R, QS-12W and QS-15W

Stockpicker Platform

QS-20R and QS-20W


500 lbs

227 kg

350 lbs

159 kg

350 lbs

159 kg

500 lbs

227 kg

350 lbs

159 kg



2 - 2 GR • QSR • QSW Part No. T110280


SPECIFICATIONS

Hydraulic Specifications

Hydraulic Oil Specifications

Hydraulic oil type

Viscosity grade

Viscosity index

Cleanliness level, minimum

Water content, maximum

Chevron Rando HD equivalent

Multi-viscosity

200

ISO 15/13

200 ppm

Chevron Rando HD oil is fully compatible and mixable with Shell Donax TG (Dexron III) oils.

Genie specifications require hydraulic oils which are designed to give maximum protection to hydraulic systems, have the ability to perform over a wide temperature range, and the viscosity index should exceed 140. They should provide excellent antiwear, oxidation, corrosion inhibition, seal conditioning, and foam and aeration suppression properties.

Optional fluids

Biodegradable

Fire resistant

Mineral based

Petro Canada Environ MV 46

Statoil Hydra Way Bio SE 32

BP Biohyd SE-S

UCON Hydrolube HP-5046

Quintolubric 822

Shell Tellus T32

Shell Tellus T46

Chevron Aviation A

Function pump

Type

Displacement per revolution

Flow rate @ 2500 psi / 172 bar

Hydraulic tank return filter

4 gpm

15 L/min

10 micron with

25 psi / 1.7 bar bypass

Function manifold

Gear

0.244 cu in

4 cc

System relief valve pressure, maximum

Lift relief valve pressure

Steer relief valve pressure

3500 psi

241 bar

1800 to 3500 psi

124 to 241 bar

1500 psi

103 bar



Continued use of Chevron

Aviation A hydraulic fluid when ambient temperatures are consistently above 32°F / 0°C may result in component damage.

Note: Use Chevron Aviation A hydraulic fluid when ambient temperatures are consistently below 0°F / -17°C.

Note: Use Shell Tellus T46 hydraulic oil when oil temperatures consistently exceed 205°F / 96°C.

Note: Genie specifications require additional equipment and special installation instructions for the approved optional fluids. Consult the Genie

Service Department before use.



SPECIFICATIONS

Manifold Component

Specifications

Plug torque

SAE No. 2

SAE No. 4

SAE No. 6

SAE No. 8

SAE No. 10

SAE No. 12

50 in-lbs / 6 Nm

13 ft-lbs / 18 Nm

18 ft-lbs / 24 Nm

50 ft-lbs / 68 Nm

55 ft-lbs / 75 Nm

75 ft-lbs / 102 Nm

Valve Coil Resistance

Note: The following coil resistance specifications are at an ambient temperature of 68°F / 20°C. As valve coil resistance is sensitive to changes in air temperature, the coil resistance will typically increase or decrease by 4% for each 18°F / -7.7°C that your air temperature increases or decreases from 68°F / 20°C.

Description

Solenoid valve, 3 position 4 way

20V DC with diode (schematic item E)


20V DC with diode (schematic item F)


20V DC with diode (schematic item H)

Solenoid valve, 2 position 2 way N.C.

with manual override

12V DC with diode (schematic item N)

Specification

27.2

Ω

19

25

6.25

Ω

Ω

Ω





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.

SAE Dash size

-4

-6

-8

-10

-12

-16

-20

-24

Seal-Lok

™

Fittings

(hose end - ORFS)

Torque

10 ft-lbs / 13.6 Nm

30 ft-lbs / 40.7 Nm

40 ft-lbs / 54.2 Nm

60 ft-lbs / 81.3 Nm

85 ft-lbs / 115 Nm

110 ft-lbs / 150 Nm

140 ft-lbs / 190 Nm

180 ft-lbs / 245 Nm

SAE Dash size

-4

-6

-8

-10

-12

-16

-20

-24

JIC 37° Fittings

(swivel nut or hose connection)

Thread Size

7

/

16

-20

9

/

16

-18

3

/

4

-16

7

/

8

-14

1

1

/

16

-12

1

5

/

16

-12

1

5

/

8

-12

1

7

/

8

-12

1

1

1

1

Flats

2

1

1

/

4

1

1

SAE O-ring Boss Port

(tube fitting - installed into Aluminum)

(all types)

SAE Dash size Torque

-12

-16

-20

-24

-4

-6

-8

-10

14 ft-lbs / 19 Nm

23 ft-lbs / 31.2 Nm

36 ft-lbs / 54.2 Nm

62 ft-lbs / 84 Nm

84 ft-lbs / 114 Nm

125 ft-lbs / 169.5 Nm

151 ft-lbs / 204.7 Nm

184 ft-lbs / 249.5 Nm

Jamb nut

Non-adjustable fitting (Nonadj)

Adjustable fitting (Adj)

SAE Dash size

SAE O-ring Boss Port

(tube fitting - installed into Steel)

-4 ORFS / 37° (Adj)

ORFS (Non-adj)

37° (Non-adj)

-6 ORFS (Adj / Non-adj)

37° (Adj / Non-adj)





-12 (All types)

-16 (All types)

-20 (All types)

-24 (All types)

Torque

15 ft-lbs / 20.3 Nm

26 ft-lbs / 35.3 Nm

22 ft-lbs / 30 Nm

35 ft-lbs / 47.5 Nm

29 ft-lbs / 39.3 Nm

60 ft-lbs / 81.3 Nm

52 ft-lbs / 70.5 Nm

100 ft-lbs / 135.6 Nm

85 ft-lbs / 115.3 Nm

135 ft-lbs / 183 Nm

200 ft-lbs / 271.2 Nm

250 ft-lbs / 339 Nm

305 ft-lbs / 413.5 Nm



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.

Note: The O-rings used in the Parker Seal Lok™ fittings and hose ends are custom-size O-rings.

They are not standard SAE size O-rings. They are available in the O-ring field service kit (Genie part number 49612).

2 Lubricate the O-ring before installation.

3 Be sure that the face seal O-ring is seated and retained properly.

4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight.

5 Tighten the nut or fitting to the appropriate torque per given size as shown in the table.

6 Operate all machine functions and inspect the hoses and fittings and related components to confirm that there are no leaks.

JIC 37° fittings

1 Align the tube flare (hex nut) against the nose of the fitting body (body hex fitting) and tighten the hex nut to the body hex fitting to hand-tight, approximately 30 in-lbs / 3.4 Nm.

2 Make a reference mark on one of the flats of the hex nut, and continue it on to the body hex fitting with a permanent ink marker. Refer to

Figure 1.

c a b

Figure 1 a hex nut b reference mark c body hex fitting

3 Working clockwise on the body hex fitting, make a second mark with a permanent ink marker to indicate the proper tightening position. Refer to Figure 2.

Note: Use the JIC 37° Fittings table on the previous page to determine the correct number of flats for the proper tightening position.

Note: The marks indicate that the correct tightening positions have been determined. Use the second mark on the body hex fitting to properly tighten the joint after it has been loosened.

b c a b

Figure 2 a body hex fitting b reference mark c second mark

4 Tighten the hex nut until the mark on the hex nut is aligned with the second mark on the body hex fitting.

5 Operate all machine functions and inspect the hoses and fittings and related components to confirm that there are no leaks.



SPECIFICATIONS

SIZE THREAD

1/4

20

28

SAE FASTENER TORQUE CHART

• This chart is to be used as a guide only unless noted elsewhere in this manual •

Grade 5

LUBED in-lbs

80

90

Nm

9

10.1

in-lbs

100

120

DRY

Nm

11.3

13.5

Grade 8

LUBED in-lbs

110

120

Nm

12.4

13.5

in-lbs

140

160

DRY

Nm

15.8

18

A574 High Strength

Black Oxide Bolts

LUBED in-lbs

130

140

Nm

14.7

15.8

5/16

3/8

7/16

1/2

9/16

5/8

3/4

7/8

1

1

1

/

8

1

1

/

4

1

1

/

2

10

16

9

14

8

12

7

12

7

12

6

12

18

24

16

24

14

20

13

20

12

18

11

18

LUBED ft-lbs

130

200

220

320

350

57

64

80

90

110

13

14

23

26

37

41

480

530

590

670

840

930

1460

1640

Nm

17.6

19

31.2

35.2

50.1

55.5

77.3

86.7

108.4

122

149

176

271

298

433

474

650

718

800

908

1138

1260

1979

2223

DRY

Nm

23

25.7

42

47.4

66.4

74.5

101.6

115

149

162

203

230

366

406

583

637

867

962

1071

1206

1518

1681

2643

2969

ft-lbs

170

270

300

430

470

75

85

110

120

150

17

19

31

35

49

55

640

710

790

890

1120

1240

1950

2190

LUBED ft-lbs

180

280

310

450

500

80

90

120

130

160

18

20

33

37

50

60

680

750

970

1080

1360

1510

2370

2670

Nm

24

27.1

44.7

50.1

67.8

81.3

108.4

122

162

176

217

244

379

420

610

678

922

1016

1315

1464

1844

2047

3213

3620

ft-lbs

240

380

420

610

670

110

120

150

170

210

25

27

44

49

70

80

910

990

1290

1440

1820

2010

3160

3560

DRY

Nm

325

515

569

827

908

149

162

203

230

284

33.9

36.6

59.6

66.4

94.7

108.4

1233

1342

1749

1952

2467

2725

4284

4826

ft-lbs

200

320

350

510

560

93

105

130

140

180

21

24

38

43

61

68

770

840

1090

1220

1530

1700

2670

3000

LUBED

Nm

271

433

474

691

759

126

142

176

189

244

28.4

32.5

51.5

58.3

82.7

92.1

1044

1139

1477

1654

2074

2304

3620

4067

METRIC FASTENER TORQUE CHART

• This chart is to be used as a guide only unless noted elsewhere in this manual •

Size

Class 4.6

Class 8.8

Class 10.9

Class 12.9

(mm)

5

6

7

LUBED in-lbs

16

19

45

Nm

1.8

3.05

5.12

DRY LUBED DRY LUBED DRY LUBED DRY in-lbs

21

Nm

2.4

36 4.07

in-lbs

41

69

Nm

4.63

7.87

in-lbs Nm

54 6.18

in-lbs

58

Nm

6.63

in-lbs

78

93 10.5

100 11.3

132

Nm

8.84

15

in-lbs Nm

68 7.75

in-lbs

91

Nm

10.3

116 13.2

155 17.6

60 6.83

116 13.2

155 17.6

167 18.9

223 25.2

1.95

22.1

260 29.4

LUBED DRY LUBED DRY LUBED DRY LUBED DRY ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm

8

5.4

7.41

7.2

9.88

14 19.1

18.8

25.5

20.1

27.3

26.9

36.5

23.6

32 31.4

42.6

10

10.8

14.7

14.4

19.6

27.9

37.8

37.2

50.5

39.9

54.1

53.2

72.2

46.7

63.3

62.3

84.4

12

18.9

25.6

25.1

34.1

48.6

66 64.9

88 69.7

94.5

92.2

125 81 110 108 147

14

30.1

40.8

40 54.3

77.4

105 103 140 110 150 147 200 129 175 172 234

16

46.9

63.6

62.5

84.8

125 170 166 226 173 235 230 313 202 274 269 365

18

64.5

87.5

86.2

117 171 233 229 311 238 323 317 430 278 377 371 503

20

91 124 121 165 243 330 325 441 337 458 450 610 394 535 525 713

22

124 169 166 225 331 450 442 600 458 622 612 830 536 727 715 970

24

157 214 210 285 420 570 562 762 583 791 778 1055 682 925 909 1233



This page intentionally left blank.


November 2014 Section 3 • Scheduled Maintenance Procedures


Observe and Obey:

Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine.

Scheduled maintenance inspections shall be completed daily, quarterly, semi-annually, annually and every 2 years as specified on the

Maintenance Inspection Report.

Failure to properly complete each inspection when required may cause death, serious injury or substantial machine damage.

Immediately tag and remove from service a damaged or malfunctioning machine.

Repair any machine damage or malfunction before operating the machine.

Use only Genie approved replacement parts.

Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection.

Unless otherwise specified, perform each procedure with the machine in the following configuration:

• Machine parked on a firm, level surface

• Platform in the stowed position

• Key switch in the off position with the key removed

• The red Emergency Stop button in the off position at both ground and platform controls

• Wheels chocked

• All external AC power supply disconnected from the machine

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.

Symbols Legend






Indicates that a specific result is expected after performing a series of steps.

Indicates that an incorrect result has occurred after performing a series of steps.

Part No. T110280 GR-12 • QSR • QSW 3 - 1

Section 3 • Scheduled Maintenance Procedures November 2014

SCHEDULED MAINTENANCE PROCEDURES

Maintenance Symbols Legend

Note: The following symbols have been used in this manual to help communicate the intent of the instructions. When one or more of the symbols appears at the beginning of a maintenance procedure, it conveys the meaning below.

Indicates that tools will be required to perform this procedure.

Indicates that new parts will be required to perform this procedure.

Indicates that a cold motor or pump will be required to perform this procedure.

Pre-delivery Preparation Report

The pre-delivery preparation report contains checklists for each type of scheduled inspection.

Make copies of the Pre-delivery Preparation report to use for each inspection. Store completed forms as required.

Maintenance Schedule

There are five types of maintenance inspections that must be performed according to a schedule— daily, quarterly, semi-annually, annually, and two year. The Scheduled Maintenance

Procedures Section and the Maintenance

Inspection Report have been divided into five subsections—A, B, C, D, and E. Use the following chart to determine which group(s) of procedures are required to perform a scheduled inspection.

Indicates that dealer service will be required to perform this procedure.

Inspection

Daily or every 8 hours

Quarterly or every 250 hours

Semi-annually or every 500 hours

Annually or every 1000 hours

Two year or every 2000 hours

Checklist

A

A + B

A + B + C

A + B + C + D

A + B + C + D + E

Maintenance Inspection Report

The maintenance inspection report contains checklists for each type of scheduled inspection.

Make copies of the Maintenance Inspection

Report to use for each inspection. Maintain completed forms for a minimum of 4 years or in compliance with employer, jobsite and governmental regulations and requirements.


Pre-Deliver y Preparation

Fundamentals

It is the responsibility of the dealer to perform the

Pre-delivery Preparation.

The Pre-delivery Preparation is performed prior to each delivery. The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service.

A damaged or modified machine must never be used.

If damage or any variation from factory delivered condition is discovered, the machine must be tagged and removed from service.

Repairs to the machine may only be made by a qualified service technician, according to the manufacturer's specifications.

Scheduled maintenance inspections shall be performed by qualified service technicians, according to the manufacturer's specifications and the requirements listed in the responsibilities manual.

Instructions

Use the operator’s manual on your machine.

The Pre-delivery Preparation consists of completing the Pre-operation Inspection, the Maintenance items and the Function Tests.

Use this form to record the results. Place a check in the appropriate box after each part is completed.

Follow the instructions in the operator’s manual.

If any inspection receives an N, remove the machine from service, repair and reinspect it. After repair, place a check in the R box.

Legend

Y = yes, completed

N = no, unable to complete

R = repaired

Comments

Pre-Delivery Preparation

Pre-operation inspection completed

Maintenance items completed

Function tests completed

Y N R

Terex South Dakota, Inc USA

500 Oak Wood Road

PO Box 1150

Watertown, SD 57201-6150

(605) 882-4000

Genie UK

The Maltings, Wharf Road

Grantham, Lincolnshire

NG31- 6BH England

(44) 1476-584333

Copyright © 2011 Terex Corporation. Genie® is a registered trademark of Terex South

Dakota, Inc. 133192 Rev D

Model

Serial number

Date

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company





Maintenance Inspection Report

Model

Serial number

Date

Hour meter

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

Instructions

• Make copies of this report to use for each inspection.

• Select the appropriate checklist(s) for the type of inspection to be performed.

Daily or 8 hours

Inspection:

Quarterly or 250 hours

Inspection:

A

A+B

Semi-annually or

500 hours

Inspection:

Annually or

1000 hours

Inspection:

A+B+C

A+B+C+D

Two year or

2000 hours

Inspection: A+B+C+D+E

• Place a check in the appropriate box after each inspection procedure is completed.

• Use the step-by-step procedures in this section to learn how to perform these inspections.

• If any inspection receives an “N”, tag and remove the machine from service, repair and re-inspect it. After repair, place a check in the “R” box.

Legend

Y = yes, acceptable

N = no, remove from service

R = repaired

Checklist A

A-1 Inspect the manuals and decals

A-2 Pre-operation inspection

A-3 Function tests

A-4 Obstruction sensing system (QSR models)

Perform after 40 hours:

A-5 30 day service

Perform every 100 hours:

A-6 Grease steer yokes

Y N R Checklist B

B-1 Batteries

B-2 Electrical wiring

B-3 Tires and wheels

B-4 Lifting chain

B-5 Clean columns

B-6 Sequencing cables

B-7 Emergency stop

B-8 Key switch

B-9 Horn (if equipped)

B-10 Inverter (if equipped)

B-11 Drive brakes

B-12 Drive speed - stowed

B-13 Drive speed - raised

B-14 Drive speed - slow

B-15 Alarm (if equipped)

B-16 Flashing beacons

(if equipped)

B-17 Hydraulic oil analysis

B-18 Breather cap

B-19 Electrical contactor

Y N R

Checklist C

C-1 Grease platform overload (if equipped)

C-2 Breather cap - models with optional oil

C-3 Test platform overload

(if equipped)

Y N R

Checklist D

D-1 Inspect Mast

D-2 Inspect/lubricate chains

D-3 Hydraulic filter

Y N R

Y N R Checklist E

E-1 Hydraulic oil

Comments


Section 3 • Scheduled Maintenance Procedures

Checklist A Procedures

November 2014

A-1

Inspect the Manuals and Decals

Maintaining the operator’s and safety manuals in good condition is essential to safe machine operation. Manuals are included with each machine and should be stored in the container provided in the platform. An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition.

In addition, maintaining all of the safety and instructional decals in good condition is mandatory for safe machine operation. Decals alert operators and personnel to the many possible hazards associated with using this machine. They also provide users with operation and maintenance information. An illegible decal will fail to alert personnel of a procedure or hazard and could result in unsafe operating conditions.

1 Check to make sure that the operator's and safety manuals are present and complete in the storage container on the platform.

2 Examine the pages of each manual to be sure that they are legible and in good condition.

Result: The operator's manual is appropriate for the machine and all manuals are legible and in good condition.

Result: The operator's manual is not appropriate for the machine or all manuals are not in good condition or is illegible. Remove the machine from service until the manual is replaced.

3 Open the operator's manual to the decals inspection section. Carefully and thoroughly inspect all decals on the machine for legibility and damage.

Result: The machine is equipped with all required decals, and all decals are legible and in good condition.

Result: The machine is not equipped with all required decals, or one or more decals are illegible or in poor condition. Remove the machine from service until the decals are replaced.

4 Always return the manuals to the storage container after use.

Note: Contact your authorized Genie distributor or

Genie if replacement manuals or decals are needed.



CHECKLIST A PROCEDURES

A-2

Perform Pre-operation Inspection

Completing a Pre-operation Inspection is essential to safe machine operation. The Pre-operation

Inspection is a visual inspection performed by the operator prior to each work shift. The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests. The Pre-operation

Inspection also serves to determine if routine maintenance procedures are required.

Complete information to perform this procedure is available in the appropriate operator's manual.

Refer to the Operator's Manual on your machine.

A-3

Perform Function Tests

Completing the function tests is essential to safe machine operation. Function tests are designed to discover any malfunctions before the machine is put into service. A malfunctioning machine must never be used. If malfunctions are discovered, the machine must be tagged and removed from service.

Complete information to perform this procedure is available in the appropriate operator's manual.

Refer to the Operator's Manual on your machine.




A-4

Test the Obstruction Sensing

System (QSR models only)

Genie specifications require that this procedure be performed every 8 hours or daily, whichever comes first.

1 Raise the platform approximately 4 feet / 1.2 m.

2 Place a 15 lb / 6.8 kg weight onto one of the obstruction sensing pads, of an area equal to

3 inches / 7.3 cm in diameter.

Note: The weight must be placed approximately in the center of the pad.

3 At the ground controls, attempt to lower the platform.

Result: The obstruction sensing alarm sounds and the platform will not lower. The system is working properly.

Result: The LCD at the ground controls should display OAC: Obstruction Above Chassis, indicating the obstruction sensing pads are working properly. The LED readout on the platform controls should display OAC. Refer to the examples below.

LCD Readout

LED Readout

Result: The obstruction sensing alarm does not sound and the platform will lower. The system is not functioning correctly. Replace the pad. Refer to Repair procedure 12-1, How to

Replace an Obstruction Sensing Pad.


November 2014

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.

5 Repeat the procedure, beginning with step 2, for each of the remaining obstruction sensing pads.


CHECKLIST A PROCEDURES a obstruction sensing pad

(battery tray) b obstruction sensing pad

(ground controls side) c obstruction sensing pad

(steer end) d obstruction sensing pad

(hydraulic tank side)




A-5

Perform 30 Day Service

The 30 day maintenance procedure is a one time procedure to be performed after the first 30 days or 40 hours of usage. After this interval, refer to the maintenance tables for continued scheduled maintenance.

1 Perform the following maintenance procedures:

• B-3

• D-3

Inspect the Tires and Wheels

(including castle nut torque)

Replace the Hydraulic Tank

Return Filter

A-6

Grease the Steer Yokes

Genie specifications require that this procedure be performed every 100 hours of operation.

Regular application of lubrication to the steer yokes is essential to good machine performance and service life. Continued use of an insufficiently greased steer yoke will result in component damage.

1 Locate the grease fitting on the top of the steer yoke.

2 Pump multipurpose grease into the steer yoke until the steer yoke is full and grease is being forced past the bearings. Repeat this step for the other steer yoke.

Grease Specification

Chevron Ultra-duty grease, EP NLGI 1 (lithium based) or equivalent



Checklist B Procedures

B-1

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.

Electrocution/burn hazard.

Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry.

Bodily injury hazard. Batteries contain acid. Avoid spilling or contacting battery acid. Neutralize battery acid spills with baking soda and water.

1 GR-12: Raise the platform approximately 3 feet / 1 m.

GR-15 and GR-20:

Raise the platform approximately 5 feet / 1.5 m.

2 Open the battery cover. Rest the cover against the chassis.

3 Lower the platform until the mast just contacts the battery cover.

Crushing hazard. Keep hands clear of the battery cover when lowering the platform.

4 Be sure that the battery cable connections are free of corrosion.

Note: Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables.

a batteries B5 b 275A fuse F6 c quick disconnect QD1

5 Be sure that the battery retainers and cable connections are tight.

6 Be sure that the battery separator wire connections are tight (if equipped).

7 Fully charge the batteries. Allow the batteries to rest 24 hours before performing this procedure to allow the battery cells to equalize.

8 Put on protective clothing and eye wear.



CHECKLIST B PROCEDURES

Models without maintenance-free or sealed batteries:

9 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer. Note the results.

10 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows:

• Add 0.004 to the reading of each cell for every 10° / 5.5° C above 80° F / 26.7° C.

• Subtract 0.004 from the reading of each cell for every 10° / 5.5° C below 80° F / 26.7° C.

Result: All battery cells display an adjusted specific gravity of 1.277 +/- 0.007. The battery is fully charged. Proceed to step 14.

Result: One or more battery cells display a specific gravity of 1.217 or below. Proceed to step 11.

11 Perform an equalizing charge OR fully charge the batteries and allow the batteries to rest at least 6 hours.

12 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer. Note the results.

13 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows:

• Add 0.004 to the reading of each cell for every 10° / 5.5° C above 80° F / 26.7° C.

• Subtract 0.004 from the reading of each cell for every 10° / 5.5° C below 80° F / 26.7° C.

Result: All battery cells display a specific gravity of 1.277 +/- 0.007. The battery is fully charged. Proceed to step 14.

Result: One or more battery cells display a specific gravity from 1.269 to 1.218. The battery is still useable, but at a lower performance so will need to be recharged more often. Proceed to step 14.

Result: One or more battery cells display a specific gravity from 1.217 to 1.173. The battery is approaching the end of its life.

Proceed to step 14.

Result: The difference in specific gravity readings between cells is greater than 0.1 OR the specific gravity of one or more cells is

1.172 or less. Replace the battery.

14 Check the battery acid level. If needed, replenish with distilled water to

1

/

8

inch / 3 mm below the bottom of the battery fill tube. Do not overfill.

15 Install the vent caps and neutralize any electrolyte that may have spilled.


November 2014

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.

18 Connect the battery charger to a properly grounded 115V/60Hz or, 230V/60Hz or 50Hz single phase AC power supply.

Result: The charger should operate and begin charging the batteries.

If, simultaneously, the charger alarm sounds and the LEDs blink one time, correct the charger connections at the fuse and battery.

The charger will then operate correctly and begin charging the batteries.

If, simultaneously, the charger alarm sounds and the LEDs blink two times, the input voltage is too low or too high. Correct the voltage issue. The charger will then operate correctly and begin charging the batteries.

If, simultaneously, the charger alarm sounds and the LEDs blink three times, the charger is overheated. Allow the charger to cool. The charger will then operate correctly and begin charging the batteries.

Note: For best results, use an extension of adequate size with a length no longer than

50 feet / 15 m.

Note: If you have any further questions regarding the battery charger operation, please contact

Genie Product Support.






B-2

Inspect the Electrical Wiring


Maintaining electrical wiring in good condition is essential to safe operation and good machine performance. Failure to find and replace burnt, chafed, corroded or pinched wires could result in unsafe operating conditions and may cause component damage.


Contact with hot or live circuits could result in death or serious injury. Remove all rings, watches and other jewelry.

1 Inspect the underside of the chassis for damaged or missing ground straps.

2 Inspect the following areas for burnt, chafed, corroded and loose wires:

• Mast cable

• Platform controls

• Power to platform wiring

3 Inspect the following areas for burnt, chafed, corroded and loose wires:

• Ground control panel

• Hydraulic power unit

4 Inspect for a liberal coating of dielectric grease in all wiring connections between the ECM and 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 controls.

6 Raise the platform approximately 8 feet / 2.4 m from the ground.

7 Place a lifting strap from an overhead crane under the platform. Support the platform. Do not apply any lifting pressure.

Component damage hazard. The platform railings can be damaged if they are used to lift the platform.

Do not attach the lifting strap to the platform railings.

8 Inspect the center chassis area for burnt, chafed and pinched cables.

9 Open the battery tray cover.

10 Inspect the battery tray for burnt, chafed and pinched cables.

11 Close the battery tray cover.

12 Remove the strap from the platform.

13 Lower the platform to the stowed position and turn the machine off.




B-3

Inspect the Tires and Wheels

(including castle nut torque)


Maintaining the tires and wheels in good condition is essential to safe operation and good performance. Tire and/or wheel failure could result in a machine tip-over. Component damage may also result if problems are not discovered and repaired in a timely fashion.

1 Check the tire surface and sidewalls for cuts, cracks, punctures and unusual wear.

2 Check each wheel for damage, bends and cracks.

3 Remove the cotter pin and check each castle nut for proper torque. Refer to Section 2,

Specifications.

Note: Always replace the cotter pin with a new one when removing the castle nut or when checking the torque of the castle nut.

4 Install a new cotter pin. Bend the cotter pin to lock it in place.

B-4

Check the Lifting Chain

Adjustments


Maintaining proper adjustment of the lifting chains is essential to safe machine operation. Failure to maintain proper chain adjustment could result in an unsafe operating condition and may cause component damage.

1 Fully lower the platform and measure the maximum height of the machine.

Result: The machine is within specification. No adjustment required.

Result: The machine is not within specification.

Adjust the chains. Refer to Repair procedure

3-3, How to Adjust the Lifting Chains and to

Section 2, Specifications.




B-5

Clean and Lubricate the Columns


Clean and properly lubricated columns are essential to good machine performance and safe operation. Extremely dirty conditions may require that the columns be cleaned and lubricated more often.

1 Raise the platform to the maximum height.




3 Visually inspect the inner and outer channels of the columns for debris or foreign material. If necessary, use a mild cleaning solvent to clean the columns.

Bodily injury hazard. This procedure will require the use of additional access equipment. Do not place ladders or scaffold on or against any part of the machine.

Performing this procedure without the proper skills and tools could result in death or serious injury.

Dealer service is strongly recommended.

4 If needed, apply a generous amount of

Boe-lube wax to the inside and outside channels of each column.

B-6

Adjust the Sequencing Cables


Maintaining proper adjustment of the sequencing cables is essential for safe machine operation. An unsafe working condition exists if the sequencing cables are improperly adjusted. A frequent check allows the inspector to identify changes in the sequencing cables operating condition that might indicate damage.

1 Fully lower the platform.

2 Locate the compression spring on each sequencing cable.

Note: The spring is located between the nylock nut and the upper sequencing bracket.

a b c d a nylock nut b spring c upper sequencing bracket d sequencing cable




3 Confirm proper tension of each sequencing cable by measuring the height of the spring between the nylock nut and the upper sequencing bracket.

Result: The measurement is within specification. Proceed to step 7.

Result: The measurement is not within specification. Proceed to step 4.

Sequencing cable spring specification

Measurement, compressed

15

/

16

inch

2.4 cm

4 Adjust the spring compressed length by turning the nylock nut clockwise to decrease the spring length or counterclockwise to increase the spring length.

Component damage hazard. Do not compress the spring to less than specification.

5 Raise and lower the platform through three complete cycles.

6 Repeat this procedure beginning with step 3.

7 Repeat steps 3 through 5 for each sequencing cable as required.

B-7

Test the Emergency Stop


A properly functioning Emergency Stop is essential for safe machine operation. An improperly operating red Emergency Stop button will fail to shut off power and stop all machine functions, resulting in a hazardous situation.

Note: As a safety feature, selecting and operating the ground controls will override the platform controls, except the platform red

Emergency Stop button.


2 Push in the red Emergency Stop button at the ground controls to the off position.

Result: No machine functions should operate.

3 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.

4 Push down the red Emergency Stop button at the platform controls to the off position.


Note: The red Emergency Stop button at the ground controls will stop all machine operation, even if the key switch is switched to platform control.

Note: If in ground controls mode and the red

Emergency Stop button at the platform controls is pushed in, the ground controls LCD will display,

Platform EStop Depressed. The machine alarm will sound at 1 beep per second.




B-8

Test the Key Switch


Proper key switch action and response is essential to safe machine operation. The machine can be operated from the ground or platform controls and the activation of one or the other is accomplished with the key switch. Failure of the key switch to activate the appropriate control panel could cause a hazardous operating situation.

Note: Perform this procedure from the ground using the platform controls. Do not stand in the platform.

1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls.

2 Turn the key switch to platform control.

3 Check the platform up/down function from the

ground controls

.

Result: The machine functions should not operate.

4 Turn the key switch to ground control.

5 Check the machine functions from the platform

controls

.

Result: The machine functions should not operate.

6 Turn the key switch to the off position.

7 Test the machine functions from the ground and platform controls.


B-9

Test the Automotive-style Horn

(if equipped)


The horn is activated at the platform controls and sounds at the ground as a warning to ground personnel. An improperly functioning horn will prevent the operator from alerting ground personnel of hazards or unsafe conditions.


2 Push down the horn button at the platform controls.

Result: The horn should sound.




B-10

Inspect the Voltage Inverter

(if equipped)


The inverter is activated whenever the power is on, and an electrical tool is connected to the inverter and turned on.

1 Inspect the inverter plug and pigtail for damage or excessive insulation wear. Replace as required.

2 Turn the key switch to the on position and pull out the red Emergency Stop button to the on position at both the ground and platform controls.

b a c d

FAUL

T

OUTPUT

25V

21V

PART

NUMBER

INVERTER

ER

a right fault LED b left fault LED c 25V LED d 21V LED

3 Connect an appropriate power tool to the inverter. Activate the tool.

Result: The power tool should operate. There may be a brief (0.5 second) delay if the power tool has not been used in the previous 10 minutes.

If the left fault LED (REV_POL) is illuminated, the inverter is connected to batteries with the incorrect polarity. Correct the polarity issue with the red wire to battery positive and the black wire to battery negative. The inverter will then operate correctly and begin supplying AC power.

If the right fault LED (123) blinks one time, the power draw is too high. The tool being used requires too much power to operate or is being used at or near the limit of the inverter for an extended period of time. Reduce the power draw. The inverter will then operate correctly and begin supplying AC power.

If the right fault LED (123) blinks two times, the

Ground Fault Interrupt (GFI) has been activated. A short circuit or partial short exists between the AC hot and ground in the tool or outlet. Check the tool for burnt, chafed, corroded and loose wires, and inspect the tool for internal moisture. Correct the short circuit or moisture issue OR inspect the wiring in the power-to-platform box. The inverter will then operate correctly and begin supplying AC power.

If right fault LED (123) blinks three times, the inverter is overheated. Allow the inverter to cool. The inverter will then operate correctly and begin supplying AC power.

If the battery 25 volt fault LED (25V) blinks one time, the battery voltage is over 30V. Operate the machine to lower the voltage level. The inverter will then operate correctly and begin supplying AC power.

If the battery 21 volt fault LED (21V) blinks one time, the battery voltage is less than 20V DC.

The inverter will continue to operate until the battery voltage falls to 17.8V DC.




B-11

Test the Drive Brakes

November 2014


Proper brake action is essential to safe machine operation. The drive brake function should operate smoothly, free of hesitation, jerking and unusual noise. Hydraulically-released individual wheel brakes can appear to operate normally when not fully operational.

Note: Perform this procedure with the machine on a firm, level surface that is free of obstructions.

Note: Be sure the platform extension deck is fully retracted and the platform is in the stowed position.

1 Mark a test line on the ground for reference.


3 Lower the platform to the stowed position.

4 Choose a point on the machine; i.e., contact patch of a tire, as a visual reference for use when crossing the test line.

5 Press and hold the drive/steer function enable switch on the control handle.

a drive/steer function enable switch b blue arrow

6 Move the control handle in the direction indicated by the blue arrow on the control panel until the machine begins to move forward.

7 Bring the machine to top drive speed before reaching the test line. Release the drive/steer function enable switch or the joystick when your reference point on the machine crosses the test line.

8 Measure the distance between the test line and your machine reference point. Refer to Section

2, Specifications.

Note: The brakes must be able to hold the machine on any slope it is able to climb.




B-12

Test the Drive Speed -

Stowed Position


Proper drive functions are essential to safe machine operation. The drive function should respond quickly and smoothly to operator control.

Drive performance should also be free of hesitation, jerking and unusual noise over the entire proportionally controlled speed range.


1 Create start and finish lines by marking two lines on the ground 40 feet / 12.2 m apart.



4 Choose a point on the machine; i.e., contact patch of a tire, as a visual reference for use when crossing the test line.

5 Check to make sure the low drive speed light is off. If the low dive speed light is on, press the drive speed select button to turn off the low drive speed function.


a drive/steer function enable switch b slow drive speed button c blue arrow


8 Bring the machine to top drive speed before reaching the start line. Begin timing when the selected reference point on the machine crosses the start line.

9 Continue at full speed and note the time when your reference point on the machine passes the finish line. Refer to Section 2,

Specifications .




B-13

Test the Drive Speed -

Raised Position

November 2014







3 Press and hold the high or low speed lift enable button.

4 Press the platform up button.

5 Raise the platform approximately 4 feet / 1.2 m from the ground.

6 Choose a point on the machine; i.e., contact patch of a tire, as a visual reference for use when crossing the start and finish lines.


a drive/steer function enable switch b platform up button c low speed lift enable button d high speed lift enable button e blue arrow



10 Continue at full speed and note the time when your reference point on the machine passes the finish line. Refer to Section 2,

Specifications .




B-14

Test the Slow Drive Speed








4 Press the drive speed select button until the low drive speed light is on.

5 Choose a point on the machine; i.e., contact patch of a tire, as a visual reference for use when crossing the start and finish lines.


a drive/steer function enable switch b drive speed select button c blue arrow



9 Continue at full speed and note the time when your reference point on the machine passes over the finish line. Refer to Section 2,

Specifications .




B-15

Test the Motion Alarm

(if equipped)


Alarms are used to alert operators and ground personnel of machine proximity and motion. The motion alarm is located in the ground control box and, when activated, will sound at 60 beeps per minute.


2 Press and hold the high speed lift enable button.

3 Press the platform up button and raise the platform approximately 1 foot / 0.3 m.

Result: The motion alarm should sound when the platform is raised.


5 Press the platform down button and lower the platform to the stowed position.

Result: The motion alarm should sound when the platform is lowered.

6 Press and hold the low speed lift enable button.

7 Press the platform up button and raise the platform approximately 1 foot / 0.3 m.





10 Turn the key switch to platform controls.


12 Press the platform up button and raise the platform approximately 4 feet / 1.2 m.






16 Press the platform up button and raise the platform approximately 4 feet / 1.2 m.








19 Press and hold the drive/steer function enable switch on the control handle. Move the control handle off center, hold for a moment and then release it. Move the control handle off center in the opposite direction, hold for a moment and then release it.

Result: The motion alarm should sound when the control handle is moved of center in either direction.

20 Press and hold the drive/steer function enable switch on the control handle. Press and hold the thumb rocker switch for a moment to the left position and then release it. Press and hold the thumb rocker switch for a moment to the right position and then release it.

Result: The motion alarm should sound when the rocker switch is moved off center in either direction.

B-16

Test the Flashing Beacons

(if equipped)


Flashing beacons are used to alert operators and ground personnel of machine proximity and motion. The flashing beacons are located on both sides of the mast.


Result: The beacons should flash.

2 Turn the key switch to platform controls.

Result: The beacons should flash.




B-17

Perform Hydraulic Oil Analysis


Replacement or testing of the hydraulic oil is essential for good machine performance and service life. Dirty oil may cause the machine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require oil changes to be performed more often.

Before replacing the hydraulic oil, the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary.

If the hydraulic oil is not replaced at the two year inspection, test the oil quarterly. Replace the oil when it fails the test.

See E-1, Test or

Replace the Hydraulic Oil.

B-18

Inspect the Breather Cap


A free-breathing hydraulic tank cap is essential for good machine performance and service life. A dirty or clogged cap may cause the machine to perform poorly. Extremely dirty conditions may require that the cap be inspected more often.

1 Remove the breather cap from the hydraulic tank.

2 Check for proper venting.

Result: Air passes through the breather cap.

Result: If air does not pass through the cap, clean or replace the cap. Proceed to step 3.

Note: When checking for positive tank cap venting, air should pass freely through the cap.

3 Using a mild solvent, carefully wash the cap venting system. Dry using low pressure compressed air. Repeat step 2.

4 Install the breather cap onto the hydraulic tank.


November 2014

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.

1 At the ground controls, turn the key switch to the off position.

2 Push in the red Emergency Stop button at the ground controls to the off position.

3 At the non-steer end of the machine, open the cover to access the electrical tray.

4 Locate and disconnect the Anderson connector.

5 Locate the electrical contactor mounted on the fuse bracket.

6 Visually inspect the contact points of the contactor for the following items:

• Excessive burns

• Excessive arcs

• Excessive pitting


Contact with hot or live circuits could result in death or serious injury. Remove all rings, watches and other jewelry.

Note: Replace the contactor if any damage is found.





Checklist C Procedures

November 2014

C-1

Grease the Platform Overload

Mechanism (if equipped)

C-2

Replace the

Hydraulic Tank Breather Cap -

Models with Optional Hydraulic Oil

Genie specifications require that this procedure be performed every 500 hours or 6 months, whichever comes first. Perform this procedure more often if dusty conditions exist.

Application of lubrication to the platform overload mechanism is essential to safe machine operation.

Continued use of an improperly greased platform overload mechanism could result in the system not sensing an overloaded platform condition and will result in component damage.

1 Locate the grease fittings on each pivot pin of the platform overload assembly.

2 Thoroughly pump grease into each grease fitting using a multi-purpose grease.

Genie specifications require that this procedure be performed every 500 hours or six months, whichever comes first OR when the machine fails to lift the maximum rated load.

The hydraulic tank is a vented-type tank. The breather cap has an internal air filter that can become clogged or, over time, can deteriorate. If the breather cap is faulty or improperly installed, impurities can enter the hydraulic system which may cause component damage. Extremely dirty conditions may require that the cap be inspected more often.

1 Remove and discard the hydraulic tank breather cap.

2 Install and new cap onto the tank.



CHECKLIST C PROCEDURES

C-3

Test the Platform Overload

System (if equipped)

Genie specifications require that this procedure be performed every 500 hours or 6 months, whichever comes first.

Testing the platform overload system regularly is essential to safe machine operation. Continued use of an improperly operating platform overload system could result in the system not sensing an overloaded platform condition. Machine stability could be compromised resulting in the machine tipping over.

Note: Perform this procedure with the machine on a firm, level surface.


2 Determine the maximum platform capacity.

Refer to the machine serial plate.

3 Using a suitable lifting device, place an appropriate test weight equal to the maximum platform capacity in the center of the platform floor.

Result: The LCD at the ground controls should display READY, the machine model and machine hours, indicating a normal condition.

The LED readout on the platform controls should display CH. Refer to the examples below.

LCD Readout

LED Readout

Result: The LCD at the ground controls displays OL: Platform Overloaded and the

LED readout on the platform controls displays a flashing OL. The platform overload system is not operating properly. Refer to Repair

Procedure 11-1, Calibrate the Platform

Overload System (if equipped).

LCD Readout

Part No. T110280 GR-12 • QSR • QSW

LED Readout

3 - 29


CHECKLIST C PROCEDURES

4 Add an additional weight to the platform not to exceed 20% of the maximum rated load. Refer to the machine serial plate.


LED readout on the platform controls displays a flashing OL. The platform overload system is operating properly.

Result: The LCD at the ground controls displays READY, the machine model and machine hours. The LED readout on the platform controls displays CH. The platform overload system is not operating properly.

Refer to Repair Procedure 11-1, Calibrate the

Platform Overload System (if equipped).

5 Test all machine functions from the platform controls.

Result: All platform control functions should not operate.

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. Turn the key switch to the off position.


Result: The LCD at the ground controls displays READY, the machine model and machine hours. The LED readout on the platform controls displays CH. The platform overload system is operating properly.


LED readout on the platform controls displays a flashing OL. The platform overload system is not operating properly. Refer to Repair

Procedure 11-1, Calibrate the Platform

Overload System (if equipped).


Result: All ground control functions should operate normally.

11 Turn the key switch to platform control.


Result: All platform control functions should operate.

Note: If the platform overload system is not operating properly, refer to Repair Procedure 11-

1, Calibrate the Platform Overload System

(if equipped).



Checklist D Procedures

D-1

Inspect the Mast Assembly for Wear

Genie specifications require that this procedure be performed every 1000 hours or annually, whichever comes first.

Detection of excessive or unusual wear in the mast assembly is essential for safe machine operation. An unsafe working condition exists if the mast assembly has excessive wear and/or does not operate smoothly, free of hesitation and binding.

a b c

2 Raise the platform until approximately

4 inches / 10 cm of each column is visible.

3 GR-12 and GR-15: Visually inspect the top of each column for clearance between the roller wheels and the adjacent column surface.

GR-20:

Visually inspect the top of each column for clearance between the slider block and the adjacent column surface.

Result: There should be an equal amount of distance between the roller wheel/slider block and the column on each side.

Note: If mast inspection results in a measurement that is not within specification, refer to Repair procedure 3-2, How to Adjust the Glide Pads.

4 Loosen but do not remove the adjustment nut on the sequencing cable located at the top of the first column.

5 Raise the platform approximately 3 feet / 1 m above the top of the drive chassis.

6 Place a jack stand on the top of the battery cover, centered under the platform. Adjust the jack stand height to 24 inches / 60 cm.

7 Lower the platform onto the jack stand just enough to take the weight off the lifting chains.

Crushing hazard. Keep hands clear of the jack stand when lowering the platform.

1 Remove the mast covers.

GR-15 shown a mast cover b idler wheel c spacer



CHECKLIST D PROCEDURES

8 Inspect each idler wheel for the following:

• Excessive wear on the side flanges

• Unusual wear

• Movement side to side in excess of

0.040 inch / 1 mm

• Any wheel movement front to back

Note: If idler wheel inspection results in a condition that is not within specification, refer to Repair procedure 3-1, How to Assemble the Mast.

9 GR-20: Inspect each wear pad for the following:

• Excessive or unusual wear

Note: If a wear pad displays excessive or unusual wear, refer to Repair procedure 3-1, How to

Assemble the Mast.

10 Raise the platform slightly and remove the jack stand. Lower the platform to the stowed position.

11 Install the mast covers and adjust the sequencing cable. See B-6, Adjust the

Sequencing Cables.

D-2

Inspect and Lubricate the

Lifting Chains


Lubricated chains are essential to good machine performance and safe operation. Extremely dirty conditions may require that the chains be cleaned and lubricated more often.

1 Thoroughly inspect the lifting chains. Refer to

Repair Procedure 3-3, How to Inspect the

Lifting Chains.

2 Raise the platform to the maximum height.




4 Lubricate each chain with a dry-type spray lubricant.

Bodily injury hazard. This procedure will require the use of additional access equipment. Do not place ladders or scaffold on or against any part of the machine.

Performing this procedure without the proper skills and tools could result in death or serious injury.

Dealer service is strongly recommended.



CHECKLIST D PROCEDURES

D-3

Replace the

Hydraulic Tank Return Filter


Replacement of the hydraulic tank return filter is essential for good machine performance and service life. A dirty or clogged filter may cause the machine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require that the filter be replaced more often.

Burn hazard. Beware of hot oil.

Contact with hot oil may cause severe burns.

Note: The hydraulic tank return filter is mounted on the function manifold next to the hydraulic power unit.

1 Clean the area around the oil filter. Remove the filter with an oil filter wrench.

2 Apply a thin layer of oil to the new oil filter gasket.

3 Install the new filter and tighten it securely by hand.

4 Use a permanent ink marker to write the date and number of hours from the hour meter onto the filter.


6 Activate and hold the platform up toggle switch.

7 Inspect the filter and related components to be sure that there are no leaks.

8 Clean up any oil that may have spilled.

Torque specifications

Hydraulic tank drain plug, dry

Hydraulic tank drain plug, lubricated

40 in-lbs

4.5 Nm

30 in-lbs

3.4 Nm



Checklist E Procedure

November 2014

E-1

Test or Replace the Hydraulic Oil

Genie specifications require that this procedure be performed every 2000 hours or every two years, whichever comes first.

Replacement or testing of the hydraulic oil is essential for good machine performance and service life. Dirty oil may cause the machine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require oil changes to be performed more often.

Note: Before replacing the hydraulic oil, the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary. If the hydraulic oil is not

replaced at the two year inspection, test the oil quarterly. Replace the oil when it fails the test.

Note: Perform this procedure with the platform in the stowed position.

1 Disconnect the battery pack from the machine.


Contact with hot or live circuits could result in death or serious injury.

Remove all rings, watches and other jewelry.

2 Open the power unit module tray.

3 Tag and disconnect the hydraulic tank return hard line from the hydraulic filter head and remove the hard line from the tank. Cap the fitting on the filter head.

4 Tag and disconnect the hydraulic pump inlet hard line and remove the hard line from the tank. Cap the fitting on the pump.

5 Remove the hydraulic tank retaining fasteners and remove the hydraulic tank from the machine.

6 Drain all of the oil into a suitable container.

Refer to Section 2, Specifications, for capacity information.

Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray.

7 Clean up any oil that may have spilled.

Properly discard the used oil.

8 Clean the inside of the hydraulic tank using a mild solvent. Allow the tank to dry completely.

9 Install the hydraulic tank and install and tighten the hydraulic tank retaining fasteners. Torque to specification.


Hydraulic tank retaining fasteners, dry 35 in-lbs

4 Nm

Hydraulic tank retaining fasteners, lubricated 26 in-lbs

2.9 Nm


November 2014

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. Install the fitting onto the hydraulic filter head and torque to specification. Refer to


12 Fill the tank with hydraulic oil until the fluid is at the

FULL

indicator on the hydraulic tank. Do not overfill.

13 Activate the pump to fill the hydraulic system with oil and bleed the system of air.

Component damage hazard. The pump can be damaged if operated without oil. Be careful not to empty the hydraulic tank while in the process of filling the hydraulic system. Do not allow the pump to cavitate.

14 Repeat steps 12 through 13 until the hydraulic system and tank are both full.


CHECKLIST E PROCEDURE





November 2014 Section 4 • Repair Procedures

Repair Procedures


Repair procedures shall be completed by a person trained and qualified on the repair of this machine.



Before Repairs Start:

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 parts are available and ready for use.

Use only Genie approved replacement parts.

Read each procedure completely and adhere to the instructions. Attempting shortcuts may produce hazardous conditions.

Unless otherwise specified, perform each repair procedure with the machine in the following configuration:





• Wheels chocked



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.

Perform disassembly procedures to the point where repairs can be completed. Then to re-assemble, perform the disassembly steps in reverse order.

Symbols Legend






Indicates that a specific result is expected after performing a series of steps.

Indicates that an incorrect result has occurred.


Section 4 • Repair Procedures

Platform Controls

November 2014

The platform controls are used to operate the machine from the platform.

Activating a function button sends a signal to the

Electronic Control Module (ECM). When the ECM is in the function mode, the platform controls are used to operate the various machine functions.

The platform controls consist of an Emergency

Stop button, electronic circuit board, proportional control handle, drive/steer enable switch, alarm, function buttons and LED display.

For further information or assistance, consult the

Genie Service Department.

Operational Indicator Codes

These codes are generated by the electrical system to indicate machine operating status.

During normal operation a code will appear in the platform controls LED readout if a condition such as off-level, overload cutout, chassis mode operation or pothole guards stuck occurs.

If the platform controls LED readout displays an operational indicator code such as LL, the fault condition must be repaired or removed before resuming machine operation. Push in and pull out the red Emergency Stop button to reset the system.

a red Emergency Stop button P2 b platform controls circuit board U3 c proportional control handle and drive/steer enable switch JC9 d alarm H1

CH

PHS

OAC

ND

Platform Controls LED Readout

Code Condition

LL

OL

Off-Level

Platform Overloaded (CE and Australia)

Chassis Mode Operation

Pothole Guard Stuck

Obstruction Above Chassis (QSR only)

No Drive (option)

Note: A code and a description of a code can also be viewed at the ground controls LCD display.



PLATFORM CONTROLS

1-1

Circuit Board

How to Remove the Platform

Controls Circuit Board

1 Push in the red Emergency Stop button to the off position at both the ground and platform controls.

2 Disconnect the platform controls from the control cable at the platform.

3 Remove the fasteners securing the platform control box to the platform control bracket.

4 Remove the fasteners securing the bottom cover to the platform control box. Open the control box.

5 Remove the ties securing the wire harness.

6 Disconnect the red and black wires from the alarm.

7 Carefully remove the alarm from the platform control box.

8 Carefully disconnect all wire harness connectors from the platform controls circuit board.



Component damage hazard.

Electrostatic discharge (ESD) can damage printed circuit board components. Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap.

9 Carefully remove the platform controls circuit board fasteners.

10 Carefully remove the platform controls circuit board from the platform control box.

11 Remove the transparent caps from the platform controls circuit board and save.

Circuit board fastener torque specifications

Hand tighten until screw seats < 5 in-lbs

< 0.6 Nm

Note: Before installing a circuit board, place the transparent caps removed in step 11, over the circuit board buttons.

Note: After installing the circuit board, check for proper button operation. Excessive torque of the circuit board fasteners will cause the buttons to bind. Moderate torque of the circuit board fasteners will not allow the buttons to engage.


Section 4 • Repair Procedures November 2014

PLATFORM CONTROLS

1-2

Joystick

How to Remove the Joystick





5 Remove the ties securing the joystick wire harness.

6 Carefully disconnect the joystick wire harness from the platform controls circuit board.





7 Carefully remove the joystick fasteners.

8 Carefully remove the joystick from the platform control box.


Joystick fasteners 9 in-lbs

1 Nm

1-3

Platform Controls Alarm


Controls Alarm





5 Disconnect the red and black wires from the alarm.





6 Carefully remove the alarm from the platform control box.



PLATFORM CONTROLS

1-4

Platform Emergency Stop Button


Controls Emergency Stop Button





5 Disconnect the white wires from the Emergency

Stop base.





6 Carefully remove the Emergency Stop base from the Emergency Stop button.

7 Carefully remove the retaining ring from the

Emergency Stop button.

8 Carefully remove the Emergency Stop button from the platform control box.



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.

Activating the function enable button and the up or down at the same time, sends a signal to the

(ECM). This allows the platform to be raised or lowered at the ground controls.

Note: Steer and drive functions are not available at the ground controls.

When the ECM is in the set up mode, the ground controls are used to adjust the function speed parameters, machine models, or machine options.

For further information or assistance, consult the

Genie Service Department.

4 - 6

November 2014 a circuit breaker CB2 b red Emergency Stop P1 c ECM U5 d machine setup, scroll down button f e machine setup, enter button platform up button i g platform down button h lift function enable button machine setup, escape button l j machine setup, scroll up button k LCD readout key switch KS1



GROUND CONTROLS

2-1

Software Revision Level

How to Determine the

Software Revision Level

The machine software revision level is displayed at the ground controls LCD display.

1 Turn the key switch to the ground controls position and pull out the red Emergency Stop button to the on position at both ground and platform controls.

Result: The display at the platform controls will show "CH". See example below.

2 Press the ground controls scroll down button.

Result: The ground controls LCD display will indicate the software revision and hour meter information. After 5 seconds, the ground controls LCD display will display machine model and hour meter information again.

See example below.

3 Push in the red Emergency Stop button to the off position at both the ground and platform controls and turn the key switch to the off position.

Result: The display at the ground controls will show the machine model and hour meter information. See example below.

a ground controls LCD display b ground controls scroll down button



GROUND CONTROLS

2-2

Machine Setup

How to Setup the Machine from

Ground Controls

The ground controls can be used to setup the machine parameters from the ground. Features that can be adjusted from the ground controls include machine Model, Options and Speed setup.

This menu can only be entered from ground controls with the key switch in the ground controls position.

Tip-over hazard. Do not adjust function speeds 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.

Tip-over hazard. This procedure must only be performed by a trained service professional.

Attempting this procedure without the necessary skills could result in death or serious injury.

Note: Select a test area that is firm, level and free of obstructions.

1 Turn the key switch to the ground controls position and pull out the red Emergency Stop button to the on position at the platform controls.

2 Press and hold the ground controls scroll up and scroll down buttons.

Ground Control Menu Buttons a scroll down button b enter button c scroll up button d escape button e LCD display

3 Pull out the red Emergency Stop button to the on position at the ground controls.

Result: The ground controls LCD display will show the following:

4 Use the ground control menu buttons to select machine Model, Options and Speed Setup parameters. Follow the menu structure indicated on the ground control LCD display.



GROUND CONTROLS

2-3

Level Sensor

The Electronic Control Module (ECM) is programmed to deactivate the lift and drive functions and activate an alarm when a signal is received from the level sensor.

The tilt alarm sounds when the incline of the chassis exceeds 1.5° to the side, or 3° to the front or rear.

How to Install and Calibrate the

Level Sensor

Tip-over hazard. Failure to install or calibrate the level sensor as instructed will compromise machine stability and cause the machine to tip over, resulting in death or serious injury. Do not install or calibrate the level sensor other than specified in this procedure.

Note: Perform this procedure with the machine on a firm, level surface, free of obstructions.


If you are not installing a new level sensor, proceed to step 6.

1 Tag and disconnect the level sensor wire harness from the chassis wire harness.

2 Remove the level sensor adjusting fasteners.

Remove the level sensor from the machine.

3 Place the new level sensor onto the level sensor base with the "X" on the level sensor closest to the mast of the machine and the "Y" on the level sensor closest to the steer end of the machine.

Tip-over hazard. The level sensor must be installed with the "X" on the level sensor closest to the mast of the machine and the "Y" on the level sensor closest to the steer end of the machine. Failure to install the tilt level sensor as instructed could result in the machine tipping over, causing death or serious injury.

a b

Y

X

b level sensor c 'X' indicator d mast b c



GROUND CONTROLS

4 Install the level sensor adjusting fasteners through the level sensor and springs, and into the mount. Tighten the fasteners and measure the distance between the level sensor and the level sensor mount.

Result: The measurement should be approximately

3

/

8

inch / 10 mm.

5 Connect the chassis wire harness to the level sensor wire harness.

6 Tighten the level sensor adjusting fasteners until the bubble in the top of the level sensor is centered in the calibration circles.

a adjusting fastener b calibration circles c ground controls


Result: The tilt sensor alarm should not sound.

8 Center a lifting jack under the drive chassis at the ground controls side of the machine.

9 Raise the machine approximately

2 inches / 5 cm.

10 GR-12, GR-15, QS-12R, QS-15R, QS-12W

and QS-15W:

Place a 0.65 x 6 x 6 inch / 1.65 x

15 x 15 cm thick steel block under both wheels at the ground controls side of the machine.

GR-20, QS-20R and QS-20W:

Place a

0.7 x 6 x 6 inch / 1.78 x 15 x 15 cm thick steel block under both wheels at the ground controls side of the machine.

11 Lower the machine onto the blocks.

12 Raise the platform approximately 1 foot / 30 cm.

Result: The level sensor alarm should not sound.

Result: The level sensor alarm does sound.

Adjust the level sensor retaining fasteners just until the level sensor alarm does not sound.


14 Raise the machine slightly.

15 Remove the blocks from under both wheels.

16 Lower the machine and remove the jack.

17 Center a lifting jack under the drive chassis at the tank side of the machine.


2 inches / 5 cm.



GROUND CONTROLS

19 GR-12, GR-15, QS-12R, QS-15R, QS-12W

and QS-15W:

Place a 0.79 x 6 x 6 inch / 2 x 15 x 15 cm thick steel block under both wheels at the tank side of the machine.

GR-20, QS-20R and QS-20W:

Place a

0.85 x 6 x 6 inch / 2.16 x 15 x 15 cm thick steel block under both wheels at the tank side of the machine.



Result: The platform should stop and an alarm should sound.

Result: The platform does not stop or the level sensor alarm does not sound. Adjust the level sensor until the alarm just begins to sound OR the down limit switch may need to be adjusted.





26 Center a lifting jack under the drive chassis at the steer end of the machine.


2 inches / 5 cm.

28 Place a 2.18 x 6 x 6 inch / 5.54 x 15 x 15 cm thick steel block under both wheels at the steer end of the machine.



Result: The level sensor alarm should not sound.

Result: The level sensor alarm does sound.

The level sensor is faulty and must be replaced. Repeat this procedure beginning with step 1.




34 Center a lifting jack under the drive chassis at the non-steer end of the machine.


2 inches / 5 cm.

36 Place a 2.4 x 6 x 6 inch / 6.1 x 15 x 15 cm thick steel block under both wheels at the non-steer end of the machine.


Result: The platform should stop and an alarm should sound.

Result: The platform does not stop or the level sensor alarm does not sound. The level sensor is faulty and must be replaced. Repeat this procedure beginning with step 1.







Hydraulic Pump

November 2014

3-1

Function Pump

The hydraulic pump is attached to the motor which makes up the hydraulic power unit.

How to Test the Hydraulic Pump

Note: When removing a hose assembly or fitting, the fitting and/or hose end must be torqued to specification during installation. Refer to Section 2,

Hydraulic Hose and Fitting Torque Specifications.

1 Tag, disconnect and plug the high pressure hydraulic hose from the hydraulic pump.


2 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to the high pressure port on the pump.


4 Activate the platform up function from the ground controls.

Result: If the pressure gauge reads

3200 psi / 221 bar, immediately stop. The pump is good.

Result: If pressure fails to reach

3200 psi / 221 bar, the pump is bad and will need to be serviced or replaced.


There is no relief valve in the hydraulic pump and the pump can be damaged if the pressure is allowed to exceed

3200 psi / 221 bar. When testing the pump, activate the pump in one second intervals until

3200 psi / 221 bar is confirmed.

Do not over-pressurize the pump.

5 Remove the pressure gauge and reconnect the hydraulic hose. Torque to specification.



November 2014

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. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications.

1 Tag, disconnect and plug the hydraulic supply hard line at the pump. Cap the fitting on the pump.

2 Tag, disconnect and plug the high pressure hose at the pump. Cap the fitting on the pump.


3 Remove the pump mounting bolts. Carefully remove the pump.

Tip-over hazard. After replacing the hydraulic pump, it is critical to return the function speed settings to original factory specifications.

Failure to restore the machine to original factory specifications could cause the machine to tip over, resulting in death or serious injury.


HYDRAULIC PUMP




November 2014

4-1

Function Manifold Components

8

9

4

5

6

7

The function manifold is mounted next to the hydraulic power unit.

2

3

Index

No.

—

1

Description

Schematic

Item Function Torque

Coil nut (items E, F and H) .......................................................................................................... 5 ft-lbs / 7 Nm

Diagnostic nipple ....................................... A ......................... Testing

Check disc ................................................. B ......................... Steer circuit ............................ 18 ft-lbs / 24 Nm

Relief valve,

1800 to 3500 psi / 124 to 241 bar .............. C ......................... Lift relief .................................. 20 ft-lbs / 27 Nm

Check valve, 10 psi / 0.7 bar ..................... D ......................... Drive circuit ............................. 20 ft-lbs / 27 Nm

Solenoid valve, 3 position 4 way ............... E ......................... Drive forward/reverse ............. 25 ft-lbs / 34 Nm

Solenoid valve, 3 position 4 way ............... F ......................... Steer left/right ......................... 25 ft-lbs / 34 Nm

Flow regulator and relief valve,

0.75 gpm / 2.8 L/min,

1500 psi / 103 bar ...................................... G ........................ Steer circuit ............................ 26 ft-lbs / 35 Nm

Solenoid valve, 2 position 4 way ............... H ......................... Platform up ............................. 25 ft-lbs / 34 Nm

Relief valve,

3500 psi / 241 bar maximum ..................... I .......................... System relief ........................... 20 ft-lbs / 27 Nm


November 2014

1


FUNCTION MANIFOLD

2

9

8

7

6

5

A

I

H

G

F

E

Y5

Y8

Y3

Y6

Y4

Part No. T110280

B

C

D

3

4

GR • QSR • QSW

Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic

Note: 'alpha-numeric' callouts refer to corresponding notes on the electrical schematic

4 - 15


FUNCTION MANIFOLD

4-2

Valve Adjustments -


How to Adjust the

System Relief Valve

Note: Be sure that the hydraulic oil level is at the

FULL

mark on the hydraulic tank.

1 Locate the system relief valve on the function manifold (hydraulic schematic item I).

a b a test port b system relief valve

2 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to the test port on the function manifold (hydraulic schematic item A).

3 Chock both sides of the wheels at the steer end of the machine.

4 Remove the platform controls from the platform.

Note: Perform this test from the ground with the platform controls. Do not stand in the platform.


6 Press and hold the function enable switch.

7 Move and hold the joystick fully in either direction while observing the pressure reading on the pressure gauge. Note the pressure.

Refer to Section 2, Specifications.

8 Turn the machine off. Hold the system relief valve with a wrench and remove the cap

(hydraulic schematic item I).

9 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure.

Tip-over hazard. Failure to adjust the relief valves to specification could result in the machine tipping over, causing death or serious injury. Do not adjust the relief valve pressures higher than specifications.

10 Install the relief valve cap.

11 Repeat steps 5 through 7 to confirm the relief valve pressure.



FUNCTION MANIFOLD

How to Adjust the

Platform Lift Relief Valve


FULL


1 Locate the system relief valve on the function manifold (hydraulic schematic item I).

a b c a test port b system relief valve c lift relief valve

2 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to the test port on the function manifold (hydraulic schematic item A).

3 Chock both sides of the wheels at the steer end of the machine.




6 Press and hold the function enable switch.

7 Move and hold the joystick fully in either direction while observing the pressure reading on the pressure gauge. Note the pressure.

Refer to Section 2, Specifications.

8 Turn the machine off. Hold the system relief valve with a wrench and remove the cap

(hydraulic schematic item I).


Tip-over hazard. Failure to adjust the relief valves to specification could result in the machine tipping over, causing death or serious injury. Do not adjust the relief valve pressures higher than specifications.



12 Place maximum rated load into the platform.

Secure the load to the platform. Refer to





FUNCTION MANIFOLD

14 Hold the lift relief valve with a wrench and remove the cap (hydraulic schematic item C).

15 While activating the platform up function, adjust the internal hex socket clockwise, just until the platform fully raises.

16 Fully lower the platform.

17 Add an additional 50 pounds / 22.7 kg to the platform. Secure the additional weight.

18 Attempt to raise the platform.

Result: The power unit should not be able to lift the platform.

Result: If the power unit lifts the platform, adjust the internal hex socket counterclockwise until the platform will not raise.


20 Remove the weight from the platform.

21 Bleed the hydraulic system by raising the platform to full height. If the pump cavitates or the platform fails to reach full height, add hydraulic oil until the pump is functioning correctly. Do not overfill the hydraulic tank.

Component damage hazard. Do not continue to operate the machine if the hydraulic pump is cavitating.

How to Adjust the Steer Relief

Valve


FULL


1 Locate the steer relief valve on the function manifold (hydraulic schematic item G).

a b a test port b steer relief valve

2 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to the test port (hydraulic schematic item A) on the function manifold.




November 2014


5 Activate the function enable switch and press and hold the steer thumb rocker switch to the right. Allow the wheels to completely turn to the right. Continue holding the switch while observing the pressure reading on the pressure gauge. Note the pressure. Refer to Section 2,

Specifications .

6 Press and hold the steer thumb rocker switch to the left. Allow the wheels to completely turn to the left. Continue holding the switch while observing the pressure reading on the pressure gauge.

7 Turn the machine off. Hold the steer relief valve with a wrench and remove the cap (hydraulic schematic item G).


Component damage hazard. Do not adjust the relief valve pressures higher than specifications.




FUNCTION MANIFOLD



FUNCTION MANIFOLD

4-3

Valve Coils

How to Test a Coil

A properly functioning coil provides an electromagnetic force which operates the solenoid valve. Critical to normal operation is continuity within the coil. Zero resistance or infinite resistance indicates the coil has failed.

Since coil resistance is sensitive to temperature, resistance values outside specification can produce erratic operation. When coil resistance decreases below specification, amperage increases. As resistance rises above specification, voltage increases.

While valves may operate when coil resistance is outside specification, maintaining coils within specification will help ensure proper valve function over a wide range of operating temperatures.



Note: If the machine has been in operation, allow the coil to cool at least 3 hours before performing this test.

1 Tag and disconnect the wiring from the coil to be tested.

2 Test the coil resistance using a multimeter set to resistance (

Ω). Refer to the Valve Coil

Resistance Specification table.

Result: If the resistance is not within the adjusted specification, plus or minus 10%, replace the coil.

Valve Coil Resistance

Specification

Note: The following coil resistance specifications are at an ambient temperature of 68°F / 20°C. As valve coil resistance is sensitive to changes in air temperature, the coil resistance will typically increase or decrease by 4% for each 18°F / -7.7°C that your air temperature increases or decreases from 68°F / 20°C.

Valve Coil Resistance Specifications

Description

Specification


27.2

Ω

20V DC with diode (schematic items E)


19

Ω

20V DC with diode (schematic item F)


25

Ω

20V DC with diode (schematic item H)

Solenoid valve, 2 position 2 way N.C.

6.25

Ω with manual override

12V DC with diode (schematic item N)



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. Faulty diodes can fail to protect the electrical system, resulting in a tripped circuit breaker or component damage.



1 Test the coil for resistance. See 4-3, How to

Test a Coil.

2 Connect a 10

Ω resistor to the negative terminal of a known good 9V DC battery. Connect the other end of the resistor to a terminal on the coil.

Note: The battery should read 9V DC or more when measured across the terminals.

Resistor, 10

Ω

Genie part number 27287

3 Set a multimeter to read DC amperage.

Note: The multimeter, when set to read DC amperage, should be capable of reading up to

800 mA.

4 Connect the negative lead to the other terminal on the coil.

Note: If testing a single-terminal coil, connect the negative lead to the internal metallic ring at either end of the coil.

a multimeter b 9V DC battery c 10

Ω resistor d coil

Note: Dotted lines in illustration indicate a reversed connection as specified in step 6

5 Momentarily connect the positive lead from the multimeter to the positive terminal on the 9V battery. Note and record the current reading.

6 At the battery or coil terminals, reverse the connections. Note and record the current reading.

Result: Both current readings are greater than

0 mA and are different by a minimum of 20%.

The coil is good.

Result: If one or both of the current readings are 0 mA, or if the two current readings do not differ by a minimum of 20%, the coil and/or its internal diode are faulty and the coil should be replaced.




5-1


The brake release hand pump manifold is mounted behind the hydraulic power unit.

1

2

Index

No.

Description

Schematic

Item Function Torque

Hand pump ....................................... J ................ Manual brake release .............................. 30 ft-lbs / 41 Nm

Needle valve, pilot operated ............. K ............... Manual brake release enable .............. 45-50 in-lbs / 5 Nm

J

1

2

K

Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic



Hydraulic Tank

6-1

Hydraulic Tank

The primary functions of the hydraulic tank are to cool and deaerate the hydraulic fluid during operation. It utilizes internal suction strainers for the pump supply lines and has an external return line filter.


Hydraulic Tank

Component damage hazard. The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system.




1 Tag, disconnect and plug the hydraulic supply hard line at the pump. Cap the fitting on the pump. Remove the hard line from the tank.

2 Tag, disconnect and plug the return hard line at the hydraulic filter. Cap the fitting on the filter.


3 Remove the hydraulic tank retaining fasteners and remove the hydraulic tank from the machine.


Hydraulic tank retaining fasteners, dry

35 in-lbs

4 Nm

Hydraulic tank retaining fasteners, lubricated

26 in-lbs



Steer Axle Components

November 2014

7-1

Yoke and Drive Motor

How to Remove the Yoke and Drive Motor Assembly



1 Block the wheels at the non-steer end of the machine.

2 Remove the cotter pin from the wheel castle nut at the steer end of the machine.

Note: Always replace the cotter pin with a new one when removing the castle nut.

3 Loosen the wheel castle nut. Do not remove it.



6 inches / 15 cm. Place blocks under the chassis for support.

Crushing hazard. The chassis could fall if not properly supported.

6 Remove the wheel castle nut. Remove the wheel.

7 Tag, disconnect and plug the hydraulic hoses on the drive motor. Cap the fittings on the drive motor.



Hoses can be damaged if they are kinked or pinched.

8 Support and secure the yoke assembly to an appropriate lifting device.

9 Remove the retaining fastener from the steer link at the yoke assembly.

Note: Observe and note the quantity and location of the spacers, when disconnecting the steer link from the yoke assembly.

10 Remove the retaining fastener from the rear of the yoke pivot shaft.

Note: The pivot shaft retaining fastener is located below the main deck.

11 Lower the yoke assembly out of the chassis.

Bodily injury hazard. The yoke/motor assembly may fall if not properly supported when removed from the machine.



STEER AXLE COMPONENTS

How to Remove a Drive Motor


2 Remove the cotter pin from the wheel castle nut of the motor to be removed at the steer end of the machine.








7 Tag, disconnect and plug the hydraulic hoses on the drive motor. Cap the fittings on the drive motor.




8 Remove the drive motor mounting fasteners.

Remove the motor.


Drive motor mounting fasteners, dry

75 ft-lbs

101.7 Nm

Drive motor mounting fasteners, lubricated

56 ft-lbs

76.3 Nm



STEER AXLE COMPONENTS

7-2

Steer Cylinder

How to

Remove the Steer Cylinder



2 Remove the steer cylinder hose guard bracket from the machine.

3 Remove the pin retaining fasteners from the steer cylinder barrel-end pivot pin. Remove the pin.

Note: Observe and note the quantity and location of the spacers when removing the pivot pin.

4 Remove the pin retaining fasteners from the steer cylinder rod-end pivot pin. Remove the pin.

Note: Observe and note the quantity and location of the spacers when removing the pivot pin.

5 Remove the steer cylinder from the machine.

6 Tag, disconnect and plug the hydraulic hoses from the steer cylinder. Cap the fittings.




7-3

Steer Bellcrank

How to

Remove the Steer Bellcrank

1 Remove the steer cylinder. See 7-2, How to

Remove the Steer Cylinder.





4 Turn the yokes fully to one side of the machine.

5 Remove the fasteners securing the bell crank to the steer yoke.

Note: Observe and note the quantity and location of the spacers between the bellcrank and the steer links.

6 Turn the yokes fully to the opposite side of the machine.


7 Remove the fasteners securing the bell crank to the steer yoke.

8 Remove the bellcrank from the machine.




Non-steer Axle Components

8-1

Drive Brake

How to Remove a Drive Brake



1 Block the wheels at the steer end of the machine.

2 Remove the cotter pin from the wheel castle nut at the non-steer end of the machine.



4 Center a lifting jack under the drive chassis at the non-steer end.





7 Tag, disconnect and plug the hydraulic hose from the brake. Cap the fitting on the brake.


8 Place a lifting jack under the brake for support.

9 Remove the fasteners that attach the brake to the drive chassis. Remove the brake.

Crushing hazard. The brake will fall if not properly supported when the mounting fasteners are removed.


Brake mounting fasteners, dry

75 ft-lbs

102 Nm

Brake mounting fasteners, lubricated

56 ft-lbs

76 Nm



Obstruction Sensing System

November 2014

9-1

Obstruction Sensing Pads

The function of the Obstruction Sensing System is to detect a person or an object standing on the machine chassis. When a person or an object is detected on top of the machine chassis, the machine platform down function will not operate, and an alarm will sound. The LCD readout at the ground controls will display OAC: Obstruction

Above Chassis and the LED readout on the platform controls will display OAC. Refer to the examples below.

LCD Readout

How to Replace an Obstruction

Sensing Pad (QSR models only)

1 GR-12: Raise the platform approximately 3 feet / 1 m.

GR-15 and GR-20:

Raise the platform approximately 5 feet / 1.5 m.

2 Open the battery cover. Rest the cover against the chassis.

3 Lower the platform until the mast just contacts the battery cover.

Crushing hazard. Keep hands clear of the battery cover when lowering the platform.

4 Turn the key switch to the off position and disconnect the battery pack from the machine.



LED Readout



OBSTRUCTION SENSING PADS

5 At the non-steer end of the machine, unlatch the covers and open the ground controls cover.

6 Working with the obstruction sensing pad to be replaced, locate the pad cables.

7 Carefully pull the cables to identify the connector cable located at the ground controls, non-steer end of the machine.

8 After the connector cable has been identified, tag and disconnect the cable from the obstruction sensing pad cables.

Note: If the ground controls side or battery box cover obstruction sensing pad is replaced, carefully remove the appropriate pin from the male

Deutsch connector. A new Deutsch pin will have to be installed onto the cable wire of the new ground controls side pad, or battery box cover pad.

9 Using a broad flat metal blade, carefully slide the metal blade under the obstruction pad and work the metal blade under the entire pad to be replaced, until the pad is separated from the chassis or the battery box cover.

10 Remove the pad from the machine and carefully scrape away any excess adhesive from the chassis or battery box cover.

11 Using a suitable solvent, clean the surface were the obstruction sensing pad was removed. Allow the surface to dry thoroughly.

12 Install the new obstruction sensing pad.

Note: It may be necessary to use touch-up paint in the area were the obstruction sensing pad was removed. Let the paint dry completely, before installing the new obstruction sensing pad.

Hydraulic Tank Side

Non-steer End

Ground Controls Side f

Steer End e

Obstruction Sensing Pads f a cable connectors b Deutsch connector c battery box obstruction sensing pad d ground controls side obstruction sensing pad e steer end obstruction sensing pad hydraulic tank side obstruction sensing pad a b c d



Platform Components

November 2014

10-1

Platform


1 Raise the platform approximately

1 foot / 30 cm.

2 Place support blocks between the platform and the drive chassis. Lower the platform onto the blocks.

Crushing hazard. Keep hands clear when lowering the platform.

3 Turn the key switch to the off position and disconnect the battery pack from the machine.



5 Disconnect the platform controls from the control cable at the platform. Remove the platform controls from the platform and set the controls to the side.

6 Carefully cut the cable ties securing the control cable to the platform.

Component damage hazard. The control cable can be damaged if cut while removing the cable ties.

7 Remove the fasteners securing the junction box bracket to the mast. Set the bracket and fasteners to the side.

3 Attach a lifting strap of suitable capacity from an overhead crane and center it around the platform railing. Support the platform. Do not apply any lifting pressure.

8 Remove the fasteners securing the platform mount to the mast and set the fasteners to the side. Remove the platform and mount from the machine.

Crushing hazard. The platform could become unbalanced and fall if not properly supported when removed from the machine.



PLATFORM COMPONENTS

10-2

Platform Extension


Platform Extension





3 Disconnect the platform controls from the control cable at the platform, and remove the platform controls from the platform. Set the platform controls to the side.

4 Slide the extension deck forward until the holes at the front of the extension deck are aligned with the fasteners of the slide blocks, at the front of the main deck.

5 Remove the fasteners securing the white slide blocks to the main deck. Set the slide blocks and the fasteners to the side.

6 Activate the foot release latch and slide the extension platform out of the platform.



PLATFORM COMPONENTS

10-3

Work Tray

How to Remove the Work Tray

(if equipped)





3 Disconnect the platform controls coli cord, from the control cable at the platform.

4 Remove the fasteners and spacer securing the platform controls to the platform controls mount. Remove the platform controls from the platform and set the controls to the side.

5 While supporting the work tray, remove the fasteners, bushings and spacers securing the work tray to the steer end, vertical platform rails. Set the fasteners, bushing and spacers to the side. Remove the work tray from the platform.

a b c

November 2014 d e g f l a k a work tray b screw c nylock nut d platform controls spacer f e platform controls assembly screw i g nylock not h screw nylock nut l j bushing k spacer washer j i h



Mast Components

11-1

Mast

How to

Remove the Mast Assembly

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 component damage. Dealer service is strongly recommended.


Note: Perform this procedure on a firm, level surface, with the mast in the stowed position.

1 Remove the Platform. See 10-1, How to

Remove the Platform .

2 Tag and disconnect the power to platform wire harness at the quick disconnect near the

Electronic Control Module (ECM).

3 Tag and disconnect the ECM wire harness at the quick disconnect near the ECM.

4 Attach a lifting strap of suitable capacity from an overhead crane to the lifting eye at the top of the mast. Support the mast. Do not apply any lifting pressure.

5 Tag, disconnect and plug the lift cylinder hoses at the function manifold. Cap the fittings.


6 Remove the fasteners securing the lower rear access cover to the chassis and remove the cover. Set the cover and the fasteners to the side.

7 Tag and disconnect the wire harness from the platform down valve coil at the base of the lift cylinder.

8 Remove the retaining nut securing the platform down coil to the platform down solenoid valve and remove the coil. Set the coil and retaining nut to the side.

9 Remove the platform down solenoid valve from the lift cylinder. Set the valve to the side and plug the cylinder port.


10 Remove the mast retaining fasteners.

11 Carefully pull the hydraulic hoses free while removing the mast from the machine.

Crushing hazard. The mast assembly could become unbalanced and fall if not properly supported when removed from the machine.


Cables and hoses can be damaged if they are kinked or pinched.

12 Place the mast assembly on a suitable structure capable of supporting it.



MAST COMPONENTS a b c

How to Disassemble the Mast


1 Remove the mast. See 3-1, How to Remove the Mast Assembly.

2 Rotate the mast until the carriage is facing up.

3 Remove the socket head retaining fastener from the clevis block on the lift cylinder rod end at the top of the number 1 column.

d

4 Remove the lift cylinder barrel end mounting fasteners.

a b c d a cylinder mounting plate b cylinder c cylinder mounting bolt d plate mounting fasteners

5 Loosen the lift cylinder mounting bracket fasteners.

6 Support the cylinder and carefully slide it out of the mast assembly.

Crushing hazard. The lift cylinder could become unbalanced and fall if not properly supported when removed from the machine.

a top of number 1 column b clevis block (not shown) c clevis block fastener d lift cylinder (not shown)



MAST COMPONENTS

7 Remove the cover from the top of each column.

8 Remove the adjustment nuts from all of the sequencing cables.

9 Slide the carriage toward the top of the mast assembly enough to remove the tension on the lifting chains.

10 Slide the column below the carriage toward the top of the mast assembly approximately

6 inches / 15 cm to access the idler wheel mounting fasteners.

11 Hold the idler wheel axle from turning by placing a screwdriver through the hole in the axle. Remove the axle mounting fasteners and remove the idler wheel assembly.

Note: Label the location and orientation of each idler wheel assembly.

12 Remove the adjustment nuts from the chain tension rocker on the carriage.

13 Slide the carriage out the bottom of the mast assembly.

14 Lay the chains out on the floor at the top of the mast.

Note: Do not allow the chains to become twisted or dirty.

15 Remove the adjustment nuts from the chain tension rocker on the column.

16 Remove the column by sliding the column out the bottom of the mast.

17 Push the next column toward the top of the mast to access the idler wheel assembly mounting fasteners.

18 Hold the idler wheel axle from turning by placing a screwdriver through the hole in the axle. Remove the axle mounting fasteners, and remove the idler wheel assembly.

19 Remove the adjustment nuts from the chain tension rocker on the column.

20 Slide the column out the bottom of the mast.

21 Repeat steps 17 through 20 for each remaining column.

Note: If the chains are to be removed, mark the location and label each chain before removal.



MAST COMPONENTS

How to Assemble the Mast


1 Thoroughly clean all columns.

2 Secure the number 1 column to the work table and lay the chains out on the floor.


3 Apply a generous amount of Boe-lube wax to the inside and outside channels of each column.

4 Slide the number 2 column into the number 1 column.

5 Lay the number 2 column chains on the floor.


6 Lay the number 1 column chains inside the number 2 column.

7 Slide the number 3 column into the number 2 column.

8 When the number 3 column is almost all the way in, guide the number 1 column chains into the chain tension rocker on the number 3 column.

9 Install the adjustment nuts on the number 1 column chains. Tighten the adjustment nuts until the lifting chains have equal tension and the chain tension rocker is centered in the inspection hole in the column.

10 Lay the number 3 column chains on the floor.


11 Lay the number 2 column chains inside the number 3 column.

12 Follow steps 4 through 11 for each remaining column and the carriage.

13 After all the columns are assembled, the idler wheel assemblies can be installed.

14 Remove the tension from the lifting chains on the number 2 column by pushing the number 3 column towards the top of the mast.

15 Install the idler wheel assembly in the top of the number 2 column. Tighten the mounting fasteners.

Note: Confirm that all idler wheels rotate smoothly with no excessive side movement, or rub on the inside of the column. Replace worn shims if necessary.

16 Repeat steps 14 and 15 for each remaining idler wheel assembly.

17 Confirm that all of the idler wheel axle mounting fasteners are flush with the column.

Component damage hazard. The roller wheels may be damaged if the idler wheel axle mounting fasteners are not flush with the column.

18 Install the mast assembly on the drive chassis.

Adjust the lifting chains. See 11-3, How to

Adjust the Lifting Chains.



MAST COMPONENTS

11-2

Glide Pads

Glide pads, used on the GR-12, GR-15, QS-12R,

QS-15R, QS-12W and QS-15W, and wear pads used on the GR-20, QS-20R and QS-20W, are used to provide a uniform fit between the columns as the mast extends and retracts. Over time, it may be necessary to adjust the glide pads to ensure good machine performance.

Wear pads are not adjustable and do not require servicing.

How to Adjust the Glide Pads

1 Locate the upper and lower glide pad adjustment bolts below each upper roller bolt, on both sides of each column.

2 Hold the glide pad adjustment bolt and loosen the lock nut on all glide pads.

3 Turn the glide pad adjustment bolt clockwise until the glide pad makes contact with the column. Adjust the glide pads on both sides of all columns. Be sure the sides of the columns are even to within

1

/

8

inch / 3 mm of each other.

4 On the number 1 column, secure the upper and lower glide pad bolts on both sides of the mast.

Hold the glide pad adjustment bolt and torque the lock nut to 12 in-lbs / 1.35 Nm. Be sure the glide pad bolt does not turn.

5 Repeat step 5 for the upper and lower glide pads on both sides of the each column of the mast, Start with the number 2 column and work toward the carriage.

11-3

Lifting Chains

How to Adjust the Lifting Chains

1 Mark the column to be adjusted.

2 Raise the platform approximately 6 feet / 2 m.

3 Place a lifting strap of suitable capacity from an overhead crane under the platform. Support the platform. Do not apply any lifting pressure.

Component damage hazard. The platform railings and platform extension deck (if equipped) can be damaged if they are used to lift the platform. Do not attach the lifting strap to the platform railings or the platform extension deck.

4 Turn the adjustment lock nuts evenly on both sides of the chain tension rocker clockwise to raise the column or counterclockwise to lower the column.

Note: The chain tensioner rocker is located near the bottom of each column.

5 Fully lower the platform and confirm the alignment of the columns. Repeat steps 2 through 5 if necessary.

6 Confirm that the chain tensioner bracket is centered in the inspection hole.

a b f c d e a lifting chain b chain terminal c chain tension rocker d adjustment lock nut f e mast column inspection hole



MAST COMPONENTS

How to Inspect the Lifting Chains

Inspection Procedure Inspection Failure

Wear

Inspection Remedy

Count out 16 chain links and measure pin to pin centerline dimension with a steel measuring tape.

Note: Measure a section of chain that moves over the idler wheels.

When the length of the

16 links (pin to pin) measure more than

8.25 inches / 21 cm for

1

/

2

inch / 12.7 mm chain or 10.31 inches / 26.1 cm for

5

/

8

inch / 15.9 mm chain.

Replace both chains on that column.

Replace entire chain.

Do not repair just

the affected portion of the chain.

Rust and Corrosion

Tight Joints

Visually inspect the chains for rust and corrosion.

Visually inspect the chains for lubrication.

Eviden ce of rust or corrosion.

When external surfaces are not protected with a layer of oil.

Remove chain and inspect for cracked plates

(see inspection of cracked plates). If no cracks are found, lubricate chain with motor oil (SAE 40) and install chain.

Lubricate chain with motor oil (SAE 40W).

Inspect chain link joints for easy movement.

Joints that do not flex freely or are binding.

If rust and corrosion is found, refer to Failure

Remedy for rust and corrosion.

If link plates or pins are bent or deformed, replace entire chain. Replace both chains on that column. Do not repair just the affected portion of the chain.

4 - 38 GR • QSR • QSW

Continued to the next page

Part No. T110280


MAST COMPONENTS

Inspection Procedure

Inspection Failure

Raised pins.

Inspection Remedy

Raised or Turned Pins

Chain Side

Chain Anchors

chain anchors

Idler Wheels

idler wheel

Cracked Link Plates

Visually inspect for raised pins.

Visually inspect for turned pins by insuring all the flats on the "V" heads are aligned.

Visually inspect for wear patterns on heads of link pins and outside link plates where they contact the idler wheel.

Visually inspect chain anchors.

threaded rod

Visually inspect chain idler wheels.

Visually inspect chain link plates for cracks.

Misalignment of flats on all "V" heads.

Wear on pin heads or noticeable wear in the profile of the outside link plate.

link plate wear

Broken chain anchor fingers.

Bent or damaged anchor.

Twisted or misaligned chain anchor.

Threaded rod not visible in inspection hole.

Idler wheels have badly worn flanges.

Idler wheels have grooves worn into chain contact surface.

Cracks in any chain link plate.

Replace both chains on that column section. Do not repair just the affected portion of the chain.



Check alignment of chain anchors and idler wheels.

Replace chain anchor.

Replace chain anchor.

Replace chain anchor and threaded rod.

Re-align chain anchor to ensure even loading of chain.

Replace idler wheel and check chain alignment.

Replace idler wheel.

Replace both chains on that column section.

Replace entire chain. Do not repair just the affected portion of the chain.



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



1 Remove the mast. See 11-1, How to Remove the Mast Assembly.

2 Rotate the mast until the carriage is facing down.

3 Remove the socket head retaining fastener from the clevis block on the lift cylinder rod end at the top of the number 1 column.

4 Remove the lift cylinder barrel end mounting fasteners.

5 Loosen the lift cylinder mounting bracket fasteners.

6 Support the cylinder and carefully slide it out of the mast assembly.

Crushing hazard. The lift cylinder could become unbalanced and fall if not properly supported when removed from the mast.

a b c d a top of number 1 column b clevis block (not shown) c clevis block fastener d lift cylinder (not shown)

M

L

N

e f g h e check valve f flow control g cylinder h manual lowering valve



Platform Overload Components

12-1

Platform Overload System

Calibrate the Platform Overload

System (if equipped)

Note: Perform this procedure with the machine on a firm, level surface.

1 Raise the platform approximately 2 feet / 70 cm.

2 At the platform junction box, tag and disconnect the load sense limit switch wire harness.

The red and orange wires disconnect from white wire, the black wire disconnects from the red/black wire and the white wire disconnects from the yellow wire.

Note: The load sense limit switch is located near the platform support.

3 Set a multi-meter to measure continuity.

Connect the leads from the multi-meter to the red and white wires disconnected in step 2.

4 Determine the maximum platform capacity.

Refer to the machine serial plate.

5 Using a suitable lifting device, place a test weight equal to that of the maximum platform capacity at the center of the platform floor.

Secure the weight to the platform. Refer to the chart below.

GR-12 and GR-15

Standard Platform

GR-20

Standard Platform

GR-12, GR-15 and GR-20

AWP Platform

QS-12R, QS-15R, QS-12W and QS-15W


QS-20R and QS-20W


500 lbs

227 kg

350 lbs

159 kg

350 lbs

159 kg

500 lbs

227 kg

350 lbs

159 kg



PLATFORM OVERLOAD COMPONENTS

Determine the limit switch trigger point:

6 Gently move the platform up and down by hand, so it bounces 1 to 2 inches / 2.5 to 5 cm.

7 Check the continuity between the red and white wires originating from the limit switch of the platform overload assembly.

Result: There is no continuity. Slowly tighten the load spring adjustment nut by turning it clockwise just until the limit switch closes and shows continuity.

Result: There is continuity. Slowly loosen the load spring adjustment nut by turning it counterclockwise just until the limit switch opens and shows no continuity.

Note: The platform will need to be continuously moved up and down while making adjustments.

Fine adjustment of the switch trigger point:

8 Continue moving the platform up and down and adjust the load spring adjustment nut clockwise or counterclockwise just until the limit switch is alternately opening and closing.

Note: When the limit switch is adjusted correctly, there will be continuity slightly longer than no continuity.

9 Remove the continuity tester from the limit switch wires. At the junction box, securely install the wires onto the limit switch harness.

Confirm the setting:

10 Turn the key switch to platform control.

11 Lift the test weight off the platform floor using a suitable lifting device.

12 Place the test weight back onto the platform floor using a suitable lifting device.

Result: The LCD display at the ground controls will show the machine model and hour meter information, indicating a normal condition, and the LED display at the platform controls will show the battery condition. Refer to examples below.

LCD Readout

LED Readout




13 Add an additional weight to the platform not to exceed 20% of the maximum rated load. Refer to the machine serial plate.

Result: The LCD display at the ground controls will show "OL: Platform Overloaded" and the

LED display at the platform controls will show

"OL". The platform overload system is operating properly. Refer to examples below.

LCD Readout

12-2

Platform Overload Recovery

Message

If the ground controls LCD screen displays OL:

PLATFORM OVERLOADED

, the emergency lowering system has been used while the platform was overloaded.

How to Clear the Platform

Overload Recovery message

Note: This message shall be cleared by a person trained and qualified on the troubleshooting and repair of this machine.

Note: Use the following chart to identify the description of each LCD screen control buttons used in this procedure.

LED Readout

Result: The LCD display at the ground controls will show the machine model and hour meter information and the LED display at the platform controls will show the battery condition. The platform overload system is not operating properly. Repeat this procedure beginning with step 1. Refer to the examples on page 4-42.


Result: All platform control functions should not operate.



Result: All ground control functions should not operate.

Escape Scroll up Scroll down Enter

1 Turn the key switch to the ground controls position and pull out the red Emergency Stop button to the on position at the platform controls.

2 Press and hold the ground control scroll up and scroll down buttons.




3 Pull out the red Emergency Stop button at the ground controls.

Result: The ground control LCD display will show the following.

LIFT SETUP+TEST

SELECT MODEL

4 Press the scroll down button.


LIFT SETUP+TEST

SELECT OPTION

5 Press the enter button.


SELECT OPTION

PLAT. OVERLOAD



PLAT. OVERLOAD

ENABLE?

7 Press and hold the scroll down button for 5 seconds.


RESET OVLD

RECOVERY?



INPUT PASSWORD

* * * *

9 Press the buttons in the following sequence:

(down)(down)(up)(enter)

.

Note: After each key press an asterisk (*) will appear on the second line of the LCD display.


OVLD RECOVERY

RESET

Note: after 3 seconds the LCD display will return to SELECT OPTION PLAT. OVERLOAD.

10 Push in the red Emergency Stop button.


November 2014 Section 5 • Diagnostics

Diagnostics


Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine.



Unless otherwise specified, perform each repair procedure with the machine in the following configuration:





• Wheels chocked


Before Troubleshooting:


Be sure that all necessary tools and test equipment are available and ready for use.

Be aware of the following hazards and follow generally accepted safe workshop practices.

Crushing hazard. When testing or replacing any hydraulic component, always support the structure and secure it from movement.





Section 5 • Diagnostics November 2014

DIAGNOSTICS


When a malfunction is discovered, the diagnostic trouble 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.

General Repair Process

Definitions

GSDS - acronym for Genie SmartLink TM

Diagnostic System

ECM - acronym for Electronic Control Module

GCON - acronym for Ground Controls

PCON - acronym for Platform Controls

OIC - acronym for Operational Indicator Codes

DTC - acronym for Diagnostic Trouble Codes



GCON LCD Diagnostic Readout

The diagnostic readout displays alpha numeric codes that provide information about the machine operating status and about malfunctions.

The codes listed in the Diagnostic Trouble Code

Charts describe malfunctions and can aid in troubleshooting the machine by pinpointing the area or component affected.

DIAGNOSTICS

Genie SmartLink Diagnostic

System

This machine is equipped with the Genie

TM SmartLink Diagnostic System (GSDS). The

GSDS indicates a machine malfunction has happened by displaying Operational Indicator

Codes (OIC) and Diagnostic Trouble Codes

(DTC). These codes are displayed at the

Platform Controls and the Ground Controls.

The Ground Controls will display a brief description of the code at the LCD display as well.

Refer to the GCON I/O Maps, Operational

Indicator Codes (OIC) and Diagnostic Trouble

Codes (DTC) in this section, to assist in troubleshooting faults.


Section 5 • Diagnostics November 2014

DIAGNOSTICS

Ground

Controls

Pin Number

J1-04

J1-05

GCON I/O MAP without LOAD SENSE

I/O Type

Circuit Function

J1 Connector - Gray

Link to PCON - CANH

Link to PCON - CANL

Wire Gauge and Color

Power Input

Power Output

Power Input

Data Bus

Data Bus

Ground Output

Ground Input

Digital Input

14 RD

18 RD

18 WH

18GN

18 OR

18 BN

14 BN

18 BK

Digital Input

Digital Input

18 WH

18 WH/BK

N/A N/A

Power Input 14 RD

J3 Connector - Green

J3-05 Pothole Switch

J3-06 Ground

J3-07 Down Switch

J3-09 Ground

J3-10 Ground

N/A N/A

Digital Output 18 BL

Digital Output 14 RD

Digital Output

Digital Input

18 WH

18 OR/RD

Ground Input

Digital Input

Digital Input

Ground Input

Ground Input

18 BN

18 OR

18 RD/BK

18 BK

18 BK

N/A N/A

Ground Input 18 BK

J2 Connector - Black

J2-01

J2-02

J2-03

Platform Up Coil

Platform Down Coil

Steer Left Coil

J2-04 Steer Coil

J2-05 Parallel Coil (not connected)

J2-08

J2-11

Motor Controller Enable

Motor Controller Throttle

Digital Output

Digital Output

Digital Output

Digital Output

Digital Output

18 OR

18 OR/BK

18 BL/BK

18 BL

18 RD/WH

Digital Output 18 WH

N/A N/A

Digital Output 18 GN/WH

N/A N/A

Digital Output 18 WH/BK

Analog Output 18 GN

N/A N/A

5 - 4 GR • QSR • QSW

Rear of Ground Controls ECM

Part No. T110280


DIAGNOSTICS

Ground

Controls

Pin Number

J1-04

J1-05

GCON I/O MAP with LOAD SENSE

I/O Type

Circuit Function

J1 Connector - Gray

Link to PCON - CANH

Link to PCON - CANL

Wire Gauge and Color

Power Input

Power Output

Power Input

Data Bus

Data Bus

Ground Output

Ground Input

Digital Input

14 RD

18 RD

18 WH

18 GN

18 OR

18 BN

14 BN

18 BK

Digital Input

Digital Input

18 WH

18 WH/BK

N/A N/A

Power Input 14 RD

J3 Connector - Green

J3-05 Pothole Limit Switch

J3-06 Ground

J3-07 Down Limit Switch

J3-09

J3-10

Platform Overload Pressure Transducer

Platform Height Sensor

N/A N/A

Digital Output 18 BL

Digital Output 14 RD

Digital Output

Digital Input

18 WH

18 OR/RD

Ground Input

Digital Input

Digital Input

Digital Input

Digital Input

18 BN

18 OR

18 RD/BK

18 BL/WH

18 WH/BK

NA NA

Ground Input 18 BK

J2 Connector - Black

J2-02 Platform Down Coil

J2-03 Steer Left Coil

J2-04 Steer Coil

J2-05 Parallel Coil (not connected)

Digital Output

Digital Output

Digital Output

Digital Output

Digital Output

18 OR

18 OR/BK

18 BL/BK

18 BL

18 RD/WH

Digital Output 18 WH

N/A N/A

Digital Output 18 GN/WH

N/A N/A

Digital Output 18 WH/BK

Analog Output 18 GN

N/A N/A


Section 5 • Diagnostics

DIAGNOSTICS

Operational Indicator Codes

(OIC)

These codes are generated by the electrical system to indicate machine operating status such as Off-level, Overload Cutout, Chassis

Mode Operation and Pothole Guard Stuck, during normal operation.

These codes are not indicators of a device malfunction in the electrical system.

Code Condition

LL

OL

CH

PHS

OAC

ND

Off-Level

Platform Overloaded (CE and Australia)

Chassis Mode Operation

Pothole Guard Stuck

Obstruction Above Chassis (QSR only)

No Drive (option)

November 2014

Diagnostic Trouble Codes (DTC)

These codes are generated by the system to indicate that a device or circuit malfunction has been detected in the electrical system.

The types of Diagnostic Trouble Codes that may occur are explained below.

Type "HXXX" - Indicate a malfunction associated with devices that control hydraulic functions in the electrical system. The "HXXX" faults are divided into short circuit battery negative, short circuit to battery positive, open circuit and generic shorts. Example of these devices are solenoid controlled hydraulic valves and motor controller.

Type "PXXX" - Indicate a malfunction associated with power type devices in the electrical system.

The "PXXX" faults are divided into short circuit to battery negative, short circuit to battery positive, open circuit and generic shorts.

Example of these devices are horns, sensor power and alarms.

Type "UXXX" - Indicate a malfunction associated with user interface devices in the electrical system. The "UXXX" faults are divided into short circuit to battery negative, short circuit to battery positive, open circuit and generic shorts. Example of these devices are GCON up and down switches and PCON drive joystick faults.

Type "FXXX" - Indicate a malfunction associated with machine feedback devices in the electrical system. The "FXXX" faults are divided into short circuit to battery negative, short circuit to battery positive, open circuit and generic shorts.

Example of these devices are limit switches, height sensors and pressure transducers.

Type "CXXX" - Indicate a malfunction associated with controls devices in the electrical system. Example of these devices are platform controls and ground controls ECM.



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

1 Check the fault device for a short or open circuit.

Replace fauled device.

Good

2

Check short or open circuit of the harness or connector between Ground Controls and faulted device.

No Good

Repair or replace harness and/or connector.

Good

3

Check GCON Electronic Control Module (ECM).

No Good

Replace ECM.

Wiring Diagram

The wiring diagram shown below illustrates how fault type "HXXX" or "PXXX" devices are typically wired.

The signal to these types of devices originates at the Ground Controls and terminates at system ground.

Signal Side Return Side

GCON

Electronic Control Module

(ECM)

Signal Wire

DEVICE

Return Wire

In order to successfully troubleshoot "HXXX" or "PXXX" type faults, the entire faulted out circuit needs to be investigated.



DIAGNOSTICS

Fault Inspection Procedure

November 2014



DIAGNOSTICS



Type "HXXX" Faults

November 2014

DTC

Number

H001

Message on

GCON LCD

H001:COILFAULT

PLAT UP1:Bat-

H002

H003

H009

H013

H014

H015

H019

H020

H021

H027

H030

H002:COILFAULT

PLAT UP1:Open

H003:COILFAULT

PLAT UP1:Bat+

H009:COILFAULT

PLAT DOWN1:Bat+

H013:COILFAULT

DRIVE FWD1:Bat-

H014:COILFAULT

DRIVE FWD1:Open

H015:COILFAULT

DRIVE FWD1:Bat+

H019:COILFAULT

DRIVE REV1:Bat-

H020:COILFAULT

DRIVE REV1:Open

H021:COILFAULT

DRIVE REV1:Bat+

H027:COILFAULT

STEER RT:Bat+

H030:COILFAULT

STEER LT:Bat+

H067

H067:FAULT

MC ENABLE:Bat-

H069

H070

H072

H078

H080

H081

H069:FAULT

MC ENABLE:Bat+

H070:FAULT

MC THROTTLE:Bat-

H072:FAULT

MC THROTTLE:Bat+

H078:COILFAULT

PLAT DOWN1

H080:COILFAULT

STEER LEFT

H081:COILFAULT

STEER RIGHT

Problem

Description

Short circuit of the platform up

#1 circuit to battery negative.

Open circuit in the platform up

#1 circuit.


#1 circuit to battery positive.


#1 circuit to battery positive.

Short circuit of the drive forward #1 circuit to battery negative.

Open circuit in the drive forward #1 circuit.

Short circuit of the drive forward #1 circuit to battery positive.

Short circuit of the drive reverse #1 circuit to battery negative.

Open circuit in the drive reverse #1 circuit.

Short circuit of the drive reverse #1 circuit to battery positive.

Short circuit of the steer right circuit to battery positive.

Short circuit of the steer left circuit to battery positive.

Short circuit of the motor controller circuit to battery negative.

Short circuit of the motor controller circuit to battery positive.

Short circuit of the motor controller throttle circuit to battery negative.

Short circuit of the motor controller throttle circuit to battery positive.

Short circuit of the platform down #1 circuit to battery positive/negative or open circuit.

Short circuit of the steer left circuit to battery negative or open circuit.

Short circuit of the steer right circuit to battery negative or open circuit.

Possible

Causes

• Short circuit in platform up #1 harness.

• Platform up #1 coil short circuit.

• GCON ECM.

• Open circuit in platform up #1 harness.

• Platform up #1 coil open circuit.

• GCON ECM.



• GCON ECM.



• GCON ECM.

• Short circuit in drive forward #1 harness.

• Drive forward #1 coil short circuit.

• GCON ECM.

• Open circuit in drive forward #1 harness.

• Drive forward #1 coil open circuit.

• GCON ECM.

• Short circuit in drive forward #1 harness.

• Drive forward #1 coil short circuit.

• GCON ECM.

• Short circuit in drive reverse #1 harness.

• Drive reverse #1 coil short circuit.

• GCON ECM.

• Open circuit in drive reverse #1 harness.

• Drive reverse #1 coil open circuit.

• GCON ECM.

• Short circuit in drive reverse #1 harness.

• Drive reverse #1 coil short circuit.

• GCON ECM.

• Short circuit in steer right harness.

• Steer right coil short circuit.

• GCON ECM.

• Short circuit in steer right harness.

• Steer right coil short circuit.

• GCON ECM.

• Short circuit in motor controller enable wire.

• Motor Controller.

• GCON ECM.

• Contactor Coil.

• Short circuit in motor controller enable wire.


• GCON ECM.

• Short circuit in motor controller throttle wire.


• GCON ECM.

• Short circuit in motor controller throttle wire.


• GCON ECM.

• Short or open circuit in platform down #1 harness.

• Platform down #1 coil short or open circuit.

• GCON ECM.

• Short or open circuit in steer left harness.

• Steer left coil short or open circuit.

• GCON ECM.

• Short or open circuit in steer right harness.

• Steer right coil short or open circuit.

• GCON ECM.

Failure

Mode

Platform up function inhibited.

Platform up function inhibited.

All functions inhibited except platform down.

All functions inhibited.

Drive forward function inhibited.

Drive forward function inhibited.


Drive reverse function inhibited.

Drive reverse function inhibited.








Platform down function inhibited.

Steer left function inhibited.

Steer right function inhibited.



Type "PXXX" Faults

DTC

Number

P001

Message on

GCON LCD

P001:PWR FAULT

SW PWR1:Bat-

P003

P004

P005

P006

P007

P009

P013

P015

P018

P019

P003:PWR FAULT

SW PWR1:Bat+

P004:DEVICEFAULT

HORN:Bat-

P005:DEVICEFAULT

HORN:Open

P006:DEVICEFAULT

HORN:Bat+

P007:DEVICEFAULT

GCON ALARM:Bat-

P009:DEVICEFAULT

GCON ALARM:Bat+

P013:PWR FAULT

PCON PWRET:Bat-

P015:PWR FAULT

PCON PWRET:Bat+

P018:PWR FAULT

PCON POWER:Bat-

P019:PWR FAULT

PCON POWER:Bat+

Problem

Description

Short circuit of the switched power #1 circuit to battery negative.

Short circuit of the switched power #1 circuit to battery positive.

Short circuit of the automotive horn circuit to battery negative.

Open circuit of the automotive horn circuit.

Short circuit of the automotive horn circuit to battery positive.

Short circuit of the GCON alarm circuit to battery negative.

Short circuit of the GCON alarm circuit to battery positive.

Short circuit of the PCON power return circuit to battery negative.

Short circuit of the PCON power return circuit to battery positive.

Short circuit of the PCON power circuit to battery negative.

Short circuit of the PCON power circuit to battery positive.

Possible

Causes

• Short circuit in switched power #1, down limit switch, pothole limit switch, digital tilt switch harness.

• GCON ECM.

• Short circuit in switched power #1, down limit switch, pothole limit switch, digital tilt switch harness.

• GCON ECM.

• Short circuit in automotive horn harness.

• Automotive horn short circuit.

• GCON ECM.

• Open circuit in automotive horn harness.

• Automotive horn open circuit.

• GCON ECM.

• Short circuit in automotive horn harness.

• Automotive horn short circuit.

• GCON ECM.

• Short circuit in GCON alarm harness.

• GCON alarm short circuit.

• GCON ECM.

• Short circuit in GCON alarm harness.

• GCON alarm short circuit.

• GCON ECM.

• Short circuit in PCON power return harness.

• GCON ECM.

• Short circuit in PCON power return harness.

• GCON ECM.

• Short circuit in PCON power harness.

• GCON ECM.

• Short circuit in PCON power harness.

• GCON ECM.

Failure

Mode



Automotive horn inhibited.



GCON alarm inhibited.

GCON alarm inhibited.







Type "UXXX" Faults

November 2014

DTC

Number

U001

Message on

GCON LCD

U001:SWITCHFAULT

GCON MAIN FTN EN

U002

U003

U004

U005

U006

U007

U014

U015

U016

U017

U018

U019

U020

U021

U022

U002: SWITCHFAULT

GCON PLAT UP

U003: SWITCHFAULT

GCON PLAT DOWN

U004:SWITCHFAULT

GCON LCD UP

U005:SWITCHFAULT

GCON LCD DOWN

U006:SWITCHFAULT

GCON LCD ENTER

U007:SWITCHFAULT

GCON LCD ESCAPE

U014:SWITCHFAULT

PCON DRIVE EN

U015:SWITCHFAULT

PCON STEER LEFT

U016:SWITCHFAULT

PCON STEER RIGHT

U017:SWITCHFAULT

PCON HORN

U018:SWITCHFAULT

PCON LO DRIV SPD

U019:SWITCHFAULT

PCON LO LIFT SPD

U020:SWITCHFAULT

PCON HI LIFT SPD

U021:SWITCHFAULT

PCON UP

U022:SWITCHFAULT

PCON DOWN

U033

U034

U035

U036

U033:JSTICKFAULT

OUT OF CAL RANGE

U034:JSTICKFAULT

OUT OF RANGE:HI

U035:JSTICKFAULT

OUT OF RANGE:LO

U036:SWITCHFAULT

GCON + PCON:ON

Problem

Description

Short circuit of the GCON main function enable switch at system startup.

Short circuit of the GCON up directional switch at system startup.

Short circuit of the GCON down directional switch at system startup.

Short circuit of the GCON LCD scroll up switch at system startup.

Short circuit of the GCON LCD scroll down switch at system startup.

Short circuit of the GCON LCD enter switch at system startup.

Short circuit of the GCON LCD escape switch at system startup.

Short circuit of the PCON drive enable switch at system startup.

Short circuit of the PCON steer left switch at system startup.

Short circuit of the PCON horn switch at system startup.

Short circuit of the PCON low drive speed switch at system startup.

Short circuit of the PCON low lift speed switch at system startup.

Short circuit of the PCON high lift speed switch at system startup.

Short circuit of the PCON up directional switch at system startup.

Short circuit of the PCON down directional switch at system startup.

PCON drive joystick signal is outside acceptable calibration range at system startup.

Short circuit of the PCON drive joystick signal to battery positive at system startup.

Short circuit of the PCON drive joystick signal to battery negative at system startup.

Mis-wiring or short circuit of

GCON key switch.

Possible

Causes

• Short circuit of the GCON main function enable switch.

• GCON ECM.

• Short circuit of the GCON up directional switch.

• GCON ECM.

• Short circuit of the GCON down directional

switch.

• GCON ECM.

• Short circuit of the GCON LCD scroll up switch.

• GCON ECM.

• Short circuit of the GCON LCD scroll down

switch.

• GCON ECM.

• Short circuit of the GCON LCD enter switch.

• GCON ECM.

• Short circuit of the GCON LCD escape switch.

• GCON ECM.

• Short circuit of the PCON drive enable switch.

• GCON ECM.

• Short circuit of the PCON steer left switch.

• GCON ECM.

Short circuit of the PCON steer right switch at system startup.

• Short circuit of the PCON steer right switch.

• GCON ECM.

• Short circuit of the PCON horn switch.

• GCON ECM.

• Short circuit of the PCON low drive speed

switch.

• GCON ECM.

• Short circuit of the PCON low lift speed switch.

• GCON ECM.

• Short circuit of the PCON hi lift speed switch.

• GCON ECM.

• Short circuit of the PCON up directional switch.

• GCON ECM.

• Short circuit of the PCON down directional

switch.

• GCON ECM.

• PCON drive joystick is not in neutral position at startup.

• PCON joystick.

• GCON ECM.

• Short circuit of PCON drive joystick signal

circuit.

• PCON joystick.

• GCON ECM.

• Short circuit of PCON drive joystick signal

circuit.

• PCON joystick.

• GCON ECM.

• Short circuit in the GCON key switch harness.

• GCON key switch.

• GCON ECM.

All PCON drive and steer functions inhibited.



Failure

Mode

All GCON functions inhibited.

All GCON functions inhibited except platform down.

All GCON functions inhibited except platform up.

All GCON LCD menu functions inhibited.







PCON horn switch function inhibited.

The machine is limited to low drive speed.

PCON platform up

& down functions inhibited.

PCON platform up

& down functions inhibited.

PCON platform up function inhibited.

PCON platform down functions inhibited.




Type "FXXX" Faults

DTC

Number

F003

F005

F007

F008

F009

F010

F011

F034

F035

F036

Message on

GCON LCD

F003:SWITCHFAULT

DOWN LIMIT1:Bat+

Problem

Description

Short circuit of the down limit

#1 switch at system start up.

Possible

Causes

• Short circuit of the down limit switch circuit.

• Down limit #1 switch short circuit.

• GCON ECM.

F005:SWITCHFAULT

POTHOLE1:Bat+

Short circuit of the pothole limit

#1 switch at system start up.

• Short circuit of the pothole switch circuit.

• Pothole limit #1 switch short circuit.

• GCON ECM.

F007:SWITCHFAULT

CHASSISTILT:Bat+

Short circuit of the chassis digital tilt switch at system start up.

• Short circuit of the chassis digital tilt switch

circuit.

• Chassis digital tilt switch short circuit.

• GCON ECM.

F008:SENSORFAULT

OVLD XDUCER:Bat+

F009: SENSORFAULT

OVLD XDUCER:Bat-

Short circuit of the Platform

Overload Transducer circuit to battery positive.


Overload Transducer circuit to battery negative.

• Short circuit in the transducer circuit.

• Faulty pressure transducer.

• GCON ECM.

• Short circuit in the transducer circuit.

• Faulty pressure transducer.

• GCON ECM.

F010:SENSORFAULT

PLAT HEIGHT:Bat+


Height Sensor circuit to battery positive.

• Short circuit in the platform height circuit.

• Faulty platform height sensor.

• GCON ECM.

F011:SENSORFAULT

PLAT HEIGHT:Bat-


Height Sensor circuit to battery negative.

• Short circuit in the platform height circuit.

• Faulty platform height sensor.

• GCON ECM.

F034:SENSORFAULT

OVLD:PLAT HEIGHT

F035:SWITCHFAULT

OVLD RANGE: LOW

F036:SWITCHFAULT

OVLD RANGE: HI

Height Sensor settings are not calibrated correctly.

Height Sensor setting is lower than calibrated stowed height.

Height Sensor setting is higher than calibrated maximum height.

• Height sensor needs calibration for stowed height and maximum height settings.

• GCON ECM or PCON ECM

• Height sensor not calibrated for stowed height correctly.


• Height sensor not calibrated for maximum height correctly.


Failure

Mode


All functions inhibited except platform down as long as machine is in the elevated position.

If machine is in stowed position, all functionality is resumed.

All functions inhibited except platform down as long as machine is in the elevated position.

If machine is in stowed position, all functionality is resumed.



All functions inhibited. Platform down, if machine is in an elevated position.

If machine is in the stowed position, all functionality is resumed.

All functions inhibited. Platform down, if machine is in an elevated position.

If machine is in the stowed position, all functionality is resumed.






Type "CXXX" Faults

November 2014

DTC

Number

C001

Message on

GCON LCD

C001:GCON ECM

FAULT TYPE 1

C003

C004

C005

C006

C007

C021

C022

C023

C024

C025

C003:GCON ECM

FAULT TYPE 3

C004:GCON ECM

FAULT TYPE 4

C005:GCON ECM

FAULT TYPE 5

C006:GCON ECM

FAULT TYPE 6

C007:GCON ECM

FAULT TYPE 7

C021:PCON NOT

DETECTED

C022:COMM FAULT

GCON-PCON

C023:MACHINE

MODEL FAULT

C024:PARAMETER

PROGRAM FAULT

C025:SYSTEMFAULT

PLAT OVLD:NoCal

C028

C028:SERVICE

OVERRIDE MODE ON

Problem

Description

GCON ECM CRC check error.

Possible

Causes

• Incorrect software file.

• GCON ECM internal failure.

Failure

Mode


GCON ECM external memory error.

GCON ECM master switch error.

GCON ECM safety switch error.

GCON ECM input redundancy error.

GCON ECM inter-processor communication error.

PCON not detected error.

Communication failure between PCON and GCON.

Discrepancy between model detected and model programmed.

Invalid machine parameters.

Platform overload system not calibrated.

• GCON ECM.

• Short circuit in the master switch circuit.

• GCON ECM.



• Short circuit in the safety switch circuit.

• GCON ECM.


• Input conditioning circuit failure.

• GCON ECM.

• Incorrectly programmed device

• Error in loading software on device.

• GCON ECM.

• PCON is missing.

• Communication bus failure.

• GCON or PCON ECM.

• CAN communication failure.

• CAN communication harness.


• Incorrect machine model programmed by user.


• Incorrect machine parameter programmed by user.


• Platform overload system not calibrated.









Machine is in service override mode.

• Machine programmed for use in service override mode

All functions inhibited except for down function and up function.

Platform can be elevated only once, with the maximum elevate time of X seconds. Elevate time X, depends on machine model.


November 2014 Section 6 • Schematics

Schematics


Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine.



Before Troubleshooting:


Be sure that all necessary tools and test equipment are available and ready for use.


There are two groups of schematics in this section.

An illustration legend precedes each group of drawings.

Electrical Schematics

Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry.

Hydraulic Schematics


General Repair Process


Section 6 • Schematics

Electrical Component and Wire Color Legends

November 2014

ELECTRICAL COMPONENT LEGEND

Item Description

B5 Battery

CB2 Circuit breaker, 7A

CON1 Contactor, Motor controller power, NOHC

D

Diode

D1 = Motor controller enable, 3A

D2 = Motor controller B+, 3A

EN4 Enclosure - AC outlet box

GND Ground

H

Horn or alarm

H1 = Horn

H2 = Automotive-style horn (option)

H5 = Multifunction alarm

LS

Limit switch

LS6 = Platform down

LS7 = Pothole

LS8 = Pothole

LS19 = Load sense (option)

M5 Hydraulic unit

P

QD

Power switch

P1 = Emergency Stop button at ground controls

P2 = Emergency Stop button at platform controls

Quick disconnect

QD1 = Battery quick disconnect

QD3 = Control cable to ground

QD4 = Control cable to platform

QD30 = AC plug

QD31 = GCON ECM, ground and platform controls

QD32 = GCON ECM, switches and sensors

QD33 = GCON ECM, function manifold

QD34 = Power buss, switches and sensors

QD35 = Ground buss, switches and sensors

QD36 = Pothole guard switches

QD37 = Down limit switch

QD38 = Level sensor

QD39 = Ground buss, function manifold

QD40 = Drive reverse coil, Y5

QD41 = Drive forward coil, Y6

QD42 = Steer right coil, Y3

QD43 = Steer left coil, Y4

QD44 = Platform up coil, Y8

QD45 = Obstruction pads, power signal in

(QS retail)

QD46 = Obstruction pads, power signal out

(QS retail)

QD47 = Platform controls PCB, power/signal in

QD48 = Platform controls PCB, E-Stop and alarm

QD49 = Platform controls PCN, joystick

ELECTRICAL COMPONENT LEGEND cont.

Item Description

R

Resistor

R27 = Resistor 25 Ohm, 25W (QS retail)

R30 = Resistor, 200 Ohm, 10W

U

Electronic component

U3 = Platform controls printed circuit board

U5 = Electronic control module

Y

U13 = Voltage inverter (option)

U47A = Obstruction sensing pad

(hydraulic tank side) (QS retail)

U47B = Obstruction sensing pad

(battery tray) (QS retail)

U47C = Obstruction sensing pad

(steer end) (QS retail)

U47D = Obstruction sensing pad

(ground controls side) (QS retail)

Valve coil

Y3 = Steer right

Y4 = Steer left

Y5 = Drive reverse

Y6 = Drive forward

Y7 = Platform down

Y8 = Platform up

WIRE COLOR LEGEND

Color Description

BK Black

BL Blue

BL/BK Blue/Black

BL/OR Blue/Orange

BN Brown

GN Green

GN/WH Green/White

GN/YL Green/Yellow

LT BL Light Blue

OR Orange

OR/BK Orange/Black

OR/RD Orange/Red

RD Red

RD/BK Red/Black

WH White

WH/BK White/Black

YL Yellow



Wiring Diagram

Ground and Platform Controls



Electrical Symbols Legend

November 2014

Limit switch

Motor controller

Key switch

Wire with description or color

Emergency Stop button

Circuit breaker

Circuits crossing no connection

Fuse

Diode

Horn or alarm

Circuit connection

Flashing beacon

Deutsch connector

Resistor

Motor

Battery charger

6V DC battery

Sensor pad

(QSR only)

Solenoid valve with diode

Level sensor

Pressure switch

Contactor


6 - 5

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)

4

5

2

3

6

7

8



•

GR and QSW



A B C D E F G H

1

I J K L M N


N M L K J I



•

GR and QSW



H G F E D C B A

1

2

6

7

8

3

4

5




•

GR and QSW


(from serial number GR10-20000 to GR11-2068

and serial number QS11-1000 to QS11-1015)

6 - 7 6 - 8



•

GR and QSW


(from serial number GR11-20684 and serial number QS11-1016)

November 2014

6 - 9 6 - 10

4

5

2

3

6

7

8



•

GR and QSW



A B C D E F

1

G H I J K L M N


N M L K J I H G



•

GR and QSW



F E D C B A

1

2

6

7

8

3

4

5




•

GR and QSW



6 - 11 6 - 12



•

QSR


(from serial number QS11-1000 to QS11-1015)

6 - 13 6 - 14

4

5

2

3

6

7

8



•

QSR



A B C D E

1

F G H I J K L M N


N M L K J I H G F



•

QSR



E D C B A

1

2

6

7

8

3

4

5




•

QSR



6 - 15 6 - 16



•

QSR


(from serial number QS11-1016)

November 2014

6 - 17 6 - 18

4

5

2

3

6

7

8



•

QSR



A B C D

1

November 2014

E F G H I J K L M N


N M L K J I H G F

November 2014

E



•

QSR



D C B A

1

2

6

7

8

3

4

5




•

QSR



6 - 19 6 - 20



•

GR and QSW

CE and AUS Models


6 - 21 6 - 22

4

5

2

3

6

7

8



•

GR and QSW



A B C D E F G H

1

I J K L M N


N M L K J I


H


•

GR and QSW



G F E D C B A

1

2

6

7

8

3

4

5




•

GR and QSW



6 - 23 6 - 24



•

GR and QSW



November 2014

6 - 25 6 - 26

4

5

2

3

6

7

8



•

GR and QSW



A B C D E F

1

G H I J K L M N


N M L K J I H G


F


•

GR and QSW



E D C B A

1

2

6

7

8

3

4

5




•

GR and QSW



6 - 27 6 - 28



•

QSR



6 - 29 6 - 30

4

5

2

3

6

7

8



•

QSR



A B C D E

1

F G H I J K L M N


N M L K J I H G F


E


•

QSR



D C B A

1

2

6

7

8

3

4

5




•

QSR



6 - 31 6 - 32



•

QSR



November 2014

6 - 33 6 - 34

4

5

2

3

6

7

8



•

QSR



A B C D

1

November 2014

E F G H I J K L M N


N M L K J I H G F

November 2014

E


D


•

QSR



C B A

1

2

6

7

8

3

4

5




•

QSR



6 - 35 6 - 36


Hydraulic Component Reference and

Symbols Legend

Orifice

M

Variable speed motor

Brake

Check valve

Y4

Solenoid operated

3 position 4 way directional valve

Y3

I

Hydraulic cylinder

Fixed displacement pump

Y8



Bi-directional motor

Relief valve

Filter

Y7


2 position 2 way directional valve normally closed with manual override

Priority flow regulator

Hand pump

J

A

B

K

L

H

F

G

Y5

Y8

Y3

Y6

Y4

E

Function manifold

D

C

Brake manifold

M

Y6



Pilot operated needle valve

Y5

T

Lift cylinder

E

N



Hydraulic Schematic

(to GR12-24138 and QS12-1063)

November 2014



HYDRAULIC SCHEMATIC

(from GR12-24139 and QS12-1064)
