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Service Manual - Genie Industries

1. BOX QD4A L RD BK DENES p RD RD RD 4 4 RD OR BK 3 WH 8 CR48 4 POWER RELAY TO 05 d 85 E STOP QD4 z z 6 6 RD BK 2 SSS EMERGENCY WH BK 1 1 r YL STOP a BL 2 2 BL RD r POWER TO PLATFORM 8 OR 5 5 OR WH 3 2 3 RD POWER TO GROUND HD SSS BK 1 1 WH GROUND x Lo PIO3 H z 2 2 BL DATALINK HIGH O PIO4 OR 5 gt 5 OR DATA LINK LOW 1t OPIO5 2 o Sa S pay DC z cruce cierta m LI 1 if T 1 N C U3 D7 svec 4 PLATFORM CONTROLS VOLTAGE PRINTED CIRCUIT BOARD REGULATOR E LEVEL SENSOR n E zo CIRCUIT 6 BOARD BN HALL EFFECT JC1 k i eENERAToR JOYSTICK S7 z GY
2. z z 4 3 RD POWER GROUND RD z Er EA PK aut 4 1 1 J WH GROUND Biba Loe L BL BL BL 2 j 2 BL DATALINK HIGH 4 oR OR 5 5 OR DATA LINK LOW lopios H 24V DC 55 BEBE BeBe eee 1 LI CONNECTED i z HERE WHEN KEYPAD OPTION IS INSTALLED 2 9 038 U3 07 5 2 PLATFORM CONTROLS VOLTAGE z PRINTED CIRCUIT BOARD REGULATOR 111 MS um z i 5 9 p MEE z _ 6 0 BN o HALL EFFECT JC1 7 WeENERHTOR JOYSTICK 3 7 GY X CONTROLLER KEYPAD OPTION gt l CR58 RD i GN KEYPAD 5 F WH RELAY BL I 1 11 SW5 SW6 80 86 2 FUNCTION ENABLE STEER J 4 E 1 LEFT RIGHT 85 l PIN9 OR R 2 GN YL 3 9 PINS BK 3 D PIN10 sn L Sas BL 2222 22 7 2 2 PLATFORM CONTROLS 1 zt MEMBRANE DECAL U47B U47A POUTI 4 LIFT LED L16 OBSTRUCTION SENSING OBSTRUCTION SENSING
3. WIRE CONNECTS TO OUTLET BOX LS19 L px _ AC __ __ GROUND SCREW AND OUTLET PLUG LOAD OUTLET GROUND TERMINAL li N O SENSE LB oR 4 OR 1 LIMIT i RD BK WH ZL WH excl SWITCH RD RD z EN4 BK ET P2 AC OUTLET BOX 5 EMERGENCY Q 3 K RD RD RD T 4 4 BK POWER PLATFORM _ _ x m RD WH IWH WH 3 3 RD POWER TO GROUND cv YL BK 1 WH GROUND x O PIOS 2 BL BL BL 2 2 BL DATALINK HIGH TO PIO4 OR OR OR 5 5 OR DATA LINK LOW s opis E gt pay DC H eee a PETTITT INOTCONNECTED HERE WHEN KEYPAD isvoc OPTION IS INSTALLED az 9 z U3 D7 z SS TEE 9 T 2 E PLATFORM CONTROLS VOLTAGE PRINTED CIRCUIT BOARD REGULATOR m 038 a a KEYPAD SH 5 BN T HALL EFFECT JC1 fT GENERATOR JOYSTICK 5 9 X CONTROLLER 1 KEYPAD OPTION 6 0 3 7 o GN CR58 RD 4 8 o HH BL KEYPAD RELAY ze SW5 SW6 2 9 FUNCTION ENABLE T STEER 30 4 86 io e t LEFT RIGHT 4 i OF Z 9 E M
4. QUICK DISCONNECT P1 KS1 EMERGENCY KEY SWITCH STOP eB ee oR i 2 RD PLATFORM CONTROL a 4 a H5 ALARM e N CHO 4 i GROUND CONTROL J a z LS7 POTHOLE CB2 G RO U N D PLATFORM SWITCH UP DOWN LI 7A J AC INPUT CIRCUIT CONTRO LS N C H O BREAKER 5 S o 110V 240V AC m 156 or DOWN Li SWITCH z ux 2 2 g MACHINE SHOWN 3 3 Q 2 9 IN THE STOWED 0 5 2 POSITION WITH 2 2 3 THE POWER OFF E m 3 vu 2 a 8 QD1 5 E LJ F6 275a FUSE 689 Eg 5 zu op el i A12 B12 11 B10 4 Bii C5 C10 C12 Di N IN N IN N NN IN z U9 GN A9 OUT BATTERY E BK A8 OUT US CHARGER i oom ELECTRONIC CONTROL MODULE A1 our B5 z OUT OUT OUT OUT OUT 4 6V B B8 B3 C7 B7 A7 BATTERY RD 2 E CAD U6 FLASHING E E
5. 3 14 B 7 Test the Emergency 4 04 044 0 00 000 00 3 15 8 Test the Key uer itr dtes ai ia 3 16 B 9 Testthe Automotive style Horn if 3 16 B 10 Inspect the Voltage Inverter if 3 17 B 11 Testthe Drive Brakes occitana niria 3 18 B 12 Test the Drive Speed Stowed 3 19 B 13 Test the Drive Speed Raised 3 20 B 14 Test the Slow Drive Speed 3 21 B 15 Test the Motion Alarm 3 22 B 16 Test the Flashing Beacons if equipped 3 23 B 17 Perform Hydraulic Oil 3 23 B 18 Inspect the Breather 3 24 D Checklist C Procedures C 1 Grease the Platform Overload Mechanism if equipped 3 25 C 2 Replace the Hydraulic Tank Breather Cap Models with Optional Hydraulic 3 25 C 3 Testthe Platform Overload System if equipped 3 26 D Checklist D Procedures D 1 Inspect the Mast Assembly for 3 28 D 2 Inspect and Lubricate the Lifting
6. u el eee X PLATFORM CONTROLS ey Ke BK RD gs JC1 H1 6 JOYSTICK Gy 4 A CONTROLLER EE I WH E E m o RD P2 5 EMERGENCY 69 5 STOP TO COIL CORD Genie Part No 84700 GR QSR QSW 6 5 Section 6 Schematics September 2009 Electrical Symbols Legend REV B N C 4 N C H O 4 DUUM C qe o1 5 f a 2 Limit switch fl E 57 LEVEL N Enn le SENSOR 1 E m o NC Level sensor Button or switch Wire with description or color us Solenoid valve with diode Toggle switch Circuits crossing no connection A CN 5 ul Capacitor Emergency Stop button Battery charger z Resistor Diode Pye dia CE 2 pu T sud Circuit breaker EE 6V DC battery Q 2 NO Circuit connection i je pO Pressure Switch 87A ter Control relay us Connector BU KS1 KEY PLATFORM Fus
7. POTHOLE DOWN GUARD d SWITCH LIMIT SWITCH NOTE MACHINE SHOWN 2001 5 50 8 IN THE STOWED B 2 2 50 2 POSITION WITH z z z 3 m 2 THE POWER OFF 5 v z 2 z 3 7 9 E F6 275 FUSE 5 2 LLLI ll L A12 B12 AM B10 4 B11 C5 C10 C12 1 IN IN IN OUT IN N N N IN z GN A9 OUT U9 U5 BATTERY A BK 1 OUT CARE ee s z ELECTRONIC CONTROL MODULE Ai OUT B5 OUT OUT OUT OUT OUT 4 6V ao gt B8 B3 c7 B7 A7 a wW Ww Q uL E mew 3 p o j AC MOTOR OPTION 4 A INPUT CONTROLLER H BK i CR5 N HORN RELAY m m 30 H2 OPTION 86 U13 8 1 87 85 DG AC INVERTER 2 4 Y5 _ OPTION 066 STEER STEER DRIVE RIGHT LEFT REVERSE H2 AUTO STYLE QD1 HORN A X A X A X OPTION Genie ES0126C GR QSR QSW Part No 84700 September 2009 Section 6 Schematics Electrical Schematic GR and QSW REV C ANSI and CSA Models Part 2 of 2 1 1 1 eNYL GNYL EN4 AC A BK 2 2 BK BK AC OUTLET ourler WH 3 3 LB LB
8. 1 This page intentionally left blank Genie 4 46 GR QSR QSW Part No 84700 Section 5 Fault Codes Fault Codes September 2009 Before Troubleshooting Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necessary tools and test equipment are available and ready for use Observe and Obey Be aware of the following hazards and follow Troubleshooting and repair procedures shall be generally accepted safe workshop practices completed by a person trained and qualified on the repair of this machine ADANGER Crushing hazard When testing or replacing any hydraulic component always support the structure and secure it from movement AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry M Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a firm level surface Bodilv ini h dS AWARNING 2 dily injury hazard Spraying Platform in the stowed position hydraulic oil can penetrate and Key switch in the off position with the key removed
9. sssssssssssssseseeeeeeennmene nnne 4 39 8 3 Steer Bellcrank n tie 4 39 Genie Part No 84700 GR QSR QSW ix September 2009 TABLE OF CONTENTS Section 4 Rev Repair Procedures continued A Non steer Axle Components 9 1 gt Dive tt 4 40 A Brake Release Hand Pump Components 10 1 Brake Release Hand Pump 4 41 B Platform Overload Components 11 1 Platform Overload System 1 4 42 A Obstruction Sensing System 11 1 Obstruction Sensing Pads QSR models only 4 44 Section 5 Rev Fault Codes ITOGUCTION 5 1 C Fault Code Chart enne nnne rnnt 5 3 Section 6 Rev Schematics 07 6 1 C Electrical Component and Wire Color LegendS 6 2 B ECM Pin OUt 6 3 C Relay or e 6 4 B Wiring Diagram Ground and Platform 6 5 B Electrical Symbols 6 6 C Electrical Schematic GR and QSW ANSI and CSA Models all models without platform overload protection 6 8 D Electrical Schematic GR and QSW CE models al
10. TIT OM z BEACONS T T 8 OPTION 1 INPUT CONTROLLER pe BK B CR5 i SAY HORN RELAY m br gt 1 30 H2 OPTION 426 no M i gU Pere 5 Lar U1 3 85 2 DC AC INVERTER 4 2 Y4 Y5 t OPTION G6 STEER STEER DRIVE HOUR RIGHT LEFT REVERSE METER H2 AUTO STYLE QD1 HORN A X A X A X OPTION Lg Lt Lt L Ld Ld ES0126E Genie GR QSR QSW Part No 84700 September 2009 Section 6 Schematics I N Electrical Schematic QSR REV A ANSI and CSA Models Part 2 of 3 GN L 1 pb GN YL A BK 2 2 BK WH 3 3 J LB QD4A 4 0 41 RD lt OR BK 3 3 WH JUNCTION BOX CR48 4 RELAY TO US 87 85 5 QD4 gp 6 6 RD BK WH BK 1 1 YL BL 2 2 BL OR 5 5 OR lim re 4 4 M Dn i ES i LEVEL SENSOR f CIRC
11. C11 T OUT IN N IN OUT IN IN IN IN IN OUT RD U5 ELECTRONIC CONTROL MODULE OR ORe A7 C6 A6 BL 2 5 A Ir R27 GN YL WH 25 OHMS 25 WATT 30 86 30 86 CR111A Jo 2 E CR111B Jo 2 22 OBSTRUCTION m OBSTRUCTION Y5 Y6 Y8 Y7 SENSING 87a 87 85 SENSING 87a 87 85 DRIVE DRIVE PLATFORM PLATFORM REVERSE FORWARD UP DOWN YE RD 9 H10 y _ _ FOR OBSTRUCTION SENSING SYSTEM OBSTRUCTION A B IS OPEN CLOSED OTHERWISE SENSING Ex E E OBSTRUCTION SENSING QS RETAIL BN hd bd BN OR ES0127F Genie Part No 84700 QSR QSW 6 19 Section 6 Schematics September 2009 Electrical Schematic QSR CE Models REVA Part 3 of 3 FOR UK PLUG OPTION GN YL GROUND WIRE CONNECTS TO OUTLET BOX LS19 BK oer 7 GROUND SCREW AND OUTLET PLUG LOAD GROUND TERMINAL NO SENSE LB OR OR 9 i RD BK C WH HwHe ez SWITCH RD RD A EN4 BK BK lll 2 AcOUTLETBOX LL fT EMERGENCY QD3 cS STOP RD C RD RD 4 gt 4 BK POWER TO PLATFORM oe SJ
12. 3 29 D 3 Replace the Hydraulic Tank Return Filter 3 30 B Checklist E Procedure E 1 Test or Replace the Hydraulic Oil 3 31 Genie viii GR eQSR QSW Part No 84700 September 2009 TABLE OF CONTENTS Section 4 Rev Repair Procedures oj iere 4 1 Platform Controls 1 1 Circuit Boards 4 2 1 2 Controller 0 00 4 3 1 3 Software Configuration 4 8 Platform Components 2 1 PE 4 12 2 2 Platform eroe 4 12 2 3 Work Tray secede RN 4 13 B Mast Components MASE C RR 4 14 3 2 Glide 2 4 18 3 23 Lifting Chains ted need Bete neers 4 18 9 4 Cylihder nece 4 21 B Ground Controls 1 ccs ERR 4 22 A Hydraulic Pump 5 1 Pump d rtt rete ederent reete ED o Exe a Qaa pore esu us 4 25 B Function Manifold 6 1 Function Manifold Components 2 0 000 4 28 6 2 Valve Adjustments Function Manifold 4 30 6 3 Coils e E 4 34 A Hydraulic Tank yet Bydraulic eben 4 36 Steer Axle Components 8 1 Yokeand Drive Molor eterni 4 37 8 2 Steer Cylinder
13. Electrical Component and Wire Color Legends September 2009 REV C ELECTRICAL COMPONENT LEGEND ELECTRICAL COMPONENT LEGEND Item Description Item Description B5 Battery BN Button BN5 Horn BN6 High torque 8 Drive enable 9 Lift enable P Power switch P1 Emergency Stop button at ground controls P2 Emergency Stop button at platform controls C5 Capacitor 4700 uF CB2 Circuit breaker 7A QD Quick disconnect QD1 Battery quick disconnect QD3 Control cable to ground QD4 Control cable to platform CR Control relay Resistor 25 Ohny25Watt QS retail Horn relay with H2 option CR27A Overload motor controller option CR27B Overload load sense option CR27C Overload down coil option CR48 Power relay to U5 e stop CR58 Keypad relay Keypad option CR111A Obstruction sensing QS retail CR111B Obstruction sensing QS retail Sw Switch SW5 Function enable SW6 Steer left right S7 Tilt level sensor TS66 Platform up down toggle switch Voltage regulator Platform controls circuit board Enclosure AC outlet box Fuse 275A Flashing beacons Gauge G6 Hour meter G8 Diagnostic display Ground Hom or alarm H1 Horn H2 Automotive style horn option H5 Multifunction alarm H10 Obstruction s
14. Model Serial number Date Machine owner Inspected by print Inspector signature Inspector title Inspector company Section Scheduled Maintenance Procedures September 2009 m m M This page intentionally left blank Genie 3 4 GR QSR QSW Part No 84700 September 2009 Section Scheduled Maintenance Procedures Maintenance Inspection Report Checklist B Rev D Y NR Model Checklist A Rev D YNR 1 Inspect the manuals Serial number and decals Date A 2 Pre operation inspection Hour meter A 3 Function tests A 4 Obstruction sensing system QSR models Machine owner Perform after 40 hours A 5 30 day service Perform every 100 hours ERE Inspected by print Inspector signature A 6 Grease steer yokes 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 A Quarterly or 250 hours Inspection A B Semi annually or 500 hours Inspection A B C Annually or 1000 hours Inspection 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 this section to learn how to perform these inspections
15. PAD Battery Tray PAD Hydraulic Tank Side POUT2 id 1 DRIVE LED L17 WH e BL i EA E POUT3 O HIGH TORQUE LED 121 t t G8 RD BN e POUT4 DIAGNOSTIC DISPLAY OBSTRUCTION SENSING QS RETAIL 4 m et ee x OR e BN BL 9 BL 1 es HIGH TORQUE BN6 U47D U47C PIN2 E HORN BN5 OBSTRUCTION SENSING OBSTRUCTION SENSING EN PAD Ground Controls Side PAD Steer End PINS DRIVE ENABLE BN8 0 1 sa LIFT ENABLE BN9 i RD 3 H1 PLATFORM BK ALARM pni O H ed CONTROLLER WERE S REM MEER RM NER MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES0127F Genie 6 20 QSR QSW Part No 84700 September 2009 Section 6 Schematics rame Se i This page intentionally left blank Genie Part No 84700 GR QSR QSW 6 21 Section 6 Schematics September 2009 Hydraulic Component Reference and Symbols Legend er a Orifice Hydraulic cylinder Relief valve Solenoid operated 2 position 2 way directional valve normally closed with manual override gt Gy 9 0 20 Variable speed motor Fixed displacement pump Bi directional motor JE Priority flow regula
16. 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 Part No 84700 burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Genie GR QSR QSW 5 1 Section 5 Fault Codes September 2009 L FAULT CODES REV C About This Section LED Diagnostic Readout When a malfunction is discovered the fault code chart in this section will help a service professional pinpoint the cause of the problem To use this section basic hand tools and certain pieces of test equipment are required voltmeter ohmmeter pressure gauges General Repair Process The diagnostic readout displays numerical codes that provide information about the machine Malfunction Identify Troubleshoot discovered symptoms operating status and about malfunctions The dot to the right of the numbers remain on when a 5 fault code is displayed problem still exists The codes listed in the Fault Code Chart describe malfunctions and can aid in Return to Perform troubleshooting the machine by pinpointing the service problem repair area or component affected solved Genie 5 2 GR QSR QSW
17. If any inspection receives an tag and remove the machine from service repair and re inspect it After repair place a check in the box Legend Y yes acceptable no remove from service R repaired Genie 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 Checklist C Rev D Y NR C 1 Grease platform overload if equipped C 2 Breather cap models with optional oil C 3 Test platform overload if equipped Checklist D Rev D Y NR D 1 Inspect Mast D 2 Inspect lubricate chains D 3 Hydraulic filter Checklist E Rev B Y NR E 1 Hydraulic oil Comments Part No 84700 GR QSR QSW Section Scheduled Maintenance Procedures September 2009 Checklist A Procedures 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
18. sau SS joystick controller JC1 alarm H1 platform controls circuit board U3 red Emergency Stop button P2 Genie GR QSR QSW REV E 1 1 Circuit Boards How to Remove the Platform Controls Circuit Board 1 Push the red Emergency Stop button to the off position at both the ground and platform controls 2 Remove the retaining fasteners securing the bottom to the platform control box Open the control box Remove the ties securing the wire harness Remove the alarm and red Emergency Stop button from the platform control box 5 Carefully disconnect the three wire harness connectors from the platform controls circuit board AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 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 6 Carefully remove the platform controls circuit board retaining fasteners 7 Carefully remove the platform controls circuit board from the platform control box lid Part No 84700 September 2009 Section 4 Repair Procedures REV 1 2 Controller Adjustments Platform lift speed stowed drive speed raise
19. spacer Genie QSR QSW REV D 2 Raise the platform until approximately 4 inches 10 cm of each column is visible 3 GR 12and 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 AWARNING Crushing hazard Keep hands clear of the jack stand when lowering the platform Part No 84700 September 2009 Section Scheduled Maintenance Procedures REV D 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 move
20. Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566 Service Manual GReQSRe 0OSW from serial number GRO5 5001 from serial number QS09 101 Part No 84700 Rev C1 G TEREX COMPANY
21. Section 6 Schemat ics September 2009 Relay Layout amp ez d QO Relay Layout GR and QSW a b sa ro platform overload CR27A motor cont option platform overload CR27B load sense option platform overload CR27C down coil option auto style horn CR5 option power relay CR48 ECM diagnostic display window electronic control module ECM U5 motor controller U6 REV C Relay Layout QSR a resistor 25 ohm 25 watt b obstruction sensing CR111A QS retail C obstruction sensing alarm d obstruction sensing CR111B QS retail e auto style horn 5 option f power relay CR48 g diagnostic display window h electronic control module ECM U5 i motor controller U6 Genie GR QSR QSW Part No 84700 September 2009 Section 6 Schematics Wiring Diagram REVB Ground and Platform Controls GROUND CONTROLS MOTOR CONTROLLER 79 TERMINAL B CB2 KS1 7A CIRCUIT KEY SWITCH 3 1 BREAKER MOTOR CONTROLLER _BK TERMINAL 1 6 PINCONNECTOR _ BN PIN 1 RD ECM PIN B12 O PLATFORM UP DOWN DOWN TOGGLE SWITCH CR48 PIN A12 B UP TS66 TERMINAL 30 RD ECM PIN A11 On 7 2 EMERGENCY STOP
22. 10 69 ft lbs 93 6 Nm 10 7 8 14 1 12 93 ft lbs 126 1 Nm 12 1 1 16 12 1 16 139 ft Ibs 188 5 Nm 16 1 5 16 12 1 20 172 ft lbs 233 2 Nm 20 1 5 e 12 1 24 208 ft lbs 282 Nm 24 1 7 8 12 1 SAE O ring Boss Port tube fitting installed into Steel SAE Dash size Torque 4 16 ft lbs 21 7 Nm 6 35 ft lbs 47 5 Nm 8 60 ft lbs 81 3 Nm 10 105 ft lbs 142 4 Nm 12 140 ft lbs 190 Nm 16 210 ft lbs 284 7 Nm 20 260 ft lbs 352 5 Nm 24 315 ft lbs 427 1 Nm Genie Part No 84700 GR QSR QSW 2 5 Section 2 Specifications September 2009 SPECIFICATIONS REV D Torq ue Procedure 3 Working clockwise on the body hex fitting make 1 S00 a second mark with a permanent ink marker to JIC 37 fittings indicate the proper tightening position Refer to Fi 2 1 Align the tube flare hex nut against the nose of aad u the fitting body body hex fitting and tighten the Use the JIC 37 Fittings table on hex nut to the body hex fitting to hand tight the previous page to determine approximately 30 in Ibs 3 4 Nm the correct number of flats for the tighteni ition 2 Make reference mark on one of the flats of the hex nut and continue it on to the body hex The marks indicate that the correct fitting with a permanent ink marker Refer to tightening positions have been Figure 1 determined Use the second mark P on the body hex fitting to properly 7 tighten th
23. A TEREX COMI li GR 12 GR 15 GR 20 Serial Number Information Genie Industries offers the following Service Manuals for these models Title Part No Genie Runabout Service Manual First Edition before serial number GRO5 5001 72965 Copyright O 2001 by Genie Industries 84700 Rev September 2009 Second Edition Third Printing Genie is a registered trademark of Genie Industries in the USA and many other countries GR is a trademark of Genie Industries ry 4 Printed on recycled paper Printed in U S A Part No 84700 September 2009 INTRODUCTION Serial Number Legend MANUFACTURED BY FABRIQUE PAR Genie Industries 18340 NE 76th Street Redmond WA 98052 USA A TEREX COMPANY i Model GR 15 Serial number GR05 1234 Model year 2008 Manufacture date 4 14 08 Elec Hydr Schematic ES0126 HS0039 Power supply voltage Pneumatic Pressure 85 264 VAC 60 50 Hz 900 W Nominal Power 8 3 Hp 6 2 kW Machine unladen weight 2 250 Ibs 1 021 kg Max Load 500 Ibs 227 kg Occupants and Equipment must not exceed 500 Ibs 227 kg Maximum allowable inclination of the chassis 1 5 Side 3 Front 3 Rear Maximum Wind Speed Indoor 28 mph 12 5 m s Outdoor 28 mph 12 5 m s Gradeability 3096 Maximum allowable side force 100 Ibs 445 Maximum platform height 14 ft 8 in 4 47 m Maximum Travel Height Full ht Maximum number of platform occup
24. Genie A TEREX BRAND Serial Number Range GR 12 GR 15 CAE GR 20 E QS 12R romasooaos QS 15R romasoose QS 20R tom asosio QS 12W QS 15W romasonso Qs 20W M even January 2011 January 2011 Introduction 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 2 3 as defined by ISO 16368 Machine Design Life Unrestricted with proper opeation inspection and scheduled maintenance Technical Publications Genie Industries 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 Contact Us www genieindustries com e mail techpub terex com
25. Hoses can be damaged if they are kinked or pinched 8 Remove the drive motor mounting fasteners Remove the motor Torque specifications Drive motor mounting fasteners dry 75 ft lbs 101 7 Nm Drive motor mounting fasteners lubricated 56 ft lbs 76 3 Nm Part No 84700 September 2009 Section 4 Repair Procedures REVA 8 2 Steer Cylinder How to Remove the Steer Cylinder 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 Block the wheels at the non steer end of the machine 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 AWARNING injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissip
26. Note Any change in software settings will not take effect until the key switch is turned to the off position September 2009 Section 4 Repair Procedures REV E How to Adjust the Slow Drive Speed Tip over hazard Do not adjust the lift and or drive speed higher than specified in this procedure Setting the function speeds greater than specifications could cause the machine to tip over resulting in death or serious injury ADANGER Tip over hazard This procedure must only be performed by a trained service professional Attempting this procedure without the necessary skills will result in death or serious injury Pull out the red Emergency Stop button to the on position at the ground controls Push in the red Emergency Stop button to the off position at the platform controls Turn the key switch to platform control 4 Atthe platform controls press and hold the lift function select and horn buttons and pull out the red Emergency Stop button to the on position Result The diagnostic display will show PS Release the lift function select and horn buttons Result The diagnostic display will show the maximum lift speed percentage Part No 84700 9 PLATFORM CONTROLS w joystick controller JC1 with thumb steering rocker SW6 horn button BN5 lift function select button BN9 diagnostic display G8 red Emergency Stop butto
27. qme E m ee 1 M IA OF E 2 D HS O eat E ME ME Y8 227 1800 to 3500 psi l 124 to 241 bar 4 ji E E FUNCTION MANIFOLD LL EN 2 Aabar maximum 5 ee Mess NP 1 T 1 A 4 gpm 2500 psi 4 M E 15 L min 172 bar C i lt gt LY BYPASS POWER UNIT HS0039A HYDRAULIC TANK Genie Part No 84700 QSR QSW 6 23 Section 6 Schematics September 2009 zat me c M This page intentionally left blank Genie 6 24 GR QSR QSW Part No 84700 Genie Scandinavia Phone 46 31 575100 Fax 46 31 579020 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Iberica Phone 434 93 579 5042 Fax 34 93 579 5059 Genie Germany Phone 0800 180 9017 Phone 49 422 149 1818 Fax 49 422 149 1820 Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 61 7 3375 1002 Genie China Phone 86 21 53852570 Fax 86 21 53852569 Genie Malaysia Phone 65 98 480 775 Fax 65 67 533 544 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Korea Phone 82 25 587 267 Fax 82 25 583 910 Genie U K Phone 44 0 1476 584333 Fax 44 0 1476 584334 Genie Brasil Phone 55 11 41 665 755 Fax 55 11 41 665 754
28. 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 7 Usinga 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 8 Remove the pad from the machine and carefully scrape away any excess adhesive from the chassis or battery box cover 9 Using a suitable solvent clean the surface were the obstruction sensing pad was removed Allow the surface to dry thoroughly 10 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 Part No 84700 September 2009 Section 4 Repair Procedures REVA OBSTRUCTOION SENSING PADS Hydraulic Tank Side Ground Controls Side Non steer End O Steer End Obstruction Sensing Pads a cable connectors Deutsch connector c battery box obstruction sensing pad d ground controls side obstruction sensing pad e steer end obstruction sensing pad f hydraulic tank side obstruction sensing pad o Genie Part No 84700 GR QSR QSW 4 45 Section 4 Repair Procedures September 2009 pum M
29. Begin timing when your reference point on the machine crosses the Note Perform this procedure with the machine on a firm level surface that is free of obstructions 1 Create start and finish lines by marking two start line lines on the ground 40 feet 12 2 m apart 7 Continue at full speed and note the time when 2 Turn the key switch to platform control and pull your reference point on the machine passes out the red Emergency Stop button to the on over the finish line Refer to Section 2 position at both the ground and platform Specifications controls 3 Lower the platform to the stowed position 4 Press the drive function select button 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 Genie Part No 84700 GR QSR QSW 3 19 Section Scheduled Maintenance Procedures September 2009 CHECKLIST B PROCEDURES B 13 Test the Drive Speed Raised Position Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper drive functions are essential to safe machine operation 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 Note Perform this procedure with the machine on a firm level surface that is f
30. PIN1 es 4 HIGH TORQUE BN6 z gt 2 4 HORN BN5 T 2 4 DRIVE ENABLE BN8 PIN4 4 ENABLE E RD POUT11 H1 PLATFORM BK ALARM z ES0126E GR QSR QSW Part No 84700 September 2009 Section 6 Schematics rame Se i This page intentionally left blank Genie Part No 84700 GR QSR QSW 6 17 Section 6 Schematics September 2009 Electrical Schematic QSR CE Models REVA Part 1 of 3 QUICK DISCONNECT P1 KS1 EMERGENCY KEY SWITCH STOP z WH B 1 OR z LI cc E RD gt i Pr On CONTROL a 4 i Bi ral H5 ALARM e F N C H O GROUND CONTROL 2 087 POTHOLE 2 RO U N D PLATFORM SWITCH UP DOWN LI 7A ly 1 a CONTROLS neno PLATFORM 8 S A 110V 240V A
31. Repair Procedures Brake Release Hand Pump Components REVA 10 1 Brake Release Hand Pump Components The brake release hand pump manifold is mounted behind the hydraulic power unit Index Schematic No Description Item Function Torque 1 Harid Manual brake 30 ft lbs 41 Nm 2 Needle valve pilot operated I eges Manual brake release enable 45 50 in lbs 5 Nm Note alpha callouts refer to corresponding notes on the hydraulic schematic Genie Part No 84700 GR QSR QSW 4 41 Section 4 Repair Procedures September 2009 Platform Overload Components 11 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 Tagand disconnect the wire harness from the load sense limit switch Note The load sense limit switch is located near the platform support 3 Setamulti meter to measure continuity Connect the leads from the multi meter to the black and red wires disconnected from the limit switch 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 f
32. X CONTROLLER m 25 m 999 mmi LEVEL SENSOR 8 Jd z 62228 z m O2 WH 3 525 2 2 g 2 BL 3 SW5 SW6 Q z FUNCTION ENABLE STEER 4 t t LEFT RIGHT re E PIN m 2 z m RS 4 2 RFS S r1 a ab b ele es pinto o PP c2 A2 B1 C11 1 4 IN IN IN IN OUT PLATFORM CONTROLS MEMBRANE DECAL z POUTI 0 1 LIFT LED 116 U5 ur ELECTRONIC CONTROL MODULE DRE LED ENT z 0 O HIGH TORQUE LED L21 z 7 OUT OUT OUT G8 z o POUTA DIAGNOSTIC T 2 DISPLAY E Uu L T A H z z z H 4 HIGH TORQUE 6 Y6 Y8 Y7 E DRIVE PLATFORM PLATFORM 7 HORN BNS z FORWARD UP DOWN l 4 DRIVE ENABLE BN8 EJ 5 z 4 LIFT ENABLE BN9 i AOX AOX AX 18 e MACHINE SHOWN H1 PLATFORM IN THE STOWED BK ALARM ew POSITION WITH CONTROLLER THE 50126 NamsmammuanmaauunuanaanmuuuucuunuuuananuuuuusuauuuunuasuuuaP Genie Part No 84700 GR QSR
33. c 25VLED d 21VLED X Genie Part No 84700 GR QSR QSW Section Scheduled Maintenance Procedures CHECKLIST B PROCEDURES 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 b
34. 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 Repeatthis procedure beginning with step 3 7 Repeat steps through 5 for each sequencing cable as required Part No 84700 Genie GR QSR QSW CHECKLIST B PROCEDURES B 7 Test the Emergency Stop Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first 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 1 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 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
35. 85 BK 2 GN YL PIN8 i pinio O RD RD um Bic PLATFORM CONTROLS L ze MEMBRANE DECAL POUT1 O 2 LIFT LED 116 3 K POUT2 O Iu a DRIVE LED L17 POUT3 4 1 HIGH TORQUE LED L21 8 POUT4 DIAGNOSTIC 1 ls DISPLAY 4 HIGH TORQUE BN6 iud a HORN BN5 PIN 4 4 DRIVE ENABLE BN8 47 ENABLE RD POUTM id PLATFORM PIN 0 5 CONTROLLER MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF 501270 Genie 6 12 GR QSR QSW Part No 84700 September 2009 Section 6 Schematics rame Se i This page intentionally left blank Genie Part No 84700 GR QSR QSW 6 13 Section 6 Schematics ees Electrical Schematic QSR ANSI and CSA Models Part 1 of 3 S eptember 2009 REVA
36. BK 6 6 RD BK 1 14 YL BL 2 2 BL Y OR 5 5 OR L 2 CR27A CR27B CR27C ae OVERLOAD OVERLOAD OVERLOAD e MOTOR CONT LOAD SENSE DOWN COIL f oe X95 7744 eA 85 85 85 SENSOR CIRCUIT BOARD C5 F 4700 uF L4 ILH sz za EG LEVEL 0 2 22 SENSOR 2622 Lee ee Hs omm miel 1 m aana 755o BK 2 5 A o z gt x 2 L e E aa 2 4 se 2 A9 C5 10 10 B6 C2 A2 Bi C11 OUT IN IN IN OUT IN IN IN IN IN our U5 ELECTRONIC CONTROL MODULE OUT OUT OUT OUT OUT C7 B7 A7 C6 AG Beene pe ee Saag 16 921 52 Ww E 2 9 Y3 Y4 Y5 Y6 Y8 Y7 STEER STEER DRIVE DRIVE PLATFORM PLATFORM RIGHT LEFT REVERSE FORWARD UP DOWN ACOX EPX vod L Ly 4 L_ e MACHINE SHOWN IN THE STOWED i GND POSITION WITH ES0127D THE POWER OFF Genie Part No 84700 GR QSR QSW 6 11 Section 6 Schematics September 2009 Electrical Schematic GR and QSW CE Models REVD Part 3 of 3 FOR UK PLUG OPTION GN YL GROUND
37. Electrocution burn hazard 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 Part No 84700 Genie GR QSR QSW 3 Tagand 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 AWARNING injury hazard Spraying ydraulic 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 Torque specifications Hydraulic tank retaining fasteners dry 35 4 Nm Hydraulic tank retaining fasteners lubricated 26 in Ibs 2 9 Nm 3 31 Section Scheduled Maintenance Procedure
38. OUT IN IN IN IN F U9 U5 BATTERY BK A8 OUT CHARGER ELECTRONIC CONTROL MODULE 1 OUT 5 7 OUT OUT 4 6V z a B8 B3 BATTERY RD x FLASHING o 9 T i i Lo INPUT CONTROLLER iuam a Via fee Te m 5 HORN RELAY 30 H2 OPTION 86 ncc Q QE FS a DC AC INVERTER 5 OPTION G6 47 0 HOUR M METER 2 AUTO STYLE HORN E OPTION 1 4 ES0127D Genie 6 10 GR QSR QSW Part No 84700 September 2009 Section 6 Schematics E Electrical Schematic GR and QSW REV D CE Models Part 2 of 3 1 1 enve 8 BK 2 2 BK wH 3 3 LB QD4A Rp 4 4 1 RD OR BK 3 3 WH gt gt JUNCTION BOX 30 4 48 CR48 Jo 2 RELAY TO US 87 85 E STOP QD4 BL
39. Part No 84700 September 2009 Section 5 Fault Codes Fault Code Chart REV C Fault Code Problem Possible Causes Solution Internal ECM error EPROM not programmed Replace ECM Malfunctioning control cable Troubleshoot control cable Ee ME OR malfunctioning platf OR troubleshoot platt communication aHa malfunctioning platform roubleshoot platform controls controls Undefined platform DIP DIP switch settings Correct DIP switch settings Switch settings incorrect Chassis up down toggle Malfunctioning up down Troubleshoot 3 closed at start up Switch 3 Malfunctioning pothole Pothole guard failure switch OR obstruction in pothole guard linkage Malfunctioning limit switch Limit switch failure OR wire disconnected from limit switch Platform left turn switch Malfunctioning steer left Troubleshoot steer left fault microswitch microswitch Platform right turn switch Malfunctioning steer right Troubleshoot steer right fault microswitch microswitch Platform drive enable Malfunctioning drive enable Troubleshoot drive enable switch fault switch switch Joystick potentiometer not centered Malfunctioning coil OR wire Troubleshoot coil OR Forward coil fault disconnected from coil inspect wire connection Malfunctioning coil OR wire Troubleshoot coil OR disconnected from coil inspect wire connection Troubleshoot limit switch OR inspect wire connection Platform joystick
40. QSW 6 9 Section 6 Schematics September 2009 p P sd Electrical Schematic GR and QSW CE Models REVD Part 1 of 3 QUICK DISCONNECT 1 KS1 z EMERGENCY KEY SWITCH A STOP B 1 WH ee or 2 RD PLATFORM t CONTROL x 8 A H5 ALARM IE eS N C H O GROUND om CONTROL 1577 POTHOLE 4 TS66 2 G RO U N D PLATFORM SWITCH in D UP DOWN AC INPUT CIRCUIT CONTROLS N C H O N C H O TO PLATFORM BREAKER 8 S js OF 110V 240V 188 156 Zonsnsuuununyusuuunuusuruns POTHOLE DOWN GUARD d SWITCH LIMIT SWITCH NOTE MACHINE SHOWN S SR E 9 9 5 5 T z z IN THE STOWED I 9 2 5 m 2 POSITION WITH a m 3 n 8 THE POWER OFF z v Do z 3 Do z w w m m 2 po o m I o IL CL lll jp B12 11 B9 B10 4 B1 c12 RD IN
41. Specifications Result The machine is not within specification Adjust the chains Refer to Repair procedure 3 3 How to Adjust the Lifting Chains Section Scheduled Maintenance Procedures September 2009 CHECKLIST B PROCEDURES B 5 Clean and Lubricate the Columns Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first 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 2 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 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 AWARNING 2 dlly 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
42. 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 Genie 32D QSR QSW Part No 84700 September 2009 Section 3 Scheduled Maintenance Procedures REV D CHECKLIST B PROCEDURES B 16 B 17 Test the Flashing Beacons if equipped Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first 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 1 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 O Result The beacons should flash 2 Turn the key switch to platform controls Result The beacons should flash Part No 84700 Genie GR QSR QSW Perform Hydraulic Oil Analysis Genie specifications require that this procedure be performed every 250 hours or quarterly 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 Before replacing the hydraulic oil the
43. chassis 9 Puton protective clothing and eye wear 4 Lowerthe platform until the mast just contacts the battery cover Models without maintenance free or sealed batteries Crushing hazard Keep hands AWARNING clear of the battery cover when 10 Remove the battery vent caps and check the lowering the platform specific gravity of each battery cell with a hydrometer Note the results 5 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 Genie 310 QSR QSW Part No 84700 September 2009 Section Scheduled Maintenance Procedures REV D 11 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 26 7 C e 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 or higher The battery is fully charged Proceed to step 15 Result One or more battery cells display a specific gravity of 1 217 or below Proceed to step 12 12 Perform an equalizing charge OR fully charge the batteries and allow the batteries to rest at least 6 hours 13 Remove the battery vent caps and check the specific gravity of each ba
44. controls Result All ground control functions should not operate Section 4 Repair Procedures September 2009 Obstruction Sensing System 12 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 How to Replace an Obstruction Sensing Pad QSR models only 1 Raise the platform approximately 5 feet 152 cm 2 Turn the key switch to the off position and disconnect the battery pack from the machine Electrocution burn hazard Contact AWARNING with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 3 Atthe non steer end of the machine unlatch the covers and open the ground controls cover 4 Working with the obstruction sensing pad to be replaced locate the pad cables Genie QSR QSW REVA 5 Carefully pull the cables to identify the connector cable located at the ground controls non steer end of the machine 6 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
45. 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 Hyaraulic Oil Section Scheduled Maintenance Procedures September 2009 CHECKLIST B PROCEDURES B 18 Inspect the Breather Cap Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first A free breathing hydraulic tank cap is essential for good machine performance and service life 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 W Result If air does not pass through the 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 3 24 GR QSR QSW Genie REV D Part No 84700 September 2009 Section 3 Scheduled Maintenance Procedures Checklist C Procedures 1 2 Grease the Platform
46. resulting in death or serious injury ADANGER Tip over hazard This procedure must only be performed by a trained service professional Attempting this procedure without the necessary skills will result in death or serious injury Pull out the red Emergency Stop button to the on position at the ground controls Push in the red Emergency Stop button to the off position at the platform controls Turn the key switch to platform control 4 Atthe platform controls press and hold the lift function select and horn buttons and pull out the red Emergency Stop button to the on position Result The diagnostic display will show PS Release the lift function select and horn buttons Result The diagnostic display will show the maximum lift speed percentage Genie GR QSR QSW Part No 84700 REV E e999 o d Co a joystick controller JC1 with thumb steering rocker SW6 horn button BN5 diagnostic display G8 red Emergency Stop button P2 drive function select button BN8 Press the drive function select button N Press and hold the horn button Result The diagnostic display will show the raised drive speed percentage 8 Use the steering thumb rocker switch on the joystick to increase or decrease the maximum lift speed percentage Refer to Section 2 Specifications for function speeds 9 Turn the key switch to the off position
47. the platform to the stowed position 4 Press the drive function select button 5 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the test line Genie GR QSR QSW REV D amp 999 gu a drive function select button BN8 6 Bring the machine to top drive speed before reaching the test line Release the function enable switch or the joystick when your reference point on the machine crosses the test line 7 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 Part No 84700 September 2009 Section 3 Scheduled Maintenance Procedures REV D CHECKLIST B PROCEDURES B 12 Test the Drive Speed 2 Stowed Position 1 7 Genie specifications require that this procedure be 4 performed every 250 hours or quarterly whichever e comes first 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 Gu hesitation jerking and unusual noise over the entire proportionally controlled speed range a drive function select button BN8 6 Bring the machine to top drive speed before reaching the start line
48. when removed from the machine Component damage hazard 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 Part No 84700 September 2009 Section 4 Repair Procedures REV B MAST COMPONENTS How to Disassemble the Mast 4 Remove the lift cylinder barrel end mounting fasteners AWARNING 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 1 Remove the mast See 3 1 How to Remove the Mast Assembly Rotate the mast until the carriage is facing up Remove the socket head retaining fastener from the clevis block on the lift cylinder rod end at the top of the number 1 column o oi cylinder mounting plate cylinder cylinder mounting bolt plate mounting fasteners LH ao oo 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 AWARNING could become unbalanced and fall if not properly supported when removed from the machine top of number 1 column clevis block not shown clevis block
49. with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 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 AWARNING Crushing hazard The platform could become unbalanced and fall if not properly supported when removed from the machine Genie GR QSR QSW Part No 84700 REV C 2 2 Platform Extension How to Remove the Platform Extension 1 Turn the key switch to the off position 2 Disconnect the battery pack from the machine Electrocution burn hazard Contact AWARNING with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 3 Disconnect the platform controls from the
50. 0 43 220 298 300 406 310 420 420 569 5 474 m 19 30 433 480 583 450 60 60 827 50 om 4 350 47 40 637 50 678 60 98 50 7 e 480 650 640 867 680 92 910 1233 70 104 2 550 78 70 962 750 1016 90 3342 80 mo LUB i JJ m o o N e e i le z o o 15 s 312 50 908 890 1205 1080 1464 1440 1955 1220 1654 T 31i2 930 1260 1240 31681 1510 2047 2010 2725 1700 2304 vr 16 1460_ 1979 1950 2643 2370 3218 3160 4284 260 3620 eo 2223 2190 2969 2670 3620 3560 4826 3000 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 03 Class 12 9 DRY Y c iv i ile c iv EP c 1 CO a c1 zal R N co et zu Blo n N cof o mi oio EN A D alo D o A A 5 e 844 clo a N A e A i B B B G B wo art A O TS IS a OO ol A gt OY Nw RININ N Go
51. 2009 Section 6 Schematics Observe and Obey M Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine M Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Troubleshooting Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necessary tools and test equipment are available and ready for use Part No 84700 Genie GR QSR QSW 6 1 Schematics About This Section There are two groups of schematics in this section An illustration legend precedes each group of drawings Electrical Schematics AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Hydraulic Schematics Bodily injury hazard Spraying AWARNING 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 General Repair Process Malfunction Identify discovered symptoms gt Troubleshoot problem still exists Return to service 1 problem solved Section 6 Schematics
52. 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 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 40 in Ibs 4 5 Nm Hydraulic tank drain plug lubricated 30 in Ibs 3 4 Nm Part No 84700 September 2009 Section Scheduled Maintenance Procedures Checklist E Procedure REV B 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 AWARNING
53. Boe lube wax to the inside and outside channels of each column Genie QSR QSW REV D B 6 Adjust the Sequencing Cables Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first 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 o nylock nut spring upper sequencing bracket sequencing cable ao oo Part No 84700 September 2009 Section Scheduled Maintenance Procedures REV D 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 15 16 inch 2 4 cm Measurement compressed
54. C S LS8 yu Zzauuunuuuauanuinuunuunuunusuuusus mumuuunuuuuuuuunumuuuuuuunuuuuuzuuzhr POTHOLE 4 GUARD DOWN 1 st ux 2 2 gt MACHINE SHOWN r 903 9 IN THE STOWED 0 5 2 POSITION WITH zs 3 m E THE POWER OFF s 2 lt 5 HE 3 QD1 1 Z T As LI F6 275a FUSE P 8 28 12 B12 11 B9 B10 4 BH c12 RD D1 IN IN OUT IN IN LJ U9 Do BATTERY BK A8 OUT U5 HARGER E C A ELECTRONIC CONTROL MODULE A1 OUT a B5 OUT OUT OUT OUT 4 6V aro B8 B3 B7 BATTERY RD fear z FLASHING o m TIT Ars OAM 3 E BEACONS 2 5 B duwa OPTION 1 MEINE INPUT CONTROLLER IST d _ BK B CR5 zi SAY HORN RELAY m Sy 304 H2 OPTION 86 aE i i ace i 5 er U13 85 2 DC AC INVERTER E fp Ve 2 4 _ OPTION G6 STEER STEER HOUR LAA RIGHT LEFT METER uuuuuuuns H2 AUTO STYLE QD1 HORN A X A X 4 Lt 4 L hd Ld ES0127F Genie 6 18 GR QSR QSW Part No 84700 September 2009 SSS Electrical Schematic
55. 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 Specification Solenoid valve 3 position 4 way 27 20 20V DC with diode schematic item E Solenoid valve 3 position 4 way 190 20V DC with diode schematic item F Solenoid valve 2 position 4 way 250 20V DC with diode schematic item H Solenoid valve 2 position 2 way N C 6 250 with manual override 12V DC with diode schematic item N Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice GR QSR QSW Part No 84700 September 2009 Section 2 Specifications REV 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 A SAE O ring Boss Pot JIC 37 Fittings tube fitting installed into Aluminum swivel nut or hose connection SAE Dash size Torque SAE Dash size Thread Size Flats 4 11 ft lbs 14 9 Nm 4 716 20 2 6 23 ft lbs 31 2 Nm 6 9 16 18 1 1 4 8 40 ft lbs 54 2 Nm 8 3 4 16 1
56. CONTROLS 18 Raise the machine approximately 2 inches 5 cm 19 GR 12 GR 15 QS 12R QS 15R QS 12W and QS 15W Place 0 79 x 6x6 inch 2x 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 20 Lower the machine onto the blocks 21 Raise the platform approximately 1 foot 30 cm O 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 22 Lower the platform to the stowed position 23 Raise the machine slightly 24 Remove the blocks from under both wheels 25 Lower the machine and remove the jack 26 Center a lifting jack under the drive chassis at the steer end of the machine 27 Raise the machine approximately 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 Genie QSR QSW REV B 29 Lower the machine onto the blocks 30 Raise the platform approximately 1 foot 30 cm Result The level sensor alarm should not sound W Result The level sensor alarm does sound The level sensor is faulty and must be replaced Repeat this procedure beginning with
57. End edge of the obstruction pad lt 5 Steer End 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 Part No 84700 September 2009 Section Scheduled Maintenance Procedures REV D 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 Inspect the Tires and Wheels including castle nut torque D 4 Replace the Hydraulic Tank Return Filter Part No 84700 Genie GR QSR QSW 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 Ult
58. Overload Replace the Mechanism if equipped 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 Part No 84700 Genie GR QSR QSW Hydraulic Tank Breather Cap Models with Optional Hydraulic Oil 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 Section Scheduled Maintenance Procedures S
59. QSR REVA Section 6 Schematics CE Models Part 2 of 3 GN T 1 1 L anwe A BK 2 2 BK WH L 3 LB QD4A RD 4 4 RD OR BK 3 WH JUNCTION BOX 9 4 POWER Jo i RELAY TOUS E STOP 87 85 QD4 BL BK 6 6 RD BK WH BK 1 1 4 YL BL 2 2 BL Y OR 5 5 OR pec 5 CR27A CR27B CR27C 1 OVERLOAD OVERLOAD OVERLOAD pez MOTOR CONT LOAD SENSE DOWN COIL i 30 86 30 2 86 30 86 SENSOR L 4 mural bec moog CIRCUIT O Z gt gt 1 BOARD 1 Tes 87A 85 e Tes E 533 a 58 65 b 22 S7 NOTE T 2 232 LEVEL nie 5 9 SENSSA MACHINE SHOWN LE ders IN THE STOWED g BK POSITION WITH THE POWER OFF 4 1 2 2 3 92 a sf E ly ls M A9 C5 C10 A10 B6 C2 A2
60. SW Part No 84700 September 2009 Section 4 Repair Procedures REV B 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 O Result The diagnostic display at the ground controls will show two flat bars and a blinking light indicating a normal condition and the diagnostic display at the platform controls will show the battery condition Refer to Repair procedure 1 3 How to Determine the Battery Voltage 13 Add an additional weight to the platform not to exceed 20 of the maximum rated load Refer to the machine serial plate O Result The diagnostic display will show OL at both the ground and platform controls The platform overload system is operating properly W Result The diagnostic display at the ground controls will show two flat bars and a blinking light and the diagnostic 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 Part No 84700 Genie GR QSR QSW PLATFORM OVERLOAD COMPONENTS 14 Test all machine functions from the platform controls O Result All platform control functions should not operate 15 Turn the key switch to ground control 16 Test all machine functions from the ground
61. TRUCTION SENSING PAD Steer End REVA z 2 Po 65 EMERGENCY QD3 STOP RD 4 BK POWER TO PLATFORM z wH L RD POWER TO GROUND BK 1 WH GROUND BL 2 BL DATALINK HIGH OR 5 OR DATA LINK LOW opio5 ree E NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF Genie CONTROLLER a z z E z z z 15V DC U3 07 PLATFORM CONTROLS VOLTAGE PRINTED CIRCUIT BOARD REGULATOR qo amp BN o HALLEFFECT JC1 7 GENERATOR JOYSTICK GY CONTROLLER z LI GN WH BL SW5 SW6 FUNCTION ENABLE T STEER E o 1 LEFT RIGHT pno 0 08 8 2 zs PINS BK 3 o PP m BK e PLATFORM CONTROLS en MEMBRANE DECAL POUTI 4 LIFT LED L16 z POUT2 O DRIVE LED 117 POUT3 O 4 HIGH TORQUE LED 121 ls E G8 POUTA O DIAGNOSTIC 1 DISPLAY z
62. UIT 1 BOARD 111 NOTE g 57 MACHINE SHOWN a SENSOR IN THE STOWED 22 2 L 2 gt 5 5 POSITION WITH E 989 THE POWER OFF 5 o 4 Boog zz 2 lg ici C2 A2 Bi C1 Cii m IN IN IN IN IN OUT RD U5 ELECTRONIC CONTROL MODULE C6 A6 B6 TUS SEC LBL BL 5 2 27 GN YL WH 25 OHMS 25 WATT 30 86 30 86 CR111A S zi CR111B S 2 ixi OBSTRUCTION OBSTRUCTION Y6 Y8 NT SENSING 87 87 85 SENSING 87a 87 85 DRIVE PLATFORM PLATFORM FORWARD UP DOWN i RD 10 OBSTRUCTION ry SENSING AEX m OBSTRUCTION SENSING QS RETAIL BN 4 4 4 GND BN ES0126E Genie Part No 84700 GR QSR QSW 6 15 Section 6 Schematics September 2009 Electrical Schematic QSR ANSI and CSA Models Part 3 of 3 CaS E 1 GN YL EN4 BK AC AC OUTLET ouTLET LB BOX L RD BK RD RD A WH WH YL BK BL BL OBSTRUCTION SENSING OBSTRUCTION SENSING PAD Battery Tray PAD Hydraulic Tank Side WH BL RD e BN 1 OBSTRUCTION SENSING QS RETAIL OR BN BL s BL t 1 U47D U47C OBSTRUCTION SENSING PAD Ground Controls Side OBS
63. ains 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 Part No 84700 Genie GR QSR QSW MAST COMPONENTS 10 Lay the number 3 column chains on the floor Note Do not allow the chains to become twisted or dirty 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 3 3 How to A
64. and Wheels including castle nut torque Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first 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 Part No 84700 Genie GR QSR QSW CHECKLIST B PROCEDURES B 4 Check the Lifting Chain Adjustments Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first 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 Refer to Section 2
65. ants 1 Country of manufacture USA This machine complies with 280 98 37 EC 05 12345 Model Sequence number Serial label GR serial number stamp 4 QSR QSW serial number stamp Genie Part No 84700 GR QSR QSW lii September 2009 BELLE LLL LL LLLI This page intentionally left blank Genie iv GR QSR QSW Part No 84700 September 2009 Genie Part No 84700 GR QSR QSW Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the appropriate Operator s Manual on your machine will result in death or serious injury Many of the hazards identified in the operator s manual are also safety hazards when maintenance and repair procedures are performed 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 September 2009 SAFETY RULES P
66. 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 Industries if replacement manuals or decals are needed Part No 84700 September 2009 Section Scheduled Maintenance Procedures REV D 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 Part No 84700 Genie GR QSR QSW CHECKLIST A PROCEDURES 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 appropri
67. assis wire harness 2 Remove the level sensor adjusting fasteners Remove the level sensor from the machine Genie QSR QSW REV B 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 ip The level ADANGER 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 c a chassis b level sensor X indicator d mast Part No 84700 September 2009 Section 4 Repair Procedures REV B 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 GROUND CONTROLS Turn the key switch t
68. ate gradually Do not allow oil to squirt or spray Component damage hazard Hoses can be damaged if they are kinked or pinched Part No 84700 Genie GR QSR QSW STEER AXLE COMPONENTS 8 3 Steer Bellcrank How to Remove the Steer Bellcrank 1 Remove the steer cylinder See 8 2 How to Remove the Steer Cylinder 2 Center a lifting jack under the drive chassis at the steer end of the machine 3 Raise the machine approximately 14 inches 36 cm Place blocks under the chassis for support AWARNING Crushing hazard The chassis could fall if not properly supported 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 Note Observe and note the quantity and location of the spacers between the bellcrank and the steer links 7 Remove the fasteners securing the bell crank to the steer yoke 8 Remove the bellcrank from the machine Note Observe and note the quantity and location of the spacers between the bellcrank and the steer links Section 4 Repair Procedures September 2009 Non steer Axle Components 9 1 Drive Brake How to Remove a Drive Brake Note When removing a hose assembly or fitting the fitting and or hose end must be torqued to specific
69. ate operator s manual Refer to the Operator s Manual on your machine Section Scheduled Maintenance Procedures September 2009 REV D A 4 Hydraulic Tank a Ground Controls Side Side 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 Ib 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 2 inches 5 08 cm from the edge of the obstruction sensing pad 3 Atthe 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 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 4 Remove the 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 Repeatthe procedure beginning with step 2 for each of the remaining obstruction sensing pads Genie GR QSR QSW Place the15 Ib 6 8 kg weight 2 inches 5 08 cm from the Non steer
70. ation during installation Refer to Section 2 Hyaraulic Hose and Fitting Torque Specifications 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 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 4 Center a lifting jack under the drive chassis at the non steer end 5 Raise the machine approximately 2 inches 5 cm Place blocks under the chassis for support AWARNING Crushing hazard The chassis could fall if not properly supported 6 Remove the wheel castle nut Remove the wheel Genie QSR QSW REVA 7 Tag disconnect and plug the hydraulic hose from the brake Cap the fitting on the brake AWARNING 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 8 Placea 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 ACAUTION fall if not properly supported when the mounting fasteners are removed Torque specifications Brake mounting fasteners dry 75 ft lbs 102 Nm Brake mounting fasteners lubricated 56 ft lbs 76 Nm Part No 84700 September 2009 Section 4
71. battery condition See 1 3 How to Determine the Battery Voltage 4 Press the lift function select button 5 Slowly move the joystick in the direction indicated by the yellow arrow Result The software revision level will appear in the diagnostic display 6 Pushin 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 Section 4 Repair Procedures September 2009 PLATFORM CONTROLS How to Adjust the Lift Speed ADANGER ADANGER Tip over hazard Do not adjust the lift and or drive speed higher than specified in this procedure Setting the function speeds greater than specifications could cause the machine to tip over resulting in death or serious injury Tip over hazard This procedure must only be performed by a trained service professional Attempting this procedure without the necessary skills will result in death or serious injury Pull out the red Emergency Stop button to the on position at the ground controls 2 Pushin the red Emergency Stop button to the off position at the platform controls Turn the key switch to platform control 4 Atthe platform controls press and hold the lift function select and horn buttons and pull out the red Emergency Stop button to the on position Result The diagnostic display will show PS 5 Release the lift function select and horn buttons Resu
72. chine 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 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 Repair Procedures About This Section Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop Select the appropriate repair procedure after troubleshooting the problem Perform disassembly procedures to the point where repairs can be completed Then to re assemble perform the disassembly steps in reverse order Symbols Legend 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 AWARNING Indicates a potentially hazardous situation which if not avoided co
73. ckpicker Platform 500 Ibs 227 kg GR 20 QS 20R and QS 20W Stockpicker Platform 350 Ibs 159 kg Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Platform up 23 to 25 seconds Platform down 20 to 22 seconds Genie 2 2 GR QSR QSW Part No 84700 September 2009 Section 2 Specifications REV D Hydraulic Specifications Hydraulic Oil Specifications Chevron Rando HD equivalent Multi viscosity Hydraulic oil type Viscosity grade Viscosity index 200 Cleanliness level minimum 15 13 Water content maximum 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 Petro Canada Environ MV 46 Statoil Hydra Way Bio SE 32 BP Biohyd SE S Biodegradable UCON Hydrolube HP 5046 Quintolubric 822 Fire resistant Shell Tellus T32 Shell Tellus T46 Chevron Aviation A Mineral based Continued use of Chevron Aviation A hydraulic fluid when ambient temperatures are consistently above 32 F 0 C may result in componen
74. 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 September 2009 Section 4 Repair Procedures REV PLATFORM COMPONENTS 2 3 Work Tray How to Remove the Work Tray if equipped 1 Turn the key switch to the off position 2 Disconnect the battery pack from the machine Electrocution burn hazard Contact AWARNING with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 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 platrom controls from the platform and set the controls to the side 5 While supporting the work tray remove the fasteners bushings and spacers se
75. counterclockwise to decrease the pressure ADANGER 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 Part No 84700 September 2009 Section 4 Repair Procedures REV B How to Adjust the Platform Lift 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 item 2 S be lt S S SS a test port b system relief valve lift relief valve 2 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the test port on the function manifold 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 Part No 84700 Genie GR QSR QSW FUNCTION MANIFOLD 5 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 6 Press and hold the function enable switch 7 Move and hold the joystick fully in either direction while observing the pressure readi
76. ct Ret ieee fel ve ter te zin cvi tds 5 ft lbs 7 Nm 1 Diagnostic nipple Testing 2 Check diS Steer circuit 18 ft lbs 24 Nm Relief valve 1800 to 3500 psi 124 to 241 bar Lift 2 222 20 ft lbs 27 Nm 4 Check valve 10 psi 0 7 bar Drive 20 ft lbs 27 Nm 5 Solenoid valve 3 position 4 way Econ Drive forward reverse 25 ft lbs 34 Nm 6 Solenoid valve 3 position 4 way E Steer left right 25 ft lbs 34 Nm 7 Flow regulator and relief valve 0 75 gpm 2 8 L min 1500 psi 103 c Steer circuit 26 ft lbs 35 Nm 8 Solenoid valve 2 position 4 way Platform up 25 ft lbs 34 Nm 9 Relief valve 3500 psi 241 bar maximum System relief 20 ft Ibs 27 Nm Genie 4 28 GR QSR QSW Part No 84700 September 2009 Section 4 Repair Procedures REV B 2 o e D Part No 84700 Genie GR QSR QSW FUNCTION MANIFOLD Note alpha callouts re
77. curing 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 work tray Screw nylock nut platform controls spacer platform controls assembly Screw nylock not Screw nylock nut bushing spacer waasher ATT p O0 a Genie Part No 84700 GR QSR QSW Section 4 Repair Procedures September 2009 Mast Components 3 1 Mast How to Remove the Mast Assembly AWARNING 200 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 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 Note Perform this procedure on a firm level surface with the mast in the stowed position 1 Remove the Platform See 2 1 How to Hemove 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
78. d drive speed and slow drive speed are adjustable to compensate for wear in the hydraulic pump and drive motors The function speeds are determined by the percentage of total controller output For further information or assistance consult the Genie Industries Service Department ADANGER Tip over hazard Do not adjust the lift and or drive speed higher than specified in this procedure Setting the function speeds greater than specifications could cause the machine to tip over resulting in death or serious injury ADANGER 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 Part No 84700 Genie GR QSR QSW 4 3 PLATFORM CONTROLS How to Determine the Software Revision Level 1 Remove the platform controls from the platform 2 Place the platform controls close to the diagnostic display on the power unit side of the machine eges C Ell joystick controller JC1 lift function select button BN9 red Emergency Stop button P2 yellow arrow ao oo 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 O Result The diagnostic display at the platform controls will show the
79. d and fall if not properly supported when removed from the mast Genie MAST COMPONENTS LIH top of number 1 column clevis block not shown clevis block fastener lift cylinder not shown check valve flow control cylinder manual lowering valve M Part No 84700 GR QSR QSW Section 4 Repair Procedures September 2009 Ground Controls 4 1 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 ADANGER 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 Note Perform this procedure with the platform in the stowed position If you are not installing a new level sensor proceed to step 6 1 Tag and disconnect the level sensor wire harness from the ch
80. 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 Genie A TEREX BRAND Genie UK The Maltings Wharf Road Grantham Lincolnshire Redmond WA 98073 9730 NG31 6BH England 425 881 1800 44 1476 584333 Copyright 2002 by Genie Industries Genie is a registered trademark of Genie Industries Rev A Genie Industries USA 18340 NE 76th Street PO Box 97030 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 re inspect it After repair place a check in the R box Legend Y yes completed no unable to complete R repaired Comments Pre Delivery Preparation Y N R Pre operation inspection completed Maintenance items completed Function tests completed
81. djust the Lifting Chains Section 4 Repair Procedures September 2009 MAST COMPONENTS 3 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 mm of each other 4 Onthe 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 Ibs 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 REV B 3 3 Lifting Chains How to Adjust the Lifting Chains 1 Markthe column to be adjusted 2 Raise the platform a
82. down the red Emergency Stop button at the platform controls to the off position Result No machine functions should operate 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 Section Scheduled Maintenance Procedures September 2009 CHECKLIST B PROCEDURES B 8 Test the Key Switch Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first 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 Q Result The machine functions should not operate 4 Turn the key switch to ground control 5 Checkthe 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
83. draulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 2 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the high pressure port on the pump 3 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 Part No 84700 Genie GR QSR QSW Hydraulic 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 Component damage hazard 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 AWARNING ae injury hazard Spraying ydraulic 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 Section 4 Repair Procedures September 2009 EE HYDRAULIC PUMP REV A How to Remove the Hydraulic Pump Note When removing a hose assembly or f
84. e SWITCH CONTROL B1 4 2 Horn or alarm CONTROL Hour meter Key switch v 2 MEE Ee 95 LED Flashing beacon ee SWO Joystick Genie 6 6 GR QSR QSW Part No 84700 September 2009 Section 6 Schematics rame Se i This page intentionally left blank Genie Part No 84700 GR QSR QSW 6 7 Section 6 Schematics September 2009 Electrical Schematic GR and QSW ANSI and CSA Models Part 1 of 2 REV C QUICK DISCONNECT z P1 KS1 EMERGENCY KEY SWITCH STOP B ote OR z z E RD gt PLATFORM CONTROL a n E H5 ALARM z N C H O GROUND O CONTROL z LS7 POTHOLE 566 GUARD 2 G RO U N D PLATFORM SWITCH gt UP DOWN AC INPUT CIRCUIT CONTROLS N C H O PLATFORM BREAKER 4 8 S on 110V 240V AC r 158 156 2
85. e joint after it has been vo d lt OEC Figure 1 hydraulic hose hex nut reference mark Figure 2 body hex fitting a body hex fitting b reference mark 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 Genie 2 6 GR QSR QSW Part No 84700 September 2009 Section 2 Specifications REV D SPECIFICATIONS SAE FASTENER TORQUE CHART e This chart is to be used as a guide only unless noted elsewhere in this manual A574 High Strength Grade8 69 Black Oxide Bolts CUBED DRY LUBED Nm inis Nm Nm inbs Nm 9 10 113 10 124 140 158 130 147 120 135 160 18 140 158 LUBED es 13 23 14 257 23 22 26 17 4 37 654 50 076 70 947 6827 di 745 60 80 1084 568 91 w C 5 73 75 1016 60 1084 110 1 93 126 20 584 867 85 115 30 i22 120 i162 105 12 61 72 15 1084 110 19 120 162 150 203 130 16 18 122 120 162 3176 1 L M 116 148 150 203 160 217 20 24 0 24 18 130 176 7170 230 180 244 240 325 200 sa 10 200 27 20 366 280 3 9 380 515 3
86. ensing QS retail Electronic component U3 Platform controls printed circuit board U5 Electronic control module U6 Motor controller U9 Battery charger U13 Voltage inverter option 038 Keypad 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 JC1 Joystick controller KS1 Key switch LED or light L16 Lift L17 Drive L21 High torque Valve coil Y3 Steer right Y4 Steer left Y5 Drive reverse Y6 Drive forward Y7 Platform down Y8 Platform up LS Limit switch LS6 Platform down LS7 Pothole LS8 Pothole LS19 Load sense option M5 Hydraulic power unit NC Normally closed NO Normally open NCHO Normally closed held open Genie WIRE COLOR LEGEND Color Description BK Black BK WH BlackWhite BL Blue BL BK Blue Black BN Brown GN Green GN BK Green Black GN YL Green Yellow GY Gray LB Light Blue OR Orange OR BK Orange Black PP Purple RD Red RD BK Red Black WH White WH BK White Black YL Yellow GR QSR QSW Part No 84700 September 2009 Section 6 Schematics ECM Pin out Lege
87. ently hazardous situation which if not avoided will result in death or serious injury ADANGER AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous ACAUTION 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 Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of steps Section Scheduled Maintenance Procedures September 2009 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 Indicates that dealer service will be required to perform this procedure Ae 2 Genie 09 GR QSR QSW Pre delivery Preparation Report The pre delivery preparation report contains checklists for each type of scheduled inspection Make copies of
88. eptember 2009 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 1 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 2 Determine the maximum platform capacity Refer to the machine serial plate REV D 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 diagnostic display at the ground controls will show two flat bars and a blinking light indicating a normal condition and the diagnostic display at the platform controls will show the battery condition Refer to Repair procedure 1 3 How to Determine the Battery Voltage Result The diagnostic display will show OL at both the ground and platform controls The platform overload system is not operating properly Refer to Repair Procedure 11 1 Calibrate the Platfor
89. ersonal 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 A Indicates an imminently hazardous situation which if not avoided will result in death or serious injury ADANGER AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous ACAUTION 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 3il such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Genie vi GR QSR QSW Workplace Safety Be sure to keep sparks flames and lighted tobacco away from flammable and d combustible materials like battery gases and engine fuels Always have an approved fire extingu
90. f gt OF ofo Ni e e 9 2 A m A E gt N e zi m m oj alo 52 NI N olo BIN lio ge oa olo ola oye ola N Od n P N ofl N N oN SS N p A uri E zi a a A m NI a A A D OTR ol o M evo co oo lolol AP po MPN S gt amp of a N e o oo 4 S oo cof po gajojn NIN ON 5 RIN m falke Co Oo M A RO OO y Ay j A C1 COFCO NI 05 N 56 Genie Part No 84700 GR QSR QSW 2 7 Section 2 Specifications September 2009 SSS SSS This page intentionally left blank Genie 2 8 GR QSR QSW Part No 84700 September 2008 Section Scheduled Maintenance Procedures Scheduled Maintenance Procedures Observe and Obey Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine M Scheduled maintenance inspect
91. fastener lift cylinder not shown ao oo Genie Part No 84700 GR QSR QSW 4 15 Section 4 Repair Procedures September 2009 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 Genie QSR QSW REV B 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 turn
92. fault Verify potentiometer setting Reverse coil fault Up coil fault Not used on Malfunctioning coil OR wire Troubleshoot coil OR GS 3232 disconnected from coil inspect wire connection Malfunctioning coil OR wire Troubleshoot coil OR Down coil fault OR disconnected from coil inspect wire connection Obstruction sensing Person OR object detected Clear the obstruction System error on the obstruction sensing sensing pads of personnel pads OR objects Malfunctioning coil OR wire Troubleshoot coil OR 5 Steer right coil fault disconnected from coil inspect wire connection Malfunctioning coil OR wire Troubleshoot coil OR 57 Steer left coil fault disconnected from coil inspect wire connection Brake fault Malfunctioning coil OR wire Troubleshoot coil OR disconnected from coil inspect wire connection DIP switch settings are Troubleshoot and correct Senes paralel faut incorrect DIP switch settings Low battery voltage Batteries discharged Charge batteries LL Off level fault Tilt of chassis exceeds level noa ico chassis angle sensor setting Too much weight in platform Overload cutout fault Remove weight Genie Part No 84700 GR QSR QSW 5 3 Section 5 Fault Codes September 2009 LLL This page intentionally left blank Genie 5 4 GR QSR QSW Part No 84700 September
93. fer i tes on to correspon the hydraulic schematic Note alpha numeric callouts f onding notes on the electrical schematic Section 4 Repair Procedures September 2009 FUNCTION MANIFOLD 6 2 Valve Adjustments Function Manifold 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 item 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 schematic item A Genie 4 30 QSR QSW REV B 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 5 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 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 schematic item I 9 Adjust the internal hex socket Turn it clockwise to increase the pressure or
94. 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 AWARNING sati injury hazard Spraying ydraulic 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 Genie QSR QSW REV B 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 Tagand 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 Bodily injury hazard Spraying AWARNING 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 10 Remove the mast retaining fasteners 11 Carefully pull the hydraulic hoses free while removing the mast from the machine AWARNING Crushing hazard The mast assembly could become unbalanced and fall if not properly supported
95. from the ground and platform controls Result No machine functions should operate Genie QSR QSW REV D B 9 Test the Automotive style Horn if equipped Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first 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 1 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 2 Push down the horn button at the platform controls Result The horn should sound Part No 84700 September 2009 um M MM REV D B 10 3 Inspect the Voltage Inverter if equipped x Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first x 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 a rightfault LED b leftfault LED
96. he 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 Note If you have any further questions regarding the battery charger operation please contact the Genie Industries Scissor Service Department Section Scheduled Maintenance Procedures September 2009 CHECKLIST B PROCEDURES B 2 Inspect the Electrical Wiring Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first 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 Electrocution burn hazard Contact AWARNING with hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Inspect the under
97. hematic item F Solenoid valve 2 position 4 way 25Q 20V DC with diode schematic item H Solenoid valve 2 position 2 way N C 6 250 with manual override 12V DC with diode schematic item N Part No 84700 September 2009 Section 4 Repair Procedures REV B 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 AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Testthe coil for resistance See 6 3 How to Test a Coil 2 Connecta 100 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 10Q Genie part number 27287 3 Seta 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
98. hine configuration at left includes this feature MACHINE CONFIGURATION CODES MACHINE CONFIGURATION CODES GR GR QSR QSW ECMs with software revisins 0 to A4 ECMs with software revisions A5 and higher Machine Machine perg Non slab Motion Lift Drive Platform 2 Non slab Motion Lift Drive Platform Option Cut Out Overload Option Cut Out Overload Diagnostic Display Diagnostic Display Machine Option Feature Definitions Non slab Option For the GR to function correctly each model is configured with this option Motion Alarm The motion alarm will sound when operating any function Lift Drive Cut Out In addition to an alarm sounding lift and drive functions are disabled when the platform is raised above the down limit switch and the incline of the chassis exceeds the rating on the serial plate Configured on all machines Platform Overload When the platform overload limit switch is tripped signaling an overload condition in the platform all machine functions are disabled The additional weight must be removed from the platform and the power cycled from off to on before any function can be resumed Required for CE models Battery Drain Alarm When the machine is turned on and in the stowed position and no function is activated for 2 minutes an alarm will sound once every 3 seconds When this option is configured a dot in the diagnostic display window wil
99. 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 W 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 Genie 3 6 GR QSR QSW REV D 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
100. ing 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 Part No 84700 September 2009 Section 4 Repair Procedures REV B How to Assemble the Mast AWARNING 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 1 Thoroughly clean all columns 2 Secure the number 1 column to the work table and lay the chains out on the floor Note Do not allow the chains to become twisted or dirty 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 Laythe number 2 column chains on the floor Note Do not allow the chains to become twisted or dirty 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 ch
101. ions shall be completed daily quarterly semi annually annually and every 2 years as specified on the Maintenance Inspection Report AWARNING Failure to properly complete each inspection when required may cause death serious injury or substantial machine damage M 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 Part No 84700 Genie GR QSR QSW 2 4 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 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 immin
102. isher within easy reach IW 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 that all tools and working areas 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 any forklift overhead crane or Be sure ds 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 A other fluids Use an approved container Please be environmentally safe Sure that your workshop or work area is properly ventilated and well lit Part No 84700 September 2009 Table of Contents Introduction Important li Serial Number Information ciet exter rane Serial Number 1 nennen nnne nnns iii Section 1 Safety Rules General Safety Rules 5 iiia eu eee Lee RE aeea Naaa Section 2 Rev Specifications D Machine Specifications sisisi iranun anon oaia iaa s 2 1 Performance Specifications 1 anina anaana 2 2 Flydraulic Specifications assie aieia aea Ene 2 3 Manifold C
103. itting 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 AWARNING te injury hazard Spraying ydraulic 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 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 Genie 4 26 GR QSR QSW Part No 84700 September 2009 Section 4 Repair Procedures SSeS SS SSS Se This page intentionally left blank Genie Part No 84700 GR QSR QSW 4 27 Section 4 Repair Procedures September 2009 Function Manifold REV B 6 1 Function Manifold Components The function manifold is mounted next to the hydraulic power unit Index Schematic No Description Item Function Torque Goil n t items EF and IH itt eiae rea
104. l models with platform overload 6 10 A Electrical Schematic QSR ANSI and CSA Models all models without platform overload protection 6 14 A Electrical Schematic QSR CE models all models with platform overload 6 18 A Hydraulic Component Reference and Symbols Legend 6 22 A Hydra lic Schematic cii eae iiti tip id Aiea 6 23 Genie x GR QSR QSW Part No 84700 September 2009 Section 2 Specifications REV D Machine Specifications Batteries Standard Voltage 6V DC Group GC2 Type T 105 Quantity 4 Battery capacity maximum 225AH Reserve capacity 25A rate 447 minutes Batteries Maintenance free option Voltage 6V DC Group GC2 Type 6V AGM Quantity 4 Battery capacity maximum 200AH Reserve capacity 25A rate 380 minutes Fluid capacities Hydraulic tank 1 5 gallons 5 7 liters Hydraulic system 2 2 gallons including tank 8 3 liters Height stowed maximum GR 12 GR 15 QS 12R QS 15R QS 12W and QS 15W 62 ANSI CSA and Australia models 1 57m GR 12 and GR 15 68 1 in CE models 1 73m GR 20 QS 20R and QS 20W 78in all models 1 98m For operational specifications refer to the Operator s Manual Part No 84700 Genie Specificatio
105. l remain continuously illuminated when the ECM is in the SC mode OR when the platform up function is activated Genie 4 10 GR QSR QSW Part No 84700 September 2009 Section 4 Repair Procedures REV E How to Activate the Battery Drain Alarm Option 1 Pull out the red Emergency Stop button to the on position at the ground controls 2 Push in the red Emergency Stop button to the off position at the platform controls 3 Turn the key switch to platform control 4 Atthe platform controls press and hold the lift function select and speed select buttons and pull out the red Emergency Stop button to the on position Result The diagnostic display at the platform controls and the ECM will show SC 5 Release the lift function select and speed select buttons Result The diagnostic display will show the current software configuration 6 Press the slow speed select button Result The ones digit setting will be activated and the current ones setting will flash in the diagnostic display 7 Press the horn button Result A dot located at the lower right of the diagnostic display window will become illuminated This indicates that the battery drain alarm option has been activated 8 Press and hold the speed select button for a minimum of 3 seconds or until the ones setting stops flashing 9 Turn the key switch to the off position Note To deactivate the battery drain alarm
106. links 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 Section Scheduled Maintenance Procedures September 2009 CHECKLIST B PROCEDURES B 11 Test the Drive Brakes Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper brake action is essential to safe machine operation 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 2 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 Lower
107. loor Secure the weight to the platform Refer to the chart below Standard Platform REV B 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 Checkthe continuity between the black and red wires originating from the limit switch of the platform overload assembly O 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 O 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 Securely install the wires onto the GR 12 and GR 15 models 227 kg diis GR 20 models 159 kg limit switch Stockpicker Platform GR 12 GR 15 QS 12R QS 15R QS 12W and QS 15W models 227 kg GR 20 QS 20R and QS 20W models 159 kg Genie GR QSR Q
108. lt The diagnostic display will show the maximum lift speed percentage 6 Press the lift function select button Genie REV E w joystick controller JC1 with thumb steering rocker SW6 horn button BN5 lift function select button BN9 diagnostic display G8 red Emergency Stop button P2 uu 7 Use the steering thumb rocker switch on the joystick to increase or decrease the maximum lift speed percentage Refer to Section 2 Specifications for function speeds 8 Turn the key switch to the off position Note Any change in software settings will not take effect until the key switch is turned to the off position GR QSR QSW Part No 84700 September 2009 Section 4 Repair Procedures REV E How to Adjust the Stowed Drive Speed ADANGER Tip over hazard Do not adjust the lift and or drive speed higher than specified in this procedure Setting the function speeds greater than specifications could cause the machine to tip over resulting in death or serious injury ADANGER Tip over hazard This procedure must only be performed by a trained service professional Attempting this procedure without the necessary skills will result in death or serious injury Pull out the red Emergency Stop button to the on position at the ground controls Push in the red Emergency Stop button to the off position at the platform controls Turn the key
109. m Overload System if equipped Add an additional weight to the platform not to exceed 20 of the maximum rated load Refer to the machine serial plate Result The diagnostic display will show OL at both the ground and platform controls The platform overload system is operating properly Result The diagnostic display at the ground controls will show two flat bars and a blinking light and the diagnostic display at the platform controls will show the battery condition The platform overload system is not operating properly Refer to Repair Procedure 11 1 Calibrate the Platform Overload System if equipped Test all machine functions from the platform controls Result All platform control functions should not operate Genie 3 26 GR QSR QSW Part No 84700 September 2009 Section 3 Scheduled Maintenance Procedures REV D CHECKLIST C PROCEDURES 6 Turn the key switch to ground control 7 Testall machine functions from the ground controls O Result All ground control functions should not operate 8 Liftthe test weight off the platform floor using a suitable lifting device Turn the key switch to the off position 9 Turn the key switch to ground control O Result The diagnostic display at the ground controls will show two flat bars and a blinking light indicating a normal condition and the diagnostic display at the platform controls will show the battery condition Wi Result The diagnostic di
110. ment 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 Part No 84700 Genie GR QSR QSW CHECKLIST D PROCEDURES D 2 Inspect and Lubricate the Lifting Chains Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first 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 3 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 4 Lubricate each chain with a dry t
111. n line filter How to Remove the 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 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 Hyaraulic Hose and Fitting Torque Specifications Note Perform this procedure with the platform in the stowed position 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 Genie QSR QSW REVA 2 Tag disconnect and plug the return hard line at the hydraulic filter Cap the fitting on the filter AWARNING sa injury hazard Spraying ydraulic 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 3 Remove the hydraulic tank retaining fasteners and remove the hydraulic tank from the machine Torque specifications 35 in Ibs 4Nm Hydraulic tank retaining fasteners dry Hydraulic tank retaining fasteners lubricated 26 in lbs 2 9 Nm Part No 84700 September 2009 Section 4 Repair Procedures REVA 8 1 Yoke and Drive Motor How to Remove the Yoke and Drive Motor Assembly Note When removing a hose assembly or fitting the fi
112. n P2 drive function select button BN8 slow speed select button BN6 Press the drive function select button Result The diagnostic display will show the stowed drive speed percentage Press and hold the slow speed select button Result The diagnostic display will show the slow drive speed percentage Use the steering thumb rocker switch on the joystick to increase or decrease the stowed high torque drive speed percentage Refer to Section 2 Specifications for function speeds Turn the key switch to the off position Note Any change in software settings will not take effect until the key switch is turned to the off position Genie QSR QSW Section 4 Repair Procedures September 2009 PLATFORM CONTROLS 1 3 Software Configuration The Electronic Control Module ECM contains programming for all configurations of the Genie Runabout The machine can be adjusted to a different configuration using the buttons at the platform controls How to Determine the Software Configuration 1 Remove the platform controls from the platform 2 Pull out the red Emergency Stop button to the on position at the ground controls 3 Pushin the red Emergency Stop button to the off position at the platform controls 4 Atthe platform controls press and hold the lift function select and speed select buttons and pull out the red Emergency Stop button to the on position Result The diagnos
113. nd REV B ECM PIN OUT LEGEND Item Description A1 Flashing beacon FB1 output 0 2 Ground from platform controls input White wire at platform controls AS Plug A4 Driver Power input A5 Level sensor power S7 output o A6 Platform up coil Y8 output A7 Drive reverse coil Y5 output if 8 Motor controller U6 terminal 1 AQ Motor controller U6 terminal 3 10 Overload sensor PS2 input C GO X OC X XX X X X X13 A11 Key switch to platform control input i 12 Platform down TS66 input X B1 Platform data link high input Blue wire at platform controls B2 Plug B3 ECM ground output B4 Plug B5 Plug B6 Platform down coil Y7 output B7 Steer left coil Y4 output B8 Automotive style horn H2 option output B9 Multi function alarm H5 output B10 Pothole limit switch input B11 Drive enable power up limit switch input B12 Platform up TS66 input C1 Platform data link low input Orange wire at platform controls C2 Power to ECM input C3 Plug C4 Plug C5 Jumper C6 Drive forward coil Y6 output C7 Steer right coil Y3 output C8 Plug C9 Plug C10 Jumper C11 Level sensor signal S7 input C12 Down limit switch LS66 input Genie Part No 84700 GR QSR QSW 6 3
114. nd 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 Turnthe machine off Hold the steer relief valve with a wrench and remove the cap schematic item G 8 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Component damage hazard Do not adjust the relief valve pressures higher than specifications 9 Install the relief valve cap 10 Repeat steps 5 through 6 to confirm the relief valve pressure Genie Part No 84700 GR QSR QSW 4 33 Section 4 Repair Procedures September 2009 FUNCTION MANIFOLD 6 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 A
115. ng 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 9 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure ADANGER 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 4 through 7 to confirm the relief valve pressure 12 Place maximum rated load into the platform Secure the load to the platform Refer to Section 2 Specifications 13 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 4 31 Section 4 Repair Procedures September 2009 FUNCTION MANIFOLD 14 Hold the lift relief valve with a wrench and remove the cap 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 p
116. ns Tires and wheels Tire size solid rubber 10x 3in 25 4 x 2 5 cm Tire contact area 6 5 sqin 41 9 cm Castle nuttorque lubricated 150 ft lbs 203 Nm Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice GR QSR QSW 2 1 Section 2 Specifications September 2009 SPECIFICATIONS Performance Specifications Drive speed maximum Platform stowed fast 2 5mph 40 ft 10 9 sec 4 km h 12 2 10 9 sec Platform stowed slow 1 1 mph 40 ft 24 8 sec 1 8 km h 12 2 24 8 sec Platform raised 0 5mph 40 ft 55 sec 0 8 km h 12 2m 55 sec Braking distance maximum 19in 6in 48 15 High range paved surface Gradeability 30 Airborne noise emissions 70 dB Maximum sound level at normal operation workstations A weighted Function speed maximum from platform controls with 1 person in platform GR 12 QS 12R and QS 12W 19 to 21 seconds 17 to 19 seconds Platform up Platform down GR 15 QS 15R and QS 15W 20 to 22 seconds 18 to 20 seconds Platform up Platform down GR 20 QS 20R and QS 20W REV D Rated work load at full height maximum GR 12 and GR 15 Standard Platform 500 Ibs 227 kg GR 20 Standard Platform 350 Ibs 159 kg GR 12 GR 15 and GR 20 AWP and Fiberglass Platform 350 Ibs 159 kg GR 12 GR 15 QS 12R QS 15R QS 12W and QS 15W Sto
117. o ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls Result The tilt sensor alarm should not sound Center a lifting jack under the drive chassis at the ground controls side of the machine Raise the machine approximately 2 inches 5 cm 10 GR 12 GR 15 QS 12R QS 15R QS 12W and QS 15W Place 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 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 W Result The level sensor alarm does sound Adjust the level sensor retaining fasteners just until the level sensor alarm does not sound 13 Lower the platform to the stowed position 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 a adjusting fastener b calibration circles ground controls Genie Part No 84700 GR QSR QSW 4 23 Section 4 Repair Procedures September 2009 GROUND
118. ocker switch on the joystick to increase or decrease the value See 1 3 Machine Configuration Code Chart for configuration settings Press and hold the lift function select button for a minimum of seconds to set the tens value Part No 84700 o PLATFORM CONTROLS o lift function select button BN9 diagnostic display red Emergency Stop button P2 speed select button BN6 ao om Press the slow speed select button Result The ones digit setting will be activated and the current ones setting will flash in the diagnostic display Use the steering thumb rocker switch on the joystick to increase or decrease the value See 1 3 Machine Configuration Code Chart for configuration settings Press and hold the slow speed select button for a minimum of 3 seconds or until the ones setting stops flashing 10 Turn the key switch to the off position Note Any change in software settings will not take effect until the key switch is turned to the off position Genie QSR QSW Section 4 Repair Procedures September 2009 E PLATFORM CONTROLS REV E Machine Configuration Code Machine Configuration Code Chart from serial number Chart after serial number GR05 5001 to GR07 8706 GR07 8705 and from QS09 101 A mark in the four right columns indicates that the A mark in the four right columns indicates that the machine configuration at left includes this feature mac
119. omponent Specifications 2 4 Hydraulic Hose and Fitting Torque Specifications 2 5 SAE and Metric Fasteners Torque 2 7 Section 3 Rev Scheduled Maintenance Procedures 3 1 Pre delivery Preparation Report 3 3 Maintenance Inspection 3 5 D Checklist A Procedures A 1 Inspect the Manuals and 3 6 2 Perform Pre operation 3 7 Perform Function Tests Jide Einb a Dues 3 7 4 Test the Obstruction Sensing System QSR models only 3 8 5 Perform 30 Day Service 3 9 6 Grease the Steer Yokes 3 9 Genie Part No 84700 GR QSR QSW vil September 2009 SSS SEW TABLE OF CONTENTS Section 3 Rev Scheduled Maintenance Procedures continued D Checklist B Procedures B 1 Inspect the Batteries cie ni teet cien d 3 10 B 2 Inspect the Electrical 0 3 12 B 3 Inspect the Tires and Wheels including castle nut torque 3 13 B 4 Check the Lifting Chain Adjustments 4 3 13 B 5 Clean and Lubricate the 3 14 B 6 Adjust the Sequencing
120. oothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range Qu a slow speed select button BN6 Note Perform this procedure with the machine on a firm level surface that is free of obstructions 6 Bring the machine to top drive speed before reaching the start line Begin timing when your 1 Create start and finish lines by marking two reference point on the machine crosses the lines on the ground 40 feet 12 2 m apart start line 2 Turn the key switch to platform control and pull 7 Continue at full speed and note the time when out the red Emergency Stop button to the on your reference point on the machine passes position at both the ground and platform over the finish line Refer to Section 2 controls Specifications 3 Lower the platform to the stowed position 4 Press the slow speed select button 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 Genie Part No 84700 GR QSR QSW 3 21 Section Scheduled Maintenance Procedures September 2009 CHECKLIST B PROCEDURES B 15 Test the Motion Alarm if equipped Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Alarms are used to alert operators and ground personnel of machine
121. option on a machine which has the option activated repeat this procedure When the ECM is in the SC mode and the option is deactivated there will not be an illuminated dot in the diagnostic display window Part No 84700 Genie GR QSR QSW PLATFORM CONTROLS How to Determine the Battery Voltage The diagnostic display on the platform controls is used to indicate the battery voltage at all times when the machine is in normal operation Limp Mode If the battery level falls to less than 17 8V DC the single bar in the diagnostic display will be flashing and machine drive speed is limited to that of the raised drive speed Refer to Section 2 Specifications the battery level is 22 6V DC or higher the battery level is 21 6 to 22 5V DC the battery level is 20 7 to 21 5V DC the battery level is 19 7 to 20 6V DC the battery level is 17 8 to 19 6V DC the battery level is less than 17 8V DC O QJ b amp y 0 Section 4 Repair Procedures September 2009 Platform Components 2 1 Platform How to Remove the 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 AWARNING 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 Electrocution burn hazard Contact AWARNING
122. ower unit lifts the platform adjust the internal hex socket counterclockwise until the platform will not raise 19 Install the relief valve cap 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 4 32 Genie QSR QSW REV B How to Adjust the Steer Relief Valve Note Be sure that the hydraulic oil level is at the FULL mark on the hydraulic tank 1 Locate the steer relief valve on the function manifold schematic item G a test port b steer relief valve 2 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the test port schematic item A on the function manifold 3 Remove the platform controls from the platform Note Perform this test from the ground with the platform controls Do not stand in the platform Part No 84700 September 2009 Section 4 Repair Procedures p REV B FUNCTION MANIFOLD 4 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 5 Activate the function enable switch and press a
123. pproximately 6 feet 2 m 3 Placea 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 lifting ud a b chain terminal chain tension rocker d adjustment lock nut e mast column f inspection hole Genie 4 18 GR QSR QSW Part No 84700 September 2009 REV B How to Inspect the Lifting Chains Section 4 Repair Procedures E MAST COMPONENTS Inspection Procedure Inspection Failure Inspection Remedy Wear 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 mo
124. proximity and motion The motion alarm is located in the ground control box and when activated will sound at 60 beeps per minute 1 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 2 Raise the platform approximately 1 foot 0 3 m O Result When raising the platform the motion alarm should sound 3 Lower the platform to the stowed position O Result When lowering the platform the motion alarm should sound REV D Turn the key switch to platform controls Press the lift function select button Press and hold the function enable switch on the joystick Move the joystick off center hold for a moment and then release it Move the joystick off center in the opposite direction hold for a moment and then release it Result The motion alarm should sound when the joystick is moved off center in either direction Press the drive function select switch Press and hold the function enable switch on the joystick Move the joystick off center hold for a moment and then release it Move the joystick off center in the opposite direction hold for a moment and then release it Result The motion alarm should sound when the joystick is moved off center in either direction Press and hold the function enable switch on the joystick Press and hold the thumb rocker Switch for a moment to the left position and then release it Press
125. ra duty grease EP NLGI 1 lithium based or equivalent Section Scheduled Maintenance Procedures September 2009 Checklist B Procedures REV D 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 AWARNING Electrocution burn hazard Contact with hot or live circuits could result in death or serious injury Remove U9 all rings watches and other Battery Charger jewelry AWARNING Bodily injury hazard Batteries batteries 5 contain acid Avoid spilling or b 275A fuse F6 contacting battery acid Neutralize c disconnect QD1 battery acid spills with baking soda d battery charger U9 and water 6 Be sure that the battery hold downs and cable 1 Puton protective clothing and eye wear connections are tight 2 GR 12 Raise the platform 7 Besure that the battery separator wire approximately 3 feet 1 m connections are tight if equipped GR 15 and GR 20 Raise the platform approximately 5 feet 1 5 m 8 Fully charge the batteries Allow the batteries to rest 24 hours before performing this procedure 3 Open the battery cover Rest the cover against to allow the battery cells to equalize the
126. re than 8 25 inches 21 cm for 1 2 inch 12 7mm 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 Visually inspect the chains for rust and corrosion Evidence of rust or corrosion 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 Visually inspect the chains for lubrication When external surfaces are not protected with a layer of oil Lubricate chain with motor oil SAE 40W Tight Joints Inspect chain link joints for easy movement Part No 84700 Genie 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 i Continued to the next page GR QSR QSW 4 19 Section 4 Repair Procedures September 2009 MAST COMPONENTS REV B Inspection Procedure Inspection Failure Inspection Remedy Raised or Turned Pins Visually inspect for raised pins Raised pins N m Replace both chains on that column section Do not repair just the affected por
127. ree of obstructions 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 2 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 3 Press the lift function select button 4 Press and hold the function enable switch on the joystick 5 Raise the platform approximately 4 feet 1 2 m from the ground 6 Press the drive function select button REV D GI c a lift function select button BN9 b drive function select button BN8 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 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 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 Genie 3 20 GR QSR QSW Part No 84700 September 2009 Section 3 Scheduled Maintenance Procedures REV D CHECKLIST B PROCEDURES B 14 Test the Slow Drive Speed Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper drive functions are essential to safe machine operation The drive function should respond quickly and sm
128. s Genie Cracks in any chain link plate Replace entire chain Do not repair just the affected portion of the chain GR QSR QSW Part No 84700 September 2009 Section 4 Repair Procedures REV B 3 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 AWARNING 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 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 Remove the mast See 3 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 AWARNING Crushing hazard The lift cylinder could become unbalance
129. s September 2009 mum SSE M SS CHECKLIST E PROCEDURE REV B 10 Install the hydraulic pump inlet hard line into the tank Install the fitting onto the pump and torque to specification Refer to Section 2 Specifications 11 Install the hydraulic pump return hard line into the tank Install the fitting onto the hydraulic filter head and torque to specification Refer to Section 2 Specifications 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 Genie 3 82 QSR QSW Part No 84700 September 2009 Section 4 Repair Procedures Observe and Obey Repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Repairs Start Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your ma
130. s 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 AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Note If the machine has been in operation allow the coil to cool at least 3 hours before performing this test 1 Tagand disconnect the wiring from the coil to be tested 2 Testthe coil resistance using a multimeter set to resistance Refer to the Valve Coil Resistance Specification table W Result If the resistance is not within the adjusted specification plus or minus 10 replace the coil 4 34 Genie QSR QSW REV B 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 496 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 Solenoid valve 3 position 4 way 27 20 20V DC with diode schematic items Solenoid valve 3 position 4 way 190 20V DC with diode sc
131. side 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 Genie QSR QSW REV D 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 Placea 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 Part No 84700 September 2009 Section Scheduled Maintenance Procedures REV D B 3 Inspect the Tires
132. splay will show OL at both the ground and platform controls The platform overload system is not operating properly Refer to Repair Procedure 11 1 Calibrate the Platform Overload System if equipped 10 Test all machine functions from the ground controls O Result All ground control functions should operate normally 11 Turn the key switch to platform control 12 Test all machine functions from the platform controls O 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 Genie Part No 84700 GR QSR QSW 3 27 Section Scheduled Maintenance Procedures September 2009 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 1 Remove the mast covers GR 15 shown a mast cover b idler wheel
133. step 1 31 Raise the machine slightly 32 Remove the blocks from under both wheels 33 Lower the machine and remove the jack 34 Center a lifting jack under the drive chassis at the non steer end of the machine 35 Raise the machine approximately 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 37 Raise the platform approximately 1 foot 30 cm O 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 38 Lower the platform to the stowed position 39 Raise the machine slightly 40 Remove the blocks from under both wheels 41 Lower the machine and remove the jack Part No 84700 September 2009 Section 4 Repair Procedures REVA 5 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 Hyaraulic Hose and Fitting Torque Specifications 1 Tag disconnect and plug the high pressure hydraulic hose from the hydraulic pump AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hy
134. switch to platform control 4 Atthe platform controls press and hold the lift function select and horn buttons and pull out the red Emergency Stop button to the on position Result The diagnostic display will show PS Release the lift function select and horn buttons Result The diagnostic display will show the maximum lift speed percentage Part No 84700 Genie QSR QSW 4 5 PLATFORM CONTROLS w joystick controller JC1 with thumb steering rocker SW6 horn button BN5 lift function select button BN9 diagnostic display G8 red Emergency Stop button P2 drive function select button BN8 oo dg 6 Press the drive function select button Result The diagnostic display will show the stowed drive speed percentage 7 Usethe steering thumb rocker switch on the joystick to increase or decrease the stowed drive speed percentage Refer to Section 2 Specifications for function speeds 8 Turn the key switch to the off position Note Any change in software settings will not take effect until the key switch is turned to the off position Section 4 Repair Procedures September 2009 PLATFORM CONTROLS How to Adjust the Raised Drive Speed Tip over hazard Do not adjust the lift and or drive speed higher than specified in this procedure Setting the function speeds greater than specifications could cause the machine to tip over
135. t damage Note Use Chevron Aviation A hydraulic fluid when ambient temperatures are consistently below O 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 Industries Service Department before use Part No 84700 Genie GR QSR QSW SPECIFICATIONS Function pump Type Gear Displacement per revolution 0 244 cu in 4 cc Flow rate 2500 psi 172 bar 4 gpm 15L min 10 micron with 25 psi 1 7 bar bypass Hydraulic tank return filter Function manifold System relief valve pressure maximum 3500 psi 241 bar Lift relief valve pressure 1800 to 3500 psi 124 to 241 bar Steer relief valve pressure 1500 psi 103 bar Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Section 2 Specifications September 2009 SPECIFICATIONS Manifold Component Specifications Plug torque SAE No 2 50 in lbs 6 Nm SAE No 4 13 ft lbs 18 Nm SAE No 6 18 ft Ibs 24 Nm SAE No 8 50 ft lbs 68 Nm SAE No 10 55 ft lbs 75 Nm SAE No 12 75 ft lbs 102 Nm 2 4 Genie REV D Valve Coil Resistance Note The following coil resistance specifications are at an ambient temperature of 68 F 20
136. the negative lead to the internal metallic ring at either end of the coil Part No 84700 Genie GR QSR QSW FUNCTION MANIFOLD COIL MULTI METER US 100 9 RESISTOR BATTERY 1 O ees a TIT 1 AR A 1 L a Jed i dil pe 4 Y multimeter 9V DC battery 10Q resistor coil ao om 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 Atthe battery or coil terminals reverse the connections Note and record the current reading Result Both current readings are greater than mA and are different by a minimum of 20 The coil is good W 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 Section 4 Repair Procedures September 2009 Hydraulic Tank 7 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 retur
137. 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 Inspection Checklist Daily or every 8 hours A Quarterly or every 250 hours A B Semi annually or every 500 hours A B C Annually or every 1000 hours A B C D Two year or every 2000 hours 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 Part No 84700 Pre Delivery 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
138. 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 Esos ACAUTION P09 injury hazard The yoke motor assembly may fall if not properly supported when removed from the machine 4 37 Section 4 Repair Procedures September 2009 STEER AXLE COMPONENTS How to Remove a Drive Motor 1 Block the wheels at the non steer end of the machine 2 Remove the cotter pin from the wheel castle nut of the motor to be removed 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 4 Center a lifting jack under the drive chassis at the steer end of the machine 5 Raise the machine approximately 2 inches 5 cm Place blocks under the chassis for support Crushing hazard The chassis AWARNING could fall if not properly supported 6 Remove the wheel castle nut Remove the wheel Genie QSR QSW REVA 7 Tag disconnect and plug the hydraulic hoses on the drive motor Cap the fittings on the drive motor AWARNING 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 Component damage hazard
139. tic display at the platform controls and the ECM will show SC 4 8 GR QSR QSW Genie REV E de o lift function select button BN9 diagnostic display red Emergency Stop button P2 speed select button BN6 ao oo Release the lift function select and speed select buttons Result The diagnostic display will show the current configuration 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 Part No 84700 September 2009 Section 4 Repair Procedures REV E How to Change the Software Configuration 1 Pull out the red Emergency Stop button to the on position at the ground controls Push in the red Emergency Stop button to the off position at the platform controls Turn the key switch to platform control At the platform controls press and hold the lift function select and speed select buttons and pull out the red Emergency Stop button to the on position Result The diagnostic display at the platform controls and the ECM will show SC Release the lift function select and speed select buttons Result The diagnostic display will show the current software configuration Press the lift function select button Result The tens digit setting will be activated and the current tens setting will flash in the diagnostic display Use the steering thumb r
140. tion of the chain Visually inspect for turned pins by insuring all the flats on the V heads are aligned Misalignment of flats on all V heads Replace both chains on that column section Do not repair just the affected portion of the chain Chain Side Visually inspect for wear patterns on heads of link pins and outside link plates where they contact the idler wheel Wear on pin heads or noticeable wear in the profile of the outside link plate Vo Q link plate wear 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 Chain Anchors Visually inspect chain anchors 9 o 9 IQ 3 Broken chain anchor fingers Replace chain anchor Bent or damaged anchor Replace chain anchor and threaded rod M threaded Twisted or misaligned Re align chain anchor to rod chain anchor ensure even loading of anchors chain Threaded rod not visible Replace idler wheel and in inspection hole check chain alignment Idler Wheels 9 Visually inspect chain Idler wheels have badly Replace idler wheel E idler wheels worn flanges in idler wheel Idler wheels have grooves worn into chain contact surface Replace both chains on that column section Cracked Link Plates Visually inspect chain link plates for crack
141. tor SGE Brake manifold T Brake m gt lt Y8 Solenoid operated 2 position 4 way directional valve e Filter REVA OW Check valve n ua LA dfe Solenoid operated 3 position 4 way directional valve the Solenoid operated 3 position 4 way directional valve Pilot operated needle valve Lift cylinder Function manifold Genie GR QSR QSW Part No 84700 September 2009 Section 6 Schematics REVA Hydraulic Schematic LIFT CYLINDER pU STEER STEER LEFT RIGHT LEFT RIGHT LEFT RIGHT DRIVE DRIVE MOTOR BRAKE HEN MANUAL gt O HAND N RELEASE PUMP E E pex Wo OR f P BRAKE HO WI Om zm RELEASE E MANIFOLD gt AX SE te B1 E L V S1 S2 B AC HP M1 M4 1 Ya mm F Ol X 1 oTi ve val
142. ttery cell with a hydrometer Note the results 14 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 26 7 C e Subtract 0 004 from the reading of each cell for every 10 5 5 C below 80 F 26 7 C O Result All battery cells display a specific gravity of 1 277 or greater The battery is fully charged Proceed to step 15 Result The difference in specific gravity readings between cells is greater than 0 1 OR the specific gravity of one or more cells is less than 1 177 Replace the battery 15 Check the battery acid level If needed replenish with distilled water to 1 inch 3 mm below the bottom of the battery fill tube Do not overfill 16 Install the vent caps and neutralize any electrolyte that may have spilled Part No 84700 Genie GR QSR QSW CHECKLIST B PROCEDURES All models 17 Check each battery pack and verify that the batteries are wired correctly 18 Inspect the battery charger plug and pigtail for damage or excessive insulation wear Replace as required 19 Connect the battery charger to a properly grounded 115V 60Hz or 230V 60Hz single phase AC power supply Result The charger should operate and begin charging the batteries W If simultaneously the charger alarm sounds and the LEDs blink one time correct the charger connections at t
143. tting and or hose end must be torqued to specification during installation Refer to Section 2 Hyaraulic Hose and Fitting Torque Specifications 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 4 Center a lifting jack under the drive chassis at the steer end of the machine 5 Raise the machine approximately 6 inches 15 cm Place blocks under the chassis for support AWARNING Crushing hazard The chassis could fall if not properly supported 6 Remove the wheel castle nut Remove the wheel Part No 84700 Genie GR QSR QSW Steer Axle Components 7 Tag disconnect and plug the hydraulic hoses on the drive motor Cap the fittings on the drive motor AWARNING 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 Component damage hazard 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
144. uld result in death or serious injury Indicates a potentially hazardous ACAUTION 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 Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of steps Genie Part No 84700 GR QSR QSW 4 1 Section 4 Repair Procedures September 2009 Platform Controls The platform controls used to operate the machine from the platform or while standing on the ground can also be used to tune the performance of the machine Moving the joystick or activating a 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 When the ECM is in the speed tuning mode PS is shown in the diagnostic display window or software configuration mode SC is shown in the diagnostic display window the platform controls are used to adjust the function speed parameters or the machine configuration The platform controls consist of an electronic circuit board joystick alarm buttons and LEDs For further information or assistance consult the Genie Industries Service Department
145. ype spray lubricant AWARNING 9 i y 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 Section Scheduled Maintenance Procedures September 2009 CHECKLIST D PROCEDURES D 3 Replace the Hydraulic Tank Return Filter Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first 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 ACAUTION 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 Genie QSR QSW REV D 4 Use a permanent ink marker to write the date and number of hours from the hour meter onto the filter

Service Manual - Genie Industries

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