Genie GR-12, GR-15, GR-20, QS-20R, QS-12W Service Manual
...
Service Manual
Serial Number Range
GR™-12
from GR10-20000
40865
GR™-15
from GR16P-40866
44699
GR™-20
from GRP-44700
101
QS™-12R
from QS11-1000
2429
QS™-15R
from QS16P-2430
4499
QS™-20R
from QSP-4500
QS™-12W
QS™-15W
QS™-20W
Part No. 1275811GT
Rev A2
May 2018
to GR16-
to GR16P-
from GRR-
to QS16-
to QS16P-
Service Manual May 2018
Introduction
Introducti on Introducti on
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.
This manual provides detailed scheduled
maintenance information for the machine owner
and user. It also provides troubleshooting and
repair procedures for qualified service
professionals.
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.
Technical Publications
Genie has endeavored to deliver the highest
degree of accuracy possible. However, continuous
improvement of our products is a Genie policy.
Therefore, product specifications are subject to
change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.
Contact Us:
Internet: www.genielift.com
E-mail: awp.techpub@terex.com
Find a Manual for this Model
Compliance
Machine Classification
Group A/Type 1 as defined by ISO 16368
Machine Design Life
Unrestricted with proper operation, inspection and
scheduled maintenance.
Go to http://www.genielift.com
Use the links to locate Service Manuals,
Maintenance Manuals, Service and Repair
Manuals, Parts Manuals and Operator's Manuals.
Copyright © 2011 by Terex Corporation
1275811 Rev A, September 2016
Fourth Edition, First Printing
Genie is a registered trademark of Terex South Dakota, Inc. in
the U.S.A. and many other countries.
"GR" and "QS" are trademarks of Terex South Dakota, Inc.
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Introduction
Revision History
Revision Date Section Procedure / Page / Description
A 9/2016
A1 2/2018 Repair 14-1 How to Remove the Batteries
A2
5/2018
Schematics
Initial release
Add serial break GRR-101 to electrical and hydraulic
schematics
Reference Examples:
Section – Maintenance, B-3
Section – Repair Procedure, 4-2
Section – Fault Codes, All charts
Section – Schematics, Legends and schematics
Electronic Version
Click on any content or procedure in the Table of Contents to view
the update.
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From September 1, 2016
Introduction
Serial Number LegendTo August 31, 2016
1 Model
2 Model year
3 Facility code
4 Sequence number
5 Serial label
6 Serial number (stamped on chassis, GR models)
7 Serial number (stamped on chassis, QS models)
1 Model
2 Facility code
3 Sequence number
4 Serial label
5 Serial number (stamped on chassis, GR models)
6 Serial number (stamped on chassis, QS models)
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Safety Rules
Section 1 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.
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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
messages that follow this symbol
to avoid possible injury or death.
Indicates a imminently hazardous
situation which, if not avoided, will
result in death or serious injury.
Indicates a potentially hazardous
situation which, if not avoided,
co
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may cause minor or moderate
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may result in property damage.
Be sure
other protective clothing if the situation
warrants it.
Be aware of potential crushing hazards
such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved
steel
Be sure to keep sparks, flames and
lighted tobacco away from flammable and
combustible materials like battery gases
and engine fuels. Always have an
approved fire extinguisher within easy
reach.
Be sure that all tools and working areas
are properly maintained and ready for
use. Keep work surfaces clean and free of
debris that could get into machine
components and cause damage.
Be sure any forklift, overhead crane or
other lifting or supporting device is fully
capable of supporting and stabilizing the
weight to be lifted. Use only chains or
straps that
ample capacity.
Be sure that fasteners intended for one
time use (i.e., cotter pins and self
nuts) are not reused. These components
may fail if they are used a second time.
Be sure to properly dispose of old oil
other fluids. Use an approved container.
Please be environmentally safe.
Be sure that your workshop or work area
is properly ventilated and well lit.
Safety Rules
Personal Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
uld result in death or serious
safety
Workplace 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.
are in good condition and of
to wear protective eye wear and
-toed shoes.
-locking
or
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Table of Contents
Introduction Introduction ........................................................................................................... ii
Important Information ............................................................................................. ii
Find a Manual for this Model .................................................................................. ii
Revision History..................................................................................................... iii
Section 1 Safety Rules .......................................................................................................... v
General Safety Rules ............................................................................................. v
Section 2 Specifications ....................................................................................................... 1
Machine Specifications ........................................................................................... 1
Performance Specifications .................................................................................... 2
Hydraulic Component and Manifold Specifications ................................................ 3
Hydraulic Oil Specifications .................................................................................... 4
Hydraulic Hose and Fitting Torque Specifications ................................................. 7
Torque Procedure .................................................................................................. 8
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Table of Contents
Section 3 Scheduled Maintenance Procedures ............................................................... 11
Introduction .......................................................................................................... 11
Maintenance Schedule ........................................................................................ 13
Pre-Delivery Preparation Report .......................................................................... 15
Scheduled and Programmed Maintenance Inspection Report ............................ 17
Commissioning Procedures ............................................................................. 19
C-1 Perform 40 Hour Service ............................................................................... 19
Quarterly Maintenance Procedures ................................................................. 20
Q-1 Check for Open Bulletins and Owner Registration ....................................... 20
Q-2 Battery Inspection ......................................................................................... 21
Q-3 Inspect the Electrical Wiring .......................................................................... 24
Q-4 Inspect the Electrical Contactor .................................................................... 24
Q-5 Inspect the Voltage Inverter (if equipped) ..................................................... 25
Q-6 Test the Flashing Beacons (if equipped) ...................................................... 26
Q-7 Test the Alarm Package (if equipped) .......................................................... 26
Q-8 Inspect the Tires and Wheels (including castle nut torque) .......................... 27
Q-9 Check the Lifting Chain Adjustments ............................................................ 28
Q-10 Clean and Lubricate the Columns .............................................................. 28
Q-11 Adjust the Sequencing Cables .................................................................... 29
Q-12 Visual Inspection of the Hydraulic Oil ......................................................... 30
Q-13 Test the Drive Brakes ................................................................................. 31
Q-14 Test the Drive Speed – Stowed Position .................................................... 32
Q-15 Test the Drive Speed - Raised Position ...................................................... 33
Annual Maintenance Procedures ..................................................................... 34
A-1 Grease the Platform Overload Mechanism (if equipped) .............................. 34
A-2 Test the Platform Overload System (if equipped) ......................................... 34
Programmed Maintenance Procedures ........................................................... 37
P0-1 Grease the Steer Yokes .............................................................................. 37
P1-1 Inspect the Mast Assembly ......................................................................... 37
P1-2 Inspect and Lubricate the Lifting Chains ..................................................... 38
P2-1 Replace the Hydraulic Filter ........................................................................ 39
P2-2 Test or Replace the Hydraulic Oil ............................................................... 39
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Table of Contents
Section 4 Repair Procedures ............................................................................................. 41
Introduction ........................................................................................................... 41
Platform Controls ............................................................................................... 43
1-1 Circuit Board................................................................................................... 45
1-2 Joystick ........................................................................................................... 46
1-3 Platfrom Controls Alarm ................................................................................. 46
1-4 Platform Emergency Stop Button ................................................................... 47
Ground Controls ................................................................................................. 48
2-1 Software Revision Level ................................................................................. 49
2-2 Machine Setup ............................................................................................... 50
2-3 Level Sensors ................................................................................................ 51
Hydraulic Pump .................................................................................................. 60
3-1 Hydraulic Pump .............................................................................................. 60
How to Remove the Hydraulic Pump .............................................................. 61
Function Manifold .............................................................................................. 62
4-1 Function Manifold Components ..................................................................... 62
4-2 Valve Adjustments – Function Manifold ......................................................... 64
4-3 Valve Coils ..................................................................................................... 67
Brake Release Hand Pump Components ......................................................... 69
5-1 Brake Release Hand Pump Components ...................................................... 69
Hydraulic Tank .................................................................................................... 70
6-1 Hydraulic Tank ............................................................................................... 70
Non-Steer Axle Components ............................................................................. 71
7-1 Drive Brake..................................................................................................... 71
Steer Axle Components ..................................................................................... 72
8-1 Yoke and Drive Motor .................................................................................... 72
8-2 Steer Cylinder ................................................................................................ 73
8-3 Steer Bellcrank ............................................................................................... 74
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Platform Components ....................................................................................... 75
9-1 Platform .......................................................................................................... 75
9-2 Platform Extension Deck ............................................................................... 76
9-3 Work Tray ...................................................................................................... 77
Mast Components .............................................................................................. 78
10-1 Mast ............................................................................................................. 78
How to Disassemble the Mast ........................................................................ 79
How to Assemble the Mast ............................................................................. 81
10-2 Glide Pads ................................................................................................... 82
10-3 Lifting Chains ............................................................................................... 83
How to Inspect the Lifting Chains ................................................................... 84
Platform Overload Components ....................................................................... 87
11-1 Platform Overload System (if equipped) ...................................................... 87
11-2 Platform Overload Recovery Message ........................................................ 89
Obstruction Sensing System ............................................................................ 91
12-1 Obstruction Sensing System (QSR models) ............................................... 91
How to Replace an Obstruction Sensing Pad (QSR models only) ................. 91
Battery Charger .................................................................................................. 93
13-1 Battery Charger ........................................................................................... 93
Selecting a Charge Profile .............................................................................. 94
Batteries .............................................................................................................. 95
14-1 How to Remove the Batteries ...................................................................... 95
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Table of Contents
Section 5 Diagnostics ......................................................................................................... 96
Introduction ........................................................................................................... 96
GCON I/O Map without Load Sense .................................................................... 98
GCON I/O Map with Load Sense ......................................................................... 99
Operation Indicator Codes (OIC)........................................................................ 100
Diagnostic Trouble Codes (DTC) ....................................................................... 100
Troubleshooting "HXXX" and "PXXX" Faults ..................................................... 101
Fault Inspection Procedure ................................................................................ 102
Type "HXXX" Faults ........................................................................................... 104
Type "PXXX" Faults............................................................................................ 105
Type "UXXX" Faults ........................................................................................... 106
Type "FXXX" Faults ............................................................................................ 107
Type "CXXX" Faults ........................................................................................... 108
Battery Charger .................................................................................................. 109
Charger Fault Codes ..................................................................................... 110
Charger Error Codes ..................................................................................... 111
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Table of Contents
Section 6 Schematics ....................................................................................................... 115
Introduction ........................................................................................................ 115
Electrical Component and Wire Color Legends ................................................. 116
Wiring Diagram Ground and Platform Controls ................................................. 118
Electrical Symbol Legend .................................................................................. 119
Hydraulic Symbols Legend ................................................................................ 120
Electrical Schematics – ANSI / CSA Models ................................................. 121
Electrical Schematic, GR • QSW, ANS / CSA
(from serial number GR10-20000 to GR11-20683 and
QS11-1000 to QS11-1015) ........................................................................ 122
Electrical Schematic, GR • QSW, ANSI / CSA
(from serial numbers GR11-20684 to GR14-29741 and
QS11-1016 to QS14-1550) ........................................................................ 126
Electrical Schematic, GR • QSW, ANSI / CSA
(from serial numbers GR14-29742 to GR1540225 and
QS14-1551 to QS15-2426) ........................................................................ 130
Electrical Schemamtic, GR • QSW, ANSI / CSA
(from serial numbers GR15-40226 to GR16P-41929 and
QS15-2427 to QS16P-2451) ...................................................................... 131
Electrical Schematic, GR • QSW, ANSI / CSA
(from serial numbers GR16P-41930 to GR16P-44173 and
QS16P-2452 to QS16P-2468) ................................................................... 134
Electrical Schemamtic, GR • QSW, ANSI / CSA (from serial numbers
GR16P-44174 to GR16P-46499 and QS16P-2469 to QS16P-4499)
(from serial numbers GRP-46500, GRR-101 and QSP-4500) ................... 135
Electrical Schematic, QSR, ANSI/CSA
(from serial number QS11-1000 - QS11-1015) .......................................... 138
Electrical Schematic, QSR, ANSI/CSA
(from serial number QS11-1016 to QS14-1550) ........................................ 142
Electrical Schematic, QSR, ANSI/CSA
(from serial number QS14-1551 to QS15-2426) ........................................ 146
Electrical Schematic, QSR, ANSI/CSA
(from serial number QS15-2427 to QS16P-2451) ..................................... 147
Electrical Schematic, QSR, ANSI/CSA
(from serial number QS16P-2452 to QS16P-2468) ................................... 150
Electrical Schematic, QSR, ANSI/CSA
(from serial number QS16P-2469 to QS16P-4499)
(from serial number QSP-4500) ................................................................. 151
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Table of Contents
Electrical Schematics – AS / CE Models ........................................................ 153
Electrical Schematic, GR/QSW, AS/CE
(from serial numbers GR10-20000 - GR11-20683 and
QS11-1000 - QS11-1015) .......................................................................... 154
Electrical Schematic, GR/QSW, AS/CE
(from serial numbers GR11-20684 to GR14-29741 and
QS11-1016 to QS14-1550) ......................................................................... 158
Electrical Schematic, GR/QSW, AS/CE
(from serial numbers GR14-29742 to GR15-40225 and
QS14-1551 to QS15-2426) ......................................................................... 162
Electrical Schematic, GR/QSW, AS/CE
(from serial numbers GR15-40226 to GR16P-41929 and
QS15-2427 to QS16P-2451) ...................................................................... 163
Electrical Schematic, GR/QSW, AS/CE
(from serial numbers GR16P-41930 to GR16P-44173 and
QS16P-2452 to QS16P-2468) .................................................................... 166
Electrical Schematic, GR/QSW, AS/CE
(from serial numbers GR16P-44174 to GR16P-46499 and
QS16P-2469 to QS16P-4499)
(from GRP-46500, GRR-101 and QSP-4500) ............................................ 167
Electrical Schematic, QSR, AS/CE
(from serial number QS11-1000 to QS11-1015 ......................................... 170
Electrical Schematic, QSR, AS/CE
(from serial number QS11-1016 to QS14-1550) ........................................ 174
Electrical Schematic, QSR, AS/CE
(from serial number QS14-1551 to QS15-2426) ........................................ 178
Electrical Schematic, QSR, AS/CE
(from serial number QS15-2427 to QS16P-2451) ...................................... 179
Electrical Schematic, QSR, AS/CE
(from serial number QS16P-2452 to QS16P-2468) ................................... 182
Electrical Schematic, QSR, AS/CE
(from serial number QS16P-2469 to QS16P-4499)
(from serial number QSP-4500) ................................................................. 183
Hydraulic Schematics ...................................................................................... 185
Hydraulic Schematic, GR • QSR • QSW,
(from GR10-20000 to GR12-24138 and QS11-1000 to QS12-1063)......... 186
Hydraulic Schematic GR • QSR • QSW,
(from GR12-24139 to GR16P-46499 and QS12-1064 to QS16P-4499)
(from GRP-46500, GRR-101 and QSP-4500) ............................................ 187
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Voltage
6V DC
Group
GC2
Type
105
Quantity
4
Battery capacity, maximum
C20 = 225AH
Reserve capacity @ 25A rate
447 minutes
Weight, each
lbs
kg
Voltage
DC
GC2
Type
AGM
Quantity
4
Battery capacity, maximum
C20 = 200AH
Reserve capacity @
380 minutes
Weight, each
lbs
kg
Voltage
24V
Horsepower
4.5 HP @ 2950 rpm
Kilowatts
3.3 kW @ 2950 rpm
Fluid capacities
Hydraulic tank
3.75 gallons
14.2 liters
Hydraulic system (including tank)
5 gallons
19 liters
GR
QS
(ANSI / CSA models)
62 in
1.57 m
GR
QS
(AS / CE models)
68.1 in
1.73 m
GR
78 in
1.98 m
Tires and wheels
Tire size (solid rubber)
10 x 3 in
25.4 x 7.62 cm
Tire contact area
6.5 sq in
2
Castle nut torque, lubricated
lbs
203 Nm
Specifications
Section 2 Specificati ons
Machine Specifications
Batteries, Standard
T-
62
Batteries, Maintenance-free (option)
6V
Group
6V-
25A rate
62
DC Motor
Height, stowed maximum
-12, GR-15, QS-12R, QS-15R,
-12W and QS15W
-12, GR-15, QS-12R, QS-15R,
-12W and QS15W
-20, QS-20R, QS-20W
28
41.9 cm
150 ft-
28
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Drive speed, maximum
Platform stowed, fast 2.5 mph
40 ft / 10.9 sec
4 km/h
10.9 sec
Platform stowed, slow 1.1 mph
40 ft / 24.8 sec
1.8 km/h
12.2 m / 24.8 sec
Platform raised 0.5 mph
40 ft / 55 sec
0.8 km/h
12.2 m / 55 sec
Braking distance, maximum
High range on paved surface
19 in ± 6 in
61 cm ± 30 cm
Gradeability
Operator's Manual
Function speed, maximum from platform controls
(with 1 person in platform)
GR
19 to 21 seconds
30 to 32 seconds
17 to 19 seconds
GR
Platform up (fast mode)
Platform up (slow mode)
Platform down
20 to 22 seconds
31 to 33 seconds
18 to 20 seconds
GR
Platform up (fast mode)
Platform up (slow mode)
Platform down
23 to 25 seconds
32 to 34 seconds
20 to 22 seconds
Rated work load at full height, maximum
GR
(standard platform)
kg
GR
(AWP platform)
350 lbs
159 kg
GR
(standard platform)
350 lbs
159 kg
QS
stockpicker platform)
500 lbs
227 kg
QS
(stockpicker platform)
350 lbs
159 kg
Specifications
Performance Specifications
12.2 m /
See
-12, QS-12R, QS-12W
Platform up (fast mode)
Platform up (slow mode)
Platform down
-15, QS-15R, QS-15W
-20, QS-20R, QS-20W
-12, GR-15
-12, GR-15, GR-20
-20
-12R, QS-15R, QS-12W, QS-15W
-20R, QS-20W
For operational specifications, refer to the
Operator's Manual.
500 lbs
227
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Function pump
Type
Gear
Displacement per revolution
0.244 cu in
4 cc
Flow rate @ 2500 psi / 172 bar
4 gpm
15 L/min
Hydraulic tank return filter
10 micron with
25 psi / 1.7 bar
bypass
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
Plug torque
SAE No. 2
lbs / 6 Nm
SAE No. 4
lbs / 18 Nm
SAE No. 6
lbs / 24 Nm
SAE No. 8
lbs / 68 Nm
SAE No. 10
lbs / 75 Nm
SAE No. 12
lbs / 102 Nm
Specifications
Hydraulic Component
Specifications
Manifold Component
Specifications
50 in-
13 ft-
18 ft-
50 ft-
55 ft-
75 ft-
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Hydraulic Fluid Specifications
Genie specifications require hydraulic oils which are
designed to give maximum protection to hydraulic
systems, have the ability to
temperature range, and the viscosity index should
exceed 140. They should provide excellent antiwear,
oxidation prevention, corrosion inhibition, seal
conditioning, and foam and aeration suppression
properties.
Cleanliness level,
minim
ISO 15/13
Water content,
maximum
250 ppm
Recommended Hydraulic Fluid
Hydraulic oil type
Chevron Rando HD Premium
Viscosity grade
32
Viscosity index
200
Optional Hydraulic Fluids
Mineral based Shell Tellus S2 V 32
Shell Tellus S2 V 46
S4 VX 32 Shell
Shell Donax TG (Dexron III)
Chevron 5606A
Biodegradable
46
Fire resistant
5046
Optional fluids may not have
the same hydraulic lifespan and
may result in component
damage.
Do not top off with incompatible
hydraulic fluids. Hydraulic fluids
may be incompatible due to the
differences in base
chemistry. When incompatible
fluids are mixed, insoluble
materials may form and deposit
in the hydraulic system,
plugging hydraulic lines, filters,
control valves and may result in
component damage.
Specifications
Hydraulic Oil Specifications
perform over a wide
um
Shell Tellus
additive
Note: Do not operate the machine when the
ambient air temperature is consistently above
120°F / 49°C.
Hydraulic Fluid Temperature
Range
Petro Canada Environ MV
UCON Hydrolube HP-
Note: Genie specifications require additional
equipment and special installation instructions for
the approved optional fluids. Consult Genie
Product Support before use.
Note: Extended machine operation can cause the
hydraulic fluid temperature to increase beyond it's
maximum allowable range. If the hydraulic fluid
temperature consistently exceeds 200°F / 90°C an
optional oil cooler may be required.
4 GR
Ambient air temperature
1 Chevron hydraulic oil 5606A
2 Petro-Canada Environ MV 46
3 UCON Hydrolube HP-5046D
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May 2018 Service Manual
ISO Grade
32
Viscosity index 200
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
7.5
33.5
Brookfield Viscosity
cP @
cP @
1040
3310
Flash point 375°F / 190°C
Pour point
50°C
Maximum continuous operating
temperature
171°F / 77°C
ISO Grade
15
Viscosity index 300
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
cSt @
5.5
15.0
510
Flash point 180°F / 82°C
Pour point
63°C
Maximum continuous operating
temperature
124°F / 51°C
Specifications
Chevron Rando HD Premium Oil
MV Fluid Properties
Chevron 5606A Hydraulic Oil
Fluid Properties
-4°F / -20°C
-22°F / -30°C
-58°F / -
Note: A hydraulic oil heating system is
recommended when the ambient temperature is
consistently below 0°F / -18°C.
Note: Do not operate the machine when the
ambient temperature is below -20°F / -29°C with
Rando HD Premium MV.
-40°F / -40°C
-81°F / -
Note: Use of Chevron 5606A hydraulic fluid, or
equivalent, is required when ambient temperatures
are consistently below 0°F / -17°C unless an oil
heating system is used.
Continued use of Chevron
5606A hydraulic fluid, or
equivalent, when ambient
temperatures are consistently
above 32°F / 0°C may result in
component damage
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ISO Grade
46
Viscosity index 154
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @
8.0
44.4
Flash point 482°F / 250°C
Pour point
45°C
Maximum continuous operating
temperature
180°F / 82°C
ISO Grade
32
Viscosity index 300
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F
9
33.8
Brookfield Viscosity
cSt @
cSt @
cSt @
481
702.4
2624
Flash point >100
Pour point
60°C
Maximum continuous operating
temperature
103°F / 75°C
ISO Grade
46
Viscosity index 192
Kinematic Viscosity
cSt @ 149°F / 65°C
cSt @ 104°F / 40°C
cSt @ 0°F /
22
46
1300
Flash point None
Pour point
63°C
Maximum continuous operating
temperature
189°F / 87°C
Specifications
Petro-Canada Environ MV 46
Fluid Properties
UCON Hydrolube HP-5046 Fluid
Properties
104°F / 40°C
-49°F / -
Shell Tellus S4 VX Fluid
Properties
/ 40°C
-4°F / -20°C
-13°F / -25°C
-40°F / -40°C
-18°C
-81°F / -
-76°F / -
6 GR
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• QS™R • QS™W Part No. 1275811GT
May 2018 Service Manual
SAE Dash Size
Torque
Specifications
Hydraulic Hose and Fitting Torque Specifications
Your machine is equipped with Parker Seal-Lok™
ORFS or 37° JIC 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.
Seal-Lok™ Fittings
(hose end - ORFS)
SAE Dash Size Torque
-4 10 ft-lbs / 13.6 Nm
-6 30 ft-lbs / 40.7 Nm
-8 40 ft-lbs / 54.2 Nm
-10 60 ft-lbs / 81.3 Nm
-12 85 ft-lbs / 115 Nm
-16 110 ft-lbs / 150 Nm
-20 140 ft-lbs / 190 Nm
-24 180 ft-lbs / 245 Nm
SAE O-ring Boss Port
(tube fitting - installed into Aluminum)
(all types)
SAE Dash Size Torque
-4 14 ft-lbs / 19 Nm
-6 23 ft-lbs / 31.2 Nm
-8 36 ft-lbs / 54.2 Nm
-10 62 ft-lbs / 84 Nm
-12 84 ft-lbs / 114 Nm
-16 125 ft-lbs / 169.5 Nm
-20 151 ft-lbs / 204.7 Nm
-24 184 ft-lbs / 249.5 Nm
Adjustable Fitting Non-adjustable fitting
1 jam nut
JIC 37° Fittings
(swivel nut or hose connection)
SAE Dash Size Thread Size Flats
-4 7/16-20 2
-6 9/16-18 1 ¼
-8 3/4-16 1
-10 7/8-14 1
-12 1 1/16-12 1
-16 1 5/16-12 1
-20 1 5/8-12 1
-24 1 7/8-12 1
SAE O-ring Boss Port
(tube fitting - installed into Steel)
-4 ORFS / 37° (Adj)
ORFS (Non-adj)
37° (Non-adj)
-6 ORFS (Adj / Non-adj)
37° (Adj / Non-adj)
-8 ORFS (Adj / Non-adj)
37° (Adj / Non-adj)
-10 ORFS (Adj / Non-adj)
37° (Adj / Non-adj)
-12 (All types) 135 ft-lbs / 183 Nm
-16 (All types) 200 ft-lbs / 271.2 Nm
-20 (All types) 250 ft-lbs / 339 Nm
-24 (All types) 305 ft-lbs / 413.5 Nm
15 ft-lbs / 20.3 Nm
26 ft-lbs / 35.3 Nm
22 ft-lbs / 30 Nm
35 ft-lbs / 47.5 Nm
29 ft-lbs / 39.3 Nm
60 ft-lbs / 81.3 Nm
52 ft-lbs / 70.5 Nm
100 ft-lbs / 135.6 Nm
85 ft-lbs / 115.3 Nm
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Specifications
Torque Procedure
Seal-Lok™ fittings
1 Replace the O-ring. The O-ring must be
replaced anytime the seal has been broken.
The O-ring cannot be re-used if the fitting or
hose end has been tightened beyond finger
tight.
Note: The O-ring in Parker Seal Lok™ fittings and
hose end are custom-size O-rings. They are not
standard size O-rings. They are available in the
O-ring field service kit (Genie part number 49612).
2 Lubricate the O-ring before installation.
3 Be sure the O-ring face seal is seated and
retained properly.
4 Position the tube and nut squarely on the face
seal end of the fitting, and tighten the nut
finger tight.
5 Tighten the nut or fitting to the appropriate
torque. Refer to the appropriate torque chart in
this section.
6 Operate all machine functions and inspect the
hose, fittings and related components to
confirm there are no leaks.
JIC 37° fittings
1 Align the tube flare (hex nut) against the nose
of the fitting body (body hex fitting) and tighten
the hex nut to the body hex fitting to hand tight,
approximately 30 in-lbs / 3.4 Nm.
2 Using a permanent ink marker, make a
reference mark on one the flats of the hex nut
and continue the mark onto the body of the
hex fitting. Refer to Illustration 1.
Illustration 1
1 hex nut
2 reference mark
3 body hex fitting
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• QS™R • QS™W Part No. 1275811GT
May 2018 Service Manual
Specifications
3 Working clockwise on the body hex fitting,
make a second mark with a permanent ink
marker to indicate the proper tightening
position. Refer to Illustration 2.
Note: Use the JIC 37° Fitting table in this section to
determine the correct number of flats, for the
proper tightening position.
Note: The marks indicate the correct tightening
positions have been determined. Use the second
mark on the body hex fitting to properly tighten the
joint after it has been loosened.
Illustration 2
1 body hex fitting
2 reference mark
3 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
hose, fittings and related components to
confirm there are no leaks.
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Failure to perform each
procedure as presented and
scheduled may cause death,
serious injury or substantial
damage.
Scheduled Maintenance Procedures
Section 3 Scheduled M ai nten ance Pr oce dures
Observe and Obey:
Maintenance inspections shall be completed
by a person trained and qualified on the
maintenance of this machine.
Scheduled maintenance inspections shall be
completed daily, quarterly, semi-annually,
annually and every 2 years as specified of the
Maintenance inspection Report. The frequency
and extent of periodic examinations and tests
may also depend on national regulations.
Machine Configuration:
Unless otherwise specified, perform each
procedure with the machine in the following
configuration:
• Machine parked on a firm, level surface
• Key switch in the off position with the key
removed
• The red Emergency Stop button in the off
position at both the ground and platform
controls
• Wheels chocked
• All external AC power supply disconnected
from the machine
• Platform in the stowed position
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.
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Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible inju
Indicates a imminently hazardous
situation which, if not avoided, will
result in death or serious injury.
Indicates a potentially hazardous
situation which, if not avoided,
could result in death or serious
injury.
Indicates a
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 tools will be required to
perform this procedure.
Indicates that new parts will be required to
perform this procedure.
Indicates
required to perform this procedure.
Indicates that a cold motor or pump will be
required to perform this procedure.
Scheduled Maintenance Procedures
About This Section
This section contains detailed procedures for each
scheduled maintenance inspection.
Each procedure includes a description, safety
warnings and step-by-step instructions.
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
appear at the beginning of a maintenance
procedure, it conveys the meaning below.
Symbols Legend
potentially hazardous
ry or death.
that dealer service will be
Indicates that a specific result is expected
after performing a series of steps.
Indicates that an incorrect result has occurred
after performing a series of steps.
12 GR
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• QS™R • QS™W Part No. 1275811GT
May 2018 Service Manual
Specific Interval: blank box is the interval to
be completed and the
as not required.
The description of the procedure or
checklist to be completed.
The procedure number or checklist to be
completed.
Check box to indicate status of inspection.
Specific interval is not required for this
procedure.
General area of the machine to complete
the procedure.
If this box has a designated time interval:
this is the specific time interval to complete
the procedure or checklist.
If this box is empty: the maintenance
checklist will include multiple time intervals,
use this box to write in the specific interval
for the inspection completed.
Scheduled Maintenance Procedures
Maintenance Schedule
The maintenance procedures have been divided
into subsections that include: Commissioning,
Quarterly, Annually and Programmed maintenance
intervals. The maintenance inspection report has
been divided into general areas of the machine that
include: Drive Chassis, Platform, Mast, Functions
and Controls, and Electrical.
Failure to perform these procedures may result in
poor performance, component damage and unsafe
operating conditions. They are essential to safe
operation, machine performance and service life.
Commissioning: A series of required one time
maintenance procedures to be performed at 50 and
150 hour intervals.
Quarterly and Annually: A series of maintenance
procedures to be performed quarterly or annually.
Programmed: A series of maintenance
procedures to be performed during a Pre-Delivery
Preparation or based on machine operating hours.
Programmed Example (under 1000 HRS):
Programmed Example:
Instructions Legend
Use the following detailed descriptions to identify
the intended use of the maintenance inspection
reports.
∅ marks the interval
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 your employer, jobsite and governmental
regulations and requirements.
Instruction Examples
Commissioning Example:
Quarterly and Annually Example:
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14 GR
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• QS™R • QS™W Part No. 1275811GT
May 2018 Service Manual
Legend
Comments
Pre
Pre
Maintenance items completed
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Pre-Delivery Preparation Report
Fundamentals
It is the responsibility of the owner or dealer to
perform the Pre-delivery Preparation.
The Pre-delivery Preparation is performed prior to
each delivery. The inspection is designed to
discover if anything is apparently wrong with a
machine before it is put into service.
A damaged or modified machine must never be
used. If damage or any variation from factory
delivered condition is discovered, the machine
must be tagged and removed from service.
Repairs to the machine may only be made by a
qualified service technician, according to the
manufacturer's specifications.
Scheduled maintenance inspections shall be
performed by qualified service technicians,
according to the manufacturer's specifications and
the requirements listed in the responsibilities
manual.
Instructions
Use the operator’s manual on your machine.
The Pre-delivery Preparation consists of
completing the Pre-operation Inspection, the
Maintenance items and the Function Tests.
Use this form to record the results. Place a check in
the appropriate box after each part is completed.
Follow the instructions in the operator’s manual.
If any inspection receives an N, remove the
machine from service, repair and re-inspect it. After
repair, place a check in the R box.
Y = yes, acceptable
N = no, remove from service
R = repaired
-delivery Preparation
-operation inspection completed
Y N R
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16 GR
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