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: [e-mail]

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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Table of Contents

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 / -

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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

Part No. 1275811GT GR

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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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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.

Part No. 1275811GT GR

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Service Manual May 2018

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.

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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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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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Scheduled and Programmed

May 2018

Maintenance Inspection Report

Model

on machine hours. This program includes the onetime

Platform

Hour meter Date

Serial number Inspector company Machine owner

Inspected by (print) Inspector signature

Scheduled Maintenance:
Inspection Type

Q = quarterly or frequent

inspections
A = annual inspections

Legend

Y = yes, acceptable
N = no, remove from
service
R = repaired
∅ = not applicable

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

Drive Chassis

Inspect the Tires, Wheels and Castle Nut Torque Q-8

Chassis Mechanicals and Hydraulics

Visual Inspection of the Hydraulic Oil Q-12

Electrical

Battery Inspection Q-2

Inspect the Electrical Wiring Q-3

Inspect the Electrical Contactor Q-4

Inspect the Voltage Inverter - (if equipped) Q-5

Mast

Check the Lifting Chain Adjustments Q-9

Clean and Lubricate the Columns Q-10

Adjust the Sequencing Cables Q-11

Make copies of this report to use for
each inspection.
Select the appropriate procedures
for the type of inspection(s) to
perform.

Intervals Q A

Intervals Q A

Intervals Q A

Q A

Commissioning

50 Hour Service - all models C-1

Programmed Maintenance - Under 1000 HRS

Grease the Steer Yokes P0-1

Programmed Maintenance

All models Perform every: 1 2

Inspect Mast Assembly for Wear P1-1

Inspect and Lubricate the Lifting
Chains

Replace the Hydraulic Filters P2-1

Test or Replace the Hydraulic Oil P2-2

Programmed Maintenance:
Programmed maintenance will be completed based

or commissioning procedures for new products. The
onetime procedures will be completed at 50 or 150
hours.

50

Hours are in thousands

P1-2

Intervals Q A

Grease the Platform Overload Mechanism A-1

∅

∅

∅

Status

Enter

Hours

100

∅

∅

Test the Platform Overload System A-2

Functions and Controls

Check for Open Bulletins and Owner Registration Q-1

Test the Flashing Beacons (if equipped) Q-6

Test the Alarm Package Q-7

Test the Drive Brakes Q-13

Test Drive Speed – Stowed Position Q-14

Test Drive Speed – Raised Position Q-15

Test the Slow Drive Speed Q-16

Part No. 1275811GT GR

∅

Intervals Q A

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Commissioning Procedures

C-1
Perform 50 Hour Service

The 50 hour maintenance procedure is a one time
sequence of procedures to be performed after the
first 50 hours of usage. After this interval, refer to
the maintenance inspection report for continued
scheduled maintenance.

1 Perform the following maintenance

procedures:

All Models:

Q-8 Inspect the Tires, Wheels and Castle Nut
Torque

P2-1 Replace the Hydraulic Filters

Part No. 1275811GT GR

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Quarterly Maintenance Procedures

Q-1 Check for Open Bulletins and Owner Registration

Genie specifications require that this procedure be
performed quarterly.

Completing required bulletins is essential to safe
machine operation. An important way to ensure
your machine has no open bulletins is to frequently
check the serial number of your Genie machine
against our bulletin database. Using the links below
you can view any open bulletins for your machine(s)
that require mandatory and immediate work to be
completed.

Note: If you are unable to access this information
on our websites, please contact your local Genie
representative using the contact information
provided on the back cover of this manual.

1 Locate the serial number plate or label on your

machine and document your Genie machine
serial number (exactly as its displayed on the
serial plate or label).

2 Confirm that Genie has the current machine

owner information on file by contacting our
warranty department at 1-800-536-1800 or
use the link included in this procedure to
download and complete a New Owner
Registration Form.

3 Using the link provided, check for current

bulletins for your machine(s).

Machines purchased in Australia:

Machines purchased in ASIA, North America
and Latin America:

ASIA, North America and Latin America

Go to

Bulletins (https://www.gogenielift.com/)

1 Select "Customer Login" to login or select

"Request New Access" to create a new
account.

2 At the homepage, select "Unit Configuration"

and enter your machine serial number.

3 Press the "Lookup" button to view your

machine configuration and to check for open
bulletins.

4 Complete all required bulletins shown for your

specific machine serial number.

Machines purchased in Europe, Middle East,
Africa, and Russia:

Go to EMEAR Bulletins
(http://www.genielift.co.uk/en/sales-and-suppo
rt/bulletin-campaigns/index.htm)

1 Enter your machine serial number and press

search to check for open bulletins.

Go to Australia Bulletins
(http://genielift.com.au/contact)

1 Contact any one of the Genie Service centers

around Australia to arrange for factory trained
technicians to attend to your equipment
needs.

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20 GR

• QS™R • QS™W Part No. 1275811GT

2 Complete all required bulletins shown for your

specific machine serial number.

May 2018 Service Manual

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

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

Quarterly Maintenance Procedures

Q-2 Battery Inspection

Genie specifications require that this procedure be
performed quarterly.

Proper battery condition is essential to good engine
and machine performance and operational safety.
Improper fluid levels or damaged cables and
connections can result in engine and component
damage and hazardous conditions.

hazard.

3 Lower the platform until the mast just contacts

the battery cover.

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

4 Be sure that the battery cable connections are

free of corrosion.

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

5 Be sure that the battery retainers and cable

connections are tight.

6 Be sure that the battery separator wire

connections are tight (if equipped).

Models without maintenance-free or sealed
batteries:

7 Put on protective clothing and eye wear.

8 Remove the battery vent caps and check the

specific gravity of each battery cell with a
hydrometer. Note the results.

Note: Fully charge the batteries and allow the
batteries to rest 24 hours before performing this
procedure to allow the battery cells to equalize.

1 GR-12, QS-12R, QS-12W: Raise the platform

to approximately 3 ft / 1 m.

GR-15, GR-20, QS-15R, QS-20R, QS-15W,
QS-20W: Raise the platform to approximately

3 ft / 1 m.

2 Open the battery cover. Rest the cover against

the chassis.

9 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° F / 5.5° C above 80° F / 26.7° C.

• Subtract 0.004 from the reading of each cell
for every 10° F / 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 11.

Result: One or more battery cells display a

specific gravity of 1.276 or below. Proceed to
step 8.

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Quarterly Maintenance Procedures

10 Perform an equalizing charge OR fully charge

the battery(s) and allow the battery(s) to rest at
least 6 hours.

11 Remove the battery vent caps and check the

specific gravity of each battery cell with a
hydrometer. Note the results.

12 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° F / 5.5° C above 80° F / 26.7° C.

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

Result: All battery cells display a specific

gravity of 1.277 or greater. The battery is fully
charged. Proceed to step 11.

14 Install the vent caps and neutralize any

electrolyte that may have spilled.

15 Check each battery pack and verify that the

batteries are wired correctly.

Result: One or more battery cells display a

specific gravity from 1.218 to 1.269. The
battery is still usable, but at a lower
performance. The battery will need to be
recharged more often. Proceed to step 11.

Result: One or more battery cells display a

specific gravity from 1.217 to 1.173. The
battery is approaching the end of its life.
Proceed to step 11.

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.

13 Check the battery acid level. If needed,

replenish with distilled water to 1/8 inch / 3 mm
below the bottom of the battery fill tube. Do not
overfill.

1 batteries B5
2 275A fuse F6
3 quick disconnect QD1

16 Inspect the battery charger plug and pigtail for

damage or excessive insulation wear. Replace
as required.

22 GR

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May 2018 Service Manual

Quarterly Maintenance Procedures

17 Connect the battery charger to a properly

grounded 115V/60Hz or, 230V/60Hz or 50Hz
single phase AC power sUpply.

Result: The charger should operate and begin

charging the batteries.

If, simultaneously, the charger alarm sounds and
the LEDs blink one time, correct the charger
connections at the fuse and battery. The charger
will then operate correctly and begin charging the
batteries.

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

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

Note: For best results, use an extension of
adequate size with a length no longer than 50 feet /
15 m.

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

Part No. 1275811GT GR

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

Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious i
watches and other jewelry.

Quarterly Maintenance Procedures

Q-3 Inspect the Electrical Wiring

Genie specifications require that this procedure be
performed quarterly.

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.

1 Inspect the underside of the chassis for

damaged or missing ground straps.

2 Inspect the following areas for burnt, chafed,

corroded pinched and loose wires:

• All wire harness connectors to ground
control box

• Ground control panel

Q-4 Inspect the Electrical Contactor

Genie specifications require that this procedure be
performed quarterly.

Maintaining the electrical contactor in good
condition is essential to safe machine performance.
Failure to locate a worn or damaged contactor
could result in unsafe operating conditions and may
cause component damage.

njury. Remove all rings,

1 At the ground controls, turn the key switch to

the off position.

2 Push in the red Emergency Stop button at the

ground controls to the off position.

3 At the non-steer end of the machine, open the

cover to access the electrical tray.

4 Locate and disconnect the Anderson

connector.

• Hydraulic power unit

• All wire harness connectors to platform

control box

• Platform controls

• Power to platform wiring

• Harness connections

• Hydraulic manifold wiring

• Contactor

• Limit switches

3 Inspect for a lite, even coating of dielectric

grease on all harness connections.

Note: Do not apply excessive amounts of dielectric
grease to harness connectors, pins or sockets.

24 GR

5 Locate the electrical contactor mounted on the

fuse bracket.

6 Visually inspect the contact points of the

contactor for the following items:

• Excessive burns

• Excessive arcs

• Excessive pitting

Note: Replace the contactor if any damage is
found.

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May 2018 Service Manual

Quarterly Maintenance Procedures

Q-5 Inspect the Voltage Inverter (if equipped)

Genie specifications require that this procedure be
performed quarterly.

Perform this procedure more often if dusty
conditions exist.

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.

3 Connect an appropriate power tool to the

inverter. Activate the tool.

Result: The power tool should operate. There

may be a brief (0.5 second) delay if the power
tool has not been used in the previous 10
minutes.

If the left fault LED (REV_POL) is illuminated,

the inverter is connected to batteries with the
incorrect polarity. Correct the polarity issue
with the red wire to battery positive and the
black wire to battery negative. The inverter will
then operate correctly and begin supplying AC
power.

If the right fault LED (123) blinks one time, the

power draw is too high. The tool being used
requires too much power to operate or is being
used at or near the limit of the inverter for an
extended period of time. Reduce the power
draw. The inverter will then operate correctly
and begin supplying AC power.

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

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

1 right fault LED
2 left fault LED
3 25V LED

Part No. 1275811GT GR

4 21V LED

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

inverter is overheated. Allow the inverter to
cool. The inverter will then operate correctly
and begin supplying AC power.

If the battery 25 volt fault LED (25V) blinks one

time, the battery voltage is over 30V. Operate
the machine to lower the voltage level. The
inverter will then operate correctly and begin
supplying AC power.

If the battery 21 volt fault LED (21V) blinks one

time, the battery voltage is less than 20V DC.
The inverter will continue to operate until the
battery voltage falls to 17.8V DC.

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Quarterly Maintenance Procedures

Q-6 Test the Flashing Beacons (if equipped)

Genie specifications require that this procedure be
performed quarterly.

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 machine.

1 Turn the key switch to ground control and pull

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

Result: The beacons should flash.

2 Turn the key switch to platform controls.

Result: The beacons should flash.

Q-7 Test the Alarm Package (if equipped)

Genie specifications require that this procedure be
performed quarterly.

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

1 Turn the key switch to ground control and pull

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

2 Press and hold the high speed lift enable

button.

3 Press the platform up button and raise the

platform approximately 1 foot / .3 m.

4 Press the platform down button and lower the

platform to the stowed position.

Result: The alarm should sound when the

platform is in motion.

5 Press and hold the low speed lift enable

button.

6 Press the platform up button and raise the

platform approximately 1 foot / .3 m.

7 Press the platform down button and lower the

platform to the stowed position.

Result: The alarm should sound when the

platform is in motion.

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Quarterly Maintenance Procedures

8 Turn the key switch to platform controls.

9 Press and hold the high speed lift enable

button.

10 Press the platform up button and raise the

platform approximately 4 feet / .2 m.

11 Press the platform down button and lower the

platform to the stowed position.

Result: The alarm should sound when the

platform is in motion.

12 Press and hold the low speed lift enable

button.

13 Press the platform up button and raise the

platform approximately 4 feet / .2 m.

14 Press the platform down button and lower the

platform to the stowed position.

Result: The alarm should sound when the

platform is in motion.

15 Press and hold the drive/steer function enable

switch on the control handle. Move the control
handle off center, hold for a moment and then
release it. Move the control handle off center
in the opposite direction, hold for a moment
and then release it.

Result: The motion alarm should sound when

the control handle is moved of center in either
direction.

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

Genie specifications require that this procedure be
performed quarterly.

Maintaining the tires and wheels, including proper
wheel fastener torque, 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

cracked welds.

3 Remove the cotter pin and check the castle

nut for proper torque. Refer to Specifications,
Tire and Wheel 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.

16 Press and hold the drive/steer function enable

switch on the control handle. Press and hold
the thumb rocker switch for a moment to the
left position and then release it. Press and
hold the thumb rocker switch for a moment to
the right position and then release it.

Result: The motion alarm should sound when

the rocker switch is moved off center in either
direction.

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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.

Bodily injury hazard. This
procedure will require the use of
additional access equipment.
Do not place ladders or scaffold
on or against any part of the
machine. Performing this
procedure without the proper
skills and tools could result in
death or serious injury. Dealer
service is strongly
recommended.

Quarterly Maintenance Procedures

Q-9 Check the Lifting Chain Adjustments

Genie specifications require that this procedure be
performed quarterly.

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 mahine.

2 Result: The machine is within specification. No

adjustment required. Refer to Specifications,
Machine Specifications.

3 Result: The machine is not within

specification. Adjust the chains. Refer to
Repair Procedure, How to Adjust the Lifting
Chains.

Q-10 Clean and Lubricate the Columns

Genie specifications require that this procedure be
performed quarterly.

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 presure.

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.

28 GR

4 If needed, apply a generous amount of

Boelube® wax to the inside and outside
channels of each column.

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Sequencing cabl

Measurement, compressed

15/16 inch

2.4 cm

Component damage hazard. Do
not
than specification.

Quarterly Maintenance Procedures

Q-11 Adjust the Sequencing Cables

Genie specifications require that this procedure be
performed quarterly.

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.

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.

e spring specification

4 Adjust the spring compressed length by

turning the nylock nut clockwise to decrease
the spring length or counterclockwise to
increase the spring length.

compress the spring to less

5 Raise and lower the platform through three

complete cycles.

1 nylock nut
2 spring
3 upper sequencing bracket
4 sequencing cable

6 Repeat this procedure beginning with step 3.

7 Repeat steps 3 through 5 for each sequencing

cable as required.

Part No. 1275811GT GR

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Quarterly Maintenance Procedures

Q-12 Visual Inspection of the Hydraulic Oil

Genie specifications require that this procedure be
performed quarterly.

Replacement or testing of the hydraulic oil is
essential for good machine performance and
service life. Dirty oil and a clogged suction strainer
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. For hydraulic oil
specifications, Refer to Specifications, Hydraulic
Specifications.

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. Replace the oil when it fails the test.
Refer to Maintenance Procedure, Test or Replace
the Hydraulic Oil.

1 Collect a sample of hydraulic oil and place in a

clear container. Visually inspect the hydraulic
oil for the following:

• Color: oil should be a clear, light-honey
colored

• Appearance, oil should be clear and not
cloudy or visibly distorts the view through
the sight glass or container

• Contains no particles, foreign objects, or
other contamination

• The hydraulic oil can be inspected by smell
(can smell “hot” but not “burnt”) or rubbing
between fingers (should feel viscous and
free of any rough feel due to particles)

If the hydraulic oil passes all of the above

inspections, continue the scheduled
maintenance intervals.

If the hydraulic oil fails any of the above

inspections, the hydraulic oil must be tested by
an oil distributor or replaced.

Note: If the hydraulic oil was not replaced at or
before the 2000 hour maintenance interval, the oil
must be tested every quarter by an oil distributor
until the oil fails the test and is replaced. After the
oil has been replaced, continue the scheduled
quarterly maintenance inspection.

30 GR

Note: When replacing the hydraulic oil, it is
recommended that all hydraulic filters be replaced
at the same time.

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Quarterly Maintenance Procedures

Q-13 Test the Drive Brakes

Genie specifications require that this procedure be
performed quarterly.

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: The platform extension deck must be fully
retracted and the platform 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.

3 Lower the platform to the stowed position.

4 Choose a point on the machine; i.e., contact

patch of a tire, as a visual reference for use
when crossing the test line.

5 Press and hold the drive/steer function enable

switch on the control handle.

1 drive /steer function enable switch
2 blue arrow

6 Move the control handle in the direction

indicated by the blue arrow on the control
panel until the machine begins to move
forward.

7 Bring the machine to top drive speed before

reaching the test line. Release the drive/steer
function enable switch or the joystick when
your reference point on the machine crosses
the test line.

8 Measure the distance between the test line

and your machine reference point. Refer
Specifications, Performance Specifications.

Part No. 1275811GT GR

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

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Quarterly Maintenance Procedures

Q-14 Test the Drive Speed – Stowed Position

Genie specifications require that this procedure be
performed quarterly.

Proper drive function is 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 free of obstructions.

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

1 Create start and finish lines by marking two

lines on the ground 40 feet / 12.2 m apart.

2 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.

Note: Be sure the low drive speed light is off. If the
low dive speed light is on, press the drive speed
select button to turn off the low drive speed
function.

3 Press and hold the drive/steer function enable

switch on the control handle.

1 drive/steer function enable switch
2 slow drive speed button
3 blue arrow

4 Move the control handle in the direction

indicated by the blue arrow on the control
panel until the machine begins to move
forward.

5 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.

6 Continue at full speed and note the time when

the machine reference point crosses the finish
line. Refer to Specifications, Performance
Specifications.

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Quarterly Maintenance Procedures

Q-15 Test the Drive Speed - Raised Position

Genie specifications require that this procedure be
performed quarterly.

Proper drive function is 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 free of obstructions.

1 Create start and finish lines by marking two

lines on the ground 40 feet / 12.2 m apart.

2 Press and hold the high or low speed lift

enable button.

3 Press the platform up button.

4 Raise the platform approximately 4 feet / 1.2 m

from the ground.

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.

6 Press and hold the drive/steer function enable

switch on the control handle.

1 drive /steer function enable switch
2 platform up button
3 low speed lift enable
4 high speed lift enable
5 blue arrow

7 Move the control handle in the direction

indicated by the blue arrow on the control
panel until the machine begins to move
forward.

8 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.

9 Continue at full speed and note the time when

the machine reference point crosses the finish
line. Refer to Specifications, Performance
Specifications.

Part No. 1275811GT GR

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Grease Specification

Chevron Ultra
or eq

Annual Maintenance Procedures

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

Genie specifications require that this procedure be
performed annually.

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.

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

Genie specifications require that this procedure be
performed annually OR when the machine fails to
lift the maximum rated load.

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.

uivalent

-duty grease, EP NLGI 1 (lithium based)

2 Determine the maximum platform capacity.

Refer to the machine serial plate.

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Annual Maintenance Procedures

3 Using a suitable lifting device, place a test

weight equal to that of the available capacity in
one of the locations shown. Refer to
Illustration 1.

4 Add additional weight to the platform that is

equal to, but does not exceed 15% of the
maximum rated load. Secure the additional
weight. Refer to the machine serial plate.

Result: The LCD at the ground controls should

display READY, the machine model and
machine hours, indicating a normal condition.
The LED readout on the platform controls
should display CH. Refer to the examples
below.

GCON LCD

PCON LCD

Result: The LCD at the ground controls

displays OL: Platform Overloaded and the
LED readout on the platform controls displays
a flashing OL. The platform overload system is
not operating properly. Refer to Repair
Procedure, Calibrate the Platform Overload
System (if equipped).

Result: The LCD at the ground controls

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

Result: The LCD at the ground controls

displays READY, the machine model and
machine hours. The LED readout on the
platform controls displays CH. The platform
overload system is not operating properly.
Refer to Repair Procedure, Calibrate the
Platform Overload System (if equipped).

5 Test all machine functions from the platform

controls.

Result: All platform control functions should

not operate.

6 Turn the key switch to ground controls.

7 Test all machine functions from the ground

controls.

Result: All ground control functions should not

operate.

8 Lift the test weight off the platform floor using a

suitable lifting device. Turn the key switch to
the off position.

GCON LCD

PCON LCD

Part No. 1275811GT GR

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Annual Maintenance Procedures

9 Turn the key switch to ground controls.

Result: The LCD at the ground controls

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

Result: The LCD at the ground controls

displays OL: Platform Overloaded and the
LED readout on the platform controls displays
a flashing OL. The platform overload system is
not operating properly. Refer to Repair
Procedure, Calibrate the Platform Overload
System (if equipped).

10 Test all machine functions from the ground

controls.

Result: All ground control functions should

operate normally.

11 Turn the key switch to platform controls.

12 Test all machine functions from the platform

controls.

13 Result: All platform control functions should

operate normally.

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Grease Specifications

Chevron Ultra
or equivalent

Programmed Maintenance Procedures

P0-1 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.

-duty grease, EP NLGI 2 (lithium based)

P1-1
Inspect the Mast Assembly for
Wear

Genie specifications require that this procedure be
performed every 1000 hours of operation.

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.

Part No. 1275811GT GR

GR-15 shown

1 mast cover
2 idler wheel
3 spacer

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Crushing hazard. Keep hands
clear
lowering the platform.

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.

Bodily injury hazard. This
procedure will require the use of
additional access equipment.
Do not place ladders or scaffold
on or against any part of the
machine. Performing this
procedure without the proper
skills and tools could result in
death or serious injury. Dealer
service is strongly
recommended.

Programmed Maintenance Procedures

2 Raise the platform until approximately 4

inches / 10 cm of each column is visible.

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

QS-15W: Visually inspect the top of each
column for clearance between the roller
wheels and the adjacent column surface.

P1-2 Inspect and Lubricate the Lifting Chains

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

of the jack stand when

Genie specifications require that this procedure be
performed every 1000 hours of operation.

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, 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 lifting pressure.

4 Lubricate each chain with a dry silicon spray

lubricant.

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May 2018 Service Manual

Beware of hot oil. Contact with
hot oil may cause severe burns.

Programmed Maintenance Procedures

P2-1
Replace the Hydraulic Return
Filter

Genie specifications require that this procedure be
performed every 1000 hours of operation.

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.

Note: The hydraulic tank return filter is mounted
next to the hydraulic tank.

1 Clean the area around the oil filter. Remove

the filter with an oil filter wrench.

2 Apply a thin layer of fresh oil to the gasket of

the new oil filter.

3 Install the new filter and tighten it securely by

hand.

4 Use a permanent ink marker to write the date

and number of hours from the hour meter on
the oil filter.

P2-2 Test or Replace the Hydraulic Oil

Genie requires that this procedure be performed
every 2000 hours.

Replacement or testing of the hydraulic oil is
essential for good machine performance and
service life. Dirty oil and a clogged suction strainer
or hydraulic filters 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
frequently.

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
2000 hour inspection, test the oil quarterly. Replace
the oil when it fails the test.

Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Specifications.

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

5 Raise the platform approximately 3 feet / 1 m.

6 Inspect the filter and related components for

leaks.

7 Clean up and properly dispose of any oil that

may have spilled during the installation
procedure.

Part No. 1275811GT GR

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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.

Torque specifications

Hydraulic t

4 Nm

Hydraulic tank retaining fasteners,
lubricated

2.9 Nm

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
hydra
the pump to cavitate.

Programmed Maintenance Procedures

Testing the oil:

1 Complete the hydraulic oil testing with an oil

distributor.

If the hydraulic oil passes testing at the 2000

hour maintenance interval, the oil must be
tested every quarter by an oil distributor until
the oil fails the test and is replaced.

If the hydraulic oil fails testing at the 2000 hour

maintenance interval, the oil must be replaced.
After the oil has been replaced, continue the
scheduled quarterly maintenance inspection.

Replacing the hydraulic oil:

1 Tag and disconnect the hydraulic tank return

hard line from the hydraulic filter head and
remove the hard line from the tank. Cap the
fitting on the filter head.

7 Install the hydraulic tank and install and

tighten the hydraulic tank retaining fasteners.
Torque to specification.

ank retaining fasteners, dry 35 in-lbs

26 in-lbs

8 Install the hydraulic pump inlet hard line into

the tank. Install the fitting onto the pump and
torque to specification. Refer to Specifications,

Hydraulic Hose and Fitting Torque
Specifications.

9 Install the hydraulic pump return hard line into

the tank. Install the fitting onto the hydraulic
filter head and torque to specification. Refer to
Specifications, Hydraulic Hose and Fitting
Torque Specifications.

10 Fill the tank with the proper hydraulic oil for

your machine. Refer to Specifications,
Hydraulic Specifications.

2 Tag and disconnect the hydraulic pump inlet

hard line and remove the hard line from the
tank. Cap the fitting on the pump.

3 Remove the hydraulic tank retaining fasteners

and remove the hydraulic tank from the
machine.

4 Drain all of the oil into a suitable container.

Refer to Machine Specifications, for capacity
information.

Note: When replacing the hydraulic oil, it is
recommended that the hydraulic tank be cleaned
using a mild solvent and all hydraulic filters and
strainers be replaced.

5 Clean up any oil that may have spilled.

Properly discard the used oil.

6 Clean the inside of the hydraulic tank using a

mild solvent. Allow the tank to dry completely.

11 Activate the pump to fill the hydraulic system

with oil and bleed the system of air.

ulic system. Do not allow

12 Repeat steps 12 and 13 until the hydraulic

system and tank are both full.

Note: After the oil has been replaced, continue the
scheduled quarterly maintenance inspection.

40 GR

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May 2018 Service Manual

Repair Procedures

Section 4 Repair Proc edur es

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 machine.

Machine Configuration:

 Unless otherwise specified, perform each

repair 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

 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.

Part No. 1275811GT GR

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Safety alert symbol—used to alert
personnel to potential person
injury hazards. Obey all safety
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
situati
could result in death or serious
injury.

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

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

Repair Procedures

About This Section

Symbols Legend

Most of the procedures in this section should only
be performed by 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.

on which, if not avoided,

property damage.

Indicates that a specific result is expected

after performing a series of steps.

al

42 GR

Indicates that an incorrect result has occurred

after performing a series of steps.

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Platform Controls

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

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

The platform controls consist of an Emergency
Stop button, electronic circuit board, proportional
control handle, drive/steer enable switch, alarm,
function buttons and LED display.

For further information or assistance, contact
Genie Product Support.

a red Emergency Stop button P2
b platform controls circuit board U3
c proportional control handle and drive/steer

enable switch JC9

Part No. 1275811GT GR

d alarm H1

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Code

Condition

LL Off

OL Platform Overload (CE and Australia)

CH Chassis Mode Operation

PHS Pothole Guard Stuck

OAC Obstruction Detected (QS models)

Platform Controls

Operational Indicator Codes

These codes are generated by the electrical
system to indicate machine operating status.
During normal operation, a code will appear in the
platform controls LED readout if a condition such
as off-level, overload cutout, chassis mode
operation or pothole guard stuck occurs.

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

Platform Controls LED Readout

Note: The Ld Operation Indicator Code will appear
when the outriggers are not fully retracted, the
machine is not auto leveled, an outrigger has lost
contact with the ground or either level sensor
detects the machine is no longer level. When any
of the above scenarios occur, the lift function is
disabled.

The lift function will also be disabled while
extending or retracting the outriggers and during
the outrigger auto level procedure. While
performing the above operations, the Ld Operation
Indicator Code will appear.

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

-level

44 GR

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• QS™R • QS™W Part No. 1275811GT

May 2018 Service Manual

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.

Circuit board fastener torque specifications

Hand tighten until screws seat

lbs

Nm

Platform Controls

1-1 Circuit Board

How to Remove the Platform
Controls Circuit Board

1 Push in the red Emergency Stop button to the

off position at both the ground and platform
controls.

2 Disconnect the platform controls from the

control cable at the platform.

3 Remove the fasteners securing the platform

control box to the platform control bracket.

4 Remove the fasteners securing the bottom

cover to the platform control box. Open the
control box.

5 Remove the ties securing the wire harness.

6 Disconnect the red and black wires from the

alarm.

7 Carefully remove the alarm from the platform

control box.

8 Carefully disconnect all wire harness

connectors from the platform controls circuit
board.

9 Carefully remove the platform controls circuit

board fasteners.

10 Carefully remove the platform controls circuit

board from the platform control box.

11 Remove the transparent caps from the

platform controls circuit board and save.

Part No. 1275811GT GR

< 5 in-

< 0.6

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

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

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• QS™R • QS™W 45

Service Manual May 2018

Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serio
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
circuit boards OR use a
grounded wrist strap.

Torque specifications

Joystick fasteners

lbs

1 Nm

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
machine that is grounded at all
times when handling printed
circuit boards OR use a
grounded wrist strap.

Platform Controls

1-2 Joystick

How to Remove the Joystick

1 Push in the red Emergency Stop button to the

off position at both the ground and platform
controls.

2 Disconnect the platform controls from the

control cable at the platform.

3 Remove the fasteners securing the platform

control box to the platform control bracket.

4 Remove the fasteners securing the bottom

cover to the platform control box. Open the
control box.

5 Remove the ties securing the joystick wire

harness.

6 Carefully disconnect the joystick wire harness

from the platform controls circuit board.

1-3
Platform Controls Alarm

How to Remove the Platform
Controls Alarm

1 Push in the red Emergency Stop button to the

off position at both the ground and platform
controls.

2 Disconnect the platform controls from the

control cable at the platform.

3 Remove the fasteners securing the platform

control box to the platform control bracket.

4 Remove the fasteners securing the bottom

cover to the platform control box. Open the
control box.

5 Disconnect the red and black wires from the

alarm.

7 Carefully remove the joystick fasteners.

8 Carefully remove the joystick from the platform

control box.

46 GR

us injury. Remove all rings,

handling printed

9 in-

™

with a metal part of the

6 Carefully remove the alarm from the platform

control box.

• QS™R • QS™W Part No. 1275811GT

May 2018 Service Manual

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
machine that is grounded at all
times when handling printed
circuit boards OR use a
grounded wrist strap.

Platform Controls

1-4 Platform Emergency Stop Button

How to Remove the Platform
Controls Emergency Stop Button

1 Push in the red Emergency Stop button to the

off position at both the ground and platform
controls.

2 Disconnect the platform controls from the

control cable at the platform.

3 Remove the fasteners securing the platform

control box to the platform control bracket.

4 Remove the fasteners securing the bottom

cover to the platform control box. Open the
control box.

5 Disconnect the white wires from the

Emergency Stop base.

with a metal part of the

6 Carefully remove the Emergency Stop base

from the Emergency Stop button.

7 Carefully remove the retaining ring from the

Emergency Stop button.

Part No. 1275811GT GR

8 Carefully remove the Emergency Stop button

from the platform control box.

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Service Manual May 2018

Ground Controls

The ground controls, used to operate the machine
from the ground, can also be used to tune the
performance of the machine.

The ground controls consist of an Electronic
Control Module (ECM), emergency stop button,
key switch and circuit breaker.

Activating the function enable button and the up or
down at the same time, sends a signal to the
(ECM). This allows the platform to be raised or
lowered at the ground controls.

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

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

For further information or assistance, contact
Genie Product Support.

1 machine setup escape button
2 machine setup scroll up button
3 LCD readout
4 machine setup scroll down button
5 machine setup enter button
6 Key switch KS1
7 red Emergency Stop P1
8 circuit breaker CB2
9 ECM U5
10 platform down button
11 lift function enable button
12 platform up button

48 GR

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• QS™R • QS™W Part No. 1275811GT

May 2018 Service Manual

Ground Controls

2-1 Software Revision Level

How to Determine the Revision
Level

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

1 Turn the key switch to the ground controls or

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

Result: The display at the platform controls will

show "CH". See example below.

2 Press the ground control scroll down button.

Result: The ground control LCD display will

indicate the software revision and hour meter
information. After 5 seconds, the ground
controls LCD display will display machine
model and hour meter information again. See
example below.

3 Push in the red Emergency Stop button to the

off position at both the ground and platform
controls and turn the key switch to the off
position.

Result: The display at the ground controls will

show the machine model and hour meter
information. After 3 seconds, the machine
model will not show on the display. See
example below.

a ground control LCD display
b ground control scroll down button

Part No. 1275811GT GR

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Service Manual May 2018

Tip
function speeds higher than
specified in this procedure.
Setting the function speeds
greater than specifications could
cause the machine to tip over
resulting in death or serious
injury.

Tip
must only be performed by a
trained service professional.
Attempting this procedure
without the necessary skills
could result in death or serious
injury.

Ground Controls

2-2 Machine Setup

How to Setup the Machine from
Ground Controls

The ground controls can be used to setup the
machine parameters from the ground. Features
that can be adjusted from the ground controls
include machine Model, Options and Speed setup.
This menu can only be entered from ground
controls with the key switch in the ground controls
position.

-over hazard. Do not adjust

-over hazard. This procedure

2 Press and hold the ground control scroll up

and scroll down buttons.

Ground Control Menu Buttons

1 scroll down button
2 enter button
3 scroll up button
4 escape button
5 LCD display

3 Pull out the red Emergency Stop button to the

on position at the ground controls.

Result: The ground controls LCD display will

show the following:

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

1 Turn the key switch to ground controls.

50 GR

4 Use the ground control menu buttons to select

machine Model, Options and Speed Setup
parameters. Follow the menu structure
indicated on the ground control LCD display.

™

• QS™R • QS™W Part No. 1275811GT

May 2018 Service Manual

Ground Controls

2-3 Level Sensors

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 and 3° to the front
or rear.

Use the illustrations to verify which type of level
sensor is installed and perform the procedure that
is appropriate for your machine.

Procedure 1

Procedure 2

Procedure 2

1 X axis
2 Y axis

Part No. 1275811GT GR

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• QS™R • QS™W 51

Service Manual May 2018

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.

Tip
sensor must be installed with the
"X" on the level sensor base
closest to the mast of the
machine. Failure to install the
level sensor as instructed could
result in the machine tipping over
causing death or serious injury.

Ground Controls

How to Install and Calibrate the
Level Sensor - Procedure 1

1 Move the machine to an area that has a firm,

level surface and is free of obstructions.

Note: The surface must be 0° +/- 0.5°.

Note: If you are not installing a new level sensor,
proceed to step 7.

2 Tag and disconnect the level sensor wire

harness from the chassis wire harness.

3 Remove the level sensor adjusting fasteners.

Remove the level sensor from the machine.

4 Place the 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.

-over hazard. The level

52 GR

1 drive chassis
2 level sensor
3 X axis
4 mast

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• QS™R • QS™W Part No. 1275811GT

May 2018 Service Manual

Ground Controls

5 Install the level sensor retaining fasteners

through the level sensor and springs, and into
the mount bracket. Tighten the fasteners and
measure the distance between the level
sensor and the level sensor mount bracket.

Result: The measurement should be

approximately 0.375 inch / 10 mm.

6 Connect the chassis wire harness to the level

sensor wire harness.

7 Adjust the level sensor retaining fasteners

until the bubble at the top of the level sensor is
centered in the circles.

8 Turn the key switch to the ground control and

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

Result: The tilt sensor alarm should not sound.

9 Center a lifting jack under the drive chassis at

the ground controls side of the machine.

10 Raise the machine approximately 2 inches / 5

cm. Place blocks under both wheels.

GR-12, GR-15, QS-12R, QS-15R, QS-12W,
QS-15W: Place a 0.65 x 6 x 6 inch / 1.65 x 15

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

GR-20, QS-20R, QS-20W: Place a 0.7 x 6 x 6
inch / 1.78 x 15 x 15 cm thick steel block under
both wheels at the ground controls side of the
machine.

11 Lower the machine onto the blocks.

1 adjustment fastener
2 calibration circle
3 ground controls

12 Raise the platform to approximately 1 ft / 30

cm.

Result: The level sensor alarm should not

sound.

Result: The level sensor alarm does sound

and fault code LL appears in the diagnostic
display. 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 approximately 2 inches / 5

cm. Remove the blocks from under both
wheels..

15 Center a lifting jack under the drive chassis at

the hydraulic tank side of the machine.

Part No. 1275811GT GR

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Service Manual May 2018

Ground Controls

16 Raise the machine approximately 2 inches / 5

cm. Place blocks under both wheels.

26 Raise the platform to approximately 1 ft / 30

cm.

GR-12, GR-15, QS-12R, QS-15R, QS-12W,
QS-15W: Place a 0.79 x 6 x 6 inch / 2 x 15 x

15 cm thick steel block under both wheels at
the hydraulic side of the machine.

GR-20, QS-20R, 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 hydraulic tank side of
the machine.

17 Lower the machine onto the blocks.

18 Raise the platform to approximately 1 ft / 30

cm.

Result: The platform should stop, an alarm

should sound and fault code LL appears in the
diagnostic display.

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.

19 Lower the platform to the stowed position.

20 Raise the machine approximately 2 inches / 5

cm. Remove the blocks from under both
wheels..

21 Lower the machine and remove the jack.

22 Center a lifting jack under the drive chassis at

the steer end of the machine.

23 Raise the machine approximately 2 inches / 5

cm.

Result: The level sensor alarm should not

sound.

Result: The level sensor alarm does sound.

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

27 Raise the machine approximately 2 inches / 5

cm. Remove the blocks from under both
wheels..

28 Lower the machine and remove the jack.

29 Center a lifting jack under the drive chassis at

the non-steer end of the machine.

30 Raise the machine approximately 2 inches / 5

cm.

31 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.

32 Raise the platform to approximately 1 ft / 30

cm.

Result: The platform should stop, an alarm

should sound and fault code LL appears in the
diagnostic display.

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.

33 Lower the platform to the stowed position.

24 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.

25 Lower the machine onto the blocks.

™

54 GR

• QS™R • QS™W Part No. 1275811GT

34 Raise the machine approximately 2 inches / 5

cm. Remove the blocks from under both
wheels..

35 Lower the machine and remove the jack.

May 2018 Service Manual

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

Tip-over hazard. Failure to install
the level sensor as instructed,
could result in the machine
tipping
serious injury.

Ground Controls

How to Install and Calibrate the
Level Sensor - Procedure 2

machine stability

Note: If you are not installing a new level sensor,
proceed to step 8.

1 Move the machine to an area that has a firm,

level surface and is free of obstructions.

Note: The surface must be 0° +/- 0.5°.

2 Tag and disconnect the level sensor wire

harness from the chassis wire harness.

3 Remove the level sensor retaining fasteners

and remove the level sensor from the
machine.

4 Place the new level sensor on to the level

sensor bracket with the "X" on the level sensor
towards the steer end of the machine.

over, causing death or

Steer End

Part No. 1275811GT GR

Non-steer End

1 drive chassis
2 X axis
3 level sensor
4 mast

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• QS™R • QS™W 55

Service Manual May 2018

Ground Controls

5 Install the level sensor retaining fasteners

through the level sensor and springs. Secure
the level sensor assembly to the machine.

6 Connect the chassis wire harness to the level

sensor.

7 Turn the key switch to ground control and pull

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

Result: GCON will display a ‘C051:

SYSTEMFAULT, TILT:NoCal fault.

8 Push in the red Emergency Stop button to the

off position at the ground controls.

9 Press and hold the ground control scroll up

and scroll down buttons.

10 Pull out the red Emergency Stop button to the

on position at the ground controls.

Result: The ground controls LCD display will

show the following:

11 Release the Scroll Up and Scroll Down

buttons after the ground controller powers up.

12 Use the Scroll Up or Scroll Down buttons to

scroll to Select Option.

Ground Control Menu Buttons

1 scroll down button
2 enter button
3 scroll up button
4 escape button
5 LCD display

13 Press the Enter button.

14 Use the Scroll Up or Scroll Down buttons to

scroll to Tilt Sensor.

15 Press the Enter button.

56 GR

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• QS™R • QS™W Part No. 1275811GT

May 2018 Service Manual

Ground Controls

16 Press and hold the Enter button to start

calibration.

19 Drive the steer end of the machine up a ramp

until it is just under 3°.

Result: An audible alarm will sound when

calibration is complete.

Note: The machine will not calibrate if it is on a
slope of one degree or greater.

Note: If the level sensor has been replaced,
continue with step 24. If the level sensor was not
replaced skip to step 27.

17 Raise the platform to approximately 1 ft / 30

cm.

18 Place a digital level on the ground control side

of the drive chassis. Zero out the digital level.

Result: No audible alarm is heard.

Result: An audible alarm is heard and Fault LL

is displayed. Repeat this procedure starting at
step 8 on a firm level surface.

20 Continue driving the machine up the ramp until

it is just over 3°.

Result: An audible alarm is heard and Fault LL

is displayed.

Result: An audible alarm is not heard and

Fault LL is not displayed. Repeat this
procedure starting at step 8 on a firm level
surface.

Part No. 1275811GT GR

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Service Manual May 2018

Ground Controls

21 Drive the non-steer end of the machine up a

ramp until it is just under 3°.

23 Place a digital level on the steer end of the

drive chassis. Zero out the digital level.

Result: No audible alarm is heard.

Result: An audible alarm is heard and Fault LL

is displayed. Repeat this procedure starting at
step 8 on a firm level surface.

22 Continue driving the machine up the ramp until

it is just over 3°.

Result: An audible alarm is heard and Fault LL

is displayed.

Result: An audible alarm is not heard and

Fault LL is not displayed. Repeat this
procedure starting at step 8 on a firm level
surface.

24 Drive the ground control side of the machine

onto a ramp until it is just under 1.5°.

Result: No audible alarm is heard.

Result: An audible alarm is heard and Fault LL

is displayed. Repeat this procedure starting at
step 8 on a firm level surface.

25 Continue driving the machine onto the ramp

until it is just over 1.5°.

Result: An audible alarm is heard and Fault LL

is displayed.

Result: An audible alarm is not heard and

Fault LL is not displayed. Repeat this
procedure starting at step 8 on a firm level
surface.

58 GR

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• QS™R • QS™W Part No. 1275811GT

May 2018 Service Manual

Ground Controls

26 Drive the hydraulic tank side of the machine

onto a ramp until it is just under 1.5°.

Result: No audible alarm is heard.

Result: An audible alarm is heard and Fault LL

is displayed. Repeat this procedure starting at
step 8 on a firm level surface.

27 Continue driving the machine onto the ramp

until it is just over 1.5°.

Result: An audible alarm is heard and Fault LL

is displayed.

Result: An audible alarm is not heard and

Fault LL is not displayed. Repeat this
procedure starting at step 8 on a firm level
surface.

28 Lower the platform to the stowed position.

Part No. 1275811GT GR

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• QS™R • QS™W 59

Service Manual May 2018

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

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

Hydraulic Pump

3-1
Function Pump

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

How to Test the Hydraulic Pump

Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Specifications.

1 Tag, disconnect and plug the high pressure

hydraulic hose from the hydraulic pump.

ic

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 the pressure gauge fails to reach

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

-pressurize the pump.

5 Remove the pressure gauge and reconnect

the hydraulic hose. Torque to specifications.

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 ground and platform controls.

60 GR

™

• QS™R • QS™W Part No. 1275811GT

May 2018 Service Manual

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

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

Tip
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 res
death or serious injury.

Hydraulic Pump

How to Remo ve t he Hydr auli c P ump

How to Remove the Hydraulic
Pump

Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Specifications.

6 Tag, disconnect and plug the high pressure

hose from the pump. Cap the fitting on the
pump.

penetrate and

1 Disconnect the battery pack from the machine.

jewelry.

2 Tag and disconnect the hydraulic power unit

cables at the motor controller.

3 Disconnect the filter head from the filter head

mounting bracket. Rotate the filter out and
away from the hydraulic power unit.

4 Remove the hydraulic power unit retaining

fasteners.

5 Tag, disconnect and plug the hydraulic tank

hard line from the pump. Cap the fitting on the
pump.

7 Remove the hydraulic power unit from the

machine.

8 Remove the pump mounting bolts. Carefully

remove the pump.

-over hazard. After replacing

ulting in

Part No. 1275811GT GR

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Service Manual May 2018

Index No.

Description

Schematic Item

Function

Torque

Coil nut (items E, F, and H)

Diagnostic port

—

Check disc

lbs / 24 Nm

Relief valve, 1800 to 3700 psi / 124 to 255
bar

lbs / 27 Nm

Check valve, 10 psi / 0.7 bar

lbs / 27 Nm

Solenoid valve, 3 position 4 way

lbs / 34 Nm

Solenoid valve, 3 position 4 way

lbs / 34 Nm

Flow regulator and relief valve,

0.75 gpm / 2.8 L/min
1500 psi / 130 bar

lbs / 35 Nm

Solenoid valve, 2 position 4 way

lbs / 34 Nm

Relief valve, 3500 psi / 241 bar maximum

lbs / 27 Nm

Function Manifold

4-1 Function Manifold Components

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

—

1

2

3

4

5

6

7

8

9

A Test port

B Steer circuit 18 ft-

— — 5 ft-lbs / 7 Nm

C Lift relief 20 ft-

D Drive circuit 20 ft-

E

F Steer left/right 25 ft-

H Platform up 25 ft-

I System relief 20 ft-

G Steer circuit 26 ft-

Drive

forward/reverse

25 ft-

62 GR

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• QS™R • QS™W Part No. 1275811GT

May 2018 Service Manual

Function Manifold

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

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

™

Part No. 1275811GT GR

• QS™R • QS™W 63

Service Manual May 2018

Function Manifold

4-2
Valve Adjustments -
Function Manifold

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

Note: Verify the hydraulic oil level is at the FULL
mark on the hydraulic tank.

How to Adjust the System Relief
Valve

1 Locate the system relief valve on the function

manifold (schematic item I).

3 Chock both sides of the wheels at the steer

end of the machine.

4 Remove the platform controls from the

platform.

5 Turn the key switch to platform controls and

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

6 Move and hold the joystick fully in either

direction while observing the pressure reading
on the pressure gauge. Note the pressure.
Refer to Specifications, Hydraulic Component
Specifications.

7 Turn the machine off. Hold the system relief

valve with a wrench and remove the cap
(schematic item I).

8 Adjust the internal hex socket. Turn it

clockwise to increase the pressure or
counterclockwise to decrease the pressure.

9 Install the relief valve cap.

1 test port
2 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).

10 Repeat steps 5 and 6 to confirm the relief

valve pressure.

64 GR

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• QS™R • QS™W Part No. 1275811GT

May 2018 Service Manual

Function Manifold

How to Adjust the
Platform Lift Relief Valve

Note: Verify the system relief is adjusted correctly
before performing this procedure.

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

Note: Verify the hydraulic oil level is at the FULL
mark on the hydraulic tank.

1 Locate the lift relief valve on the function

manifold (schematic item C).

5 Remove the platform controls from the

platform.

6 Hold the lift relief valve with a wrench and

remove the cap (schematic item C).

7 While activating the platform up function,

adjust the internal hex socket clockwise, just
until the platform fully rises.

8 Fully lower the platform to the stowed position.

9 Add an additional 50 pounds / 22.7 kg to the

platform. Secure the additional weight.

10 Attempt to raise the platform.

Result: The power unit should not be able to

lift platform.

Result: If the power unit lifts the platform,

adjust the internal hex nut socket
counterclockwise until the platform will not
rise.

1 test port
2 system relief valve
3 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 Place maximum rated load into the platform.

Secure the load to the platform. Refer to
Specifications, Machine Specifications.

4 Turn the key switch to platform controls and

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

11 Install the relief valve cap.

12 Remove the weight from the platform.

Part No. 1275811GT GR

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Service Manual May 2018

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

Function Manifold

How to Adjust the Steer Relief
Valve

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

Note: Verify 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).

3 Remove the platform controls from the

platform.

4 Turn the key switch to platform controls and

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

5 Activate the function enable switch and press

and hold the steer thumb rocker switch to the
right. Allow the wheels to completely turn to
the right. Continue holding the switch while
observing the pressure reading on the
pressure gauge. Note the pressure. Refer to
Specifications, Hydraulic Component
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.

1 test port
2 steer 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).

7 Turn the 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.

9 Install the relief valve cap.

10 Repeat steps 5 and 6 to confirm the relief

valve pressure.

66 GR

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• QS™R • QS™W Part No. 1275811GT

May 2018 Service Manual

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

Description

Specification

Solenoid valve, 3 position 4 way,
20V DC with diode (schematic item E)

Ω

Solenoid valve, 3 position 4 way,
20V DC with diode (schematic item F)

Ω

Solenoid valve, 2
20V DC with diode (schematic item H)

Ω

Solenoid valve, 2 position 2 way,
N.C. 20V DC with diode (schematic item
N)

Ω

Function Manifold

4-3 Valve Coils

How to Test a Coil

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

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

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

or

Valve Coil Resistance
Specifications

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

position 4 way,

27.2

19

25

6.25

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

1 Tag and disconnect the wiring from the coil to

be tested.

2 Test the coil resistance using a multimeter set

to resistance (W). Refer to the Valve Coil
Resistance Specification table.

Result: If the resistance is not within the

adjusted specification, plus or minus 10%,
replace the coil.

Part No. 1275811GT GR

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• QS™R • QS™W 67

Service Manual May 2018

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

Resistor, 10

Genie part number 27287

Function Manifold

How to Test a Coil Diode

Genie incorporates spike suppressing diodes in all
of its coils. Properly functioning coil diodes protect
the electrical circuit by suppressing voltage spikes.
Voltage spikes naturally occur within a function
circuit following the interruption of electrical current
to a coil. Faulty diodes can fail to protect the
electrical system, resulting in a tripped circuit
breaker or component damage.

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

1 Test the coil resistance. Refer to Repair

Procedure, How to Test a Coil.

2 Connect a 10Ω 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.

Ω

3 Set a multimeter to read DC amperage.

Note: The multimeter, when set to read DC
amperage, should be capable of reading up to 800
mA.

4 Connect the negative lead to the other

terminal on the coil.

1 multimeter
2 9V DC battery
3 10Ω resistor
4 coil

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

5 Momentarily connect the positive lead from

the multimeter to the positive terminal on the
9V battery. Note and record the reading.

6 At the battery or coil terminals, reverse the

connections. Note and record the current
reading.

Result: Both current readings are greater than

0 mA and are different by a minimum of 20%.
The coil is good.

Result: if one or both current readings are

greater than 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.

68 GR

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• QS™R • QS™W Part No. 1275811GT

May 2018 Service Manual

Index No.

Description

Schematic Item

Function

Torque

Brake Release Hand Pump Components

5-1 Brake Release Hand Pump Components

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

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

2 Needle valve K Manual brake release enable 45-50 in-lbs / 5 Nm

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

™

Part No. 1275811GT GR

• QS™R • QS™W 69

Service Manual May 2018

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.

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.

Torque specifications

Hydraulic retaining fasteners, dry

4 Nm

Hydraulic tank retaining fasteners,
lubricated

2.9 Nm

Hydraulic Tank

6-1 Hydraulic Tank

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

How to Remove the Hydraulic
Tank

Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Specifications.

3 Remove the hydraulic tank retaining fasteners

and remove the hydraulic tank from the
machine.

4 Remove the hydraulic tank cap and drain the

tank into a suitable container.

35 in-lbs

26 in-lbs

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.

2 Tag, disconnect and plug the return hard line

at the hydraulic filter. Cap the fitting on the
filter. Remove the hard line from the tank.

70 GR

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• QS™R • QS™W Part No. 1275811GT

May 2018 Service Manual

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

Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually.
squirt or spray.

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

Torque specifications

Brake mounting fasteners, dry

lbs

102 Nm

Brake mounting fasteners, lubricated

lbs

76 Nm

Non-Steer Axle Components

7-1 Drive Brake

How to Remove the Drive Brake

Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Specifications.

1 Block the steer wheels.

2 Remove the cotter pin from the wheel castle

nut.

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 of the machine.

5 Raise the machine approximately 2 inches / 5

cm. Place blocks under the chassis for
support.

7 Tag, disconnect and plug the hydraulic hose

from the brake. Cap the fitting on the brake.

Do not allow oil to

8 Place a lifting jack under the brake for support.

9 Remove the fasteners that attach the brake to

the drive chassis. Remove the brake.

75 ft-

56 ft-

6 Remove the wheel castle nut. Remove the

wheel.

Part No. 1275811GT GR

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• QS™R • QS™W 71

Service Manual May 2018

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

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

Component damage hazard.
Hoses can be damaged if they
are kinked or pinched.

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

Steer Axle Components

8-1 Yoke and Drive Motor

How to Remove the Yoke
and Drive Motor Assembly

Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Specifications.

1 Block the non-steer tires.

2 Remove the cotter pin from the wheel castle

nut.

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.

7 Tag, disconnect and plug the hydraulic hoses

on the drive motor. Cap the fittings on the
drive motor.

spray.

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: While removing the retaining fasteners, take
note of the quantity and location of the spacers
when disconnecting the steer link from the yoke
assembly.

5 Raise the machine approximately 6 inches /

15 cm. Place blocks under the chassis for
support.

6 Remove the wheel castle nut. Remove the

wheel.

10 Remove the retaining fastener from the top of

the yoke pivot shaft.

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

11 Lower the yoke assembly out of the chassis.

72 GR

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• QS™R • QS™W Part No. 1275811GT

May 2018 Service Manual

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

Bodily
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

Torque specifications

Drive motor mounting fasteners,
dry

lbs

101.7 Nm

Drive motor mounting fasteners,
lubricated

lbs

76.3 Nm

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
are kinked or pinched.

Steer Axle Components

How to Remove a Drive Motor

1 Block the non-steer tires.

2 Remove the cotter pin from the wheel castle

nut of the motor to be removed.

3 Note: Always replace the cotter pin with a new

one when removing the castle nut.

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

5 Raise the machine approximately 2 inches / 5

cm. Place blocks under the chassis for
support.

8-2 Steer Cylinder

How to Remove the Steer
Cylinder

Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Specifications.

6 Remove the wheel castle nut. Remove the

wheel.

7 Tag, disconnect and plug the hydraulic hoses

on the drive motor. Cap the fittings on the
drive motor.

injury hazard. Spraying

kinked or pinched.

8 Remove the drive motor mounting fasteners.

Remove the motor.

75 ft-

56 ft-

1 Block the non-steer tires.

2 Remove the steer cylinder hose guard bracket

from the machine.

3 Remove the pin retaining fasteners from the

steer cylinder pivot pins. Remove the pins.

Note: While removing the pin retaining fasteners,
take note of the quantity and location of the
spacers when removing the pivot pin.

4 Remove the steer cylinder from the machine.

5 Tag, disconnect and plug the hydraulic hoses

from the steer cylinder. Cap the fittings on the
cylinder.

they

Part No. 1275811GT GR

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Service Manual May 2018

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

Steer Axle Components

8-3 Steer Bellcrank

How to Remove the Tie Rod

1 Remove the steer cylinder. Refer to Repair

Procedure, 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.

4 Turn the yokes fully to one side of the

machine.

5 Remove the fasteners securing the tie rod to

the steer yoke.

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

6 Turn the yokes fully to the opposite side of the

machine.

7 Remove the fasteners securing the tie rod to

the steer yoke.

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

8 Remove the bellcrank from the machine.

Note: Before re-installing the tie rod onto the
machine, apply a small amount of removable
thread lock onto the threads of the fasteners.
Torque the fasteners to 31 ft-lbs / 42 Nm.

74 GR

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• QS™R • QS™W Part No. 1275811GT

May 2018 Service Manual

Crushing hazard. Keep hands
clear when lowering the
platform.

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

Crushing hazard. The platform
will fall if not properly supported.

Platform Components

9-1 Platform

How to Remove the Platform

Perform this procedure with the platform extension
fully retracted and locked in position.

1 Raise the platform to approximately 1 ft / 30

cm.

2 Place support blocks between the platform

and the drive chassis. Lower the platform onto
the blocks.

3 Turn the key switch to the off position and

disconnect the battery pack from the machine.

6 Remove the fasteners securing the junction

box bracket to the mast. Set the bracket and
fasteners to the side.

7 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.

4 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.

5 Carefully cut the cable ties securing the

control cable to the platform.

Part No. 1275811GT GR

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• QS™R • QS™W 75

Service Manual May 2018

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

Platform Components

9-2 Platform Extension Deck

How to Remove the Platform
Extension Deck

1 Turn the key switch to the off position.

2 Disconnect the battery pack from the machine.

3 Disconnect the platform controls from the

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

4 Slide the extension deck forward until the

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

5 Remove the fasteners securing the white slide

blocks to the main deck. Set the slide blocks
and the fasteners to the side.

6 Activate the foot release latch and slide the

extension platform out of the platform.

76 GR

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• QS™R • QS™W Part No. 1275811GT

May 2018 Service Manual

Electrocution/burn hazard.
Contact with electrically charged
circuits coul
serious injury. Remove all rings,
watches and other jewelry.

Platform Components

9-3 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.

d result in death or

3 Disconnect the platform controls coli cord,

from the control cable at the platform.

4 Remove the fasteners and spacer securing

the platform controls to the platform controls
mount. Remove the platform controls from the
platform and set the controls to the side.

5 While supporting the work tray, remove the

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

1 work tray
2 screw
3 nylock nut
4 platform controls spacer
5 platform controls assembly
6 bushing
7 spacer
8 washer

Part No. 1275811GT GR

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• QS™R • QS™W 77

Service Manual May 2018

Bodily injury hazard. This
procedure requires specific repair
skills, lifting
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.

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
squirt or spray.

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.

Mast Components

10-1 Mast

How to Remove the Mast
Assembly

equipment and a

Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Specifications.

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

1 Remove the Platform. Refer to Repair

Procedure, How to Remove the Platform.

2 Tag and disconnect the power to platform wire

harness at the quick disconnect near the
Electronic Control Module (ECM).

5 Tag, disconnect and plug the lift cylinder

hoses at the function manifold. Cap the
fittings.

oil to

6 Remove the fasteners securing the lower rear

access cover to the chassis and remove the
cover. Set the cover and the fasteners to the
side.

7 Tag and disconnect the wire harness from the

platform down valve coil at the base of the lift
cylinder.

8 Remove the retaining nut securing the

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

9 Remove the platform down solenoid valve

from the lift cylinder. Set the valve to the side
and plug the cylinder port.

3 Tag and disconnect the ECM wire harness at

the quick disconnect near the ECM.

4 Attach a lifting strap of suitable capacity from

an overhead crane to the lifting eye at the top
of the mast. Support the mast. Do not apply
any lifting pressure.

78 GR

10 Remove the mast retaining fasteners.

™

• QS™R • QS™W Part No. 1275811GT

May 2018 Service Manual

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

Component damage
Hoses and cables can be
damaged if they are kinked or
pinched.

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.

Mast Components

11 Carefully pull the hydraulic hoses free while

removing the mast from the machine.

How to Disas sem bl e th e M ast

How to Disassemble the Mast

hazard.

12 Place the mast assembly on a suitable

structure capable of supporting it.

1 Remove the Mast. Refer to Repair Procedure,

How to Remove the Mast Assembly.

2 Rotate the mast until the carriage is facing up.

3 Remove the socket head retaining fastener

from the clevis block on the lift cylinder rod
end at the top of the number 1 column.

Part No. 1275811GT GR

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• QS™R • QS™W 79

Service Manual May 2018

Crushing hazard. The lift cylinder
will become unbalanced and fall
if not properly supported and
secured to the lifting device.

Mast Components

4 Remove the lift cylinder barrel end mounting

fasteners.

1 top of number 1 column
2 clevis block (not shown)
3 clevis block fastener
4 lift cylinder (not shown)

1 cylinder mounting plate
2 cylinder
3 cylinder mounting bolt

5 Loosen the lift cylinder mounting bracket

4 plate mounting fasteners

fasteners.

6 Support the cylinder and carefully slide it out of

the mast assembly.

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.

80 GR

™

• QS™R • QS™W Part No. 1275811GT

May 2018 Service Manual

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
comp
service is strongly recommended.

Mast Components

10 Slide the column below the carriage toward

the top of the mast assembly approximately 6
inches / 15 cm to access the idler wheel
mounting fasteners.

11 Hold the idler wheel axle from turning by

placing a screwdriver through the hole in the
axle. Remove the axle mounting fasteners and
remove the idler wheel assembly.

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

12 Remove the adjustment nuts from the chain

tension rocker on the carriage.

13 Slide the carriage out the bottom of the mast

assembly.

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

mast.

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

15 Remove the adjustment nuts from the chain

tension rocker on the column.

16 Remove the column by sliding the column out

the bottom of the mast.

17 Push the next column toward the top of the

mast to access the idler wheel assembly
mounting fasteners.

18 Hold the idler wheel axle from turning by

placing a screwdriver through the hole in the
axle. Remove the axle mounting fasteners,
and remove the idler wheel assembly.

19 Remove the adjustment nuts from the chain

tension rocker on the column.

20 Slide the column out the bottom of the mast.

21 Repeat steps 17 through 20 for each

remaining column.

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

How to Ass embl e th e M ast

How to Assemble the Mast

onent damage. Dealer

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 Boelube® wax to

the inside and outside channels of each
column.

4 Slide the number 2 column into the number 1

column.

5 Lay the number 2 column chains on the floor.

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 chains into
the chain tension rocker on the number 3
column.

9 Install the adjustment nuts on the number 1

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

Part No. 1275811GT GR

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• QS™R • QS™W 81

Service Manual May 2018

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

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.

nent damage hazard.

10-2 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 on the GR-20, QS-20R and QS-20W.

How to Adjust the Glide Pads

1 Locate the upper and lower glide pad

adjustment bolts below each upper roller bolt,
on both sides of each column.

2 Hold the glide pad adjustment bolt and loosen

the lock nut on all glide pads.

3 Turn the glide pad adjustment bolt clockwise

until the glide pad makes contact with the
column. Adjust the glide pads on both sides of
all columns. Be sure the sides of the columns
are even to within 1/8 inch / 3 mm of each
other.

4 On the number 1 column, secure the upper

and lower glide pad bolts on both sides of the
mast. Hold the glide pad adjustment bolt and
torque the lock nut to 12 in-lbs / 1.35 Nm. Be
sure the glide pad bolt does not turn.

18 Install the mast assembly on the drive chassis.

Adjust the lifting chains. Refer to Repair
Procedure, How to Adjust the Lifting Chains.

82 GR

5 Repeat step 4 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.

™

• QS™R • QS™W Part No. 1275811GT

May 2018 Service Manual

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.

Mast Components

10-3 Lifting Chains

How to Adjust the Lifting Chains

1 Mark the column to be adjusted.

2 Raise the platform approximately 6 feet / 2 m.

3 Place a lifting strap of suitable capacity from

an overhead crane under the platform.
Support the platform. Do not apply any lifting
pressure.

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.

4 Fully lower the platform and confirm the

alignment of the columns. Repeat steps 2
through 5 if necessary.

5 Confirm that the chain tensioner bracket is

centered in the inspection hole.

1 lifting chain
2 chain terminal
3 chain tension rocker
4 adjustment lock nut
5 mast column
6 inspection hole

Part No. 1275811GT GR

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• QS™R • QS™W 83

Service Manual May 2018

Inspection

Procedure

Inspection Failure

Inspection Remedy

Wear

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

When the length of the 16
links (pin to pin) measure
more 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
column. Replace entire
chain. Do not repair just the
affected portion of the chain.
Note: Measure a section of
chain that moves over the
idler wheels.

Rust and Corrosion

Visually inspect the chains
for rust and corrosion.

Evidence of
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
not protected with a layer of
oil.

Lubricate chain with motor
oil (SAE 40W).

Tight Joints

Inspect chain link joints for
easy movement.

Joints that do not flex freely
or are binding.

If rust and corrosion is
found, refer to Failure
Remedy for rust
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.

Mast Components

How to Inspect th e Lifti ng Chai ns

How to Inspect the Lifting Chains

chains on that

rust or

are

and

84 GR

™

• QS™R • QS™W Part No. 1275811GT

May 2018 Service Manual

Inspection

Procedure

Inspection Failure

Inspection Remedy

Raised or

Visually inspect for raised
pins.

Raised pins.

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

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

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

Check alignment of chain
anchors and

Chain Anchors

Visually inspect chain
anchors.

Broken chain anchor
fingers.

Replace chain anchor.
Bent or damaged anchor.

Replace chain anchor.

Twisted or misaligned chain
anchor.

Re
ensure even loading of
chain.

Threaded rod not visible in
inspection hole.

Replace chain anchor and
threaded rod.

Idler Wheels

Visually inspect chain idler
wheels.

Idler wheels have badly
worn flanges.

Replace idler wheel and
check chain alignment.

Idler wheels have grooves
worn into chain contact
surface.

Replace idler wheel.

Cracked Link Plates

Visually inspect chain link
plates for cracks.

Cracks in any chain link
plate.

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

Mast Components

Turned Pins

chain anchors

threaded rod

idler

idler wheels.

link plate wear

-align chain anchor to

idler wheel

Part No. 1275811GT GR

™

• QS™R • QS™W 85

Replace

Service Manual May 2018

Bodily injury hazard. This
procedure requires specific repair
sk
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.

Crushing hazard. The lift cylinder
could become unbalanced and
fall if not properly supported and
secured to t

Repair Procedures

10-4 How to Remove the Lift
Cylinder

10-4
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

ills, lifting equipment and a

1 Remove the Mast. Refer to Repair Procedure,

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.

86 GR

he lifting device.

1 top of number 1 column
2 clevis block (not shown)
3 clevis block fastener
4 lift cylinder (not shown)
5 check valve
6 flow control
7 cylinder

™

• QS™R • QS™W Part No. 1275811GT

8 manual lowering valve