Terex Genie GR -12 Bedienungsanleitung

Service Manual

Part No. 84700

Rev C1

January 2011

from GR05-5001

Serial Number Range

from GR05-5001

GR -12

GR -15

GR -20

from QS09-101

QS-12R

QS-15R

QS-20R

from QS09-101

QS-12W

QS-15W

QS-20W

January 2011

GR-12 • GR-15 • GR-20 Part No. 84700

Important

Read, understand and obey the safety rules and

operating instructions in the appropriate Operator's

Manual on your machine before attempting any

maintenance procedure.

Basic mechanical, hydraulic and electrical

skills are required to perform most procedures.

However, several procedures require specialized

skills, tools, lifting equipment and a suitable

workshop. In these instances, we strongly

recommend that maintenance and repair be

performed at an authorized Genie dealer

service center.

Compliance

Machine Classification

Group A/Type 2,3 as defined by ISO 16368

Machine Design Life

Unrestricted with proper opeation, inspection and

scheduled maintenance.

Technical Publications

Genie Industries has endeavored to deliver the

highest degree of accuracy possible. However,

continuous improvement of our products is a Genie

policy. Therefore, product specifications

are subject to change without notice.

Readers are encouraged to notify Genie of errors

and send in suggestions for improvement. All

communications will be carefully considered for

future printings of this and all other manuals.

www.genieindustries.com

e-mail: [email protected]

84700 Rev C September 2009

Second Edition, Third Printing

"Genie" is a registered trademark of Genie

Industries in the USA and many other countries.

"GR" is a trademark of Genie Industries.

Printed on recycled paper

Printed in U.S.A.

Serial Number Information

Genie Industries offers the following Service

Manuals for these models:

Title Part No.

Genie Runabout Service Manual,

First Edition

(before serial number GR05-5001) ....................... 72965

Introduction

September 2009

Part No. 84700 GR • QSR • QSW

Serial Number Legend

iii

INTRODUCTION

GR 05 - 12345

Model Sequence

number

Model year

(serial number stamp)

Serial label

MANUFACTURED BY/FABRIQUE PAR:

Genie Industries

18340 NE 76th Street

Redmond, WA 98052 USA

Model: GR-15

Serial number: GR05-1234

Model year: 2008 Manufacture date:

Elec/Hydr Schematic:

Power supply voltage/Pneumatic Pressure:

85-264 VAC, 60/50 Hz, 900 W

Nominal Power: 8.3 Hp / 6.2 kW

Machine unladen weight: 2,250 lbs / 1,021 kg

4/14/08

ES0126/HS0039

Max Load: 500 lbs / 227 kg

Occupants and Equipment must not exceed:

500 lbs / 227 kg

Maximum allowable inclination of the chassis:

1.5°(Side) 3°(Front) 3°(Rear)

Maximum Wind Speed:

Indoor:

Outdoor:

28 mph / 12.5 m/s

Gradeability: 30%

Maximum allowable side force: 100 lbs / 445 N

Maximum platform height: 14 ft 8 in / 4.47 m

Maximum Travel Height: Full ht

Maximum number of platform occupants: 1

Country of manufacture: USA

This machine complies with:

EN 280

98/37/EC

PN- 77172 07

QSR/QSW

(serial number stamp)

September 2009

GR • QSR • QSW Part No. 84700

This page intentionally left blank.

September 2009

Part No. 84700 GR • QSR • QSW

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.

Safety Rules

September 2009

GR • QSR • QSW Part No. 84700

SAFETY RULES

Workplace Safety

Be sure to keep sparks, flames and

lighted tobacco away from flammable and

combustible materials like battery gases

and engine fuels. Always have an approved fire

extinguisher within easy reach.

Be sure that all tools and working areas

are properly maintained and ready for

use. Keep work surfaces clean and free of

debris that could get into machine components and

cause damage.

Be sure any forklift, overhead crane or

other lifting or supporting device is fully

capable of supporting and stabilizing the

weight to be lifted. Use only chains or straps that

are in good condition and of ample capacity.

Be sure that fasteners intended for one

time use (i.e., cotter pins and self-locking

nuts) are not reused. These components

may fail if they are used a second time.

Be sure to properly dispose of old oil or

other fluids. Use an approved container.

Please be environmentally safe .

Be sure that your workshop or work area

is properly ventilated and well lit.

Personal Safety

Any person working on or around a machine must

be aware of all known safety hazards. Personal

safety and the continued safe operation of the

machine should be your top priority.

Read each procedure thoroughly. This

manual and the decals on the machine,

use signal words to identify the following:

Safety alert symbol—used to alert

personnel to potential personal

injury hazards. Obey all safety

messages that follow this symbol

to avoid possible injury or death.

Indicates an imminently hazardous

situation which, if not avoided, will

result in death or serious injury.

Indicates a potentially hazardous

situation which, if not avoided,

could result in death or serious

injury.

Indicates a potentially hazardous

situation which, if not avoided,

may cause minor or moderate

injury.

Indicates a potentially hazardous

situation which, if not avoided,

may result in property damage.

Be sure to wear protective eye wear and

other protective clothing if the situation

warrants it.

Be aware of potential crushing hazards

such as moving parts, free swinging or

unsecured components when lifting or

placing loads. Always wear approved steel-toed

shoes.

September 2009

Part No. 84700 GR • QSR • QSW

Table of Contents

Introduction

Important Information .........................................................................................

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

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

iii

Section 1 Safety Rules

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

Section 2 Rev Specifications

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

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

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

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

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

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

Section 3 Rev Scheduled Maintenance Procedures

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

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

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

DChecklist A Procedures

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

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

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

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

A-5 Perform 30 Day Service ..................................................................... 3 - 9

A-6 Grease the Steer Yokes ..................................................................... 3 - 9

vii

September 2009

GR • QSR • QSW Part No. 84700

TABLE OF CONTENTS

Section 3 Rev Scheduled Maintenance Procedures, continued

DChecklist B Procedures

B-1 Inspect the Batteries ......................................................................... 3 - 10

B-2 Inspect the Electrical Wiring ............................................................. 3 - 12

B-3 Inspect the Tires and Wheels (including castle nut torque) ............... 3 - 13

B-4 Check the Lifting Chain Adjustments ................................................ 3 - 13

B-5 Clean and Lubricate the Columns..................................................... 3 - 14

B-6 Adjust the Sequencing Cables .......................................................... 3 - 14

B-7 Test the Emergency Stop ................................................................. 3 - 15

B-8 Test the Key Switch .......................................................................... 3 - 16

B-9 Test the Automotive-style Horn (if equipped) .................................... 3 - 16

B-10 Inspect the Voltage Inverter (if equipped) ......................................... 3 - 17

B-11 Test the Drive Brakes ....................................................................... 3 - 18

B-12 Test the Drive Speed - Stowed Position ........................................... 3 - 19

B-13 Test the Drive Speed - Raised Position ............................................ 3 - 20

B-14 Test the Slow Drive Speed ............................................................... 3 - 21

B-15 Test the Motion Alarm (if equipped) .................................................. 3 - 22

B-16 Test the Flashing Beacons (if equipped) .......................................... 3 - 23

B-17 Perform Hydraulic Oil Analysis ......................................................... 3 - 23

B-18 Inspect the Breather Cap .................................................................. 3 - 24

DChecklist C Procedures

C-1 Grease the Platform Overload Mechanism (if equipped) .................. 3 - 25

C-2 Replace the Hydraulic Tank Breather Cap -

Models with Optional Hydraulic Oil ................................................... 3 - 25

C-3 Test the Platform Overload System (if equipped) ............................. 3 - 26

DChecklist D Procedures

D-1 Inspect the Mast Assembly for Wear ................................................ 3 - 28

D-2 Inspect and Lubricate the Lifting Chains ........................................... 3 - 29

D-3 Replace the Hydraulic Tank Return Filter ......................................... 3 - 30

BChecklist E Procedure

E-1 Test or Replace the Hydraulic Oil ..................................................... 3 - 31

viii

September 2009

Part No. 84700 GR • QSR • QSW

TABLE OF CONTENTS

Section 4 Rev Repair Procedures

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

EPlatform Controls

1-1 Circuit Boards .................................................................................... 4 - 2

1-2 Controller Adjustments ....................................................................... 4 - 3

1-3 Software Configuration ....................................................................... 4 - 8

CPlatform Components

2-1 Platform ........................................................................................... 4 - 12

2-2 Platform Extension ........................................................................... 4 - 12

2-3 Work Tray ........................................................................................ 4 - 13

BMast Components

3-1 Mast ................................................................................................. 4 - 14

3-2 Glide Pads ....................................................................................... 4 - 18

3-3 Lifting Chains ................................................................................... 4 - 18

3-4 Lift Cylinder ...................................................................................... 4 - 21

BGround Controls

4-1 Level Sensor .................................................................................... 4 - 22

AHydraulic Pump

5-1 Function Pump ................................................................................. 4 - 25

BFunction Manifold

6-1 Function Manifold Components ........................................................ 4 - 28

6-2 Valve Adjustments - Function Manifold ............................................ 4 - 30

6-3 Valve Coils ....................................................................................... 4 - 34

AHydraulic Tank

7-1 Hydraulic Tank ................................................................................. 4 - 36

ASteer Axle Components

8-1 Yoke and Drive Motor ...................................................................... 4 - 37

8-2 Steer Cylinder .................................................................................. 4 - 39

8-3 Steer Bellcrank ................................................................................. 4 - 39

September 2009

GR • QSR • QSW Part No. 84700

Section 4 Rev Repair Procedures, continued

ANon-steer Axle Components

9-1 Drive Brake ...................................................................................... 4 - 40

ABrake Release Hand Pump Components

10-1 Brake Release Hand Pump Components ......................................... 4 - 41

BPlatform Overload Components

11-1 Platform Overload System ............................................................... 4 - 42

AObstruction Sensing System

11-1 Obstruction Sensing Pads (QSR models only) ................................. 4 - 44

Section 5 Rev Fault Codes

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

C Fault Code Chart ......................................................................................... 5 - 3

Section 6 Rev Schematics

Introduction .................................................................................................. 6 - 1

C Electrical Component and Wire Color Legends ........................................... 6 - 2

B ECM Pin-out Legend ................................................................................... 6 - 3

C Relay Layout ................................................................................................ 6 - 4

B Wiring Diagram - Ground and Platform Controls .......................................... 6 - 5

B Electrical Symbols Legend........................................................................... 6 - 6

C Electrical Schematic - GR and QSW - ANSI and CSA Models

(all models without platform overload protection) ......................................... 6 - 8

D Electrical Schematic - GR and QSW - CE models

(all models with platform overload protection) ............................................ 6 - 10

A Electrical Schematic - QSR - ANSI and CSA Models

(all models without platform overload protection) ....................................... 6 - 14

A Electrical Schematic - QSR - CE models

(all models with platform overload protection) ............................................ 6 - 18

A Hydraulic Component Reference and Symbols Legend ............................. 6 - 22

A Hydraulic Schematic .................................................................................. 6 - 23

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