Professional Documents
Culture Documents
GR -12
GR -15
GR -20
QS-12R
QS-15R
QS-20R
QS-12W
QS-15W
QS-20W
from GR05-5001
from GR05-5001
from GR05-5001
from QS09-101
from QS09-101
from QS09-101
from QS09-101
from QS09-101
Rev C1
January 2011
January 2011
Introduction
Important
Title
Part No.
Compliance
Machine Classification
Group A/Type 2,3 as defined by ISO 16368
Machine Design Life
Unrestricted with proper opeation, inspection and
scheduled maintenance.
Technical Publications
Genie Industries has endeavored to deliver the
highest degree of accuracy possible. However,
continuous improvement of our products is a Genie
policy. Therefore, product specifications
are subject to change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.
Contact Us:
www.genieindustries.com
e-mail: techpub@terex.com
ii
September 2009
INTRODUCTION
GR 05 - 12345
Model
PN- 77172
Sequence
number
07
Model year
Serial label
GR
(serial number stamp)
QSR/QSW
(serial number stamp)
GR QSR QSW
iii
September 2009
iv
GR QSR QSW
September 2009
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
operators manual are also safety hazards
when maintenance and repair procedures
are performed.
GR QSR QSW
September 2009
SAFETY RULES
Personal Safety
Workplace Safety
vi
GR QSR QSW
September 2009
Table of Contents
Introduction
Important Information ......................................................................................... ii
Serial Number Information ................................................................................. ii
Serial Number Legend ...................................................................................... iii
Section 1
Safety Rules
General Safety Rules ........................................................................................ v
Section 2
Rev
D
Specifications
Machine Specifications ................................................................................ 2 - 1
Performance Specifications ......................................................................... 2 - 2
Hydraulic Specifications ............................................................................... 2 - 3
Manifold Component Specifications ............................................................. 2 - 4
Hydraulic Hose and Fitting Torque Specifications ........................................ 2 - 5
SAE and Metric Fasteners Torque Charts ................................................... 2 - 7
Section 3
Rev
Checklist A Procedures
A-1
A-2
A-3
A-4
A-5
A-6
GR QSR QSW
vii
September 2009
TABLE OF CONTENTS
Section 3
Rev
D
B-2
B-3
Inspect the Tires and Wheels (including castle nut torque) ............... 3 - 13
B-4
B-5
B-6
B-7
B-8
B-9
Checklist C Procedures
C-1 Grease the Platform Overload Mechanism (if equipped) .................. 3 - 25
C-2 Replace the Hydraulic Tank Breather Cap Models with Optional Hydraulic Oil ................................................... 3 - 25
C-3 Test the Platform Overload System (if equipped) ............................. 3 - 26
Checklist 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
Checklist E Procedure
E-1
viii
GR QSR QSW
September 2009
TABLE OF CONTENTS
Section 4
Rev
Repair Procedures
Introduction .................................................................................................. 4 - 1
Platform Controls
1-1
1-2
1-3
Platform Components
2-1
Platform ........................................................................................... 4 - 12
2-2
2-3
Mast Components
3-1
Mast ................................................................................................. 4 - 14
3-2
3-3
3-4
Ground Controls
4-1
Hydraulic Pump
5-1
Function Manifold
6-1
6-2
6-3
Hydraulic Tank
7-1
8-2
8-3
GR QSR QSW
ix
September 2009
TABLE OF CONTENTS
Section 4
Rev
Section 5
Rev
Fault Codes
Introduction .................................................................................................. 5 - 1
C
Section 6
Rev
GR QSR QSW
September 2009
Section 2 Specifications
Specifications
REV D
Machine Specifications
Batteries, Standard
Voltage
6V DC
Group
GC2
Type
T-105
Quantity
Battery capacity, maximum
Reserve capacity @ 25A rate
10 x 3 in
25.4 x 2.5 cm
6.5 sq in
41.9 cm2
150 ft-lbs
203 Nm
4
225AH
447 minutes
6V DC
Group
Type
GC2
6V-AGM
Quantity
Battery capacity, maximum
Reserve capacity @ 25A rate
4
200AH
380 minutes
Fluid capacities
Hydraulic tank
1.5 gallons
5.7 liters
Hydraulic system
(including tank)
2.2 gallons
8.3 liters
62 in
1.57 m
68.1 in
1.73 m
78 in
1.98 m
GR QSR QSW
2-1
Section 2 Specifications
September 2009
SPECIFICATIONS
REV D
Performance Specifications
2.5 mph
40 ft / 10.9 sec
4 km/h
12.2 m / 10.9 sec
1.1 mph
40 ft / 24.8 sec
1.8 km/h
12.2 m / 24.8 sec
Standard Platform
GR-20
Standard Platform
0.5 mph
40 ft / 55 sec
0.8 km/h
12.2 m / 55 sec
19 in 6 in
48 cm 15 cm
Gradeability
Stockpicker Platform
500 lbs
227 kg
30%
350 lbs
159 kg
350 lbs
159 kg
Platform raised
500 lbs
227 kg
350 lbs
159 kg
19 to 21 seconds
17 to 19 seconds
20 to 22 seconds
18 to 20 seconds
2-2
23 to 25 seconds
20 to 22 seconds
GR QSR QSW
September 2009
Section 2 Specifications
SPECIFICATIONS
REV D
Hydraulic Specifications
Function pump
Type
Gear
0.244 cu in
4 cc
4 gpm
15 L/min
15/13
200 ppm
10 micron with
25 psi / 1.7 bar bypass
Function manifold
System relief valve pressure, maximum
Lift relief valve pressure
Steer relief valve pressure
3500 psi
241 bar
1800 to 3500 psi
124 to 241 bar
1500 psi
103 bar
Optional fluids
Biodegradable
Fire resistant
Mineral based
GR QSR QSW
2-3
Section 2 Specifications
September 2009
SPECIFICATIONS
REV D
Manifold Component
Specifications
SAE No. 2
50 in-lbs / 6 Nm
SAE No. 4
13 ft-lbs / 18 Nm
SAE No. 6
18 ft-lbs / 24 Nm
Description
SAE No. 8
50 ft-lbs / 68 Nm
27.2
SAE No. 10
55 ft-lbs / 75 Nm
75 ft-lbs / 102 Nm
19
SAE No. 12
25
6.25
Plug torque
Specification
2-4
GR QSR QSW
September 2009
Section 2 Specifications
SPECIFICATIONS
REV D
JIC 37 Fittings
Torque
-4
11 ft-lbs / 14.9 Nm
-6
Thread Size
Flats
-4
7/16-20
23 ft-lbs / 31.2 Nm
-6
9/16-18
1 1/4
-8
40 ft-lbs / 54.2 Nm
-8
3/4-16
-10
69 ft-lbs / 93.6 Nm
-10
7/8-14
-12
93 ft-lbs / 126.1 Nm
-12
1 1/16-12
-16
-16
1 5/16-12
-20
-20
1 5/8-12
-24
-24
1 7/8-12
Torque
-4
16 ft-lbs / 21.7 Nm
-6
35 ft-lbs / 47.5 Nm
-8
60 ft-lbs / 81.3 Nm
-10
-12
-16
-20
-24
GR QSR QSW
2-5
Section 2 Specifications
September 2009
SPECIFICATIONS
REV D
Torque Procedure
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.
b
c
b
a
c
b
Figure 1
a
b
c
d
hydraulic hose
hex nut
reference mark
body hex fitting
Figure 2
a
b
c
2-6
GR QSR QSW
September 2009
Section 2 Specifications
SPECIFICATIONS
REV D
SIZE
Grade 5
THREAD
LUBED
20
28
1/4
DRY
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 1/2
LUBED
DRY
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
80
90
9
10.1
100
120
11.3
13.5
110
120
12.4
13.5
140
160
15.8
18
130
140
14.7
15.8
LUBED
5/16
Grade 8
DRY
LUBED
DRY
LUBED
ft - lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
13
14
23
26
37
41
57
64
80
90
110
130
200
220
320
350
480
530
590
670
840
930
1460
1640
17.6
19
31.2
35.2
50.1
55.5
77.3
86.7
108.4
122
149
176
271
298
433
474
650
718
800
908
1138
1260
1979
2223
17
19
31
35
49
55
75
85
110
120
150
170
270
300
430
470
640
710
790
890
1120
1240
1950
2190
23
25.7
42
47.4
66.4
74.5
101.6
115
149
162
203
230
366
406
583
637
867
962
1071
1206
1518
1681
2643
2969
18
20
33
37
50
60
80
90
120
130
160
180
280
310
450
500
680
750
970
1080
1360
1510
2370
2670
24
27.1
44.7
50.1
67.8
81.3
108.4
122
162
176
217
244
379
420
610
678
922
1016
1315
1464
1844
2047
3213
3620
25
27
44
49
70
80
110
120
150
170
210
240
380
420
610
670
910
990
1290
1440
1820
2010
3160
3560
33.9
36.6
59.6
66.4
94.7
108.4
149
162
203
230
284
325
515
569
827
908
1233
1342
1749
1952
2467
2725
4284
4826
21
24
38
43
61
68
93
105
130
140
180
200
320
350
510
560
770
840
1090
1220
1530
1700
2670
3000
28.4
32.5
51.5
58.3
82.7
92.1
126
142
176
189
244
271
433
474
691
759
1044
1139
1477
1654
2074
2304
3620
4067
Class 4.6
Size
(m m )
5
6
7
LUBED
DRY
LUBED
Class 10.9
8.8
DRY
LUBED
Class 12.9
10.9
DRY
LUBED
12.9
DRY
in- lbs
Nm
in- lbs
Nm
in-lbs
Nm
in-lbs
Nm
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
16
19
45
1.8
3.05
5.12
21
36
60
2.4
4.07
6.83
41
69
116
4.63
7.87
13.2
54
93
155
6.18
10.5
17.6
58
100
167
6.63
11.3
18.9
78
132
223
8.84
15
25.2
68
116
1.95
7.75
13.2
22.1
91
155
260
10.3
17.6
29.4
LUBED
8
10
12
14
16
18
20
22
24
Class 8.8
4.6
DRY
LUBED
DRY
LUBED
DRY
LUBED
DRY
f t- lbs
Nm
f t- lbs
Nm
f t -lbs
Nm
f t -lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
ft - lbs
Nm
5.4
10.8
18.9
30.1
46.9
64.5
91
124
157
7.41
14.7
25.6
40.8
63.6
87.5
124
169
214
7.2
14.4
25.1
40
62.5
86.2
121
166
210
9.88
19.6
34.1
54.3
84.8
117
165
225
285
14
27.9
48.6
77.4
125
171
243
331
420
19.1
37.8
66
105
170
233
330
450
570
18.8
37.2
64.9
103
166
229
325
442
562
25.5
50.5
88
140
226
311
441
600
762
20.1
39.9
69.7
110
173
238
337
458
583
27.3
54.1
94.5
150
235
323
458
622
791
26.9
53.2
92.2
147
230
317
450
612
778
36.5
72.2
125
200
313
430
610
830
1055
23.6
46.7
81
129
202
278
394
536
682
32
63.3
110
175
274
377
535
727
925
31.4
62.3
108
172
269
371
525
715
909
42.6
84.4
147
234
365
503
713
970
1233
GR QSR QSW
2-7
Section 2 Specifications
September 2009
2-8
GR QSR QSW
September 2008
Symbols Legend
Safety alert symbolused to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
GR QSR QSW
3-1
September 2009
Checklist
A
A+B
A+B+C
A+B+C+D
A+B+C+D+E
3-2
GR QSR QSW
Pre-Deliver
Pre-Deliveryy Preparation
September 2008
Fundamentals
Instructions
Pre-Delivery Preparation
Pre-operation inspection
completed
Maintenance items completed
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Genie Industries USA
18340 NE 76th Street
PO Box 97030
Redmond, WA 98073-9730
(425) 881-1800
Genie UK
The Maltings, Wharf Road
Grantham, Lincolnshire
NG31- 6BH England
(44) 1476-584333
GR QSR QSW
3-3
September 2009
3-4
GR QSR QSW
September 2009
Checklist A - Rev D
Serial number
B-1 Batteries
Date
A-2 Pre-operation
inspection
Hour meter
Machine owner
Y N R
Inspected by (print)
Inspector signature
Checklist B - Rev D
Y N R
Inspector title
Instructions
Make copies of this report to use for
each inspection.
Checklist C - Rev D
Y N R
A+B
Semi-annually or
500 hours
Inspection:
Two year or
2000 hours
Inspection:
Annually or
1000 hours
Inspection:
A+B+C
A+B+C+D
Checklist D - Rev D
Y N R
A+B+C+D+E
Checklist E - Rev B
Y N R
GR QSR QSW
3-5
September 2009
Checklist A Procedures
A-1
Inspect the Manuals and Decals
Maintaining the operators and safety manuals in
good condition is essential to safe machine
operation. Manuals are included with each
machine and should be stored in the container
provided in the platform. An illegible or missing
manual will not provide safety and operational
information necessary for a safe operating
condition.
In addition, maintaining all of the safety and
instructional decals in good condition is mandatory
for safe machine operation. Decals alert operators
and personnel to the many possible hazards
associated with using this machine. They also
provide users with operation and maintenance
information. An illegible decal will fail to alert
personnel of a procedure or hazard and could
result in unsafe operating conditions.
REV D
3-6
GR QSR QSW
September 2009
REV D
CHECKLIST A
PROCEDURES
A-2
Perform Pre-operation Inspection
A-3
Perform Function Tests
GR QSR QSW
3-7
September 2009
REV D
Hydraulic Tank
Side
A-4
Test the Obstruction Sensing
System (QSR models only)
Ground Controls
Side
Place the15 lb / 6.8 kg weight
2 inches / 5.08 cm from the
edge of the obstruction pad.
Non-steer End
Steer End
c
a
b
c
d
3-8
GR QSR QSW
September 2009
REV D
A-5
Perform 30 Day Service
A-6
Grease the Steer Yokes
GR QSR QSW
3-9
September 2009
Checklist B Procedures
+
B-1
Inspect the Batteries
REV D
b
F6
275A Fuse
+ -
BK
QD1
RD
U9
Battery Charger
a
b
c
d
batteries B5
275A fuse F6
quick disconnect QD1
battery charger U9
3 - 10
GR QSR QSW
September 2009
REV D
CHECKLIST B
PROCEDURES
All models:
17 Check each battery pack and verify that the
batteries are wired correctly.
18 Inspect the battery charger plug and pigtail for
damage or excessive insulation wear. Replace
as required.
19 Connect the battery charger to a properly
grounded 115V/60Hz or 230V/60Hz single
phase AC power supply.
Result: The charger should operate and begin
charging the batteries.
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 the
Genie Industries Scissor Service Department.
GR QSR QSW
3 - 11
September 2009
CHECKLIST B
PROCEDURES
REV D
B-2
Inspect the Electrical Wiring
Platform controls
3 - 12
GR QSR QSW
September 2009
REV D
CHECKLIST B
PROCEDURES
B-3
Inspect the Tires and Wheels
(including castle nut torque)
B-4
Check the Lifting Chain
Adjustments
GR QSR QSW
3 - 13
September 2009
CHECKLIST B
PROCEDURES
REV D
B-5
Clean and Lubricate the Columns
B-6
Adjust the Sequencing Cables
a
b
c
d
nylock nut
spring
upper sequencing bracket
sequencing cable
3 - 14
GR QSR QSW
September 2009
REV D
CHECKLIST B
B-7
Test the Emergency Stop
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
A properly functioning Emergency Stop is essential
for safe machine operation. An improperly
operating red Emergency Stop button will fail to
shut off power and stop all machine functions,
resulting in a hazardous situation.
Measurement, compressed
PROCEDURES
15/16
inch
2.4 cm
GR QSR QSW
3 - 15
September 2009
CHECKLIST B
PROCEDURES
REV D
B-8
Test the Key Switch
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
Proper key switch action and response is essential
to safe machine operation. The machine can be
operated from the ground or platform controls and
the activation of one or the other is accomplished
with the key switch. Failure of the key switch to
activate the appropriate control panel could cause
a hazardous operating situation.
B-9
Test the Automotive-style Horn
(if equipped)
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
The horn is activated at the platform controls and
sounds at the ground as a warning to ground
personnel. An improperly functioning horn will
prevent the operator from alerting ground
personnel of hazards or unsafe conditions.
3 - 16
GR QSR QSW
September 2009
REV D
CHECKLIST B
B-10
Inspect the Voltage Inverter
(if equipped)
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
The inverter is activated whenever the power is on,
and an electrical tool is connected to the inverter
and turned on.
1 Inspect the inverter plug and pigtail for damage
or excessive insulation wear. Replace as
required.
2 Turn the key switch to the on position and pull
out the red Emergency Stop button to the on
position at both the ground and platform
controls.
b
FAUL
T O
UTPU
T
POW
ER IN
VERT
ER
25V
24V-2
21V
2V
d
PART
NUM
BER
XXX
a
b
c
d
PROCEDURES
GR QSR QSW
3 - 17
September 2009
CHECKLIST B
PROCEDURES
REV D
B-11
Test the Drive Brakes
3 - 18
GR QSR QSW
September 2009
REV D
CHECKLIST B
PROCEDURES
B-12
Test the Drive Speed Stowed Position
GR QSR QSW
3 - 19
September 2009
CHECKLIST B
PROCEDURES
REV D
B-13
Test the Drive Speed Raised Position
a
b
3 - 20
GR QSR QSW
September 2009
REV D
CHECKLIST B
PROCEDURES
B-14
Test the Slow Drive Speed
GR QSR QSW
3 - 21
September 2009
CHECKLIST B
PROCEDURES
REV D
B-15
Test the Motion Alarm
(if equipped)
3 - 22
GR QSR QSW
September 2009
REV D
CHECKLIST B
B-16
Test the Flashing Beacons
(if equipped)
B-17
Perform Hydraulic Oil Analysis
PROCEDURES
GR QSR QSW
3 - 23
CHECKLIST B
PROCEDURES
September 2009
REV D
B-18
Inspect the Breather Cap
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
A free-breathing hydraulic tank cap is essential for
good machine performance and service life. A dirty
or clogged cap may cause the machine to perform
poorly. Extremely dirty conditions may require that
the cap be inspected more often.
1 Remove the breather cap from the hydraulic
tank.
2 Check for proper venting.
Result: Air passes through the breather cap.
Result: If air does not pass through the cap,
clean or replace the cap. Proceed to step 3.
Note: When checking for positive tank cap venting,
air should pass freely through the cap.
3 Using a mild solvent, carefully wash the cap
venting system. Dry using low pressure
compressed air. Repeat step 2.
4 Install the breather cap onto the hydraulic tank.
3 - 24
GR QSR QSW
September 2009
Checklist C Procedures
REV D
C-1
Grease the Platform Overload
Mechanism (if equipped)
C-2
Replace the
Hydraulic Tank Breather Cap Models with Optional Hydraulic Oil
GR QSR QSW
3 - 25
September 2009
CHECKLIST
REV D
PROCEDURES
C-3
Test the Platform Overload
System (if equipped)
3 - 26
GR QSR QSW
September 2009
REV D
CHECKLIST
C PROCEDURES
GR QSR QSW
3 - 27
September 2009
Checklist D Procedures
REV D
D-1
Inspect the Mast Assembly
for Wear
a
c
GR-15 shown
a
b
c
3 - 28
mast cover
idler wheel
spacer
GR QSR QSW
September 2009
REV D
CHECKLIST
D PROCEDURES
D-2
Inspect and Lubricate the
Lifting Chains
GR QSR QSW
3 - 29
September 2009
CHECKLIST
REV D
PROCEDURES
D-3
Replace the
Hydraulic Tank Return Filter
40 in-lbs
4.5 Nm
30 in-lbs
3.4 Nm
3 - 30
GR QSR QSW
September 2009
Checklist E Procedure
REV B
E-1
Test or Replace the Hydraulic Oil
35 in-lbs
4 Nm
26 in-lbs
2.9 Nm
GR QSR QSW
3 - 31
CHECKLIST
PROCEDURE
September 2009
REV B
3 - 32
GR QSR QSW
September 2009
Repair Procedures
About This Section
Most of the procedures in this section should only
be performed by a trained service professional
in a suitably equipped workshop. Select the
appropriate repair procedure after troubleshooting
the problem.
Wheels chocked
All external AC power supply disconnected
from the machine
GR QSR QSW
4-1
September 2009
Platform Controls
The platform controls, used to operate the machine
from the platform or while standing on the ground,
can also be used to tune the performance of the
machine.
Moving the joystick or activating a button sends a
signal to the Electronic Control Module (ECM).
When the ECM is in the function mode, the
platform controls are used to operate the various
machine functions. When the ECM is in the speed
tuning mode (PS is shown in the diagnostic display
window) or software configuration mode (SC is
shown in the diagnostic display window), the
platform controls are used to adjust the function
speed parameters or the machine configuration.
REV E
1-1
Circuit Boards
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 Remove the retaining fasteners securing the
bottom to the platform control box. Open the
control box.
3 Remove the ties securing the wire harness.
a
b
c
d
4-2
GR QSR QSW
September 2009
REV E
PLATFORM CONTROLS
1-2
Controller Adjustments
a
b
c
d
GR QSR QSW
4-3
September 2009
PLATFORM CONTROLS
REV E
b
c
d
f
4-4
GR QSR QSW
September 2009
REV E
PLATFORM CONTROLS
b
c
d
e
f
GR QSR QSW
4-5
September 2009
PLATFORM CONTROLS
REV E
4-6
b
c
d
e
GR QSR QSW
September 2009
REV E
PLATFORM CONTROLS
b
c
d
e
f
g
GR QSR QSW
4-7
September 2009
REV E
PLATFORM CONTROLS
1-3
Software Configuration
The Electronic Control Module (ECM) contains
programming for all configurations of the Genie
Runabout. The machine can be adjusted to a
different configuration using the buttons at the
platform controls.
4-8
GR QSR QSW
September 2009
REV E
PLATFORM CONTROLS
a
b
c
d
GR QSR QSW
4-9
September 2009
REV E
PLATFORM CONTROLS
M achine
Function
Non-slab M otion Lift/Driv e Platform
Code at
Option
Alarm
Cut Out Ov erload
Diagnostic
Display
M achine
Function
Non-slab M otion Lift/Driv e Platform
Code at
Option
Alarm
Cut Out Ov erload
Diagnostic
Display
05
23
25
26
27
29
30
31
05
23
25
26
27
29
30
31
4 - 10
GR QSR QSW
September 2009
REV E
PLATFORM CONTROLS
How to
Determine the Battery Voltage
GR QSR QSW
4 - 11
September 2009
Platform Components
REV C
2-1
Platform
2-2
Platform Extension
GR QSR QSW
September 2009
REV C
PLATFORM COMPONENTS
2-3
Work Tray
c
g
a
b
c
d
e
f
g
h
i
j
k
l
GR QSR QSW
work tray
screw
nylock nut
platform controls spacer
platform controls assembly
screw
nylock not
screw
nylock nut
bushing
spacer
waasher
4 - 13
September 2009
Mast Components
REV B
3-1
Mast
How to
Remove the Mast Assembly
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
4 - 14
GR QSR QSW
September 2009
REV B
MAST COMPONENTS
a
b
c
d
GR QSR QSW
4 - 15
September 2009
REV B
MAST COMPONENTS
4 - 16
GR QSR QSW
September 2009
REV B
MAST COMPONENTS
GR QSR QSW
4 - 17
September 2009
MAST COMPONENTS
REV B
3-2
Glide Pads
3-3
Lifting Chains
c
d
e
a
b
c
d
e
f
4 - 18
GR QSR QSW
lifting chain
chain terminal
chain tension rocker
adjustment lock nut
mast column
inspection hole
September 2009
REV B
MAST COMPONENTS
Procedure
Inspection Failure
Inspection Remedy
Wear
Tight Joints
Evidence of rust or
corrosion.
GR QSR QSW
4 - 19
September 2009
MAST COMPONENTS
REV B
Inspection
Procedure
Inspection Failure
Inspection Remedy
Raised pins.
Misalignment of flats on
all "V" heads.
Chain Side
Chain Anchors
chain
anchors
Idler Wheels
threaded
rod
idler wheel
4 - 20
Twisted or misaligned
chain anchor.
GR QSR QSW
September 2009
REV B
MAST COMPONENTS
3-4
Lift Cylinder
a
b
a
b
c
d
e
f
g
h
check valve
flow control
cylinder
manual lowering valve
GR QSR QSW
4 - 21
September 2009
Ground Controls
REV B
4-1
Level Sensor
The Electronic Control Module (ECM) is
programmed to deactivate the lift and drive
functions and activate an alarm when a signal is
received from the level sensor.
4 - 22
GR QSR QSW
a
b
c
d
chassis
level sensor
'X' indicator
mast
September 2009
REV B
GROUND CONTROLS
adjusting fastener
calibration circles
ground controls
GR QSR QSW
4 - 23
September 2009
GROUND CONTROLS
REV B
4 - 24
GR QSR QSW
September 2009
Hydraulic Pump
REV A
5-1
Function Pump
The hydraulic pump is attached to the motor which
makes up the hydraulic power unit.
GR QSR QSW
4 - 25
September 2009
REV A
HYDRAULIC PUMP
4 - 26
GR QSR QSW
September 2009
GR QSR QSW
4 - 27
September 2009
Function Manifold
REV B
6-1
Function Manifold Components
The function manifold is mounted next to the hydraulic power unit.
Index
No.
Description
Relief valve,
1800 to 3500 psi / 124 to 241 bar ............. C ......................... Lift relief .................................. 20 ft-lbs / 27 Nm
Check valve, 10 psi / 0.7 bar ..................... D ......................... Drive circuit ............................. 20 ft-lbs / 27 Nm
Solenoid valve, 3 position 4 way ............... E ......................... Drive forward/reverse ............. 25 ft-lbs / 34 Nm
Solenoid valve, 3 position 4 way ............... F ......................... Steer left/right ......................... 25 ft-lbs / 34 Nm
Relief valve,
3500 psi / 241 bar maximum ..................... I .......................... System relief ........................... 20 ft-lbs / 27 Nm
4 - 28
Schematic
Item
GR QSR QSW
Function
Torque
September 2009
REV B
FUNCTION MANIFOLD
Y8
H
Y4
Y3
D
F
Y6
6
Y5
GR QSR QSW
4 - 29
September 2009
REV B
FUNCTION MANIFOLD
6-2
Valve Adjustments Function Manifold
a
b
test port
system relief valve
4 - 30
GR QSR QSW
September 2009
REV B
FUNCTION MANIFOLD
a
b
c
test port
system relief valve
lift relief valve
GR QSR QSW
4 - 31
September 2009
FUNCTION MANIFOLD
REV B
a
b
test port
steer relief valve
4 - 32
GR QSR QSW
September 2009
REV B
FUNCTION MANIFOLD
GR QSR QSW
4 - 33
September 2009
REV B
FUNCTION MANIFOLD
6-3
Valve Coils
19
25
6.25
Description
Solenoid valve, 3 position 4 way
20V DC with diode (schematic items E)
Specification
27.2
4 - 34
GR QSR QSW
September 2009
REV B
FUNCTION MANIFOLD
10 W
RESISTOR
Resistor, 10
Genie part number
27287
9V
BATTERY
a
b
c
d
MULTI
METER
COIL
multimeter
9V DC battery
10 resistor
coil
GR QSR QSW
4 - 35
September 2009
Hydraulic Tank
REV A
7-1
Hydraulic Tank
35 in-lbs
4 Nm
26 in-lbs
2.9 Nm
4 - 36
GR QSR QSW
September 2009
REV A
8-1
Yoke and Drive Motor
GR QSR QSW
4 - 37
September 2009
REV A
4 - 38
75 ft-lbs
101.7 Nm
GR QSR QSW
56 ft-lbs
76.3 Nm
September 2009
REV A
8-2
Steer Cylinder
8-3
Steer Bellcrank
How to
Remove the Steer Cylinder
How to
Remove the Steer Bellcrank
GR QSR QSW
4 - 39
September 2009
REV A
9-1
Drive Brake
Torque specifications
Brake mounting fasteners, dry
75 ft-lbs
102 Nm
56 ft-lbs
76 Nm
4 - 40
GR QSR QSW
September 2009
REV A
10-1
Brake Release Hand Pump Components
The brake release hand pump manifold is mounted behind the hydraulic power unit.
Index
No.
Description
Schematic
Item
Function
Torque
Needle valve, pilot operated ............. K ............... Manual brake release enable .............. 45-50 in-lbs / 5 Nm
2
K
GR QSR QSW
4 - 41
September 2009
REV B
11-1
Platform Overload System
227 kg
159 kg
Stockpicker Platform
(GR-12, GR-15, QS-12R, QS-15R, QS-12W
and QS-15W models)
(GR-20, QS-20R and QS-20W models)
227 kg
159 kg
4 - 42
GR QSR QSW
September 2009
REV B
GR QSR QSW
4 - 43
September 2009
REV A
12-1
Obstruction Sensing Pads
4 - 44
GR QSR QSW
September 2009
REV A
Steer End
cable connectors
Deutsch connector
battery box
obstruction sensing pad
ground controls side
obstruction sensing pad
steer end
obstruction sensing pad
hydraulic tank side
obstruction sensing pad
GR QSR QSW
4 - 45
September 2009
4 - 46
GR QSR QSW
September 2009
Fault Codes
Before Troubleshooting:
Read, understand and obey the safety rules
and operating instructions in the appropriate
operator's manual on your machine.
Be sure that all necessary tools and test
equipment are available and ready for use.
Wheels chocked
All external AC power supply disconnected
from the machine
GR QSR QSW
5-1
September 2009
FAULT CODES
REV C
Identify
symptoms
Malfunction
discovered
Troubleshoot
problem
still exists
Return to
service
5-2
problem
solved
Inspect
and test
Perform
repair
GR QSR QSW
September 2009
REV C
Fault Code
Problem
01
02
ECM/Platform
communication error.
03
Possible Causes
Solution
Replace ECM.
Troubleshoot control cable
OR troubleshoot platform
controls.
12
Malfunctioning up/down
switch.
Troubleshoot up/down
switch.
18
19
42
43
Malfunctioning pothole
switch OR obstruction in
pothole guard linkage.
Malfunctioning limit switch
OR wire disconnected from
limit switch.
Malfunctioning steer left
microswitch.
46
47
52
53
Troubleshoot coil OR
inspect wire connection.
Troubleshoot coil OR
inspect wire connection.
54
55
56
Troubleshoot coil OR
inspect wire connection.
Troubleshoot coil OR
inspect wire connection.
Clear the obstruction
sensing pads of personnel
OR objects.
Troubleshoot coil OR
inspect wire connection.
57
58
Troubleshoot coil OR
inspect wire connection.
Troubleshoot coil OR
inspect wire connection.
59
68
Batteries discharged.
Charge batteries.
LL
OL
Remove weight.
GR QSR QSW
5-3
September 2009
5-4
GR QSR QSW
September 2009
Section 6 Schematics
Schematics
About This Section
There are two groups of schematics in this section.
An illustration legend precedes each group of
drawings.
Electrical Schematics
Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.
Hydraulic Schematics
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.
Before Troubleshooting:
Read, understand and obey the safety rules
and operating instructions in the appropriate
operator's manual on your machine.
Be sure that all necessary tools and test
equipment are available and ready for use.
Malfunction
discovered
Identify
symptoms
Troubleshoot
problem
still exists
Return to
service
GR QSR QSW
problem
solved
Inspect
and test
Perform
repair
6-1
Section 6 Schematics
September 2009
Description
Item
Description
B5
BN
Battery
Button
BN5 = Horn
BN6 = High torque
BN8 = Drive enable
BN9 = Lift enable
Capacitor, 4700 uF
Circuit breaker, 7A
Control relay
CR5 = Horn relay (with H2 option)
CR27A = Overload (motor controller) (option)
CR27B = Overload (load sense) (option)
CR27C = Overload (down coil) (option)
CR48 = Power relay to U5 (e-stop)
CR58 = Keypad relay (Keypad option)
CR111A = Obstruction sensing (QS retail)
CR111B = Obstruction sensing (QS retail)
Voltage regulator (Platform controls circuit board)
Enclosure - AC outlet box
Fuse, 275A
Flashing beacons
Gauge
G6 = Hour meter
G8 = Diagnostic display
Ground
Horn or alarm
H1 = Horn
H2 = Automotive-style horn (option)
H5 = Multifunction alarm
H10 = Obstruction sensing (QS retail)
Joystick controller
Key switch
LED or light
L16 = Lift
L17 = Drive
L21 = High torque
Limit switch
LS6 = Platform down
LS7 = Pothole
LS8 = Pothole
LS19 = Load sense (option)
Hydraulic power unit
Normally closed
Normally open
Normally closed held open
Power switch
P1 = Emergency Stop button at ground controls
P2 = Emergency Stop button at platform controls
Quick disconnect
QD1 = Battery quick disconnect
QD3 = Control cable to ground
QD4 = Control cable to platform
Resistor 25 Ohm/25Watt (QS retail)
Switch
SW5 = Function enable
SW6 = Steer left/right
Tilt level sensor
Platform up/down toggle switch
Electronic component
U3 = Platform controls printed circuit board
U5 = Electronic control module
U6 = Motor controller
U9 = Battery charger
U13 = Voltage inverter (option)
U38 = Keypad (option)
U47A = Obstruction sensing pad
(hydraulic tank side) (QS retail)
U47B = Obstruction sensing pad
(battery tray) (QS retail)
U47C = Obstruction sensing pad
(steer end) (QS retail)
U47D = Obstruction sensing pad
(ground controls side) (QS retail)
Valve coil
Y3 = Steer right
Y4 = Steer left
Y5 = Drive reverse
Y6 = Drive forward
Y7 = Platform down
Y8 = Platform up
C5
CB2
CR
D7
EN4
F6
FB
G
GND
H
JC1
KS1
L
LS
M5
NC
NO
NCHO
QD
R
SW
S7
TS66
U
6-2
GR QSR QSW
Description
Black
Black/White
Blue
Blue/Black
Brown
Green
Green/Black
Green/Yellow
Gray
Light Blue
Orange
Orange/Black
Purple
Red
Red/Black
White
White/Black
Yellow
September 2009
Section 6 Schematics
C 1
B 1
A 1
12
12
12
Item
Description
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
B1
B2
B3
B4
B5
B6
B7
B8
B9
B10
B11
B12
C1
C2
C3
C4
C5
C6
C7
C8
C9
C10
C11
C12
GR QSR QSW
6-3
Section 6 Schematics
September 2009
Relay Layout
REV C
a
b
b
c
d
e
f
g
h
6-4
GR QSR QSW
c
d
e
f
g
h
i
September 2009
Section 6 Schematics
Wiring Diagram
Ground and Platform Controls
REV B
GROUND CONTROLS
MOTOR CONTROLLER
TERMINAL B+
WH
CB2
KS1
7A CIRCUIT
BREAKER
KEY SWITCH
1
B1
4
MOTOR CONTROLLER
TERMINAL 1
BK
6-PIN CONNECTOR
PIN 1
BN
CR48
TERMINAL 30
ECM PIN A11
RD
(UP)
BL
TS66
PLATFORM UP/DOWN
TOGGLE SWITCH
(DOWN)
RD
OR
P1
EMERGENCY STOP
NC
RD
BK
PLATFORM CONTROLS
JC1
JOYSTICK
CONTROLLER
H1
GY
ALARM
BK
RD
WH
RD
BL
OR
RD
RD
BK
OR
PP
BL
YL
GY
WH/BL
NC 1
BN
WH
1 4.
P2
EMERGENCY
STOP
2 5.
BK
TO COIL CORD
GR QSR QSW
6-5
Section 6 Schematics
September 2009
N.C.
N.C.H.O.
B+
A2
B-
N.O.
LEVEL SENSOR
CIRCUIT BOARD
S7
Motor controller
LEVEL
SENSOR
RD
Limit switch
T2
Level sensor
D1
Wire with
description or color
Button or switch
M5
A1
Motor
Solenoid valve with diode
U9
Circuits crossing
no connection
Toggle switch
Capacitor
Emergency Stop button
Diode
Battery charger
Resistor
CB2
Circuit breaker
6V DC battery
N.O.
Circuit connection
30
N.C.
86
Pressure Switch
87A
87
85
Control relay
WH
Connector
OR
KS1
KEY
SWITCH
Fuse
PLATFORM
CONTROL
B1
Hour meter
Horn or alarm
GROUND
CONTROL
Key switch
LED
JC1
HALL
GENERATOR
Flashing beacon
JOYSTICK
CONTROLLER
SW6
STEER LEFT/ RIGHT
LEFT
RIGHT
SW5
FUNCTION
ENABLE
Joystick
6-6
GR QSR QSW
September 2009
Section 6 Schematics
GR QSR QSW
6-7
Section 6 Schematics
September 2009
6-8
REV C
GR QSR QSW
September 2009
Section 6 Schematics
REV C
GR QSR QSW
6-9
Section 6 Schematics
September 2009
6 - 10
REV D
GR QSR QSW
September 2009
Section 6 Schematics
REV D
GR QSR QSW
6 - 11
Section 6 Schematics
September 2009
6 - 12
REV D
GR QSR QSW
September 2009
Section 6 Schematics
GR QSR QSW
6 - 13
Section 6 Schematics
September 2009
REV A
TO
(QUICK DISCONNECT)
P1
KS1
EMERGENCY
STOP
KEY SWITCH
WH
1
2
OR
RD
PLATFORM
CONTROL
B1
WH
H5
ALARM
N.C.H.O.
GROUND
CONTROL
LS7
GROUND
CONTROLS
CB2
N.C.H.O.
N.C.H.O.
UP
AC INPUT
POWER TO PLATFORM
(110V-240V AC)
PLATFORM
UP/DOWN
DOWN
7A
CIRCUIT
BREAKER
POTHOLE
GUARD
SWITCH
TS66
LS8
LS6
POTHOLE
GUARD
SWITCH
A1
A9 OUT
BK
A8 OUT
WH
A1 OUT
B-
CR5
U13
+
OUT
B3
FLASHING
BEACONS
(OPTION)
30
OUT
B8
HORN RELAY
(H2 OPTION)
87
DC/AC INVERTER
(OPTION)
G6
HOUR
METER
86
85
OUT
C7
OUT
B7
OUT
A7
WH/BK
C12
IN
BL
A2
B11
IN
BL/BK
MOTOR
CONTROLLER
BK
FB
ECM GROUND
AC
INPUT
BN
U6
BK
B+
A4
IN
U5
OR
RD
B10
IN
B5
4-6V
BATTERY
RD
BATTERY
CHARGER
GN
DOWN LIMIT
M5
U9
WH
D1
WH
BL
M5
MOTOR
DRIVER POWER
ALARM
RD
OR
F6 275A FUSE
RD
RD
KEY SWITCH
B12 A11 B9
IN IN OUT
QD1 (+)
UP/DOWN SW UP
BL
A12
IN
WH
UP/DOWN SW DWN
DOWN
LIMIT
SWITCH
Y3
Y4
Y5
STEER
RIGHT
STEER
LEFT
DRIVE
REVERSE
H2
AUTO-STYLE
HORN
(OPTION)
QD1 ( )
ES0126E
6 - 14
GR QSR QSW
September 2009
Section 6 Schematics
REV A
GN
GN/YL
BK
BK
WH
LB
QD4A
30
87
RD
RD
OR/BK
WH
TO
85
(JUNCTION BOX)
CR48
86
POWER
RELAY TO U5
QD4
(E-STOP)
YL
BL
BL
OR
OR
WH/BK
RD/BK
WH
RD
N.C.
LEVEL
SENSOR
CIRCUIT
BOARD
LEVEL SNSR - RD
GN
RD
A2 B1 C1 C11 A5
IN IN IN IN OUT
MACHINE SHOWN
IN THE STOWED
POSITION WITH
THE POWER OFF
BK
LEVEL SNSR - WH
BL
OR
WH/BK
WH
ECM POWER
C2
IN
- NOTE -
S7
LEVEL
SENSOR
WH
RD
U5
ELECTRONIC CONTROL MODULE
OUT
C6
OUT
A6
OR
OUT
B6
BL
BK
GN/BK
BK/WH
WH
BL
R27
GN/YL
CR111A
Y6
Y8
Y7
DRIVE
FORWARD
PLATFORM
UP
PLATFORM
DOWN
OR
OBSTRUCTION
SENSING
25 OHMS
25 WATT
WH
30
87a 87
YL
86
85
CR111B
OBSTRUCTION
SENSING
30
86
87a 87
85
RD
H10
OBSTRUCTION
SENSING
ALARM
OR
OR
BN
GND
BN
ES0126E
GR QSR QSW
6 - 15
Section 6 Schematics
September 2009
AC
OUTLET
LB
REV A
EN4
AC
OUTLET
BOX
P2
QD3
RD/BK
BK
RD
RD
BK
POWER TO PLATFORM
WH
WH
WH
RD
POWER TO GROUND
YL
BK
BK
WH
GROUND
PIO3
BL
BL
BL
BL
PIO4
OR
OR
OR
OR
PIO5
RD
EMERGENCY
STOP
RD
PIO2
24V DC
D7
U3
BN
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
JC1
HALL EFFECT
GENERATOR
JOYSTICK
CONTROLLER
GY
GN
WH
BL
PP
OR
BK
RD
BK
WH
BL
RD
BN
U47B
U47A
OBSTRUCTION SENSING
PAD (Battery Tray)
OBSTRUCTION SENSING
PAD (Hydraulic Tank Side)
BL
PLATFORM CONTROLS
MEMBRANE DECAL
POUT1
POUT2
POUT3
G8
POUT4
DIAGNOSTIC
DISPLAY
PIN1
BN
PIN2
HORN BN5
PIN3
PIN4
BL
U47D
U47C
OBSTRUCTION SENSING
PAD (Ground Controls Side)
OBSTRUCTION SENSING
PAD (Steer End)
RIGHT
PIN10
SW6
STEER
LEFT/ RIGHT
LEFT
PIN9
PIN8
SW5
FUNCTION ENABLE
POUT11
PIN11
BK
H1
ALARM
PLATFORM
CONTROLLER
6 - 16
ES0126E
GR QSR QSW
September 2009
Section 6 Schematics
GR QSR QSW
6 - 17
Section 6 Schematics
September 2009
REV A
TO
(QUICK DISCONNECT)
P1
KS1
EMERGENCY
STOP
KEY SWITCH
WH
1
2
OR
RD
PLATFORM
CONTROL
B1
WH
H5
-
ALARM
N.C.H.O.
GROUND
CONTROL
LS7
GROUND
CONTROLS
CB2
N.C.H.O.
N.C.H.O.
UP
AC INPUT
POWER TO PLATFORM
(110V-240V AC)
PLATFORM
UP/DOWN
DOWN
7A
CIRCUIT
BREAKER
POTHOLE
GUARD
SWITCH
TS66
LS8
LS6
POTHOLE
GUARD
SWITCH
B12 A11 B9
IN IN OUT
BATTERY
CHARGER
A1
BK
A8 OUT
WH
A1 OUT
A2
B-
FB
OUT
B8
OUT
B3
OUT
C7
FLASHING
BEACONS
(OPTION)
U13
HORN RELAY
(H2 OPTION)
87
DC/AC INVERTER
(OPTION)
G6
HOUR
METER
86
85
ECM GROUND
CR5
30
OUT
B7
BL
MOTOR
CONTROLLER
BK
T2
BL/BK
U6
AC
INPUT
B+
BN
C12
IN
U5
OR
RD
B11
IN
B5
4-6V
BATTERY
A4
IN
M5
U9
B10
IN
RD
D1
DOWN LIMIT
MOTOR
WH
M5
RD
BK
WH
BL
A12
IN
F6 275A FUSE
DRIVER POWER
BL
QD1 (+)
RD
ALARM
RD
OR
UP/DOWN SW UP
KEY SWITCH
WH
UP/DOWN SW DWN
DOWN
LIMIT
SWITCH
Y3
Y4
STEER
RIGHT
STEER
LEFT
H2
AUTO-STYLE
HORN
(OPTION)
QD1 ( )
ES0127F
6 - 18
GR QSR QSW
September 2009
Section 6 Schematics
REV A
GN
GN/YL
BK
BK
WH
LB
QD4A
RD
RD
OR/BK
WH
30
POWER
RELAY TO U5
87
(E-STOP)
86
QD4
85
BL/BK
WH/BK
YL
BL
BL
OR
OR
CR27B
CR27C
OVERLOAD
OVERLOAD
(LOAD SENSE)
(DOWN COIL)
86
30
87
C5
85
4700 uF
- NOTE -
S7
MACHINE SHOWN
IN THE STOWED
POSITION WITH
THE POWER OFF
LEVEL
SENSOR
BK
RD
GN
BL
OR
B6
OUT
WH
A10
IN
WH/BK
C10
IN
GN/BK
WH
C5
IN
WH
GN
A9
OUT
LEVEL
SENSOR
CIRCUIT
BOARD
86
85
87A
86
85
N.C.
ECM POWER
87
30
RD/BK
WH
RD
CR27A
OVERLOAD
(MOTOR CONT)
30
TO
(JUNCTION BOX)
CR48
C2 A2 B1 C1 C11 A5
IN IN IN IN IN OUT
WH
RD
U5
ELECTRONIC CONTROL MODULE
OUT
A7
OUT
C6
OR
OUT
A6
BK
BK/WH
WH
WH/BK
BL
R27
GN/YL
CR111A
Y6
Y8
Y7
DRIVE
REVERSE
DRIVE
FORWARD
PLATFORM
UP
PLATFORM
DOWN
YL
30
87a 87
86
85
CR111B
OBSTRUCTION
SENSING
OBSTRUCTION
SENSING
ALARM
GR QSR QSW
30
86
87a 87
85
RD
H10
FOR OBSTRUCTION SENSING SYSTEM
A-B IS OPEN, CLOSED OTHERWISE
GND
25 OHMS
25 WATT
WH
OR
Y5
OBSTRUCTION
SENSING
ES0127F
OR
OR
BN
BN
OR
6 - 19
Section 6 Schematics
September 2009
REV A
GN/YL
AC
OUTLET
BK
LS19
LB
OR
RD/BK
WH
WH
RD
RD
BK
BK
EN4
LOAD
SENSE
LIMIT
SWITCH
N.O.
OR
N.C.
P2
AC OUTLET BOX
EMERGENCY
STOP
QD3
BK
RD
RD
RD
BK
POWER TO PLATFORM
WH
WH
WH
RD
POWER TO GROUND
YL
BK
BK
WH
GROUND
PIO3
BL
BL
BL
BL
PIO4
OR
OR
OR
OR
PIO5
RD
PIO2
24V DC
7
4
K
C
WH
BL
GN
WH
PP
GN/YL
PIN8
RD
PIN10
BL
WH
BL
RD
BN
OR
BK
RD
BK
BN
BL
BL
PLATFORM CONTROLS
MEMBRANE DECAL
U47B
U47A
POUT1
OBSTRUCTION SENSING
PAD (Battery Tray)
OBSTRUCTION SENSING
PAD (Hydraulic Tank Side)
POUT2
POUT3
G8
POUT4
DIAGNOSTIC
DISPLAY
SW6
STEER
LEFT/ RIGHT
RIGHT
PIN9
85
SW5
FUNCTION ENABLE
LEFT
87
JOYSTICK
CONTROLLER
1
2
86
JC1
HALL EFFECT
GENERATOR
GN
RD
KEYPAD
RELAY
30
BN
GY
LO
CR58
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
KEYPAD
(KEYPAD OPTION)
D7
U3
U38
GN
WH
RD
NOT CONNECTED
HERE WHEN KEYPAD
OPTION IS INSTALLED
PIN1
U47D
U47C
PIN2
HORN BN5
OBSTRUCTION SENSING
PAD (Ground Controls Side)
OBSTRUCTION SENSING
PAD (Steer End)
PIN3
PIN4
POUT11
PIN11
BK
H1
ALARM
PLATFORM
CONTROLLER
6 - 20
ES0127F
GR QSR QSW
September 2009
Section 6 Schematics
GR QSR QSW
6 - 21
Section 6 Schematics
September 2009
REV A
Orifice
Check valve
Brake
Variable speed motor
Y3
Y4
Solenoid operated
3 position 4 way
directional valve
Hydraulic cylinder
Y8
Solenoid operated
2 position 4 way
directional valve
Y5
Y6
Bi-directional motor
Solenoid operated
3 position 4 way
directional valve
Relief valve
Filter
Y7
Solenoid operated
2 position 2 way
directional valve
normally closed
with manual override
Hand pump
Y8
Y4
Y3
Brake manifold
Y6
Y5
Lift cylinder
Function manifold
6 - 22
GR QSR QSW
September 2009
Section 6 Schematics
Hydraulic Schematic
REV A
STEER
LEFT
LIFT CYLINDER
LEFT
STEER
RIGHT
LEFT
DRIVE
MOTOR
RIGHT
RIGHT
DRIVE
MOTOR
BRAKE
MANUAL
RELEASE
HAND
PUMP
Y7
REVERSE
BRAKE
RELEASE
MANIFOLD
1 gpm
3.8 L/min
FORWARD
5 psi
0.3 bar
B1
T
E
L
S2
S1
Y3
Y4
AC
10 psi
0.7 bar
M4
M1
HP
Y5
Y6
1500 psi
103 bar
0.75 gpm
2.8 L/min
TP
10 psi
0.7 bar
I
Y8
1800 to 3500 psi
124 to 241 bar
FUNCTION MANIFOLD
10 MICRON WITH
25 psi / 1.7 bar
BYPASS
POWER UNIT
HS0039A
HYDRAULIC TANK
GR QSR QSW
6 - 23
Section 6 Schematics
September 2009
6 - 24
GR QSR QSW
Phone 425.881.1800
Toll Free USA and Canada
800.536.1800
Fax 425.883.3475
Genie Scandinavia
Phone +46 31 575100
Fax +46 31 579020
Genie China
Phone +86 21 53852570
Fax +86 21 53852569
Genie France
Phone +33 (0)2 37 26 09 99
Fax +33 (0)2 37 26 09 98
Genie Malaysia
Phone +65 98 480 775
Fax +65 67 533 544
Genie Iberica
Phone +34 93 579 5042
Fax +34 93 579 5059
Genie Japan
Phone +81 3 3453 6082
Fax +81 3 3453 6083
Genie Germany
Phone
Phone
Fax
Genie U.K.
Phone +44 (0)1476 584333
Fax +44 (0)1476 584334
Genie Korea
Phone +82 25 587 267
Fax +82 25 583 910
Genie Brasil
Phone +55 11 41 665 755
Fax +55 11 41 665 754
Genie Holland
Phone +31 183 581 102
Fax +31 183 581 566
Distributed By:
Service Manual
GR QSR QSW
Part No.
84700
Rev C1