Terex Genie GR-12 Manuel utilisateur

Service Manual

Part No. T110280

Rev B1

November 2014

from GR10-20000

Serial Number Range

from GR10-20000

GR -12

GR -15

GR -20

from QS11-1000

QS-12R

QS-15R

QS-20R

from QS11-1000

QS-12W

QS-15W

QS-20W

November 2014

GR • QSR • QSW Part No. T110280

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 3 as defined by ISO 16368

Machine Design Life

Unrestricted with proper operation, inspection and

scheduled maintenance.

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.

T110280 Rev B October 2011

Third Edition, Second Printing

"Genie" is a registered trademark of Terex South

Dakota in the USA and many other countries.

"GR" is a trademark of Terex South Dakota, Inc.

Printed on recycled paper

Printed in U.S.A.

www.genielift.com

e-mail:[email protected]

Serial Number Information

Genie offers the following Service Manuals for

these models:

Title Part No.

Genie Runabout Service Manual,

First Edition

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

Genie Runabout Service Manual,

Second Edition

(GR - from serial number 5001 to 19999)

(QS - from 101 to 999) .......................................... 84700

Introduction

November 2014

Part No. T110280 GR • QSR • QSW

Revision History

Revision Date Section Procedure / Schematic Page / Description

A 4/2011 New release

B 10/2011 2 - Spec. 2-1

3 - Maint. 3-5, 3-27

6 - Schem. 6-2, 6-3, 6-4, 6-6, 6-10, 6-14, 6-18, 6-22, 6-26, 6-30, 6-34

B1 11/2014 6 - Spec. 2-5, 2-6

4 - Repair 12-2

6 - Schem. 6-39

REFERENCE EXAMPLES:

Section 3_Maintenance, B-3.

Section 4_Repair Procedure, 4-2.

Section 5_Diagnostic Codes, All charts.

Section 6_Schematics, Legends diagrams and

schematics.

Electronic Version

Click on any procedure or page number

highlighted in blue to view the update.

iii

November 2014

GR • QSR • QSW Part No. T110280

REVISION HISTORY, CONTINUED

Revision Date Section Procedure / Schematic Page / Description

REFERENCE EXAMPLES:

Kubota Engine_Section 2_Specifications.

A-6,B-3,C-7_Section 3_Maintenance Procedure.

3-2, 6-4, 9-1_Section 4_Repair Procedure.

Fault Codes_Section 5.

6-35, 6-56, 6-104_Section 6_Schematic Page #.

Electronic Version

Click on any procedure or page number

highlighted in blue to view the update.

November 2014

Part No. T110280 GR • QSR • QSW

Serial Number Legend

INTRODUCTION

November 2014

GR • QSR • QSW Part No. T110280

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

November 2014

Part No. T110280 GR • QSR • QSW

SAFETY RULES

vii

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.

November 2014

GR • QSR • QSW Part No. T110280

Table of Contents

Introduction

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

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

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

iii

Section 1 Safety Rules

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

Section 2 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 Scheduled Maintenance Procedures

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

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

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

Checklist 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 - 10

A-6 Grease the Steer Yokes ................................................................... 3 - 10

viii

November 2014

Part No. T110280 GR • QSR • QSW

TABLE OF CONTENTS

Section 3 Scheduled Maintenance Procedures, continued

Checklist B Procedures

B-1 Inspect the Batteries......................................................................... 3 - 11

B-2 Inspect the Electrical Wiring ............................................................. 3 - 14

B-3 Inspect the Tires and Wheels (including castle nut torque) .............. 3 - 15

B-4 Check the Lifting Chain Adjustments ............................................... 3 - 15

B-5 Clean and Lubricate the Columns .................................................... 3 - 16

B-6 Adjust the Sequencing Cables ......................................................... 3 - 16

B-7 Test the Emergency Stop ................................................................. 3 - 17

B-8 Test the Key Switch.......................................................................... 3 - 18

B-9 Test the Automotive-style Horn (if equipped) ................................... 3 - 18

B-10 Inspect the Voltage Inverter (if equipped) ........................................ 3 - 19

B-11 Test the Drive Brakes ....................................................................... 3 - 20

B-12 Test the Drive Speed - Stowed Position ........................................... 3 - 21

B-13 Test the Drive Speed - Raised Position............................................ 3 - 22

B-14 Test the Slow Drive Speed ............................................................... 3 - 23

B-15 Test the Motion Alarm (if equipped) ................................................. 3 - 24

B-16 Test the Flashing Beacons (if equipped) .......................................... 3 - 25

B-17 Perform Hydraulic Oil Analysis ......................................................... 3 - 26

B-18 Inspect the Breather Cap ................................................................. 3 - 26

B-19 Inspect the Electrical Contactor ........................................................ 3 - 27

Checklist C Procedures

C-1 Grease the Platform Overload Mechanism (if equipped) ................. 3 - 28

C-2 Replace the Hydraulic Tank Breather Cap -

Models with Optional Hydraulic Oil ................................................... 3 - 29

C-3 Test the Platform Overload System (if equipped)............................. 3 - 29

Checklist D Procedures

D-1 Inspect the Mast Assembly for Wear ................................................ 3 - 31

D-2 Inspect and Lubricate the Lifting Chains .......................................... 3 - 32

D-3 Replace the Hydraulic Tank Return Filter......................................... 3 - 33

Checklist E Procedure

E-1 Test or Replace the Hydraulic Oil ..................................................... 3 - 34

November 2014

GR • QSR • QSW Part No. T110280

TABLE OF CONTENTS

Section 4 Repair Procedures

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

Platform Controls

1-1 Circuit Board ...................................................................................... 4 - 3

1-2 Joystick .............................................................................................. 4 - 4

1-3 Platform Controls Alarm ..................................................................... 4 - 4

1-4 Platform Emergency Stop Button ....................................................... 4 - 5

Ground Controls

2-1 Software Revision Level .................................................................... 4 - 7

2-2 Machine Setup ................................................................................... 4 - 8

2-3 Level Sensor ...................................................................................... 4 - 9

Hydraulic Pump

3-1 Function Pump ................................................................................. 4 - 12

Function Manifold

4-1 Function Manifold Components ....................................................... 4 - 14

4-2 Valve Adjustments - Function Manifold ............................................ 4 - 16

4-3 Valve Coils ....................................................................................... 4 - 20

Brake Release Hand Pump Components

5-1 Brake Release Hand Pump Components ........................................ 4 - 22

Hydraulic Tank

6-1 Hydraulic Tank ................................................................................. 4 - 23

Steer Axle Components

7-1 Yoke and Drive Motor ...................................................................... 4 - 24

7-2 Steer Cylinder .................................................................................. 4 - 26

7-3 Steer Bellcrank ................................................................................ 4 - 26

Non-steer Axle Components

8-1 Drive Brake ...................................................................................... 4 - 27

Obstruction Sensing System

9-1 Obstruction Sensing Pads (QSR models only) ................................ 4 - 28

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