Service Manual

Serial Number Range

GR™-12
from GR10-20000
to GR16-40865

GR™-15
from GR16P-40866
to GR16P-44699

GR™-20
from GRP-44700
to GRP-59999

QS™-12R
from GRR-101
to GRR-10000

QS™-15R
from QS11-1000
to QS16-2429

QS™-20R
from QS16P-2430
to QS16P-4499

QS™-12W
from QSP-4500
to QSP-5999

QS™-15W
QS™-20W
Original Instructions
Part No. 1275811GT
Rev B
February 2022
Service Manual February 2022

Introduction
Introduction Introduction

Important Technical Publications

Read, understand and obey the safety rules and Genie has endeavored to deliver the highest
operating instructions in the appropriate Operator's degree of accuracy possible. However, continuous
Manual on your machine before attempting any improvement of our products is a Genie policy.
maintenance procedure. Therefore, product specifications are subject to
change without notice.
This manual provides detailed scheduled
maintenance information for the machine owner Readers are encouraged to notify Genie of errors
and user. It also provides troubleshooting and and send in suggestions for improvement. All
repair procedures for qualified service communications will be carefully considered for
professionals. future printings of this and all other manuals.

Basic mechanical, hydraulic and electrical skills

are required to perform most procedures.
However, several procedures require specialized Contact Us:
skills, tools, lifting equipment and a suitable
Internet: www.genielift.com
workshop. In these instances, we strongly
E-mail: [email protected]
recommend that maintenance and repair be
performed at an authorized Genie dealer service
center.
Find a Manual for this Model
Go to http://www.genielift.com
Compliance Use the links to locate Service Manuals,
Maintenance Manuals, Service and Repair
Machine Classification Manuals, Parts Manuals and Operator's Manuals.
Group A/Type 3 as defined by ISO 16368

Machine Design Life

Unrestricted with proper operation, inspection and Copyright © 2011 by Terex Corporation
scheduled maintenance. 1275811GT Rev B, February 2022

Fourth Edition, Second 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 Initial Release
A1 2/2018 Repair 14-1 How to Remove the Batteries
A2 5/2018 Schematics Add serial break GRR-101 to electrical and hydraulic
schematics
A3 11/2018 Diagnostics Op. Indicator Codes
B 2/2022 Add ending serial break
Repair 11-1
Schematics Electrical schematics
Hydraulic schematics

Reference Examples:
Section – Maintenance, B-3
Section – Repair Procedure, 4-2 Electronic Version
Click on any content or procedure in the Table of Contents to view
Section – Fault Codes, All charts the update.
Section – Schematics, Legends and schematics

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Introduction

Serial Number Legend

To August 31, 2016

1 Model 5 Serial label

2 Model year 6 Serial number (stamped on chassis, GR
3 Facility code models)
4 Sequence number 7 Serial number (stamped on chassis, QS
models)
From September 1, 2016

1 Model 4 Serial label

2 Facility code 5 Serial number (stamped on chassis, GR
3 Sequence number 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 modify or alter a MEWP without prior
written permission from the manufacturer.

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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Safety Rules

Personal Safety Workplace Safety

Any person working on or around a machine Any person working on or around a machine
must be aware of all known safety hazards. must be aware of all known safety hazards.
Personal safety and the continued safe Personal safety and the continued safe
operation of the machine should be your top operation of the machine should be your top
priority. priority.

Read each procedure thoroughly. This Be sure to keep sparks, flames and
manual and the decals on the lighted tobacco away from flammable
machine, use signal words to identify and combustible materials like battery
the following: gases and engine fuels. Always have
an approved fire extinguisher within
Safety alert symbol—used to easy reach.
alert personnel to potential
personal injury hazards. Obey Be sure that all tools and working
all safety messages that follow areas are properly maintained and
this symbol to avoid possible ready for use. Keep work surfaces
injury or death. clean and free of debris that could get
into machine components and cause
Indicates a imminently damage.
hazardous situation which, if
not avoided, will result in death Be sure any forklift, overhead crane or
or serious injury. other lifting or supporting device is
fully capable of supporting and
Indicates a potentially stabilizing the weight to be lifted. Use
hazardous situation which, if only chains or straps that are in good
not avoided, could result in condition and of ample capacity.
death or serious injury.
Be sure that fasteners intended for
Indicates a potentially one time use (i.e., cotter pins and self-
hazardous situation which, if locking nuts) are not reused. These
not avoided, may cause minor components may fail if they are used
or moderate injury. a second time.
Indicates a potentially Be sure to properly dispose of old oil
hazardous situation which, if or other fluids. Use an approved
not avoided, may result in container. Please be environmentally
property damage. safe.
Be sure to wear protective eye wear Be sure that your workshop or work
and other protective clothing if the area is properly ventilated and well lit.
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.

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Table of Contents

Introduction Introduction........................................................................................................... ii
Important Information ............................................................................................. ii
Find a Manual for this Model .................................................................................. ii
Revision History..................................................................................................... iii
Serial Number Legend .......................................................................................... iv

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
Manifold Component 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 ............................................................... 10

Introduction .......................................................................................................... 10
Maintenance Schedule ........................................................................................ 12
Pre-Delivery Preparation Report .......................................................................... 13
Scheduled and Programmed Maintenance Inspection Report ............................ 14

Commissioning Procedures ............................................................................. 15

C-1 Perform 40 Hour Service............................................................................... 15

Quarterly Maintenance Procedures ................................................................. 16

Q-1 Check for Open Bulletins and Owner Registration ....................................... 16
Q-2 Battery Inspection ......................................................................................... 17
Q-3 Inspect the Electrical Wiring.......................................................................... 19
Q-4 Inspect the Electrical Contactor .................................................................... 20
Q-5 Inspect the Voltage Inverter (if equipped) ..................................................... 20
Q-6 Test the Flashing Beacons (if equipped) ...................................................... 21
Q-7 Test the Alarm Package (if equipped) .......................................................... 22
Q-8 Inspect the Tires, Wheels and Castle Nut Torque ........................................ 22
Q-9 Check the Lifting Chain Adjustments ............................................................ 23
Q-10 Clean and Lubricate the Columns .............................................................. 23
Q-11 Adjust the Sequencing Cables .................................................................... 24
Q-12 Visual Inspection of the Hydraulic Oil ......................................................... 25
Q-13 Test the Drive Brakes ................................................................................. 26
Q-14 Test the Drive Speed – Stowed Position .................................................... 26
Q-15 Test the Drive Speed - Raised Position ...................................................... 27

Annual Maintenance Procedures ..................................................................... 28

A-1 Grease the Platform Overload Mechanism (if equipped) .............................. 28
A-2 Test the Platform Overload System (if equipped) ......................................... 28

Programmed Maintenance Procedures ........................................................... 31

P0-1 Grease the Steer Yokes .............................................................................. 31
P1-1 Inspect the Mast Assembly ......................................................................... 31
P1-2 Inspect and Lubricate the Lifting Chains ..................................................... 32
P1-3 Replace the Hydraulic Return Filter ............................................................ 33
P2-1 Test or Replace the Hydraulic Oil ............................................................... 33

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Table of Contents

Section 4 Repair Procedures ............................................................................................. 35

Introduction ........................................................................................................... 35

Platform Controls ............................................................................................... 37

1-1 Circuit Board .................................................................................................. 38
1-2 Joystick........................................................................................................... 39
1-3 Platfrom Controls Alarm ................................................................................. 40
1-4 Platform Emergency Stop Button ................................................................... 40

Ground Controls ................................................................................................. 42

2-1 Software Revision Level................................................................................. 43
2-2 Machine Setup ............................................................................................... 44
2-3 Level Sensors ................................................................................................ 45

Hydraulic Pump .................................................................................................. 53

3-1 Hydraulic Pump .............................................................................................. 53
How to Remove the Hydraulic Pump .............................................................. 54

Function Manifold .............................................................................................. 55

4-1 Function Manifold Components ..................................................................... 55
4-2 Valve Adjustments – Function Manifold ......................................................... 57
4-3 Valve Coils ..................................................................................................... 60

Brake Release Hand Pump Components......................................................... 62

5-1 Brake Release Hand Pump Components ...................................................... 62

Hydraulic Tank .................................................................................................... 63

6-1 Hydraulic Tank ............................................................................................... 63

Non-Steer Axle Components............................................................................. 64

7-1 Drive Brake..................................................................................................... 64

Steer Axle Components ..................................................................................... 65

8-1 Yoke and Drive Motor .................................................................................... 65
8-2 Steer Cylinder ................................................................................................ 66
8-3 Steer Bellcrank ............................................................................................... 67

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Platform Components ....................................................................................... 68

9-1 Platform.......................................................................................................... 68
9-2 Platform Extension Deck (if equipped) .......................................................... 69
How to Remove the Platform Extension Deck, GR Models ........................... 69
9-3 Work Tray (if equipped) ................................................................................. 70

Mast Components .............................................................................................. 71

10-1 Mast ............................................................................................................. 71
How to Remove the Mast Assembly ............................................................... 71
How to Disassemble the Mast ........................................................................ 72
How to Assemble the Mast ............................................................................. 75
10-2 Glide Pads ................................................................................................... 76
10-3 Lifting Chains ............................................................................................... 76
How to Inspect the Lifting Chains ................................................................... 78
10-4 How to Remove the Lift Cylinder ................................................................. 80

Platform Overload Components ....................................................................... 81

11-1 Platform Overload System ........................................................................... 81
11-2 Platform Overload Recovery Message ........................................................ 82

Obstruction Sensing System ............................................................................ 84

12-1 Obstruction Sensing System - QSR Models................................................ 84
How to Replace an Obstruction Sensing Pad ................................................ 84

Battery Charger .................................................................................................. 86

13-1 Battery Charger ........................................................................................... 86
Selecting a Charge Profile .............................................................................. 87

Batteries .............................................................................................................. 88
14-1 How to Remove the Batteries ...................................................................... 88

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Table of Contents

Section 5 Diagnostics ......................................................................................................... 89

Introduction ........................................................................................................... 89
GCON I/O Map without Load Sense .................................................................... 91
GCON I/O Map with Load Sense ......................................................................... 92
Operation Indicator Codes (OIC).......................................................................... 93
Diagnostic Trouble Codes (DTC) ......................................................................... 93
Troubleshooting "HXXX" and "PXXX" Faults ....................................................... 94
Fault Inspection Procedure .................................................................................. 95
Type "HXXX" Faults ............................................................................................. 97
Type "PXXX" Faults.............................................................................................. 98
Type "UXXX" Faults ............................................................................................. 99
Type "FXXX" Faults ............................................................................................ 100
Type "CXXX" Faults ........................................................................................... 101
Battery Charger .................................................................................................. 103
Charger Fault Codes ..................................................................................... 104
Charger Error Codes ..................................................................................... 105

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Table of Contents

Section 6 Schematics ....................................................................................................... 109

Introduction ........................................................................................................ 109
Electrical Component and Wire Color Legends ................................................. 110
Wiring Diagram Ground and Platform Controls ................................................. 112
Electrical Symbol Legend .................................................................................. 113
Hydraulic Symbols Legend ................................................................................ 114

Electrical Schematics – Options .................................................................... 115

Electrical Schematic, Options ............................................................................ 115

Electrical Schematics – ANSI / CSA Models ................................................. 117

Electrical Schematic, GR • QSW, ANS / CSA (from serial number
GR10-20000 to GR11-20683 and QS11-1000 to QS11-1015).................. 118
Electrical Schematic, GR • QSW, ANSI / CSA (from serial numbers
GR11-20684 to GR14-29741 and QS11-1016 to QS14-1550).................. 122
Electrical Schematic, GR • QSW, ANSI / CSA (from serial numbers
GR14-29742 to GR1540225 and QS14-1551 to QS15-2426) ................... 126
Electrical Schemamtic, GR • QSW, ANSI / CSA (from serial numbers
GR15-40226 to GR16P-41929 and QS15-2427 to QS16P-2451) ............. 127
Electrical Schematic, GR • QSW, ANSI / CSA (from serial numbers
GR16P-41930 to GR16P-44173 and QS16P-2452 to QS16P-2468) ........ 130
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)................... 131
Electrical Schematic, GR • QSW • QSR, ANSI/CSA (from serial number
GRP-52301, GRR-3871, QSP-4654) ......................................................... 133
Electrical Schematic, QSR, ANSI/CSA
(from serial number QS11-1000 - QS11-1015).......................................... 136
Electrical Schematic, QSR, ANSI/CSA
(from serial number QS11-1016 to QS14-1550) ........................................ 140
Electrical Schematic, QSR, ANSI/CSA
(from serial number QS14-1551 to QS15-2426) ........................................ 144
Electrical Schematic, QSR, ANSI/CSA
(from serial number QS15-2427 to QS16P-2451) ..................................... 145
Electrical Schematic, QSR, ANSI/CSA
(from serial number QS16P-2452 to QS16P-2468) ................................... 148
Electrical Schematic, QSR, ANSI/CSA
(from serial number QS16P-2469 to QS16P-4499)
(from serial number QSP-4500 to QSP-4653) ........................................... 149

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Table of Contents

Electrical Schematics – AS / CE Models ........................................................ 151

Electrical Schematic, GR/QSW, AS/CE (from serial numbers
GR10-20000 - GR11-20683 and QS11-1000 - QS11-1015)...................... 152
Electrical Schematic, GR/QSW, AS/CE (from serial numbers
GR11-20684 to GR14-29741 and QS11-1016 to QS14-1550) .................. 156
Electrical Schematic, GR/QSW, AS/CE (from serial numbers
GR14-29742 to GR15-40225 and QS14-1551 to QS15-2426) .................. 160
Electrical Schematic, GR/QSW, AS/CE (from serial numbers
GR15-40226 to GR16P-41929 and QS15-2427 to QS16P-2451) ............. 161
Electrical Schematic, GR/QSW, AS/CE (from serial numbers
GR16P-41930 to GR16P-44173 and QS16P-2452 to QS16P-2468) ........ 164
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) ............................................ 165
Electrical Schematic, GR • QSW • QSR, ANSI/CSA (from serial number
GRP-52301, GRR-3871, QSP-4654) ......................................................... 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 to QSP-4653) ........................................... 183

Hydraulic Schematics ...................................................................................... 185

Hydraulic Schematic, GR • QSR • QSW, (from serial number
GR10-20000 to GR12-24138 and QS11-1000 to QS12-1063) .................. 186
Hydraulic Schematic GR • QSR • QSW, (from serial number
GR12-24139 to GR16P-46499 and QS12-1064 to QS16P-4499)
(from GRP-46500, GRR-101 and QSP-4500) ............................................ 187

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Specifications
Section 2 Specifications

Machine Specifications
Batteries, Standard
Voltage 6V DC
Group GC2
Type T-105
Quantity 4
Battery capacity, maximum 225AH
Reserve capacity @ 25A rate 447 minutes
Weight, each 62 lbs
28 kg
Batteries, Maintenance-free (option)
Voltage 6V DC
Group GC2
Type 6V-AGM
Quantity 4
Battery capacity, maximum 200AH
Reserve capacity @ 25A rate 385 minutes
Weight, each 65 lbs
29 kg
DC Motor
Voltage 24V
Horsepower 4.5 HP @ 2950 rpm
Kilowatts 3.3 kW @ 2950 rpm
Fluid capacities
Hydraulic tank 1.5 gallons
5,7 liters
Hydraulic system (including tank) 2.2 gallons
8,3 liters
Tires and wheels
Tire size (solid rubber) 10 x 3 in
25,4 x 7,62 cm
Castle nut torque, lubricated 150 ft-lbs
203 Nm

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Specifications

Performance Specifications Rated work load at full height, maximum

GR-12, GR-15 500 lbs
Drive speed, maximum (standard platform) 227 kg
Platform stowed, fast 2.5 mph GR-12, GR-15, GR-20 350 lbs
40 ft / 10.9 sec (AWP platform) 159 kg
4 km/h
12.2 m / 10.9 sec GR-20 350 lbs
(standard platform) 159 kg
Platform stowed, slow 1.1 mph
40 ft / 24.8 sec QS-12R, QS-15R, QS-12W, QS-15W 500 lbs
1.8 km/h stockpicker platform) 227 kg
12.2 m / 24.8 sec QS-20R, QS-20W 350 lbs
Platform raised 0.5 mph (stockpicker platform) 159 kg
40 ft / 55 sec For operational specifications, refer to the
0.8 km/h
12.2 m / 55 sec
Operator's Manual.

Braking distance, maximum

High range on paved surface 19 in ± 6 in
61 cm ± 30 cm
Gradeability See Operator's Manual
Function speed, maximum from platform controls
(with 1 person in platform)
GR-12, QS-12R, QS-12W
Platform up (fast mode) 19 to 21 seconds
Platform up (slow mode) 30 to 32 seconds
Platform down 17 to 19 seconds
GR-15, QS-15R, QS-15W
Platform up (fast mode) 20 to 22 seconds
Platform up (slow mode) 31 to 33 seconds
Platform down 18 to 20 seconds
GR-20, QS-20R, QS-20W
Platform up (fast mode) 23 to 25 seconds
Platform up (slow mode) 32 to 34 seconds
Platform down 20 to 22 seconds

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Specifications

Hydraulic Component Manifold Component

Specifications Specifications
Function Pump Plug torque
Type gear pump SAE No. 2 36 in-lbs / 4 Nm
Displacement per revolution 0.244 cu in SAE No. 4 10 ft-lbs / 13 Nm
4 cc
SAE No. 6 14 ft-lbs / 19 Nm
Flow rate @ 2500 psi / 172 bar 4 gpm
SAE No. 8 38 ft-lbs / 51 Nm
15 L/min
SAE No.10 41 ft-lbs / 55 Nm
Hydraulic tank return filter 10 micron with
25 psi / 1,7 bar SAE No. 12 56 ft-lbs / 76 Nm
bypass
Function manifold
System relief valve pressure, 3500 psi
maximum 241 bar
Lift relief valve pressure 1800 to 3500 psi
124 to 241 bar
Steer relief valve pressure 1500 psi
103 bar

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Specifications

Hydraulic Oil Specifications Do not top off with incompatible

hydraulic fluids. Hydraulic fluids
Hydraulic Fluid Specifications may be incompatible due to the
Genie specifications require hydraulic oils which are differences in base additive
designed to give maximum protection to hydraulic chemistry. When incompatible
systems, have the ability to perform over a wide fluids are mixed, insoluble
temperature range, and the viscosity index should materials may form and deposit
exceed 140. They should provide excellent antiwear, in the hydraulic system,
oxidation prevention, corrosion inhibition, seal plugging hydraulic lines, filters,
conditioning, and foam and aeration suppression control valves and may result in
properties. component damage.
Cleanliness level, ISO 15/13
minimum Note: Do not operate the machine when the
Water content, 250 ppm ambient air temperature is consistently above
maximum 120°F / 49°C.
Recommended Hydraulic Fluid
Hydraulic Fluid Temperature
Hydraulic oil type Chevron Rando HD Premium
Range
Viscosity grade 32
Viscosity index 200
Optional Hydraulic Fluids
Mineral based Shell Tellus S2 V 32
Shell Tellus S2 V 46
Shell Tellus S4 VX 32
Shell Donax TG (Dexron III)
Chevron 5606A
Biodegradable Petro Canada Environ MV 46
Fire resistant UCON Hydrolube HP-5046
Note: Genie specifications require additional Ambient air temperature
equipment and special installation instructions for
the approved optional fluids. Consult Genie 1 Chevron hydraulic oil 5606A
Product Support before use. 2 Petro-Canada Environ MV 46
3 UCON Hydrolube HP-5046D
Optional fluids may not have 4 Chevron Rando HD premium oil MV
the same hydraulic lifespan and
may result in component
damage.

Note: Extended machine operation can cause the

hydraulic fluid temperature to increase beyond its
maximum allowable range. If the hydraulic fluid
temperature consistently exceeds 200°F / 90°C an
optional oil cooler may be required.

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Specifications

Chevron Rando HD Premium Oil Chevron 5606A Hydraulic Oil

MV Fluid Properties Fluid Properties
ISO Grade 32 ISO Grade 15
Viscosity index 200 Viscosity index 300
Kinematic Viscosity Kinematic Viscosity
cSt @ 200°F / 100°C 7.5 cSt @ 200°F / 100°C 5.5
cSt @ 104°F / 40°C 33.5 cSt @ 104°F / 40°C 15.0
cSt @ -40°F / -40°C 510
Brookfield Viscosity
cP @ -4°F / -20°C 1040 Flash point 180°F / 82°C
cP @ -22°F / -30°C 3310
Pour point -81°F / -63°C
Flash point 375°F / 190°C
Maximum continuous operating 124°F / 51°C
Pour point -58°F / -50°C temperature
Maximum continuous operating 171°F / 77°C
temperature Note: Use of Chevron 5606A hydraulic fluid, or
equivalent, is required when ambient temperatures
Note: A hydraulic oil heating system is are consistently below 0°F / -17°C unless an oil
recommended when the ambient temperature is heating system is used.
consistently below 0°F / -18°C.
Continued use of Chevron
Note: Do not operate the machine when the 5606A hydraulic fluid, or
ambient temperature is below -20°F / -29°C with equivalent, when ambient
Rando HD Premium MV. temperatures are consistently
above 32°F / 0°C may result in
component damage

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Specifications

Petro-Canada Environ MV 46 UCON Hydrolube HP-5046 Fluid

Fluid Properties Properties
ISO Grade 46 ISO Grade 46
Viscosity index 154 Viscosity index 192
Kinematic Viscosity Kinematic Viscosity
cSt @ 200°F / 100°C 8.0 cSt @ 149°F / 65°C 22
cSt @ 104°F / 40°C 44.4 cSt @ 104°F / 40°C 46
cSt @ 0°F / -18°C 1300
Flash point 482°F / 250°C
Flash point None
Pour point -49°F / -45°C
Pour point -81°F / -63°C
Maximum continuous operating 180°F / 82°C
temperature Maximum continuous operating 189°F / 87°C
temperature

Shell Tellus S4 VX Fluid

Properties
ISO Grade 32
Viscosity index 300
Kinematic Viscosity
cSt @ 200°F / 100°C 9
cSt @ 104°F / 40°C 33.8
Brookfield Viscosity
cSt @ -4°F / -20°C 481
cSt @ -13°F / -25°C 702.4
cSt @ -40°F / -40°C 2624
Flash point >100
Pour point -76°F / -60°C
Maximum continuous operating 103°F / 75°C
temperature

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Specifications

Hydraulic Hose and Fitting SAE O-ring Boss Port

Torque Specifications (tube fitting - installed into Aluminum)
(all types)
Your machine is equipped with Parker Seal-Lok™
SAE Dash Size Torque
ORFS or 37° JIC fittings and hose ends. Genie
specifications require that fittings and hose ends -4 14 ft-lbs / 19 Nm
be torqued to specification when they are removed -6 23 ft-lbs / 31,2 Nm
and installed or when new hoses or fittings are -8 36 ft-lbs / 49 Nm
installed.
-10 62 ft-lbs / 84 Nm
-12 84 ft-lbs / 114 Nm
Seal-Lok™ Fittings -16 125 ft-lbs / 169,5 Nm
(hose end - ORFS)
-20 151 ft-lbs / 204,7 Nm
SAE Dash Size Torque
-24 184 ft-lbs / 249,5 Nm
-4 18 ft-lbs / 25 Nm
-6 30 ft-lbs / 41 Nm
-8 40 ft-lbs / 55 Nm
-10 60 ft-lbs / 81 Nm
-12 85 ft-lbs / 115 Nm
-16 110 ft-lbs / 150 Nm
-20 150 ft-lbs / 205 Nm
Adjustable Fitting Non-adjustable fitting
-24 230 ft-lbs / 315 Nm
1 jam nut

JIC 37° Fittings

(swivel nut or hose connection)
SAE O-ring Boss Port
SAE Dash Size Thread Size Flats (tube fitting - installed into Steel)
-4 7/16-20 2
SAE Dash Size Torque
-6 9/16-18 1 1/2 -4 ORFS / 37° (Adj) 15 ft-lbs / 20,3 Nm
-8 3/4-16 1 1/2 ORFS (Non-adj) 26 ft-lbs / 35,3 Nm
37° (Non-adj) 22 ft-lbs / 30 Nm
-10 7/8-14 1 1/2
-6 ORFS (Adj / Non-adj) 35 ft-lbs / 47,5 Nm
-12 1 1/16-12 1 1/4
37° (Adj / Non-adj) 29 ft-lbs / 39,3 Nm
-16 1 5/16-12 1
-8 ORFS (Adj / Non-adj) 60 ft-lbs / 81,3 Nm
-20 1 5/8-12 1 37° (Adj / Non-adj) 52 ft-lbs / 70,5 Nm
-24 1 7/8-12 1 -10 ORFS (Adj / Non-adj) 100 ft-lbs / 135,6 Nm
37° (Adj / Non-adj) 85 ft-lbs / 115,3 Nm
-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

Part No. 1275811GT GR™ • QS™R • QS™W 7

Service Manual February 2022

Specifications

Torque Procedure JIC 37° fittings

1 Align the tube flare (hex nut) against the nose
Seal-Lok™ fittings of the fitting body (body hex fitting) and
tighten the hex nut to the body hex fitting to
1 Replace the O-ring. The O-ring must be
hand tight, approximately 30 in-lbs / 3.4 Nm.
replaced anytime the seal has been broken.
The O-ring cannot be re-used if the fitting or 2 Using a permanent ink marker, make a
hose end has been tightened beyond finger reference mark on one the flats of the hex nut
tight. and continue the mark onto the body of the
hex fitting. Refer to Illustration 1.
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. Illustration 1

5 Tighten the nut or fitting to the appropriate 1 hex nut

torque. Refer to the appropriate torque chart 2 reference mark
in this section. 3 body hex fitting
6 Operate all machine functions and inspect the
hose, fittings and related components to
confirm there are no leaks.

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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.

Part No. 1275811GT GR™ • QS™R • QS™W 9

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Scheduled Maintenance Procedures

Section 3 Scheduled Maintenance Procedures

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
Observe and Obey: removed
 Maintenance inspections shall be completed • The red Emergency Stop button in the off
by a person trained and qualified on the position at both the ground and platform
maintenance of this machine. controls
 Scheduled maintenance inspections shall be • Wheels chocked
completed daily, quarterly, semi-annually,
annually and every 2 years as specified of the • All external AC power supply disconnected
Maintenance inspection Report. The frequency from the machine
and extent of periodic examinations and tests • Platform in the stowed position
may also depend on national regulations.
Failure to perform each
procedure as presented and
scheduled may cause death,
serious injury or substantial
damage.

 Immediately tag and remove from service a

damaged or malfunctioning machine.
 Repair any machine damage or malfunction
before operating the machine.
 Use only Genie approved replacement parts.
 Machines that have been out of service for a
period longer than 3 months must complete
the quarterly inspection.

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Scheduled Maintenance Procedures

About This Section Maintenance Symbols Legend

This section contains detailed procedures for each Note: The following symbols have been used in
scheduled maintenance inspection. this manual to help communicate the intent of the
instructions. When one or more of the symbols
Each procedure includes a description, safety appear at the beginning of a maintenance
warnings and step-by-step instructions. procedure, it conveys the meaning below.

Symbols Legend Indicates that tools will be required to

perform this procedure.
Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety Indicates that new parts will be required to
messages that follow this symbol perform this procedure.
to avoid possible injury or death.

Indicates a imminently hazardous Indicates that dealer service will be

situation which, if not avoided, will required to perform this procedure.
result in death or serious injury.

Indicates a potentially hazardous Indicates that a cold motor or pump will be

situation which, if not avoided, required to perform this procedure.
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.

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.

Part No. 1275811GT GR™ • QS™R • QS™W 11

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Scheduled Maintenance Procedures

Maintenance Schedule Programmed Example (under 1000 HRS):

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.
Programmed Example:
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 Instructions Legend
50 and 150 hour intervals. Use the following detailed descriptions to identify
the intended use of the maintenance inspection
Quarterly and Annually: A series of maintenance reports.
procedures to be performed quarterly or annually.
Programmed: A series of maintenance Specific Interval: blank box is the interval to
procedures to be performed during a Pre-Delivery be completed and the  marks the interval
Preparation or based on machine operating hours. as not required.

The description of the procedure or

Maintenance Inspection Report
checklist to be completed.
The maintenance inspection report contains
checklists for each type of scheduled inspection. The procedure number or checklist to be
completed.
Make copies of the Maintenance Inspection Report
to use for each inspection. Maintain completed Check box to indicate status of inspection.
forms for a minimum of 4 years or in compliance
with your employer, jobsite and governmental
regulations and requirements. Specific interval is not required for this
procedure.
Instruction Examples
General area of the machine to complete
Commissioning Example: the procedure.

If this box has a designated time interval:

this is the specific time interval to complete
the procedure or checklist.
Quarterly and Annually Example:
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.

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Pre-Delivery Preparation Report

Fundamentals Instructions
It is the responsibility of the owner or dealer to Use the operator’s manual on your machine.
perform the Pre-delivery Preparation.
The Pre-delivery Preparation consists of
The Pre-delivery Preparation is performed prior to completing the Pre-operation Inspection, the
each delivery. The inspection is designed to Maintenance items and the Function Tests.
discover if anything is apparently wrong with a
machine before it is put into service. Use this form to record the results. Place a check
in the appropriate box after each part is
A damaged or modified machine must never be completed. Follow the instructions in the operator’s
used. If damage or any variation from factory manual.
delivered condition is discovered, the machine
must be tagged and removed from service. If any inspection receives an N, remove the
machine from service, repair and re-inspect it.
Repairs to the machine may only be made by a After repair, place a check in the R box.
qualified service technician, according to the
manufacturer's specifications. Legend
Y = yes, acceptable
Scheduled maintenance inspections shall be N = no, remove from service
performed by qualified service technicians, R = repaired
according to the manufacturer's specifications and Comments
the requirements listed in the responsibilities
manual.

Pre-delivery Preparation Y N R
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
February 2022
Scheduled and Programmed
Maintenance Inspection Report
Model Hour meter Date
Serial number Inspector company Machine owner
Inspected by (print) Inspector signature
Scheduled Maintenance: Legend Make copies of this report to use Programmed Maintenance:
Inspection Type Y = yes, acceptable for each inspection. Programmed maintenance will be completed based
Q = quarterly or frequent N = no, remove from Select the appropriate procedures on machine hours. This program includes the
inspections service for the type of inspection(s) to onetime or commissioning procedures for new
A = annual inspections R = repaired perform. products. The onetime procedures will be completed
 = not applicable at 50 or 150 hours.

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 Intervals Q A Commissioning 50

Inspect the Tires, Wheels and Castle Nut Torque Q-8 50 Hour Service - all models C-1
Chassis Mechanicals and Hydraulics Intervals Q A Programmed Maintenance - Under 1000 HRS Status Enter
Hours
Visual Inspection of the Hydraulic Oil Q-12
Grease the Steer Yokes P0-1 100
Electrical Intervals Q A
Hours are in thousands
Programmed Maintenance
Battery Inspection Q-2

Inspect the Electrical Wiring Q-3 All models Perform every: 1 2

Inspect the Mast Assembly P1-1 
Inspect the Electrical Contactor Q-4
Inspect and Lubricate the Lifting P1-2 
Inspect the Voltage Inverter - (if equipped) Q-5 Chains

Mast Q A Replace the Hydraulic Filters P1-3 

Check the Lifting Chain Adjustments Q-9 Test or Replace the Hydraulic Oil P2-2 

Clean and Lubricate the Columns Q-10

Adjust the Sequencing Cables Q-11

Platform Intervals Q A
Grease the Platform Overload Mechanism A-1 
Test the Platform Overload System A-2 
Functions and Controls Intervals Q A
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

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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™ • QS™R • QS™W 15

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Quarterly Maintenance Procedures

Q-1 Machines purchased in ASIA, North America

and Latin America:
Check for Open Bulletins and
Owner Registration Go to ASIA, North America and Latin America
Bulletins
(https://www.gogenielift.com/)

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 1 Select "Customer Login" to login or select
against our bulletin database. Using the links "Request New Access" to create a new
below you can view any open bulletins for your account.
machine(s) that require mandatory and immediate 2 At the homepage, select "Unit Configuration"
work to be completed. and enter your machine serial number.
Note: If you are unable to access this information 3 Press the "Lookup" button to view your
on our websites, please contact your local Genie machine configuration and to check for open
representative using the contact information bulletins.
provided on the back cover of this manual.
4 Complete all required bulletins shown for your
1 Locate the serial number plate or label on specific machine serial number.
your machine and document your Genie Machines purchased in Europe, Middle East,
machine serial number (exactly as its Africa, and Russia:
displayed on the serial plate or label).
2 Confirm that Genie has the current machine Go to EMEAR Bulletins
owner information on file by contacting our (http://www.genielift.co.uk/en/sales-and-
warranty department at 1-800-536-1800 or support/bulletin-campaigns/index.htm)
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: 1 Enter your machine serial number and press
search to check for open bulletins.
Go to Australia Bulletins
(http://genielift.com.au/contact) 2 Complete all required bulletins shown for your
specific machine serial number.
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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Quarterly Maintenance Procedures

Q-2 3 Lower the platform until the mast just contacts

the battery cover.
Battery Inspection
Crushing hazard. Keep hands
clear of the battery cover when
lowering the platform.
Genie specifications require that this procedure be
performed quarterly. 4 Be sure that the battery cable connections are
free of corrosion.
Proper battery condition is essential to good
engine and machine performance and operational Note: Adding terminal protectors and a corrosion
safety. Improper fluid levels or damaged cables preventative sealant will help eliminate corrosion
and connections can result in engine and on the battery terminals and cables.
component damage and hazardous conditions.
5 Be sure that the battery retainers and cable
Electrocution/burn hazard. connections are tight.
Contact with electrically charged 6 Be sure that the battery separator wire
circuits could result in death or connections are tight (if equipped).
serious injury. Remove all rings,
watches and other jewelry. Models without maintenance-free or sealed
batteries:
Bodily injury hazard. Batteries 7 Put on protective clothing and eye wear.
contain acid. Avoid spilling or
8 Remove the battery vent caps and check the
contacting battery acid.
specific gravity of each battery cell with a
Neutralize battery acid spills with
hydrometer. Note the results.
baking soda and water.
9 Check the ambient air temperature and adjust
Note: Fully charge the batteries and allow the the specific gravity reading for each cell as
batteries to rest 24 hours before performing this follows:
procedure to allow the battery cells to equalize.
• Add 0.004 to the reading of each cell for
1 GR-12, QS-12R, QS-12W: Raise the platform every 10° F / 5.5° C above 80° F / 26.7° C.
to approximately 3 ft / 1 m.
• Subtract 0.004 from the reading of each
GR-15, GR-20, QS-15R, QS-20R, QS-15W, cell for every 10° F / 5.5° C below 80° F /
QS-20W: Raise the platform to approximately 26.7° C.
5 ft / 1,5m.
Result: All battery cells display an adjusted
2 Open the battery cover. Rest the cover specific gravity of 1.277 or higher. The battery
against the chassis. 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 14 Install the vent caps and neutralize any
the battery(s) and allow the battery(s) to rest electrolyte that may have spilled.
at least 6 hours.
15 Check each battery pack and verify that the
11 Remove the battery vent caps and check the batteries are wired correctly.
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.
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 1 batteries B5
specific gravity from 1.217 to 1.173. The 2 275A fuse F6
battery is approaching the end of its life. 3 quick disconnect QD1
Proceed to step 11.
Result: The difference in specific gravity 16 Inspect the battery charger plug and pigtail for
readings between cells is greater than 0.1 OR damage or excessive insulation wear.
the specific gravity of one or more cells is less Replace as required.
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.

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Quarterly Maintenance Procedures

17 Connect the battery charger to a properly Q-3

grounded 115V/60Hz or, 230V/60Hz or 50Hz
single phase AC power sUpply.
Inspect the Electrical Wiring
Result: The charger should operate and begin
charging the batteries.
If, simultaneously, the charger alarm sounds and Genie specifications require that this procedure be
the LEDs blink one time, correct the charger performed quarterly.
connections at the fuse and battery. The charger Maintaining electrical wiring in good condition is
will then operate correctly and begin charging the essential to safe operation and good machine
batteries. performance. Failure to find and replace burnt,
If, simultaneously, the charger alarm sounds and chafed, corroded or pinched wires could result in
the LEDs blink two times, the input voltage is too unsafe operating conditions and may cause
low or too high. Correct the voltage issue. The component damage.
charger will then operate correctly and begin
Electrocution/burn hazard.
charging the batteries.
Contact with electrically charged
If, simultaneously, the charger alarm sounds and circuits could result in death or
the LEDs blink three times, the charger is serious injury. Remove all rings,
overheated. Allow the charger to cool. The charger watches and other jewelry.
will then operate correctly and begin charging the
batteries. 1 Inspect the underside of the chassis for
damaged or missing ground straps.
Note: For best results, use an extension of
2 Inspect the following areas for burnt, chafed,
adequate size with a length no longer than 50 feet
corroded pinched and loose wires:
/ 15 m.
• All wire harness connectors to ground
Note: If you have any further questions regarding control box
the battery charger operation, please contact
Genie Product Support. • Ground control panel
• 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.

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Quarterly Maintenance Procedures

Q-4 Q-5
Inspect the Electrical Contactor Inspect the Voltage Inverter
(if equipped)

Genie specifications require that this procedure be

performed quarterly. Genie specifications require that this procedure be
Maintaining the electrical contactor in good performed quarterly.
condition is essential to safe machine Perform this procedure more often if dusty
performance. Failure to locate a worn or damaged conditions exist.
contactor could result in unsafe operating
conditions and may cause component damage. 1 Inspect the inverter plug and pigtail for
damage or excessive insulation wear.
Electrocution/burn hazard. Replace as required.
Contact with electrically charged
circuits could result in death or 2 Turn the key switch to ground control and pull
serious injury. Remove all rings, out the red Emergency Stop button to the on
watches and other jewelry. position at both ground and platform controls.

1 At the ground controls, turn the key switch to

the off position and push in the red
Emergency Stop button to the off position.
2 At the non-steer end of the machine, open the
cover to access the electrical tray.
3 Disconnect the battery pack from the
machine.
4 Locate the electrical contactor mounted on
the fuse bracket.
5 Visually inspect the contact points of the
contactor for the following items:
• Excessive burns
• Excessive arcs
1 right fault LED
• Excessive pitting 2 left fault LED
Note: Replace the contactor if any damage is 3 25V LED
found. 4 21V LED

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Quarterly Maintenance Procedures

3 Connect an appropriate power tool to the Q-6

inverter. Activate the tool.
Test the Flashing Beacons
Result: The power tool should operate. There (if equipped)
may be a brief (0.5 second) delay if the power
tool has not been used in the previous Genie specifications require that this procedure be
10 minutes. performed quarterly.
If the left fault LED (REV_POL) is illuminated, Flashing beacons are used to alert operators and
the inverter is connected to batteries with the ground personnel of machine proximity and
incorrect polarity. Correct the polarity issue motion. The flashing beacons are located on both
with the red wire to battery positive and the sides of the machine.
black wire to battery negative. The inverter
will then operate correctly and begin 1 Turn the key switch to ground control and pull
supplying AC power. out the red Emergency Stop button to the on
position at both ground and platform controls.
If the right fault LED (123) blinks one time, the
power draw is too high. The tool being used Result: The beacons should flash.
requires too much power to operate or is 2 Turn the key switch to platform controls.
being used at or near the limit of the inverter
for an extended period of time. Reduce the Result: The beacons should flash.
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.
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-7 Q-8
Test the Alarm Package Inspect the Tires, Wheels and
(if equipped) Castle Nut Torque
Genie specifications require that this procedure be
performed quarterly.
Alarms are used to alert operators and ground Genie specifications require that this procedure be
personnel of machine proximity and motion. The performed quarterly.
motion alarm is located in the ground control box
and, when activated, will sound at 60 beeps per Maintaining the tires and wheels, including proper
minute. wheel fastener torque, is essential to safe
operation and good performance. Tire and/or
1 Perform the following functions from the wheel failure could result in a machine tip-over.
ground and platform controls to verify the Component damage may also result if problems
motion alarm is functioning properly. are not discovered and repaired in a timely
fashion.
Ground controls 1 Check the tire surface and sidewalls for cuts,
• Platform raise/lower cracks, punctures and unusual wear.
2 Check each wheel for damage, bends and
Platform controls cracks.
• Platform raise/lower 3 Remove the cotter pin and check the castle
• Drive forward/reverse nut for proper torque. Refer to Specifications,
Machine Specifications.
• Steer right/left
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 in place.

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Quarterly Maintenance Procedures

Q-9 Q-10
Check the Lifting Chain Clean and Lubricate the Columns
Adjustments
Genie specifications require that this procedure be
performed quarterly. 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 Clean and properly lubricated columns are
an unsafe operating condition and may cause essential to good machine performance and safe
component damage. operation. Extremely dirty conditions may require
that the columns be cleaned and lubricated more
often.
1 Fully lower the platform and measure the
maximum height of the mahine. 1 Raise the platform to the maximum height.
2 Result: The machine is within specification. 2 Place a lifting strap from an overhead crane
No adjustment required. Refer to under the platform. Support the platform. Do
Specifications, Machine Specifications. not apply any lifting presure.
3 Result: The machine is not within Component damage hazard. The
specification. Adjust the chains. Refer to platform railings can be damaged
Repair Procedure, How to Adjust the Lifting if they are used to lift the platform.
Chains. Do not attach the lifting strap to
the platform railings.
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.
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.

4 If needed, apply a generous amount of

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

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Q-11 3 Confirm proper tension of each sequencing

cable by measuring the height of the spring
Adjust the Sequencing Cables between the nylock nut and the upper
sequencing bracket.
Result: The measurement is within
Genie specifications require that this procedure be specification. Proceed to step 7.
performed quarterly. Result: The measurement is not within
Maintaining proper adjustment of the sequencing specification. Proceed to step 4.
cables is essential for safe machine operation. An Sequencing cable spring specification
unsafe working condition exists if the sequencing
cables are improperly adjusted. A frequent check Measurement, compressed 15/16 inch
allows the inspector to identify changes in the 2.4 cm
sequencing cables operating condition that might
indicate damage. 4 Adjust the spring compressed length by
turning the nylock nut clockwise to decrease
1 Fully lower the platform. the spring length or counterclockwise to
increase the spring length.
2 Locate the compression spring on each
sequencing cable. Component damage hazard. Do
Note: The spring is located between the nylock nut not compress the spring to less
and the upper sequencing bracket. than specification.

5 Raise and lower the platform through three

complete cycles.
6 Repeat this procedure beginning with step 3.
7 Repeat steps 3 through 5 for each
sequencing cable as required.

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

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Quarterly Maintenance Procedures

Q-12 1 Collect a sample of hydraulic oil and place in

a clear container. Visually inspect the
Visual Inspection of the Hydraulic hydraulic oil for the following:
Oil
• Color: oil should be a clear, light-honey
colored
• Appearance, oil should be clear and not
Genie specifications require that this procedure be cloudy or visibly distorts the view through
performed quarterly. the sight glass or container
Replacement or testing of the hydraulic oil is • Contains no particles, foreign objects, or
essential for good machine performance and other contamination
service life. Dirty oil and a clogged suction strainer
may cause the machine to perform poorly and • The hydraulic oil can be inspected by smell
continued use may cause component damage. (can smell “hot” but not “burnt”) or rubbing
Extremely dirty conditions may require oil changes between fingers (should feel viscous and
to be performed more often. For hydraulic oil free of any rough feel due to particles)
specifications, Refer to Specifications, Hydraulic If the hydraulic oil passes all of the above
Specifications. inspections, continue the scheduled
maintenance intervals.
Note: Before replacing the hydraulic oil, the oil
may be tested by an oil distributor for specific If the hydraulic oil fails any of the above
levels of contamination to verify that changing the inspections, the hydraulic oil must be tested
oil is necessary. Replace the oil when it fails the by an oil distributor or replaced.
test. Refer to Maintenance Procedure, Test or
Note: If the hydraulic oil was not replaced at or
Replace the Hydraulic Oil.
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.
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 Q-14
Test the Drive Brakes Test the Drive Speed – Stowed
Genie specifications require that this procedure be Position
performed quarterly. Genie specifications require that this procedure be
Proper brake action is essential to safe machine performed quarterly.
operation. The drive brake function should operate Proper drive function is essential to safe machine
smoothly, free of hesitation, jerking and unusual operation. The drive function should respond
noise. Hydraulically-released individual wheel quickly and smoothly to operator control. Drive
brakes can appear to operate normally when not performance should also be free of hesitation,
fully operational. jerking and unusual noise over the entire
Note: Perform this procedure with the machine on proportionally controlled speed range.
a firm, level surface that is free of obstructions. Note: Perform this procedure with the machine on
Note: The platform extension deck must be fully a firm, level surface that is free of obstructions.
retracted and the platform in the stowed position. Note: Perform this procedure with the machine in
1 Mark a test line on the ground for reference. the stowed position.

2 Turn the key switch to platform control and Note: Perform this procedure in high drive mode.
pull out the red Emergency Stop button to the Verify the low speed drive light is off.
on position at both the ground and platform
controls. 1 Create start and finish lines by marking two
lines on the ground 40 feet / 12.2 m apart.
Note: Perform this procedure in high drive mode.
Verify the low speed drive light is off. 2 Choose a point on the machine (i.e., contact
patch of a tire) as a visual reference for use
3 Choose a point on the machine (i.e., contact when crossing the start and finish lines.
patch of a tire) as a visual reference for use 3 Bring the machine to top drive speed before
when crossing the test line. reaching the start line. Begin timing when
4 Bring the machine to top drive speed before your reference point on the machine crosses
reaching the test line. Release the drive the start line.
joystick when your reference point on the 4 Continue at full speed and note the time when
machine crosses the test line. the machine reference point crosses the finish
5 Measure the distance between the test line line. Refer to Specifications, Performance
and your machine reference point. Refer to Specifications.
Specifications, Performance Specifications.
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-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 Raise the platform approximately 4 feet /
1,2 m.
3 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.
4 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.
5 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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Annual Maintenance Procedures

A-1 A-2
Grease the Platform Overload Test the Platform Overload
Mechanism (if equipped) System (if equipped)

Genie specifications require that this procedure be Genie specifications require that this procedure be
performed annually. performed annually OR when the machine fails to
lift the maximum rated load.
Perform this procedure more often if dusty
conditions exist. Testing the platform overload system regularly is
essential to safe machine operation. Continued
Application of lubrication to the platform overload use of an improperly operating platform overload
mechanism is essential to safe machine operation. system could result in the system not sensing an
Continued use of an improperly greased platform overloaded platform condition. Machine stability
overload mechanism could result in the system not could be compromised resulting in the machine
sensing an overloaded platform condition and will tipping over.
result in component damage.
Note: Perform this procedure with the machine on
1 Locate the grease fittings on each pivot pin of a firm, level surface.
the platform overload assembly.
1 Turn the key switch to platform control and
2 Thoroughly pump grease into each grease pull out the red Emergency Stop button to the
fitting. on position at both the ground and platform
Grease Specification controls.
Chevron Ultra-duty grease, EP NLGI 1 (lithium based) 2 Determine the maximum platform capacity.
or equivalent Refer to the machine serial plate.

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Annual Maintenance Procedures

3 Using a suitable lifting device, place a test 4 Add additional weight to the platform that is
weight equal to that of the available capacity equal to, but does not exceed 15% of the
in one of the locations shown. Refer to maximum rated load. Secure the additional
Illustration 1. weight. Refer to the machine serial plate.
Result: The LCD at the ground controls Result: The LCD at the ground controls
should display READY, the machine model displays OL: Platform Overloaded and the
and machine hours, indicating a normal LED readout on the platform controls displays
condition. The LED readout on the platform a flashing OL. The platform overload system
controls should display CH. Refer to the is operating properly
examples below.
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).
GCON LCD
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
PCON LCD controls.
Result: The LCD at the ground controls Result: All ground control functions should not
displays OL: Platform Overloaded and the operate.
LED readout on the platform controls displays
8 Lift the test weight off the platform floor using
a flashing OL. The platform overload system
a suitable lifting device. Turn the key switch to
is not operating properly. Refer to Repair
the off position.
Procedure, Calibrate the Platform Overload
System (if equipped).

GCON LCD

PCON LCD

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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 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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Programmed Maintenance Procedures

P0-1 P1-1
Grease the Steer Yokes Inspect the Mast Assembly for
Wear

Genie specifications require that this procedure be

performed every 100 hours of operation. Genie specifications require that this procedure be
Regular application of lubrication to the steer performed every 1000 hours of operation.
yokes is essential to good machine performance Detection of excessive or unusual wear in the
and service life. Continued use of an insufficiently mast assembly is essential for safe machine
greased steer yoke will result in component operation. An unsafe working condition exists if the
damage. mast assembly has excessive wear and/or does
1 Locate the grease fitting on the top of the not operate smoothly, free of hesitation and
steer yoke. binding.

2 Pump multipurpose grease into the steer yoke 1 Remove the mast covers.
until the steer yoke is full and grease is being
forced past the bearings. Repeat this step for
the other steer yoke.
Grease Specifications
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)
or equivalent

GR-15 shown
1 mast cover
2 idler wheel
3 spacer

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Programmed Maintenance Procedures

2 Raise the platform until approximately P1-2

4 inches / 10 cm of each column is visible.
Inspect and Lubricate the Lifting
3 GR-12, GR-15, QS-12R, QS-15R, QS-12W, Chains
QS-15W: Visually inspect the top of each
column for clearance between the roller
wheels and the adjacent column surface.
GR-20, QS-20R, QS-20W: Visually inspect Genie specifications require that this procedure be
the top of each column for clearance between performed every 1000 hours of operation.
the slider block and the adjacent column
surface. Lubricated chains are essential to good machine
performance and safe operation. Extremely dirty
Result: There should be an equal amount of conditions may require that the chains be cleaned
distance between the roller wheel/slider block and lubricated more often.
and the column on each side.
1 Thoroughly inspect the lifting chains. Refer to
Note: If mast inspection results in a measurement Repair Procedure, How to Inspect the Lifting
that is not within specification, refer to Repair Chains.
Procedure, How to Adjust the Glide Pads.
2 Raise the platform to the maximum height.
4 Loosen but do not remove the adjustment nut
on the sequencing cable located at the top of 3 Place a lifting strap from an overhead
the first column. supporting device under the platform. Support
the platform. Do not apply lifting pressure.
5 Raise the platform approximately 3 feet / 1 m
above the top of the drive chassis. Component damage hazard.
The platform railings can be
6 Place a jack stand on the top of the battery damaged if they are used to lift
cover, centered under the platform. Adjust the the platform. Do not attach the
jack stand height to 24 inches / 60 cm. lifting strap to the platform
7 Lower the platform onto the jack stand just railings.
enough to take the weight off the lifting
chains. 4 Lubricate each chain with a dry silicon spray
lubricant.
Crushing hazard. Keep hands
clear of the jack stand when Bodily injury hazard. This
lowering the platform. 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.

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Programmed Maintenance Procedures

P1-3 P2-1
Replace the Hydraulic Return Test or Replace the Hydraulic Oil
Filter

Genie requires that this procedure be performed

Genie specifications require that this procedure be every 2000 hours.
performed every 1000 hours of operation. Replacement or testing of the hydraulic oil is
Replacement of the hydraulic tank return filter is essential for good machine performance and
essential for good machine performance and service life. Dirty oil and a clogged suction strainer
service life. A dirty or clogged filter may cause the or hydraulic filters may cause the machine to
machine to perform poorly and continued use may perform poorly and continued use may cause
cause component damage. Extremely dirty component damage. Extremely dirty conditions
conditions may require that the filter be replaced may require oil changes to be performed more
more often. frequently.
Note: Before replacing the hydraulic oil, the oil
Beware of hot oil. Contact with may be tested by an oil distributor for specific
hot oil may cause severe burns. levels of contamination to verify that changing the
oil is necessary. If the hydraulic oil is not replaced
Note: The hydraulic tank return filter is mounted
at the 2000 hour inspection, test the oil quarterly.
next to the hydraulic tank.
Replace the oil when it fails the test.
1 Clean the area around the return filter.
Note: When removing a hose assembly or fitting,
2 Remove the filter element from the housing. the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
3 Apply a thin layer of fresh oil to the gasket of
torqued to specification during installation. Refer to
the new oil filter.
Specifications, Hydraulic Hose and Fitting Torque
4 Install the new filter element and hand tighten Specifications.
the housing onto the filter head.
Note: Perform this procedure on a firm, level
5 Use a permanent ink marker to write the date surface with the machine in the stowed position.
and number of hours from the hour meter on
the oil filter.
6 Raise the platform to approximately 3 ft / 1 m.
7 Inspect the filter for leaks.
8 Clean up and properly dispose of any oil that
may have spilled during the installation
procedure.

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Programmed Maintenance Procedures

Testing the oil: 7 Install the hydraulic tank and install and
tighten the hydraulic tank retaining fasteners.
1 Complete the hydraulic oil testing with an oil Torque to specification.
distributor.
Torque specifications
If the hydraulic oil passes testing at the
2000 hour maintenance interval, the oil must Hydraulic retaining fasteners, dry 35 in-lbs
be tested every quarter by an oil distributor 4 Nm
until the oil fails the test and is replaced. Hydraulic retaining fasteners, lubricated 26 in-lbs
If the hydraulic oil fails testing at the 2,9 Nm
2000 hour maintenance interval, the oil must 8 Install the hydraulic pump inlet hard line into
be replaced. After the oil has been replaced, the tank. Install the fitting onto the pump and
continue the scheduled quarterly maintenance torque to specification. Refer to
inspection. Specifications, Hydraulic Hose and Fitting
Replacing the hydraulic oil: Torque Specifications.
9 Install the hydraulic pump return hard line into
1 Tag and disconnect the hydraulic tank return
the tank. Install the fitting onto the hydraulic
hard line from the hydraulic filter head and
filter head and torque to specification. Refer to
remove the hard line from the tank. Cap the
Specifications, Hydraulic Hose and Fitting
fitting on the filter head.
Torque Specifications.
Bodily injury hazard. Spraying 10 Fill the tank with the proper hydraulic oil for
hydraulic oil can penetrate and your machine. Refer to Specifications,
burn skin. Loosen hydraulic Hydraulic Specifications.
connections very slowly to allow
the oil pressure to dissipate 11 Activate the pump to fill the hydraulic system
gradually. Do not allow oil to with oil and bleed the system of air.
squirt or spray.
Component damage hazard.
2 Tag and disconnect the hydraulic pump inlet The pump can be damaged if
hard line and remove the hard line from the operated without oil. Be careful
tank. Cap the fitting on the pump. not to empty the hydraulic tank
while in the process of filling the
3 Remove the hydraulic tank retaining fasteners hydraulic system. Do not allow
and remove the hydraulic tank from the the pump to cavitate.
machine.
12 Repeat steps 10 and 11 until the hydraulic
4 Drain all of the oil into a suitable container.
system and tank are both full.
Refer to Machine Specifications, for capacity
information. Note: After the oil has been replaced, continue the
scheduled quarterly maintenance inspection.
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.

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Repair Procedures
Section 4 Repair Procedures

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
Observe and Obey: removed
 Repair procedures shall be completed by a • The red Emergency Stop button in the off
person trained and qualified on the repair of position at both the ground and platform
this machine. controls
 Immediately tag and remove from service a • Wheels chocked
damaged or malfunctioning machine.
• All external AC power supply disconnected
 Repair any machine damage or malfunction from the machine
before operating the machine.
• Platform in the stowed position

Before Repairs Start:

 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 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.

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Repair Procedures

About This Section Symbols Legend

Most of the procedures in this section should only Safety alert symbol—used to alert
be performed by trained service professional in a personnel to potential personal
suitably equipped workshop. Select the injury hazards. Obey all safety
appropriate repair procedure after troubleshooting messages that follow this symbol
the problem. to avoid possible injury or death.

Perform disassembly procedures to the point Indicates a imminently hazardous

where repairs can be completed. Then to re- situation which, if not avoided, will
assemble, perform the disassembly steps in result in death or serious injury.
reverse order.
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.

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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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.

1 red Emergency Stop button P2

2 platform controls circuit board U3
3 proportional control handle and drive/steer
enable switch JC9
4 alarm H1

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Platform Controls

Operational Indicator Codes 1-1

These codes are generated by the electrical Circuit Board
system to indicate machine operating status.
During normal operation, a code will appear in the
platform controls LED readout if a condition such How to Remove the Platform
as off-level, overload cutout, chassis mode Controls Circuit Board
operation or pothole guard stuck occurs.
1 Push in the red Emergency Stop button to the
If the platform controls LED readout displays an off position at both the ground and platform
operational indicator code such as LL, the fault controls.
condition must be repaired or removed before
resuming machine operation. Push in and pull out 2 Disconnect the platform controls from the
the red Emergency Stop button to reset the control cable at the platform.
system. 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
Platform Controls LED Readout alarm.
7 Carefully remove the alarm from the platform
Code Condition
control box.
LL Off-level
OL Platform Overload
CH Chassis Mode Operation
PHS Pothole Guard Stuck
OAC Obstruction Detected (QS models)
CHrgr Charger

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Platform Controls

8 Carefully disconnect all wire harness 1-2

connectors from the platform controls circuit
board.
Joystick
Electrocution/burn hazard.
Contact with electrically charged How to Remove the Joystick
circuits could result in death or 1 Push in the red Emergency Stop button to the
serious injury. Remove all rings, off position at both the ground and platform
watches and other jewelry. controls.
2 Disconnect the platform controls from the
Component damage hazard. control cable at the platform.
Electrostatic discharge (ESD)
can damage printed circuit board 3 Remove the fasteners securing the platform
components. Maintain firm control box to the platform control bracket.
contact with a metal part of the 4 Remove the fasteners securing the bottom
machine that is grounded at all cover to the platform control box. Open the
times when handling printed control box.
circuit boards OR use a
grounded wrist strap. 5 Remove the ties securing the joystick wire
harness.
9 Carefully remove the platform controls circuit
6 Carefully disconnect the joystick wire harness
board fasteners.
from the platform controls circuit board.
10 Carefully remove the platform controls circuit
board from the platform control box. Electrocution/burn hazard.
Contact with electrically charged
11 Remove the transparent caps from the circuits could result in death or
platform controls circuit board and save. serious injury. Remove all rings,
watches and other jewelry.
Circuit board fastener torque specifications
Hand tighten until screws seat < 5 in-lbs
< 0.6 Nm
Component damage hazard.
Electrostatic discharge (ESD)
Note: Before installing a circuit board, place the can damage printed circuit board
transparent caps removed in step 11, over the components. Maintain firm
circuit board buttons. contact with a metal part of the
machine that is grounded at all
Note: After installing the circuit board, check for
times when handling printed
proper button operation. Excessive torque of the
circuit boards OR use a
circuit board fasteners will cause the buttons to
grounded wrist strap.
bind. Moderate torque of the circuit board
fasteners will not allow the buttons to engage.
7 Carefully remove the joystick fasteners.
8 Carefully remove the joystick from the
platform control box.

Torque specifications
Joystick fasteners 9 in-lbs
1 Nm

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Platform Controls

1-3 1-4
Platform Controls Alarm Platform Emergency Stop Button

How to Remove the Platform How to Remove the Platform

Controls Alarm Controls Emergency Stop Button
1 Push in the red Emergency Stop button to the 1 Push in the red Emergency Stop button to the
off position at both the ground and platform off position at both the ground and platform
controls. controls.
2 Disconnect the platform controls from the 2 Disconnect the platform controls from the
control cable at the platform. control cable at the platform.
3 Remove the fasteners securing the platform 3 Remove the fasteners securing the platform
control box to the platform control bracket. control box to the platform control bracket.
4 Remove the fasteners securing the bottom 4 Remove the fasteners securing the bottom
cover to the platform control box. Open the cover to the platform control box. Open the
control box. control box.
5 Disconnect the red and black wires from the
alarm.
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.

6 Carefully remove the alarm from the platform

control box.

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Platform Controls

5 Disconnect the white wires from the

Emergency Stop base.
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.

6 Carefully remove the Emergency Stop base

from the Emergency Stop button.
7 Carefully remove the retaining ring from the
Emergency Stop button.
8 Carefully remove the Emergency Stop button
from the platform control box.

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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 Diagnostic port (if equipped)
10 platform down button
11 lift function enable button
12 platform up button

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Ground Controls

2-1 2 Press the ground control scroll down button.

Software Revision Level Result: The ground control LCD display will
indicate the software revision and hour meter
information. After 5 seconds, the ground
How to Determine the Revision controls LCD display will display machine
Level model and hour meter information again.

The machine software revision level is displayed at 3 Push in the red Emergency Stop button to the
the ground controls LCD display. off position at both the ground and platform
controls and turn the key switch to the off
1 Turn the key switch to the ground controls or position.
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.

Result: The display at the ground controls will

show the machine model and hour meter
information. After 3 seconds, the machine a ground control LCD display
model will not show on the display. See
b ground control scroll down button
example below.

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Ground Controls

2-2 2 Press and hold the ground control scroll up

and scroll down buttons.
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.
Ground Control Menu Buttons
Tip-over hazard. Do not adjust
function speeds higher than 1 scroll down button
specified in this procedure. 2 enter button
Setting the function speeds 3 scroll up button
greater than specifications could 4 escape button
cause the machine to tip over 5 LCD display
resulting in death or serious
injury. 3 Pull out the red Emergency Stop button to the
on position at the ground controls.
Tip-over hazard. This procedure Result: The ground controls LCD display will
must only be performed by a show the following:
trained service professional.
Attempting this procedure
without the necessary skills
could result in death or serious
injury.

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

4 Use the ground control menu buttons to select
of obstructions.
machine Model, Options and Speed Setup
1 Turn the key switch to ground controls. parameters. Follow the menu structure
indicated on the ground control LCD display.

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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 Procedure 2
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 2
1 X axis
2 Y axis
Procedure 1

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Ground Controls

How to Install and Calibrate the 4 Place the level sensor onto the level sensor
Level Sensor - Procedure 1 base with the "X" on the level sensor closest
to the mast of the machine and the "Y" on the
Tip-over hazard. Failure to install level sensor closest to the steer end of the
or calibrate the level sensor as machine.
instructed will compromise
Tip-over hazard. The level
machine stability and cause the
sensor must be installed with the
machine to tip over, resulting in
"X" on the level sensor base
death or serious injury. Do not
closest to the mast of the
install or calibrate the level
machine. Failure to install the
sensor other than specified in
level sensor as instructed could
this procedure.
result in the machine tipping
1 Move the machine to an area that has a firm, over causing death or serious
level surface and is free of obstructions. injury.

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.

1 drive chassis
2 level sensor
3 X axis
4 mast

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Ground Controls

5 Install the level sensor retaining fasteners 8 Turn the key switch to the ground control and
through the level sensor and springs, and into pull out the red Emergency Stop button to the
the mount bracket. Tighten the fasteners and on position at the ground controls.
measure the distance between the level
Result: The tilt sensor alarm should not
sensor and the level sensor mount bracket.
sound.
Result: The measurement should be
9 Center a lifting jack under the drive chassis at
approximately 0.375 inch / 10 mm.
the ground controls side of the machine.
6 Connect the chassis wire harness to the level
10 Raise the machine approximately 2 inches /
sensor wire harness.
5 cm. Place blocks under both wheels.
7 Adjust the level sensor retaining fasteners
GR-12, GR-15, QS-12R, QS-15R, QS-12W,
until the bubble at the top of the level sensor
QS-15W: Place a 0.65 x 6 x 6 inch / 1.65 x
is centered in the circles.
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.
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.
1 adjustment fastener
2 calibration circle
3 ground controls

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Ground Controls

16 Raise the machine approximately 2 inches / 26 Raise the platform to approximately 1 ft /

5 cm. Place blocks under both wheels. 30 cm.
GR-12, GR-15, QS-12R, QS-15R, QS-12W, Result: The level sensor alarm should not
QS-15W: Place a 0.79 x 6 x 6 inch / 2 x 15 x sound.
15 cm thick steel block under both wheels at
Result: The level sensor alarm does sound.
the hydraulic side of the machine.
The level sensor is faulty and must be
GR-20, QS-20R, QS-20W: Place a 0.85 x 6 x replaced. Repeat this procedure beginning
6 inch / 2.16 x 15 x 15 cm thick steel block with step 1.
under both wheels at the hydraulic tank side
27 Raise the machine approximately 2 inches /
of the machine.
5 cm. Remove the blocks from under both
17 Lower the machine onto the blocks. wheels..
18 Raise the platform to approximately 1 ft / 28 Lower the machine and remove the jack.
30 cm.
29 Center a lifting jack under the drive chassis at
Result: The platform should stop, an alarm the non-steer end of the machine.
should sound and fault code LL appears in
30 Raise the machine approximately 2 inches /
the diagnostic display.
5 cm.
Result: The platform does not stop or the level
31 Place a 2.4 x 6 x 6 inch / 6.1 x 15 x 15 cm
sensor alarm does not sound. Adjust the level
thick steel block under both wheels at the
sensor until the alarm just begins to sound
non-steer end of the machine.
OR the down limit switch may need to be
adjusted. 32 Raise the platform to approximately 1 ft /
30 cm.
19 Lower the platform to the stowed position.
Result: The platform should stop, an alarm
20 Raise the machine approximately 2 inches /
should sound and fault code LL appears in
5 cm. Remove the blocks from under both
the diagnostic display.
wheels..
Result: The platform does not stop or the level
21 Lower the machine and remove the jack.
sensor alarm does not sound. The level
22 Center a lifting jack under the drive chassis at sensor is faulty and must be replaced. Repeat
the steer end of the machine. this procedure beginning with step 1.
23 Raise the machine approximately 2 inches / 33 Lower the platform to the stowed position.
5 cm.
34 Raise the machine approximately 2 inches /
24 Place a 2.18 x 6 x 6 inch / 5.54 x 15 x 15 cm 5 cm. Remove the blocks from under both
thick steel block under both wheels at the wheels..
steer end of the machine.
35 Lower the machine and remove the jack.
25 Lower the machine onto the blocks.

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Ground Controls

How to Install and Calibrate the 4 Place the new level sensor on to the level
Level Sensor - Procedure 2 sensor bracket with the "X" on the level
sensor towards the steer end of the machine.
Tip-over hazard. Failure to install
Tip-over hazard. Failure to install
the level sensor as instructed
the level sensor as instructed,
will compromise machine
could result in the machine
stability and cause the machine
tipping over, causing death or
to tip over, resulting in death or
serious injury.
serious injury. Do not install the
level sensor other than specified
in this procedure. Steer End

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.

Non-steer End
1 drive chassis
2 X axis
3 level sensor
4 mast

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Ground Controls

5 Install the level sensor retaining fasteners 10 Pull out the red Emergency Stop button to the
through the level sensor and springs. Secure on position at the ground controls.
the level sensor assembly to the machine.
Result: The ground controls LCD display will
6 Connect the chassis wire harness to the level show the following:
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. 11 Release the Scroll Up and Scroll Down
buttons after the ground controller powers up.
8 Push in the red Emergency Stop button to the
off position at the ground controls. 12 Use the Scroll Up or Scroll Down buttons to
scroll to Select Option.
9 Press and hold the ground control scroll up
and scroll down buttons.

13 Press the enter button.

14 Use the Scroll Up or Scroll Down buttons to
scroll to Tilt Sensor.

Ground Control Menu Buttons

1 scroll down button
15 Press the enter button.
2 enter button
3 scroll up button
4 escape button
5 LCD display

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Ground Controls

16 Press and hold the Enter button to start 20 Continue driving the machine up the ramp
calibration. until it is just over 3°.

Result: An audible alarm will sound when Result: An audible alarm is heard and Fault
calibration is complete. LL is displayed.

Note: The machine will not calibrate if it is on a Result: An audible alarm is not heard and
slope of one degree or greater. Fault LL is not displayed. Repeat this
procedure starting at step 8 on a firm level
Note: If the level sensor has been replaced, surface.
continue with step 24. If the level sensor was not
21 Drive the non-steer end of the machine up a
replaced skip to step 27.
ramp until it is just under 3°.
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.

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.
19 Drive the steer end of the machine up a ramp
until it is just under 3°.
Result: No audible alarm is heard.
22 Continue driving the machine up the ramp
Result: An audible alarm is heard and Fault until it is just over 3°.
LL is displayed. Repeat this procedure
starting at step 8 on a firm level surface. 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.

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Ground Controls

23 Place a digital level on the steer end of the 26 Drive the hydraulic tank side of the machine
drive chassis. Zero out the digital level. onto a ramp until it is just under 1.5°.
24 Drive the ground control side of the machine Result: No audible alarm is heard.
onto a ramp until it is just under 1.5°.
Result: An audible alarm is heard and Fault
Result: No audible alarm is heard. LL is displayed. Repeat this procedure
starting at step 8 on a firm level surface.
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°.
25 Continue driving the machine onto the ramp Result: An audible alarm is heard and Fault
until it is just over 1.5°. LL is displayed.
Result: An audible alarm is heard and Fault Result: An audible alarm is not heard and
LL is displayed. Fault LL is not displayed. Repeat this
procedure starting at step 8 on a firm level
Result: An audible alarm is not heard and surface.
Fault LL is not displayed. Repeat this
procedure starting at step 8 on a firm level 28 Lower the platform to the stowed position.
surface.

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Hydraulic Pump

3-1 4 Activate the platform up function in one

second intervals from the ground controls until
Function Pump the pressure gauge reaches 3200 psi /
221 bar.
The hydraulic pump is attached to the motor which
makes up the hydraulic power unit. Result: If the pressure gauge reads 3200 psi /
221 bar, immediately stop. The pump is good.
How to Test the Hydraulic Pump Result: If the pressure gauge fails to reach
3200 psi / 221 bar, the pump is bad and will
Note: When removing a hose assembly or fitting, need to be serviced or replaced.
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be Component damage hazard.
torqued to specification during installation. Refer to There is no relief valve in the
Specifications, Hydraulic Hose and Fitting Torque hydraulic pump and the pump
Specifications. can be damaged if the pressure
is allowed to exceed
1 Tag, disconnect and plug the high pressure 3200 psi / 221 bar. When testing
hydraulic hose from the hydraulic pump. the pump, activate the pump in
one second intervals until
Bodily injury hazard. Spraying
3200 psi / 221 bar is confirmed.
hydraulic oil can penetrate and
Do not over-pressurize the
burn skin. Loosen hydraulic
pump.
connections very slowly to allow
the oil pressure to dissipate
5 Remove the pressure gauge and reconnect
gradually. Do not allow oil to
the hydraulic hose. Torque to specifications.
squirt or spray.
Bodily injury hazard. Spraying
2 Connect a 0 to 5000 psi / 0 to 350 bar hydraulic oil can penetrate and
pressure gauge to the high pressure port on burn skin. Loosen hydraulic
the pump. connections very slowly to allow
3 Turn the key switch to ground control and pull the oil pressure to dissipate
out the red Emergency Stop button to the on gradually. Do not allow oil to
position at both ground and platform controls. squirt or spray.

Part No. 1275811GT GR™ • QS™R • QS™W 53

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Hydraulic Pump
How to Remove the Hydraulic Pump

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.
1 Tag, disconnect and plug the hydraulic tank
hard line from the pump. Cap the fitting on the
pump.
2 Tag, disconnect and plug the high pressure
hose from the pump. Cap the fitting on the
pump.
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.

3 Remove the pump mounting bolts. Carefully

remove the pump.
Tip-over hazard. After replacing
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 resulting in
death or serious injury.

54 GR™ • QS™R • QS™W Part No. 1275811GT

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Function Manifold

4-1
Function Manifold Components
The function manifold is mounted next to the hydraulic power unit.

Index No. Description Schematic Item Function Torque

— Coil nut (items E, F, and H) — — 5 ft-lbs / 7 Nm
1 Diagnostic port A Test port —
2 Check disc B Steer circuit 18 ft-lbs / 24 Nm
Relief valve, 1800 to 3500 psi / 124 to
3 C Lift relief 20 ft-lbs / 27 Nm
241 bar
4 Check valve, 10 psi / 0,7 bar D Drive circuit 20 ft-lbs / 27 Nm
Drive
5 Solenoid valve, 3 position 4 way E 25 ft-lbs / 34 Nm
forward/reverse
6 Solenoid valve, 3 position 4 way F Steer left/right 25 ft-lbs / 34 Nm
7 Flow regulator and relief valve, G Steer circuit 26 ft-lbs / 35 Nm
0.75 gpm / 2,8 L/min
1500 psi / 103 bar
8 Solenoid valve, 2 position 4 way H Platform up 25 ft-lbs / 34 Nm
9 Relief valve, 3500 psi / 241 bar maximum I System relief 20 ft-lbs / 27 Nm

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Function Manifold

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

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Function Manifold

4-2 3 Chock both sides of the wheels at the steer

end of the machine.
Valve Adjustments - Function
Manifold 4 Remove the platform controls from the
platform.
Note: Perform this test from the ground with the 5 Turn the key switch to platform controls and
platform controls. Do not stand in the platform. pull out the red Emergency Stop button to the
on position at both ground and platform
Note: Verify the hydraulic oil level is at the FULL
controls.
mark on the hydraulic tank.
6 Move and hold the joystick fully in either
direction while observing the pressure reading
How to Adjust the System Relief on the pressure gauge. Note the pressure.
Valve Refer to Specifications, Hydraulic Component
Specifications.
1 Locate the system relief valve on the function
manifold. 7 Turn the machine off. Hold the system relief
valve with a wrench and remove the cap.
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.

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.

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Function Manifold

How to Adjust the Platform Lift 5 Remove the platform controls from the
platform.
Relief Valve
6 Hold the lift relief valve with a wrench and
Note: Verify the system relief is adjusted correctly
remove the cap (schematic item
before performing this procedure.
7 While activating the platform up function,
Note: Perform this test from the ground with the adjust the internal hex socket clockwise, just
platform controls. Do not stand in the platform. until the platform fully rises.
Note: Verify the hydraulic oil level is at the FULL 8 Fully lower the platform to the stowed
mark on the hydraulic tank. position.
1 Locate the lift relief valve on the function 9 Add an additional 50 pounds / 22,7 kg to the
manifold. 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.
11 Install the relief valve cap.
12 Remove the weight from the platform.

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.
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.

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Function Manifold

How to Adjust the Steer Relief 3 Remove the platform controls from the
platform.
Valve
4 Turn the key switch to platform controls and
Note: Perform this test from the ground with the
pull out the red Emergency Stop button to the
platform controls. Do not stand in the platform.
on position at both ground and platform
Note: Verify the hydraulic oil level is at the FULL controls.
mark on the hydraulic tank. 5 Activate the function enable switch and press
1 Locate the steer relief valve on the function and hold the steer thumb rocker switch to the
manifold. 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.
7 Turn the machine off. Hold the steer relief
valve with a wrench and remove the cap.
8 Adjust the internal hex socket. Turn it
clockwise to increase the pressure or
counterclockwise to decrease the pressure.
1 test port Component damage hazard. Do
2 steer relief valve not adjust the relief valve
2 Connect a 0 to 5000 psi / 0 to 350 bar pressures higher than
pressure gauge to the test port on the function specifications.
manifold.
9 Install the relief valve cap.
10 Repeat steps 5 and 6 to confirm the relief
valve pressure.

Part No. 1275811GT GR™ • QS™R • QS™W 59

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Function Manifold

4-3 Valve Coil Resistance

Valve Coils Specification
Note: The following coil resistance specifications
How to Test a Coil are at an ambient temperature of 68°F / 20°C. As
valve coil resistance is sensitive to changes in air
A properly functioning coil provides an temperature, the coil resistance will typically
electromagnetic force which operates the solenoid increase or decrease by 4% for each 18°F / 10°C
valve. Critical to normal operation is continuity that your air temperature increases or decreases
within the coil. Zero resistance or infinite from 68°F / 20°C.
resistance indicates the coil has failed.
Description Specification
Since coil resistance is sensitive to temperature,
resistance values outside specification can Solenoid valve, 3 position 4 way, 27.2Ω
produce erratic operation. When coil resistance 20V DC with diode (schematic item E)
decreases below specification, amperage
Solenoid valve, 3 position 4 way, 19Ω
increases. As resistance rises above specification, 20V DC with diode (schematic item F)
voltage increases.
Solenoid valve, 2 position 4 way, 25Ω
While valves may operate when coil resistance is 20V DC with diode (schematic item H)
outside specification, maintaining coils within Solenoid valve, 2 position 2 way, 6.25Ω
specification will help ensure proper valve function N.C. 20V DC with diode (schematic item
over a wide range of operating temperatures. N)

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

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.

60 GR™ • QS™R • QS™W Part No. 1275811GT

February 2022 Service Manual

Function Manifold

How to Test a Coil Diode Note: If testing a single terminal coil, connect the
negative lead to the internal metallic ring at either
Genie incorporates spike suppressing diodes in all end of the coil.
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.

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

1 Test the coil resistance. Refer to Repair

Procedure, How to Test a Coil.
1 multimeter
2 Connect a 10Ω resistor to the negative 2 9V DC battery
terminal of a known good 9V DC battery. 3 10Ω resistor
Connect the other end of the resistor to a 4 coil
terminal on the coil.
Note: Dotted lines in illustration indicate a reversed
Note: The battery should read 9V DC or more connection as specified in step 6.
when measured across the terminals.
5 Momentarily connect the positive lead from
Resistor, 10Ω the multimeter to the positive terminal on the
Genie part number 27287 9V battery. Note and record the reading.
3 Set a multimeter to read DC amperage. 6 At the battery or coil terminals, reverse the
connections. Note and record the current
Note: The multimeter, when set to read DC reading.
amperage, should be capable of reading up to
800 mA. Result: Both current readings are greater than
0 mA and are different by a minimum of 20%.
4 Connect the negative lead to the other The coil is good.
terminal on the coil.
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.

Part No. 1275811GT GR™ • QS™R • QS™W 61

Service Manual February 2022

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.

Index No. Description Schematic Item Function Torque

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

62 GR™ • QS™R • QS™W Part No. 1275811GT

February 2022 Service Manual

Hydraulic Tank

6-1 3 Remove the hydraulic tank retaining fasteners

and remove the hydraulic tank from the
Hydraulic Tank machine.
The primary functions of the hydraulic tank are to 4 Remove the hydraulic tank cap and drain the
cool and deaerate the hydraulic fluid during tank into a suitable container.
operation. It utilizes internal suction strainers for
the pump supply lines and has an external return Torque specifications
line filter.
Hydraulic retaining fasteners, dry 35 in-lbs
4 Nm
How to Remove the Hydraulic Hydraulic retaining fasteners, lubricated 26 in-lbs
2.9 Nm
Tank
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.

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.
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.
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.

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.

Part No. 1275811GT GR™ • QS™R • QS™W 63

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Non-Steer Axle Components

7-1 7 Tag, disconnect and plug the hydraulic hose

from the brake. Cap the fitting on the brake.
Drive Brake
Bodily injury hazard. Spraying
How to Remove the Drive Brake hydraulic oil can penetrate and
burn skin. Loosen hydraulic
Note: When removing a hose assembly or fitting, connections very slowly to allow
the O-ring (if equipped) on the fitting and/or hose the oil pressure to dissipate
end must be replaced. All connections must be gradually. Do not allow oil to
torqued to specification during installation. Refer to squirt or spray.
Specifications, Hydraulic Hose and Fitting Torque
Specifications. 8 Place a lifting jack under the brake for
support.
1 Block the steer wheels.
9 Remove the fasteners that attach the brake to
2 Remove the cotter pin from the wheel castle
the drive chassis. Remove the brake.
nut.
Note: Always replace the cotter pin with a new one Crushing hazard. The brake will
when removing the castle nut. fall if not properly supported
when the mounting fasteners are
3 Loosen the wheel castle nut. Do not remove removed.
it.
4 Center a lifting jack under the drive chassis at
the non-steer end of the machine. Torque specifications
Brake mounting fasteners, dry 75 ft-lbs
5 Raise the machine approximately 2 inches / 102 Nm
5 cm. Place blocks under the chassis for
support. Brake mounting fasteners, lubricated 56 ft-lbs
76 Nm
Crushing hazard. The chassis
will fall if not properly supported.

6 Remove the wheel castle nut. Remove the

wheel.

64 GR™ • QS™R • QS™W Part No. 1275811GT

February 2022 Service Manual

Steer Axle Components

8-1 7 Tag, disconnect and plug the hydraulic hoses

on the drive motor. Cap the fittings on the
Yoke and Drive Motor drive motor.

How to Remove the Yoke and Bodily injury hazard. Spraying

hydraulic oil can penetrate and
Drive Motor burn skin. Loosen hydraulic
Note: When removing a hose assembly or fitting, connections very slowly to allow
the O-ring (if equipped) on the fitting and/or hose the oil pressure to dissipate
end must be replaced. All connections must be gradually. Do not allow oil to
torqued to specification during installation. Refer to squirt or spray.
Specifications, Hydraulic Hose and Fitting Torque
Specifications. Component damage hazard.
Hoses can be damaged if they
1 Block the non-steer tires. are kinked or pinched.
2 Remove the cotter pin from the wheel castle
8 Support and secure the yoke assembly to an
nut.
appropriate lifting device.
Note: Always replace the cotter pin with a new one
9 Remove the retaining fastener from the steer
when removing the castle nut.
link at the yoke assembly.
3 Loosen the wheel castle nut. Do not remove Note: While removing the retaining fasteners, take
it. note of the quantity and location of the spacers
4 Center a lifting jack under the drive chassis at when disconnecting the steer link from the yoke
the steer end of the machine. assembly.
5 Raise the machine approximately 6 inches / 10 Remove the retaining fastener from the top of
15 cm. Place blocks under the chassis for the yoke pivot shaft.
support.
Note: The pivot shaft retaining fastener is located
Crushing hazard. The chassis above the main deck.
will fall if not properly supported.
11 Lower the yoke assembly out of the chassis.
6 Remove the wheel castle nut. Remove the Bodily injury hazard. The yoke
wheel. assembly may fall if not
properly supported when it is
removed from the machine.

Part No. 1275811GT GR™ • QS™R • QS™W 65

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Steer Axle Components

How to Remove a Drive Motor 8-2

1 Block the non-steer tires. Steer Cylinder
2 Remove the cotter pin from the wheel castle
nut of the motor to be removed. How to Remove the Steer
3 Note: Always replace the cotter pin with a new Cylinder
one when removing the castle nut.
Note: When removing a hose assembly or fitting,
4 Loosen the wheel castle nut. Do not remove the O-ring (if equipped) on the fitting and/or hose
it. end must be replaced. All connections must be
5 Raise the machine approximately 2 inches / torqued to specification during installation. Refer to
5 cm. Place blocks under the chassis for Specifications, Hydraulic Hose and Fitting Torque
support. Specifications.

Crushing hazard. The chassis 1 Block the non-steer tires.

will fall if not properly supported. 2 Remove the steer cylinder hose guard bracket
from the machine.
6 Remove the wheel castle nut. Remove the
wheel. 3 Remove the pin retaining fasteners from the
steer cylinder pivot pins. Remove the pins.
7 Tag, disconnect and plug the hydraulic hoses
on the drive motor. Cap the fittings on the Note: While removing the pin retaining fasteners,
drive motor. take note of the quantity and location of the
spacers when removing the pivot pin.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and 4 Remove the steer cylinder from the machine.
burn skin. Loosen hydraulic 5 Tag, disconnect and plug the hydraulic hoses
connections very slowly to allow from the steer cylinder. Cap the fittings on the
the oil pressure to dissipate cylinder.
gradually. Do not allow oil to
squirt or spray. Bodily injury hazard. Spraying
hydraulic oil can penetrate and
Component damage hazard. burn skin. Loosen hydraulic
Hoses can be damaged if they connections very slowly to allow
are kinked or pinched. the oil pressure to dissipate
gradually. Do not allow oil to
8 Remove the drive motor mounting fasteners. squirt or spray.
Remove the motor.
Component damage hazard.
Torque specifications Hoses can be damaged if they
Drive motor mounting fasteners, dry 75 ft-lbs are kinked or pinched.
101,7 Nm
Drive motor mounting fasteners, 56 ft-lbs
lubricated 76,3 Nm

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Steer Axle Components

8-3
Tie Rod
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.
Crushing hazard. The chassis
will fall if not properly supported.

4 Fully turn the yokes in either direction.

5 Remove the fasteners securing the tie rod to
the steer yoke.
Note: Note the quantity and location of the spacers
between the tie rod and the steer links.
6 Fully turn the yokes in the opposite direction.
7 Remove the fasteners securing the tie rod to
the steer yoke.
Note: Note the quantity and location of the spacers
between the tie rod and the steer links.
8 Remove the tie rod from the machine.
Note: Apply removable thread locker to the
retaining fasteners.
Torque = 31 ft-lbs / 42 Nm.

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Platform Components

9-1 8 Remove the fasteners securing the junction

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

How to Remove the Platform 9 Attach a lifting strap of suitable capacity from
an overhead supporting device and center it
Perform this procedure with the platform extension around the platform railing. Support the
fully retracted and locked in position. platform. Do not apply any lifting pressure.
1 Raise the platform to approximately 1 ft / 10 Remove the fasteners securing the platform
30 cm. mount to the mast and set the fasteners to the
side. Remove the platform and mount from
2 Place support blocks between the platform the machine.
and the drive chassis. Lower the platform onto
the blocks. Crushing hazard. The platform
will fall if not properly supported.
Crushing hazard. Keep hands
clear when lowering the
platform.

3 Turn the key switch to the off position and

push in the red Emergency Stop button to the
off position at the ground controls.
4 Disconnect the battery pack from the
machine.
Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.

5 Disconnect the platform controls from the

control cable at the platform.
6 Remove the platform controls from the
platform.
7 Cut and discard the cable ties securing the
control cable to the platform.
Component damage hazard. The
control cable can be damaged if
cut while removing the cable ties.

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Platform Components

9-2 5 Remove the fasteners securing the white slide

blocks to the main deck. Set the slide blocks
Platform Extension Deck and the fasteners to the side.
(if equipped)
6 Activate the foot release latch and slide the
extension platform out of the platform.
How to Remove the Platform Extension Deck, GR Models

How to Remove the Platform

Extension Deck, GR Models
1 Turn the key switch to the off position and
push in the red Emergency Stop button to the
off position at the ground controls.
2 Disconnect the battery pack from the
machine.
Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.

3 Disconnect the platform controls from the

control cable at the platform, and remove the
platform controls from the platform and set
aside.
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.

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

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

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Mast Components

10-1 5 Tag, disconnect and plug the lift cylinder

hoses at the function manifold. Cap the
Mast fittings.
How to Remove the Mast Assembly

How to Remove the Mast Bodily injury hazard. Spraying

hydraulic oil can penetrate and
Assembly burn skin. Loosen hydraulic
Bodily injury hazard. This connections very slowly to allow
procedure requires specific repair the oil pressure to dissipate
skills, lifting equipment and a gradually. Do not allow oil to
suitable workshop. Attempting squirt or spray.
this procedure without these
skills and tools could result in 6 Remove the fasteners securing the lower rear
death or serious injury and access cover to the chassis and remove the
significant component damage. cover. Set the cover and the fasteners to the
Dealer service is strongly side.
recommended. 7 Tag and disconnect the wire harness from the
platform down valve coil at the base of the lift
Note: When removing a hose assembly or fitting, cylinder.
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be 8 Remove the retaining nut securing the
torqued to specification during installation. Refer to platform down coil to the platform down
Specifications, Hydraulic Hose and Fitting Torque solenoid valve and remove the coil. Set the
Specifications. coil and retaining nut to the side.

Note: Perform this procedure on a firm, level 9 Remove the platform down solenoid valve
surface with the machine in the stowed position. from the lift cylinder. Set the valve to the side
and plug the cylinder port.
1 Remove the Platform. Refer to Repair
Procedure, How to Remove the Platform. Bodily injury hazard. Spraying
hydraulic oil can penetrate and
2 Tag and disconnect the power to platform burn skin. Loosen hydraulic
wire harness at the quick disconnect near the connections very slowly to allow
Electronic Control Module (ECM). the oil pressure to dissipate
gradually. Do not allow oil to
3 Tag and disconnect the ECM wire harness at
squirt or spray.
the quick disconnect near the ECM.
4 Attach a lifting strap from an overhead 10 Remove the mast retaining fasteners.
supporting device to the lifting eye at the top
of the mast. Support the mast. Do not apply
any lifting pressure.
Note: Maximum mast weight is 350 lbs / 160 kg.

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11 Carefully pull the hydraulic hoses free while

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

Component damage hazard.

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

12 Place the mast assembly on a suitable

structure capable of supporting it.

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Mast Components
How to Disassemble the Mast

How to Disassemble the Mast

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.

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.

1 top of number 1 column

2 clevis block (not shown)
3 clevis block fastener
4 lift cylinder (not shown)

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4 Remove the lift cylinder barrel end mounting 9 Slide the carriage toward the top of the mast
fasteners. assembly enough to remove the tension on
the lifting chains.
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.
1 cylinder mounting plate
2 cylinder 15 Remove the adjustment nuts from the chain
3 cylinder mounting bolt
tension rocker on the column.
4 plate mounting fasteners 16 Remove the column by sliding the column out
the bottom of the mast.
5 Loosen the lift cylinder mounting bracket
fasteners. 17 Push the next column toward the top of the
mast to access the idler wheel assembly
6 Support the cylinder and carefully slide it out mounting fasteners.
of the mast assembly.
18 Hold the idler wheel axle from turning by
Crushing hazard. The lift placing a screwdriver through the hole in the
cylinder will become unbalanced axle. Remove the axle mounting fasteners,
and fall if not properly supported and remove the idler wheel assembly.
and secured to the lifting device.
19 Remove the adjustment nuts from the chain
7 Remove the cover from the top of each tension rocker on the column.
column. 20 Slide the column out the bottom of the mast.
8 Remove the adjustment nuts from all of the 21 Repeat steps 17 through 20 for each
sequencing cables. remaining column.
Note: If the chains are to be removed, mark the
location and label each chain before removal.

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Mast Components
How to Assemble the Mast

How to Assemble the Mast 10 Lay the number 3 column chains on the floor.

Bodily injury hazard. This Note: Do not allow the chains to become twisted or
procedure requires specific repair dirty.
skills, lifting equipment and a 11 Lay the number 2 column chains inside the
suitable workshop. Attempting number 3 column.
this procedure without these
skills and tools could result in 12 Follow steps 4 through 11 for each remaining
death or serious injury and column and the carriage.
significant component damage. 13 After all the columns are assembled, the idler
Dealer service is strongly wheel assemblies can be installed.
recommended.
14 Remove the tension from the lifting chains on
1 Thoroughly clean all columns. the number 2 column by pushing the number
3 column towards the top of the mast.
2 Secure the number 1 column to the work table
and lay the chains out on the floor. 15 Install the idler wheel assembly in the top of
the number 2 column. Tighten the mounting
Note: Do not allow the chains to become twisted or
fasteners.
dirty.
Note: Confirm that all idler wheels rotate smoothly
3 Apply a generous amount of Boelube® wax to with no excessive side movement, or rub on the
the inside and outside channels of each inside of the column. Replace worn shims if
column. necessary.
4 Slide the number 2 column into the number
16 Repeat steps 14 and 15 for each remaining
1 column.
idler wheel assembly.
5 Lay the number 2 column chains on the floor.
17 Confirm that all of the idler wheel axle
Note: Do not allow the chains to become twisted or mounting fasteners are flush with the column.
dirty.
Component damage hazard.
6 Lay the number 1 column chains inside the The roller wheels may be
number 2 column. damaged if the idler wheel axle
mounting fasteners are not flush
7 Slide the number 3 column into the number with the column.
2 column.
8 When the number 3 column is almost all the 18 Install the mast assembly on the drive
way in, guide the number 1 column chains chassis. Adjust the lifting chains. Refer to
into the chain tension rocker on the number Repair Procedure, How to Adjust the Lifting
3 column. Chains.
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.

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Mast Components

10-2 10-3
Glide Pads Lifting Chains
Glide pads, used on the GR-12, GR-15, QS-12R,
QS-15R, QS-12W and QS-15W, and wear pads How to Adjust the Lifting Chains
used on the GR-20, QS-20R and QS-20W, are
1 Mark the column to be adjusted.
used to provide a uniform fit between the columns
as the mast extends and retracts. Over time, it 2 Raise the platform approximately 6 feet / 2 m.
may be necessary to adjust the glide pads to
ensure good machine performance. 3 Place a lifting strap of suitable capacity from
an overhead crane under the platform.
Wear pads are not adjustable and do not require Support the platform. Do not apply any lifting
servicing on the GR-20, QS-20R and QS-20W. pressure.
Component damage hazard.
How to Adjust the Glide Pads The platform railings can be
damaged if they are used to lift
1 Locate the upper and lower glide pad the platform. Do not attach the
adjustment bolts below each upper roller bolt, lifting strap to the platform
on both sides of each column. railings.
2 Hold the glide pad adjustment bolt and loosen
the lock nut on all glide pads. Turn the adjustment lock nuts evenly on both sides
of the chain tension rocker clockwise to raise the
3 Turn the glide pad adjustment bolt clockwise column or counterclockwise to lower the column.
until the glide pad makes contact with the
column. Adjust the glide pads on both sides of Note: The chain tensioner rocker is located near
all columns. Be sure the sides of the columns the bottom of each column.
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.
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.

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Mast Components

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

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Mast Components
How to Inspect the Lifting Chains

How to Inspect the Lifting Chains

Inspection Procedure Inspection Failure Inspection Remedy

Wear Count out 16 chain links and When the length of the Replace both chains on that
measure pin to pin 16 links (pin to pin) measure column. Replace entire
centerline dimension with a more than 8.25 inches / chain. Do not repair just the
steel measuring tape. 21 cm for 1/2 inch / 12.7mm affected portion of the chain.
chain or 10.31 inches /
26.1 cm for 5/8 inch /
15.9 mm chain.
Note: Measure a section of
chain that moves over the
idler wheels.
Rust and Corrosion Visually inspect the chains Evidence of rust or Remove chain and inspect
for rust and corrosion. corrosion. 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 When external surfaces are Lubricate chain with motor
for lubrication. not protected with a layer of oil (SAE 40W).
oil.
Tight Joints Inspect chain link joints for Joints that do not flex freely If rust and corrosion is
easy movement. or are binding. found, refer to Failure
Remedy for rust and
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.

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Mast Components

Inspection Procedure Inspection Failure Inspection Remedy

Raised or Turned Pins Visually inspect for raised Raised pins. Replace both chains on that
pins. column section. Do not
repair just the affected
portion of the chain.

Visually inspect for turned Misalignment of flats on all Replace both chains on that
pins by insuring all the flats "V" heads. column section. Do not
on the "V" heads are repair just the affected
aligned. portion of the chain.
Chain Side Visually inspect for wear Wear on pin heads or Replace both chains on that
patterns on heads of link noticeable wear in the column section. Do not
pins and outside link plates profile of the outside link repair just the affected
where they contact the idler plate. portion of the chain.
wheel.
Check alignment of chain
anchors and idler wheels.

link plate wear

Chain Anchors Visually inspect chain Broken chain anchor Replace chain anchor.
anchors. fingers.
Bent or damaged anchor. Replace chain anchor.
Twisted or misaligned chain Re-align chain anchor to
anchor. ensure even loading of
chain.
Threaded rod not visible in Replace chain anchor and
chain anchors threaded rod inspection hole. threaded rod.
Idler Wheels Visually inspect chain idler Idler wheels have badly Replace idler wheel and
wheels. worn flanges. check chain alignment.
Idler wheels have grooves Replace idler wheel.
worn into chain contact
surface.

idler wheel
Cracked Link Plates Visually inspect chain link Cracks in any chain link Replace both chains on that
plates for cracks. plate. column section. Replace
entire chain. Do not repair
just the affected portion of
the chain.

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Repair Procedures

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

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.

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.
Crushing hazard. The lift
cylinder could become
unbalanced and fall if not
properly supported and secured
to the 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
8 manual lowering valve

80 GR™ • QS™R • QS™W Part No. 1275811GT

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Platform Overload Components

11-1 Confirm the setting:

Platform Overload System 5 Using a suitable lifting device, lift the
additional test weight from the platform.
How to Calibrate the Platform 6 Pull out the red Emergency Stop button to the
Overload System on position at the ground controls.

Note: Perform this procedure with the machine on Result: The LCD display at the ground
a firm, level surface with all weight, tools and controls show the hour meter information,
equipment removed from the platform. indicating a normal condition.

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

QS-15R, QS-15W
Maximum platform capacity 500 lbs / 227 kg
Additional weight 100 lbs / 45 kg
GR-20, QS-20R, QS-20W
Maximum platform capacity 350 lbs / 159 kg
Additional weight 70 lbs / 31 kg
Note: The combined weight must not exceed 20%
of the maximum rated load.
1 Using a suitable lifting device, place an
appropriate test weight equal to that of the
maximum platform capacity at the center of
the platform floor.
2 Using a suitable lifting device, place additional
weight in the platform.
3 Raise the platform to approximately 3 ft / 1 m.
Result: No error codes are displayed and
functions operate normally. Begin shaking the
platform gently by hand while slowly turning
the load spring adjustment nut
counterclockwise until the alarm sounds and
the LCD at the ground controls shows “OL
Platform Overload”. Push in the red
Emergency Stop button to the off position.
Calibration is complete.
Result: The platform stops, the LCD display at
the ground controls shows “OL Platform
Overloaded”. Turn the load spring adjustment
nut clockwise three full turns. Push in the red
Emergency Stop button to the off position.
Repeat step 3.
4 Do not lower the platform after calibration.

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Platform Overload Components

7 Add the additional test weight to the platform. 11-2

Result: The LCD display at the ground Platform Overload Recovery
controls show "OL: Platform Overloaded". The Message
platform overload system is operating
properly. If the ground controls LCD screen displays OL:
PLATFORM OVERLOADED, the emergency
lowering system has been used while the platform
was overloaded.

How to Clear the Platform

Result: The LCD display at the ground Overload Recovery Message
controls show the hour meter information. The
platform overload system is not operating Note: This message shall be cleared by a person
properly. Repeat this procedure. trained and qualified on the troubleshooting and
repair of this machine.
8 Test machine functions from the ground
controls. Note: Use the following chart to identify the
description of each LCD screen control button
Result: Ground control functions do not
used in this procedure.
operate.

Escape Scroll up Scroll down Enter

1 Turn the key switch to the ground controls

position and pull out the red Emergency Stop
button to the on position at the platform
controls.
2 Press and hold the ground control scroll up
and scroll down buttons.

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Platform Overload Components

3 Pull out the red Emergency Stop button at the 7 Press and hold the scroll down button for
ground controls. 5 seconds.
Result: The ground control LCD display will Result: The ground control LCD display will
show the following. show the following.

4 Press the scroll down button. 8 Press the enter button.

Result: The ground control LCD display will Result: The ground control LCD display will
show the following. show the following.

5 Press the enter button. 9 Press the buttons in the following sequence:
(down)(down)(up)(enter).
Result: The ground control LCD display will
show the following. Note: After each key press an asterisk (*) will
appear on the second line of the LCD display.
Result: The ground control LCD display will
show the following.

6 Press the enter button.

Result: The ground control LCD display will
show the following.
Note: After 3 seconds the LCD display will return
to SELECT OPTION PLAT. OVERLOAD.
10 Push in the red Emergency stop button.

Part No. 1275811GT GR™ • QS™R • QS™W 83

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Obstruction Sensing System

How to Replace an Obstruction Sensing Pad

12-1 How to Replace an Obstruction

Obstruction Sensing Pads - QSR Sensing Pad
Models 1 QS-12R: Raise the platform approximately
3 feet / 1 m.
The function of the Obstruction Sensing System is
to detect a person or an object standing on the QS-15R and QS-20R: Raise the platform
machine chassis. When a person or an object is approximately 5 feet / 1.5 m.
detected on top of the machine chassis, the 2 Open the battery cover. Rest the cover
machine platform down function will not operate, against the chassis.
and an alarm will sound. The LCD readout at the
ground controls will display OAC: Obstruction 3 Lower the platform until the mast just contacts
Above Chassis and the LED readout on the the battery cover.
platform controls will display OAC. Refer to the Crushing hazard. Keep hands
examples below. clear of the battery cover when
lowering the platform.

Turn the key switch to the off position and

disconnect the battery pack from the machine.

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

4 At the non-steer end of the machine, unlatch

the covers and open the ground controls
cover.
LED Readout 5 Working with the obstruction sensing pad to
be replaced, locate the pad cables.
6 Carefully pull the cables to identify the
connector cable located at the ground
controls, non-steer end of the machine.
7 After the connector cable has been identified,
tag and disconnect the cable from the
obstruction sensing pad cables.
Note: If the ground controls side or battery box
cover obstruction sensing pad is replaced,
carefully remove the appropriate pin from the male
Deutsch connector. A new Deutsch pin will have to
be installed onto the cable wire of the new ground
controls side pad, or battery box cover pad.

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Obstruction Sensing System

8 Using a broad flat metal blade, carefully slide Non-steer End

the metal blade under the obstruction pad and
work the metal blade under the entire pad to
be replaced, until the pad is separated from
the chassis or the battery box cover.
9 Remove the pad from the machine and
carefully scrape away any excess adhesive
from the chassis or battery box cover.
10 Using a suitable solvent, clean the surface
were the obstruction sensing pad was
removed. Allow the surface to dry thoroughly.
11 Install the new obstruction sensing pad.
Note: It may be necessary to use touch-up paint in
the area were the obstruction sensing pad was
removed. Let the paint dry completely, before
installing the new obstruction sensing pad.

Steer End
Obstruction Sensing Pads
1 cable connectors
2 Deutsch connector
3 battery box obstruction sensing pad
4 ground controls side obstruction sensing
pad
5 steer end obstruction sensing pad
6 hydraulic tank side obstruction sensing
pad

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Battery Charger

13-1
Battery Charger
The charger contains selectable charging profiles
stored in its internal memory to charge batteries.
These profiles are specific to each battery type.
The charging profile must be programmed to
match the specific battery type on the machine.

Remote charger status indicators

1 Error / Fault / USB indicator
2 Error / Fault
3 Charge complete
4 Charging, high state of charge
5 Charging, low state of charge

Charger status indicators

1 Error / Fault / USB indicator
2 AC power indicator
3 Battery charging indicator
4 USB port
5 Charging output indicator
6 Charger profile / Error display
7 Charge profile selection button

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Battery Charger
Selecting a Charge Profile

Selecting a Charge Profile 5 Press and hold the charge profile selection
button until the error indicator and charging
Electrocution/burn hazard. indicator lights turn off and the AC status
Contact with electrically charged indicator light turns on to confirm selection
circuits could result in death or and exit charge profile mode. Release the
serious injury. Remove all rings, button.
watches and other jewelry.
Note: Charge profile mode will time out and exit if
1 At the ground controls, turn the key switch to there is 15 seconds of inactivity, the charge profile
the off position and push in the red number has been displayed three times or the AC
Emergency Stop button to the off position. power source had been disconnected.

2 Open the battery compartment. 6 Press and release the charge profile selection
button to confirm the correct charge profile
3 Press and hold the charge profile selection has been selected.
button and plug the battery charger into an
AC power source. Continue to hold the button
until the amber error indicator is on and the
green charging indicator light is flashing.
Release the button.
4 Press and release the charge profile selection
button to navigate to the charge profile
appropriate for your machine and battery
type. Refer to the chart below.
Profile Description
P001 Flooded lead acid batteries - Temperature
compensated *
P003 Flooded lead acid batteries - Not
temperature compensated **
P007 Flooded lead acid batteries - Not
temperature compensated **
P043 AGM batteries - Temperature compensated
*
* Temperature compensated: Battery temperature
sensor has been installed on the machine.
** Not temperature compensated: Battery
temperature sensor has not been installed on the
machine.

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Batteries

14-1 All models:

How to Remove the Batteries 8 Disconnect the battery pack from the
machine.
Note: Perform this procedure with the machine on
a firm, level surface. Electrocution/burn hazard.
Contact with electrically charged
Models with working batteries: circuits could result in death or
serious injury. Remove all rings,
1 GR-12, QS-12R, QS-12W: Raise the platform watches and other jewelry.
approximately 3 feet / 1 m.
GR-15, GR-20, QS-15R, QS-20R, QS-15W, 9 Disconnect the battery cables and set aside.
QS-20W: Raise the platform approximately 10 Remove the batteries from the machine.
5 feet / 1.5 m.
2 Open the battery cover. Rest the cover
against the chassis.
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.

Models with non-working batteries:

4 Secure the platform to an overhead lifting
device.
5 GR-12, QS-12R, QS-12W: Carefully lift the
platform approximately 3 feet / 1 m.
GR-15, GR-20, QS-15R, QS-20R, QS-15W,
QS-20W: Carefully lift the platform
approximately 5 feet / 1.5 m.
Crushing hazard. The platform
will fall if not properly supported.

6 Open the battery cover. Rest the cover

against the chassis.
7 Lower the platform until the mast just contacts
the battery cover.
Crushing hazard. Keep hands
clear of the battery cover when
lowering the platform.

88 GR™ • QS™R • QS™W Part No. 1275811GT

February 2022 Service Manual

Diagnostics
Section 5 Diagnostics

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.
Observe and Obey:  Read each appropriate fault code thoroughly.
 Troubleshooting and repair procedures shall Attempting short cuts may produce hazardous
be completed by a person trained and conditions.
qualified on the repair of this machine  Be aware of the following hazards and follow
 Immediately tag and remove from service a generally accepted safe workshop practices.
damaged or malfunctioning machine.
Crushing hazard. When testing
 Repair any machine damage or malfunction or replacing any hydraulic
before operating the machine. component, always support
the structure and secure it
 Unless otherwise specified, perform each from movement
procedure with the machine in the following
configuration: Electrocution/burn hazard.
• Machine parked on a firm, level surface Contact with electrically charged
circuits could result in death or
• Key switch in the off position with the key serious injury. Remove all rings,
removed watches and other jewelry.
• The red Emergency Stop button in the off Bodily injury hazard. Spraying
position at both the ground and platform hydraulic oil can penetrate and
controls burn skin. Loosen hydraulic
• Wheels chocked connections very slowly to allow
the oil pressure to dissipate
• All external AC power supply disconnected gradually. Do not allow oil to
from the machine squirt or spray.
• Platform in the stowed position
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.

About This Section

When a malfunction is discovered, the fault code
charts in this section will help a service
professional pinpoint the cause of the problem.
To use this section, basic hand tools and certain
pieces of test equipment are required — voltmeter,
ohmmeter, pressure gauges.

Part No. 1275811GT GR™ • QS™R • QS™W 89

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Diagnostics

Definitions Genie® SmartLink™ Diagnostic

GSDS – Genie SmartLink™ Diagnostic System System
ECM – Electronic Control Module This machine is equipped with the Genie
SmartLink™ Diagnostic System (GSDS). The
GCON – Ground Controls GSDS indicates a machine malfunction has
happened by displaying Operational Indicator
PCON – Platform Controls Codes (OIC) and Diagnostic Trouble Codes
OIC – Operational Indicator Codes (DTC). These codes are displayed at the Platform
Controls and the Ground Controls. The Ground
DTC – Diagnostic Trouble Codes Controls will display a brief description of the code
at the LCD display as well. Refer to the GCON I/O
GCON LCD Diagnostic Readout Maps, Operational Indicator Codes (OIC) and
Diagnostic Trouble Codes (DTC) in this section, to
assist in troubleshooting faults.

GCON ECM Connector Layout

The diagnostic readout displays alpha numeric

codes that provide information about the machine
operating status and about malfunctions.
The codes listed in the Diagnostic Trouble Code
Charts describe malfunctions and can aid in
troubleshooting the machine by pinpointing the
area or component affected.
Models are listed below each code to assist in the
troubleshooting codes for a specific model.

Rear of Ground Controls

90 GR™ • QS™R • QS™W Part No. 1275811GT

February 2022 Service Manual

Diagnostics
GCON I/O Map without Load Sense
GCON Pin Number Circuit Function I/O Type Wire Gauge and Color
J1 Connector – Gray
J1-01 ECM Power Power Input 14 RD
J1-02 PCON, E-Stop Power Power Output 18 RD
J1-03 PCON, E-Stop Return Power Input 18 WH
J1-04 Link to PCON — CANH Data Bus 18 GR
J1-05 Link to PCON — CANL Data Bus 18 OR
J1-06 PCON — Ground Ground Output 18 BR
J1-07 GCON — Ground Ground Input 14 BR
J1-08 Key Switch — PCON Mode Digital Input 18 BK
J1-09 Key Switch — GCON Mode Digital Input 18 WH
J1-10 GCON — Emergency Mode Digital Input 18 WH/BK
J1-11 No Circuit N/A N/A
J1-12 Driver Power Power Input 14 RD
J-2 Connector – Black
J2-01 Platform Up Coil Digital Output 18 OR
J2-02 Platform Down Coil Digital Output 18 OR/BK
J2-03 Steer Left Coil Digital Output 18 BL/BK
J2-04 Steer Right Coil Digital Output 18 BL
J2-05 Parallel Coil (not connected) Digital Output 18 RD/WH
J2-06 Drive Forward Coil Digital Output 18 WH
J2-07 No Circuit N/A N/A
J2-08 Motor Controller Enable Digital Output 18 GR/WH
J2-09 No Circuit N/A N/A
J2-10 Drive Reverse Coil Digital Output 18 WH/BK
J2-11 Motor Controller Throttle Analog Output 18 GR
J2-12 No Circuit N/A N/A
J-3 Connector – Green
J3-01 No Circuit N/A N/A
J3-02 GCON — Alarm Digital Output 18 BL
J3-03 Switch/Sensor Power Digital Output 14 RD
J3-04 Automotive Horn Digital Output 18 WH
J3-05 Pothole Limit Switch Digital Input 18 OR/RD
J3-06 Ground Ground Input 18 BR
J3-07 Down Limit Switch Digital Input 18 OR
J3-08 Level Sensor Digital Input 18 RD/BK
J3-09 Ground Ground Input 18 BK
J3-10 Ground Ground Input 18 BK
J3-11 No Circuit N/A N/A
J3-12 Load Sense — Ground Ground Input 18 BK

Part No. 1275811GT GR™ • QS™R • QS™W 91

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Diagnostics
GCON I/O Map with Load Sense
GCON Pin Number Circuit Function I/O Type Wire Gauge and Color
J1 Connector – Gray
J1-01 ECM Power Power Input 14 RD
J1-02 PCON, E-Stop Power Power Output 18 RD
J1-03 PCON, E-Stop Return Power Input 18 WH
J1-04 Link to PCON — CANH Data Bus 18 GR
J1-05 Link to PCON — CANL Data Bus 18 OR
J1-06 PCON — Ground Ground Output 18 BR
J1-07 GCON — Ground Ground Input 14 BR
J1-08 Key Switch — PCON Mode Digital Input 18 BK
J1-09 Key Switch — GCON Mode Digital Input 18 WH
J1-10 GCON — Emergency Mode Digital Input 18 WH/BK
J1-11 No Circuit N/A N/A
J1-12 Driver Power Power Input 14 RD
J-2 Connector – Black
J2-01 Platform Up Coil Digital Output 18 OR
J2-02 Platform Down Coil Digital Output 18 OR/BK
J2-03 Steer Left Coil Digital Output 18 BL/BK
J2-04 Steer Right Coil Digital Output 18 BL
J2-05 Parallel Coil (not connected) Digital Output 18 RD/WH
J2-06 Drive Forward Coil Digital Output 18 WH
J2-07 No Circuit N/A N/A
J2-08 Motor Controller Enable Digital Output 18 GR/WH
J2-09 No Circuit N/A N/A
J2-10 Drive Reverse Coil Digital Output 18 WH/BK
J2-11 Motor Controller Throttle Analog Output 18 GR
J2-12 No Circuit N/A N/A
J-3 Connector – Green
J3-01 No Circuit N/A N/A
J3-02 GCON — Alarm Digital Output 18 BL
J3-03 Switch/Sensor Power Digital Output 14 RD
J3-04 Automotive Horn Digital Output 18 WH
J3-05 Pothole Limit Switch Digital Input 18 OR/RD
J3-06 Ground Ground Input 18 BR
J3-07 Down Limit Switch Digital Input 18 OR
J3-08 Level Sensor Digital Input 18 RD/BK
J3-09 Platform Overload Pressure Transducer Ground Input 18 BL/WH
J3-10 Platform Height Sensor Ground Input 18 OR/WH
J3-11 No Circuit N/A N/A
J3-12 Load Sense — Ground Ground Input 18 BK

92 GR™ • QS™R • QS™W Part No. 1275811GT

February 2022 Service Manual

Diagnostics

Operational Indicator Codes Diagnostic Trouble Codes (DTC)

(OIC) These codes are generated by the system to
These codes are generated by the electrical indicate that a device or circuit malfunction has
system to indicate machine operating status. been detected in the electrical system.
During normal operation a code will appear in the The types of Diagnostic Trouble Codes that may
platform controls LED readout if a condition such occur are explained below.
as off-level, overload cutout, chassis mode Type "HXXX" – Indicate a malfunction associated
operation or pothole guards stuck occurs. These with devices that control hydraulic functions in the
codes are not indicators of a device malfunction in electrical system. The "HXXX" faults are divided
the electrical system. into short circuit battery negative, short circuit to
battery positive, open circuit and generic shorts.
Code Condition Examples of these devices are solenoid controlled
LL Off-Level hydraulic valves and motor controller.
OL Platform Overload (CE and Australia)
Type "PXXX" – Indicate a malfunction associated
CH Chassis Mode Operation with power type devices in the electrical system.
PHS Pothole Guard Stuck The "PXXX" faults are divided into short circuit to
battery negative, short circuit to battery positive,
OAC Obstruction Above Chassis (QSR only)
open circuit and generic shorts. Examples of these
CHrg Charger Interlock (option) devices are horns, sensor power and alarms.
ObS Obstruction (option)
Type "UXXX" – Indicate a malfunction associated
Note: The CHrgr code indicates the charger is with user interface devices in the electrical system.
connected to an AC power source and The "UXXX" faults are divided into short circuit to
functionality is limited. To clear the code, battery negative, short circuit to battery positive,
disconnect the charger from the AC power source. open circuit and generic shorts. Examples of these
devices are GCON up and down switches and
Note: The ObS code indicates the contact alarm
PCON drive joystick.
has been actuated by an obstruction. Move the
machine away from the obstruction to clear the Type "FXXX" – Indicate a malfunction associated
code. with machine feedback devices in the electrical
system. The "FXXX" faults are divided into short
circuit to battery negative, short circuit to battery
positive, open circuit and generic shorts. Examples
of these devices are limit switches, height sensors
and pressure transducers.
Type "CXXX" – Indicate a malfunction associated
with controls devices in the electrical system.
Examples of these devices are platform controls
and ground controls ECM.

Part No. 1275811GT GR™ • QS™R • QS™W 93

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Diagnostics

Troubleshooting "HXXX" and "PXXX" Faults

The procedure below illustrates typical steps for diagnosing and fixing faults of type "HXXX" and "PXXX".

Diagnostic Chart
No
1 Check the faulted device for a short or open circuit. Good Replace faulted device.
➔
Good 
No
Check short or open circuit of the harness or Good Repair or replace harness an/or
2
connector between Ground Controls and faulted device. connector.
➔
Good  No
Good

3 Check GCON Electronic Control Module (ECM). Replace ECM.

➔

Wiring Diagram
The wiring diagram shown below illustrates how fault type "HXXX" and "PXXX" devices are typically
wired.
The signal of these types of devices originates at the Ground Controls and terminates at system ground.

GCON
Electronic Control Module
(ECM) Signal Wire Signal Side Device Return Side Return Wire

In order to successfully troubleshoot "HXXX" or "PXXX" type faults, the entire faulted out circuit must be
investigated.

94 GR™ • QS™R • QS™W Part No. 1275811GT

February 2022 Service Manual

Diagnostics

Fault Inspection Procedure

1 Check the device associated with the faulted circuit
1 Disconnect the faulted device connector.
2 Using a multi-meter, measure resistance between the two
terminals of the faulted device.
3 Resistance should be as follows.
Device Typical Resistance
Solenoid Valve, Drive 27.2 
Solenoid Valve, Steer 19 
Solenoid Valve, Platform Up 25 
Solenoid Valve, Platform Down 6.25 
GCON and PCON Alarm >1M 
Automotive Horn 1.0 
Contactor Coil 47 
OK Go to step 2 No Good Replace faulted device

2 Check the harness between the ground controls and the faulted device
1 Disconnect the GCON ECM connectors, J1/QD31,
J2/QD33 and J3/QD32.
2 Disconnect the faulted device connector.
3 Check the continuity between the GCON ECM connector
and the signal side of the faulted device.
 Result: Resistance should be close to 0 
4 Check the continuity between the return side of faulted
device and system ground.
 Result: Resistance should be close to 0 
5 Check resistance between return side and signal side of
the harness plug of faulted device.
 Result: Resistance should be 1M  or higher.

OK Go to step 3 No Good Replace or repair harness

3 Check the GCON ECM

Part No. 1275811GT GR™ • QS™R • QS™W 95

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Diagnostics

1 Disconnect the GCON ECM connectors, J1/QD31,

J2/QD33 and J3/QD32.
2 For short to B- type faults, measure resistance between
pins J1-7/QD31-7 (ground) and the GCON pin associated
with the
fault code. Refer to the GCON I/O Map in this section to
identify the faulted out circuit pin.
3 Short to ground resistance should be greater than 5k .
4 For short to B+ type faults, measure resistance between
pins J1-12/QD31-12 (driver power) and the GCON pin
associated
with the fault code. Refer to the GCON I/O Map in this
section to identify the faulted out circuit pin.
5 Short to power resistance should be greater than 50k .

No Good Replace GCON ECM

96 GR™ • QS™R • QS™W Part No. 1275811GT

February 2022 Service Manual

Diagnostics

Type "HXXX" Faults

DTC Message on
Description Possible Causes Failure Mode
Number GCON LCD
• Short circuit in platform up #1 harness.
H001:COILFAULT Short circuit of the platform up #1 circuit to Platform up function
H001: • Platform up #1 coil short circuit.
PLAT UP1:BAT- battery negative. inhibited.
• GCON ECM.
• Short circuit in platform up #1 harness.
H002:COILFAULT Platform up function
H002: Open circuit in the platform up #1 circuit. • Platform up #1 coil open circuit.
PLAT UP1:OPEN inhibited.
• GCON ECM.
• Short circuit in platform up #1 harness. All functions inhibited
H003:COILFAULT Short circuit of the platform up #1 circuit to
H003: • Platform up #1 coil short circuit. except platform
PLAT UP1:BAT+ battery positive.
• GCON ECM. down.
• Short circuit in platform down #1 harness.
H009:COILFAULT Short circuit of the platform down #1 circuit All functions
H009: • Platform down #1 coil short circuit.
PLAT DOWN1:BAT+ to battery positive. inhibited.
• GCON ECM.
• Short circuit in drive forward #1 harness.
H013:COILFAULT Short circuit of the drive forward #1 circuit to Drive forward
H013: • Drive forward #1 coil short circuit.
DRIVE FWD1:BAT- battery negative. function inhibited.
• GCON ECM.
• Open circuit in drive forward #1 harness.
H014:COILFAULT Drive forward
H014: Open circuit in the drive forward #1 circuit. • Drive forward #1 coil open circuit.
DRIVE FWD1:OPEN function inhibited.
• GCON ECM.
• Short circuit in drive forward #1 harness. All functions inhibited
H015:COILFAULT Short circuit of the drive forward #1 circuit to
H015: • Drive forward #1 coil short circuit. except platform
DRIVE FWD1:BAT+ battery positive.
• GCON ECM. down.
• Short circuit in drive reverse #1 harness.
H019:COILFAULT Short circuit of the drive reverse #1 circuit to Drive reverse
H019: • Drive reverse #1 coil short circuit.
DRIVE REV1:BAT- battery negative. function inhibited.
• GCON ECM.
• Open circuit in drive reverse #1 harness.
H020:COILFAULT Drive reverse
H020: Open circuit in the drive reverse #1 circuit. • Drive reverse #1 coil open circuit.
DRIVE REV1:OPEN function inhibited.
• GCON ECM.
• Short circuit in drive reverse #1 harness. All functions inhibited
H021:COILFAULT Short circuit of the drive reverse #1 circuit to
H021: • Drive reverse #1 coil short circuit. except platform
DRIVE REV1:BAT+ battery positive.
• GCON ECM. down.
• Short circuit in steer right harness. All functions inhibited
H027:COILFAULT Short circuit of the steer right circuit to
H027: • Steer right coil short circuit. except platform
DRIVE STEER RIGHT:BAT+ battery positive.
• GCON ECM. down.
• Short circuit in steer left harness. All functions inhibited
H030:COILFAULT Short circuit of the steer left circuit to battery
H030: • Steer left coil short circuit. except platform
DRIVE STEER LEFT:BAT+ positive.
• GCON ECM. down.
• Short circuit in motor controller enable wire.
All functions inhibited
H067:FAULT Short circuit of the motor controller circuit to • Motor Controller.
H067: except platform
MC ENABLE:BAT- battery negative. • Contactor coil shorted to battery negative.
down.
• GCON ECM.
• Short circuit in motor controller enable wire.
All functions inhibited
H069:FAULT Short circuit of the motor controller circuit to • Motor Controller.
H069: except platform
MC ENABLE:BAT+ battery positive. • Contactor Coil.
down.
• GCON ECM.
• Short circuit in motor controller throttle wire. All functions inhibited
H070:FAULT Short circuit of the motor controller throttle
H070: • Motor Controller. except platform
MC THROTTLE:BAT- circuit to battery negative.
• GCON ECM. down.
• Short circuit in motor controller throttle wire. All functions inhibited
H072:FAULT Short circuit of the motor controller throttle
H072: • Motor Controller. except platform
MC THROTTLE:BAT+ circuit to battery positive.
• GCON ECM. down.
• Short or open circuit in platform down
H078:COILFAULT Short circuit of the platform down #1 circuit #1 harness. Platform down
H078:
PLAT DOWN1 to battery positive/negative or open circuit. • Platform down #1 coil short or open circuit. function inhibited.
• GCON ECM.
• Short or open circuit in steer left harness.
H080:COILFAULT Short circuit of the steer left circuit to battery Steer left function
H080: • Steer left coil short or open circuit.
STEER LEFT negative or open circuit. inhibited.
• GCON ECM.
All functions
• Short or open circuit in steer right harness.
H081:COILFAULT Short circuit of the steer right circuit to inhibited except
H081: • Steer right coil short or open circuit.
STEER RIGHT battery negative or open circuit. platform down while
• GCON ECM.
above limit switch.

Part No. 1275811GT GR™ • QS™R • QS™W 97

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Diagnostics

Type "PXXX" Faults

DTC Message on
Description Possible Causes Failure Mode
Number GCON LCD
• Short circuit in switched power #1, down limit
P001:PWR FAULT Short circuit of the switched power #1 switch, pothole limit switch, digital tilt switch All functions
P001:
SW PWR1:BAT- circuit to battery negative. harness. inhibited.
• GCON ECM.
• Short circuit in switched power #1, down limit
P003:PWR FAULT Short circuit of the switched power #1 switch, pothole limit switch, digital tilt switch All functions
P003:
SW PWR1:BAT+ circuit to battery positive. harness. inhibited.
• GCON ECM.
• Short circuit in automotive horn harness.
P004:DEVICEFAULT Short circuit of the automotive horn circuit to Automotive horn
P004: • Automotive horn short circuit.
HORN:BAT- battery negative. inhibited.
• GCON ECM.
• Open circuit in automotive horn harness.
P005:DEVICEFAULT Automotive horn
P005: Open circuit of the automotive horn circuit. • Automotive horn open circuit.
HORN:OPEN inhibited.
• GCON ECM.
• Short circuit in automotive horn harness.
P006:DEVICEFAULT Short circuit of the automotive horn circuit to Automotive horn
P006: • Automotive horn short circuit.
HORN:BAT+ battery positive. inhibited.
• GCON ECM.
• Short circuit in GCON alarm harness.
P007:DEVICEFAULT Short circuit of the GCON alarm circuit to GCON alarm
P007: • GCON alarm short circuit.
GCON ALARM:BAT- battery negative. inhibited.
• GCON ECM.
• Short circuit in GCON alarm harness.
P009:DEVICEFAULT Short circuit of the GCON alarm circuit to GCON alarm
P009: • GCON alarm short circuit.
GCON ALARM:BAT+ battery positive. inhibited.
• GCON ECM.
P013:PWR FAULT Short circuit of the PCON power return • Short circuit in PCON power return harness. All functions
P013:
PCON PWRET:BAT- circuit to battery negative. • GCON ECM. inhibited.
P015:PWR FAULT Short circuit of the PCON power return • Short circuit in PCON power return harness. All functions
P015:
PCON PWRET:BAT+ circuit to battery positive. • GCON ECM. inhibited.
P018: 018:PWR FAULT Short circuit of the PCON power circuit to • Short circuit in PCON power harness. All functions
PCON POWER:BAT- battery negative. • GCON ECM. inhibited.
018:PWR FAULT Short circuit of the PCON power circuit to • Short circuit in PCON power harness. All functions
P019:
PCON POWER:BAT+ battery positive. • GCON ECM. inhibited.

98 GR™ • QS™R • QS™W Part No. 1275811GT

February 2022 Service Manual

Diagnostics

Type "UXXX" Faults

DTC Message on Description Possible Causes Failure Mode
Number GCON LCD
• Short circuit of the GCON main function enable
U001:SWITCHFAULT Short circuit of the GCON main function All GCON functions
U001: switch.
GCON MAIN FTN EN enable switch at system startup. inhibited.
• GCON ECM.
All GCON functions
U002:SWITCHFAULT Short circuit of the GCON up directional • Short circuit of the GCON up directional switch.
U002: inhibited except
GCON PLAT UP switch at system startup. • GCON ECM.
platform down.
• Short circuit of the GCON down directional All GCON functions
U003:SWITCHFAULT Short circuit of the GCON down directional
U003: switch. inhibited except
GCON PLAT DOWN switch at system startup.
• GCON ECM. platform up.
All GCON LCD
U004:SWITCHFAULT Short circuit of the GCON LCD scroll up • Short circuit of the GCON LCD scroll up switch.
U004: menu functions
GCON LCD UP switch at system startup. • GCON ECM.
inhibited.
• Short circuit of the GCON LCD scroll down All GCON LCD
U005:SWITCHFAULT Short circuit of the GCON LCD scroll down
U005: switch. menu functions
GCON LCD DOWN switch at system startup.
• GCON ECM. inhibited.
All GCON LCD
U006:SWITCHFAULT Short circuit of the GCON LCD enter switch • Short circuit of the GCON LCD enter switch.
U006: menu functions
GCON LCD ENTER at system startup. • GCON ECM.
inhibited.
All GCON LCD
U007:SWITCHFAULT Short circuit of the GCON LCD escape • Short circuit of the GCON LCD escape switch.
U007: menu functions
GCON LCD ESCAPE switch at system startup. • GCON ECM.
inhibited.
All PCON drive and
U014:SWITCHFAULT Short circuit of the PCON drive enable • Short circuit of the PCON drive enable switch.
U014: steer functions
PCON DRIVE EN switch at system startup. • GCON ECM.
inhibited.
All PCON drive and
U015:SWITCHFAULT Short circuit of the PCON steer left switch at • Short circuit of the PCON steer left switch.
U015: steer functions
PCON STEER LEFT system startup. • GCON ECM.
inhibited.
All PCON drive and
U016:SWITCHFAULT Short circuit of the PCON steer right switch • Short circuit of the PCON steer right switch.
U016: steer functions
PCON STEER RIGHT at system startup. • GCON ECM.
inhibited.
U017:SWITCHFAULT Short circuit of the PCON horn switch at • Short circuit of the PCON horn switch. PCON horn switch
U017:
PCON HORN system startup. • GCON ECM. function inhibited.
The machine is
U018:SWITCHFAULT Short circuit of the PCON low drive speed • Short circuit of the PCON low drive speed switch.
U018: limited to low drive
PCON LO DRIV SPD switch at system startup. • GCON ECM.
speed.
• PCON drive joystick is not in neutral position at
PCON drive joystick signal is outside All PCON drive and
U033:JSTICKFAULT startup.
U033: acceptable calibration range at system steer functions
OUT OF CAL RANGE • PCON joystick.
startup. inhibited.
• GCON ECM.
• Short circuit of the PCON drive joystick signal
All PCON drive and
U034:JSTICKFAULT Short circuit of the PCON drive joystick circuit.
U034: steer functions
OUT OF RANGE:HI signal to battery positive at system startup. • PCON joystick.
inhibited.
• GCON ECM.
• Short circuit of the PCON drive joystick signal
All PCON drive and
U035:JSTICKFAULT Short circuit of the PCON drive joystick circuit.
U035: steer functions
OUT OF RANGE:LO signal to battery negative at system startup. • PCON joystick.
inhibited.
• GCON ECM.
U036:SWITCHFAULT Mis-wiring or short circuit of GCON key • Short circuit of the PCON drive enable switch. All functions
U036:
GCON + PCON:ON switch. • GCON ECM. inhibited.
• Drive mode switch stuck closed.
U042:SWITCHFAULT PCON drive mode switch stuck closed, or • Drive mode switch is depressed at system Drive functions
U042:
PCON DRIVE MODE depressed prior to startup. startup. inhibited.
• PCON ECM.
• Short circuit of the PCON drive enable switch.
U045:SWITCHFAULT Short circuit of the PCON drive enable All drive and steer
U045: • PCON ECM.
PCON DRIVE EN switch at system startup. functions inhibited.
• GCON ECM.
• PCON lift mode switch depressed at system All functions operate
U046:SWITCHFAULT PCON function enable switch stuck closed,
U046: startup. except platform
PCON LIFT MODE or depressed at system startup.
• PCON ECM. up/down.

Part No. 1275811GT GR™ • QS™R • QS™W 99

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Diagnostics

Type "FXXX" Faults

DTC Message on
Description Possible Causes Failure Mode
Number GCON LCD
• Short circuit of the up limit switch circuit.
F001:SWITCHFAULT Short circuit of the up limit #1 switch at Platform up function
F001: • Up limit #1 switch short circuit.
UP LIMIT1:BAT+ system startup. inhibited.
• GCON ECM.
• Short circuit of the down limit switch circuit.
F003:SWITCHFAULT Short circuit of the down limit #1 switch at All functions inhibited
F003: • Down limit #1 switch short circuit.
DOWN LIMIT1:BAT+ system startup. except platform down.
• GCON ECM.
All functions inhibited
except platform down
as long as machine is
• Short circuit of the pothole switch circuit.
F005:SWITCHFAULT Short circuit of the pothole limit #1 switch at in the elevated
F005: • Pothole limit #1 switch short circuit.
POTHOLE:BAT+ system startup. position. If machine is
• GCON ECM.
in stowed position, all
functionality is
resumed.
All functions inhibited
except platform down
• Short circuit of the chassis digital tilt switch as long as machine is
F007:SWITCHFAULT Short circuit of the chassis digital tilt switch circuit. in the elevated
F007:
CHASSISTILT:BAT+ at system startup. • Chassis digital tilt switch short circuit. position. If machine is
• GCON ECM. in stowed position, all
functionality is
resumed.
F031:SWITCHFAULT Short circuit of the obstruction sensing circuit • Short circuit in the obstruction sensing harness.
F031: All functions inhibited.
OAC SWITCH:Bat+ to battery positive. • GCON ECM.
F032:SWITCHFAULT Short circuit of pressure switch to battery • Short circuit in the limit switch harness.
F032: All functions inhibited.
OVLD SWITCH:Bat+ positive. • GCON ECM.
F033:SWITCHFAULT • Open or short circuit in the limit switch harness.
F033: Open or short circuit of pressure switch. All functions inhibited.
OVLD:Open/Bat- • GCON ECM.
• Faulty extension deck limit switch.
F072:SENSORFAULT
F072: Function Cutout sensor B+ fault. • Faulty gate proximity switch. All functions inhibited.
FUNCTION CUT B+
• GCON ECM.
All functions inhibited
except platform down
as long as machine is
UTS mismatch fault. Two accelerometers in the elevated
F129: F129:TILT SENSOR FAULT • Faulty UTS.
inside UTS mismatch.(universal tilt sensor) position. If machine is
in stowed position, all
functionality is
resumed.

100 GR™ • QS™R • QS™W Part No. 1275811GT

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Diagnostics

Type "CXXX" Faults

DTC Message on Description
Possible Causes Failure Mode
Number GCON LCD
C001:GCON ECM • Incorrect software file. All functions
C001: GCON ECM CRC check error.
FAULT TYPE 1 • GCON ECM internal failure. inhibited.
C004:GCON ECM • Short circuit in the master switch circuit. All functions
C004: GCON ECM master switch error.
FAULT TYPE 4 • GCON ECM. inhibited.
C005:GCOM ECM • Short circuit in the safety switch circuit. All functions
C005: GCON ECM safety switch error.
FAULT TYPE 5 • GCON ECM. inhibited.
C006:GCON ECM • Input conditioning circuit failure. All functions
C006: GCON input redundancy error.
FAULT TYPE 6 • GCON ECM. inhibited.
• Incorrectly programmed device.
C007:GCON ECM GCON ECM inter-processor communication All functions
C007: • Error in loading software on device.
FAULT TYPE 7 error. inhibited.
• GCON ECM.
C009:GCON ECM FAULT All functions
C009: GCON ECM fault type 9. • Contact Genie support.
FAULT TYPE 9 inhibited.
• Incorrectly programmed device.
C010:SECONDARY GCON secondary processor not All functions
C010: • Error in loading software on device.
NOT PROGRAMMED programmed. inhibited.
• GCON ECM.
• PCON disconnected.
C021:PCON NOT All functions
C021: PCON not detected error. • CAN communication failure.
DETECTED inhibited.
• GCON or PCON ECM.
C023:MACHINE Discrepancy between model detected and • Incorrect machine model programmed. All functions
C023:
MODEL FAULT model programmed. • GCON or PCON ECM. inhibited.
All functions inhibited
except for down
function and up
function.
Platform can be
C028:SERVICE • Machine programmed for use in service override elevated only once
C028: Machine is in service override mode.
OVERRIDE MODE ON mode. with the maximum
elevate time of XX
seconds.
Elevate time XX
depends on machine
model.
All functions inhibited
except platform
down as long as
• UTS level sensor calibration has not been
machine is in the
C051:SYSTEMFAULT performed.
C051: UTS level sensor not calibrated. elevated position. If
TILT:NoCal • New level sensor connected.
machine is in stowed
• System parameters reset to default.
position, all
functionality is
resumed.
All functions inhibited
except platform
down as long as
machine is in the
C052:TILT SENSOR • UTS level sensor disconnected.
C052: No level sensor detected. elevated position. If
NOT DETECTED • Open circuit in level sensor harness.
machine is in stowed
position, all
functionality is
resumed.

Part No. 1275811GT GR™ • QS™R • QS™W 101

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Diagnostics
DTC Message on
Description Possible Causes Failure Mode
Number GCON LCD
• C053 displayed at GCON, PCON with older
software revision connected to GCON with newer
C053:PCON-GCON Software revisions do not match between the software revision. All functions
C053:
SOFTWARE MISMATCH PCON and GCON. • C053 displayed at PCON, PCON with newer inhibited.
software revision connected to GCON with older
software revision.
C054:GCON ECM • Short or open circuit to GCOM ECM. All functions
C054: GCON ECM Fault: Type 54.
FAULT TYPE 54 • GCON ECM. inhibited.
C077:DISABLED All functions
C077: Telematics Remote Disable. • Machine disabled.
BY OWNER inhibited.
Telematics is
installed:
Connect the
telematics device to
the GCON.
C078:TELEMATICS • Telematics device not connected.
C078: Telematics device not detected by GCON. Telematics is not
NOT DETECTED • Telematics device not installed.
installed:
Navigate to the
options menu on the
machine and disable
telematics.

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Diagnostics

Battery Charger
The charger continuously monitors internal and external conditions. Fault and Error codes are generated
by the charger to indicate that an internal or external malfunction has been detected in the electrical
system. The types of Diagnostic Trouble Codes that may occur are explained below.
Type "F" codes – Indicate an internal fault condition has occurred and caused charging to stop.
Type "E" codes - Indicate an external fault condition has occurred and caused charging to stop.
Type "P" code - Indicates charger programming mode is active. This will occur when the charger profile is
being configured.
Type "USB" code - Indicates the USB interface is active, and the USB should not be removed. This will
occur when the charger firmware is being updated.

Solid red - Internal fault condition. Type "F" fault code.

Flashing amber - External fault condition. Type "E" error code.

Flashing green - USB interface is active.

Solid green - Firmware update is complete. Remove USB from charger.

Codes are displayed as F, E or P and followed by three numbers and a period (example: E-0-0-4). The
charger can display multiple codes.
If the batteries are changed from one type to another, (example: flooded lead acid to AGM), the charger
profile must be programmed. Refer to Repair Procedure, Programming the Charger Profile.

Part No. 1275811GT GR™ • QS™R • QS™W 103

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Diagnostics

Charger status indicators

Remote charger status indicators

1 Error / Fault / USB indicator
2 Charger profile / Error display
3 Error / Fault
Charger Fault Codes

Charger Fault Codes

Fault Code Description Possible Causes Solution
DC-DC failure: LLC excessive leakage
F-0-0-1
fault.
PFC failure: PFC excessive leakage
F-0-0-2 Disconnect AC input and battery
fault.
pack for 30 seconds.
F-0-0-3 PFC taken too long to boost. Internal charger fault.
If fault does not clear, contact
Charger unable to calibrate current Genie Product Support.
F-0-0-4
offset.
Output relay voltage too high when
F-0-0-5
closed.

104 GR™ • QS™R • QS™W Part No. 1275811GT

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Diagnostics
Charger Error Codes

Charger Error Codes

Error Code Description Condition Possible Causes
E-0-0-1 High battery voltage Battery voltage too high to charge. Check battery voltage and cable
connections.
Self clearing when condition has
been corrected.
E-0-0-2 Low battery voltage detected prior to Battery voltage too low to charge. Check battery voltage and cable
starting charge cycle connections.
Check battery condition.
Self clearing when condition has
been corrected.
E-0-0-3 Charge timeout Charge timeout caused by battery Charge output reduced due to
pack not reaching required voltage high temperature. Charge at
within safe time limit. lower temperature.
Check battery condition.
Replace damaged battery.
Check battery connections.
Battery pack deep discharge.
Disconnect battery pack for
30 seconds to clear fault when
condition has been corrected.
E-0-0-4 Defective battery Battery pack could not be trickle Check battery condition.
charged up to the minimum voltage. Replace damaged battery.
Check battery connections.
Disconnect battery pack for
30 seconds to clear fault when
condition has been corrected.
E-0-0-7 Amp hour limit exceeded Safety limit exceeded. Check battery condition.
Replace damaged battery.
Check battery connections.
Battery pack deep discharge.
High parasitic loads on battery
pack while charging.
Disconnect parasitic loads.
Disconnect battery pack for
30 seconds to clear fault when
condition has been corrected.

Part No. 1275811GT GR™ • QS™R • QS™W 105

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Diagnostics

Charger Error Codes

Error Code Description Condition Possible Causes
E-0-0-8 Battery temperature out of range Battery temperature sensor. Check temperature sensor and
electrical connections.
Rest charger. Disconnect AC
power for 30 seconds.
Self clearing when condition has
been corrected.
E-0-1-1 Charger disabled by external command Battery pack not being charged.. Power outage.
AC power disconnected before
charging complete.
E-0-1-2 Reverse polarity Battery connected incorrectly. Check battery connections.
Self clearing when condition has
been corrected.
E-0-1-3 Battery does not take current Battery voltage is detected, but Incorrect profile for battery type.
charger is unable to charge the Installed from a different machine
battery pack.. with different battery type.
Disconnect battery pack for
30 seconds to clear fault when
condition has been corrected.
E-0-1-6 Software update failed Software update failed. Confirm USB Flash Drive is
formatted with correct software.
If software update continues to
fail, contact Genie Product
support.
E-0-1-7 USB error USB not connected correctly. Remove and re-insert USB Flash
Drive.
Disconnect AC input and battery
pack for 30 seconds.
E-0-1-8 Slot CRC error Software update failed. Confirm USB Flash Drive is
formatted with correct software.
If software update continues to
fail, contact Genie Product
support.
E-0-1-9 Hardware does not support software Charger hardware does not support Confirm USB Flash Drive is
software version being formatted with correct software.
programmed. If software update continues to
fail, contact Genie Product
support.
E-0-2-0 No algorithm selected Charger profile not programmed. Program the charger for the
proper battery profile.

106 GR™ • QS™R • QS™W Part No. 1275811GT

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Diagnostics

Charger Error Codes

Error Code Description Condition Possible Causes
E-0-2-1 High battery voltage detected while Battery voltage too high as Check battery voltage and cable
charging detected by charger profile. connections.
Confirm charger profile is
programmed for correct battery
type.
Self clearing when condition has
been corrected.
E-0-2-2 Low battery voltage detected while Battery voltage too low as Check battery voltage and cable
charging detected by charger profile. connections.
Confirm charger profile is
programmed for correct battery
type.
Self clearing when condition has
been corrected.
E-0-2-3 High AC voltage AC voltage greater than 270 VAC. Connect to a stable AC source
between 85 - 270 VAC / 45 - 65
Hz.
Self clearing when condition has
been corrected.
E-0-2-4 Failure to initialize Charger failed to turn on correctly. Disconnect AC input and battery
pack for 30 seconds.
Contact Genie Product Support.
E-0-2-5 Low AC voltage oscillation AC voltage unstable. Connect to a stable AC source
between 85 - 270 VAC / 45 - 65
Hz.
Using an undersized generator.
Self clearing when condition has
been corrected.
E-0-2-6 Script failure Software update failed. Confirm USB Flash Drive is
formatted with correct software.
If software update continues to fail,
contact Genie Product support.
E-0-2-7 USB over current fault USB over current protection has Remove and re-insert USB Flash
been tripped. Drive.
Use different USB Flash drive.
E-0-2-8 Charge profile incompatibility Selected charger profile is not Update charger software.
compatible with charger software. Confirm charger profile is
programmed for correctly.
Updating current firmware and
error occurs, contact Genie
Product Support.

Part No. 1275811GT GR™ • QS™R • QS™W 107

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Diagnostics

Charger Error Codes

Error Code Description Condition Possible Causes
E-0-2-9 CAN Bus error CAN Bus network error. Check CAN Bus connections.
CAN modules not functioning
correctly.
Termination resistance is
~60 ohms.
E-0-3-0 COMM battery module error CAN Bus battery module error. CAN Buss battery module not
functioning correctly.
E-0-3-1 Vref for ADC measurements triggered Internal charger error. Disconnect AC input and battery
alarm pack for 30 seconds.
Contact Genie Product Support.
E-0-3-2 CAN Bus heartbeat error CAN Bus heartbeat error. CAN Bus devices not functioning
correctly.
E-0-3-6 Battery temperature sensor charge Battery temperature sensor is Check battery temperature sensor
profile required by charger profile but is connections.
not installed. Check charger profile and confirm
battery temperature sensor is
installed.
E-0-3-8 CAN Open Error CAN Open reprogramming failed. Download CAN Open software.
Reprogram charger using USB
Flash Drive.

108 GR™ • QS™R • QS™W Part No. 1275811GT

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Schematics
Section 6 Schematics

About This Section

There are two groups of schematics in this section.

Electrical Schematics
Electrocution/burn hazard.
Contact with electrically charged
Observe and Obey: circuits could result in death or
serious injury. Remove all rings,
 Troubleshooting and repair procedures shall watches and other jewelry.
be completed by a person trained and
qualified on the repair of this machine
Hydraulic Schematics
 Immediately tag and remove from service a
damaged or malfunctioning machine. Bodily injury hazard. Spraying
 Repair any machine damage or malfunction hydraulic oil can penetrate and
before operating the machine. burn skin. Loosen hydraulic
connections very slowly to allow
Before Troubleshooting: the oil pressure to dissipate
gradually. Do not allow oil to
 Read, understand and obey the safety rules squirt or spray.
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.

Part No. 1275811GT GR™ • QS™R • QS™W 109

Service Manual February 2022

Electrical Component and Wire Color Legends

Electrical Component Legend Electrical Component Legend, continued

Item Description Item Description
B1 - B4 Battery, 6V DC C, J, Connector, Plug, Quick disconnect
CB1 Circuit breaker, 7A QD

CON1 Contactor, Motor controller power QD1 = Battery quick disconnect

C8 / QD3 = Control cable to ground
D Diode C4 / QD4 = Control cable to platform
D1 = Motor controller enable, 3A C6 / QD30 = AC plug
D2 = Motor controller, 3A J1 / QD31 = GCON ECM, ground and platform
EN1 Enclosure, AC outlet box controls
J3 / QD32 = GCON ECM, switches and sensors
F Fuse J2 / QD33 = GCON ECM, function manifold
F1 = 275A QD34 = Power buss, switches and sensors
FB1 Flashing beacon QD35 = Ground buss, switches and sensors
QD36 = Pothole guard switches
GND Ground QD37 = Down limit switch
H Horn or alarm C18 / QD38 = Level sensor
H1 = Alarm, GCON QD39 = Ground buss, function manifold
H2 = Automotive style horn (option) C40 / QD40 = Drive reverse coil
H3 = Alarm, PCON C41 / QD41 = Drive forward coil
C42 / QD42 = Steer right coil
JC1 Joystick C43 / QD43 = Steer left coil
KS1 Key switch C44 / QD44 = Platform up coil
C63 = Platform down coil
LS Limit switch J23 / QD45 = Obstruction pads, power signal in/out
LS6 = Platform down J6 / QD47 = Platform controls PCB, power/signal
LS7 = Pothole in/out
LS8 = Pothole J5 / QD48 = Platform controls PCB, E-Stop and
LS18 = Load sense (option) alarm
J4 / QD49 = Platform controls PCB, joystick
M1 Hydraulic power unit
R Resistor
NC Normally closed
R1 = 1k Ohm, 2W
NCHO Normally closed held open R2 = 200 Ohm, 10W
R27 = 25 Ohm, 2W
NOHC Normally open held closed
R30 = 200 Ohm, 10W
OSP Obstruction sensing pads (QSR models)
S7 Level sensor
P Red emergency stop button
U Electronic component
P1 = At ground controls
P2 = At platform controls U1 = Electronic Control Module, GCON
U2 = Printed Circuit Board, PCON
U4 = AC/DC Inverter (option)
U6 = Motor Controller
U9 = Battery Charger
U47A = Obstruction sensing pad (hydraulic tank
side)
U47B = Obstruction sensing pad (battery tray)
U47C = Obstruction sensing pad (steer end)
U47D = Obstruction sensing pad (ground control
side)
Y Valve coil
Y3 = Steer right
Y4 = Steer left
Y5 = Drive reverse
Y6 = Drive forward
Y7 = Platform Down
Y8 = Platform Up
Z1 Zener diode

110 GR™ • QS™R • QS™W Part No. 1275811GT

February 2022 Service Manual

Electrical Component and Wire Color Legends

WIRE COLOR LEGEND

Color Description
BK Black
BK/RD Black/Red
BL Blue
BL/BK Blue/Black
BL/OR Blue/Orange
BL/WH Blue/White
BR Brown
GR Green
GR/BK Green/Black
GR/WH Green/White
GR/YL Green/Yellow
LB Light Blue
OR Orange
OR/BK Orange/Black
OR/RD Orange/Red
OR/WH Orange/White
RD Red
RD/BK Red/Black
RD/WH Red/White
WH White
WH/BK White/Black
YL Yellow

Part No. 1275811GT GR™ • QS™R • QS™W 111

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Wiring Diagram Ground and Platform Controls

112 GR™ • QS™R • QS™W Part No. 1275811GT

February 2022 Service Manual

Electrical Symbol Legend

Wire with description or color Limit switch Limit switch N.C.H.O Limit switch N.O.H.C.

Circuits crossing no connection Emergency Stop button Motor Solenoid valve with diode

Diode Circuit breaker Battery charger Level sensor

Circuit connection Fuse 6V or 12V DC battery Deutsch connector

Resistor Contactor Horn or alarm Flashing beacon

Motor controller Key switch

Part No. 1275811GT GR™ • QS™R • QS™W 113

Service Manual February 2022

Hydraulic Symbols Legend

Orifice with size Hydraulic hand pump Hydraulic cylinder Solenoid operated
2 position 4 way
directional valve

Check valve Fixed displacement pump Relief valve Solenoid operated 2 position
2 way directional valve,
normally closed with manual
override

Filter Bi-directional motor Priority flow regulator Solenoid operated 3 position

4 way directional valve

Brake Variable speed motor Pilot operated needle valve

114 GR™ • QS™R • QS™W Part No. 1275811GT

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Electrical Schematic, Options

Part No. 1275811GT GR™ • QS™R • QS™W 115

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Electrical Schematic, Options

116
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Electrical Schematic, GR • QSW, ANSI / CSA

(from serial number GR10-20000 to GR11-20683 and QS11-1000 to QS11-1015)

117
Service Manual February 2022

Electrical Schematic, GR • QSW, ANSI / CSA

(from serial number GR10-20000 to GR11-20683 and QS11-1000 to QS-1015)

118 GR™ • QS™R • QS™W Part No. 1275811GT

February 2022 Service Manual

Electrical Schematic, GR • QSW, ANSI / CSA

(from serial number GR10-20000 to GR11-20683 and QS11-1000 to QS11-1015)

Part No. 1275811GT GR™ • QS™R • QS™W 119

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Electrical Schematic, GR • QSW, ANSI / CSA

(from serial number GR10-20000 to GR11-20683 and QS11-1000 to QS11-1015)

120
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Electrical Schematic, GR • QSW, ANSI / CSA

(from serial numbers GR11-20684 to GR14-29741 and QS11-1016 to QS14-1550)

121
Service Manual February 2022

Electrical Schematic, GR • QSW, ANSI / CSA

(from serial numbers GR11-20684 to GR14-29741 and QS11-1016 to QS14-1550)

122 GR™ • QS™R • QS™W Part No. 1275811GT

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Electrical Schematic, GR • QSW, ANSI / CSA

(from serial numbers GR11-20684 to GR14-29741 and QS11-1016 to QS14-1550)

Part No. 1275811GT GR™ • QS™R • QS™W 123

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Electrical Schematic, GR • QSW, ANSI / CSA

(from serial numbers GR11-20684 to GR14-29741 and QS11-1016 to QS14-1550)

124
February 2022 Service Manual

Electrical Schematic, GR • QSW, ANSI / CSA

(from serial numbers GR14-29742 to GR15-40225 and QS14-1551 to QS15-2426)

125
Service Manual February 2022

Electrical Schematic, GR • QSW, ANSI / CSA

(from serial numbers GR14-29742 to GR15-40225 and QS14-1551 to QS15-2426)

126 GR™ • QS™R • QS™W Part No. 1275811GT

February 2022 Service Manual

Electrical Schematic, GR • QSW, ANSI / CSA

(from serial numbers GR15-40226 to GR16P-41919 and QS15-2427 to QS16P-2451)

Part No. 1275811GT GR™ • QS™R • QS™W 127

Service Manual February 2022

Electrical Schematic, GR • QSW, ANSI / CSA

(from serial numbers GR15-40226 to GR16P-41929 and QS15-2427 to QS16P-2451)

128
February 2022 Service Manual

Electrical Schematic, GR • QSW, ANSI / CSA

(from serial numbers GR16P-41930 to GR16P-44173 and QS16P-2452 to QS16P-2469)

129
Service Manual February 2022

Electrical Schematic, GR • QSW, ANSI / CSA

(from serial numbers GR16P-41930 to GR16P-44173 and QS16P-2452 to QS16P-2468)

130 GR™ • QS™R • QS™W Part No. 1275811GT

February 2022 Service Manual

Electrical Schematic, GR • QSW, ANSI / CSA

(from serial numbers GR16P-44174 to GR16P-46499 and QS16P-2469 to QS16P-4499)
(from serial numbers GRP-46500 to 52300, GRR-101 to 3870 and QSP-4500 - 4653)

Part No. 1275811GT GR™ • QS™R • QS™W 131

Service Manual February 2022

Electrical Schematic, GR • QSW, ANSI / CSA

(from serial numbers GR16P-44174 to GR16P-46499 and QS16P-2469 to QS16P-4499)
(from serial numbers GRP-46500 to 52300, GRR-101 to 3870 and QSP-4500 to 4653)

132
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Electrical Schematic, GR • QSW • QSR, ANSI / CSA

(from serial number GRP-52301, GRR-3871 and QSP-4654)

Part No. 1275811GT GR™ • QS™R • QS™W 133

Service Manual February 2022

Electrical Schematic, GR • QSW • QSR, ANSI / CSA

(from serial numbers GRP-52301, GRR-3871 and QSP-4654)

134
February 2022 Service Manual

Electrical Schematic, QSR, ANSI / CSA

(from serial number QS11-1000 to QS11-1015)

135
Service Manual February 2022

Electrical Schematic, QSR, ANSI / CSA

(from serial number QS11-1000 to QS11-1015)

136 GR™ • QS™R • QS™W Part No. 1275811GT

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Electrical Schematic, QSR, ANSI / CSA

(from serial number QS11-1000 to QS11-1015)

Part No. 1275811GT GR™ • QS™R • QS™W 137

Service Manual February 2022

Electrical Schematic, QSR, ANSI / CSA

(from serial number QS11-1000 to QS11-1015)

138
February 2022 Service Manual

Electrical Schematic, QSR, ANSI / CSA

(from serial number QS11-1016 to QS14-1550)

139
Service Manual February 2022

Electrical Schematic, QSR, ANSI / CSA

(from serial number QS11-1016 to QS14-1550)

140 GR™ • QS™R • QS™W Part No. 1275811GT

February 2022 Service Manual

Electrical Schematic, QSR, ANSI / CSA

(from serial number QS11-1016 to QS14-1550)

Part No. 1275811GT GR™ • QS™R • QS™W 141

Service Manual February 2022

Electrical Schematic, QSR, ANSI / CSA

(from serial number QS11-1016 to QS14-1550)

142
February 2022 Service Manual

Electrical Schematic, QSR, ANSI / CSA

(from serial number QS14-1551 to QS15-2426)

143
Service Manual February 2022

Electrical Schematic, QSR, ANSI / CSA

(from serial number QS14-1551 to QS15-2426)

144 GR™ • QS™R • QS™W Part No. 1275811GT

February 2022 Service Manual

Electrical Schematic, QSR, ANSI / CSA

(from serial number QS15-2427 to QS16P-2451)

Part No. 1275811GT GR™ • QS™R • QS™W 145

Service Manual February 2022

Electrical Schematic, QSR, ANSI / CSA

(from serial number QS15-2427 to QS16P-2451)

146
February 2022 Service Manual

Electrical Schematic, QSR, ANSI / CSA

(from serial number QS16P-2452 to QS16P-2468)

147
Service Manual February 2022

Electrical Schematic, QSR, ANSI / CSA

(from serial number QS16P-2452 to QS16P-2468)

148 GR™ • QS™R • QS™W Part No. 1275811GT

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Electrical Schematic, QSR, ANSI / CSA

(from serial number QS16P-2469 to QS16P-4499)
(from serial number QSP-4500 to QSP-4653)

Part No. 1275811GT GR™ • QS™R • QS™W 149

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Electrical Schematic, QSR, ANSI / CSA

(from serial number QS16P-2469 to QS16P-4499)
(from serial number QSP-4500 to QSP-4653)

150
February 2022 Service Manual

Electrical Schematic, GR • QSW, AS / CE

(from serial numbers GR10-20000 to GR11-20683 and QS11-1000 to QS11-1015)

151
Service Manual February 2022

Electrical Schematic, GR • QSW, AS / CE

(from serial numbers GR10-20000 to GR11-20683 and QS11-1000 to QS11-1015)

152 GR™ • QS™R • QS™W Part No. 1275811GT

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Electrical Schematic, GR • QSW, AS / CE

(from serial numbers GR10-20000 to QR11-20683 and QS11-1000 to QS11-1015)

Part No. 1275811GT GR™ • QS™R • QS™W 153

Service Manual February 2022

Electrical Schematic, GR • QSW, AS / CE

(from serial numbers GR10-20000 to GR11-20683 and QS11-1000 to QS11-1015)

154
February 2022 Service Manual

Electrical Schematic, GR • QSW, AS / CE

(from serial numbers GR11-20684 to GR14-29741 and QS11-1016 to QS14-1550)

155
Service Manual February 2022

Electrical Schematic, GR • QSW, AS / CE

(from serial numbers GR11-20684 to GR14-29741 and QS11-1016 to QS14-1550)

156 GR™ • QS™R • QS™W Part No. 1275811GT

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Electrical Schematic, GR • QSW, AS / CE

(from serial numbers GR11-20684 to GR14-29741 and QS11-1016 to QS14-1550)

Part No. 1275811GT GR™ • QS™R • QS™W 157

Service Manual February 2022

Electrical Schematic, GR • QSW, AS / CE

(from serial numbers GR11-20684 to GR14-29741 and QS11-1016 to QS14-1550)

158
February 2022 Service Manual

Electrical Schematic, GR • QSW, AS / CE

(from serial numbers GR14-29742 to GR15-40225 and QS14-1551 to QS15-2426)

159
Service Manual February 2022

Electrical Schematic, GR • QSW, AS / CE

(from serial numbers GR14-29742 to GR15-40225 and QS14-1551 to QS15-2426)

160 GR™ • QS™R • QS™W Part No. 1275811GT

February 2022 Service Manual

Electrical Schematic, GR • QSW, AS / CE

(from serial numbers GR15-40226 to GR16P-41929 and QS15-2427 to QS16P-2451)

Part No. 1275811GT GR™ • QS™R • QS™W 161

Service Manual February 2022

Electrical Schematic, GR • QSW, AS / CE

(from serial numbers GR15-40226 to GR16P-41929 and QS15-2427 to QS16P-2451)

162
February 2022 Service Manual

Electrical Schematic, GR • QSW, AS / CE

(from serial numbers GR16P-41930 to GR16P-44173 and QS16P-2452 to QS16P-2468)

163
Service Manual February 2022

Electrical Schematic, GR • QSW, AS / CE

(from serial numbers GR16P-41930 to GR16P-44173 and QS16P-2452 to QS16P-2468)

164 GR™ • QS™R • QS™W Part No. 1275811GT

February 2022 Service Manual

Electrical Schematic, GR • QSW, AS / CE

(from serial numbers GR16P-44174 to GR16P-46499 and QS16P-2469 to QS16P-4499)
(from serial numbers GRP-46500 to 52300, GRR-101 to 3870 and QSP-4500 to 4653)

Part No. 1275811GT GR™ • QS™R • QS™W 165

Service Manual February 2022

Electrical Schematic, GR • QSW, AS / CE

(from serial numbers GR16P-44174 to GR16P-46499 and QS16P-2469 to QS16P-4499)
(from serial numbers GRP-46500 to 52300, GRR-101 to 3870 and QSP-4500 to 4653)

166
February 2022 Service Manual

Electrical Schematic, GR • QSW • QSR, AS / CE

(from serial number GRP-52301, GRR-3871 and QSP-4654)

Part No. 1275811GT GR™ • QS™R • QS™W 167

Service Manual February 2022

Electrical Schematic, GR • QSW • QSR, AS / CE

(from serial numbers GRP-52301, GRR-3871 and QSP-4654)

168
February 2022 Service Manual

Electrical Schematic, QSR, AS / CE

(from serial number QS11-1000 to QS11-1015)

169
Service Manual February 2022

Electrical Schematic, QSR, AS / CE

(from serial number QS11-1000 to QS11-1015)

170 GR™ • QS™R • QS™W Part No. 1275811GT

February 2022 Service Manual

Electrical Schematic, QSR, AS / CE

(from serial numbers QS11-1000 to QS11-1015)

Part No. 1275811GT GR™ • QS™R • QS™W 171

Service Manual February 2022

Electrical Schematic, QSR, AS / CE

(from serial number QS11-1000 to QS11-1015)

172
February 2022 Service Manual

Electrical Schematic, QSR, AS / CE

(from serial numbers QS11-1016 to QS14-1550)

173
Service Manual February 2022

Electrical Schematic, QSR, AS / CE

(from serial number QS11-1016 to QS14-1550)

174 GR™ • QS™R • QS™W Part No. 1275811GT

February 2022 Service Manual

Electrical Schematic, QSR, AS / CE

(from serial number QS11-1016 to QS14-1550)

Part No. 1275811GT GR™ • QS™R • QS™W 175

Service Manual February 2022

Electrical Schematic, QSR, AS / CE

(from serial number QS11-1016 to QS14-1550)

176
February 2022 Service Manual

Electrical Schematic, QSR, AS / CE

(from serial numbers QS14-1551 to QS15-2426)

177
Service Manual February 2022

Electrical Schematic, QSR, AS / CE

(from serial number QS14-1551 to QS15-2426)

178 GR™ • QS™R • QS™W Part No. 1275811GT

February 2022 Service Manual

Electrical Schematic, QSR, AS / CE

(from serial number QS15-2427 to QS16P-2451)

Part No. 1275811GT GR™ • QS™R • QS™W 179

Service Manual February 2022

Electrical Schematic, QSR, AS / CE

(from serial number QS15-2427 to QS16P-2451)

180
February 2022 Service Manual

Electrical Schematic, QSR, AS / CE

(from serial numbers QS16P-2452 to QS16P-2468)

181
Service Manual February 2022

Electrical Schematic, QSR, AS / CE

(from serial number QS16P-2452 to QS16P-2468)

182 GR™ • QS™R • QS™W Part No. 1275811GT

February 2022 Service Manual

Electrical Schematic, QSR, AS / CE

(from serial number QS16P-2469 to QS16P-4499)
(from serial number QSP-4500 to QSP-4653)

Part No. 1275811GT GR™ • QS™R • QS™W 183

Service Manual February 2022

Electrical Schematic, QSR, AS / CE

(from serial number QS16P-2469 to QS16P-4499)
(from serial number QSP-4500 to QSP-4653)

184
February 2022 Service Manual

Hydraulic Schematic, GR • QSR • QSW,

(from serial number GR10-20000 to GR12-24138 and QS11-1000 to QS12-1063)

185
Service Manual February 2022

Hydraulic Schematic, GR • QSR • QSW,

(from serial number GR10-20000 to GR12-24138 and QS11-1000 to QS12-1063)

186 GR™ • QS™R • QS™W Part No. 1275811GT

February 2022 Service Manual

Hydraulic Schematic, GR • QSR • QSW,

(from serial number GR12-24139 to GR16P-46499 and QS12-1064 to QS16P-4499)
(from serial number GRP-46500, GRR-101 and QSP-4500)

LEFT RIGHT
BRAKE BRAKE

LIFT CYLINDER CYLINDER K

MANIFOLD MANUAL RELEASE
HAND PUMP
LEFT RIGHT
Y5 DRIVE MOTOR DRIVE MOTOR
STEER STEER
M LEFT RIGHT J
L
MANUAL
RELEASE FORWARD REVERSE

L (LIFT) V (VENT) S1 (STEER 1) S2 (STEER 2) AC (ACC) B (BRAKE) HP (HAND PUMP) M1 (MOT 1) M4 (MOT 4)

Y2 Y1
F 10 psi
B 0,7 bar

1500 psi
A G 103 bar
H 0.75 gpm Y4 Y3
TP (TEST PORT) D
2,8 L/min E
1800-3500 psi
124-241 bar 10 psi
0,7 bar
3500 psi
241 bar Y6
C

P (PRESS) T (TANK)
FUNCTION MANIFOLD

M HS0039B

MOTOR FILTER ASSY

AND PUMP
TANK

Part No. 1275811GT GR™ • QS™R • QS™W 187

Service Manual February 2022

Hydraulic Schematic, GR • QSR • QSW,

(from serial number GR12-24139 to GR16P-46499 and QS12-1064 to QS16P-4499)
(from serial number GRP-46500, GRR-101 and QSP-4500)
GR™ • QS™R • QS™W Part No. 1275811GT Service Manual February 2022

188