Terex Genie GR-12 User manual

Service Manual
Part No. T110280
Rev B1
November 2014
from GR10-20000
Serial Number Range
from GR10-20000
from GR10-20000
GR -12
GR -15
GR -20
from QS11-1000
from QS11-1000
from QS11-1000
QS-12R
QS-15R
QS-20R
from QS11-1000
from QS11-1000
from QS11-1000
QS-12W
QS-15W
QS-20W

November 2014
GR • QSR • QSW Part No. T110280
ii
Important
Read, understand and obey the safety rules and
operating instructions in the appropriate
Operator's Manual on your machine before
attempting any maintenance procedure.
Basic mechanical, hydraulic and electrical
skills are required to perform most procedures.
However, several procedures require specialized
skills, tools, lifting equipment and a suitable
workshop. In these instances, we strongly
recommend that maintenance and repair be
performed at an authorized Genie dealer
service center.
Compliance
Machine Classification
Group A/Type 3 as defined by ISO 16368
Machine Design Life
Unrestricted with proper operation, inspection and
scheduled maintenance.
Technical Publications
Genie has endeavored to deliver the highest
degree of accuracy possible. However, continuous
improvement of our products is a Genie policy.
Therefore, product specifications
are subject to change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.
Copyright © 2011 by Terex Corporation
T110280 Rev B October 2011
Third Edition, Second Printing
"Genie" is a registered trademark of Terex South
Dakota in the USA and many other countries.
"GR" is a trademark of Terex South Dakota, Inc.
Printed on recycled paper
Printed in U.S.A.
Contact Us:
www.genielift.com
e-mail:[email protected]
Serial Number Information
Genie offers the following Service Manuals for
these models:
Title Part No.
Genie Runabout Service Manual,
First Edition
(GR - before serial number 5001) ......................... 72965
Genie Runabout Service Manual,
Second Edition
(GR - from serial number 5001 to 19999)
(QS - from 101 to 999) .......................................... 84700
Introduction

November 2014
Part No. T110280 GR • QSR • QSW
Revision History
Revision Date Section Procedure / Schematic Page / Description
A 4/2011 New release
B 10/2011 2 - Spec. 2-1
3 - Maint. 3-5, 3-27
6 - Schem. 6-2, 6-3, 6-4, 6-6, 6-10, 6-14, 6-18, 6-22, 6-26, 6-30, 6-34
B1 11/2014 6 - Spec. 2-5, 2-6
4 - Repair 12-2
6 - Schem. 6-39
REFERENCE EXAMPLES:
Section 3_Maintenance, B-3.
Section 4_Repair Procedure, 4-2.
Section 5_Diagnostic Codes, All charts.
Section 6_Schematics, Legends diagrams and
schematics.
Electronic Version
Click on any procedure or page number
highlighted in blue to view the update.
iii

November 2014
GR • QSR • QSW Part No. T110280
iv
REVISION HISTORY, CONTINUED
Revision Date Section Procedure / Schematic Page / Description
REFERENCE EXAMPLES:
Kubota Engine_Section 2_Specifications.
A-6,B-3,C-7_Section 3_Maintenance Procedure.
3-2, 6-4, 9-1_Section 4_Repair Procedure.
Fault Codes_Section 5.
6-35, 6-56, 6-104_Section 6_Schematic Page #.
Electronic Version
Click on any procedure or page number
highlighted in blue to view the update.

November 2014
Part No. T110280 GR • QSR • QSW
Serial Number Legend
v
INTRODUCTION

November 2014
GR • QSR • QSW Part No. T110280
vi
Danger
Failure to obey the instructions and safety rules
in this manual and the appropriate Operator's
Manual on your machine will result in death or
serious injury.
Many of the hazards identified in the
operator’s manual are also safety hazards
when maintenance and repair procedures
are performed.
Do Not Perform Maintenance
Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
- manufacturer’s instructions and safety rules
- employer’s safety rules and worksite
regulations
- applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.
Safety Rules

November 2014
Part No. T110280 GR • QSR • QSW
SAFETY RULES
vii
Workplace Safety
Be sure to keep sparks, flames and
lighted tobacco away from flammable and
combustible materials like battery gases
and engine fuels. Always have an approved fire
extinguisher within easy reach.
Be sure that all tools and working areas
are properly maintained and ready for
use. Keep work surfaces clean and free
of debris that could get into machine components
and cause damage.
Be sure any forklift, overhead crane or
other lifting or supporting device is fully
capable of supporting and stabilizing the
weight to be lifted. Use only chains or straps that
are in good condition and of ample capacity.
Be sure that fasteners intended for one
time use (i.e., cotter pins and self-locking
nuts) are not reused. These components
may fail if they are used a second time.
Be sure to properly dispose of old oil or
other fluids. Use an approved container.
Please be environmentally safe .
Be sure that your workshop or work area
is properly ventilated and well lit.
Personal Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Read each procedure thoroughly. This
manual and the decals on the machine,
use signal words to identify the following:
Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicates an imminently
hazardous situation which, if not
avoided, will result in death or
serious injury.
Indicates a potentially hazardous
situation which, if not avoided,
could result in death or serious
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may cause minor or moderate
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may result in property damage.
Be sure to wear protective eye wear and
other protective clothing if the situation
warrants it.
Be aware of potential crushing hazards
such as moving parts, free swinging or
unsecured components when lifting or placing
loads. Always wear approved steel-toed shoes.

November 2014
GR • QSR • QSW Part No. T110280
Table of Contents
Introduction
Important Information ........................................................................................ ii
Serial Number Information................................................................................. ii
Serial Number Legend ..................................................................................... iii
Section 1 Safety Rules
General Safety Rules ....................................................................................... v
Section 2 Specifications
Machine Specifications ................................................................................ 2 - 1
Performance Specifications ......................................................................... 2 - 2
Hydraulic Specifications .............................................................................. 2 - 3
Manifold Component Specifications ............................................................ 2 - 4
Hydraulic Hose and Fitting Torque Specifications ....................................... 2 - 5
SAE and Metric Fasteners Torque Charts ................................................... 2 - 7
Section 3 Scheduled Maintenance Procedures
Introduction .................................................................................................. 3 - 1
Pre-delivery Preparation Report .................................................................. 3 - 3
Maintenance Inspection Report ................................................................... 3 - 5
Checklist A Procedures
A-1 Inspect the Manuals and Decals ........................................................ 3 - 6
A-2 Perform Pre-operation Inspection ...................................................... 3 - 7
A-3 Perform Function Tests ...................................................................... 3 - 7
A-4 Test the Obstruction Sensing System (QSR models only) ................. 3 - 8
A-5 Perform 30 Day Service ................................................................... 3 - 10
A-6 Grease the Steer Yokes ................................................................... 3 - 10
viii

November 2014
Part No. T110280 GR • QSR • QSW
TABLE OF CONTENTS
Section 3 Scheduled Maintenance Procedures, continued
Checklist B Procedures
B-1 Inspect the Batteries......................................................................... 3 - 11
B-2 Inspect the Electrical Wiring ............................................................. 3 - 14
B-3 Inspect the Tires and Wheels (including castle nut torque) .............. 3 - 15
B-4 Check the Lifting Chain Adjustments ............................................... 3 - 15
B-5 Clean and Lubricate the Columns .................................................... 3 - 16
B-6 Adjust the Sequencing Cables ......................................................... 3 - 16
B-7 Test the Emergency Stop ................................................................. 3 - 17
B-8 Test the Key Switch.......................................................................... 3 - 18
B-9 Test the Automotive-style Horn (if equipped) ................................... 3 - 18
B-10 Inspect the Voltage Inverter (if equipped) ........................................ 3 - 19
B-11 Test the Drive Brakes ....................................................................... 3 - 20
B-12 Test the Drive Speed - Stowed Position ........................................... 3 - 21
B-13 Test the Drive Speed - Raised Position............................................ 3 - 22
B-14 Test the Slow Drive Speed ............................................................... 3 - 23
B-15 Test the Motion Alarm (if equipped) ................................................. 3 - 24
B-16 Test the Flashing Beacons (if equipped) .......................................... 3 - 25
B-17 Perform Hydraulic Oil Analysis ......................................................... 3 - 26
B-18 Inspect the Breather Cap ................................................................. 3 - 26
B-19 Inspect the Electrical Contactor ........................................................ 3 - 27
Checklist C Procedures
C-1 Grease the Platform Overload Mechanism (if equipped) ................. 3 - 28
C-2 Replace the Hydraulic Tank Breather Cap -
Models with Optional Hydraulic Oil ................................................... 3 - 29
C-3 Test the Platform Overload System (if equipped)............................. 3 - 29
Checklist D Procedures
D-1 Inspect the Mast Assembly for Wear ................................................ 3 - 31
D-2 Inspect and Lubricate the Lifting Chains .......................................... 3 - 32
D-3 Replace the Hydraulic Tank Return Filter......................................... 3 - 33
Checklist E Procedure
E-1 Test or Replace the Hydraulic Oil ..................................................... 3 - 34
ix

November 2014
GR • QSR • QSW Part No. T110280
TABLE OF CONTENTS
Section 4 Repair Procedures
Introduction .................................................................................................. 4 - 1
Platform Controls
1-1 Circuit Board ...................................................................................... 4 - 3
1-2 Joystick .............................................................................................. 4 - 4
1-3 Platform Controls Alarm ..................................................................... 4 - 4
1-4 Platform Emergency Stop Button ....................................................... 4 - 5
Ground Controls
2-1 Software Revision Level .................................................................... 4 - 7
2-2 Machine Setup ................................................................................... 4 - 8
2-3 Level Sensor ...................................................................................... 4 - 9
Hydraulic Pump
3-1 Function Pump ................................................................................. 4 - 12
Function Manifold
4-1 Function Manifold Components ....................................................... 4 - 14
4-2 Valve Adjustments - Function Manifold ............................................ 4 - 16
4-3 Valve Coils ....................................................................................... 4 - 20
Brake Release Hand Pump Components
5-1 Brake Release Hand Pump Components ........................................ 4 - 22
Hydraulic Tank
6-1 Hydraulic Tank ................................................................................. 4 - 23
Steer Axle Components
7-1 Yoke and Drive Motor ...................................................................... 4 - 24
7-2 Steer Cylinder .................................................................................. 4 - 26
7-3 Steer Bellcrank ................................................................................ 4 - 26
Non-steer Axle Components
8-1 Drive Brake ...................................................................................... 4 - 27
Obstruction Sensing System
9-1 Obstruction Sensing Pads (QSR models only) ................................ 4 - 28
x

November 2014
Part No. T110280 GR • QSR • QSW
Section 4 Repair Procedures, continued
Platform Components
10-1 Platform ........................................................................................... 4 - 30
10-2 Platform Extension ........................................................................... 4 - 31
10-3 Work Tray ........................................................................................ 4 - 32
Mast Components
11-1 Mast ................................................................................................. 4 - 33
11-2 Glide Pads ....................................................................................... 4 - 37
11-3 Lifting Chains ................................................................................... 4 - 37
11-4 Lift Cylinder ...................................................................................... 4 - 40
Platform Overload Components
12-1 Platform Overload System ............................................................... 4 - 41
12-2 Platform Overload Recovery Message ............................................ 4 - 43
Section 5 Diagnostics
Introduction .................................................................................................. 5 - 1
GCON I/O Map without Load Sense............................................................ 5 - 4
GCON I/O Map with Load Sense ................................................................ 5 - 5
Operational Indicator Codes ........................................................................ 5 - 6
Diagnostic Trouble Codes ........................................................................... 5 - 6
Troubleshooting "HXXX" and "PXXX" Faults ............................................... 5 - 7
Fault Inspection Procedure.......................................................................... 5 - 8
Type "HXXX" Faults .................................................................................. 5 - 10
Type "PXXX" Faults ................................................................................... 5 - 11
Type "UXXX" Faults .................................................................................. 5 - 12
Type "FXXX" Faults ................................................................................... 5 - 13
Type "CXXX" Faults .................................................................................. 5 - 14
TABLE OF CONTENTS
xi

November 2014
GR • QSR • QSW Part No. T110280
Section 6 Schematics
Introduction .................................................................................................. 6 - 1
Electrical Component and Wire Color Legends ........................................... 6 - 2
Wiring Diagram - Ground and Platform Controls ......................................... 6 - 3
Electrical Symbols Legend .......................................................................... 6 - 4
Electrical Schematic - GR and QSW - ANSI and CSA Models
(from GR10-20000 to GR11-20683 and from QS11-1000 to QS11-1015) .. 6 - 6
Electrical Schematic - GR and QSW - ANSI and CSA Models
(from GR11-20684 and from QS11-1016) ................................................. 6 - 10
Electrical Schematic - QSR - ANSI and CSA Models
(from QS11-1000 to QS11-1015) .............................................................. 6 - 14
Electrical Schematic - QSR - ANSI and CSA Models
(from QS11-1016) ..................................................................................... 6 - 18
Electrical Schematic - GR and QSW - CE and AUS models
(from GR10-20000 to GR11-20683 and from QS11-1000 to QS11-1015) 6 - 22
Electrical Schematic - GR and QSW - CE and AUS models
(from GR11-20684 and from QS11-1016) ................................................. 6 - 26
Electrical Schematic - QSR - CE and AUS models
(from QS11-1000 to QS11-1015) .............................................................. 6 - 30
Electrical Schematic - QSR - CE and AUS models
(from QS11-1016) ..................................................................................... 6 - 34
Hydraulic Component Reference and Symbols Legend ............................ 6 - 37
Hydraulic Schematic .................................................................................. 6 - 38
xii
TABLE OF CONTENTS

Section 2 • SpecificationsNovember 2014
Part No. T110280 GR • QSR • QSW 2 - 1
Machine Specifications
Batteries, Standard
Voltage 6V DC
Group GC2
Type T-105
Quantity 4
Battery capacity, maximum C20 = 225AH
Reserve capacity @ 25A rate 447 minutes
Batteries, Maintenance-free (option)
Voltage 6V DC
Group GC2
Type 6V-AGM
Quantity 4
Battery capacity, maximum 200AH
Reserve capacity @ 25A rate 380 minutes
DC Motor
Voltage 24 V
Horse Power 4.5 HP @ 2950 RPM
Kilowatts 3.3 kW @ 2950 RPM
Fluid capacities
Hydraulic tank 1.5 gallons
5.7 liters
Hydraulic system 2.2 gallons
(including tank) 8.3 liters
For operational specifications, refer to the
Operator's Manual.
Height, stowed maximum
GR-12, GR-15, QS-12R , QS-15R
QS-12W and QS-15W 62 in
(ANSI and CSA) 1.57 m
GR-12, GR-15, QS-12R , QS-15R
QS-12W and QS-15W 68.1 in
(CE models and Australia models) 1.73 m
GR-20, QS-20R and QS-20W 78 in
(all models) 1.98 m
Tires and wheels
Tire size (solid rubber) 10 x 3 in
25.4 x 7.62 cm
Tire contact area 6.5 sq in
41.9 cm2
Castle nut torque, lubricated 150 ft-lbs
203 Nm
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.
Specifications

Section 2 • Specifications November 2014
2 - 2 GR • QSR • QSW Part No. T110280
SPECIFICATIONS
Performance Specifications
Drive speed, maximum
Platform stowed, fast 2.5 mph
40 ft / 10.9 sec
4 km/h
12.2 m / 10.9 sec
Platform stowed, slow 1.1 mph
40 ft / 24.8 sec
1.8 km/h
12.2 m / 24.8 sec
Platform raised 0.5 mph
40 ft / 55 sec
0.8 km/h
12.2 m / 55 sec
Braking distance, maximum
High range on paved surface 19 in ± 6 in
48 cm ± 15 cm
Gradeability 30%
Airborne noise emissions
Sound pressure level at ground workstation < 70 dBA
Sound pressure level at platform workstation < 70 dBA
Maximum slope rating,
Function speed, maximum from platform controls
(with 1 person in platform)
GR-12, QS-12R and 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 and 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 and QS-20W
Platform up (fast mode) 23 to 25 seconds
Platform up (slow mode) 32 to 34 seconds
Platform down 20 to 22 seconds
Rated work load at full height, maximum
GR-12 and GR-15
Standard Platform 500 lbs
227 kg
GR-20
Standard Platform 350 lbs
159 kg
GR-12, GR-15 and GR-20
AWP Platform 350 lbs
159 kg
QS-12R, QS-15R, QS-12W and QS-15W
Stockpicker Platform 500 lbs
227 kg
QS-20R and QS-20W
Stockpicker Platform 350 lbs
159 kg
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.

Section 2 • SpecificationsNovember 2014
Part No. T110280 GR • QSR • QSW 2 - 3
Hydraulic Specifications
Hydraulic Oil Specifications
Hydraulic oil type Chevron Rando HD equivalent
Viscosity grade Multi-viscosity
Viscosity index 200
Cleanliness level, minimum ISO 15/13
Water content, maximum 200 ppm
Chevron Rando HD oil is fully compatible and
mixable with Shell Donax TG (Dexron III) oils.
Genie specifications require hydraulic oils which are
designed to give maximum protection to hydraulic
systems, have the ability to perform over a wide
temperature range, and the viscosity index should
exceed 140. They should provide excellent antiwear,
oxidation, corrosion inhibition, seal conditioning, and
foam and aeration suppression properties.
Optional fluids
Biodegradable Petro Canada Environ MV 46
Statoil Hydra Way Bio SE 32
BP Biohyd SE-S
Fire resistant UCON Hydrolube HP-5046
Quintolubric 822
Mineral based Shell Tellus T32
Shell Tellus T46
Chevron Aviation A
Continued use of Chevron
Aviation A hydraulic fluid when
ambient temperatures are
consistently above 32°F / 0°C
may result in component damage.
Note: Use Chevron Aviation A hydraulic fluid
when ambient temperatures are consistently
below 0°F / -17°C.
Note: Use Shell Tellus T46 hydraulic oil when oil
temperatures consistently exceed 205°F / 96°C.
Note: Genie specifications require additional
equipment and special installation instructions for
the approved optional fluids. Consult the Genie
Service Department before use.
Function pump
Type Gear
Displacement per revolution 0.244 cu in
4 cc
Flow rate @ 2500 psi / 172 bar 4 gpm
15 L/min
Hydraulic tank return filter 10 micron with
25 psi / 1.7 bar bypass
Function manifold
System relief valve pressure, maximum 3500 psi
241 bar
Lift relief valve pressure 1800 to 3500 psi
124 to 241 bar
Steer relief valve pressure 1500 psi
103 bar
SPECIFICATIONS
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.

Section 2 • Specifications November 2014
2 - 4 GR • QSR • QSW Part No. T110280
SPECIFICATIONS
Manifold Component
Specifications
Plug torque
SAE No. 2 50 in-lbs / 6 Nm
SAE No. 4 13 ft-lbs / 18 Nm
SAE No. 6 18 ft-lbs / 24 Nm
SAE No. 8 50 ft-lbs / 68 Nm
SAE No. 10 55 ft-lbs / 75 Nm
SAE No. 12 75 ft-lbs / 102 Nm
Valve Coil Resistance
Note: The following coil resistance specifications are at
an ambient temperature of 68°F / 20°C. As valve coil
resistance is sensitive to changes in air temperature, the
coil resistance will typically increase or decrease by 4%
for each 18°F / -7.7°C that your air temperature
increases or decreases from 68°F / 20°C.
Description Specification
Solenoid valve, 3 position 4 way 27.2Ω
20V DC with diode (schematic item E)
Solenoid valve, 3 position 4 way 19Ω
20V DC with diode (schematic item F)
Solenoid valve, 2 position 4 way 25Ω
20V DC with diode (schematic item H)
Solenoid valve, 2 position 2 way N.C. 6.25Ω
with manual override
12V DC with diode (schematic item N)
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.

Section 2 • SpecificationsNovember 2014
Part No. T110280 GR • QSR • QSW 2 - 5
Hydraulic Hose and Fitting
Torque Specifications
Your machine is equipped with JIC 37° flared
fittings and hose ends. Genie specifications
require that fittings and hose ends be torqued to
specification when they are removed and installed
or when new hoses or fittings are installed.
SPECIFICATIONS
Seal-Lok™Fittings
(hose end - ORFS)
SAE Dash size Torque
-4 10 ft-lbs / 13.6 Nm
-6 30 ft-lbs / 40.7 Nm
-8 40 ft-lbs / 54.2 Nm
-10 60 ft-lbs / 81.3 Nm
-12 85 ft-lbs / 115 Nm
-16 110 ft-lbs / 150 Nm
-20 140 ft-lbs / 190 Nm
-24 180 ft-lbs / 245 Nm
JIC 37° Fittings
(swivel nut or hose connection)
SAE Dash size Thread Size Flats
-4 7/16-20 2
-6 9/16-18 1 1/4
-8 3/4-16 1
-10 7/8-14 1
-12 1 1/16-12 1
-16 1 5/16-12 1
-20 1 5/8-12 1
-24 1 7/8-12 1
SAE O-ring Boss Port
(tube fitting - installed into Aluminum)
(all types)
SAE Dash size Torque
-4 14 ft-lbs / 19 Nm
-6 23 ft-lbs / 31.2 Nm
-8 36 ft-lbs / 54.2 Nm
-10 62 ft-lbs / 84 Nm
-12 84 ft-lbs / 114 Nm
-16 125 ft-lbs / 169.5 Nm
-20 151 ft-lbs / 204.7 Nm
-24 184 ft-lbs / 249.5 Nm
SAE O-ring Boss Port
(tube fitting - installed into Steel)
SAE Dash size Torque
-4 ORFS / 37° (Adj) 15 ft-lbs / 20.3 Nm
ORFS (Non-adj) 26 ft-lbs / 35.3 Nm
37° (Non-adj) 22 ft-lbs / 30 Nm
-6 ORFS (Adj / Non-adj) 35 ft-lbs / 47.5 Nm
37° (Adj / Non-adj) 29 ft-lbs / 39.3 Nm
-8 ORFS (Adj / Non-adj) 60 ft-lbs / 81.3 Nm
37° (Adj / Non-adj) 52 ft-lbs / 70.5 Nm
-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
Adjustable
fitting (Adj)
Non-adjustable
fitting (Non-
adj)
Jamb nut

Section 2 • Specifications November 2014
2 - 6 GR • QSR • QSW Part No. T110280
SPECIFICATIONS
Torque Procedure
Seal-Lok™ fittings
1 Replace the O-ring. The O-ring must be
replaced anytime the seal has been broken.
The O-ring cannot be re-used if the fitting or
hose end has been tightened beyond finger
tight.
Note: The O-rings used in the Parker Seal Lok™
fittings and hose ends are custom-size O-rings.
They are not standard SAE 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 that the face seal O-ring is seated and
retained properly.
4 Position the tube and nut squarely on the face
seal end of the fitting and tighten the nut finger
tight.
5 Tighten the nut or fitting to the appropriate
torque per given size as shown in the table.
6 Operate all machine functions and inspect the
hoses and fittings and related components to
confirm that there are no leaks.
JIC 37° fittings
1 Align the tube flare (hex nut) against the nose
of the fitting body (body hex fitting) and tighten
the hex nut to the body hex fitting to hand-tight,
approximately 30 in-lbs / 3.4 Nm.
2 Make a reference mark on one of the flats of
the hex nut, and continue it on to the body hex
fitting with a permanent ink marker. Refer to
Figure 1.
Figure 1
a hex nut
b reference mark
c body hex fitting
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 Figure 2.
Note: Use the JIC 37° Fittings table on the
previous page to determine the correct number of
flats for the proper tightening position.
Note: The marks indicate that 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.
Figure 2
a body hex fitting
b reference mark
c 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
hoses and fittings and related components to
confirm that there are no leaks.
a
b
c
a
b
c
b

Section 2 • SpecificationsNovember 2014
Part No. T110280 GR • QSR • QSW 2 - 7
SPECIFICATIONS
SIZE THREAD
in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm
20 80 9 100 11.3 110 12.4 140 15.8 130 14.7
28 90 10.1 120 13.5 120 13.5 160 18 140 15.8
ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm
18 13 17.6 17 23 18 24 25 33.9 21 28.4
2
4
14 19 19 25.7 20 27.1 27 36.6 24 32.5
16 23 31.2 31 42 33 44.7 44 59.6 38 51.5
2
4
26 35.2 35 47.4 37 50.1 49 66.4 43 58.3
1
4
37 50.1 49 66.4 50 67.8 70 94.7 61 82.7
20 41 55.5 55 74.5 60 81.3 80 108.4 68 92.1
13 57 77.3 75 101.6 80 108.4 110 149 93 126
20 64 86.7 85 115 90 122 120 162 105 142
12 80 108.4 110 149 120 162 150 203 130 176
18 90 12
2
120 162 130 176 170 230 140 189
11 110 149 150 203 160 217 210 284 180 244
18 130 176 170 230 180 244 240 325 200 271
10 200 271 270 366 280 379 380 515 320 433
16 220 298 300 406 310 420 420 569 350 474
9320 433 430 583 450 610 610 827 510 691
1
4
350 474 470 637 500 678 670 908 560 759
8480 650 640 867 680 922 910 1233 770 1044
12 530 718 710 962 750 1016 990 1342 840 1139
7590 800 790 1071 970 1315 1290 1749 1090 1477
12 670 908 890 1206 1080 1464 1440 1952 1220 1654
7840 1138 1120 1518 1360 1844 1820 2467 1530 2074
12 930 1260 1240 1681 1510 2047 2010 2725 1700 2304
6
1460 1979 1950 2643 2370 3213 3160 4284 2670 3620
12 1640 2223 2190 2969 2670 3620 3560 4826 3000 4067
5/16
3/8
7/16
1/2
1 1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
LUBED
1/4
LUBED DRY LUBED DRY
LUBEDDRYLUBED
SAE FASTENER TORQUE CHART
Grade 5
DRYLUBED
• Thischart is to beused as aguideonlyunlessnotedelsewhereinthismanual •
A574 High Strength
Black Oxide Bolts
Grade 8
Size
(mm) in-lbs Nm in-lb
s
N
m
in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lb
s
Nm in-lbs N
m
5
16 1.8 21 2.4 41 4.63 54 6.18 58 6.63 78 8.84 68 7.75 91 10.3
6
19 3.05 36 4.07 69 7.87 93 10.5 100 11.3 13
2
15 116 13.2 155 17.6
745 5.12 60 6.83 116 13.2 155 17.6 167 18.9 223 25.2 1.95 22.1 260 29.4
ft-lbsNmft-lbsNmft-lbsNmft-lbsNmft-lbsNmft-lbsNmft-lbsNmft-lbsNm
85.4 7.41 7.2 9.88 14 19.1 18.8 25.5 20.1 27.3 26.9 36.5 23.6 32 31.4 42.6
10 10.8 14.7 14.4 19.6 27.9 37.8 37.2 50.5 39.9 54.1 53.2 72.2 46.7 63.3 62.3 84.4
12 18.9 25.6 25.1 34.1 48.6 66 64.9 88 69.7 94.5 92.2 125 81 110 108 14
7
14 30.1 40.8 40 54.3 77.4 105 103 140 110 150 14
7
200 129 175 17
2
234
16 46.9 63.6 62.5 84.8 125 170 166 226 173 235 230 313 20
2
274 269 365
18 64.5 87.5 86.2 117 171 233 229 311 238 323 31
7
430 278 37
7
371 503
20 91 124 121 165 243 330 325 441 337 458 450 610 394 535 525 713
22 124 169 166 225 331 450 442 600 458 622 61
2
830 536 72
7
715 970
24 157 214 210 285 420 570 562 762 583 791 778 1055 68
2
925 909 1233
LUBED DRY LUBED DRYLUBED DRY LUBED DRY
LUBEDDRYLUBED
Class 12.9Class 4.6
DRYLUBED
METRIC FASTENER TORQUE CHAR
T
• Thischartis tobeused as aguideonlyunlessnotedelsewhereinthismanual •
LUBED DRY
Class 10.9Class 8.8
DRY

Section 2 • Specifications November 2014
2 - 8 GR • QSR • QSW Part No. T110280
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