Terex Genie GRC-12 Bedienungsanleitung

Service Manual

Serial Number Range

GRC™-12

from GRC11-1000

to GRC16P-

2369

from GRC16P-2370

to GRC16P-

4599

from GRCP-4600

to GRCP-

5999

Original Instructions

Part No. 1314708GT

Rev A

February 2022

Service Manual February 2022

Introduction

ii GRC™Part No. 1314708GT

Intro ductio n Intro ductio n

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.

This manual provides detailed scheduled

maintenance information for the machine owner

and user. It also provides troubleshooting and

repair procedures for qualified service

professionals.

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.

Internet: www.genielift.com

E-mail: awp.techpub@terex.com

Find a Manual for this Model

Go to http://www.genielift.com

Use the links to locate Service Manuals,

Maintenance Manuals, Service and Repair

Manuals, Parts Manuals and Operator's Manuals.

1314708GT Rev A, February 2022

Third Edition, First Printing

Genie is a registered trademark of Terex South Dakota, Inc. in

the U.S.A. and many other countries.

“GRC” is a trademark of Terex South Dakota, Inc.

February 2022 Service Manual

Introduction

Part No. 1314708GT GRC™iii

Revision History

Revision Date Section Procedure / Page / Description

A 2/2022

Initial Release

Reference Examples:

Section – Maintenance, B-3

Electronic Version

Click on any content or procedure in the Table of Contents to view

the update.

Section – Repair Procedure, 4-2

Section – Fault Codes, All charts

Section – Schematics, Legends and schematics

Service Manual February 2022

Safety Rules

4 GRC™Part No. 1314708GT

Serial Number Legend

August 31, 2016

1 Model

2 Model year

3 Facility code

4 Sequence number

5 Serial label (behind covers)

6 Serial number stamped on chassis

From September 1, 2016

1 Model

2 Facility code

3 Sequence number

4 Serial label (behind covers)

5 Serial number stamped on chassis

February 2022 Service Manual

Safety Rules

Part No. 1314708GT GRC™v

Sec ti on 1 Safety Rul es

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.

Service Manual February 2022

Safety Rules

vi GRC™Part No. 1314708GT

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 a 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 co

mponents

when lifting or placing loads. Always

wear approved steel

-toed shoes.

Workplace 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.

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 m

ay 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.

February 2022

Table of Contents

Part No. 1314708GT GRC™vii

Introduction Introduction ......................................................................................................ii

Important Information ......................................................................................... ii

Find a Manual for this Model............................................................................... ii

Revision History ................................................................................................ iii

Serial Number Legend........................................................................................4

Section 1 Safety Rules......................................................................................................v

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

Section 2 Specifications...................................................................................................1

Machine Specifications .......................................................................................1

Performance Specifications ................................................................................1

Hydraulic Component and Manifold Specifications..............................................2

Manifold Component Specifications ....................................................................2

Hydraulic Oil Specifications ................................................................................3

Hydraulic Hose and Fitting Torque Specifications ...............................................6

Torque Procedure ..............................................................................................7

February 2022

Table of Contents

viii GRC™Part No. 1314708GT

Section 3 Scheduled Maintenance Procedures .............................................................. 9

Introduction........................................................................................................ 9

Pre-Delivery Preparation Report....................................................................... 12

Maintenance Inspection Report ........................................................................ 13

Checklist A Procedures ................................................................................. 14

A-1 Perform 50 Hour Service ........................................................................... 14

A-2 Grease the Steer Yokes............................................................................. 14

Checklist B Procedures ................................................................................. 15

B-1 Inspect the Batteries .................................................................................. 15

B-2 Inspect the Electrical Wiring....................................................................... 18

B-3 Inspect the Electrical Contactor.................................................................. 18

B-4 Inspect the Voltage Inverter (if equipped) ................................................... 19

B-5 Test the Flashing Beacons......................................................................... 20

B-6 Test the Alarm Package (if equipped) ........................................................ 20

B-7 Inspect the Tires, Wheels and Castle Nut Torque....................................... 21

B-8 Test the Drive Brakes ................................................................................ 21

B-9 Test the Drive Speed – Stowed Position .................................................... 22

B-10 Test the Drive Speed - Raised Position.................................................... 22

B-11 Visual Inspection of the Hydraulic Oil ....................................................... 23

B-12 Inspect the Breather Cap ......................................................................... 24

Checklist C Procedures ................................................................................. 25

C-1 Repalce the Hydraulic Tank Breather Cap –

Models with Optional Hydraulic Oil............................................................ 25

Checklist D Procedures ................................................................................. 26

D-1 Replace the Hydraulic Return Filter ........................................................... 26

Checklist E Procedures ................................................................................. 27

E-1 Test or Replace the Hydraulic Oil............................................................... 27

February 2022

Table of Contents

Part No. 1314708GT GRC™ix

Section 4 Repair Procedures..........................................................................................29

Introduction ......................................................................................................29

Platform Controls ...........................................................................................31

1-1 Circuit Board ..............................................................................................32

1-2 Joystick ......................................................................................................33

1-3 Platfrom Controls Alarm..............................................................................34

1-4 Platform Emergency Stop Button................................................................34

Ground Controls.............................................................................................35

2-1 Software Revision Level .............................................................................36

2-2 Machine Setup ...........................................................................................37

2-3 Level Sensor ..............................................................................................38

Hydraulic Pump ..............................................................................................41

3-1 Hydraulic Pump ..........................................................................................41

How to Remove the Hydraulic Pump............................................................42

Function Manifold...........................................................................................43

4-1 Function Manifold Components ..................................................................43

4-2 Valve Adjustments – Function Manifold ......................................................45

4-3 Valve Coils .................................................................................................48

Brake Release Hand Pump Components ......................................................50

5-1 Brake Release Hand Pump Components....................................................50

Hydraulic Tank................................................................................................51

6-1 Hydraulic Tank ...........................................................................................51

Non-Steer Axle Components .........................................................................52

7-1 Drive Brake ................................................................................................52

Steer Axle Components .................................................................................53

8-1 Yoke and Drive Motor.................................................................................53

8-2 Steer Cylinder ............................................................................................54

8-3 Tie Rod ......................................................................................................55

February 2022

Table of Contents

x GRC™Part No. 1314708GT

Platform Components.................................................................................... 56

9-1 Platform ..................................................................................................... 56

9-2 Platform Extension Deck ............................................................................ 57

How to Remove the Platform Extension Deck, GRC Models........................ 57

Mast Components.......................................................................................... 58

10-1 Mast......................................................................................................... 58

How to Remove the Mast Assembly............................................................ 58

How to Disassemble the Mast ..................................................................... 60

How to Assemble the Mast.......................................................................... 64

10-2 Wear Pads............................................................................................... 70

10-3 Lift Cylinders ............................................................................................ 70

How to Remove the Lift Cylinder ................................................................. 70

10-4 Lift Cylinder Wear Block ........................................................................... 73

10-5 Mast Coil Cord ......................................................................................... 73

Battery Charger.............................................................................................. 74

11-1 Battery Charger........................................................................................ 74

Selecting a Charge Profile........................................................................... 75

Batteries ......................................................................................................... 76

12-1 How to Remove the Batteries ................................................................... 76

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