Terex Genie GRC-12 Service Manual
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Terex Genie GRC-12 Service Manual

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Service Manual
GRC
-12
™
Serial Number Range
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

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Summary of Contents for Terex Genie GRC-12

  • Page 1 Service Manual Serial Number Range ™ 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...

  • Page 2: Find A Manual For This Model

    Unrestricted with proper operation, inspection and scheduled maintenance. 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. ™...

  • Page 3: Revision History

    February 2022 Service Manual Introduction Revision History Revision Date Section Procedure / Page / Description 2/2022 Initial Release Reference Examples: Section – Maintenance, B-3 Electronic Version Section – Repair Procedure, 4-2 Click on any content or procedure in the Table of Contents to view Section –...

  • Page 4: Serial Number Legend

    Service Manual February 2022 Safety Rules Serial Number Legend To August 31, 2016 1 Model 5 Serial label (behind covers) 2 Model year 6 Serial number stamped on chassis 3 Facility code 4 Sequence number From September 1, 2016 1 Model 4 Serial label (behind covers) 2 Facility code 5 Serial number stamped on chassis...
  • Page 5 February 2022 Service Manual Safety Rules Secti 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.
  • Page 6 Service Manual February 2022 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...

  • Page 7: Table Of Contents

    February 2022 Table of Contents 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 ....................
  • Page 8 February 2022 Table of Contents 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 .................
  • Page 9 February 2022 Table of Contents 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 .....................
  • Page 10 February 2022 Table of Contents 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 ..............
  • Page 11 February 2022 Table of Contents Section 5 Diagnostics ..................... 77 Introduction ...................... 77 GCON I/O MAP ....................79 Operation Indicator Codes (OIC) ..............80 Diagnostic Trouble Codes (DTC) ..............80 Troubleshooting "HXXX" and "PXXX" Faults ............. 81 Fault Inspection Procedure ................82 Type "HXXX"...
  • Page 12 February 2022 Table of Contents Section 6 Schematics ..................... 96 Introduction ...................... 96 Electrical Component and Wire Color Legends ..........97 Wiring Diagram Ground and Platform Controls ..........98 Electrical Symbol Legend ................. 99 Hydraulic Symbols Legend ................100 Electrical Schematics – Options ..............101 Electrical Schematic, GRC - Options ..............

  • Page 13: Specifications

    February 2022 Service Manual Specifications Performance Specifications Secti on 2 Specificatio ns Machine Specifications Drive speed, maximum Batteries, Standard Platform stowed, fast 2.5 mph Voltage 6V DC 40 ft / 10.9 sec Group 4 km/h 12,2 m / 10,9 sec Type T-105 Platform stowed, slow...

  • Page 14: Hydraulic Component And Manifold Specifications

    Service Manual February 2022 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.

  • Page 15: Hydraulic Oil Specifications

    February 2022 Service Manual Specifications Hydraulic Oil Specifications Do not top off with incompatible hydraulic fluids. Hydraulic fluids may be incompatible due to the Hydraulic Fluid Specifications differences in base additive Genie specifications require hydraulic oils which are chemistry. When incompatible designed to give maximum protection to hydraulic fluids are mixed, insoluble systems, have the ability to perform over a wide...
  • Page 16 Service Manual February 2022 Specifications Chevron Rando HD Premium Oil Chevron 5606A Hydraulic Oil MV Fluid Properties Fluid Properties ISO Grade ISO Grade Viscosity index Viscosity index Kinematic Viscosity Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 200°F / 100°C cSt @ 104°F / 40°C cSt @ 104°F / 40°C 15.0...
  • Page 17 February 2022 Service Manual Specifications Petro-Canada Environ MV 46 UCON Hydrolube HP-5046 Fluid Fluid Properties Properties ISO Grade ISO Grade Viscosity index Viscosity index Kinematic Viscosity Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 149°F / 65°C cSt @ 104°F / 40°C cSt @ 104°F / 40°C 44.4 cSt @ 0°F / -18°C...

  • Page 18: Hydraulic Hose And Fitting Torque Specifications

    Service Manual February 2022 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 14 ft-lbs / 19 Nm specifications require that fittings and hose ends be torqued to specification when they are removed...

  • Page 19: Torque Procedure

    February 2022 Service Manual Specifications Torque Procedure JIC 37° fittings 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 Replace the O-ring. The O-ring must be hand tight, approximately 30 in-lbs / 3.4 Nm.
  • Page 20 Service Manual February 2022 Specifications 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.

  • Page 21: Scheduled Maintenance Procedures

    February 2022 Service Manual Scheduled Maintenance Procedures Machine Configuration: Secti on 3 Schedule d M ainte nanc e Proc edu res Unless otherwise specified, perform each  procedure with the machine in the following configuration: • Machine parked on a firm, level surface •...
  • Page 22 Service Manual February 2022 Scheduled Maintenance Procedures About This Section Maintenance Symbols Legend Note: The following symbols have been used in This section contains detailed procedures for each this manual to help communicate the intent of the scheduled maintenance inspection. instructions.
  • Page 23 February 2022 Service Manual Scheduled Maintenance Procedures Pre-delivery Preparation Report The pre-delivery preparation report contains checklists for each type of scheduled inspection. Make copies for each inspection. Store completed forms as required. Maintenance Schedule The Scheduled Maintenance Procedures section and the Maintenance Inspection Report have been divided into subsections.

  • Page 24: Pre-Delivery Preparation Report

    Service Manual February 2022 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.

  • Page 25: Maintenance Inspection Report

    February 2022 Service Manual Maintenance Inspection Report Model Checklist A Y N R Checklist C Y N R Serial number Breather cap - models Perform after 50 hours: with optional oil Date 50 Hour Service Hour meter Perform after 100 hours: Machine owner Grease steer yokes Checklist D...

  • Page 26: Checklist A Procedures

    Service Manual February 2022 Checklist A Procedures Grease the Steer Yokes Perform 50 Hour Service Genie specifications require that this procedure be The 50 hour maintenance procedure is a one time performed every 100 hours of operation. sequence of procedures to be performed after the first 50 hours of usage.

  • Page 27: Checklist B Procedures

    February 2022 Service Manual Checklist B Procedures Inspect the Batteries Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper battery condition is essential to good machine performance and operational safety. Improper fluid levels or damaged cables and connections can result in component damage and hazardous conditions.
  • Page 28 Service Manual February 2022 Checklist B Procedures 13 Check the ambient air temperature and adjust Models without maintenance-free or sealed the specific gravity reading for each cell as batteries: follows: Remove the battery vent caps and check the • Add 0.004 to the reading of each cell for specific gravity of each battery cell with a every 10°...
  • Page 29 February 2022 Service Manual Checklist B Procedures All models: 16 Check each battery pack and verify that the batteries are wired correctly. 17 Inspect the battery charger plug and pigtail for damage or excessive insulation wear. Replace as required. 18 Connect the battery charger to a properly grounded 115V/60Hz or, 230V/60Hz or 50Hz single phase AC power supply.

  • Page 30: Inspect The Electrical Wiring

    Service Manual February 2022 Checklist B Procedures Inspect the Electrical Wiring Inspect the Electrical Contactor Genie specifications require that this procedure be Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever performed every 250 hours or quarterly, whichever comes first.

  • Page 31: Inspect The Voltage Inverter (If Equipped)

    February 2022 Service Manual Checklist B Procedures Connect an appropriate power tool to the inverter. Activate the tool. Inspect the Voltage Inverter (if equipped) Result: The power tool should operate. There may be a brief (0.5 second) delay if the power tool has not been used in the previous 10 minutes.

  • Page 32: Test The Flashing Beacons

    Service Manual February 2022 Checklist B Procedures Test the Flashing Beacons Test the Alarm Package (if equipped) (if equipped) Genie specifications require that this procedure be Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever performed every 250 hours or quarterly, whichever comes first.

  • Page 33: Inspect The Tires, Wheels And Castle Nut Torque

    February 2022 Service Manual Checklist B Procedures Inspect the Tires, Wheels and Test the Drive Brakes Castle Nut Torque Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper brake action is essential to safe machine Genie specifications require that this procedure be operation.

  • Page 34: Test The Drive Speed - Stowed Position

    Service Manual February 2022 Checklist B Procedures B-10 Test the Drive Speed – Stowed Test the Drive Speed - Raised Position Position Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever Proper drive function is essential to safe machine comes first.

  • Page 35: Visual Inspection Of The Hydraulic Oil

    February 2022 Service Manual Checklist B Procedures B-11 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: • Color: oil should be a clear, light-honey colored •...

  • Page 36: Inspect The Breather Cap

    Service Manual February 2022 Checklist B Procedures B-12 Inspect the Breather Cap Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first. Perform this procedure more often if dusty conditions exist. A free-breathing hydraulic tank cap is essential for good machine performance and service life.

  • Page 37: Checklist C Procedures

    February 2022 Service Manual Checklist C Procedures Replace the Hydraulic Tank Breather Cap - Models with Optional Hydraulic Oil Remove and discard the hydraulic tank breather cap.Genie specifications require that this procedure be performed every 500 hours or six months, whichever comes first OR when the machine fails to lift the maximum rated load.

  • Page 38: Checklist D Procedures

    Service Manual February 2022 Checklist D Procedures Replace the Hydraulic Return Filter Genie specifications require that this procedure be performed every 1000 hours or annually, whichever comes first. Replacement of the hydraulic tank return filter is essential for good machine performance and service life.

  • Page 39: Checklist E Procedures

    February 2022 Service Manual Checklist E Procedures Testing the oil: Test or Replace the Hydraulic Oil Complete the hydraulic oil testing with an oil distributor. If the hydraulic oil passes testing at the 2000 hour maintenance interval, the oil must Genie specifications require that this procedure be be tested every quarter by an oil distributor performed every 2000 hours or every two years,...
  • Page 40 Service Manual February 2022 Checklist E Procedures Install the hydraulic tank and install and tighten the hydraulic tank retaining fasteners. Torque to specification. Torque specifications Hydraulic retaining fasteners, dry 35 in-lbs 4 Nm Hydraulic retaining fasteners, lubricated 26 in-lbs 2,9 Nm Install the hydraulic pump inlet hard line into the tank.

  • Page 41: Repair Procedures

    February 2022 Service Manual Repair Procedures Machine Configuration: Secti on 4 Repair P roce dur es 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...
  • Page 42 Service Manual February 2022 Repair Procedures About This Section Symbols Legend Safety alert symbol—used to alert Most of the procedures in this section should only personnel to potential personal be performed by trained service professional in a injury hazards. Obey all safety suitably equipped workshop.

  • Page 43: Platform Controls

    February 2022 Service Manual 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.

  • Page 44: Circuit Board

    Service Manual February 2022 Platform Controls Operational Indicator Codes Circuit Board These codes are generated by the electrical system to indicate machine operating status. During normal operation, a code will appear in the How to Remove the Platform platform controls LED readout if a condition such Controls Circuit Board as off-level, overload cutout, chassis mode operation or pothole guard stuck occurs.

  • Page 45: Joystick

    February 2022 Service Manual Platform Controls Carefully disconnect all wire harness connectors from the platform controls circuit Joystick board. Electrocution/burn hazard. How to Remove the Joystick Contact with electrically charged circuits could result in death or Push in the red Emergency Stop button to the serious injury.

  • Page 46: Platfrom Controls Alarm

    Service Manual February 2022 Platform Controls Platform Controls Alarm Platform Emergency Stop Button How to Remove the Platform How to Remove the Platform Controls Alarm Controls Emergency Stop Button Push in the red Emergency Stop button to the 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.

  • Page 47: Ground Controls

    February 2022 Service Manual 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.

  • Page 48: Software Revision Level

    Service Manual February 2022 Ground Controls 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.

  • Page 49: Machine Setup

    February 2022 Service Manual Ground Controls 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.

  • Page 50: Level Sensor

    Service Manual February 2022 Ground Controls Place the level sensor onto the level sensor base with the "X" on the level sensor closest Level Sensor to the mast of the machine and the "Y" on the level sensor closest to the steer end of the The Electronic Control Module (ECM) is machine.
  • Page 51 February 2022 Service Manual Ground Controls Install the level sensor adjusting fasteners Turn the key switch to ground control and pull through the level sensor and springs, and into out the red Emergency Stop button to the on the mount. Tighten the fasteners and position at both ground and platform controls.
  • Page 52 Service Manual February 2022 Ground Controls 21 Raise the platform to approximately 1 ft / 34 Center a lifting jack under the drive chassis at 30 cm. the non-steer end of the machine. Result: The platform should stop, an alarm 35 Raise the machine approximately 2 inches / should sound and fault code LL appears in 5 cm.

  • Page 53: Hydraulic Pump

    February 2022 Service Manual Hydraulic Pump 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.

  • Page 54: How To Remove The Hydraulic Pump

    Service Manual February 2022 Hydraulic Pump How to Re mov e th e Hyd raulic Pu mp 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.

  • Page 55: Function Manifold

    February 2022 Service Manual Function Manifold 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 Diagnostic port Test port —...
  • Page 56 Service Manual February 2022 Function Manifold Note: 'alpha-numeric' callouts refer to corresponding notes on the electrical schematic. ™ Part No. 1314708GT...

  • Page 57: Valve Adjustments - Function Manifold

    February 2022 Service Manual Function Manifold Chock both sides of the wheels at the steer end of the machine. Valve Adjustments - Function Manifold Remove the platform controls from the platform. Note: Perform this test from the ground with the Turn the key switch to platform controls and platform controls.
  • Page 58 Service Manual February 2022 Function Manifold How to Adjust the Platform Lift Remove the platform controls from the platform. Relief Valve 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.
  • Page 59 February 2022 Service Manual Function Manifold How to Adjust the Steer Relief Remove the platform controls from the platform. Valve 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.

  • Page 60: Valve Coils

    Service Manual February 2022 Function Manifold Valve Coil Resistance Specification Valve Coils 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...
  • Page 61 February 2022 Service Manual Function Manifold Note: If testing a single terminal coil, connect the How to Test a Coil Diode negative lead to the internal metallic ring at either Genie incorporates spike suppressing diodes in all end of the coil. of its coils.

  • Page 62: Brake Release Hand Pump Components

    Service Manual February 2022 Brake Release Hand Pump Components 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 Hand pump Manual brake release 30 ft-lbs / 41 Nm Needle valve Manual brake release enable...

  • Page 63: Hydraulic Tank

    February 2022 Service Manual Hydraulic Tank 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 Remove the hydraulic tank cap and drain the cool and deaerate the hydraulic fluid during tank into a suitable container.

  • Page 64: Non-Steer Axle Components

    Service Manual February 2022 Non-Steer Axle Components 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.

  • Page 65: Steer Axle Components

    February 2022 Service Manual Steer Axle Components 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.

  • Page 66: Steer Cylinder

    Service Manual February 2022 Steer Axle Components How to Remove a Drive Motor Steer Cylinder Block the non-steer tires. Remove the cotter pin from the wheel castle How to Remove the Steer nut of the motor to be removed. Cylinder Note: Always replace the cotter pin with a new one when removing the castle nut.

  • Page 67: Tie Rod

    February 2022 Service Manual Steer Axle Components Tie Rod How to Remove the Tie Rod Remove the steer cylinder. Refer to Repair Procedure, How to Remove the Steer Cylinder. Center a lifting jack under the drive chassis at the steer end of the machine. Raise the machine approximately 14 inches / 36 cm.

  • Page 68: Platform Components

    Service Manual February 2022 Platform Components Cut and discard the cable ties securing the control cable to the platform. Platform Component damage hazard. The control cable can be How to Remove the Platform damaged if cut while removing Perform this procedure with the platform extension the cable ties.

  • Page 69: Platform Extension Deck

    February 2022 Service Manual Platform Components Attach a lifting strap from an overhead supporting device and center it around the Platform Extension Deck extension deck railing. Remove the extension deck from the machine. How to Re mov e th e Platfo rm Ext ensio n Deck , GRC Model s How to Remove the Platform Crushing hazard.

  • Page 70: Mast Components

    Service Manual February 2022 Mast Components 10-1 Tag, disconnect and plug the lift cylinder hose at the function manifold. Cap the fitting. Mast Bodily injury hazard. Spraying How to Re mov e th e M ast Asse mbly How to Remove the Mast hydraulic oil can penetrate and burn skin.
  • Page 71 February 2022 Service Manual Mast Components Remove the fasteners securing the lower rear 12 Carefully pull the cables and hydraulic hoses access cover to the chassis and remove the free while removing the mast from the cover. Set the cover and the fasteners to the machine.

  • Page 72: How To Disassemble The Mast

    Service Manual February 2022 Mast Components How to Disa ssem ble t he Mast How to Disassemble the Mast Using a drill, carefully drill out the rivets securing the number 2 inner wear pads to the Bodily injury hazard. This bottom half of the number 2 mast section, the procedure requires specific repair number 3 inner wear pads to the bottom half...
  • Page 73 February 2022 Service Manual Mast Components 12 Using a drill, carefully drill out the rivets 10 Attach a lifting strap from an overhead securing the number 3 outer wear pads to the supporting device to the mast assembly and top half of the number 3 mast section. Refer carefully rotate the mast 180°.
  • Page 74 Service Manual February 2022 Mast Components 14 Attach a lifting strap from an overhead 16 Using a drill, carefully drill out the rivets supporting device to the number 4 mast securing the number 2 outer wear pads to the section and carefully remove the number top half of the number 2 mast section.
  • Page 75 February 2022 Service Manual Mast Components 18 Attach a lifting strap from an overhead 21 Using a drill, carefully drill out the rivets supporting device to the number 3 mast securing the number 2 inner wear pads to the section and carefully remove the number bottom half of the number 2 mast section.

  • Page 76: How To Assemble The Mast

    Service Manual February 2022 Mast Components Using the appropriate rivets, install the upper How to Asse mble the Mas t How to Assemble the Mast corner wear pads, to the upper half of the number 1 mast. Bodily injury hazard. This procedure requires specific repair skills, lifting equipment and a suitable workshop.
  • Page 77 February 2022 Service Manual Mast Components Attach a lifting strap from an overhead Slide the number 2 mast towards the bottom supporting device to the number 2 mast and of the number 1 mast and align the lower carefully slide the number 2 mast onto the number 2 mast access holes to the lower number 1 mast, with the cylinder mount number 1 rivet holes.
  • Page 78 Service Manual February 2022 Mast Components 11 Using the appropriate rivets, install the upper 12 Attach a lifting strap from an overhead corner wear pads, to the upper half of the supporting device to the number 3 mast and number 2 mast. carefully slide the number 3 mast onto the number 2 mast, with the cylinder mount brackets facing the work table.
  • Page 79 February 2022 Service Manual Mast Components 14 Slide the number 3 mast towards the bottom 18 Using the appropriate rivets, install the upper of the number 2 mast and align the lower corner wear pads, to the upper half of the number 3 mast access holes to the lower number 3 mast.
  • Page 80 Service Manual February 2022 Mast Components 20 Slide the lower, inner corner wear pads 21 Slide the number 4 mast towards the bottom between the number 4 mast and the number of the number 3 mast and align the lower 3 mast.
  • Page 81 February 2022 Service Manual Mast Components 25 Attach a lifting strap from an overhead 28 Carefully collapse the mast assembly. supporting device to the mast assembly and 29 Attach a lifting strap from an overhead carefully rotate the mast 180°. Set the mast supporting device to the lift cylinder.

  • Page 82: Wear Pads

    Service Manual February 2022 Mast Components 10-2 10-3 Wear Pads Lift Cylinders Wear pads on the GRC are used to provide a The lift cylinder is equipped with a normally closed uniform fit between the mast sections, as the mast solenoid valve to prevent movement in the event assembly extends and retracts.
  • Page 83 February 2022 Service Manual Mast Components Remove the hair pin clips securing the mast cylinder pin to the lower half of the mast assembly. Set the clips to the side. Support the lift cylinder and use a soft metal drift to remove the mast cylinder pin from the lower mast assembly.
  • Page 84 Service Manual February 2022 Mast Components 1 lift cylinder 2 manual lowering valve knob 3 coil 4 platform down solenoid valve 5 orifice 6 connector fitting 7 hydraulic hose assembly ™ Part No. 1314708GT...

  • Page 85: Lift Cylinder Wear Block

    February 2022 Service Manual Repair Procedures 10-4 10-5 Lift Cylinder Wear Block Mast Coil Cord How to Remove the Lift Cylinder How to Remove the Mast Coil Wear Block Cord Bodily injury hazard. This Bodily injury hazard. This procedure requires specific repair procedure requires specific repair skills, lifting equipment and a skills, lifting equipment and a...

  • Page 86: Battery Charger

    Service Manual February 2022 Battery Charger 11-1 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...

  • Page 87: Selecting A Charge Profile

    February 2022 Service Manual Battery Charger Selecting a Cha rge Profile Selecting a Charge Profile 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.

  • Page 88: Batteries

    Service Manual February 2022 Batteries 12-1 All Models: How to Remove the Batteries Disconnect the battery pack from the machine. Note: Perform this procedure with the machine on Electrocution/burn hazard. a firm, level surface. Contact with electrically charged Models with working batteries: circuits could result in death or serious injury.

  • Page 89: Diagnostics

    February 2022 Service Manual Diagnostics Secti on 5 Diagnostic s 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.
  • Page 90 Service Manual February 2022 Diagnostics Definitions Genie SmartLink Diagnostic ® ™ System GSDS – Genie SmartLink™ Diagnostic System This machine is equipped with the Genie ECM – Electronic Control Module SmartLink™ Diagnostic System (GSDS). The GCON – Ground Controls GSDS indicates a machine malfunction has happened by displaying Operational Indicator PCON –...

  • Page 91: Gcon I/O Map

    February 2022 Service Manual Diagnostics GCON I/O MAP Pin number Circuit function I/O Type Wire color J1 / QD31 Connector – Gray J1-1 / QD31-01 Power, ECM Power Input J1-2 / QD31-02 Power, PCON Power Output J1-3 / QD31-03 Emergency stop, PCON Power Input White J1-4 / QD31-04...

  • Page 92: Operation Indicator Codes (Oic)

    Service Manual February 2022 Diagnostics Operational Indicator Codes Diagnostic Trouble Codes (DTC) (OIC) These codes are generated by the system to indicate that a device or circuit malfunction has These codes are generated by the electrical been detected in the electrical system. system to indicate machine operating status such The types of Diagnostic Trouble Codes that may as Off-level, Chassis Mode Operation and Pothole...

  • Page 93: Troubleshooting "Hxxx" And "Pxxx" Faults

    February 2022 Service Manual Diagnostics Troubleshooting "HXXX" and "PXXX" Faults The procedure below illustrates typical steps for diagnosing and fixing faults of type "HXXX" and "PXXX". Diagnostic Chart Good 1 Check the faulted device for a short or open circuit. Replace faulted device.

  • Page 94: Fault Inspection Procedure

    Service Manual February 2022 Diagnostics Fault Inspection Procedure Check the device associated with the faulted circuit Disconnect the faulted device connector. Using a multi-meter, measure resistance between the two terminals of the faulted device. Resistance should be as follows. Device Typical Resistance Solenoid Valve, Drive 27.2 Ω...
  • Page 95 February 2022 Service Manual Diagnostics Disconnect the GCON ECM connectors, J1/QD31, J2/QD33 and J3/QD32. 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.

  • Page 96: Type "Hxxx" Faults

    Service Manual February 2022 Diagnostics Type "HXXX" Faults 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: •...

  • Page 97: Type "Pxxx" Faults

    February 2022 Service Manual Diagnostics Type "PXXX" Faults 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: harness.

  • Page 98: Type "Uxxx" Faults

    Service Manual February 2022 Diagnostics Type "UXXX" Faults 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.

  • Page 99: Type "Fxxx" Faults

    February 2022 Service Manual Diagnostics Type "FXXX" Faults 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: •...

  • Page 100: Type "Cxxx" Faults

    Service Manual February 2022 Diagnostics Type "CXXX" Faults 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.
  • Page 101 February 2022 Service Manual Diagnostics Type “CXXX” Faults, (continued) 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.

  • Page 102: Battery Charger

    Service Manual February 2022 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"...

  • Page 103: Charger Fault Codes

    February 2022 Service Manual Diagnostics Charger status indicators Remote charger status indicators 1 Error / Fault / USB indicator 2 Charger profile / Error display 3 Error / Fault Charg er Fault Cod es Charger Fault Codes Description Possible Causes Fault Code Solution DC-DC failure: LLC excessive leakage...

  • Page 104: Charger Error Codes

    Service Manual February 2022 Diagnostics Charg er Er ror Cod es Charger Error Codes Description Possible Causes Error Code Condition 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.
  • Page 105 February 2022 Service Manual 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.
  • Page 106 Service Manual February 2022 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.
  • Page 107 February 2022 Service Manual 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.

  • Page 108: Schematics

    Service Manual February 2022 Schematics About This Section Secti on 6 Schematic s 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 ...

  • Page 109: Electrical Component And Wire Color Legends

    February 2022 Service Manual 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 Circuit breaker, 7A QD1 = Battery quick disconnect CON1 Contactor, Motor controller power C8 / QD3 = Control cable to ground...

  • Page 110: Wiring Diagram Ground And Platform Controls

    Service Manual February 2022 Wiring Diagram Ground and Platform Controls ™ Part No. 1314708GT...

  • Page 111: Electrical Symbol Legend

    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...

  • Page 112: Hydraulic Symbols Legend

    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...

  • Page 113: Electrical Schematics - Options

    February 2022 Service Manual Electrical Schematic, GRC - Options...

  • Page 114: Electrical Schematic, Grc - Options

    Service Manual February 2022 Electrical Schematic, GRC - Options SMARTLINK GCON CHARGER INTERLOCK OPTION (BLACK) J2 PLATFORM UP COIL PLATFORM DOWN COIL STEER LEFT COIL DC MOTOR STEER RIGHT COIL POWER TO PLATFORM CONTROLLER PARALLEL COIL 24V BATTERY DRIVE FORWARD COIL THROTTLE 4 LIFT PRESSURE SELECTOR CHARGER...

  • Page 115: Electrical Schematics

    February 2022 Service Manual Electrical Schematic, GRC (from GRC11-1000 to GRC11-1078)

  • Page 116: Electrical Schematic, Grc (From Grc11-1000 To Grc11-1078)

    Service Manual February 2022 Electrical Schematic, GRC (from GRC11-1000 to GRC11-1078) QD30 QD4A GR YL LT BL 110 - 240V AC PCON QD31 QD32 ECM LOGIC V + GRAY PCON V + OUT ALARM OUT E-STOP SENSOR V + OUT DATA LINK + AUTO HORN OUT DATA LINK -...
  • Page 117 February 2022 Service Manual Electrical Schematic, GRC (from GRC11-1000 to GRC11-1078) GR YL LT BL QD47 QD48 PCON V + E-STOP DATA LINK + E-STOP + DATA LINK - E-STOP - PCON V - JOYSTICK AXIS 1 STEER SW ITCH COM DRIVE ENABLE COM BL OR DRIVE ENABLE...
  • Page 118 Service Manual February 2022 Electrical Schematic, GRC (from GRC11-1000 to GRC11-1078)
  • Page 119 February 2022 Service Manual Electrical Schematic, GRC (from GRC11-1079 to GRC14-1780)

  • Page 120: Electrical Schematic, Grc (From Grc11-1079 To Grc14-1780)

    Service Manual February 2022 Electrical Schematic, GRC (from GRC11-1079 to GRC14-1780) QD30 QD4A GR YL LT BL 110 - 240V AC PCON QD34 QD31 QD32 ECM LOGIC V + GRAY PCON V + OUT ALARM OUT E-STOP SENSOR V + OUT DATA LINK + AUTO HORN OUT DATA LINK -...
  • Page 121 February 2022 Service Manual Electrical Schematic, GRC (from GRC11-1079 to GRC14-1780) GR YL LT BL QD47 QD48 PCON V + E-STOP DATA LINK + E-STOP + DATA LINK - E-STOP - PCON V - JOYSTICK AXIS 1 STEER SWITCH COM DRIVE ENABLE COM BL OR DRIVE ENABLE...
  • Page 122 Service Manual February 2022 Electrical Schematic, GRC (from GRC11-1079 to GRC14-1780)
  • Page 123 February 2022 Service Manual Electrical Schematic, GRC (from GRC14-1781 to GRC15-2343)

  • Page 124: Electrical Schematic, Grc (From Grc14-1781 To Grc15-2343)

    Service Manual February 2022 Electrical Schematic, GRC (from GRC14-1781 to GRC15-2343) GR YL 110 - 240V AC LT BL PCON V- PCONV+ ALARM+ E-STOP ALARM- DATA LINK + STOP DATA LINK - STOP PCON J1 ( GRAY GREEN ) J3 ECM LOGIC V+ JOYSTICK AXIS 1 PCON...

  • Page 125: Electrical Schematics, Grc (From Grc15-2344 To Grc16P-2481)

    February 2022 Service Manual Electrical Schematic, GRC (from GRC15-2344 to GRC16P-2481) 110 - 240V AC GR YL DATA LINK - DATA LINK + LT BL PCON V- PCONV+ ALARM+ ALARM- E-STOP STOP DATA LINK + DATA LINK - STOP J1 ( GRAY GREEN ) J3...
  • Page 126 Service Manual February 2022 Electrical Schematic, GRC (from GRC15-2344 to GRC16P-2481)
  • Page 127 February 2022 Service Manual Electrical Schematic, GRC (from GRC16P-2482 to GRC16P-2562)

  • Page 128: Electrical Schematic, Grc (From Grc16P-2482 To Grc16P-2562)

    Service Manual February 2022 Electrical Schematic, GRC (from GRC16P-2482 to GRC16P-2562) 110 - 240V AC GR YL DATA LINK - DATA LINK + LT BL PCON V- PCONV+ ALARM+ E-STOP ALARM- DATA LINK + STOP STOP DATA LINK - J1 ( GRAY GREEN ) J3...

  • Page 129: Electrical Schematic, Grc (From Grc16P-2563 To Grcp-5999)

    February 2022 Service Manual Electrical Schematic, GRC (from GRC16P-2563 to GRCP-5999) PCON DATA LINK DATA LINK PCON STOP PCON PCON ALARM+ 2 ALARM- 3 J-BOX STOP TILT SENSOR V+ 1 GND 2 STOP DATA LINK + 3 DATA LINK - 4 JOYSTICK J3 ( GREEN...
  • Page 130 Service Manual February 2022 Electrical Schematic, GRC (from GRC16P-2563 to GRCP-5999)

  • Page 131: Hydraulic Schematics

    February 2022 Service Manual Hydraulic Schematic, GRC (from GRC11-1000 to GRC12-1168)

  • Page 132: Hydraulic Schematic, Grc (From Grc11-1000 To Grc12-1168)

    Service Manual February 2022 Hydraulic Schematic, GRC (from GRC11-1000 to GRC12-1168) LEFT RIGHT BRAKE BRAKE LIFT CYLINDER CYLINDER MANIFOLD MANUAL RELEASE HAND PUMP LEFT RIGHT DRIVE MOTOR DRIVE MOTOR STEER STEER LEFT RIGHT 0.059 inch MANUAL 1,5 mm RELEASE FORWARD REVERSE L (LIFT) V (VENT)

  • Page 133: Hydraulic Schematic, Grc (From Grc12-1169 To Grcp-5999)

    February 2022 Service Manual Hydraulic Schematic, GRC (from GRC12-1169 to GRCP-5999) LEFT RIGHT BRAKE BRAKE LIFT CYLINDER CYLINDER MANIFOLD MANUAL RELEASE HAND PUMP LEFT RIGHT DRIVE MOTOR DRIVE MOTOR STEER STEER LEFT RIGHT 0.059 inch MANUAL 1,5 mm RELEASE FORWARD REVERSE L (LIFT) V (VENT)
  • Page 134 Service Manual February 2022 Electrical Schematic, GRC (from GRC12-1169 to GRCP-5999) GRC™ Part No. 131 470 8GT Service Manu al Feb rua ry 20 22...

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