Terex Genie GRC-12 User manual

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.
Contact Us:
Internet: www.genielift.com
E-mail: [e-mail]
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.
Copyright © 2001 by Terex Corporation
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
To
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