Terex Genie GRT-1101 User manual

Service Manual
Serial Number Range
GR™-12
from GRR-10001
from GRP-
60000
from GRT-1101
GR™-15
GR™-20
GRC™-12
from GRCP-6000
QS™-12R
from QSP-6000
QS™-15R
QS™-20R
QS™-12W
QS™-15W
QS
™
-20W
Original Instructions
Part No. 1307550GT
Rev A
1
December 2023

Service Manual December 2023
Introduction
ii GR™• GRC™• QS™R • QS™W Part No. 1307550GT
Intr od ucti o n Intr od ucti o 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 © 2011 by Terex Corporation
1307550GT Rev A, February 2022
Fifth Edition, First Printing
Genie is a registered trademark of Terex South Dakota, Inc. in
the U.S.A. and many other countries.
"GR", "GRC" and "QS" are trademarks of Terex South Dakota,
Inc.

December 2023 Service Manual
Introduction
Part No. 1307550GT GR™• GRC™• QS™R • QS™W iii
Revision History
Revision Date Section Procedure / Page / Description
A 2/2022 Initial Release
A1 12/2023 Front cover Add facility code and serial break
Schematics Add facility code and serial break for GR models
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 December 2023
Introduction
iv GR™• GRC™• QS™R • QS™W Part No. 1307550GT
Serial Number Legend
1 Model
2 Facility code
3 Sequence number
4 Serial label
5 Serial number (stamped on chassis, GR, GRC models)
6 Serial number (stamped on chassis, QS models)

December 2023 Service Manual
Safety Rules
Part No. 1307550GT GR™• GRC™• QS™R • QS™W v
Section 1 Safet y R ul 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 December 2023
Safety Rules
vi GR™• GRC™• QS™R • QS™W Part No. 1307550GT
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 in
jury.
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.
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
condit
ion 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.

December 2023
Table of Contents
Part No. 1307550GT GR™• GRC™• QS™R • QS™W vii
Introduction Introduction...........................................................................................................ii
Important Information ............................................................................................. ii
Find a Manual for this Model .................................................................................. ii
Revision History..................................................................................................... iii
Serial Number Legend .......................................................................................... iv
Section 1 Safety Rules ..........................................................................................................v
General Safety Rules ............................................................................................. v
Section 2 Specifications .......................................................................................................1
Machine Specifications...........................................................................................1
Performance Specifications....................................................................................2
Hydraulic Component and Manifold Specifications................................................3
Manifold Component Specifications .......................................................................3
Hydraulic Oil Specifications....................................................................................4
Hydraulic Hose and Fitting Torque Specifications .................................................7
Torque Procedure ..................................................................................................8

December 2023
Table of Contents
viii GR™• GRC™• QS™R • QS™W Part No. 1307550GT
Section 3 Scheduled Maintenance Procedures ............................................................... 10
Introduction .......................................................................................................... 10
Maintenance Schedule ........................................................................................ 12
Pre-Delivery Preparation Report.......................................................................... 13
Scheduled and Programmed Maintenance Inspection Report ............................ 14
Commissioning Procedures ............................................................................. 16
C-1 Perform 40 Hour Service............................................................................... 16
Quarterly Maintenance Procedures ................................................................. 17
Q-1 Check for Open Bulletins and Owner Registration ....................................... 17
Q-2 Battery Inspection ......................................................................................... 18
Q-3 Inspect the Electrical Wiring.......................................................................... 21
Q-4 Inspect the Electrical Contactor .................................................................... 21
Q-5 Inspect the Voltage Inverter (if equipped)..................................................... 22
Q-6 Test the Flashing Beacons ........................................................................... 23
Q-7 Test the Alarm Package (if equipped) .......................................................... 23
Q-8 Inspect the Tires, Wheels and Castle Nut Torque ........................................ 24
Q-9 Check the Lifting Chain Adjustments - GR, QS Models ............................... 24
Q-10 Clean and Lubricate the Columns - GR, QS Models.................................. 25
Q-11 Adjust the Sequencing Cables - GR, QS Models ....................................... 25
Q-12 Visual Inspection of the Hydraulic Oil ......................................................... 26
Q-13 Test the Drive Brakes ................................................................................. 27
Q-14 Test the Drive Speed – Stowed Position .................................................... 28
Q-15 Test the Drive Speed - Raised Position...................................................... 28
Annual Maintenance Procedures ..................................................................... 29
A-1 Grease the Platform Overload Mechanism - GR, QS Models ...................... 29
A-2 Test the Platform Overload System - GR, QS Models.................................. 29
A-3 Test the Outdoor Height Limit System .......................................................... 31
Programmed Maintenance Procedures ........................................................... 32
P0-1 Grease the Steer Yokes .............................................................................. 32
P1-1 Inspect the Mast Assembly - GR, QS Models............................................. 32
P1-2 Inspect and Lubricate the Lifting Chains - GR, QS Models ........................ 33
P1-3 Replace the Hydraulic Return Filter ............................................................ 34
P2-1 Test or Replace the Hydraulic Oil ............................................................... 34

December 2023
Table of Contents
Part No. 1307550GT GR™• GRC™• QS™R • QS™W ix
Section 4 Repair Procedures .............................................................................................36
Introduction...........................................................................................................36
Platform Controls ...............................................................................................38
1-1 Circuit Board...................................................................................................39
1-2 Joystick...........................................................................................................40
1-3 Platfrom Controls Alarm .................................................................................41
1-4 Platform Emergency Stop Button...................................................................41
Ground Controls.................................................................................................43
2-1 Software Revision Level.................................................................................44
2-2 Machine Setup ...............................................................................................45
2-3 Level Sensors ................................................................................................46
Hydraulic Pump ..................................................................................................51
3-1 Hydraulic Pump..............................................................................................51
How to Remove the Hydraulic Pump ..............................................................52
Function Manifold ..............................................................................................53
4-1 Function Manifold Components .....................................................................53
4-2 Valve Adjustments – Function Manifold.........................................................55
4-3 Valve Coils .....................................................................................................58
Brake Release Hand Pump Components.........................................................60
5-1 Brake Release Hand Pump Components ......................................................60
Hydraulic Tank....................................................................................................61
6-1 Hydraulic Tank ...............................................................................................61
Non-Steer Axle Components.............................................................................62
7-1 Drive Brake.....................................................................................................62
Steer Axle Components.....................................................................................63
8-1 Yoke and Drive Motor ....................................................................................63
8-2 Steer Cylinder ................................................................................................64
8-3 Steer Bellcrank ...............................................................................................65

December 2023
Table of Contents
x GR™• GRC™• QS™R • QS™W Part No. 1307550GT
Platform Components ....................................................................................... 66
9-1 Platform.......................................................................................................... 66
9-2 Platform Extension Deck (if equipped) .......................................................... 67
How to Remove the Platform Extension Deck, GR Models ........................... 67
How to Remove the Platform Extension Deck, GRC Models......................... 68
9-3 Work Tray (if equipped) ................................................................................. 69
Mast Components.............................................................................................. 70
10-1 Mast ............................................................................................................. 70
How to Remove the Mast Assembly - GR, QS Models .................................. 70
How to Disassemble the Mast - GR, QS Models............................................ 72
How to Assemble the Mast - GR, QS Models ................................................ 74
How to Remove the Mast Assembly - GRC models....................................... 75
How to Disassemble the Mast - GRC Models ................................................ 77
How to Assemble the Mast - GRC Models ..................................................... 81
10-2 Lifting Chains - GR, QS Models................................................................... 87
How to Inspect the Lifting Chains ................................................................... 88
10-3 Lift Cylinders ................................................................................................ 90
How to Remove the Lift Cylinder - GR, QS Models........................................ 90
How to Remove the Lift Cylinder - GRC Models ............................................ 91
10-4 Lift Cylinder Wear Block - GRC Models ...................................................... 93
10-5 Wear Pads - GRC Models ........................................................................... 94
10-6 Mast Coil Cord - GRC Models ..................................................................... 94
10-7 Mast Control Cable ...................................................................................... 95
Platform Overload Components....................................................................... 97
11-1 Platform Overload System - GR, QS Models .............................................. 97
11-2 Platform Overload Recovery Message - GR, QS Models ........................... 98
Obstruction Sensing System.......................................................................... 100
12-1 Obstruction Sensing System - QSR Models.............................................. 100
How to Replace an Obstruction Sensing Pad .............................................. 100
Battery Charger ................................................................................................ 102
13-1 Battery Charger ......................................................................................... 102
Selecting a Charge Profile ............................................................................ 103
Batteries............................................................................................................ 104
14-1 How to Remove the Batteries .................................................................... 104