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Genie GR-12
Terex Genie GR-12 Service Manual
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Servic
e Manual
Februar
y 2022
132
GR
™
• G
RC
™
• QS
™
R •
Q
S
™
W
Part
No. 1307550GT
Electr
i
cal
Sc
hem
atic
, G
R
• QS
(from
GRP
-
6000
0
t
o 63
822,
GRR
-
1000
1 t
o 1038
4,
Q
SP
-
6
00
0
t
o 60
50)
275A
F1
C1
N.O.H.C
CONT
ACTOR
24V
THROTTLE 4
ENABLE
5
DC MOTOR
CONTROLLER
B+
B-
M-
U5
24V BA
TTERY
CHARGER
U3
6 DA
T
A
LINK+
10 DA
T
A LINK-
2
KS1
P1
CB1
7A
TELEMA
TICS
READY
1 V+
2 GND
3 MC ENABLE
7 DA
TA
LINK+
8 DA
TA
LINK-
C102
J
1
(
G
R
AY
)
2 PCON V+
6 PCON V
-
3 PCON E-ST
OP
5 DA
T
A
L
INK-
4 DA
T
A
L
INK+
8 KEY SW PL
A
T POS
9 KEY SW GRND POS
10 GROUND E-STOP
12 ECM DRIVER V+
1 ECM LOGIC V+
7
E
C
M
V-
KEY SWITCH
P
L
AT
1
OFF
GRND 3
B
P2
H3
JC1
D2
J3 (GREEN)
SENSOR V+ 3
DZ LIMIT S
W 8
DOWN LIMIT
SW 7
POTHOLE LIMIT
SW 5
ALARM
2
HORN 4
MACHINE ID SELECT 6
LED BEACON 1
OVLD1 9
OVLD2 10
J2 (BLACK)
PLA
TFORM DOWN COIL 2
PLA
TFORM UP COIL 1
STEER LEFT COIL
3
STEER RIGHT COIL
4
DRIVE FORWARD COIL
6
DRIVE REVERSE COIL 10
MOTOR CONTROLLER THROTTLE 1
1
MOTOR CONTROLLER ENABLE 8
TECH PRO LINK
1 V+
2 GND
3 DA
TA
LINK+
4 DA
TA
LINK-
C106
D1
R1
200?
,10W
H1
U1
GCON
4 4
3 3
2 2
5 5
1 1
TIL
T SENSOR
V+ 1
GND 2
DA
TA
LINK+ 3
DA
TA
LINK- 4
TS1
4 4
3 3
2 2
5 5
1 1
J6
5 DA
T
A
LINK-
4 DA
T
A
LINK+
3 PCON E-STOP
2 PCON V
-
1 PCON V+
J5
ALARM
+ 2
ALARM- 3
E-STOP+ 4
E-STOP- 5
J4
JOYSTICK
AXIS 1
STEER SWTICH COM 3
DRIVE ENABLE COM 4
DRIVE ENABLE 5
STEER LEFT 6
STEER RIGHT 7
JOYSTICK 5VDC 8
JOYSTICK GND 10
GND 12
J
O
Y
S
T
I
C
K
WH
WH
WH
BK
BK
RD
RD
BK
RD
RD
RD
RD
RD
RD
RD
RD
RD
RD
WH/BK
BR
WH
OR
GR
BK
WH
RD
RD
BR
BR
GR
OR
GR/WH
BR
GR
OR
GR
OR
BK
WH
BR
BR
BR
BR
BR
WH
GR
OR
WH
BL
OR
RD
BR
WH
BL
OR
RD
BR
WH
BL
OR
RD/BK
RD
OR
OR/RD
WH
RD
GR
GR/WH
GR
RD
BR
OR
GR
GR/WH
BK
BR
OR
GR
BR
RD
OR
GR
OR
GR
WH
BR
RD
RD
BK
BK
RD
RD
RD
RD
BK
WH
WH
BK
WH
BK
BR
BR
BR
BR
GR
GR/WH
OR/RD
BL
RD
BK
RD
C17-2
C17-1
C16-1
C16-2
C16-3
C16-4
C47
C52
C104
C
11
0
C
11
2
C
111
C
11
3
C64
C83
C80
C73
C38
C4
C8
C74
C75
C104
U2
PCON
OR
OR/BK
BL/BK
BL
WH
WH/BK
BR
BR
BR
BR
BR
BR
OR
BR
C63-1
C63-2
C44-1
C44-2
C43-1
C43-2
C42-2
C42-1
C41-2
C41-1
C40-2
C40-1
Y1
Y3
Y4
Y2
Y5
Y6
J-BOX
RD
BR
WH
BL
OR
RD
BR
WH
BL
OR
WH/BK
C7-1
C7-2
WH
WH
RD/BK
BK
BK
WH
RD
OR
C104
WH
J-BOX
J-BOX
J-BOX
S4A
S4B
S6A
S6B
OUTDOOR
INDOOR
S5A
S5B
S3A
S3B
LIFT
DRIVE
S2A
S2B
S1
TURT
LE
HORN
PCBA
MOUNTED SWITCHES
WH
BK
WH
BK
BL
ES0523 P
M1
INTERLOCK NC
INTERLOCK COMM
3
143
145
Table of Contents
Table of Contents
7
Find a Manual for this Model
2
Revision History
3
Serial Number Legend
4
Safety Rules
5
Table of Contents
7
Specifications
13
Machine Specifications
13
Performance Specifications
14
Hydraulic Component and Manifold Specifications
15
Manifold Component Specifications
15
Hydraulic Oil Specifications
16
Hydraulic Hose and Fitting Torque Specifications
19
Torque Procedure
20
Scheduled Maintenance Procedures
22
Introduction
22
Observe and Obey
22
Immediately Tag and Remove from Service a Damaged or Malfunctioning Machine
22
Repair any Machine Damage or Malfunction before Operating the Machine
22
Maintenance Schedule
24
Pre-Delivery Preparation Report
25
Scheduled and Programmed Maintenance Inspection Report
26
Commissioning Procedures
28
Perform 40 Hour Service
28
Quarterly Maintenance Procedures
29
Check for Open Bulletins and Owner Registration
29
Battery Inspection
30
Inspect the Electrical Wiring
33
Inspect the Electrical Contactor
33
Inspect the Voltage Inverter (if Equipped)
34
Test the Flashing Beacons
35
Test the Alarm Package (if Equipped)
35
Inspect the Tires, Wheels and Castle Nut Torque
36
Check the Lifting Chain Adjustments - GR, QS Models
36
Clean and Lubricate the Columns - GR, QS Models
37
Adjust the Sequencing Cables - GR, QS Models
37
Visual Inspection of the Hydraulic Oil
38
Test the Drive Brakes
39
Test the Drive Speed - Stowed Position
40
Test the Drive Speed - Raised Position
40
Annual Maintenance Procedures
41
Grease the Platform Overload Mechanism - GR, QS Models
41
Test the Platform Overload System - GR, QS Models
41
Test the Outdoor Height Limit System
43
Programmed Maintenance Procedures
44
P0-1 Grease the Steer Yokes
44
P1-1 Inspect the Mast Assembly - GR, QS Models
44
P1-2 Inspect and Lubricate the Lifting Chains - GR, QS Models
45
P1-3 Replace the Hydraulic Return Filter
46
P2-1 Test or Replace the Hydraulic Oil
46
Repair Procedures
48
Introduction
48
Read, Understand and Obey the Safety Rules and Operating Instructions in the Appropriate Operator's Manual on Your Machine
48
Platform Controls
50
Circuit Board
51
Joystick
52
Platfrom Controls Alarm
53
Platform Emergency Stop Button
53
Ground Controls
55
Software Revision Level
56
Machine Setup
57
Level Sensors
58
Hydraulic Pump
63
How to Remove the Hydraulic Pump
64
Function Manifold Components
65
Function Manifold
65
Valve Adjustments - Function Manifold
67
Valve Coils
70
Brake Release Hand Pump Components
72
Hydraulic Tank
73
Non-Steer Axle Components
74
Drive Brake
74
Steer Axle Components
75
Yoke and Drive Motor
75
Steer Cylinder
76
Steer Bellcrank
77
Platform Components
78
Platform
78
Platform Extension Deck (if Equipped)
79
How to Remove the Platform Extension Deck, GR Models
79
How to Remove the Platform Extension Deck, GRC Models
80
Work Tray (if Equipped)
81
How to Remove the Mast Assembly - GR, QS Models
82
Mast
82
Mast Components
82
How to Disassemble the Mast - GR, QS Models
84
How to Assemble the Mast - GR, QS Models
86
How to Remove the Mast Assembly - GRC Models
87
How to Disassemble the Mast - GRC Models
89
How to Assemble the Mast - GRC Models
93
Lifting Chains - GR, QS Models
99
How to Inspect the Lifting Chains
100
Lift Cylinders
102
How to Remove the Lift Cylinder - GR, QS Models
102
How to Remove the Lift Cylinder - GRC Models
103
Lift Cylinder Wear Block - GRC Models
105
Wear Pads - GRC Models
106
Mast Coil Cord - GRC Models
106
Mast Control Cable
107
Platform Overload Components
109
Platform Overload System - GR, QS Models
109
Platform Overload Recovery Message - GR, QS Models
110
How to Replace an Obstruction Sensing Pad
112
Obstruction Sensing System - QSR Models
112
Obstruction Sensing System
112
Battery Charger
114
Selecting a Charge Profile
115
Batteries
116
How to Remove the Batteries
116
Bodily Injury Hazard. Spraying
117
About this Section
117
Contact with Electrically Charged Circuits Could Result in Death or Serious Injury. Remove All Rings, Watches and Other Jewelry
117
Electrocution/Burn Hazard
117
Introduction
117
Equipment Are Available and Ready for Use
117
Be Sure that All Necessary Tools and Test
117
Before Troubleshooting
117
Troubleshooting and Repair Procedures Shall be Completed by a Person Trained and Qualified on the Repair of this Machine
117
Diagnostics
117
GCON I/O Map
119
Operation Indicator Codes (OIC)
120
Diagnostic Trouble Codes (DTC)
120
Troubleshooting "HXXX" and "PXXX" Faults
121
Fault Inspection Procedure
122
Type "HXXX" Faults
124
Type "PXXX" Faults
125
Type "UXXX" Faults
126
Type "FXXX" Faults
128
Type "CXXX" Faults
129
Battery Charger
131
Charger Fault Codes
132
Charger Error Codes
133
Schematics
137
Introduction
137
Electrical Component and Wire Color Legends
138
Wiring Diagram Ground and Platform Controls
140
Electrical Symbol Legend
141
Hydraulic Symbols Legend
142
Electrical Schematics
143
Electrical Schematic, GR • QS (from GRP-60000 to 63822, GRR-10001 to 10384, QSP-6000 to 6050)
144
Electrical Schematic, GR • QS (from GRP-63823, GRR-10385, QSP-6051)
145
Electrical Schematic, GRC (from GRCP-6000)
148
Electrical Schematic, GR • GRC • QS - Options
149
Hydraulic Schematics
151
Hydraulic Schematic, GR • QS, (from GRP-60000, GRR-10001, QSP-6000)
152
Hydraulic Schematic GRC, (from GRCP-6000)
153
Other manuals for Terex Genie GR-12
Operator's Manual
56 pages
4
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Terex Genie GR-12 Specifications
General
Brand
Terex
Model
Genie GR-12
Category
Lifting Systems
Language
English
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