Terex Genie GRT-1101 - User Manual

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Service Manual

Serial Number Range

™

-12

from GRR-10001

from GRP-

60000

from GRT-1101

™

-15

™

-20

GRC

™

-12

from GRCP-6000

™

-12R

from QSP-6000

™

-15R

™

-20R

™

-12W

™

-15W

™

-20W

Original Instructions

Part No. 1307550GT

Rev A

December 2023

Main Page

Find a Manual for this Model2
Serial Number Legend4
Safety Rules5
Table of Contents7
Specifications13
Machine Specifications13
Performance Specifications14
Hydraulic Component and Manifold Specifications15
Manifold Component Specifications15
Hydraulic Oil Specifications16
Hydraulic Hose and Fitting Torque Specifications19
Torque Procedure20
Scheduled Maintenance Procedures22
Introduction22
Maintenance Schedule24
Pre-Delivery Preparation Report25
Scheduled and Programmed Maintenance Inspection Report26
Commissioning Procedures28
Perform 40 Hour Service28
Quarterly Maintenance Procedures29
Check for Open Bulletins and Owner Registration29
Battery Inspection30
Inspect the Electrical Wiring33
Inspect the Electrical Contactor33
Inspect the Voltage Inverter (if Equipped)34
Test the Flashing Beacons35
Test the Alarm Package (if Equipped)35
Inspect the Tires, Wheels and Castle Nut Torque36
Check the Lifting Chain Adjustments - GR, QS Models36
Clean and Lubricate the Columns - GR, QS Models37
Adjust the Sequencing Cables - GR, QS Models37
Visual Inspection of the Hydraulic Oil38
Test the Drive Brakes39
Test the Drive Speed - Stowed Position40
Test the Drive Speed - Raised Position40
Annual Maintenance Procedures41
Grease the Platform Overload Mechanism - GR, QS Models41
Test the Platform Overload System - GR, QS Models41
Test the Outdoor Height Limit System43
Programmed Maintenance Procedures44
P0-1 Grease the Steer Yokes44
P1-1 Inspect the Mast Assembly - GR, QS Models44
P1-2 Inspect and Lubricate the Lifting Chains - GR, QS Models45
P1-3 Replace the Hydraulic Return Filter46
P2-1 Test or Replace the Hydraulic Oil46
Repair Procedures48
Introduction48
Platform Controls50
Circuit Board51
Joystick52
Platfrom Controls Alarm53
Platform Emergency Stop Button53
Ground Controls55
Software Revision Level56
Machine Setup57
Level Sensors58
Hydraulic Pump63
How to Remove the Hydraulic Pump64
Function Manifold65
Function Manifold Components65
Valve Adjustments - Function Manifold67
Valve Coils70
Brake Release Hand Pump Components72
Hydraulic Tank73
Non-Steer Axle Components74
Drive Brake74
Steer Axle Components75
Yoke and Drive Motor75
Steer Cylinder76
Steer Bellcrank77
Platform Components78
Platform78
Platform Extension Deck (if Equipped)79
How to Remove the Platform Extension Deck, GR Models79
How to Remove the Platform Extension Deck, GRC Models80
Work Tray (if Equipped)81
Mast Components82
Mast82
How to Remove the Mast Assembly - GR, QS Models82
How to Disassemble the Mast - GR, QS Models84
How to Assemble the Mast - GR, QS Models86
How to Remove the Mast Assembly - GRC Models87
How to Disassemble the Mast - GRC Models89
How to Assemble the Mast - GRC Models93
Lifting Chains - GR, QS Models99
How to Inspect the Lifting Chains100
Lift Cylinders102
How to Remove the Lift Cylinder - GR, QS Models102
How to Remove the Lift Cylinder - GRC Models103
Lift Cylinder Wear Block - GRC Models105
Wear Pads - GRC Models106
Mast Coil Cord - GRC Models106
Mast Control Cable107
Platform Overload Components109
Platform Overload System - GR, QS Models109
Platform Overload Recovery Message - GR, QS Models110
Obstruction Sensing System112
Obstruction Sensing System - QSR Models112
How to Replace an Obstruction Sensing Pad112
Battery Charger114
Selecting a Charge Profile115
Batteries116
How to Remove the Batteries116
Diagnostics117
Introduction117
GCON I/O Map119
Operation Indicator Codes (OIC)120
Diagnostic Trouble Codes (DTC)120
Troubleshooting "HXXX" and "PXXX" Faults121
Fault Inspection Procedure122
Type "HXXX" Faults124
Type "PXXX" Faults125
Type "UXXX" Faults126
Type "FXXX" Faults128
Type "CXXX" Faults129
Battery Charger131
Charger Fault Codes132
Charger Error Codes133
Schematics137
Introduction137
Electrical Component and Wire Color Legends138
Wiring Diagram Ground and Platform Controls140
Electrical Symbol Legend141
Hydraulic Symbols Legend142
Electrical Schematics143
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, GRT-1101, QSP-6051)146
Electrical Schematic, GRC (from GRCP-6000)148
Electrical Schematic, GR • GRC • QS - Options149
Hydraulic Schematics151
Hydraulic Schematic, GR • QS, (from GRP-60000, GRR-10001, GRT-1101, QSP-6000)152
Hydraulic Schematic GRC, (from GRCP-6000)153

Brand	Terex
Model	Genie GRT-1101
Category	Lifting Systems
Language	English

Terex Genie GRT-1101 - User Manual

Table of Contents

Terex Genie GRT-1101 Specifications

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