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Serial Number Range

Service Manual

Serial Number Range

Part No. 227656

Rev D1

September 2016

GR-20JGR-26J

from GRJ10-101to GRJ16-1151

from GRJ16L-1152to GRJ16L-1999

from GRJL-2000

September 2016

GR-20J • GR-26J Part No. 227656ii

Important

Read, understand and obey the safety rules andoperating instructions in the appropriate Operator'sManual on your machine before attempting anymaintenance procedure.

Basic mechanical, hydraulic and electricalskills are required to perform most procedures.However, several procedures require specializedskills, tools, lifting equipment and a suitableworkshop. In these instances, we stronglyrecommend that maintenance and repair beperformed at an authorized Genie dealerservice center.

Compliance

Machine ClassificationGroup B/Type 3 as defined by ISO 16368

Machine Design LifeUnrestricted with proper operation, inspection andscheduled maintenance.

Technical Publications

Genie has endeavored to deliver the highestdegree of accuracy possible. However, continuousimprovement of our products is a Genie policy.Therefore, product specifications are subject tochange without notice.

Readers are encouraged to notify Genie of errorsand send in suggestions for improvement. Allcommunications will be carefully considered forfuture printings of this and all other manuals.

Contact Us:

www.genielift.come-mail: [email protected]

Copyright © 2011 by Terex Corporation

227656 Rev D December 2013First Edition, Fourth Printing

"Genie" is a registered trademark of Terex SouthDakota in the U.S.A. and many other countries.

Printed on recycled paper

Printed in U.S.A.

Introduction

September 2016

Part No. 227656 GR-20J • GR-26J

Revision History

Revision Date Section Procedure / Schematic Page / Description

A 4/2011 New release

B 6/2011 4 - Repair 2-2

B1 9/2011 3 - Maint. B-15

C 7/2012 2 - Spec. 2-1, 2-2, 2-4, 2-5, 2-6

3 - Maint. A-4, C-1

6 - Schem. 6-2, 6-3, 6-4, 6-5, 6-6, 6-8

D 11/2012 4 - Repair 1-2

6 - Schem. 6-7, 6-9, 6-11

D1 9/2016 Cover Add serial ranges

Introduction Serial Number Ledgend

REFERENCE EXAMPLES:

Section 3_Maintenance, B-3.Section 4_Repair Procedure, 4-2.Section 5_Diagnostic Codes, All charts.Section 6_Schematics, Legends diagrams andschematics.

Electronic Version

Click on any procedure or page numberhighlighted in blue to view the update.

iii

September 2016

GR-20J • GR-26J Part No. 227656

Revision Date Section Procedure / Schematic Page / Description

REFERENCE EXAMPLES:

Section 3_Maintenance, B-3.Section 4_Repair Procedure, 4-2.Section 5_Diagnostic Codes, All charts.Section 6_Schematics, Legends diagrams andschematics.

Electronic Version

Click on any procedure or page numberhighlighted in blue to view the update.

iv

REVISION HISTORY, CONTINUED

September 2016

Part No. 227656 GR-20J • GR-26J v

INTRODUCTION

Serial Number Legend

Model:

Serial number:

Electrical schematic number:

Year of manufacture:

Machine unladen weight:

GRJL-1234

2016

GRJ L - 1234

1 2 3

Maximum allowable inclination of the chassis:

Gradeability:

Rated work load (including occupants):

4

5

Model:

Serial number:

Model year:

Electrical schematic number:

Manufacture date:

Machine unladen weight:

Maximum allowable inclination of the chassis:

GRJ16L-1234

1/2/16 2016

Gradeability:

Rated work load (including occupants):

GRJ 16 L - 1234

1 2 3 4

5

6

To August 31, 2016

1 Model2 Model year3 Facility code

4 Sequence number5 Serial label6 Serial number (stamped on chassis)

From September 1, 2016

1 Model2 Facility code3 Sequence number

4 Serial label5 Serial number (stamped on chassis)

September 2016

GR-20J • GR-26J Part No. 227656vi

Section 1 • Safety Rules

DangerFailure to obey the instructions and safety rulesin this manual and the appropriate Operator'sManual on your machine will result in death orserious injury.

Many of the hazards identified in theoperator’s manual are also safety hazardswhen maintenance and repair proceduresare performed.

Do Not Perform MaintenanceUnless:

You are trained and qualified to performmaintenance 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, liftingequipment and a suitable workshop.

Safety Rules

September 2016

Part No. 227656 GR-20J • GR-26J

Workplace SafetyBe sure to keep sparks, flames andlighted tobacco away from flammable andcombustible materials like battery gases

and engine fuels. Always have an approved fireextinguisher within easy reach.

Be sure that all tools and working areasare properly maintained and ready foruse. Keep work surfaces clean and free of

debris that could get into machine components andcause damage.

Be sure any forklift, overhead crane orother lifting or supporting device is fullycapable of supporting and stabilizing the

weight to be lifted. Use only chains or straps thatare in good condition and of ample capacity.

Be sure that fasteners intended for onetime use (i.e., cotter pins and self-lockingnuts) are not reused. These components

may fail if they are used a second time.

Be sure to properly dispose of old oil orother fluids. Use an approved container.Please be environmentally safe .

Be sure that your workshop or work areais properly ventilated and well lit.

SAFETY RULES

Personal SafetyAny person working on or around a machine mustbe aware of all known safety hazards. Personalsafety and the continued safe operation of themachine should be your top priority.

Read each procedure thoroughly. Thismanual and the decals on the machine,use signal words to identify the following:

Safety alert symbol—used to alertpersonnel to potential personalinjury hazards. Obey all safetymessages that follow this symbolto avoid possible injury or death.

Indicates an imminently hazardoussituation which, if not avoided, willresult in death or serious injury.

Indicates a potentially hazardoussituation which, if not avoided,could result in death or seriousinjury.

Indicates a potentially hazardoussituation which, if not avoided,may cause minor or moderateinjury.

Indicates a potentially hazardoussituation which, if not avoided,may result in property damage.

Be sure to wear protective eye wear andother protective clothing if the situationwarrants it.

Be aware of potential crushing hazardssuch as moving parts, free swinging orunsecured components when lifting or

placing loads. Always wear approved steel-toedshoes.

vii

Section 1 • Safety Rules

September 2016

GR-20J • GR-26J Part No. 227656viii

Table of Contents

Introduction

Important Information ......................................................................................... ii

Revision History ................................................................................................ iii

Serial Number Legend ...................................................................................... v

Section 1 Safety Rules

General Safety Rules ........................................................................................ vi

Section 2 Specifications

Machine Specifications ................................................................................ 2 - 1

Performance Specifications ......................................................................... 2 - 2

Hydraulic Specifications ............................................................................... 2 - 2

Manifold Component Specifications ............................................................. 2 - 3

Hydraulic Hose and Fitting Torque Specifications ........................................ 2 - 4

SAE and Metric Fasteners Torque Charts ................................................... 2 - 6

Section 3 Scheduled Maintenance Procedures

Introduction .................................................................................................. 3 - 1

Pre-delivery Preparation Report .................................................................. 3 - 3

Maintenance Inspection Report ................................................................... 3 - 5

Checklist A Procedures

A-1 Inspect the Manuals and Decals ......................................................... 3 - 7

A-2 Perform Pre-operation Inspection ....................................................... 3 - 8

A-3 Perform Function Tests ...................................................................... 3 - 8

A-4 Perform 30 Day Service ..................................................................... 3 - 8

A-5 Hydraulic Suction Strainer .................................................................. 3 - 9

September 2016

Part No. 227656 GR-20J • GR-26J

TABLE OF CONTENTS

Section 3 Scheduled Maintenance Procedures, continued

Checklist B Procedures

B-1 Inspect the Batteries ......................................................................... 3 - 10

B-2 Inspect the Electrical Wiring ............................................................. 3 - 11

B-3 Inspect the Tires, Wheels ................................................................. 3 - 12

B-4 Test the Emergency Stop ................................................................. 3 - 13

B-5 Test the Horn .................................................................................... 3 - 13

B-6 Test the Key Switch .......................................................................... 3 - 14

B-7 Test the Drive Brakes ....................................................................... 3 - 15

B-8 Test the Drive Speed - Stowed Position ........................................... 3 - 16

B-9 Test the Drive Speed - Raised Position ............................................ 3 - 17

B-10 Inspect the Flashing Beacons (if equipped) ...................................... 3 - 18

B-11 Test the Motion Alarm ...................................................................... 3 - 19

B-12 Perform Hydraulic Oil Analysis ......................................................... 3 - 20

B-13 Inspect the Breather Cap .................................................................. 3 - 20

B-14 Inspect the Rear Axle Free-wheeling ................................................ 3 - 21

B-15 Inspect the Lateral Offset of the Mast ............................................... 3 - 22

B-16 Inspect the Mast Wear Pads ............................................................ 3 - 23

Checklist C Procedures

C-1 Calibrate the Platform Overload System (if equipped) ...................... 3 - 24

C-2 Replace the Hydraulic Tank Breather Cap -Models with Optional Hydraulic Oil ................................................... 3 - 25

Checklist D Procedures

D-1 Replace the Hydraulic Tank Return Filter Element ........................... 3 - 26

Checklist E Procedure

E-1 Test or Replace the Hydraulic Oil ..................................................... 3 - 27

ix

September 2016

GR-20J • GR-26J Part No. 227656x

TABLE OF CONTENTS

Section 4 Repair Procedures

Introduction .................................................................................................. 4 - 1

Platform Controls

1-1 Circuit Boards .................................................................................... 4 - 2

1-2 Controller Adjustments ....................................................................... 4 - 3

Platform Components

2-1 Platform ............................................................................................. 4 - 7

2-2 Platform Overload System ................................................................. 4 - 8

Jib Components

3-1 Jib Cylinder ...................................................................................... 4 - 10

Mast Components

4-1 Mast Assembly................................................................................. 4 - 11

4-2 Lift Cylinder ...................................................................................... 4 - 24

Ground Controls

5-1 Level Sensor .................................................................................... 4 - 26

Hydraulic Pump

6-1 Function Pump ................................................................................. 4 - 27

Function Manifold

7-1 Function Manifold Components ........................................................ 4 - 30

7-2 Valve Adjustments - Function Manifold ............................................ 4 - 32

Steer Axle Components

8-1 Hydraulic Tank ................................................................................. 4 - 35

September 2016

Part No. 227656 GR-20J • GR-26J

Section 4 Repair Procedures, continued

Turntable Components

9-1 Turntable Rotation Motor .................................................................. 4 - 36

9-2 Battery ............................................................................................. 4 - 38

9-3 Battery Charger ................................................................................ 4 - 39


10-1 Yoke................................................................................................. 4 - 40

10-2 Steer Cylinder .................................................................................. 4 - 41

10-3 Steering Rod .................................................................................... 4 - 42

10-4 Steer Angle Sensor .......................................................................... 4 - 42

Non-steer Axle Components

11-1 Drive Motors ..................................................................................... 4 - 44

11-2 Drive Brake ...................................................................................... 4 - 46

Section 5 Fault Codes

Introduction .................................................................................................. 5 - 1

Fault Code Chart ......................................................................................... 5 - 3

Section 6 Schematics

Introduction .................................................................................................. 6 - 1

Electrical Component and Wire Color Legend ............................................. 6 - 2

ECM Pin-out legend ..................................................................................... 6 - 3

Limit Switch and Sensor Legend.................................................................. 6 - 4

Electrical Symbols Legend........................................................................... 6 - 5

Electrical Schematics - ANSI Models

GR-26J ........................................................................................................ 6 - 6

Electrical Schematics - CE Models

GR-20J and GR-26J .................................................................................... 6 - 8

Hydraulic Schematic

Component Reference and Hydraulic Symbols Legend ............................. 6 - 10

GR-20J and GR-26J .................................................................................. 6 - 11

TABLE OF CONTENTS

xi

September 2016

GR-20J • GR-26J Part No. 227656

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Section 2 • SpecificationsSeptember 2016

Part No. 227656 GR-20J • GR-26J 2 - 1

Machine Specifications

Battery, Standard

Voltage 2V DC

Group C5

Quantity 12

Battery capacity, maximum ANSI - 280 AHCE - 250 AH

Fluid capacities

Hydraulic tank 5.8 gallons22 liters

Height, stowed maximum

GR-20J (CE only) & GR-26J 78 in1.99 m

For operational specifications, refer to theOperator's Manual.

Tires and wheels

Tire size (solid rubber) 16 x 5 x 11 in40.6 x 12.7 x 28 cm

Castle nut torque, dry (non-steer end) 89 ft-lbs120 Nm

Castle nut torque, lubricated (non-steer end) 66 ft-lbs90 Nm

Lug bolt torque, dry (steer end) 132 ft-lbs180 Nm

Lug bolt torque, lubricated (steer end) 96 ft-lbs130 Nm

Specifications

Section 2 • Specifications September 2016

2 - 2 GR-20J • GR-26J Part No. 227656

Hydraulic Specifications

Hydraulic Oil Specifications

Hydraulic oil type Shell PW 46Viscosity grade Multi-viscosityViscosity index 152

Cleanliness level, minimum 15/13

Water content, maximum 200 ppm

Genie specifications require hydraulic oils which aredesigned to give maximum protection to hydraulicsystems, have the ability to perform over a widetemperature range, and the viscosity index shouldexceed 140. They should provide excellent antiwear,oxidation, corrosion inhibition, seal conditioning, andfoam and aeration suppression properties.

Optional fluids

Biodegradable Texaco Hydra 46Shell Naturelle HF-E 46

Note: Genie specifications require additionalequipment and special installation instructions forthe approved optional fluids. Consult the GenieIndustries Service Department before use.

Function pump

Type Gear

Displacement per revolution 0.256 cu in 4.2 cc

Function manifold

System relief valve pressure, maximum 2030 psi140 bar

Lift relief valve pressure 930 psi64 bar

Filter cap torque 37 ft-lbs50 Nm

SPECIFICATIONS

Performance Specifications

Drive speed, maximum

Platform stowed 2.8 mph40 ft / 9.8 sec

4.5 km/h12.2 m / 9.8 sec

Platform raised 0.4 mph40 ft / 54.8 sec

0.65 km/h12.2 m / 54.8 sec

Braking distance, maximum

High range on paved surface 60 in152 cm

Gradeability 25%

Airborne noise emissions

Sound pressure level at ground workstation <70 dBA

Sound pressure level at platform workstation <70 dBA

Function speed, maximum

GR-20J

Platform up 24 to 26 secondsPlatform down 19 to 21 seconds

GR-26J

Platform up 54 to 56 secondsPlatform down 40 to 42 seconds

Rated work load at full height, maximum

Platform, ANSI (GR-20J) 500 lbs227 kg

Platform, CE (GR-20J & GR-26J) 440 lbs200 kg


Part No. 227656 GR-20J • GR-26J 2 - 3

SPECIFICATIONS

Manifold ComponentSpecifications

Plug torque

SAE No. 2 50 in-lbs / 6 Nm

SAE No. 4 13 ft-lbs / 18 Nm





Torque specifications

Brake mounting fasteners, dry 75 ft-lbs102 Nm

Brake mounting fasteners, lubricated 56 ft-lbs76 Nm

Grease Specification

RETINAX HDX2 grease, NLGI (lithium based)or equivalent


2 - 4 GR-20J • GR-26J Part No. 227656

SPECIFICATIONS

Hydraulic Hose and Fitting TorqueSpecificationsYour machine is equipped with Parker Seal-Lok™

ORFS or 37° JIC fittings and hose ends.Genie specifications require that fittings and hoseends be torqued to specification when they areremoved and installed or when new hoses orfittings are installed.

Seal-Lok™ Fittings(hose end - ORFS)

SAE Dash size Torque

-4 10 ft-lbs / 13.6 Nm

-6 30 ft-lbs / 40.7 Nm

-8 40 ft-lbs / 54.2 Nm

-10 60 ft-lbs / 81.3 Nm

-12 85 ft-lbs / 115 Nm

-16 110 ft-lbs / 150 Nm

-20 140 ft-lbs / 190 Nm

-24 180 ft-lbs / 245 Nm

JIC 37° Fittings(swivel nut or hose connection)

SAE Dash size Thread Size Flats

-4 7/16-20 2

-6 9/16-18 1 1/4

-8 3/4-16 1

-10 7/8-14 1

-12 1 1/16-12 1

-16 1 5/16-12 1

-20 1 5/8-12 1

-24 1 7/8-12 1

SAE O-ring Boss Port(tube fitting - installed into Aluminum)

(all types)


-4 14 ft-lbs / 19 Nm

-6 23 ft-lbs / 31.2 Nm

-8 36 ft-lbs / 54.2 Nm

-10 62 ft-lbs / 84 Nm

-12 84 ft-lbs / 114 Nm

-16 125 ft-lbs / 169.5 Nm

-20 151 ft-lbs / 204.7 Nm

-24 184 ft-lbs / 249.5 Nm

SAE O-ring Boss Port(tube fitting - installed into Steel)


-4 ORFS / 37° (Adj) 15 ft-lbs / 20.3 NmORFS (Non-adj) 26 ft-lbs / 35.3 Nm37° (Non-adj) 22 ft-lbs / 30 Nm

-6 ORFS (Adj / Non-adj) 35 ft-lbs / 47.5 Nm37° (Adj / Non-adj) 29 ft-lbs / 39.3 Nm



-12 (All types) 135 ft-lbs / 183 Nm

-16 (All types) 200 ft-lbs / 271.2 Nm

-20 (All types) 250 ft-lbs / 339 Nm

-24 (All types) 305 ft-lbs / 413.5 Nm

Adjustablefitting (Adj)

Non-adjustablefitting (Non-adj)

Jamb nut


Part No. 227656 GR-20J • GR-26J 2 - 5

Torque ProcedureSeal-Lok™ fittings

1 Replace the O-ring. The O-ring must bereplaced anytime the seal has been broken.The O-ring cannot be re-used if the fitting orhose end has been tightened beyond fingertight.

Note: The O-rings used in the Parker Seal Lok™fittings and hose ends are custom-size O-rings.They are not standard SAE size O-rings. They areavailable in the O-ring field service kit (Genie partnumber 49612).

2 Lubricate the O-ring before installation.

3 Be sure that the face seal O-ring is seated andretained properly.

4 Position the tube and nut squarely on the faceseal end of the fitting and tighten the nut fingertight.

5 Tighten the nut or fitting to the appropriatetorque per given size as shown in the table.

6 Operate all machine functions and inspect thehoses and fittings and related components toconfirm that there are no leaks.

JIC 37° fittings

1 Align the tube flare (hex nut) against the noseof the fitting body (body hex fitting) and tightenthe hex nut to the body hex fitting to hand-tight, approximately 30 in-lbs / 3.4 Nm.

2 Make a reference mark on one of the flats ofthe hex nut, and continue it on to the body hexfitting with a permanent ink marker. Refer toFigure 1.

Figure 1

a hex nutb reference markc body hex fitting

3 Working clockwise on the body hex fitting,make a second mark with a permanent inkmarker to indicate the proper tighteningposition. Refer to Figure 2.

Note: Use the JIC 37° Fittings table on theprevious page to determine the correct number offlats for the proper tightening position.

Note: The marks indicate that the correcttightening positions have been determined. Usethe second mark on the body hex fitting toproperly tighten the joint after it has beenloosened.

Figure 2

a body hex fittingb reference markc second mark

4 Tighten the hex nut until the mark on the hexnut is aligned with the second mark on thebody hex fitting.

5 Operate all machine functions and inspect thehoses and fittings and related components toconfirm that there are no leaks.

a

bc

a

bc

b

SPECIFICATIONS


2 - 6 GR-20J • GR-26J Part No. 227656

SPECIFICATIONS

SIZE THREAD

in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm20 80 9 100 11.3 110 12.4 140 15.8 130 14.728 90 10.1 120 13.5 120 13.5 160 18 140 15.8

ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm18 13 17.6 17 23 18 24 25 33.9 21 28.424 14 19 19 25.7 20 27.1 27 36.6 24 32.516 23 31.2 31 42 33 44.7 44 59.6 38 51.524 26 35.2 35 47.4 37 50.1 49 66.4 43 58.314 37 50.1 49 66.4 50 67.8 70 94.7 61 82.720 41 55.5 55 74.5 60 81.3 80 108.4 68 92.113 57 77.3 75 101.6 80 108.4 110 149 93 12620 64 86.7 85 115 90 122 120 162 105 14212 80 108.4 110 149 120 162 150 203 130 17618 90 122 120 162 130 176 170 230 140 18911 110 149 150 203 160 217 210 284 180 24418 130 176 170 230 180 244 240 325 200 27110 200 271 270 366 280 379 380 515 320 43316 220 298 300 406 310 420 420 569 350 4749 320 433 430 583 450 610 610 827 510 691

14 350 474 470 637 500 678 670 908 560 7598 480 650 640 867 680 922 910 1233 770 1044

12 530 718 710 962 750 1016 990 1342 840 11397 590 800 790 1071 970 1315 1290 1749 1090 1477

12 670 908 890 1206 1080 1464 1440 1952 1220 16547 840 1138 1120 1518 1360 1844 1820 2467 1530 2074

12 930 1260 1240 1681 1510 2047 2010 2725 1700 23046 1460 1979 1950 2643 2370 3213 3160 4284 2670 3620

12 1640 2223 2190 2969 2670 3620 3560 4826 3000 4067

5/16

3/8

7/16

1/2

1 1/2

9/16

5/8

3/4

7/8

1

1 1/8

1 1/4

LUBED

1/4

LUBED DRY LUBED DRY

LUBEDDRYLUBED

SAE FASTENER TORQUE CHART

Grade 5DRYLUBED

• This chart is to be used as a guide only unless noted elsewhere in this manual •A574 High Strength Black Oxide BoltsGrade 8

Size(mm)

in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm5 16 1.8 21 2.4 41 4.63 54 6.18 58 6.63 78 8.84 68 7.75 91 10.36 19 3.05 36 4.07 69 7.87 93 10.5 100 11.3 132 15 116 13.2 155 17.67 45 5.12 60 6.83 116 13.2 155 17.6 167 18.9 223 25.2 1.95 22.1 260 29.4

ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm8 5.4 7.41 7.2 9.88 14 19.1 18.8 25.5 20.1 27.3 26.9 36.5 23.6 32 31.4 42.610 10.8 14.7 14.4 19.6 27.9 37.8 37.2 50.5 39.9 54.1 53.2 72.2 46.7 63.3 62.3 84.412 18.9 25.6 25.1 34.1 48.6 66 64.9 88 69.7 94.5 92.2 125 81 110 108 14714 30.1 40.8 40 54.3 77.4 105 103 140 110 150 147 200 129 175 172 23416 46.9 63.6 62.5 84.8 125 170 166 226 173 235 230 313 202 274 269 36518 64.5 87.5 86.2 117 171 233 229 311 238 323 317 430 278 377 371 50320 91 124 121 165 243 330 325 441 337 458 450 610 394 535 525 71322 124 169 166 225 331 450 442 600 458 622 612 830 536 727 715 97024 157 214 210 285 420 570 562 762 583 791 778 1055 682 925 909 1233

LUBED DRY LUBED DRYLUBED DRY LUBED DRY

LUBEDDRYLUBED

Class 12.9Class 4.6DRYLUBED

METRIC FASTENER TORQUE CHART• This chart is to be used as a guide only unless noted elsewhere in this manual •

LUBED DRY

Class 10.9Class 8.8DRY

Section 3 • Scheduled Maintenance Procedures

Part No. 227656 GR-20J • GR-26J 3 - 1

September 2016

Scheduled Maintenance Procedures

Observe and Obey:

Maintenance inspections shall be completedby a person trained and qualified on themaintenance of this machine.

Scheduled maintenance inspections shall becompleted daily, quarterly, semi-annually,annually and every 2 years as specified on theMaintenance Inspection Report.

Failure to properly complete eachinspection when required maycause death, serious injury orsubstantial machine damage.

Immediately tag and remove from service adamaged or malfunctioning machine.

Repair any machine damage or malfunctionbefore operating the machine.

Use only Genie approved replacement parts.

Machines that have been out of service for aperiod longer than 3 months must complete thequarterly inspection.

Unless otherwise specified, perform eachprocedure with the machine in the followingconfiguration:

• Machine parked on a firm, level surface

• Platform in the stowed position

• Key switch in the off position with the keyremoved

• The red Emergency Stop button in the offposition at both ground and platform controls

• Wheels chocked

• All external AC power supply disconnectedfrom the machine

About This Section

This section contains detailed procedures for eachscheduled maintenance inspection.

Each procedure includes a description, safetywarnings and step-by-step instructions.

Symbols Legend






Indicates that a specific result is expected afterperforming a series of steps.

Indicates that an incorrect result has occurredafter performing a series of steps.


3 - 2 GR-20J • GR-26J Part No. 227656

September 2016

SCHEDULED MAINTENANCE PROCEDURES

Maintenance Symbols Legend

Note: The following symbols have been used inthis manual to help communicate the intent of theinstructions. When one or more of the symbolsappears at the beginning of a maintenanceprocedure, it conveys the meaning below.

Indicates that tools will be required toperform this procedure.

Indicates that new parts will be requiredto perform this procedure.

Indicates that a cold motor or pump willbe required to perform this procedure.

Indicates that dealer service will berequired to perform this procedure.

Pre-delivery Preparation Report

The pre-delivery preparation report containschecklists for each type of scheduled inspection.

Make copies of the Pre-delivery Preparation reportto use for each inspection. Store completed formsas required.

Maintenance Schedule

There are five types of maintenance inspectionsthat must be performed according to a schedule—daily, quarterly, semi-annually, annually, andtwo year. The Scheduled Maintenance ProceduresSection and the Maintenance Inspection Reporthave been divided into five subsections—A, B, C,D, and E. Use the following chart to determinewhich group(s) of procedures are required toperform a scheduled inspection.

Inspection Checklist

Daily or every 8 hours A

Quarterly or every 250 hours A + B

Semi-annually or every 500 hours A + B + C

Annually or every 1000 hours A + B + C + D

Two year or every 2000 hours A + B + C + D + E

Maintenance Inspection Report

The maintenance inspection report containschecklists for each type of scheduled inspection.

Make copies of the Maintenance Inspection Reportto use for each inspection. Maintain completedforms for a minimum of 4 years or in compliancewith employer, jobsite and governmentalregulations and requirements.

Terex South Dakota, Inc USA500 Oak Wood RoadPO Box 1150Watertown, SD 57201-6150(605) 882-4000

Copyright © 2011 Terex Corporation. Genie® is a registered trademark of Terex SouthDakota, Inc. 133192 Rev D

Genie UKThe Maltings, Wharf Road

Grantham, LincolnshireNG31- 6BH England

(44) 1476-584333

Pre-DeliverPre-DeliverPre-DeliverPre-DeliverPre-Delivery Preparationy Preparationy Preparationy Preparationy Preparation

Pre-Delivery Preparation Y N R

Pre-operation inspectioncompleted

Maintenance items completed

Function tests completed

Model

Serial number

Date

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

Instructions

Use the operator’s manual on your machine.

The Pre-delivery Preparation consists of completingthe Pre-operation Inspection, the Maintenance itemsand the Function Tests.

Use this form to record the results. Place a check inthe appropriate box after each part is completed.Follow the instructions in the operator’s manual.

If any inspection receives an N, remove the machinefrom service, repair and reinspect it. After repair, placea check in the R box.

LegendY = yes, completedN = no, unable to completeR = repaired

Comments

Fundamentals

It is the responsibility of the dealer to perform thePre-delivery Preparation.

The Pre-delivery Preparation is performed prior toeach delivery. The inspection is designed to discover ifanything is apparently wrong with a machine before itis put into service.

A damaged or modified machine must never be used.If damage or any variation from factory deliveredcondition is discovered, the machine must be taggedand removed from service.

Repairs to the machine may only be made by aqualified service technician, according to themanufacturer's specifications.

Scheduled maintenance inspections shall beperformed by qualified service technicians, accordingto the manufacturer's specifications and therequirements listed in the responsibilities manual.


3 - 4 GR-20J • GR-26J Part No. 227656

September 2016



Part No. 227656 GR-20J • GR-26J 3 - 5

September 2016

Maintenance Inspection Report

Checklist B Y N R

B-1 Inspect the battery

B-2 Electrical wiring

B-3 Tires and wheels

B-4 Emergency stop

B-5 Horn

B-6 Key switch

B-7 Drive brakes

B-8 Drive speed - stowed

B-9 Drive speed - raised

B-10 Flashing beacon(if equipped)

B-11 Motion alarm

B-12 Hydraulic oil analysis

B-13 Breather cap

B-14 Rear axle free-wheeling

B-15 Lateral offset ofthe mast

B-16 Mast wear pads

Checklist C Y N R

C-1 Calibrate platformoverload (if equipped)

C-2 Breather cap - modelswith optional oil

Checklist D Y N R

D-1 Tank return filter

Checklist E Y N R

E-1 Hydraulic oil

Checklist A Y N R

A-1 Inspect the manualsand decals

A-2 Pre-operationinspection

A-3 Function tests

Perform after 40 hours:

A-4 30 day service

Perform every 100 hours:

A-5 Hydraulic suctionstrainer

Instructions• Make copies of this report to use for

each inspection.

• Select the appropriate checklist(s) forthe type of inspection to beperformed.

Daily or 8 hoursInspection: A

Quarterly or 250 hoursInspection: A+B

Semi-annually or500 hoursInspection: A+B+C

Annually or1000 hoursInspection: A+B+C+D

Two year or2000 hoursInspection: A+B+C+D+E

• Place a check in the appropriate boxafter each inspection procedure iscompleted.

• Use the step-by-step procedures inthis section to learn how to performthese inspections.

• If any inspection receives an “N”, tagand remove the machine from service,repair and re-inspect it. After repair,place a check in the “R” box.

LegendY = yes, acceptableN = no, remove from service

R = repaired

Model

Serial number

Date

Hour meter

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

Comments


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Part No. 227656 GR-20J • GR-26J 3 - 7

September 2016

A-1Inspect the Manuals and DecalsGenie specifications require that this procedure beperformed every 8 hours or daily, whichevercomes first.

Maintaining the operator’s and safety manuals ingood condition is essential to safe machineoperation. Manuals are included with eachmachine and should be stored in the containerprovided in the platform. An illegible or missingmanual will not provide safety and operationalinformation necessary for a safe operatingcondition.

In addition, maintaining all of the safety andinstructional decals in good condition is mandatoryfor safe machine operation. Decals alert operatorsand personnel to the many possible hazardsassociated with using this machine. They alsoprovide users with operation and maintenanceinformation. An illegible decal will fail to alertpersonnel of a procedure or hazard and couldresult in unsafe operating conditions.

1 Check to make sure that the operator's andsafety manuals are present and complete in thestorage container on the platform.

2 Examine the pages of each manual to be surethat they are legible and in good condition.

Result: The operator's manual is appropriate forthe machine and all manuals are legible and ingood condition.

Result: The operator's manual is notappropriate for the machine or all manuals arenot in good condition or is illegible. Remove themachine from service until the manual isreplaced.

Checklist A Procedures

3 Open the operator's manual to the decalsinspection section. Carefully and thoroughlyinspect all decals on the machine for legibilityand damage.

Result: The machine is equipped with allrequired decals, and all decals are legible andin good condition.

Result: The machine is not equipped with allrequired decals, or one or more decals areillegible or in poor condition. Remove themachine from service until the decals arereplaced.

4 Always return the manuals to the storagecontainer after use.

Note: Contact your authorized Genie distributor orGenie Industries if replacement manuals or decalsare needed.


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A-4Perform 30 Day Service

The 30 day maintenance procedure is a one timeprocedure to be performed after the first 30 days or40 hours of usage. After this interval, refer to themaintenance tables for continued scheduledmaintenance.

1 Perform the following maintenance procedures:

• B-3 Inspect the Tires and Wheels(including castle nut torque)

• D-1 Replace the Hydraulic TankReturn Filter

CHECKLIST A PROCEDURES

A-2Perform Pre-operation InspectionGenie specifications require that this procedure beperformed every 8 hours or daily, whichevercomes first.

Completing a Pre-operation Inspection is essentialto safe machine operation. The Pre-operationInspection is a visual inspection performed by theoperator prior to each work shift. The inspection isdesigned to discover if anything is apparentlywrong with a machine before the operator performsthe function tests. The Pre-operation Inspectionalso serves to determine if routine maintenanceprocedures are required.

Complete information to perform this procedure isavailable in the appropriate operator's manual.Refer to the Operator's Manual on your machine.

A-3Perform Function TestsGenie specifications require that this procedure beperformed every 8 hours or daily, whichevercomes first.

Completing the function tests is essential to safemachine operation. Function tests are designed todiscover any malfunctions before the machine isput into service. A malfunctioning machine mustnever be used. If malfunctions are discovered, themachine must be tagged and removed fromservice.

Complete information to perform this procedure isavailable in the appropriate operator's manual.Refer to the Operator's Manual on your machine.


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September 2016

CHECKLIST A PROCEDURES

A-5Replace the Hydraulic SuctionStrainer

Genie specifications require that this procedure beperformed every 100 hours or monthly, whichevercomes first.

Replacement of the hydraulic suction strainer isessential for good machine performance andservice life. A dirty or clogged suction strainer maycause the machine to perform poorly andcontinued use may cause component damage.Extremely dirty conditions may require that thesuction strainer be replaced more often.

Beware of hot oil. Contact with hotoil may cause severe burns.

Note: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.

Note: Perform this procedure with the machine instowed position.

1 Disconnect the battery pack from the machine.

2 Open and remove the turntable cover at thehydraulic power unit side of the machine.

3 Working next to the hydraulic tank, remove thefasteners securing the chassis side cover to thechassis. Remove the side cover. Lay the sidecover and fasteners to the side.

4 Tag and disconnect the wire harnessconnectors from the function manifold.

5 Tag and disconnect the cables from the motor.

6 Tag, disconnect and plug the hydraulic hoses atthe function manifold. Cap the fittings on themanifold.

Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.

7 Place a suitable container under the hydraulictank. Refer to Section 2, Specifications.

8 Locate and remove the hydraulic tank filler cap.Set the filler cap to the side.

9 Remove the drain plug and drain all of the oilinto a suitable container.

10 Clean up any oil that may have spilled. Properlydiscard the used oil.

11 Remove the fasteners securing the functionmanifold to the hydraulic tank. Set the fastenersto the side.

12 Loosen the clamp securing the hydraulic powerunit to the hydraulic tank. Do not remove theclamp.

13 Remove the clamp securing the hydraulicpower unit to the chassis. Set the clamp to theside.

14 Carefully remove the hydraulic power unit fromthe tank and place it on a clean work bench.

Note: If necessary, loosen the bottom connector ofauxiliary pump to more easily remove the hydraulicpower unit.

15 Remove the suction strainer from the end of theplastic tube.

16 Install the new suction strainer at the end of theplastic tube.


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Checklist B Procedures

B-1Inspect the Battery

Genie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.

Proper battery condition is essential to goodmachine performance and operational safety.Improper fluid levels or damaged cables andconnections can result in component damage andhazardous conditions.

Electrocution/burn hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.

Bodily injury hazard. Batteriescontain acid. Avoid spilling orcontacting battery acid. Neutralizebattery acid spills with baking sodaand water.

1 Open the turntable covers of the machine.

2 Confirm that the battery cable connections aretight and free of corrosion.

Note: Adding terminal protectors and a corrosionpreventative sealant will help eliminate corrosionon the battery terminals and cables.

3 Locate the bolts between the battery pack andthe counterweight. Confirm that the head ofeach bolt is firmly in contact with the batterypack so that the battery pack does not move.

a battery B9b fuse 250A F9c emergency stop button P1d motor controller U6e battery charger indicator G7f battery charger U9

4 Put on protective clothing and eye wear.

5 Remove the battery vent caps and check thebattery acid level. If needed, replenish withdistilled water to 1/8 inch / 3 mm below thebottom of the battery fill tube. Do not overfill.

6 Install the vent caps and neutralize anyelectrolyte that may have spilled.

U9Battery Charger

F9250A Fuse

U6Motor Controller

B912-2V

a

P1

G7

b

c

d

f

e


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4 Turn the key switch to off position and push inthe red Emergency Stop button to the offposition at the ground control.

5 Tag and disconnect the cables from the groundterminal of the battery.

6 Remove the fasteners securing the rear chassiscover to the chassis at the non-steer end of themachine. Remove the chassis cover. Lay thecover and fasteners to the side.

7 Inspect the drive motors connections for burnt,chafed, pinched cables and loose connections.

8 Install the rear chassis cover at the non-steerend of the machine and securely install thefasteners.

9 Install the cables onto the ground terminal of thebattery, and securely tighten.

10 Inspect the battery pack for burnt, chafed andpinched cables.

11 Inspect the following areas for burnt, chafed,corroded and loose wires:

• Ground control panel

• Battery charger

• Hydraulic power unit

12 Turn the key switch to ground control and pullout the red Emergency Stop button to the onposition at the ground control.

Note: Rotate the red Emergency Stop button atplatform control one quarter turn in a clockwisedirection to restore the power supply. The redEmergency Stop button returns automatically tothe out, or on position.

CHECKLIST B PROCEDURES

B-2Inspect the Electrical Wiring


Maintaining electrical wiring in good condition isessential to safe operation and good machineperformance. Failure to find and replace burnt,chafed, corroded or pinched wires could result inunsafe operating conditions and may causecomponent damage.


1 Open and remove the turntable covers from themachine.

2 Turn the key switch to ground control and pullout the red Emergency Stop button to the onposition at both the ground and platformcontrols.


3 Raise the jib boom until the platform isapproximately 8 feet / 2.4 m from the ground.


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13 Lower the jib boom until the platform isapproximately 2 feet / 0.5 m from the ground.

14 Turn the key switch to off position and push inthe red Emergency Stop button to the offposition at both the ground and platformcontrols.

15 Inspect the following areas for burnt, chafed,corroded and loose wires:

• Mast cable

• Platform controls

• Power to platform wiring

16 Inspect for a liberal coating of dielectric greasein all wiring connections between the groundcontrol panel and the platform controls, andlevel sensor wiring.

17 Install both the turntable covers on the machine.

B-3Inspect the Tires and Wheels


Maintaining the tires and wheels in good condition,including proper castle nut torque, is essential tosafe operation and good performance. Tire and/orwheel failure could result in a machine tip-over.Component damage may also result if problemsare not discovered and repaired in a timely fashion.

1 Check the tire surface and sidewalls for cuts,cracks and unusual wear.

2 Check each wheel for damage, bends andcracks.

Non-steer end:

3 Remove the lock washer flange from the slot ofthe castle nut. Check the castle nut for propertorque. Refer to Section 2, Specifications.

4 Install the lock washer flange into a slot of thecastle nut.

Steer end:

5 Check each lug bolt for proper torque. Refer toSection 2, Specifications.


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B-4Test the Emergency StopGenie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.

A properly functioning Emergency Stop is essentialfor safe machine operation. An improperlyoperating red Emergency Stop button will fail toshut off power and stop all machine functions,resulting in a hazardous situation.



2 Push in the red Emergency Stop button at theground controls to the off position.

3 Check the machine functions from the groundcontrols.

Result: The machine functions should notoperate.

4 Turn the key switch to platform control and pullout the red Emergency Stop button to the onposition at both the ground and platformcontrols.

5 Push the red Emergency Stop button at theplatform controls to the off position.

6 Check the machine functions from the platformcontrols.


Note: The red Emergency Stop button at theground controls will stop all machine operations,even if the key switch is turned to the platformcontrol.

B-5Test the HornGenie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.

The horn is activated at the platform controls andsounds at the ground as a warning to groundpersonnel. An improperly functioning horn willprevent the operator from alerting groundpersonnel of hazards or unsafe conditions.

1 Turn the key switch to platform control andpull out the red Emergency Stop button to theon position at both the ground andplatform controls.


2 Push down the horn button at the platformcontrols.

Result: The horn should sound.


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B-6Test the Key SwitchGenie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.

Proper key switch action and response is essentialto safe machine operation. The machine can beoperated from the ground or platform controls andthe activation of one or the other is accomplishedwith the key switch. Failure of the key switch toactivate the appropriate control panel could causea hazardous operating situation.

1 Turn the key switch to platform control and pullout the red Emergency stop button to the onposition at both the ground and platformcontrols.


2 Check the machine functions from the groundcontrols.


a platform controlb machine switch offc ground control

3 Turn the key switch to ground control.

4 Check the machine functions from the platformcontrols.


5 Turn the key switch to the off position.

6 Test the machine functions from the ground andplatform controls.


b

a

OFF

c


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B-7Test the Drive Brakes


Proper brake action is essential to safe machineoperation. The drive brake function should operatesmoothly, free of hesitation, jerking and unusualnoise. Hydraulically-released individual wheelbrakes can appear to operate normally when notfully operational.

Note: Perform this procedure with the machine ona firm, level surface that is free of obstructions.

1 Mark a test line on the ground for reference.



3 Lower the platform to the stowed position.

4 Press the drive function select button.

a drive function select button BN130

5 Choose a point on the machine i.e. contactpatch of a tire, as a visual reference for usewhen crossing the test line.

6 Bring the machine to top drive speed beforereaching the test line. Release the functionenable switch or the joystick when yourreference point on the machine crosses the testline.

7 Measure the distance between the test line andyour machine reference point. Refer toSection 2, Specifications.

Note: The brakes must be able to hold the machineon any slope it is able to climb.

a


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a drive function select button BN130

5 Choose a point on the machine i.e. contactpatch of a tire, as a visual reference for usewhen crossing the start and finish lines.

6 Bring the machine to top drive speed beforereaching the start line. Begin timing when yourreference point on the machine crosses thestart line.

7 Continue at full speed and note the time whenyour reference point on the machine passesover the finish line. Refer to Section 2,Specifications.

B-8Test the Drive Speed -Stowed Position


Proper drive functions are essential to safemachine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free ofhesitation, jerking and unusual noise over theentire proportionally controlled speed range.


1 Create start and finish lines by marking twolines on the ground 40 feet / 12.2 m apart.





a


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a lift function select button BN63b drive function select button BN130

5 Raise the platform approximately 2 feet / 70 cmfrom the ground.


7 Choose a point on the machine i.e. contactpatch of a tire, as a visual reference for usewhen crossing the start and finish lines.

8 Bring the machine to top drive speed beforereaching the start line. Begin timing when yourreference point on the machine crosses thestart line.

9 Continue at full speed and note the time whenyour reference point on the machine passesover the finish line. Refer to Section 2,Specifications.

B-9Test the Drive Speed -Raised Position


Proper drive functions are essential to safemachine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free ofhesitation, jerking and unusual noise over theentire proportionally controlled speed range.


1 Create start and finish lines by marking twolines on the ground 40 feet / 12.2 m apart.



3 Press the lift function select button.

4 Press and hold the function enable switch onthe joystick.

ab


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B-10Test the Flashing Beacon(if equipped)Genie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.

Flashing beacon is used to alert operators andground personnel of machine proximity andmotion.



2 Activate any machine function from the groundcontrol (as indicated on the ground control box).

Result: The beacon should flash.

3 Turn the key switch to platform controls.

4 Activate any machine function from the platformcontrol (as indicated on the platform controlbox).

Result: The beacon should flash.

Note: Beacon will flash only when you activate anymachine function either from ground control orplatform control.


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6 Press and hold the function enable switch onthe joystick. Move the joystick off center, holdfor a moment and then release it. Move thejoystick off center in the opposite direction, holdfor a moment and then release it.

Result: The motion alarm will sound when thejoystick is moved off center in either direction.


8 Press and hold the function enable switch onthe joystick. Move the joystick off center, holdfor a moment and then release it. Move thejoystick off center in the opposite direction, holdfor a moment and then release it.

Result: The motion alarm will sound when thejoystick is moved off center in either direction.

9 Press and hold the function enable switch onthe joystick. Press and hold the thumb rockerswitch for a moment to the left position and thenrelease it. Press and hold the thumb rockerswitch for a moment to the right position andthen release it.

Result: The motion alarm will sound when therocker switch is moved off center in eitherdirection.

B-11Test the Motion AlarmGenie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.

Alarm is used to alert operators and groundpersonnel of machine proximity and motion.



2 Raise the platform approximately 1 ft / 30.5 cm.

Result: When raising the platform, the motionalarm will sound.


Result: When lowering the platform, the motionalarm will sound.

4 Turn the key switch to platform controls.

5 Press the lift function select button.


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B-12Perform Hydraulic Oil Analysis


Replacement or testing of the hydraulic oil isessential for good machine performance andservice life. Dirty oil may cause the machine toperform poorly and continued use may causecomponent damage. Extremely dirty conditionsmay require oil changes to be performed moreoften. Refer to Section 2, Specifications.

Before replacing the hydraulic oil, the oil may betested by an oil distributor for specific levels ofcontamination to verify that changing the oil isnecessary.If the hydraulic oil is not replaced at the twoyear inspection, test the oil quarterly. Replacethe oil when it fails the test. See E-1, Test orReplace the Hydraulic Oil.

B-13Inspect the Breather CapGenie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first. Perform this procedure more often ifdusty conditions exist.

A free-breathing hydraulic tank cap is essential forgood machine performance and service life. A dirtyor clogged cap may cause the machine to performpoorly. Extremely dirty conditions may require thatthe cap be inspected more often.

1 Open the turntable cover at the hydraulic powerunit side of the machine.

2 Locate and remove the breather cap from thehydraulic tank.

3 Check the breather cap for proper venting.

Result: Air passes through the breather cap.Proceed to step 5.

Result: If air does not pass through the cap,clean or replace the cap. Proceed to step 4.

Note: When checking the hydraulic tank breathercap for venting, air should pass freely through thecap.

4 Using a mild solvent, carefully wash the capventing system. Dry using low pressurecompressed air. Repeat this procedurebeginning with step 3.

5 Install the breather cap onto the hydraulic tank.


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B-14Inspect the Rear AxleFree-wheel


Note: Perform this procedure with the machine ona firm, level surface that is free of obstructions,with the wheels chocked.

1 Secure the steer end of the machine to a forkliftor similar device using a connecting bar nogreater than 3 ft / 1 m in length. Set the brakeson forklift.

2 Open the turntable cover at the ground controlside of the machine.

3 Using the illustration as a guide, locate thefree-wheel selector switch on the top of theground control box.

4 Move the free-wheel selector switch to the rightto set the machine to free-wheel condition.

Result: The parking brakes will release and thehorn will sound softly.

5 Remove the wheel chocks and, using a fork liftor similar device, apply force to the machine.

Result: The machine will move freely.

Component damage hazard. Themachine can be damaged if itbreaks free from the forklift. Do notattempt to test the free-wheelingfunction unless a connecting barof adequate size and strength isused to secure the GR-J to theforklift or similar device.


a free-wheel selector switchb ground control box

6 Move the free-wheel selector switch to the left.

Result: The parking brakes will set and the hornwill not sound.

7 Using a fork lift or similar device, apply force tothe machine.

Result: The machine will not move freely.

b

a


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B-15Inspect the Lateral Offset of theMast


Note: Perform this procedure with the machine ona firm, level surface that is free of obstructions,with the wheels chocked.



2 Raise the jib boom to a horizontal position.

3 Raise the mast head approximately8 inches / 20 cm.


4 Using a suitable torque measuring device, applya lateral force of 29.5 ft-lb / 40 Nm near thefloor of the platform at location "F". Refer to theillustration.

Result: Lateral offset of the mast i.e. distanceL1 and L2 as shown in the illustration shouldnot exceed 13.75 inches / 350 mm.

L2

F

L1

F


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September 2016


B-16Inspect the Mast Wear Pads


Mast wear pads should always be in goodcondition and greased for good machineperformance and service life. A damaged wearpads may cause the unsafe machine operation.


Note: Perform this procedure in a location that issheltered from the wind.

1 Using the illustration as a guide, install a plumbline of a suitable length onto the platform.

2 Using a suitable lifting device, place a440 lbs / 200 Kg test weight in the center of theplatform. Secure the weight to the platform.



a number 1 mastb plumb line

4 Raise the jib boom to a horizontal position.

5 Activate the mast up function and fully raise themast.

6 Using a suitable measuring device, measurethe distance between plumb line and the face ofthe number 1 mast. Refer to illustration.

Result: The distance between the plumb lineand the face of the number 1 mast does notexceed 66.9 inches / 1700 mm. The wear padsare in good condition.

Result: The distance between the plumb lineand the face of the number 1 mast exceeds66.9 inches / 1700 mm. The wear pads are notin good condition. Install new wear pads. Referto Repair Procedure 4-1, How to Remove theMast Assembly.

ba


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Checklist C Procedure

C-1Calibrate the Platform OverloadSystem (if equipped)

Genie specifications require that this procedure beperformed every 500 hours or six months,whichever comes first OR when the machine failsto lift the maximum rated load.

Calibrating the platform overload system regularlyis essential to safe machine operation. Continueduse of an improperly operating platform overloadsystem could result in the system not sensing anoverloaded platform condition. Machine stabilitycould be compromised resulting in the machinetipping over.

The platform overload system is designed toprevent machine operation in the event theplatform is overloaded. Models equipped with theplatform overload option are provided with twooverload pressure sensors.

Models equipped with the platform overload optionare provided with additional machine components:an adjustable spring-loaded subassembly, a limitswitch harness, an electronic module whichreceives the overload signal and interrupts power,and an audio/visual warning indication to alert theoperator of the overload.

Refer to Repair Procedure 2-2, How to Calibratethe Platform Overload System (if equipped).

a adjustable spring-loadedsubassembly and limit switchharness


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C-2Replace the Hydraulic TankBreather Cap - Models withOptional Hydraulic Oil

Genie specifications require that this procedure beperformed every 500 hours or six months,whichever comes first OR when the machine failsto lift the maximum rated load.

The hydraulic tank is a vented-type tank. Thebreather cap has an internal air filter that canbecome clogged or, over time, can deteriorate. Ifthe breather cap is faulty or improperly installed,impurities can enter the hydraulic system whichmay cause component damage. Extremely dirtyconditions may require that the cap be inspectedmore often.

1 Remove breather cap from the hydraulic tank.Discard the breather cap.

Note: The tank filler cap and breather are onepiece component.

2 Install a new breather cap onto the hydraulictank.

CHECKLIST C PROCEDURES


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Checklist D Procedure

D-1Replace the Hydraulic TankReturn Filter

Genie specifications require that this procedure beperformed every 1000 hours or annually,whichever comes first.

Replacement of the hydraulic tank return filter isessential for good machine performance andservice life. A dirty or clogged filter may cause themachine to perform poorly and continued use maycause component damage. Extremely dirtyconditions may require that the filter be replacedmore often.

Beware of hot oil. Contact with hotoil may cause severe burns.

Note: Perform this procedure on a firm, levelsurface.


2 Using the illustration as a guide, locate the filtercap of the function manifold. Clean the areaaround the filter cap.

3 Remove the filter cap from the functionmanifold. Set it to the side.

4 Remove the oil filter placed underneath the filtercap.

5 Apply a thin layer of oil to the new oil filtergasket.

a filter cap

6 Install the new filter into the function manifold,and securely tighten.

7 Install the filter cap onto the function manifoldand torque to specification. Refer to Section 2,Specifications.



9 Press and hold the function enable button.

10 Activate the mast up function and raise themast slightly.

11 Inspect the filter and related components tobe sure that there are no oil leaks.

12 Clean up any oil that may have spilled.

a


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Checklist E Procedure

E-1Test or Replace the Hydraulic Oil

Genie specifications require that this procedure beperformed every 2000 hours or every two years,whichever comes first.

Replacement or testing of the hydraulic oil isessential for good machine performance andservice life. Dirty oil may cause the machine toperform poorly and continued use may causecomponent damage. Extremely dirty conditionsmay require oil changes to be performed moreoften.

Before replacing the hydraulic oil, the oil may betested by an oil distributor for specific levels ofcontamination to verify that changing the oil isnecessary. If the hydraulic oil is not replaced atthe two year inspection, test the oil quarterly.Replace the oil when it fails the test.

Note: Perform this procedure with the machine inthe stowed position.

1 Open the turntable covers of the machine.



3 Remove the fasteners securing the chassis sidecover next to the tank to the chassis. Removethe side cover. Lay the side cover andfasteners to the side.





Note: To clean the inside of the hydraulic tankusing a mild solvent, it may be helpful to removethe hydraulic power unit from the tank. Refer toRepair Procedure 6-1, How to Remove theFunction Pump.

8 Install the drain plug onto the hydraulic tank andtorque to specification.

Torque specification

Hydraulic tank drain plug 44 in-lbs5 Nm

9 Fill the tank with hydraulic oil until the fluid is atthe full indicator on the hydraulic tank. Do notoverfill.

10 Install the filler cap onto the hydraulic tank, andsecurely tighten. Do not over tighten.

11 Activate the pump to fill the hydraulic systemwith oil and bleed the system of air.

Component damage hazard. Thepump can be damaged if operatedwithout oil. Be careful not to emptythe hydraulic tank while in theprocess of filling the hydraulicsystem. Do not allow the pump toactivate.


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Section 4 • Repair Procedures

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Repair Procedures

Observe and Obey:

Repair procedures shall be completed by aperson trained and qualified on the repair of thismachine.



Before Repairs Start:

Read, understand and obey the safety rulesand operating instructions in the appropriateoperator's manual on your machine.

Be sure that all necessary tools and parts areavailable and ready for use.

Use only Genie approved replacement parts.

Read each procedure completely and adhere tothe instructions. Attempting shortcuts mayproduce hazardous conditions.

Unless otherwise specified, perform each repairprocedure with the machine in the followingconfiguration:





• Wheels chocked


About This Section

Most of the procedures in this section should onlybe performed by a trained service professionalin a suitably equipped workshop. Select theappropriate repair procedure after troubleshootingthe problem.

Perform disassembly procedures to the pointwhere repairs can be completed. Then toreassemble, perform the disassembly steps inreverse order.

Symbols Legend






Indicates that a specific result is expected afterperforming a series of steps.

Indicates that an incorrect result has occurredafter performing a series of steps.


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The platform controls, used to operate the machinefrom the platform. The platform controls are usedto operate the various machine functions.

The platform controls consist of an electroniccircuit board, joystick, alarm, buttons and LEDs.

For further information or assistance, consult theGenie Service Department.

1-1Circuit Boards

How to Remove the PlatformControls Circuit Board1 Push in the red Emergency Stop button to the

off position at both the ground and platformcontrols.

2 Remove the fasteners securing the top plateassembly to the platform control box. Carefullyremove the top plate assembly from the box toexpose the circuit boards.

3 Tag and disconnect the wire harnessconnectors from the platform controls circuitboard.


Component damage hazard.Electrostatic discharge (ESD) candamage printed circuit boardcomponents. Maintain firm contactwith a metal part of the machinethat is grounded at all times whenhandling printed circuit boards ORuse a grounded wrist strap.

4 Remove the fasteners securing the platformcontrols circuit board to the top plate assembly.Set the fasteners to the side.

5 Remove the platform controls circuit boardsfrom the top plate assembly.

Platform Controls


Part No. 227656 GR-20J • GR-26J 4 - 3

September 2016

5 Press and hold the drive function button for3 seconds.

Result: All 3 indicator lights will flash for 3seconds and turn off.

6 Push in the red Emergency Stop button atplatform controls to confirm the procedure.

Result: The motion alarm will sound during allmachine movements.

Note: To deactivate the motion alarm, perform thisprocedure beginning with step 1.

PLATFORM CONTROLS

1-2Controller Adjustments

How to Activate or Deactivatethe Motion AlarmThe alarm is activated at the platform controls andsounds at the ground as a warning to groundpersonnel. An improperly functioning alarm willprevent the operator from alerting groundpersonnel of hazards or unsafe conditions.



2 Simultaneously press and hold all three functionbuttons for 3 seconds.

Result: A beep sounds and three functionindicator lights will flash one after another.

3 Simultaneously press and hold the drivefunction and the lift function buttons for 3seconds.

Result: All three function indicator lights will stopflashing.

4 Briefly press and release the drive functionbutton to turn the motion alarm on or off.

Result: The drive indicator light will be on if themotion alarm is activated.It will be off if themotion alarm is deactivated.

a joystick function enable switchb thumb rocker switchc joystickd jib boom function button BN97e lift function and turntable rotate

function button BN63f drive function button BN130g function indicator lightsh red Emergency Stop button P2

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4 - 4 GR-20J • GR-26J Part No. 227656

September 2016

PLATFORM CONTROLS

How to Activate or Deactivate theFlashing Beacon(if equipped)The Flashing Beacon is installed to alert operatorsand ground personnel of machine proximity andmotion. The Flashing Beacon is installed on theground control side of the mast.





3 Simultaneously press and hold the drivefunction and lift function buttons for 3 seconds.


4 Briefly press and release the lift function buttonto turn the flashing beacon on or off.

Result: The lift indicator light will be on if theflashing beacon is activated.It will be off if theflashing beacon is deactivated.




Result: All 3 indicator lights will flash for 3seconds and turn off.

6 Push in the red Emergency Stop button atplatform controls to confirm the procedure.

Result: The beacon will flash during all machinemovements.

Note: To deactivate the flashing beacon option,perform this procedure beginning with step 1.

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Part No. 227656 GR-20J • GR-26J 4 - 5

September 2016

How to Calibrate the JoystickCalibration of the joystick is essential for safemachine operation. The joystick on this machineutilize Hall Effect technology for proportionalcontrol. If a joystick is disconnected or replaced, itmust be calibrated before operating the machine.





3 Simultaneously press and hold the drivefunction and jib boom function buttons for 3seconds.


4 Using the illustration as a guide, move thejoystick fully to the left, then return the joystickto the neutral position.

Note: Do not squeeze or activate the joystickfunction enable switch. No machine functionshould operate while performing the joystickcalibration procedure.

PLATFORM CONTROLS



5 Move the joystick fully to the right, then returnthe joystick to the neutral position.

6 Move the joystick fully to the rear, then returnthe joystick to the neutral position.

7 Move the joystick fully to the front, then returnthe joystick to the neutral position.


Result: All three function indicator lights willflash three times. Joystick calibration iscomplete.

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September 2016

How to Calibrate the Steer AngleSensorCalibration of the Steer Angle Sensor is essentialfor safe machine operation. The Steer AngleSensor controls the maximum steering angle thatcan be attained.

1 Adjust the wheels at the steer end of themachine so they are in straight driving position.


3 Tag and disconnect the steer angle sensor wireharness from the machine wire harness.

4 With a multimeter set to read 4K±0.2 ohms,connect the leads to the green and black wiresof the potentiometer.

Result: The reading is 4K±0.2 ohms.Proceed to step 5.

Result: The reading is not 4K±0.2 ohms.See 10-4, How to Replace the Steer AngleSensor.

5 Connect the steer angle sensor wire harness tothe machine wire harness.



7 Simultaneously press and hold all three functionselect buttons for 3 seconds.




8 Simultaneously press and hold the lift functionand jib boom function buttons for 3 seconds.


9 Press and hold the joystick function enableswitch and activate the thumb rocker switchturning the wheels fully to the left.

10 Press the drive function button for 1 second tovalidate the left side steering limit.

11 Press and hold the joystick function enableswitch and activate the thumb rocker switchturning the wheels fully to the right.

12 Press the jib boom function button for 1 secondto validate the right side steering limit.

13 Press and hold the joystick function enableswitch and activate the thumb rocker switchplacing the wheels in line with the chassis.

14 Press the lift function button for 1 second.

15 Press the drive function button for 3 seconds.Steer Sensor calibration is complete.

PLATFORM CONTROLS

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Part No. 227656 GR-20J • GR-26J 4 - 7

September 2016

Platform Components

2-1Platform

How to Remove the Platform1 Push in the red Emergency Stop button to the

off position at both the ground and platformcontrols.


3 Remove the fasteners securing the top plateassembly to the platform control box.

4 Tag and disconnect the wire harnessconnectors from the platform controls circuitboards.


Component damage hazard.Electrostatic discharge (ESD) candamage printed circuit boardcomponents. Maintain firm contactwith a metal part of the machinethat is grounded at all times whenhandling printed circuit boards ORuse a grounded wrist strap.

5 Tag and disconnect the wire harnessconnectors from the joystick. Set the top plateassembly to the side.

6 Remove the fasteners securing the bottom plateassembly to the platform control box. Lay thebottom plate assembly and fasteners to theside.

7 Remove the fasteners securing the outletmounting plate to the platform. Set themounting plate assembly and fasteners to theside.

8 Attach a lifting strap of suitable capacity from anoverhead crane to the bottom of the platform.Support the platform. Do not apply any liftingpressure.

Component damage hazard. Theplatform railings can be damagedif they are used to lift the platform.Do not attach the lifting strap tothe platform railings or putpressure on the railings.

9 Remove the platform mounting pins retainingfasteners. Set the fasteners to the side.

10 Remove the pins securing the platform to the jibboom.

11 Remove the platform from the machine.

Crushing hazard. The platformcould become unbalanced and fallwhen removed from the machine.Use caution when removing theplatform from the machine.

Note: During platform removal, the overhead cranestrap will need to be carefully adjusted for properbalancing.


4 - 8 GR-20J • GR-26J Part No. 227656

September 2016

2-2Platform Overload System

How to Calibrate the PlatformOverload System (if equipped)Calibration of the platform overload system isessential to safe machine operation. Continueduse of an improperly calibrated platform overloadsystem could result in the system failing to sensean overloaded platform. The stability of themachine is compromised and it could tip over.

Note: Perform this procedure with the machine ona firm, level surface that is free of obstructions, andthe machine in stowed position.

1 Block the wheels at the steer end of themachine.

2 Remove all weight, tools and accessories fromthe platform.

Note: Failure to remove all weight, tools andaccessories from the platform will result in anincorrect calibration.

3 Fully tighten the adjusting screws of both theoverload sensors. Do not over tighten.


5 Tighten the overload spring adjustmentscrew just until the screw and lock nut willrotate freely, and the clearance between thelock nut and sensor mounting bracket isminimal.

a adjusting screwb overload sensor number 1c overload spring adjustment screwd overload sensor number 2e overload sensor mounting bracketf overload springg spacer

6 Place an additional 44 lbs / 20 kg test weight inthe center of the platform. Secure the weight tothe platform.



a b c

daefge

PLATFORM COMPONENTS


Part No. 227656 GR-20J • GR-26J 4 - 9

September 2016

8 Turn the adjusting screw of the number 1overload sensor 10° in a counterclockwisedirection.

Result: The overload indicator lights areflashing at the ground and platform controls,and the alarm is sounding intermittently.Proceed to step 9.

Result: The overload indicator lights are off atthe ground and platform controls and the alarmdoes not sound intermittently. Repeat theprocedure beginning with step 8.

9 Turn the adjusting screw of the number 2overload sensor 10° in a counterclockwisedirection.

Result: The overload indicator lights areflashing at the ground and platform controls,and the alarm is sounding continuously.Proceed to step 10.

Result: The overload indicator lights are off atthe ground and platform controls and the alarmdoes not sound continuously. Repeat theprocedure beginning with step 9.

10 Test all machine functions from the platformcontrols.

Result: All platform control functions should notoperate.

11 Turn the key switch to the ground control.

12 Test all machine functions from the groundcontrols.

Result: All ground control functions should notoperate.

13 Using a suitable lifting device, remove the testweight from the platform.

Result: The platform overload indicator lightshould be off at both the ground and platformcontrols and the alarm should not sound.

14 Test all machine functions from ground controls.

Result: All ground control functions shouldoperate normally.

15 Turn the key switch to the platform control.

16 Test all machine functions from the platformcontrols.

Result: All platform control functions shouldoperate normally.

PLATFORM COMPONENTS


4 - 10 GR-20J • GR-26J Part No. 227656

September 2016

Jib Components

3-1Jib Cylinder

How to Remove the Jib CylinderBodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage.




2 Raise the jib boom to a comfortable workingheight and place blocks under the platform forsupport. Lower the jib boom until the platform isresting on the blocks.


a jib boomb jib cylinderc platform

4 Tag, disconnect and plug the jib cylinderhydraulic hoses. Cap the fittings on thecylinder.


5 Remove the pin retaining fasteners from the jibcylinder rod-end pivot pin. Do not remove thepin.

6 Remove the pin retaining fasteners from the jibcylinder barrel-end pivot pin. Do not remove thepin.

7 Attach a lifting strap from an overhead crane tothe lug on the rod-end of the jib cylinder.

8 Place a block across both sides of the jib boomunder the jib cylinder.

9 Use a soft metal drift to remove the barrel-endpivot pin and rod-end pivot pin.

10 Carefully remove the jib cylinder from themachine.

Crushing hazard. The jib cylindercould become unbalanced and fallif not properly supported whenremoved from the machine.

c b a


Part No. 227656 GR-20J • GR-26J 4 - 11

September 2016

Illustration 2

a mast head coverb mast head cover fastenersc mast headd jib boome proximity sensorf lift cylinderg mast head fastenersh lift cylinder fasteners

4-1Mast Assembly

How to Remove the MastAssembly

Bodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.



1 Check the condition of the wear pads. Refer toMaintenance Procedure B-16, Inspect the MastWear Pads.

2 Using Illustration 1 as a guide, create a safetysteel plate using the dimensions specified.


4 Open and remove the turntable covers.

5 Remove the fasteners securing the mast headcover to the mast. Set the fasteners to the side.

6 Remove the mast head cover from the masthead.

7 Tag and disconnect the proximity sensor. Laythe proximity sensor to the side.

8 Tag, disconnect and plug the hydraulic hose atthe top of the lift cylinder. Remove the hoseconnector from the lift cylinder. Plug the liftcylinder.


Mast Components

Illustration 1

a safety steel plate

a300 mm

10

mm

130 mm

50 mm

25 mm

85 mm

2 x Ø18 mm

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4 - 12 GR-20J • GR-26J Part No. 227656

September 2016

MAST COMPONENTS

Illustration 3

a stopsb mast assembly

14 Using the mast head fasteners, install the safetysteel plate onto the top of the mast assembly.Securely tighten the fasteners. Do not overtighten.

9 Attach a lifting strap of suitable capacity from anoverhead crane to the mast head, jib boom andplatform assembly. Support the assembly. Donot apply any lifting pressure.

Component damage hazard. Theplatform railings can be damagedif they are used to lift theassembly. Do not attach the liftingstrap to the platform railings or putpressure on the railings.

10 Remove the fasteners securing the mast headto the mast assembly. Set the fasteners to theside.

11 Raise the mast head, jib boom and platformassembly and move the assemblyapproximately 20 inches / 50 cm towards thenon-steer end of the machine.

Crushing hazard. The mast head,jib boom and platform assemblycould become unbalanced and fallwhen removed from the machine.

Component damage hazard.Cables and hose can be damagedif they are kinked or pinched.

Note: During removal the mast head, jib boom andplatform assembly, the overhead crane strap willneed to be carefully adjusted for proper balancing.A properly balanced lifting strap is essential whenremoving the assembly from the machine.

12 Remove the fasteners securing the lift cylinderto the mast head. Set the fasteners to the side.

13 Using Illustration 3 as a guide, remove thefasteners securing the stops to the mastassembly and remove the stops. Set thefasteners and stops to the side.

ba

P

Illustration 4

a M16 shacklesb mast assemblyc safety steel plate

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Part No. 227656 GR-20J • GR-26J 4 - 13

September 2016

15 Using an overhead crane, attach a lifting strapof suitable capacity equipped with the M16shackles to the threaded rings at the top of theouter mast.

16 Lift the mast assembly approximately12 inches / 30 cm. Use a permanent marker toindicate the face closest to the platform with themark 'P' on the number 1 mast. Refer toIllustration 3.

17 Remove the mast assembly from the machine,while carefully pulling the cables and hydraulichose from the mast. With the 'P' mark facingupwards, place the mast assembly on a levelworkbench capable of supporting it.

Crushing hazard. The mastassembly could becomeunbalanced and fall if not properlysupported when removed from themachine.

Component damage hazard.Cables and hoses can bedamaged if they are kinked orpinched.

MAST COMPONENTS


4 - 14 GR-20J • GR-26J Part No. 227656

September 2016

Illustration 1

1 number 1 mast2 shims3 wear pads4 fasteners5 stops6 number 2 mast7 number 3 mast8 number 4 mast9 cover plate

MAST COMPONENTS

P

Steer End

Power Unit SidePlatform

(Non-Steer End)

Ground Controls Side

Illustration 2

1

3

54

2

6 7

8

9

TOP

BOTTOM

P P P P


Part No. 227656 GR-20J • GR-26J 4 - 15

September 2016

TOP

BOTTOM

P

P

P

P

dcba

How to Disassemble the Mast,GR-26J


1 Remove the mast assembly. See 4-1, How toRemove the Mast Assembly.

2 With the 'P' mark facing upwards, use a clampto secure the mast assembly to the workbench.Securely tighten the clamp. Do not over tighten.

3 Working from the top of the mast assembly, pullthe number 2, 3 and 4 mast sectionsapproximately 12 inches / 30 cm. Out of mast 1,use a permanent marker to indicate the faceclosest to the platform with the 'P' mark on thenumber 2, 3 and 4 mast sections correspondingto the 'P' mark on mast 1. Refer to Illustration 3.

4 Working from the top of the mast assembly,push the number 2, 3 and 4 mast sections fullyinto the number 1 mast.

5 Remove the fasteners securing the safety steelplate to the mast assembly. Remove the safetysteel plate. Set the fasteners and safety steelplate to the side.

Illustration 3

a number 1 mastb number 2 mastc number 3 mastd number 4 mast

6 Working from the bottom of the mast assembly,pull the number 4 mast half way out.

7 Attach a lifting strap from an overhead crane tothe number 4 mast section. Remove thenumber 4 mast while carefully pulling it out fromthe bottom of the number 3 mast. With the 'P'mark facing upwards, place the number 4 maston a level workbench capable of supporting it.

Crushing hazard. The mastsection could become unbalancedand fall if not properly supportedwhen removed from the mastassembly.

Note: During removal, the overhead crane strapwill need to be carefully adjusted for properbalancing.

MAST COMPONENTS


4 - 16 GR-20J • GR-26J Part No. 227656

September 2016

8 Slide the number 2 mast and the number 3mast towards the top of the number 1 mast togain the access to the stops at the bottom ofthe number 1 mast.

9 Remove the fasteners securing stops to theinside of the number 1 mast. Remove thestops. Set the fasteners and stops to the side.

10 Push the number 3 mast fully into the number 2mast. Working from the bottom of the number 1mast, pull the number 2 mast and the number 3mast half way out.

11 Attach a lifting strap from an overhead crane tothe number 2 mast section. Remove both thenumber 2 mast and the number 3 mast whilecarefully pulling the assembly out from thebottom of the number 1 mast. With the 'P' markfacing upwards, place the number 2 mast andthe number 3 mast assembly on a levelworkbench capable of supporting it.

Crushing hazard. The mastsections could becomeunbalanced and fall if not properlysupported when removed from themast assembly.


12 Slide the number 3 mast towards the top of thenumber 2 mast to gain the access to the stopsat the bottom of the number 2 mast.


14 Working from the bottom of the number 2 mast,pull the number 3 mast half way out.

15 Attach a lifting strap from an overhead crane tothe number 3 mast section. Remove thenumber 3 mast while carefully pulling the it outfrom the bottom of the number 2 mast. With the'P' mark facing upwards, place the number 3mast on a level workbench capable ofsupporting it.



16 Using Illustration 1 as a guide, tag and removethe outer wear pads and shims from the bottomof the number 4 mast section. Set the shims tothe side. Discard the wear pads.

Note: For ease of mast reassembly, make carefulnote of the location, order and orientation of theshims.

Note: Use a hammer and chisel if necessary togently loosen the wear pads from the mast.

17 Using Illustration 1 as a guide, carefully tag andremove the outer wear pads and shims fromthe bottom of the number 3 mast section. Setthe shims to the side. Discard the wear pads.

Note: For ease of reassembly of the mast, makecareful note of the location, order and orientation ofthe shims.


MAST COMPONENTS


Part No. 227656 GR-20J • GR-26J 4 - 17

September 2016

MAST COMPONENTS

18 Using Illustration 1 as a guide, tag and removethe inner wear pads from the top of the number3 mast section. Set the shims to the side.Discard the wear pads.






20 Using Illustration 1 as a guide, tag and removethe inner wear pads from the top of the number2 mast section. Set the shims to the side.Discard the wear pads.






22 Using Illustration 1 as a guide, tag and removethe inner wear pads and shims from the top ofthe number 1 mast section. Set the shims to theside. Discard the wear pads.




4 - 18 GR-20J • GR-26J Part No. 227656

September 2016

Illustration 1

a wear pad 10 mmb mast section (mast 1 shown)

2 Install six 12 mm wear pads, and thecorresponding shims removed in the mastdisassembly process, onto the bottom of mastsections 1, 2, 3 and 4.

3 Using Illustration 1 as a guide, install two 10mm wear pads, and the corresponding shimsremoved in the mast disassembly process, ontothe top of mast sections 1, 2 and 3.

4 Install six 12 mm wear pads, and thecorresponding shims removed in the mastdisassembly process, onto the top of mastsections 1, 2 and 3.

5 Using Illustration 2 as a guide, apply greaseonto the inner faces of the mast sections 1, 2and 3.



MAST COMPONENTS

How to Assemble the Mast,GR-26J


1 Using Illustration 1 as a guide, install two 10mm wear pads, and the corresponding shimsremoved in the mast disassembly process, ontothe bottom of mast sections 1, 2, 3 and 4.

Illustration 2

a greaseb mast section (mast 1 shown)

P

a b

TOP

BOTTOM

a

a

a

b

b


Part No. 227656 GR-20J • GR-26J 4 - 19

September 2016

MAST COMPONENTS

6 Using Illustration 3 as a guide, apply greaseonto the outer faces of the mast sections 1, 2, 3and 4.

7 Carefully assemble the mast sections using themast disassembly procedure in reverse order.See 4-1, How to Disassemble the Mast,GR-26J.

a

b

Illustration 3



4 - 20 GR-20J • GR-26J Part No. 227656

September 2016

MAST COMPONENTS

Illustration 1

1 number 1 mast2 stops3 shims4 wear pads5 number 2 mast6 cover plate

P

Steer End

Power Unit SidePlatform

(Non-Steer End)

Ground Controls Side

Illustration 2

1 5

2

43

6

TOP

BOTTOM

PP


Part No. 227656 GR-20J • GR-26J 4 - 21

September 2016

MAST COMPONENTS

How to Disassemble the Mast,GR-20J


1 Remove the mast assembly. See 4-1, How toRemove the Mast Assembly.

2 With the 'P' mark facing upwards, use a clampto secure the mast assembly to the workbench.Securely tighten the clamp. Do not over tighten.

3 Working from the top of the mast assembly, pullthe number 2 mast section approximately12 inches / 30 cm. Out of mast 1, use apermanent marker to indicate the face closestto the platform with the 'P' mark on the number2 mast section corresponding to the 'P' mark onmast 1. Refer to Illustration 3.

4 Remove the fasteners securing the safety steelplate to the mast assembly. Remove the safetysteel plate. Set the fasteners and safety steelplate to the side.


6 Working from the bottom of the number 1 mast,pull the number 2 mast half way out.

Illustration 3

a number 1 mastb number 2 mast

7 Attach a lifting strap from an overhead crane tothe number 2 mast section. Remove thenumber 2 mast while carefully pulling the it outfrom the bottom of the number 1 mast. With the'P' mark facing upwards, place the number 2mast on a level workbench capable ofsupporting it.



TOP

BOTTOM

P

P

ba


4 - 22 GR-20J • GR-26J Part No. 227656

September 2016

MAST COMPONENTS







10 Using Illustration 1 as a guide, tag and removethe inner wear pads and shims from the top ofthe number 1 mast section. Set the shims to theside. Discard the wear pads.



How to Assemble the Mast,GR-20J


1 Using Illustration 1 as a guide, install two 10mm wear pads, and the corresponding shimsremoved in the mast disassembly process, ontothe bottom of mast sections 1 and 2.

Illustration 1

a wear pad 10 mmb mast section (mast 1 shown)

P

a b

TOP

BOTTOM

a


Part No. 227656 GR-20J • GR-26J 4 - 23

September 2016

MAST COMPONENTS

2 Install six 12 mm wear pads, and thecorresponding shims removed in the mastdisassembly process, onto the bottom mastsections 1 and 2.

3 Using Illustration 1 as a guide, install two 10mm wear pads, and the corresponding shimsremoved in the mast disassembly process, ontothe top of mast section 1.

4 Install six 12 mm wear pads, and thecorresponding shims removed in the mastdisassembly process, onto the top mastsection 1.

5 Using Illustration 2 as a guide, apply the greaseonto the inner faces of the mast section 1.



Illustration 2


6 Using Illustration 3 as a guide, apply greaseonto the outer faces of the mast sections 1 and2.

7 Carefully assemble the mast sections using themast disassembly procedure in reverse order.See 4-1, How to Disassemble the Mast,GR-20J.

a

b

a

a

b

b

Illustration 3



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September 2016

MAST COMPONENTS

4-2Lift Cylinder

How to Remove the Lift CylinderBodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage.



1 Block the wheels at the non-steer end of themachine.

2 Open and remove the turntable covers of themachine.

3 Center a lifting jack under the drive chassis atthe steer end of the machine.

4 Raise the steer end of the machineapproximately 10 inches / 25 cm to access thenut at the bottom of the lift cylinder.

5 Place blocks under the chassis for support.Lower the machine onto the blocks.

Crushing hazard. The chassiscould fall if not properly supported.

a mast head coverb mast head cover fastenersc mast headd jib boome proximity sensorf lift cylinderg mast head fastenersh lift cylinder fasteners

6 Remove the nut securing the bottom of the liftcylinder to the chassis. Set it to the side.

7 Raise the machine slightly. Remove the blocksfrom under the chassis and lower the machineonto the ground. Remove the jack.

8 Remove the fasteners securing the mast headcover to the mast. Remove the mast headcover. Set the mast head cover and fastenersto the side.

9 Tag and disconnect the proximity sensor. Laythe proximity sensor to the side.

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Part No. 227656 GR-20J • GR-26J 4 - 25

September 2016

10 Tag, disconnect and plug the hydraulic hose atthe top of the lift cylinder. Remove the hoseconnector from the lift cylinder. Plug the liftcylinder.


11 Attach a lifting strap of suitable capacity from anoverhead crane to the mast head, jib boom andplatform assembly. Support the assembly. Donot apply any lifting pressure.

Component damage hazard. Theplatform railings can be damagedif they are used to lift theassembly. Do not attach the liftingstrap to the platform railings or putpressure on the railings.

12 Remove the fasteners securing the mast headto the mast assembly. Set the fasteners to theside.

MAST COMPONENTS

13 Raise the mast head, jib boom and platformassembly and move the assemblyapproximately 20 inches / 50 cm towards thenon-steer end of the machine.

Crushing hazard. The mast head,jib boom and platform assemblycould become unbalanced and fallwhen removed from the machine.

Component damage hazard.Cables and hose can be damagedif they are kinked or pinched.

Note: During removal the mast head, jib boom andplatform assembly, the overhead crane strap willneed to be carefully adjusted for proper balancing.

14 Remove the fasteners securing the lift cylinderto the mast head. Set the fasteners to the side.

15 Attach a lifting strap from an overhead crane tothe lift cylinder.

16 Carefully remove the lift cylinder from themachine.

Crushing hazard. The lift cylindercould become unbalanced and fallif not properly supported whenremoved from the machine.

Component damage hazard. Thelift cylinder can be damaged if itfalls.


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September 2016

Ground Controls

5-1Level Sensor

The tilt alarm sounds when the incline of thechassis exceeds 2° to the side, front or rear.

How to Install and Calibrate theLevel Sensor

Tip-over hazard. Failure to installor calibrate the level sensor asinstructed will compromisemachine stability and cause themachine to tip over, resulting indeath or serious injury. Do notinstall or calibrate the level sensorother than specified in thisprocedure.



2 Locate the level sensor which is mounted onthe turntable base below the battery charger.

3 Tag and disconnect the level sensor pigtail fromthe machine wire harness.

4 After noting the orientation of level sensorassembly, remove the fasteners securing thebase of level sensor assembly to the chassis.

5 Install the new level sensor onto the machine.Install and securely tighten the fasteners. Donot over tighten.

6 Securely install the level sensor pigtail into themachine wire harness, disconnected in step 3.

7 Remove the plastic cap from the end of thelevel sensor calibration wire.

8 Using a length of wire approximately40 inches / 1 m long, connect the level sensorcalibration wire to the negative post of thebattery.

Result: The green LED underneath the levelsensor flashes several times and stops. Thelevel sensor calibration is complete.

Result: The green LED underneath the levelsensor does not flash. Check the calibrationwire connection. Contact Genie IndustriesService Department.

Note: The green LED is on during normal machineoperation and it only goes out when the tilt angle ofthe machine exceeds 2°.

9 After the green LED stops flashing, disconnectthe calibration wire from the battery, andsecurely install the plastic cap removed instep 7.


Part No. 227656 GR-20J • GR-26J 4 - 27

September 2016

Hydraulic Pump

6-1Function Pump

The hydraulic pump is attached to the motor whichmakes up the hydraulic power unit.

How to Test the Function PumpSee 7-2, How to Adjust the System Relief Valve.

How to Remove the FunctionPumpNote: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.






bd

c

a

e

Illustration 1

a motorb function manifoldc hydraulic tankd connector fittingse hydraulic hoses


4 - 28 GR-20J • GR-26J Part No. 227656

September 2016






9 Carefully remove the hydraulic power unit fromthe tank and place it on a clean work bench.

Note: If necessary, loosen the bottom connector ofauxiliary pump to more easily remove the hydraulicpower unit.

Illustration 2

a function pumpb hydraulic tank

10 Remove the fasteners securing the functionpump to the function manifold. Set the fastenersto the side.

11 Carefully remove the function pump from thehydraulic power unit.

Tip-over hazard. After replacingthe hydraulic pump, it is critical toreturn the relief valve settings tooriginal factory specifications.Failure to restore the machine tooriginal factory specificationscould cause the machine to tipover, resulting in death or seriousinjury.

HYDRAULIC PUMP

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Part No. 227656 GR-20J • GR-26J 4 - 29

September 2016



4 - 30 GR-20J • GR-26J Part No. 227656

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Function Manifold

Index SchematicNo. Description Item Function Torque

1 Filter,Filter cap .................................................... H ......................... Suction filter ............................ 37 ft-lbs / 50 Nm

2 Solenoid valve, 2 position 4 way ............... B ......................... Steer/Turntable directional ..... 18 ft-lbs / 25 Nm

3 Check valve ............................................... I .......................... Blocks flow from auxiliary pump to function pump . 29 ft-lbs / 40 Nm

4 Solenoid valve, 2 position 2 way ............... D ......................... Platform up ............................. 18 ft-lbs / 25 Nm

5 Solenoid valve, 2 position 4 way ............... C ......................... Turntable rotate left/right ........ 18 ft-lbs / 25 Nm

6 Solenoid valve, 2 position 2 way ............... E ......................... Platform down and jib down ... 18 ft-lbs / 25 Nm

7 Relief valve,930 psi / 64 bar .......................................... G......................... Platform up ............................. 18 ft-lbs / 25 Nm

8 Solenoid valve, 2 position 4 way ............... A ......................... Steer left/right ......................... 18 ft-lbs / 25 Nm

9 Relief valve,2030 psi / 140 bar ...................................... F ......................... System relief ........................... 18 ft-lbs / 25 Nm

7-1Function Manifold Components

The function manifold is mounted underneath the hydraulic power unit.


Part No. 227656 GR-20J • GR-26J 4 - 31

September 2016

FUNCTION MANIFOLD

Note: 'alpha' callouts referto corresponding notes onthe hydraulic schematic

Note: 'alpha' callouts referto corresponding notes onthe hydraulic schematic

Note: 'alpha-numeric' calloutsrefer to corresponding noteson the electrical schematic

Note: 'alpha-numeric' calloutsrefer to corresponding noteson the electrical schematic

6E

7G

8A

9F

H

1

2

4

5C

B

D

Y117

Y21Y118 Y22

Y116

3I


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September 2016

7-2Valve Adjustments -Function Manifold

How to Adjust the System ReliefValveNote: Be sure that the hydraulic oil level is at theFULL mark on the hydraulic tank.


2 Open the turntable cover at the hydraulic powerunit side of the machine.




6 Rotate the function manifold and locate thesystem relief valve on the function manifold(schematic item F).

7 Connect a 0 to 2500 psi / 0 to 175 barpressure gauge to the test port on the hydraulichose reel.

a system relief valve



9 At the ground controls, press and hold thefunction enable button.

FUNCTION MANIFOLD

a


Part No. 227656 GR-20J • GR-26J 4 - 33

September 2016

FUNCTION MANIFOLD

10 Press and hold the jib function button to fullyraise the jib boom, then continue to activate thejib lift function while observing the pressurereading on the pressure gauge. Note thepressure. Refer to Section 2, Specifications.


12 Hold the system relief valve with a wrench andremove the cap.

13 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counterclockwise todecrease the pressure. Install the relief valvecap.

Tip-over hazard. Failure to adjustthe relief valves to specificationcould result in the machine tippingover, causing death or seriousinjury. Do not adjust the reliefvalve pressures higher thanspecifications.

14 Turn the key switch to the ground controls.

15 Repeat this procedure, beginning with step 8, toconfirm the system relief valve pressure.


17 Install and tighten the fasteners securing thefunction manifold to the hydraulic tank.

18 Install and securely tighten the hydraulic powerunit clamps. Do not over tighten.


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September 2016

FUNCTION MANIFOLD

How to Adjust the Platform LiftRelief ValveNote: Be sure that the hydraulic oil level is at theFULL mark on the hydraulic tank.



3 Locate the lift relief valve on the functionmanifold (schematic item G).



5 Press and hold the function enable button.

6 Press and hold the lift function button and raisethe platform approximately 12 inches / 30 cm.

Result: The platform should lift the weight.Proceed to step 12.

Result: The platform does not lift the weight.Proceed to step 7.

Component damage hazard. Donot continue to operate themachine if the hydraulic pump iscavitating.


8 Hold the lift relief valve with a wrench andremove the cap (schematic item G).

b

a

a lift relief valveb system relief valve

9 Adjust the internal hex socket. Turn it clockwiseto increase the pressure. Install the relief valvecap.

10 Turn the key switch to ground control.

11 Repeat the procedure beginning with step 5.



14 Adjust the internal hex socket. Turn itcounterclockwise to decrease the pressure justuntil the platform will not lift the weight. Installthe relief valve cap.

15 Turn the key switch to the ground control.

16 Activate the platform up function and attempt toraise the platform.

Result: The platform does not lift the weight.Proceed to step 18.

Result: The platform lifts the weight. Proceed tostep 12.

17 Turn the key switch to the off position andremove the weight from the platform.


Part No. 227656 GR-20J • GR-26J 4 - 35

September 2016

8-1Hydraulic Tank

The primary functions of the hydraulic tank are tocool and deaerate the hydraulic fluid duringoperation.

How to Remove the HydraulicTank

Component damage hazard. Thework area and surfaces where thisprocedure will be performed mustbe clean and free of debris thatcould get into the hydraulicsystem.




3 Working next to the hydraulic tank, remove thefasteners securing the chassis side cover to thechassis. Remove the side cover. Lay the sidecover and fasteners to the side.





Hydraulic Tank





11 Install the drain plug onto the hydraulic tank andtighten to finger tight.

12 Install the filler cap onto the hydraulic tank andtighten to finger tight.


14 Carefully remove the hydraulic tank along withhydraulic power unit from the machine andplace it on a clean work bench.


16 Remove the clamp securing the hydraulicpower unit to the hydraulic tank. Set the clampto the side.

17 Remove the hydraulic power unit from thehydraulic tank.


Hydraulic oil reservoir drain plug 44 in-lbs5 Nm

Manifold to tank fasteners 40 in-lbs4.5 Nm


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September 2016

Turntable Components

9-1Turntable Rotation Motor

How to Remove the TurntableRotation MotorNote: When removing a hose assembly or fitting,the fitting and/or hose end must be torqued tospecification during installation. Refer to Section 2,Hydraulic Hose and Fitting Torque Specifications.




2 Raise the jib boom to the maximum height.


a turntable rotation motorb fastenersc hydraulic hoses


5 Remove the fasteners securing the side coversto the chassis. Remove the side covers fromthe machine. Lay the side covers and fastenersto the side.

6 Remove the fasteners securing the turntablemotor protection plate to the chassis. Removethe protection plate from the machine. Lay theprotection plate and fasteners to the side.

Note: The turntable motor protection plate islocated above the turntable rotation motor.

a

b

c


Part No. 227656 GR-20J • GR-26J 4 - 37

September 2016

7 Tag, disconnect and plug the hydraulic hoses atthe turntable rotation motor. Cap the fittings.


8 Remove fasteners securing the turntablerotation motor to the chassis. Set the fastenersto the side.

9 Carefully remove the turntable rotation motorfrom the machine.

Bodily injury hazard. Theturntable rotation motor may fall ifnot properly supported whenremoved from the machine.

TURNTABLE COMPONENTS


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September 2016

9-2Battery

How to Remove the BatteryElectrocution/burn hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.

Bodily injury hazard. Batteriescontain acid. Avoid spilling orcontacting battery acid. Neutralizebattery acid spills with baking sodaand water.



2 Open and remove the turntable covers.

3 Tag and disconnect the cables connected to theground terminal of the battery.

4 Tag and disconnect the cables connected to thepositive terminal of the battery.

5 Locate the bolts between the battery pack andthe counterweight. Loosen the bolts holding thebattery pack in position.


a battery

6 Attach a lifting strap from an overhead1100 lbs / 500 Kg crane to the battery pack.

7 Carefully remove the battery pack from themachine.

Crushing hazard. The battery packcould become unbalanced and fallif not properly supported.

Component damage hazard. Thebattery pack can be damaged if itfalls.

a


Part No. 227656 GR-20J • GR-26J 4 - 39

September 2016

9-3Battery Charger

How to Remove the BatteryCharger



2 Open and remove the turntable cover at theground control side of the machine.

3 Tag and disconnect the cables connected to theground terminal of the battery.

4 Tag and disconnect the black and red batterycharger wires from the battery.

5 Tag and disconnect the power cable from thebattery charger.

6 Locate the LED at the bottom of the bulkhead.Tag and disconnect the LED wire harnessconnector.

7 Tag and disconnect the charger cutout harnessconnector.

a power cableb charger cutout harness connectorc LEDd charger-to-battery wires

8 Locate and remove the nut holding the groundcontrol box closed, and open the ground controlbox.

9 Remove the fasteners securing the top of thebattery charger to the machine. Set thefasteners to the side.

10 Close the ground control box and install the nut.

11 Remove the fasteners securing the bottom ofthe battery charger to the machine. Set thefasteners to the side.

12 Lower the battery charger towards the tiltsensor, and remove the battery charger fromthe machine.


b

ad

c


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September 2016


10-1Yoke

How to Remove the YokeNote: When removing a hose assembly or fitting,the fitting and/or hose end must be torqued tospecification during installation. Refer to Section 2,Hydraulic Hose and Fitting Torque Specifications.


2 Loosen the bolts of the wheel at the steer end ofthe machine. Do not remove the bolts.


4 Raise the machine approximately6 inches / 15 cm. Place blocks under thechassis for support. Lower the chassis ontoblocks.


5 Remove the bolts from the wheel at the steerend of the machine. Remove the wheel fromthe machine.

6 Support and secure the yoke assembly to anappropriate lifting device.

7 Remove the top cir-clip from the pin at thesteering rod.

8 Remove the plastic cap above the yoke pivotshaft. Set the cap to the side.

9 Ground control side: Remove the steersensor from the yoke pivot.

10 Remove the retaining fasteners from the yokepivot shaft. Set the fasteners to the side.

11 Remove the yoke assembly from the machine.

Bodily injury hazard. Theyoke assembly may fall if notproperly supported when removedfrom the machine.


Part No. 227656 GR-20J • GR-26J 4 - 41

September 2016

STEER AXLE COMPONENTS

10-2Steer Cylinder

How to Remove the SteerCylinderNote: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.



2 Turn the wheels at the steer end of themachine, 20° to 25° to the right.



5 Remove the pin retaining fasteners from the topof the steer cylinder barrel-end pivot pin.


7 Raise the machine approximately6 inches / 15 cm. Place blocks under thechassis for support.


8 Turn the wheels at the steer end of the machinefully to the left.

9 Tag, disconnect and plug the steer cylinderhydraulic hoses. Cap the fittings on thecylinder.


10 Remove the pin retaining fasteners from thesteer cylinder rod-end pivot pin. Set thewashers to the side. Discard the cotter pin.

Note: Always replace the cotter pin with a new onewhen removing the fasteners.

11 Carefully remove the steer cylinder from themachine.


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September 2016

10-3Steering Rod

How to Remove the Steering Rod1 Remove the steer cylinder. See 10-2, How to

Remove the Steer Cylinder.

2 Remove the top cir-clips securing the steeringrod to the steer yoke at both the ends of thesteering rod.

3 Lift the steering rod up and off of the yoke, andremove the steering rod from the machine.


10-4Steer Angle Sensor

How to Replace the Steer AngleSensor1 Adjust the wheels at the steer end of the

machine so they are in straight driving position.


3 Tag and disconnect the steer angle sensor wireharness from the machine wire harness.

4 Remove the plastic cap above the steer yokepivot. Set the cap to the side.

5 Carefully remove the sensor activator pin fromthe steer yoke pivot. Set the pin to the side.

Note: Inspect the sensor activator pin to confirm itis not broken or twisted. If the sensor activator pinis broken or twisted, it must be replaced. Note theinstallation and orientation of the old sensor to besure the new one is installed correctly.

6 Remove the steer angle sensor retainingfasteners. Remove the steer angle sensorassembly.




Part No. 227656 GR-20J • GR-26J 4 - 43

September 2016

8 Using the illustration as a guide, mount thepotentiometer on to the plate and securelytighten with the nut.

a steer yoke pivot capb potentiometerc potentiometer mounting plated fastenerse bottom platef sensor activator ping chassish screw

9 With a multimeter set to read 4K±0.2 ohms,connect the leads to the green and black wiresof the potentiometer.

10 Adjust the potentiometer until a reading of4K±0.2 ohms is obtained.

11 Install the bottom plate and it's fasteners on thesteer yoke pivot.

12 Install the sensor activator pin on to the steeryoke pivot.

Note: Be sure the sensor activator pin is engagedinto the sensor.

13 Install the plate along with potentiometer on thesteer yoke pivot and securely tighten thepotentiometer stem with the screw. Do not overtighten.

14 Install the plastic cap on to the steer yoke pivot.

15 Connect the steer angle sensor wire harness tothe machine wire harness.

16 Calibrate the steer sensor. See 1-2, ControllerAdjustments for How to Calibrate the SteerSensor.


f

a

b

c

d

eh

g


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September 2016

11-1Drive Motors

How to Remove the Drive MotorsBodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.







Non-steer Axle Components

a cable guardb right drive motor assemblyc left drive motor assemblyd fastenerse chassis



8 Tag and disconnect the two wire harnessconnectors at the steel bar above the drivemotors.

9 Remove the fasteners securing the steel bar tothe chassis. Set the fasteners to the side.

10 Turn over the steel bar and cut the zip tiesattaching the two wire harness connectors tothe steel bar. Lay the steel bar to the side.

d

c

b

e

a


Part No. 227656 GR-20J • GR-26J 4 - 45

September 2016

11 Tag and disconnect the cables from the drivemotor assembly.

12 Loosen the castle nut of the wheel at thenon-steer end of the machine. Do not removethe castle nut.

Note: To remove the right drive motor assembly,first it is necessary to remove the left drive motorassembly.

13 Center a lifting jack under the drive chassis atthe non-steer end of the machine.

14 Raise the machine approximately6 inches / 15 cm. Place blocks under thechassis for support. Lower the chassis onto theblocks.


15 Remove the castle nut from the wheel at thenon-steer end of the machine. Remove thewheel from the machine.

Note: A properly sized puller may be needed toremove the wheel from the tapered shaft.

NON-STEER AXLE COMPONENTS

16 Place a 2 x 4 x 6 inch / 5 x 10 x 15 cm longwood block under the left drive motor.

Note: The wood block will support to the drivemotor assembly when the fasteners are removed.

17 Remove the fasteners securing the left drivemotor assembly to the chassis. Set thefasteners to the side.

18 Carefully remove the left drive motor assemblyfrom the machine. Place it onto a suitableworkbench capable of supporting it.

Bodily injury hazard. Thedrive motor assembly may fall ifnot properly supported whenremoved from the machine.


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September 2016

NON-STEER AXLE COMPONENTS

11-2Drive Brake

How to Remove the Drive Brake1 Block the wheels at the steer end of the

machine.








8 Tag and disconnect the two wire harnessconnectors at the steel bar.

a b c d e

a drive brakeb drive motor assemblyc speed reducer assemblyd mounting platee fasteners

9 Remove the fasteners securing the steel bar tothe chassis. Set the fasteners to the side.

10 Turn over the steel bar and cut the zip tiesattaching the two wire harness connectors tothe steel bar. Lay the steel bar to the side.

11 Remove the fasteners securing the drive braketo the drive motor assembly. Set the fastenersto the side.

12 Carefully remove the drive brake from the drivemotor assembly.


Brake mounting fasteners, dry 75 ft-lbs102 Nm

Brake mounting fasteners, lubricated 56 ft-lbs76 Nm

Section 5 • Fault Codes

Part No. 227656 GR-20J • GR-26J 5 - 1

September 2016

Before Troubleshooting:


Be sure that all necessary tools and testequipment are available and ready for use.

Be aware of the following hazards and followgenerally accepted safe workshop practices.

Crushing hazard. When testingor replacing any hydrauliccomponent, always supportthe structure and secure itfrom movement.


Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.

Fault Codes

Observe and Obey:

Troubleshooting and repair procedures shall becompleted by a person trained and qualified onthe repair of this machine.



Unless otherwise specified, perform eachrepair procedure with the machine in thefollowing configuration:





• Wheels chocked



5 - 2 GR-20J • GR-26J Part No. 227656

September 2016

General Repair Process

About This SectionWhen a malfunction is discovered, the fault codechart in this section will help a service professionalpinpoint the cause of the problem. To use thissection, basic hand tools and certain pieces of testequipment are required—voltmeter, ohmmeter,pressure gauges.

Malfunctiondiscovered

Identifysymptoms

Troubleshoot

Performrepair

Return toservice problem

solved

problemstill exists

Inspectand test

LED Diagnostic ReadoutThe diagnostic readout displays numerical codesthat provide the information about the machineoperating status and malfunctions.

FAULT CODES

a

b

c

a Error Source: First two digits indicates theaffected machine area or component.

• '01' Controller interface board

• '02' Controller logic board

• '08' Platform controls circuit board

• '16' Diagnostic display

b Third digit always an alphabet "A" when faultcode is displayed.

c Error Type: Last two digits indicates the faultnumber.

The codes listed in the Fault Code Chartdescribe malfunctions and can aid introubleshooting the machine by pinpointing thearea or component affected.


Part No. 227656 GR-20J • GR-26J 5 - 3

September 2016

Fault Code Chart

Error Source Error TypeID Name ID Name

Condition Solution

02 Logic fault #1The base board is waitingfor the controller tocomplete its internal test.

This alarm may appear fromtime to time upon starting. Anyinitialization delay can causethis alarm to appear. If the alarmappears too often or if it ispermanent, there is an internalerror. Check the currentsoftware version or replace thecontroller.

03 Valv. Drv. offline

The internal device whichcontrols all the auxiliaryoutputs has a problemand is not communicatingcorrectly with themicrocontroller.

Replace the controller.

04Outputmismatchovercharge

This alarm is due to adisparity between theoperating states detectedby the two computers. Thecontroller has asked thebase board to activate theoutput for the drive or thepump but the interfacedoes not identify acommand or an operatingstate where the drive orpump must be allowed.

Check whether the softwareversions installed on the twoconsoles are correct. If so, theremust be an internal fault.

05 EEPROM

There is a fault in themanagement/verificationof the internal EEPROM.

It is an internal fault. Replacethe controller. The platform canstill function but the controllerwill use default values for theinternal parameters.

06 Wrong RAMmemory

The algorithm used toverify the main memory isworking with erroneousdata.

Try to break the contact. If thealarm is still present, replace thecontroller.

10 Flash checkIncorrect softwaredownloaded or the Flashmemory is corrupted.

Check the installed softwareversion or replace the controller.

01 Controllerinterfaceboard

15 Analog inputThere is a fault in the A/Dconverter of the micro-controller.



5 - 4 GR-20J • GR-26J Part No. 227656

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FAULT CODE CHART


Condition Solution

19 Serial error#1

The controller has notresponded to the requestfrom the base board asexpected.


32 Logic failure#1

Under-voltage or over-voltage has beendetected.

If the fault occurs on starting orduring an alarm, the fault ismost likely to be linked to anunder-voltage. Check whetherthe main voltage SI is stable. Ifthe fault occurs on accelerationof the motor or activation of thepump, the fault may be due tounder-voltage. Check thecharge and the batteryconnections. If the fault isdetected during braking, thefault may be due to over-voltage: Check the batteryvoltage during braking. In anyother case, the fault may be dueto an internal fault of thecontroller then replace it. Checkwhether there is contact or lowimpedance between pin A12and the battery. Otherwise thecircuit is damaged.

33 Eb. Drv.Shorted

The electric cable of thebrake is in short-circuit.

Check whether there is a shortcircuit or low impedancebetween pin A10 and thebattery.

34 Drivershorted

The main conductor of thedriver is short-circuited.

Check whether there is a shortcircuit in parallel with the brakesolenoid valve coil. Otherwisethe conductor circuit is damagedand the controller must bereplaced.

36 Emergencybutton wire

Excitation wire onemergency button isdisconnected.

Repair wire on the emergencybutton.

37 Eb. Drv. / coilfail

The electric circuit of thebreak is open.


40 Mc enableshort.

The EB coil can notactivate. Replace the controller.


41 Eb. enableshort

The power contactor isshort-circuited.

Check the wiring or change thecontroller.


Part No. 227656 GR-20J • GR-26J 5 - 5

September 2016

FAULT CODE CHART

Error Source Error TypeCondition Solution

ID Name ID Name

01 Controller interface board

50 Multi selection

The electric brake is short-circuited. Several movements activated simultaneously.

Check the conformity of the control selectors.

51 Plat. double required

The controller receives several commands simultaneously from the platform controls circuit board.

Check the wiring or change the controller.

52 GND double required

The controller receives several commands simultaneously from the platform controls circuit board.

Check the wiring or change the controller.

53 Tilted Tilt triggers audible warning beep.

Check the conformity of the tilt sensor and its connection or change the controller.

54 Overload HBT

Overload of HBT2 and HBT1 signals Overload incoherence.

Check the condition of the overload sensors or change the controller.

55 Overcharge Overload fault. Check the condition of the overload sensors or change the controller.

56 Battery low Low battery voltage. If the alarm is triggered when the battery is fully charged, change the controller.

57 No CAN signal

The interface board has not received the CAN signal.

Check the BUSCAN connection between the modules or change the controller.

58 No alarm on the console

There is a large disparity between the hour counter stored in the diagnostic display and the hour counter stored in the controller. The maximum acceptable difference is 10 hours. If it is greater, this alarm will appear.

After two minutes, the hour counter of the controller will automatically find the diagnostic display.

59 Temperature of pump high

The temperature sensor of the pump has detected a high temperature.

The alarm should disappear as soon as the pump motor cools down. If this does not happen, there is a problem with the connection of terminal A16 or the temperature sensor.


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FAULT CODE CHART


Condition Solution

61 JoystickJoystick is pushed whenmachine is switching on.

Repair or replace the joystick.

62

Short-circuiton functionswitches

The function switch hasbeen closed for more than2.5 seconds.

It should be possible to stop thealarm by stopping the maincontactor or via the emergencystop. If the problem persists,check the wiring connection. Ifthere is no problem, the alarm isdue to an internal fault.

63 Battery out ofadjustment

The battery parameterdiffers by more than 20%from the nominal batteryvoltage.

Check the battery typeparameter.

64 Charge inprogress

The platform has beenstarted up with the batterycharger in operation.

If the alarm appears with thecharger disconnected from themains, there may be a problemwith the connection of terminalA17. Otherwise, it is an internalfault of the controller.

65Value ofangle sensorincorrect

The value read by thepotentiometer is differentfrom the programmedvalue.

Check that the angle sensorpotentiometer is functioningcorrectly. Otherwise, check thewiring.


80 Lifting valve

There is a problem on oneof the following outputs:terminal A32, terminalA26.

Check the condition of thevalves and their connections.Otherwise, it is an internal faultof the controller.


Part No. 227656 GR-20J • GR-26J 5 - 7

September 2016

FAULT CODE CHART


Condition Solution

81 Descent valve

There is a problem on oneor other of the followingoutputs: terminal A30,terminal A26.


82 Rotation valve



83 Steering valve



84 Aux. Valve

There is a problem on oneor other of the followingoutputs: "FLASHINGLIGHT" and "TILT LAMP"

Repair or replace the option.

86 Brake coilopen

The main driver coil is notconnected to pin A12 ofNEB.

Check the connections of theBRAKE coil. Otherwise theconductor circuit is damagedand the controller must bereplaced.


89 Hornconductor

There is a problem(short-circuit to negativeor positive, to absenthorn) on the "WARNING"product.

Check the horn and its wiring.If the wiring is correct and thealarm persists, there is aninternal fault.


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September 2016

FAULT CODE CHART


Condition Solution

7 Type disparity

The controller and thebase board are notsuitable for the type ofoperation chosen by theoperator.

It is an internal fault.Replace the controller.

8 HBT disparity

The HBT status is verifiedby the controller and thebase board. If a differenceis found between the two,this alarm appears.


9 Faulty RAM

The algorithm used toverify the main memorydetects an error. The fileis corrupt.

Disconnect the key and then, ifthe alarm is still present, replacethe controller.

10 Instantaneoussum

The instantaneous sum isdifferent from thatexpected. Incorrectsoftware has beendownloaded or the flashmemory is corrupted.


11Thermalsensorfaulty

The thermal sensor is notfunctioning correctly: itsoutput voltage is outsidethe acceptable range.


12 Stand bymotor right

The right armature currentsensor detects a currentother than zero when theright motor is not running.


13 Stand bymotor left

The left armature currentsensor detects a currentother than zero when theleft motor is not running.


14 High fieldcurrent

A current other than zeropasses through the fieldcircuit even if the fieldconductor is not active.


15 Analog inputThere is a fault in the A/Dconverter of themicrocontroller.


02 Controllerlogicboard

16 Trac. I sensor

The current sensor for thearmature of motor 1and/or motor 2 is notfunctioning correctly: itsoutput voltage is outsidethe acceptable range.



Part No. 227656 GR-20J • GR-26J 5 - 9

September 2016

FAULT CODE CHART


Condition Solution

17 Stand bypump

The current sensor of thepump detects a currentother than zero when thepump is not working.


18 Pump I=0

The current sensor of thepump detects a current ofzero even though thepump is working.

Check the connection of thepump: if the pump is notconnected, current cannot flowand the diagnostic fails.Otherwise, it is an internalproblem.

19 Periodic error#1

The base board has notresponded to the requestas expected. Thecontroller board has askedthe base board to leave itsdrive input inactive but it isactive.


20 Capacitorcharge

1) An external charge is inparallel with the capacitorand reduces the current ofthe recharge circuit,thereby preventing thecapacitors from charging.2) There is a problem withthe charging circuit andthe controller must bereplaced.

When the key is connected, thecontroller tries to charge thepower capacitors via a resistorand checks whether thecapacitors are charged. If theydo not charge, an alarm isgenerated. The main driver isnot closed.

21Chargecontrol lampincorrect

During stand-by the fieldvoltage should be approx.½ V. This alarm isgenerated if the fieldvoltage differs from thisvalue.

The possible external causesare: incorrect connection of theexcitation wires, leakage to theframework of the platform.Otherwise, it is an internal fault.


22 VMN lowThe VMN voltage of oneof the drive motors is low.

This alarm appears duringstand-by. Check : internal motorconnections; electric cableconnections; leakage from themotor to the framework of theplatform. If everything is OK, thecontroller has an internal fault


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September 2016

FAULT CODE CHART


Condition Solution

23 VMN high

The VMN voltage of oneof the motors is high whenit should be low.

This alarm appears only onstart-up. Check: internal motorconnections. Electric cableconnections, leakage from themotor to the framework of thelorry. If everything is OK, thecontroller has an internal fault.

24 Pump VMNlow

The VMN voltage of thepump is low when itshould be high.

This alarm may appear duringstand-by or during pumpoperation. Check: internal pumpconnections. Electric cableconnections, leakage from thepump to the framework of theplatform. If everything is OK, thecontroller has an internal fault.

25 Pump VMNhigh

The VMN voltage of thepump is high when itshould be low.

This alarm appears while thepump is working. Check:internal pump connections.Electric cable connections,leakage from the pump to theframework of the platform. Ifeverything is OK, the controllerhas an internal fault.

26 VMN right lowThe VMN voltage of theright motor is low when itshould be high.

This alarm only appears whenthe drive motors are activated.Check: internal motorconnections. Electric cableconnections, leakage from themotors to the framework of theplatform. If everything is OK, thecontroller has an internal fault.


27 VMN righthigh

The VMN voltage of theright motor is high when itshould be low.

This alarm only appears whenthe drive motors are activated.Check: internal motorconnections. Electric cableconnections, leakage from themotor to the framework of theplatform. If everything is OK, thecontroller has an internal fault.


Part No. 227656 GR-20J • GR-26J 5 - 11

September 2016

FAULT CODE CHART


Condition Solution

28 VMN left low

The VMN voltage of theleft motor is low when itshould be high.


29 VMN left high

The VMN voltage of theleft motor is high when itshould be low.


30 Driver closed

Before activating thepower relay, the controllerchecks whether the driveris closed. If the test is notconclusive, this alarmappears.

Check the contacts of the powerrelay. Replace the power relay ifnecessary.

31 Driver open

The power relay iscontrolled by thecontroller, but this will notclose.

The power relay is probably notworking. Replace it.


32 Logic fault #1Under-voltage or over-voltage has been detected

If the fault is detected onstarting or during an alarm, it ismost likely to be under-voltage.Check whether the main voltageSI is stable. If the fault isdetected during acceleration ofthe drive motors or pump, thefault may be due to under-voltage: check the batterycharge and connections. If thefault is detected during braking,the fault may be due to over-voltage: check the batteryvoltage during braking.


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September 2016

FAULT CODE CHART


Condition Solution

42 Drive shortedThe drive output of thebase board is short-circuited.


42 Driver 3

The base board and thecontroller have performed acheck of the signals for thedrive conductor. If thecontroller board detects aproblem in its own controlcircuit (right or left motor),this alarm will appear.


43 Driver2

The base board and thecontroller perform a checkof the signals for the pump.If the controller boarddetects a problem in itsown control circuit, thisalarm appears.


44 Driver1

The interface and logicboard performs a counter-check of signals for thesteering choice. If the logicdetects a problem in itsown control circuit (fieldconductor circuit), thisalarm appears.


46 No groundcurrent

Although the groundconductor is active, nocurrent through the field isdetected.

Check the connection of themotor to the controller or lookfor possible leakage to theframework of the platform. Ifeverything is OK, the controllerhas an internal fault.


47 Pump sensor

The current sensor of thepump is not workingcorrectly. Its output voltageis outside the acceptablerange.



Part No. 227656 GR-20J • GR-26J 5 - 13

September 2016

FAULT CODE CHART


Condition Solution

49 Pump shortedThe pump inputs of thebase board are short-circuited.


57 No CANmessage

The interface board hasnot received the messagefrom CAN "N"(1= CMD+TRAC2=MESG_EV+INTERFACE5 = MESG_EV +IN_TRAC)

Check the BUSCANconnection between themodules. Otherwise, there isan internal fault in a modulewhich causes a transmissionerror, or there is excessivenoise on the BUSCAN linewhich is interfering with thesignal.

60 Hightemperatures

The power section of thefuse has reached thetemperature limit: themaximum current isautomatically reduced.

The alarm disappears as soonas the cutout cools down. If thisdoes not happen, there is aproblem with the internaltemperature sensor.

65Value ofangle sensorincorrect

The value read by thepotentiometer is differentfrom the programmedvalue.

Check that the angle sensorpotentiometer is functioningcorrectly. Otherwise, check thewiring.


87 Time delay

The controller board asksthe base board to activatethe drive motors or thepump. If they are notactivated after 400 ms, thisalarm is activated.

Check the software versionsinstalled on the interface andlogic board. This alarm may bedue to a software disparity.Otherwise, there is an internalfault.


5 - 14 GR-20J • GR-26J Part No. 227656

September 2016

FAULT CODE CHART


Condition Solution

16 Diagnosticdisplay

06 Nocommunication

The diagnostic display isnot working properly.

Check wire connections. Repairor replace the diagnosticdisplay.


Condition Solution

70 Systemsurveillance

Internal systemsurveillance has been putinto operation. If thesurveillance detects afault in the execution ofthis surveillance, thisalarm appears.


72 SV1 incorrect

There is a problem(short-circuit to ground orto positive) on outputCNE-10.

Check the wiring. If the wiringis correct and the alarmpersists, there is an internalfault.

73 SV2 incorrect

There is a problem(short-circuit to ground orto positive) on outputCNE-5.


74 SV3-4incorrect

There is a problem(short-circuit to negativeor to positive) on outputCNE-1 or CNE-3.


08 Platformcontrolscircuitboard

75 BUSCANincorrect

The platform controlscircuit board is notreceiving the CAN signalfrom the controller.

There may be an interruption ofthe BUSCAN signal. Check theconnection of the BUSCANbetween the modules.Otherwise, there is an internalfault in a module which causesa transmission error, or there isexcessive noise on theBUSCAN line.

Section 6 • Schematics

Part No. 227656 GR-20J • GR-26J 6 - 1

September 2016

Schematics

Observe and Obey:

Troubleshooting and repair procedures shall becompleted by a person trained and qualified onthe repair of this machine.



Before Troubleshooting:


Be sure that all necessary tools and testequipment are available and ready for use.

About This SectionThere are two groups of schematics in this section.An illustration legend precedes each group ofdrawings.

Electrical Schematics


Hydraulic Schematics


General Repair Process

Malfunctiondiscovered

Identifysymptoms

Troubleshoot

Performrepair

Return toservice problem

solved

problemstill exists

Inspectand test


6 - 2 GR-20J • GR-26J Part No. 227656

September 2016

Electrical Schematic Abbreviation and Wire Color Legends

ELECTRICAL COMPONENT LEGENDDescriptionBatteryButtonBN

BN5 = HornBN8 = Drive enableBN9 = Lift enable/selectBN57 = Turntable rotate enableBN63 = Mast enableBN97 = Jib enableBN128 = Descend/Rotate left enableBN129 = Lift/Rotate right enableBN130 = Drive select

FuseFF6 = Fuse, 250AF9 = Fuse, 5A

Flashing beaconHour meter/Battery charge indicator/Fault code displayGroundHorn or AlarmH

H1 = HornH2 = Automotive-style horn

Joystick controllerKey switchLED or Indicator lightL

L4 = Platform overloadL17 = Drive select

L48 = Machine levelL68 = Platform overloadL79 = Out of levelL81 = Mast up-down/turntable rotateL82 = Jib

Limit switchLS

LS11 = Jib boomLS18 = Mast downLS31 = Platform overload

B9Item

JC1KS1

FB1G6/G7/G8GND

F9A = FuseF9B = Fuse

L1 = Drive enable

LS3 = Drive enable

Parking Brake RelayCR89

L30 = Work light (Option)


Part No. 227656 GR-20J • GR-26J 6 - 3

September 2016

ECM Pin-out Legend


6 - 4 GR-20J • GR-26J Part No. 227656

September 2016

Limit Switch and Sensor Legend

Limit and Sensor Legend

a Platform overload LS31b Mast down LS18c Steer angle S21d Tilt sensor S7e Jib down LS11


Part No. 227656 GR-20J • GR-26J 6 - 5

September 2016

Electrical Symbols Legend

Circuits Crossing(no connection)

Diode

Connection(no terminal)

Connector

Flashing Beacon

LED

Fuse

Switch or Button

Toggle Switch

Emergency Stop Button

Key Switch

Horn or Alarm

Sensor(hydraulic oil temperature)

Motor

Battery Charger

Battery

Control Relay

Level Sensor

Solenoid Valve

Parking Brake

Electric Motor

Joystick Controller


6 - 6 GR-20J • GR-26J Part No. 227656

September 2016

Electrical Schematic - GR-26JANSI - Part 1 of 2

+ -

6

5

4

3

2

1

1

7

6

12

1234

J3

J2

J1

F9B

F9A

L4 L79

KS1

PLA

TF

OR

M

GR

OU

ND

OR

-1

OR

-2

OR

-3

OR

-4

BN129

BN128

BN97

BN57

BN9

3

6

1

4

BR-1

BL-4

GR/YL-2

RD-3

BL-13

RD-11

BL-10

RD-12

Y-7

Y-5

Y-6

OR-16

Y-8

OR-15

Y-9

OR-14

1514

7

6

9

8

131

1819202122

24

31

35

26

23

163428253230

12

29

17

2

3

11

10

H2

+

-

OR

BR

BL

BK

2

1

3

C

A

B

1

221

BK

RD

1

2

1

2

1

2

3

123

F6250A

F95A

RD-7

PP-22

PP-5

PP-4

PP-3

PP-2

PP-1

RD-23

BR-1

BL-4GR/YL-2

RD-3

OR-14

OR-15

OR-16

Y-9Y-8

Y-7Y-6Y-5

BL-13

BL-10

RD-11

RD-12

B912-2V

GR/YL

2

1

BR

OR

GR BL

RD

BK

WH

GR

\YL

RD

-2

BL-

2

1

2

V/J

BR

GR

WH

1

2

21

PP-22

PP-7

PP-5

PP-3

PP-4

PP-2

PP-1

RD-6

RD-6

RD-6

RD-6

RD-6

RD-6

GND

+24V dc

OUTPUT

REF

U9

AC INPUT

P1

S7

B-

B+

P

T1

F2

F1

T2

D2

A2

F1

A2

A1

A1

F2

D1

G6G7G8

Y22

Y21

FB1

Y117

Y118

LS3

U6

M5

BK

GR

RD

BK

RD

GR

RD

F2 F1

M7A

M7

R29

1500

Ώ

S21

Y116

Y121

U53

U54

TS75

AC INPUT

S4

30

86

87

87A

85

ES0525C

CR89


Part No. 227656 GR-20J • GR-26J 6 - 7

September 2016

Electrical Schematic - GR-26JANSI - Part 2 of 2

1

654321

1

7

14

1234

J2J1

J3

BN

5

BN

97

BN

63

BN

130

BN

8

8

RD-4

WH-1

RD-5

H1BK-18 +

-RD-17

3

4

6

12

1

510

6

7

8

14

1

5

6

10

1

3

4

6

1

BL-

2

RD

-2 BR

GR

/YL

WH

BK

RD BL

GR

OR

8 5 10 3 4 9 11 1 2 12

C

D

A

B

E

F

BR-10

Y-2

GY-9

GR-7

BK

Y-14

Y-13

Y-12

Y-15

OR-6

4

BK

BL-3

BK

OR/BK-8

BK

BK-20

1

BK-19

RD-16GR/YL

2

BK-23

BK-22

BK-21

P2

RD

RD1

2

GR/YL

Y102

Y101U3A

LS11

LS18

L68

L17

L1

BK

BK

BK

BK

L48

L81

L82

SW

5S

W6L

SW

6R

U10

JC14

1

2

BK

RD

RD

LS31BK

BK

BK

PLATFORMCONTROLLER

ES0525C

L30

NOTE: DASHED LINES INDICATE OPTIONS.


6 - 8 GR-20J • GR-26J Part No. 227656

September 2016

Electrical Schematic - GR-20J and GR-26JCE - Part 1 of 2

+ -

6

5

4

3

2

1

1

7

6

12

1234

J3

J2

J1

F9B

F9A

L4 L79

KS1

PLA

TF

OR

M

GR

OU

ND

OR

-1

OR

-2

OR

-3

OR

-4

BN129

BN128

BN97

BN57

BN9

3

6

1

4

BR-1

BL-4

GR/YL-2

RD-3

BL-13

RD-11

BL-10

RD-12

Y-7

Y-5

Y-6

OR-16

Y-8

OR-15

Y-9

OR-14

1514

7

6

9

8

131

1819202122

24

31

35

26

23

163428253230

12

29

17

2

3

11

10

H2

+

-

OR

BR

BL

BK

2

1

3

C

A

B

1

221

BK

RD

1

2

1

2

1

2

3

123

F6250A

F95A

RD-7

PP-22

PP-5

PP-4

PP-3

PP-2

PP-1

RD-23

BR-1

BL-4GR/YL-2

RD-3

OR-14

OR-15

OR-16

Y-9Y-8

Y-7Y-6Y-5

BL-13

BL-10

RD-11

RD-12

B912-2V

GR/YL

2

1

BR

OR

GR BL

RD

BK

WH

GR

\YL

RD

-2

BL-

2

1

2

V/J

BR

GR

WH

1

2

21

PP-22

PP-7

PP-5

PP-3

PP-4

PP-2

PP-1

RD-6

RD-6

RD-6

RD-6

RD-6

RD-6

GND

+24V dc

OUTPUT

REF

U9

AC INPUT

P1

S7

B-

B+

P

T1

F2

F1

T2

D2

A2

F1

A2

A1

A1

F2

D1

G6G7G8

Y22

Y21

FB1

Y117

Y118

LS3

U6

M5

BK

GR

RD

BK

RD

GR

RD

F2 F1

M7A

M7

R29

1500

Ώ

S21

Y116

Y121

U53

U54

TS75

AC INPUT

S4

ES0525C

30

86

87

87A

85

CR89


Part No. 227656 GR-20J • GR-26J 6 - 9

September 2016

Electrical Schematic - GR-20J and GR-26JCE - Part 2 of 2

1

654321

1

7

14

1234

J2J1

J3

BN

5

BN

97

BN

63

BN

130

BN

8

8

RD-4

WH-1

RD-5

H1BK-18 +

-RD-17

3

4

6

12

1

510

6

7

8

14

1

5

6

10

1

3

4

6

1

BL-

2

RD

-2 BR

GR

/YL

WH

BK

RD BL

GR

OR

8 5 10 3 4 9 11 1 2 12

C

D

A

B

E

F

BR-10

Y-2

GY-9

GR-7

BK

Y-14

Y-13

Y-12

Y-15

OR-6

4

BK

BL-3

BK

OR/BK-8

BK

BK-20

1

BK-19

RD-16GR/YL

2

BK-23

BK-22

BK-21

J11

814

7

P2

4

1

2

BK

RD

RD

RD

RD1

2

GR/YL

Y102

Y101

LS31

U3A

LS11

LS18

L68

L17

L1

BK

BK

BK

BK

BK

BK

BK

L48

L81

L82

SW

5S

W6L

SW

6R

U3B

U10

JC1

ES0525C

L30

PLATFORMCONTROLLER

NOTE: DASHED LINES INDICATE OPTIONS.


6 - 10 GR-20J • GR-26J Part No. 227656

September 2016

Hydraulic Component Reference andSymbols Legend

M

Auxiliary pump Variable speed motor Fixed displacement pump Check valve

Hydraulic cylinder Filter Relief valve Bi-directional motor

Solenoid operated2 position 2 waydirectional valve






Hose reel

Fucntion pump and manifold

E

G

A

F

H

C

B

D

Y117

Y21Y118 Y22

Y116

I


Part No. 227656 GR-20J • GR-26J 6 - 11

September 2016

Hydraulic Schematic

HS0255C

Hydraulic ComponentLegend

A = Steer selectB = Steer/Turntable DirectionalC = Turntable selectD = Platform upE = Platform downF = System reliefG = Platform up/down reliefH = FilterI = Check valveJ = Turntable rotate right reliefK = Turntable rotate left reliefL = Test portM = Lift cylinder selectN = Jib upO = Jib downP = Jib up/down flow controlQ = Check valve

STEER RIGHT

TURNTABLE ROTATE RIGHTSTEER LEFT

TURNTABLE ROTATE LEFTMAST CYLINDER RAISEMAST CYLINDER LOWERJIB CYLINDER RAISEJIB CYLINDER LOWER

Y21 Y22 Y101 Y102 Y116 Y117 Y118 Y121FUNCTION

VALVE ACTIVATION

FUNCTION MANIFOLD

HYDRAULIC TANK

M POWER UNITT1

2030 psi140 bar

P2 P3

STEERCYLINDER

P5 P6

TURNTABLEROTATE

1450 psi100 bar

A DR B

T2

+TP

HOSEREEL

P1

930 psi64 bar

P4

(GR26-J ONLY)

JIB MANIFOLD

B10 = 100

LIFT CYLINDER

JIB CYLINDER

AUXILIARYPUMP

Y116

Y117Y118

Y101 Y102

Y121

Y119

Y21Y22

A

B

C

D

E

FG

H

J K

L

M

N

P

I

O

1450 psi100 bar

Q


6 - 12 GR-20J • GR-26J Part No. 227656

September 2016


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