Genie GR-20J Service Manual
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Genie GR-20J Service Manual

Genie GR-20J Service Manual

Serial number range from grj10-101 to grj16-1151, from grj16l-1152 to grj16l-1999, from grjl-2000
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See also: Operator's Manual , Instruction and Installation Manual
Service Manual
GR-20J
GR-26J
Serial Number Range
Serial Number Range
from GRJ10-101
to GRJ16-1151
from GRJ16L-1152
to GRJ16L-1999
from GRJL-2000
Part No. 227656
Rev D1
September 2016

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Summary of Contents for Genie GR-20J

  • Page 1 Service Manual Serial Number Range Serial Number Range from GRJ10-101 GR-20J to GRJ16-1151 from GRJ16L-1152 GR-26J to GRJ16L-1999 from GRJL-2000 Part No. 227656 Rev D1 September 2016...

  • Page 2: Section 3_Maintenance,

    Technical Publications Genie has endeavored to deliver the highest degree of accuracy possible. However, continuous improvement of our products is a Genie policy. Therefore, product specifications are subject to change without notice. Readers are encouraged to notify Genie of errors and send in suggestions for improvement.

  • Page 3: Introduction

    Section 3_Maintenance, B-3. Electronic Version Section 4_Repair Procedure, 4-2. Click on any procedure or page number Section 5_Diagnostic Codes, All charts. highlighted in blue to view the update. Section 6_Schematics, Legends diagrams and schematics. Part No. 227656 GR-20J • GR-26J...

  • Page 4: Section 5_Diagnostic Codes, All Charts

    Section 3_Maintenance, B-3. Electronic Version Section 4_Repair Procedure, 4-2. Click on any procedure or page number Section 5_Diagnostic Codes, All charts. highlighted in blue to view the update. Section 6_Schematics, Legends diagrams and schematics. GR-20J • GR-26J Part No. 227656...

  • Page 5: Serial Number Legend

    Electrical schematic number: Machine unladen weight: Maximum allowable inclination of the chassis: Gradeability: Rated work load (including occupants): 1 Model 4 Serial label 2 Facility code 5 Serial number (stamped on chassis) 3 Sequence number Part No. 227656 GR-20J • GR-26J...

  • Page 6: Safety Rules

    You read, understand and obey: - manufacturer’s instructions and safety rules - employer’s safety rules and worksite regulations - applicable governmental regulations You have the appropriate tools, lifting equipment and a suitable workshop. GR-20J • GR-26J Part No. 227656...
  • Page 7 Be sure to wear protective eye wear and other protective clothing if the situation warrants it. Be aware of potential crushing hazards such as moving parts, free swinging or unsecured components when lifting or placing loads. Always wear approved steel-toed shoes. Part No. 227656 GR-20J • GR-26J...

  • Page 8: Table Of Contents

    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 viii GR-20J • GR-26J Part No. 227656...
  • Page 9 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 Part No. 227656 GR-20J • GR-26J...
  • Page 10 Hydraulic Pump Function Pump ................. 4 - 27 Function Manifold Function Manifold Components ............4 - 30 Valve Adjustments - Function Manifold ..........4 - 32 Steer Axle Components Hydraulic Tank ................. 4 - 35 GR-20J • GR-26J Part No. 227656...
  • Page 11 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 Part No.

  • Page 12: Part

    September 2016 This page intentionally left blank. GR-20J • GR-26J Part No. 227656...

  • Page 13: Specifications

    96 ft-lbs Fluid capacities 130 Nm Hydraulic tank 5.8 gallons 22 liters Height, stowed maximum GR-20J (CE only) & GR-26J 78 in 1.99 m For operational specifications, refer to the Operator's Manual. Part No. 227656 GR-20J • GR-26J 2 - 1...

  • Page 14: Performance Specifications

    Water content, maximum 200 ppm 40 ft / 54.8 sec 0.65 km/h Genie specifications require hydraulic oils which are 12.2 m / 54.8 sec designed to give maximum protection to hydraulic systems, have the ability to perform over a wide...

  • Page 15: Manifold Component Specifications

    RETINAX HDX2 grease, NLGI (lithium based) or equivalent SAE No. 8 50 ft-lbs / 68 Nm SAE No. 10 55 ft-lbs / 75 Nm SAE No. 12 75 ft-lbs / 102 Nm Part No. 227656 GR-20J • GR-26J 2 - 3...

  • Page 16: Hydraulic Hose And Fitting Torque Specifications

    ™ SAE Dash size Torque ORFS or 37° JIC fittings and hose ends. Genie specifications require that fittings and hose 14 ft-lbs / 19 Nm ends be torqued to specification when they are 23 ft-lbs / 31.2 Nm removed and installed or when new hoses or fittings are installed.
  • Page 17 They are not standard SAE size O-rings. They are reference mark body hex fitting available in the O-ring field service kit (Genie part number 49612). 3 Working clockwise on the body hex fitting, make a second mark with a permanent ink 2 Lubricate the O-ring before installation.
  • Page 18 50.5 39.9 54.1 53.2 72.2 46.7 63.3 62.3 84.4 18.9 25.6 25.1 34.1 48.6 64.9 69.7 94.5 92.2 30.1 40.8 54.3 77.4 46.9 63.6 62.5 84.8 64.5 87.5 86.2 1055 1233 2 - 6 GR-20J • GR-26J Part No. 227656...

  • Page 19: Scheduled Maintenance Procedures

    Repair any machine damage or malfunction may cause minor or moderate before operating the machine. injury. Use only Genie approved replacement parts. Indicates a potentially hazardous situation which, if not avoided, Machines that have been out of service for a may result in property damage.

  • Page 20: Pre-Delivery Preparation Report

    Make copies of the Maintenance Inspection Report to use for each inspection. Maintain completed forms for a minimum of 4 years or in compliance with employer, jobsite and governmental regulations and requirements. 3 - 2 GR-20J • GR-26J Part No. 227656...
  • Page 21 500 Oak Wood Road The Maltings, Wharf Road PO Box 1150 Grantham, Lincolnshire Watertown, SD 57201-6150 NG31- 6BH England (605) 882-4000 (44) 1476-584333 Copyright © 2011 Terex Corporation. Genie® is a registered trademark of Terex South Dakota, Inc. 133192 Rev D...
  • Page 22 Section 3 • Scheduled Maintenance Procedures September 2016 This page intentionally left blank. 3 - 4 GR-20J • GR-26J Part No. 227656...

  • Page 23: Maintenance Inspection Report

    After repair, place a check in the “R” box. Legend Y = yes, acceptable N = no, remove from service R = repaired Part No. 227656 GR-20J • GR-26J 3 - 5...
  • Page 24 Section 3 • Scheduled Maintenance Procedures September 2016 This page intentionally left blank. 3 - 6 GR-20J • GR-26J Part No. 227656...

  • Page 25: Checklist A Procedures

    Carefully and thoroughly Inspect the Manuals and Decals inspect all decals on the machine for legibility and damage. Genie specifications require that this procedure be performed every 8 hours or daily, whichever Result: The machine is equipped with all comes first.

  • Page 26: Perform Pre-Operation Inspection

    September 2016 CHECKLIST A PROCEDURES Perform Pre-operation Inspection Perform Function Tests Genie specifications require that this procedure be Genie specifications require that this procedure be performed every 8 hours or daily, whichever performed every 8 hours or daily, whichever comes first.

  • Page 27: Hydraulic Suction Strainer

    Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic Genie specifications require that this procedure be connections very slowly to allow performed every 100 hours or monthly, whichever the oil pressure to dissipate comes first.

  • Page 28: Checklist B Procedures

    Section 3 • Scheduled Maintenance Procedures September 2016 Checklist B Procedures Inspect the Battery 250A Fuse Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Battery Charger Proper battery condition is essential to good machine performance and operational safety.

  • Page 29: Inspect The Electrical Wiring

    5 Tag and disconnect the cables from the ground terminal of the battery. 6 Remove the fasteners securing the rear chassis Genie specifications require that this procedure be cover to the chassis at the non-steer end of the performed every 250 hours or quarterly, whichever machine.

  • Page 30: Inspect The Tires, Wheels

    Emergency Stop button to the off position at both the ground and platform controls. Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever 15 Inspect the following areas for burnt, chafed, comes first.

  • Page 31: Test The Emergency Stop

    Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES Test the Emergency Stop Test the Horn Genie specifications require that this procedure be Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever performed every 250 hours or quarterly, whichever comes first.

  • Page 32: Test The Key Switch

    Section 3 • Scheduled Maintenance Procedures September 2016 CHECKLIST B PROCEDURES Test the Key Switch Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper key switch action and response is essential to safe machine operation. The machine can be...

  • Page 33: Test The Drive Brakes

    September 2016 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES Test the Drive Brakes Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper brake action is essential to safe machine drive function select button BN130 operation.

  • Page 34: Test The Drive Speed - Stowed Position

    September 2016 CHECKLIST B PROCEDURES Test the Drive Speed - Stowed Position Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. drive function select button BN130 Proper drive functions are essential to safe 5 Choose a point on the machine i.e.

  • Page 35: Test The Drive Speed - Raised Position

    Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES Test the Drive Speed - Raised Position Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper drive functions are essential to safe lift function select button BN63 machine operation.
  • Page 36 CHECKLIST B PROCEDURES B-10 Test the Flashing Beacon (if equipped) Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Flashing beacon is used to alert operators and ground personnel of machine proximity and motion.

  • Page 37: Test The Motion Alarm

    Test the Motion Alarm for a moment and then release it. Move the joystick off center in the opposite direction, hold Genie specifications require that this procedure be for a moment and then release it. performed every 250 hours or quarterly, whichever comes first.

  • Page 38: Perform Hydraulic Oil Analysis

    B-12 B-13 Perform Hydraulic Oil Analysis Inspect the Breather Cap Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Perform this procedure more often if Genie specifications require that this procedure be dusty conditions exist.

  • Page 39: Inspect The Rear Axle Free-Wheeling

    CHECKLIST B PROCEDURES B-14 Inspect the Rear Axle Free-wheeling Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Note: Perform this procedure with the machine on a firm, level surface that is free of obstructions, free-wheel selector switch with the wheels chocked.

  • Page 40: Inspect The Lateral Offset Of The Mast

    Result: Lateral offset of the mast i.e. distance L1 and L2 as shown in the illustration should not exceed 13.75 inches / 350 mm. Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first.

  • Page 41: Inspect The Mast Wear Pads

    Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES B-16 Inspect the Mast Wear Pads Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Mast wear pads should always be in good condition and greased for good machine performance and service life.

  • Page 42: Checklist C Procedures

    Genie specifications require that this procedure be Refer to Repair Procedure 2-2, How to Calibrate performed every 500 hours or six months, the Platform Overload System (if equipped).

  • Page 43: Replace The Hydraulic Tank Breather Cap - Models With Optional Hydraulic Oil

    Replace the Hydraulic Tank Breather Cap - Models with Optional Hydraulic Oil Genie specifications require that this procedure be performed every 500 hours or six months, whichever comes first OR when the machine fails to lift the maximum rated load.

  • Page 44: Checklist D Procedures

    September 2016 Checklist D Procedure Replace the Hydraulic Tank Return Filter Genie specifications require that this procedure be performed every 1000 hours or annually, whichever comes first. Replacement of the hydraulic tank return filter is essential for good machine performance and service life.

  • Page 45: Checklist E Procedure

    6 Remove the drain plug and drain all of the oil into a suitable container. Genie specifications require that this procedure be performed every 2000 hours or every two years, 7 Clean up any oil that may have spilled. Properly whichever comes first.
  • Page 46 Section 3 • Scheduled Maintenance Procedures September 2016 This page intentionally left blank. 3 - 28 GR-20J • GR-26J Part No. 227656...
  • Page 47 Be sure that all necessary tools and parts are situation which, if not avoided, available and ready for use. could result in death or serious Use only Genie approved replacement parts. injury. Indicates a potentially hazardous Read each procedure completely and adhere to situation which, if not avoided, the instructions.

  • Page 48: Platform Controls

    4 Remove the fasteners securing the platform controls circuit board to the top plate assembly. Set the fasteners to the side. 5 Remove the platform controls circuit boards from the top plate assembly. 4 - 2 GR-20J • GR-26J Part No. 227656...

  • Page 49: Controller Adjustments

    Result: The drive indicator light will be on if the motion alarm is activated.It will be off if the motion alarm is deactivated. Part No. 227656 GR-20J • GR-26J 4 - 3...
  • Page 50 Result: The lift indicator light will be on if the flashing beacon is activated.It will be off if the flashing beacon is deactivated. 4 - 4 GR-20J • GR-26J Part No. 227656...
  • Page 51 Joystick calibration is to the neutral position. complete. Note: Do not squeeze or activate the joystick function enable switch. No machine function should operate while performing the joystick calibration procedure. Part No. 227656 GR-20J • GR-26J 4 - 5...
  • Page 52 3 seconds. 15 Press the drive function button for 3 seconds. Steer Sensor calibration is complete. Result: A beep sounds and three function indicator lights will flash one after another. 4 - 6 GR-20J • GR-26J Part No. 227656...

  • Page 53: Platform Components

    Set the top plate assembly to the side. 6 Remove the fasteners securing the bottom plate assembly to the platform control box. Lay the bottom plate assembly and fasteners to the side. Part No. 227656 GR-20J • GR-26J 4 - 7...

  • Page 54: Platform Overload System

    Emergency Stop button returns automatically to screw just until the screw and lock nut will the out, or on position. rotate freely, and the clearance between the lock nut and sensor mounting bracket is minimal. 4 - 8 GR-20J • GR-26J Part No. 227656...
  • Page 55 Repeat the procedure beginning with step 9. 10 Test all machine functions from the platform controls. Result: All platform control functions should not operate. Part No. 227656 GR-20J • GR-26J 4 - 9...

  • Page 56: Jib Components

    10 Carefully remove the jib cylinder from the machine. Crushing hazard. The jib cylinder could become unbalanced and fall if not properly supported when removed from the machine. 4 - 10 GR-20J • GR-26J Part No. 227656...

  • Page 57: Mast Components

    2 x Ø18 mm Illustration 2 mast head cover mast head cover fasteners Illustration 1 mast head jib boom safety steel plate proximity sensor lift cylinder mast head fasteners lift cylinder fasteners Part No. 227656 GR-20J • GR-26J 4 - 11...
  • Page 58 13 Using Illustration 3 as a guide, remove the Illustration 4 fasteners securing the stops to the mast M16 shackles assembly and remove the stops. Set the mast assembly fasteners and stops to the side. safety steel plate 4 - 12 GR-20J • GR-26J Part No. 227656...
  • Page 59 Crushing hazard. The mast assembly could become unbalanced and fall if not properly supported when removed from the machine. Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched. Part No. 227656 GR-20J • GR-26J 4 - 13...
  • Page 60 1 mast shims wear pads fasteners Ground Controls Side stops Steer End number 2 mast number 3 mast number 4 mast cover plate Platform Power Unit Side (Non-Steer End) Illustration 2 4 - 14 GR-20J • GR-26J Part No. 227656...
  • Page 61 Note: During removal, the overhead crane strap will need to be carefully adjusted for proper balancing. Part No. 227656 GR-20J • GR-26J 4 - 15...
  • Page 62 Set the fasteners and stops to the side. the shims. Note: Use a hammer and chisel if necessary to gently loosen the wear pads from the mast. 4 - 16 GR-20J • GR-26J Part No. 227656...
  • Page 63 Note: For ease of mast reassembly, make careful note of the location, order and orientation of the shims. Note: Use a hammer and chisel if necessary to gently loosen the wear pads from the mast. Part No. 227656 GR-20J • GR-26J 4 - 17...
  • Page 64 1, 2, 3 and 4. Grease Specification RETINAX HDX2 grease, NLGI (lithium based) BOTTOM or equivalent Illustration 1 wear pad 10 mm Illustration 2 mast section (mast 1 shown) grease mast section (mast 1 shown) 4 - 18 GR-20J • GR-26J Part No. 227656...
  • Page 65 4. 7 Carefully assemble the mast sections using the mast disassembly procedure in reverse order. See 4-1, How to Disassemble the Mast, GR-26J. Illustration 3 grease mast section (mast 4 shown) Part No. 227656 GR-20J • GR-26J 4 - 19...
  • Page 66 September 2016 MAST COMPONENTS BOTTOM Illustration 1 Ground Controls Side number 1 mast Steer End stops shims wear pads number 2 mast cover plate Platform Power Unit Side (Non-Steer End) Illustration 2 4 - 20 GR-20J • GR-26J Part No. 227656...
  • Page 67 Note: During removal, the overhead crane strap will need to be carefully adjusted for proper 6 Working from the bottom of the number 1 mast, balancing. pull the number 2 mast half way out. Part No. 227656 GR-20J • GR-26J 4 - 21...
  • Page 68 Note: Use a hammer and chisel if necessary to gently loosen the wear pads from the mast. Illustration 1 wear pad 10 mm mast section (mast 1 shown) 4 - 22 GR-20J • GR-26J Part No. 227656...
  • Page 69 1. Grease Specification RETINAX HDX2 grease, NLGI (lithium based) or equivalent Illustration 3 grease mast section (mast 2 shown) Illustration 2 grease mast section (mast 1 shown) Part No. 227656 GR-20J • GR-26J 4 - 23...

  • Page 70: Lift Cylinder

    5 Place blocks under the chassis for support. Lower the machine onto the blocks. Crushing hazard. The chassis could fall if not properly supported. 4 - 24 GR-20J • GR-26J Part No. 227656...
  • Page 71 Set the fasteners to the could become unbalanced and fall side. if not properly supported when removed from the machine. Component damage hazard. The lift cylinder can be damaged if it falls. Part No. 227656 GR-20J • GR-26J 4 - 25...

  • Page 72: Ground Controls

    Result: The green LED underneath the level machine to tip over, resulting in sensor does not flash. Check the calibration death or serious injury. Do not wire connection. Contact Genie Industries install or calibrate the level sensor Service Department. other than specified in this procedure.

  • Page 73: Hydraulic Pump

    3 Tag and disconnect the wire harness connectors from the function manifold. 4 Tag and disconnect the cables from the motor. Illustration 1 motor function manifold hydraulic tank connector fittings hydraulic hoses Part No. 227656 GR-20J • GR-26J 4 - 27...
  • Page 74 Failure to restore the machine to power unit. original factory specifications could cause the machine to tip over, resulting in death or serious injury. 4 - 28 GR-20J • GR-26J Part No. 227656...
  • Page 75 September 2016 Section 4 • Repair Procedures This page intentionally left blank. Part No. 227656 GR-20J • GR-26J 4 - 29...

  • Page 76: Function Manifold

    Solenoid valve, 2 position 4 way ....A ......Steer left/right ......18 ft-lbs / 25 Nm Relief valve, 2030 psi / 140 bar ........F ......System relief ......18 ft-lbs / 25 Nm 4 - 30 GR-20J • GR-26J Part No. 227656...
  • Page 77 Note: 'alpha-numeric' callouts Note: 'alpha-numeric' callouts refer to corresponding notes refer to corresponding notes on the electrical schematic on the electrical schematic Part No. 227656 GR-20J • GR-26J 4 - 31...

  • Page 78: Valve Adjustments - Function Manifold

    (schematic item F). 7 Connect a 0 to 2500 psi / 0 to 175 bar pressure gauge to the test port on the hydraulic hose reel. 4 - 32 GR-20J • GR-26J Part No. 227656...
  • Page 79 16 Turn the key switch to the off position. 17 Install and tighten the fasteners securing the function manifold to the hydraulic tank. 18 Install and securely tighten the hydraulic power unit clamps. Do not over tighten. Part No. 227656 GR-20J • GR-26J 4 - 33...
  • Page 80 8 Hold the lift relief valve with a wrench and step 12. remove the cap (schematic item G). 17 Turn the key switch to the off position and remove the weight from the platform. 4 - 34 GR-20J • GR-26J Part No. 227656...

  • Page 81: Hydraulic Tank

    40 in-lbs hydraulic oil can penetrate and 4.5 Nm burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Part No. 227656 GR-20J • GR-26J 4 - 35...

  • Page 82: Turntable Components

    2 Raise the jib boom to the maximum height. 3 Turn the key switch to off position and push in the red Emergency Stop button to the off position at both the ground and platform controls. 4 - 36 GR-20J • GR-26J Part No. 227656...
  • Page 83 9 Carefully remove the turntable rotation motor from the machine. Bodily injury hazard. The turntable rotation motor may fall if not properly supported when removed from the machine. Part No. 227656 GR-20J • GR-26J 4 - 37...

  • Page 84: Battery

    4 Tag and disconnect the cables connected to the falls. positive terminal of the battery. 5 Locate the bolts between the battery pack and the counterweight. Loosen the bolts holding the battery pack in position. 4 - 38 GR-20J • GR-26J Part No. 227656...

  • Page 85: Battery Charger

    6 Locate the LED at the bottom of the bulkhead. sensor, and remove the battery charger from Tag and disconnect the LED wire harness the machine. connector. 7 Tag and disconnect the charger cutout harness connector. Part No. 227656 GR-20J • GR-26J 4 - 39...

  • Page 86: Steer Axle Components

    7 Remove the top cir-clip from the pin at the steering rod. 8 Remove the plastic cap above the yoke pivot shaft. Set the cap to the side. 4 - 40 GR-20J • GR-26J Part No. 227656...

  • Page 87: Steer Cylinder

    11 Carefully remove the steer cylinder from the controls. machine. 4 Block the wheels at the non-steer end of the machine. 5 Remove the pin retaining fasteners from the top of the steer cylinder barrel-end pivot pin. Part No. 227656 GR-20J • GR-26J 4 - 41...

  • Page 88: Steering Rod

    Note: Rotate the red Emergency Stop button at platform control one quarter turn in a clockwise direction to restore the power supply. The red Emergency Stop button returns automatically to the out, or on position. 4 - 42 GR-20J • GR-26J Part No. 227656...
  • Page 89 9 With a multimeter set to read 4K±0.2 ohms, connect the leads to the green and black wires of the potentiometer. 10 Adjust the potentiometer until a reading of 4K±0.2 ohms is obtained. Part No. 227656 GR-20J • GR-26J 4 - 43...

  • Page 90: Non-Steer Axle Components

    10 Turn over the steel bar and cut the zip ties 5 Open the turntable cover at the ground control attaching the two wire harness connectors to side of the machine. the steel bar. Lay the steel bar to the side. 4 - 44 GR-20J • GR-26J Part No. 227656...
  • Page 91 15 Remove the castle nut from the wheel at the non-steer end of the machine. Remove the wheel from the machine. Note: A properly sized puller may be needed to remove the wheel from the tapered shaft. Part No. 227656 GR-20J • GR-26J 4 - 45...

  • Page 92: Drive Brake

    8 Tag and disconnect the two wire harness Brake mounting fasteners, dry 75 ft-lbs connectors at the steel bar. 102 Nm Brake mounting fasteners, lubricated 56 ft-lbs 76 Nm 4 - 46 GR-20J • GR-26J Part No. 227656...

  • Page 93: Fault Codes

    • The red Emergency Stop button in the off gradually. Do not allow oil to position at both ground and platform controls squirt or spray. • Wheels chocked • All external AC power supply disconnected from the machine Part No. 227656 GR-20J • GR-26J 5 - 1...
  • Page 94 Error Type: Last two digits indicates the fault number. The codes listed in the Fault Code Chart describe malfunctions and can aid in troubleshooting the machine by pinpointing the area or component affected. 5 - 2 GR-20J • GR-26J Part No. 227656...

  • Page 95: Fault Code Chart

    Flash check downloaded or the Flash version or replace the controller. memory is corrupted. There is a fault in the A/D Analog input converter of the micro- Replace the controller. controller. Part No. 227656 GR-20J • GR-26J 5 - 3...
  • Page 96 Mc enable The EB coil can not Replace the controller. short. activate. Eb. enable The power contactor is Check the wiring or change the short short-circuited. controller. 5 - 4 GR-20J • GR-26J Part No. 227656...
  • Page 97 Temperature down. If this does not happen, the pump has detected a of pump high there is a problem with the high temperature. connection of terminal A16 or the temperature sensor. Part No. 227656 GR-20J • GR-26J 5 - 5...
  • Page 98 There is a problem on one Check the condition of the of the following outputs: valves and their connections. Lifting valve terminal A32, terminal Otherwise, it is an internal fault A26. of the controller. 5 - 6 GR-20J • GR-26J Part No. 227656...
  • Page 99 Check the horn and its wiring. (short-circuit to negative Horn If the wiring is correct and the or positive, to absent conductor alarm persists, there is an horn) on the "WARNING" internal fault. product. Part No. 227656 GR-20J • GR-26J 5 - 7...
  • Page 100 The current sensor for the armature of motor 1 and/or motor 2 is not It is an internal fault. Trac. I sensor functioning correctly: its Replace the controller. output voltage is outside the acceptable range. 5 - 8 GR-20J • GR-26J Part No. 227656...
  • Page 101 VMN low of the drive motors is low. connections; leakage from the motor to the framework of the platform. If everything is OK, the controller has an internal fault Part No. 227656 GR-20J • GR-26J 5 - 9...
  • Page 102 Electric cable high should be low. connections, leakage from the motor to the framework of the platform. If everything is OK, the controller has an internal fault. 5 - 10 GR-20J • GR-26J Part No. 227656...
  • Page 103 If the fault is detected during braking, the fault may be due to over- voltage: check the battery voltage during braking. Part No. 227656 GR-20J • GR-26J 5 - 11...
  • Page 104 The current sensor of the pump is not working It is an internal fault. Pump sensor correctly. Its output voltage Replace the controller. is outside the acceptable range. 5 - 12 GR-20J • GR-26J Part No. 227656...
  • Page 105 This alarm may be Time delay pump. If they are not due to a software disparity. activated after 400 ms, this Otherwise, there is an internal alarm is activated. fault. Part No. 227656 GR-20J • GR-26J 5 - 13...
  • Page 106 BUSCAN line. Error Source Error Type Condition Solution Name Name Check wire connections. Repair Diagnostic The diagnostic display is or replace the diagnostic communication display not working properly. display. 5 - 14 GR-20J • GR-26J Part No. 227656...
  • Page 107 Be sure that all necessary tools and test equipment are available and ready for use. Malfunction Identify Troubleshoot discovered symptoms problem still exists Return to Inspect Perform service repair and test problem solved Part No. 227656 GR-20J • GR-26J 6 - 1...
  • Page 108 L79 = Out of level L81 = Mast up-down/turntable rotate L82 = Jib Limit switch LS3 = Drive enable LS11 = Jib boom LS18 = Mast down LS31 = Platform overload 6 - 2 GR-20J • GR-26J Part No. 227656...

  • Page 109: Ecm Pin-Out Legend

    September 2016 Section 6 • Schematics ECM Pin-out Legend Part No. 227656 GR-20J • GR-26J 6 - 3...

  • Page 110: Limit Switch And Sensor Legend

    September 2016 Section 6 • Schematics Limit Switch and Sensor Legend Limit and Sensor Legend Platform overload LS31 Mast down LS18 Steer angle S21 Tilt sensor S7 Jib down LS11 6 - 4 GR-20J • GR-26J Part No. 227656...

  • Page 111: Electrical Symbols Legend

    Solenoid Valve Connection Battery Charger Emergency Stop Button (no terminal) Parking Brake Connector Battery Key Switch Fuse Electric Motor Horn or Alarm Control Relay Flashing Beacon Sensor (hydraulic oil temperature) Joystick Controller Part No. 227656 GR-20J • GR-26J 6 - 5...

  • Page 112: Gr-26J

    PP-4 RD-7 RD-23 Y117 RD-6 PP-22 PP-3 PP-5 Y118 RD-6 PP-4 PP-2 PP-3 RD-6 PP-2 PP-1 PP-1 TS75 RD-6 PP-7 CR89 250A OUTPUT +24V dc AC INPUT AC INPUT 12-2V ES0525C 6 - 6 GR-20J • GR-26J Part No. 227656...
  • Page 113 Y102 GR-7 Y101 GR/YL Y-14 Y-13 Y-12 Y-15 OR-6 BL-3 OR/BK-8 BK-20 BK-19 BK-18 RD-17 RD-16 GR/YL RD-5 BK-23 RD-4 BK-22 WH-1 BK-21 PLATFORM CONTROLLER NOTE: DASHED LINES INDICATE OPTIONS. ES0525C Part No. 227656 GR-20J • GR-26J 6 - 7...

  • Page 114: Gr-20J And Gr-26J

    September 2016 Section 6 • Schematics Electrical Schematic - GR-20J and GR-26J CE - Part 1 of 2 BR-1 BL-4 GR/YL-2 RD-3 BN57 GR/YL BN97 BN128 BN129 BR-1 BL-4 GR/YL-2 BL-13 RD-11 RD-3 BL-10 RD-12 OR-14 OR-15 OR-16 OR-16 OR-15...

  • Page 115: Gr-20J And Gr-26J

    September 2016 Section 6 • Schematics Electrical Schematic - GR-20J and GR-26J CE - Part 2 of 2 LS31 LS11 LS18 BR-10 GY-9 Y102 GR-7 Y101 GR/YL Y-14 Y-13 Y-12 Y-15 OR-6 BL-3 OR/BK-8 BK-20 BK-19 BK-18 RD-17 RD-16 GR/YL...
  • Page 116 Hose reel Solenoid operated Solenoid operated 2 position 2 way 2 position 4 way directional valve directional valve Y117 Y116 Y118 Fucntion pump and manifold 6 - 10 GR-20J • GR-26J Part No. 227656...
  • Page 117 MAST CYLINDER RAISE N = Jib up MAST CYLINDER LOWER O = Jib down P = Jib up/down flow control JIB CYLINDER RAISE Q = Check valve JIB CYLINDER LOWER HS0255C Part No. 227656 GR-20J • GR-26J 6 - 11...
  • Page 118 September 2016 Section 6 • Schematics This page intentionally left blank. 6 - 12 GR-20J • GR-26J Part No. 227656...
  • Page 119 Genie North America Phone 425.881.1800 Toll Free USA and Canada 800.536.1800 425.883.3475 Genie Australia Pty Ltd. Phone + 61 7 3375 1660 Fax + 61 7 3375 1002 Genie China Genie Scandinavia Phone + 86 21 53852570 Phone + 46 31 575100...

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