Terex Genie GR-26J Service Manual
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Terex Genie GR-26J Service Manual

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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
to GRJL-2297
Part No. 227656GT
Rev E
March 2022

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Summary of Contents for Terex Genie GR-26J

  • 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 to GRJL-2297 Part No. 227656GT Rev E March 2022...
  • Page 2 Genie is a registered trademark of Terex South e-mail: awp.techpub@terex.com Dakota in the U.S.A. and many other countries. "GR" is a trademark of Terex South Dakota, Inc. Printed on recycled paper Printed in U.S.A. GR™-20J • GR™-26J Part No. 227656GT...

  • Page 3: Introduction

    March 2022 Revision History Revision Date Section Procedure / Schematic Page / Description 4/2011 New release 6/2011 4 - Repair 9/2011 3 - Maint. B-15 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 11/2012 4 - Repair...
  • Page 4 March 2022 REVISION HISTORY, CONTINUED Revision Date Section Procedure / Schematic Page / Description REFERENCE EXAMPLES: Electronic Version Section 3_Maintenance, B-3. Section 4_Repair Procedure, 4-2. Section 5_Diagnostic Codes, All charts. Section 6_Schematics, Legends diagrams and schematics. GR™-20J • GR™-26J Part No. 227656GT...

  • Page 5: Serial Number Legend

    March 2022 INTRODUCTION Serial Number Legend To August 31, 2016 GRJ 16 L - 1234 Model: Serial number: GRJ16L-1234 Manufacture date: 1/2/16 Model year: 2016 Electrical schematic number: Machine unladen weight: Maximum allowable inclination of the chassis: Gradeability: Rated work load (including occupants): 1 Model 4 Sequence number 2 Model year...

  • Page 6: Safety Rules

    Section 1 • Safety Rules March 2022 Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the appropriate Operator's Manual on your machine will result in death or serious injury. Many of the hazards identified in the operator’s manual are also safety hazards when maintenance and repair procedures are performed.
  • Page 7 March 2022 Section 1 • Safety Rules SAFETY RULES Personal Safety Workplace Safety Any person working on or around a machine must Be sure to keep sparks, flames and be aware of all known safety hazards. Personal lighted tobacco away from flammable and safety and the continued safe operation of the combustible materials like battery gases machine should be your top priority.

  • Page 8: Table Of Contents

    March 2022 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 ................
  • Page 9 March 2022 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 ..............
  • Page 10 March 2022 TABLE OF CONTENTS Section 4 Repair Procedures Introduction ....................4 - 1 Platform Controls Circuit Boards ..................4 - 2 Controller Adjustments ............... 4 - 3 Platform Components Platform ..................... 4 - 7 Platform Overload System ..............4 - 8 Jib Components Jib Cylinder ..................
  • Page 11 March 2022 TABLE OF CONTENTS Section 4 Repair Procedures, continued Turntable Components Turntable Rotation Motor ..............4 - 36 Battery ..................... 4 - 38 Battery Charger ................4 - 39 Steer Axle Components 10-1 Yoke ....................4 - 40 10-2 Steer Cylinder .................. 4 - 41 10-3 Steering Rod ..................
  • Page 12 March 2022 This page intentionally left blank. GR™-20J • GR™-26J Part No. 227656GT...

  • Page 13: Specifications

    March 2022 Section 2 • Specifications Specifications Machine Specifications Tires and wheels Tire size (solid rubber) 16 x 5 x 11 in Battery, Standard 40.6 x 12.7 x 28 cm Voltage 2V DC Castle nut torque, dry (non-steer end) 89 ft-lbs 120 Nm Group Castle nut torque, lubricated (non-steer end)

  • Page 14: Performance Specifications

    Section 2 • Specifications March 2022 SPECIFICATIONS Performance Specifications Hydraulic Specifications Drive speed, maximum Hydraulic Oil Specifications Platform stowed 2.8 mph Hydraulic oil type Shell PW 46 40 ft / 9.8 sec Viscosity grade Multi-viscosity 4.5 km/h Viscosity index 12.2 m / 9.8 sec Cleanliness level, minimum 15/13 Platform raised...

  • Page 15: Manifold Component Specifications

    March 2022 Section 2 • Specifications SPECIFICATIONS Manifold Component Torque specifications Specifications Brake mounting fasteners, dry 75 ft-lbs 102 Nm Plug torque Brake mounting fasteners, lubricated 56 ft-lbs SAE No. 2 50 in-lbs / 6 Nm 76 Nm SAE No. 4 13 ft-lbs / 18 Nm Grease Specification SAE No.

  • Page 16: Hydraulic Hose And Fitting Torque Specifications

    Section 2 • Specifications March 2022 SPECIFICATIONS Hydraulic Hose and Fitting Torque SAE O-ring Boss Port (tube fitting - installed into Aluminum) Specifications (all types) Your machine is equipped with Parker Seal-Lok ™ 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...
  • Page 17 March 2022 Section 2 • Specifications SPECIFICATIONS Torque Procedure Seal-Lok™ fittings 1 Replace the O-ring. The O-ring must be replaced anytime the seal has been broken. The O-ring cannot be re-used if the fitting or hose end has been tightened beyond finger tight.
  • Page 18 Section 2 • Specifications March 2022 SPECIFICATIONS SAE FASTENER TORQUE CHART • This chart is to be used as a guide only unless noted elsewhere in this manual • A574 High Strength Grade 5 Grade 8 SIZE THREAD Black Oxide Bolts LUBED LUBED LUBED...

  • Page 19: Scheduled Maintenance Procedures

    March 2022 Section 3 • Scheduled Maintenance Procedures Scheduled Maintenance Procedures About This Section This section contains detailed procedures for each scheduled maintenance inspection. Each procedure includes a description, safety warnings and step-by-step instructions. Observe and Obey: Symbols Legend Maintenance inspections shall be completed Safety alert symbol—used to alert by a person trained and qualified on the personnel to potential personal...

  • Page 20: Pre-Delivery Preparation Report

    Section 3 • Scheduled Maintenance Procedures March 2022 SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend Pre-delivery Preparation Report Note: The following symbols have been used in The pre-delivery preparation report contains this manual to help communicate the intent of the checklists for each type of scheduled inspection. instructions.
  • 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 March 2022 This page intentionally left blank. 3 - 4 GR™-20J • GR™-26J Part No. 227656GT...

  • Page 23: Maintenance Inspection Report

    March 2022 Section 3 • Scheduled Maintenance Procedures Maintenance Inspection Report Model Checklist A Y N R Checklist B Y N R A-1 Inspect the manuals B-1 Inspect the battery Serial number and decals B-2 Electrical wiring A-2 Pre-operation B-3 Tires and wheels Date inspection B-4 Emergency stop...
  • Page 24 Section 3 • Scheduled Maintenance Procedures March 2022 This page intentionally left blank. 3 - 6 GR™-20J • GR™-26J Part No. 227656GT...

  • Page 25: Checklist A Procedures

    March 2022 Section 3 • Scheduled Maintenance Procedures Checklist A Procedures 3 Open the operator's manual to the decals inspection section. 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

    Section 3 • Scheduled Maintenance Procedures March 2022 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

    March 2022 Section 3 • Scheduled Maintenance Procedures CHECKLIST A PROCEDURES 5 Tag and disconnect the cables from the motor. Replace the Hydraulic Suction 6 Tag, disconnect and plug the hydraulic hoses at the function manifold. Cap the fittings on the Strainer manifold.

  • Page 28: Checklist B Procedures

    Section 3 • Scheduled Maintenance Procedures March 2022 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

    March 2022 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES 4 Turn the key switch to off position and push in the red Emergency Stop button to the off Inspect the Electrical Wiring position at the ground control. 5 Tag and disconnect the cables from the ground terminal of the battery.

  • Page 30: Inspect The Tires, Wheels

    Section 3 • Scheduled Maintenance Procedures March 2022 CHECKLIST B PROCEDURES 13 Lower the jib boom until the platform is approximately 2 feet / 0.5 m from the ground. Inspect the Tires and Wheels 14 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.

  • Page 31: Test The Emergency Stop

    March 2022 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 March 2022 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 operated from the ground or platform controls and the activation of one or the other is accomplished with the key switch.

  • Page 33: Test The Drive Brakes

    March 2022 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

    Section 3 • Scheduled Maintenance Procedures March 2022 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

    March 2022 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 Section 3 • Scheduled Maintenance Procedures March 2022 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

    March 2022 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES B-11 6 Press and hold the function enable switch on the joystick. Move the joystick off center, hold 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.

  • Page 38: Perform Hydraulic Oil Analysis

    Section 3 • Scheduled Maintenance Procedures March 2022 CHECKLIST B PROCEDURES 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

    March 2022 Section 3 • Scheduled Maintenance Procedures 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 ground control box...

  • Page 40: Inspect The Lateral Offset Of The Mast

    Section 3 • Scheduled Maintenance Procedures March 2022 CHECKLIST B PROCEDURES B-15 4 Using a suitable torque measuring device, apply a lateral force of 29.5 ft-lb / 40 Nm near the Inspect the Lateral Offset of the floor of the platform at location "F". Refer to the Mast illustration.

  • Page 41: Inspect The Mast Wear Pads

    March 2022 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

    Section 3 • Scheduled Maintenance Procedures March 2022 Checklist C Procedure Models equipped with the platform overload option are provided with additional machine components: Calibrate the Platform Overload an adjustable spring-loaded subassembly, a limit System (if equipped) switch harness, an electronic module which receives the overload signal and interrupts power, and an audio/visual warning indication to alert the operator of the overload.

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

    March 2022 Section 3 • Scheduled Maintenance Procedures CHECKLIST C PROCEDURES 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

    Section 3 • Scheduled Maintenance Procedures March 2022 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

    March 2022 Section 3 • Scheduled Maintenance Procedures Checklist E Procedure 4 Place a suitable container under the hydraulic tank. Refer to Section 2, Specifications. Test or Replace the Hydraulic Oil 5 Locate and remove the hydraulic tank filler cap. Set the filler cap to the side.
  • Page 46 Section 3 • Scheduled Maintenance Procedures March 2022 This page intentionally left blank. 3 - 28 GR™-20J • GR™-26J Part No. 227656GT...
  • Page 47 March 2022 Section 4 • Repair Procedures Repair Procedures About This Section Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop. Select the appropriate repair procedure after troubleshooting the problem.

  • Page 48: Platform Controls

    Section 4 • Repair Procedures March 2022 Platform Controls The platform controls, used to operate the machine from the platform. The platform controls are used Circuit Boards to operate the various machine functions. The platform controls consist of an electronic How to Remove the Platform circuit board, joystick, alarm, buttons and LEDs.

  • Page 49: Controller Adjustments

    March 2022 Section 4 • Repair Procedures PLATFORM CONTROLS Controller Adjustments How to Activate or Deactivate the Motion Alarm The alarm is activated at the platform controls and sounds at the ground as a warning to ground personnel. An improperly functioning alarm will prevent the operator from alerting ground joystick function enable switch personnel of hazards or unsafe conditions.
  • Page 50 Section 4 • Repair Procedures March 2022 PLATFORM CONTROLS How to Activate or Deactivate the Flashing Beacon (if equipped) The Flashing Beacon is installed to alert operators and ground personnel of machine proximity and motion. The Flashing Beacon is installed on the ground control side of the mast.
  • Page 51 March 2022 Section 4 • Repair Procedures PLATFORM CONTROLS How to Calibrate the Joystick Calibration of the joystick is essential for safe machine operation. The joystick on this machine utilize Hall Effect technology for proportional control. If a joystick is disconnected or replaced, it must be calibrated before operating the machine.
  • Page 52 Section 4 • Repair Procedures March 2022 PLATFORM CONTROLS How to Calibrate the Steer Angle Sensor Calibration of the Steer Angle Sensor is essential for safe machine operation. The Steer Angle Sensor controls the maximum steering angle that can be attained. 1 Adjust the wheels at the steer end of the machine so they are in straight driving position.

  • Page 53: Platform Components

    March 2022 Section 4 • Repair Procedures Platform Components 7 Remove the fasteners securing the outlet mounting plate to the platform. Set the Platform mounting plate assembly and fasteners to the side. How to Remove the Platform 8 Attach a lifting strap of suitable capacity from an overhead crane to the bottom of the platform.

  • Page 54: Platform Overload System

    Section 4 • Repair Procedures March 2022 PLATFORM COMPONENTS Platform Overload System How to Calibrate the Platform Overload System (if equipped) Calibration of the platform overload system is essential to safe machine operation. Continued use of an improperly calibrated platform overload system could result in the system failing to sense an overloaded platform.
  • Page 55 March 2022 Section 4 • Repair Procedures PLATFORM COMPONENTS 8 Turn the adjusting screw of the number 1 11 Turn the key switch to the ground control. overload sensor 10° in a counterclockwise 12 Test all machine functions from the ground direction.

  • Page 56: Jib Components

    Section 4 • Repair Procedures March 2022 Jib Components Jib Cylinder How to Remove the Jib Cylinder Bodily injury hazard. This procedure requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant jib boom jib cylinder...

  • Page 57: Mast Components

    March 2022 Section 4 • Repair Procedures Mast Components 3 Turn the key switch to off position and push in the red Emergency Stop button to the off Mast Assembly position at both the ground and platform controls. How to Remove the Mast 4 Open and remove the turntable covers.
  • Page 58 Section 4 • Repair Procedures March 2022 MAST COMPONENTS 9 Attach a lifting strap of suitable capacity from an overhead crane to the mast head, jib boom and platform assembly. Support the assembly. Do not apply any lifting pressure. Component damage hazard. The platform railings can be damaged if they are used to lift the assembly.
  • Page 59 March 2022 Section 4 • Repair Procedures MAST COMPONENTS 15 Using an overhead crane, attach a lifting strap of suitable capacity equipped with the M16 shackles to the threaded rings at the top of the outer mast. 16 Lift the mast assembly approximately 12 inches / 30 cm.
  • Page 60 Section 4 • Repair Procedures March 2022 MAST COMPONENTS BOTTOM Illustration 1 number 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...
  • Page 61 March 2022 Section 4 • Repair Procedures MAST COMPONENTS How to Disassemble the Mast, BOTTOM GR-26J Bodily injury hazard. This procedure requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage.
  • Page 62 Section 4 • Repair Procedures March 2022 MAST COMPONENTS 8 Slide the number 2 mast and the number 3 14 Working from the bottom of the number 2 mast, mast towards the top of the number 1 mast to pull the number 3 mast half way out. gain the access to the stops at the bottom of 15 Attach a lifting strap from an overhead crane to the number 1 mast.
  • Page 63 March 2022 Section 4 • Repair Procedures MAST COMPONENTS 18 Using Illustration 1 as a guide, tag and remove 21 Using Illustration 1 as a guide, tag and remove the inner wear pads from the top of the number the outer wear pads and shims from the bottom 3 mast section.
  • Page 64 Section 4 • Repair Procedures March 2022 MAST COMPONENTS How to Assemble the Mast, 2 Install six 12 mm wear pads, and the corresponding shims removed in the mast GR-26J disassembly process, onto the bottom of mast sections 1, 2, 3 and 4. Bodily injury hazard.
  • Page 65 March 2022 Section 4 • Repair Procedures MAST COMPONENTS 6 Using Illustration 3 as a guide, apply grease onto the outer faces of the mast sections 1, 2, 3 and 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.
  • Page 66 Section 4 • Repair Procedures March 2022 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 •...
  • Page 67 March 2022 Section 4 • Repair Procedures MAST COMPONENTS How to Disassemble the Mast, BOTTOM GR-20J Bodily injury hazard. This procedure requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage.
  • Page 68 Section 4 • Repair Procedures March 2022 MAST COMPONENTS 8 Using Illustration 1 as a guide, tag and remove How to Assemble the Mast, the outer wear pads and shims from the bottom GR-20J of the number 2 mast section. Set the shims to the side.
  • Page 69 March 2022 Section 4 • Repair Procedures MAST COMPONENTS 2 Install six 12 mm wear pads, and the 6 Using Illustration 3 as a guide, apply grease corresponding shims removed in the mast onto the outer faces of the mast sections 1 and disassembly process, onto the bottom mast sections 1 and 2.

  • Page 70: Lift Cylinder

    Section 4 • Repair Procedures March 2022 MAST COMPONENTS Lift Cylinder How to Remove the Lift Cylinder Bodily injury hazard. This procedure requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage.
  • Page 71 March 2022 Section 4 • Repair Procedures MAST COMPONENTS 10 Tag, disconnect and plug the hydraulic hose at 13 Raise the mast head, jib boom and platform the top of the lift cylinder. Remove the hose assembly and move the assembly connector from the lift cylinder.

  • Page 72: Ground Controls

    Section 4 • Repair Procedures March 2022 Ground Controls 6 Securely install the level sensor pigtail into the machine wire harness, disconnected in step 3. Level Sensor 7 Remove the plastic cap from the end of the level sensor calibration wire. The tilt alarm sounds when the incline of the chassis exceeds 2°...

  • Page 73: Hydraulic Pump

    March 2022 Section 4 • Repair Procedures Hydraulic Pump How to Remove the Function Function Pump Pump Note: When removing a hose assembly or fitting, The hydraulic pump is attached to the motor which the O-ring on the fitting and/or hose end must be makes up the hydraulic power unit.
  • Page 74 Section 4 • Repair Procedures March 2022 HYDRAULIC PUMP 5 Tag, disconnect and plug the hydraulic hoses at the function manifold. Cap the fittings on the manifold. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually.
  • Page 75 March 2022 Section 4 • Repair Procedures This page intentionally left blank. Part No. 227656GT GR™-20J • GR™-26J 4 - 29...

  • Page 76: Function Manifold

    Section 4 • Repair Procedures March 2022 Function Manifold Function Manifold Components The function manifold is mounted underneath the hydraulic power unit. Index Schematic Description Item Function Torque Filter, Filter cap ............ H ......Suction filter ......37 ft-lbs / 50 Nm Solenoid valve, 2 position 4 way ....
  • Page 77 March 2022 Section 4 • Repair Procedures FUNCTION MANIFOLD Y117 Y116 Y118 Note: 'alpha' callouts refer Note: 'alpha' callouts refer to corresponding notes on to corresponding notes on the hydraulic schematic the hydraulic schematic Note: 'alpha-numeric' callouts Note: 'alpha-numeric' callouts refer to corresponding notes refer to corresponding notes on the electrical schematic...

  • Page 78: Valve Adjustments - Function Manifold

    Section 4 • Repair Procedures March 2022 FUNCTION MANIFOLD Valve Adjustments - Function Manifold How to Adjust the System Relief Valve Note: Be sure that the hydraulic oil level is at the mark on the hydraulic tank. FULL 1 Block the wheels at the steer end of the machine.
  • Page 79 March 2022 Section 4 • Repair Procedures FUNCTION MANIFOLD 10 Press and hold the jib function button to fully raise the jib boom, then continue to activate the jib lift function while observing the pressure reading on the pressure gauge. Note the pressure.
  • Page 80 Section 4 • Repair Procedures March 2022 FUNCTION MANIFOLD How to Adjust the Platform Lift Relief Valve Note: Be sure that the hydraulic oil level is at the mark on the hydraulic tank. FULL 1 Block the wheels at the steer end of the machine.

  • Page 81: Hydraulic Tank

    March 2022 Section 4 • Repair Procedures Hydraulic Tank 7 Place a suitable container under the hydraulic tank. Refer to Section 2, Specifications. Hydraulic Tank 8 Locate and remove the hydraulic tank filler cap. Set the filler cap to the side. The primary functions of the hydraulic tank are to cool and deaerate the hydraulic fluid during 9 Remove the drain plug and drain all of the oil...

  • Page 82: Turntable Components

    Section 4 • Repair Procedures March 2022 Turntable Components Turntable Rotation Motor How to Remove the Turntable Rotation Motor Note: When removing a hose assembly or fitting, the fitting and/or hose end must be torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications.
  • Page 83 March 2022 Section 4 • Repair Procedures TURNTABLE COMPONENTS 7 Tag, disconnect and plug the hydraulic hoses at the turntable rotation motor. Cap the fittings. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually.

  • Page 84: Battery

    Section 4 • Repair Procedures March 2022 TURNTABLE COMPONENTS Battery How to Remove the Battery Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Bodily injury hazard. Batteries contain acid.

  • Page 85: Battery Charger

    March 2022 Section 4 • Repair Procedures TURNTABLE COMPONENTS Battery Charger How to Remove the Battery Charger Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches power cable and other jewelry. charger cutout harness connector 1 Turn the key switch to off position and push in charger-to-battery wires...

  • Page 86: Steer Axle Components

    Section 4 • Repair Procedures March 2022 Steer Axle Components 10-1 9 Ground control side: Remove the steer sensor from the yoke pivot. Yoke 10 Remove the retaining fasteners from the yoke pivot shaft. Set the fasteners to the side. How to Remove the Yoke 11 Remove the yoke assembly from the machine.

  • Page 87: Steer Cylinder

    March 2022 Section 4 • Repair Procedures STEER AXLE COMPONENTS 10-2 6 Center a lifting jack under the drive chassis at the steer end of the machine. Steer Cylinder 7 Raise the machine approximately 6 inches / 15 cm. Place blocks under the How to Remove the Steer chassis for support.

  • Page 88: Steering Rod

    Section 4 • Repair Procedures March 2022 STEER AXLE COMPONENTS 10-3 10-4 Steering Rod Steer Angle Sensor How to Remove the Steering Rod How to Replace the Steer Angle Sensor 1 Remove the steer cylinder. See 10-2, How to Remove the Steer Cylinder. 1 Adjust the wheels at the steer end of the machine so they are in straight driving position.
  • Page 89 March 2022 Section 4 • Repair Procedures STEER AXLE COMPONENTS 8 Using the illustration as a guide, mount the 11 Install the bottom plate and it's fasteners on the potentiometer on to the plate and securely steer yoke pivot. tighten with the nut. 12 Install the sensor activator pin on to the steer yoke pivot.

  • Page 90: Non-Steer Axle Components

    Section 4 • Repair Procedures March 2022 Non-steer Axle Components 11-1 Drive Motors How to Remove the Drive Motors Bodily injury hazard. This procedure requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage.
  • Page 91 March 2022 Section 4 • Repair Procedures NON-STEER AXLE COMPONENTS 11 Tag and disconnect the cables from the drive 16 Place a 2 x 4 x 6 inch / 5 x 10 x 15 cm long motor assembly. wood block under the left drive motor. 12 Loosen the castle nut of the wheel at the Note: The wood block will support to the drive non-steer end of the machine.

  • Page 92: Drive Brake

    Section 4 • Repair Procedures March 2022 NON-STEER AXLE COMPONENTS 11-2 Drive Brake How to Remove the Drive Brake 1 Block the wheels at the steer end of the machine. 2 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls.

  • Page 93: Fault Codes

    March 2022 Section 5 • Fault Codes Fault Codes Before Troubleshooting: Read, understand and obey the safety rules and operating instructions in the appropriate operator's manual on your machine. Be sure that all necessary tools and test equipment are available and ready for use. Observe and Obey: Be aware of the following hazards and follow generally accepted safe workshop practices.
  • Page 94 Section 5 • Fault Codes March 2022 FAULT CODES About This Section LED Diagnostic Readout When a malfunction is discovered, the fault code The diagnostic readout displays numerical codes chart in this section will help a service professional that provide the information about the machine pinpoint the cause of the problem.

  • Page 95: Fault Code Chart

    March 2022 Section 5 • Fault Codes Fault Code Chart Error Source Error Type Condition Solution Name Name This alarm may appear from Controller time to time upon starting. Any interface initialization delay can cause board The base board is waiting this alarm to appear.
  • Page 96 Section 5 • Fault Codes March 2022 FAULT CODE CHART Error Source Error Type Condition Solution Name Name The controller has not Controller Serial error responded to the request interface Replace the controller. from the base board as board expected. If the fault occurs on starting or during an alarm, the fault is most likely to be linked to an...
  • Page 97 March 2022 Section 5 • Fault Codes FAULT CODE CHART Error Source Error Type Condition Solution Name Name The electric brake is short- Controller Multi circuited. Check the conformity of the interface selection Several movements control selectors. board activated simultaneously. The controller receives several commands Plat.
  • Page 98 Section 5 • Fault Codes March 2022 FAULT CODE CHART Error Source Error Type Condition Solution Name Name Joystick is pushed when Controller Joystick Repair or replace the joystick. machine is switching on. interface It should be possible to stop the board alarm by stopping the main Short-circuit...
  • Page 99 March 2022 Section 5 • Fault Codes FAULT CODE CHART Error Source Error Type Condition Solution Name Name There is a problem on one Check the condition of the Controller or other of the following valves and their connections. interface Descent valve outputs: terminal A30, Otherwise, it is an internal fault...
  • Page 100 Section 5 • Fault Codes March 2022 FAULT CODE CHART Error Source Error Type Condition Solution Name Name The controller and the Controller base board are not logic It is an internal fault. Type disparity suitable for the type of board Replace the controller.
  • Page 101 March 2022 Section 5 • Fault Codes FAULT CODE CHART Error Source Error Type Condition Solution Name Name The current sensor of the Controller Stand by pump detects a current It is an internal fault. logic pump other than zero when the Replace the controller.
  • Page 102 Section 5 • Fault Codes March 2022 FAULT CODE CHART Error Source Error Type Condition Solution Name Name This alarm appears only on Controller start-up. Check: internal motor logic The VMN voltage of one connections. Electric cable board of the motors is high when VMN high connections, leakage from the it should be low.
  • Page 103 March 2022 Section 5 • Fault Codes FAULT CODE CHART Error Source Error Type Condition Solution Name Name This alarm only appears when Controller the drive motors are activated. logic The VMN voltage of the Check: internal motor board left motor is low when it connections.
  • Page 104 Section 5 • Fault Codes March 2022 FAULT CODE CHART Error Source Error Type Condition Solution Name Name The drive output of the Controller It is an internal fault. Drive shorted base board is short- logic Replace the controller. circuited. board The base board and the controller have performed a...
  • Page 105 March 2022 Section 5 • Fault Codes FAULT CODE CHART Error Source Error Type Condition Solution Name Name The pump inputs of the Controller It is an internal fault. Pump shorted base board are short- logic Replace the controller. circuited. board Check the BUSCAN connection between the...
  • Page 106 Section 5 • Fault Codes March 2022 FAULT CODE CHART Error Source Error Type Condition Solution Name Name Platform Internal system surveillance has been put controls into operation. If the circuit System It is an internal fault. surveillance detects a surveillance Replace the controller.
  • Page 107 March 2022 Section 6 • Schematics Schematics About This Section There are two groups of schematics in this section. An illustration legend precedes each group of drawings. Electrical Schematics Observe and Obey: Electrocution/burn hazard. Contact with electrically charged circuits Troubleshooting and repair procedures shall be could result in death or serious completed by a person trained and qualified on injury.
  • Page 108 March 2022 Section 6 • Schematics Electrical Schematic Abbreviation and Wire Color Legends ELECTRICAL COMPONENT LEGEND Item Description Battery Button BN5 = Horn BN8 = Drive enable BN9 = Lift enable/select BN57 = Turntable rotate enable BN63 = Mast enable BN97 = Jib enable BN128 = Descend/Rotate left enable BN129 = Lift/Rotate right enable...

  • Page 109: Ecm Pin-Out Legend

    March 2022 Section 6 • Schematics ECM Pin-out Legend Part No. 227656GT GR™-20J • GR™-26J 6 - 3...

  • Page 110: Limit Switch And Sensor Legend

    March 2022 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. 227656GT...

  • Page 111: Electrical Symbols Legend

    March 2022 Section 6 • Schematics Electrical Symbols Legend Circuits Crossing Switch or Button (no connection) Level Sensor Motor Diode Toggle Switch 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...
  • Page 112 March 2022 Section 6 • Schematics Electrical Schematic - GR-26J ANSI - Part 1 of 2 BR-1 BL-4 GR/YL-2 RD-3 GR/YL BN57 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 BL-13 OR-14 BL-10 RD-11 RD-12...
  • Page 113 March 2022 Section 6 • Schematics Electrical Schematic - GR-26J ANSI - 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 RD-5 BK-23 RD-4 BK-22 WH-1...
  • Page 114 March 2022 Section 6 • Schematics Electrical Schematic - GR-20J and GR-26J CE - Part 1 of 2 BR-1 BL-4 GR/YL-2 RD-3 GR/YL BN57 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 BL-13 OR-14 BL-10...
  • Page 115 March 2022 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 RD-5 BK-23 RD-4...
  • Page 116 March 2022 Section 6 • Schematics Hydraulic Component Reference and Symbols Legend Auxiliary pump Variable speed motor Fixed displacement pump Check valve Hydraulic cylinder Filter Relief valve Bi-directional motor Solenoid operated Solenoid operated Solenoid operated Solenoid operated 2 position 2 way 2 position 2 way 2 position 2 way 2 position 4 way...
  • Page 117 March 2022 Section 6 • Schematics Hydraulic Schematic (GR26-J ONLY) TURNTABLE ROTATE Y119 HOSE Y101 Y102 REEL JIB MANIFOLD Y121 JIB CYLINDER STEER CYLINDER 1450 psi 1450 psi 100 bar 100 bar LIFT CYLINDER Y117 Y118 Y116 B10 = 100 930 psi 64 bar 2030 psi...
  • Page 118 March 2022 Section 6 • Schematics This page intentionally left blank. 6 - 12 GR ™-20J • GR™-26J Part No. 227656GT...

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