Terex Genie GR-20J Operator's Manual
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Terex Genie GR-20J Operator's Manual

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Operator's Manual
GR
-20J
™
GR
-26J
™
Serial Number Range
CE
with
Maintenance
Information
Original Instructions
Third Edition
First Printing
Part No. 1319686GT

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Summary of Contents for Terex Genie GR-20J

  • Page 1 Operator's Manual Serial Number Range -20J ™ -26J ™ with Maintenance Information Original Instructions Third Edition First Printing Part No. 1319686GT...

  • Page 2: Table Of Contents

    NG31 6BH Copyright © 2010 Terex Corporation Third Edition: First Printing, April 2023 Genie is a registered trademark of Terex South Dakota, Inc. in the U.S.A. and many other countries. “GR” is a trademark of Terex South Dakota, Inc. Complies with EC Directive 2006/42/EC...

  • Page 3: Introduction

    Third Edition • First Printing Operator's Manual Introduction Introduction About this manual Intended Use and Familiarization Guide Genie appreciates your choice of our machine for your application. Our number one priority is user The intended use of this machine is to lift safety, which is best achieved by our joint efforts.
  • Page 4 Operator's Manual Third Edition • First Printing Introduction Platform controls symbology and related Mast up/down machine movement: Jib boom function button Mast down, Jib boom down Mast function and turntable rotate function button Mast Up, Jib boom Up Function switch for drive and boom functions Key switch Proportional control handle for...
  • Page 5 Third Edition • First Printing Operator's Manual Introduction Bulletin Distribution and Contacting the Manufacturer Compliance At times it may be necessary to contact Genie. When you do, be ready to supply the model Safety of product users is of paramount number and serial number of your machine, along importance to Genie.
  • Page 6 Operator's Manual Third Edition • First Printing Introduction Safety Sign Maintenance Replace any missing or damaged safety signs. Keep operator safety in mind at all times. Use mild soap and water to clean safety signs. Do not use solvent-based cleaners because they may damage the safety sign material.

  • Page 7: Symbol And Hazard Pictorials Definitions

    Third Edition • First Printing Operator's Manual Symbol and Hazard Pictorials Definitions Symbol and Hazard Pictorials Definitions Crush hazard Electrocution hazard Fire hazard Explosion hazard Burn hazard Fall hazard Batteries used as No Open Flames Tip-over hazard No smoking counterweights Voltage rating for Electrocution hazard Maintain required...
  • Page 8 Operator's Manual Third Edition • First Printing Symbol and Hazard Pictorials Definitions Crush hazard Keep away from Collision hazard Do not stand under Tip-over hazard elevated components raised platform while servicing machine 1 When tilt alarm Grounded AC 3-wire Replace damaged Lanyard anchorage Wheel load sounds.

  • Page 9: General Safety

    Third Edition • First Printing Operator's Manual General Safety General Safety ™ ™ Part No. 1319686GT -20J • GR -26J...
  • Page 10 Operator's Manual Third Edition • First Printing General Safety ™ ™ -20J • GR -26J Part No. 1319686GT...
  • Page 11 Third Edition • First Printing Operator's Manual General Safety ™ ™ Part No. 1319686GT -20J • GR -26J...

  • Page 12: Personal Safety

    Operator's Manual Third Edition • First Printing Personal Safety Personal Safety Personal Fall Protection Personal fall protection equipment (PFPE) is required when operating this machine. Occupants must wear a safety belt or harness in accordance with governmental regulations. Attach the lanyard to the anchor provided in the platform. Operators must comply with employer, job site and governmental rules regarding the use of personal protective equipment.

  • Page 13: Work Area Safety

    Third Edition • First Printing Operator's Manual Work Area Safety Work Area Safety Electrocution Hazards Tip-over Hazards Occupants, equipment and materials shall not This machine is not exceed the maximum platform capacity. electrically insulated and will not provide protection Maximum platform capacity 200 kg from contact with or proximity to electrical...
  • Page 14 Operator's Manual Third Edition • First Printing Work Area Safety When raising the platform, follow ratings for Do not push off or pull allowable manual force and number of occupants toward any object outside below. of the platform. Do not operate the machine in strong or gusty winds.
  • Page 15 Third Edition • First Printing Operator's Manual Work Area Safety Do not place or attach fixed Do not use batteries that weigh less than the or overhanging loads to any original equipment. Batteries are used as part of this machine. counterweight and are critical to machine stability.
  • Page 16 Operator's Manual Third Edition • First Printing Work Area Safety Fall Hazards Collision Hazards Occupants must wear a Be aware of limited sight safety belt or harness in distance and blind spots accordance with when driving or operating. governmental regulations. Attach the lanyard to the anchor provided in the platform.
  • Page 17 Third Edition • First Printing Operator's Manual Work Area Safety Bodily Injury Hazard Do not lower the platform unless the area below is Do not operate the machine with a hydraulic oil or clear of personnel and air leak. An air leak or hydraulic leak can penetrate obstructions.
  • Page 18 Operator's Manual Third Edition • First Printing Work Area Safety Battery Safety Electrocution/Burn Hazards Connect the battery charger to a Burn Hazards grounded, AC 3-wire electrical outlet only. Batteries contain acid. Always wear protective Inspect daily for damaged cords, clothing and eye wear when cables and wires.
  • Page 19 Third Edition • First Printing Operator's Manual Work Area Safety Lockout After Each Use Select a safe parking location—firm level surface, clear of obstruction and traffic. Lower the Jib boom and the mast to the stowed position. Rotate the turntable so that the platform is between the non-steer wheels.

  • Page 20: Legend

    Operator's Manual Third Edition • First Printing Legend Legend Steer tire Platform Auxiliary lowering controls (also under cover on 10 Sliding mid-rail opposite side) 11 Lanyard anchorage points Ground controls 12 Manual storage container Batteries (under cover) 13 Red Emergency Stop button Mast 14 Power to charger Jib boom...

  • Page 21: Controls

    Third Edition • First Printing Operator's Manual Controls Controls The ground control station is to be used as a means to raise the platform for function tests and for storage purposes. The ground control station can be used in the event of an emergency to rescue an incapacitated person in the platform.
  • Page 22 Operator's Manual Third Edition • First Printing Controls Jib boom function button with indicator light Drive enable button Push the jib boom function button to select the To drive when the drive enable light is on, jib boom function. The indicator light will be on. push the drive enable button and the drive button and slowly move the drive control Mast function and turntable rotate function...
  • Page 23 Third Edition • First Printing Operator's Manual Controls Ground Control Panel Mast up/down button Key switch for platform/off/ground selection Turntable rotate left/right button Jib boom up/down button Machine not level indicator light Function enable button for mast up, jib boom up and turntable rotate left functions Platform overload indicator light Function enable button for mast down, jib boom...
  • Page 24 Operator's Manual Third Edition • First Printing Controls Mast up/down button Key switch for platform/off/ground selection Push and hold the mast up/down button to Turn the key switch to the platform position select the mast up/down function. and the platform controls will operate. Turn the key switch to the off position and the machine Turntable rotate left/right button will be off.

  • Page 25: Inspections

    Third Edition • First Printing Operator's Manual Inspections Inspections Pre-operation Inspection Fundamentals It is the responsibility of the operator to perform a pre-operation inspection and routine maintenance. The pre-operation inspection is a visual inspection performed by the operator prior to each work shift. Do Not Operate Unless: The inspection is designed to discover if anything is apparently wrong with a machine before the...
  • Page 26 Operator's Manual Third Edition • First Printing Inspections Pre-operation Inspection Check entire machine for: ❑ Cracks in welds or structural components ❑ Be sure that the operator’s manual is ❑ Dents or damage to machine complete, legible and in the storage container located in the platform.
  • Page 27 Third Edition • First Printing Operator's Manual Inspections Function Test Fundamentals The function tests are designed to discover any malfunctions before the machine is put into service. The operator must follow the step-by-step instructions to test all machine functions. A malfunctioning machine must never be used. If Do Not Operate Unless: malfunctions are discovered, the machine must be tagged and removed from service.
  • Page 28 Operator's Manual Third Edition • First Printing Inspections At the Ground Controls Press and hold the function enable button for mast down, jib boom down and turntable Select a test area that is firm, level and free of rotate right. Press and hold the button for the hazards.
  • Page 29 Third Edition • First Printing Operator's Manual Inspections At the Platform Controls Test Machine Functions and Descent Alarm 15 Turn the key switch to platform control. 23 Push the jib boom function button. 16 Twist the red Emergency Stop button to the on Result: The indicator light above the function position.
  • Page 30 Operator's Manual Third Edition • First Printing Inspections Test Drive and Braking 32 Move the control handle in the direction indicated by the yellow arrow. 41 Press the drive function button. Result: The mast should lower. The descent Result: The indicator light above the function alarm should sound when the mast is button should be on.
  • Page 31 Third Edition • First Printing Operator's Manual Inspections Test the Drive Enable System Test Limited Drive Speed 45 Push the mast function and turntable rotate 53 Push the mast function and turntable rotate function button. function button. 46 Press and hold the function enable switch on 54 Press and hold the function enable switch on the control handle.
  • Page 32 Operator's Manual Third Edition • First Printing Inspections Test Auxiliary Functions To Rotate the Turntable 69 Open the turntable cover opposite the ground To Lower the Mast controls. 62 Open the turntable cover opposite the ground 70 Locate the valve on the function manifold, controls.
  • Page 33 Third Edition • First Printing Operator's Manual Inspections To Lower the Jib Boom To Steer 77 Lower the mast using the Auxiliary Lowering 85 Open the turntable cover opposite the ground procedure To Lower the Mast. controls. 78 Locate the valve on 86 Locate the steer valve on the jib boom.
  • Page 34 Operator's Manual Third Edition • First Printing Inspections Workplace Inspection Checklist Be aware of and avoid the following hazardous situations: ❑ drop-offs or holes ❑ bumps, floor obstructions, or debris ❑ sloped surfaces Do Not Operate Unless: ❑ unstable or slippery surfaces ...
  • Page 35 Third Edition • First Printing Operator's Manual Inspections Decals Inspection Part No. Decal Description 37053 Arrow – Blue Determine whether the decals on your machine T110017 Label - Emergency Lowering have words or symbols. Use the appropriate inspection to verify that all decals are legible and T110018 Label - Brake Release Safety &...
  • Page 36 Operator's Manual Third Edition • First Printing Inspections 114334 82614 1281175 1281175 T110009 T110015 1296017 T110018 82487 133015 1 1 33015 T110017 T108702 97899 82666 82666 82666 97899 1272242 82666 43658 T110014 T110014 T110014 1263542 T110014 T108701 37056 37054 37053 37055 37055 52475...

  • Page 37: Operating Instructions

    Third Edition • First Printing Operator's Manual Operating Instructions Operating Instructions Fundamentals The Operating Instructions section provides instructions for each aspect of machine operation. It is the operator’s responsibility to follow all the safety rules and instructions in the operator’s manual.
  • Page 38 Operator's Manual Third Edition • First Printing Operating Instructions Emergency Stop To Rotate the Turntable Open the turntable cover opposite the ground Push in the red Emergency Stop button to the off controls. position at the ground controls or the platform controls to stop all functions.
  • Page 39 Third Edition • First Printing Operator's Manual Operating Instructions To Lower the Jib Boom To Steer Lower the mast using the Auxiliary Lowering Open the turntable cover opposite the ground procedure To Lower the Mast. controls. Locate the steer valve on the function Locate the valve on manifold.
  • Page 40 Operator's Manual Third Edition • First Printing Operating Instructions Operation from Ground Operation from Platform Turn the key switch to ground control. Turn the key switch to platform control. Pull out the red Emergency Stop button to the Pull out the red Emergency Stop button at the on position.
  • Page 41 Third Edition • First Printing Operator's Manual Operating Instructions To Drive Drive Enable Press the drive function select button. The Light on indicates indicator light next to the drive function will be that the boom has moved just past either nonsteer If the control handle is not moved within 5 seconds wheel and drive of selecting a function, the function will not...
  • Page 42 Operator's Manual Third Edition • First Printing Operating Instructions To determine the slope grade: Driving on a slope Measure the slope with a digital inclinometer OR Determine the slope and side slope ratings for the use the following procedure. machine and determine the slope grade. You will need: Platform downhill 25% (14°)
  • Page 43 Third Edition • First Printing Operator's Manual Operating Instructions Tilt Sensor Activation Settings Machine Not Level Indicator Light Model Chassis Angle Chassis Angle (front Light flashing indicates the (side to side) to back) machine is not level. The tilt alarm will be sounding when this light is GRJ 26 1.5°...
  • Page 44 Operator's Manual Third Edition • First Printing Operating Instructions To Charge Battery Open the Turntable covers. The covers should remain open for the entire charging cycle. Push in the red Emergency Stop button on the turntable. Remove the battery vent caps and check the Battery and Charger Instructions battery electrolyte level.
  • Page 45 Third Edition • First Printing Operator's Manual Operating Instructions Dry Battery Filling and Charging Instructions Open the Turntable covers. The covers should remain open for the entire charging cycle. Remove the battery vent caps and permanently remove the plastic seal from the battery vent openings.

  • Page 46: Transport And Lifting Instructions

    Operator's Manual Third Edition • First Printing Transport and Lifting Instructions Transport and Lifting Instructions  The machine must be on a level surface or secured before releasing the brakes.  Do not drive the machine on a slope that exceeds the uphill, downhill or side slope rating.
  • Page 47 Third Edition • First Printing Operator's Manual Transport and Lifting Instructions Securing to Truck or Trailer for Tie down the machine by the mast Transit Turn the key switch to the off position and remove the key before transporting. Inspect the entire machine for loose or unsecured items.
  • Page 48 Operator's Manual Third Edition • First Printing Transport and Lifting Instructions Lifting Instructions Fully lower the mast and jib boom. Remove all loose items on the machine. Attach the rigging only to the designated lifting points on the machine. There are two lifting points on the top of the mast.
  • Page 49 Third Edition • First Printing Operator's Manual Transport and Lifting Instructions Lifting Instructions with Forklift Forks C maximum 6.3 in (0.16 m) Fully lower the mast and jib boom. Remove all loose items on the machine. D maximum 2.35 in (0.06 m) E minimum 45.3 in (1.15 m) Position the forklift forks in position with the forklift...

  • Page 50: Maintenance

    Operator's Manual Third Edition • First Printing Maintenance Maintenance Check the Batteries Proper battery condition is essential to good machine performance and operational safety. Improper fluid levels or damaged cables and Observe and Obey: connections can result in component damage and ...
  • Page 51 Third Edition • First Printing Operator's Manual Maintenance Check the Hydraulic Oil Level Scheduled Maintenance Maintenance performed quarterly, annually and every two years must be completed by a person trained and qualified to perform maintenance on Maintaining the hydraulic oil at the proper level is this machine according to the procedures found in essential to machine operation.

  • Page 52: Specifications

    Operator's Manual Third Edition • First Printing Specifications Specifications Model GR-20J Platform dimensions (length x 75 cm x 90 cm width) Height, working maximum 7.7 m Platform leveling self-leveling Height, platform maximum 5.7 m Turntable rotation 350° Height, stowed maximum 1.99 m Controls 24V DC proportional...
  • Page 53 Third Edition • First Printing Operator's Manual Specifications Model GR-26J Platform dimensions (length x 75 cm x 90 cm width) Height, working maximum 9.9 m Platform leveling self-leveling Height, platform maximum 7.9 m Turntable rotation 350° Height, stowed maximum 1.99 m Controls 24V DC proportional Horizontal reach, maximum...
  • Page 54 Operator's Manual Third Edition • First Printing Specifications Contents of EC Declaration of Conformity - 1 <Manufacturer’s name> hereby declares that the machinery described below complies with the provisions of the following Directives: 1. EC Directive 2006/42/EC, Machinery Directive, under consideration of harmonized European standard EN280 as described in EC type-examination certificate <variable field>...
  • Page 55 Third Edition • First Printing Operator's Manual Specifications Contents of EC Declaration of Conformity - 2 <Manufacturer’s name> hereby declares that the machinery described below complies with the provisions of the following Directives: 1. EC Directive 2006/42/EC, Machinery Directive, Conformity assessment procedure: art.12 (3) (a), with the application of European Harmonized Standard EN 280:2013+A1:2015.
  • Page 56 Operator's Manual Third Edition • First Printing Specifications Contents of UK Declaration of Conformity - 1 <Manufacturer’s name> hereby declares that the machinery described below complies with the provisions of the following Legislation: 1. Supply of Machinery (Safety) Regulations 2008 (SI 2008/1597) as amended (SI 2011/1043, SI 2011/2157, SI 2019/696) under consideration of designated standard EN280 as described in type- examination certificate <variable field>...
  • Page 57 Third Edition • First Printing Operator's Manual Specifications Contents of UK Declaration of Conformity - 2 <Manufacturer’s name> hereby declares that the machinery described below complies with the provisions of the following Legislation: 1. Supply of Machinery (Safety) Regulations 2008 (SI 2008/1597) as amended (SI 2011/1043, SI 2011/2157, SI 2019/696) conformity assessment procedure according to Part 3, 11.

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