Terex Genie GR-20J Bedienungsanleitung

Service Manual

Serial Number Range

GR™-20J

from GRJL-2298

GR™-26J

Original

Instructions

Part No. 1312899GT

Rev A

March 2022

Service Manual March 2022

Introduction

ii GR™-20J • GR™-26J Part No. 1312899GT

Intro ductio n Intro ductio n

Importan t Inf or matio n

Important

Read, understand and obey the safety rules and

operating instructions in the appropriate Operator's

Manual on your machine before attempting any

maintenance procedure.

This manual provides detailed scheduled

maintenance information for the machine owner

and user. It also provides troubleshooting and

repair procedures for qualified service

professionals.

Basic mechanical, hydraulic and electrical skills

are required to perform most procedures.

However, several procedures require specialized

skills, tools, lifting equipment and a suitable

workshop. In these instances, we strongly

recommend that maintenance and repair be

performed at an authorized Genie dealer service

center.

Compliance

Machine Classification

Group B/Type 3 as defined by ISO 16368

Machine Design Life

Unrestricted with proper operation, inspection and

scheduled 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. All

communications will be carefully considered for

future printings of this and all other manuals.

Internet: www.genielift.com

E-mail: awp.techpub@terex.com

1312899GT Rev A, March 2022

Second Edition, First Printing

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.

March 2022 Service Manual

Introduction

Part No. 1312899GT GR™-20J • GR™-26J iii

RevisionHistory

Revision History

Revision Date Section Procedure / Page / Description

A 3/2022

Initial Release

Reference Examples:

Section – Maintenance, B-3

Electronic Version

Click on any content or procedure in the Table of Contents to view

the update.

Section – Repair Procedure, 4-2

Section – Fault Codes, All charts

Section – Schematics, Legends and schematics

Service Manual March 2022

Introduction

iv GR™-20J • GR™-26J Part No. 1312899GT

Serial Number Legend

1 Model

2 Facility code

3 Sequence number

4 Serial label

5 Serial number (stamped on chassis)

March 2022 Service Manual

Safety Rules

Part No. 1312899GT GR™-20J • GR™-26J v

Sec ti on 1 Safety Rul es

Gene ral Saf ety Rul es

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.

Do not modify or alter a MEWP without prior

written permission from the manufacturer.

Do Not Perform Maintenance

Unless:

You are trained and qualified to perform

maintenance 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, lifting

equipment and a suitable workshop.

Service Manual March 2022

Safety Rules

vi GR™-20J • GR™-26J Part No. 1312899GT

Personal Safety

Any person working on or around a machine

must be aware of all known safety hazards.

Personal safety and the continued safe

operation of the machine should be your top

priority.

Read each procedure thoroughly. This

manual and the decals on the

machine, use signal

words to identify

the following:

Safety alert symbol

—used to

alert personnel to potential

personal injury hazards. Obey

all safety messages that follow

this symbol to avoid possible

injury or death.

Indicates a imminently

hazardous situation

which, if

not avoided, will result in death

or serious injury.

Indicates a potentially

hazardous situation which, if

not avoided, could result in

death or serious injury.

Indicates a potentially

hazardous situation which, if

not avoided, may cause mi

nor

or moderate injury.

Indicates a potentially

hazardous situation which, if

not avoided, may result in

property damage.

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.

Workplace Safety

Any person working on or around a machine

must be aware of all known safety hazards.

Personal safety and the continued safe

operation of the machine should be your top

priority.

Be sure to keep sparks, flames and

lighted tobacco away from flammable

and combustible materials like battery

gases and engine fuels. Always have

an approved fire extinguisher within

easy reach.

Be sure that all tools and working

areas are properly maintained and

ready for use. Keep work surfaces

clean and free of debris that could get

into machine components and cause

damage.

Be sure any forklift, overhead crane or

other lifting or supporting device is

fully capable of supporting and

stabilizing the weight to be lifted. Use

only chains or straps that are in good

condition and of ample capacity.

Be sure that fasteners intended for

one time

use (i.e., cotter pins and self

locking nuts) are not reused. These

components may fail if they are used

a second time.

Be sure to properly dispose of old oil

or other fluids. Use an approved

container. Please be environmentally

safe.

Be sure

that your workshop or work

area is properly ventilated and well lit.

March 2022

Table of Contents

Part No. 1312899GT GR™-20J • GR™-26J vii

Introduction Introduction ......................................................................................................ii

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

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

Serial Number Legend....................................................................................... iv

Section 1 Safety Rules......................................................................................................v

General Safety Rules .........................................................................................v

Section 2 Specifications...................................................................................................1

Machine Specifications .......................................................................................1

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

Hydraulic Component and Manifold Specifications..............................................3

Manifold Component Specifications ....................................................................3

Hydraulic Oil Specifications ................................................................................4

Hydraulic Hose and Fitting Torque Specifications ...............................................5

Torque Procedure ..............................................................................................6

SAE and Metric Fasteners Torque Charts...........................................................8

March 2022

Table of Contents

viii GR™-20J • GR™-26J Part No. 1312899GT

Section 3 Scheduled Maintenance Procedures .............................................................. 9

Introduction........................................................................................................ 9

Pre-Delivery Preparation Report....................................................................... 12

Maintenance Inspection Report ........................................................................ 14

Checklist A Procedures ................................................................................. 15

A-1 Perform 30 Day Service............................................................................. 15

A-2 Replace the Hydraulic Suction Strainer ...................................................... 15

Checklist B Procedures ................................................................................. 17

B-1 Inspect the Batteries .................................................................................. 17

B-2 Inspect the Electrical Wiring....................................................................... 19

B-3 Inspect the Tires and Wheels..................................................................... 20

B-4 Test the Drive Brakes ................................................................................ 21

B-5 Test the Drive Speed – Stowed Position .................................................... 22

B-6 Test the Drive Speed – Raised Position ..................................................... 23

B-7 Test the Flashing Beacon (if equipped) ...................................................... 24

B-8 Test the Motion Alarm................................................................................ 24

B-9 Visual Inspection of the Hydraulic Oil ......................................................... 25

B-10 Inspect the Breather Cap ......................................................................... 26

B-11 Inspect the Rear Axle Free-wheel ............................................................ 27

B-12 Inspect the Lateral Offset of the Mast....................................................... 28

B-13 Inspect the Mast Wear Pads .................................................................... 29

Checklist C Procedures ................................................................................. 30

C-1 Calibrate the Platform Overload System .................................................... 30

C-2 Repalce the Hydraulic Tank Breather Cap –

Models with Optional Hydraulic Oil............................................................ 31

Checklist E Procedures ................................................................................. 32

E-1 Test or Replace the Hydraulic Oil............................................................... 32

March 2022

Table of Contents

Part No. 1312899GT GR™-20J • GR™-26J ix

Section 4 Repair Procedures..........................................................................................33

Introduction ......................................................................................................33

Platform Controls ...........................................................................................35

1-1 Circuit Boards.............................................................................................35

1-2 Controller Adjustments ...............................................................................35

How to Activate or Deactivate the Motion Alarm...........................................36

How to Activate or Deactivate the Flashing Beacon (if equipped) .................37

How to Calibrate the Joystick.......................................................................38

How to Calibrate the Steer Angle Sensor.....................................................39

Platform Components ....................................................................................41

2-1 Platform......................................................................................................41

2-2 Platform Overload System ..........................................................................42

Jib Components .............................................................................................44

3-1 Jib Cylinder ................................................................................................44

Mast Components ..........................................................................................46

4-1 Mast Assembly...........................................................................................46

How to Remove the Mast Assembly ............................................................46

How to Disassemble the Mast, GR-26J........................................................50

How to Assemble the Mast, GR-26J ............................................................53

How to Disassemble the Mast, GR-20J........................................................56

How to Assemble the Mast, GR-20J ............................................................57

4-2 Lift Cylinder ................................................................................................59

Ground Controls.............................................................................................61

5-1 Level Sensor ..............................................................................................61

Hydraulic Pump ..............................................................................................62

6-1 Hydraulic Pump ..........................................................................................62

March 2022

Table of Contents

x GR™-20J • GR™-26J Part No. 1312899GT

Function Manifold .......................................................................................... 64

7-1 Function Manifold Components.................................................................. 64

7-2 Valve Adjustments – Function Manifold ...................................................... 66

Hydraulic Tank ............................................................................................... 68

8-1 Hydraulic Tank........................................................................................... 68

Turntable Components.................................................................................. 69

9-1 Turntable Rotation Hydraulic Motor ............................................................ 69

9-2 Battery ....................................................................................................... 70

Steer Axle Components................................................................................. 71

10-1 Yoke ........................................................................................................ 71

10-2 Steer Cylinder .......................................................................................... 71

10-3 Steering Rod............................................................................................ 72

10-4 Steer Angle Sensor.................................................................................. 73

Non-Steer Axle Components......................................................................... 75

11-1 Drive Motors ............................................................................................ 75

11-2 Drive Brake.............................................................................................. 77

Battery Charger.............................................................................................. 78

12-1 Battery Charger........................................................................................ 78

Battery Charger Staus Indicator ....................................................................... 79

Battery Charger not Operating.......................................................................... 79

How to Reset the Battery Charger .................................................................... 80

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