Genie GR-20J Manuale utente

Serial Number Range

Service Manual

Serial Number Range

Part No. 227656

Rev D1

September 2016

GR-20J

GR-26J

from GRJ10-101

to GRJ16-1151

from GRJ16L-1152

to GRJ16L-1999

from GRJL-2000

September 2016

GR-20J • GR-26J Part No. 227656

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.

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.

www.genielift.com

e-mail: [email protected]

227656 Rev D December 2013

First Edition, Fourth Printing

"Genie" is a registered trademark of Terex South

Dakota in the U.S.A. and many other countries.

Printed on recycled paper

Printed in U.S.A.

Introduction

September 2016

Part No. 227656 GR-20J • GR-26J

Revision History

Revision Date Section Procedure / Schematic Page / Description

A 4/2011 New release

B 6/2011 4 - Repair 2-2

B1 9/2011 3 - Maint. B-15

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

3 - Maint. A-4, C-1

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

D 11/2012 4 - Repair 1-2

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

D1 9/2016 Cover Add serial ranges

Introduction Serial Number Ledgend

REFERENCE EXAMPLES:

Section 3_Maintenance, B-3.

Section 4_Repair Procedure, 4-2.

Section 5_Diagnostic Codes, All charts.

Section 6_Schematics, Legends diagrams and

schematics.

Electronic Version

Click on any procedure or page number

highlighted in blue to view the update.

iii

September 2016

GR-20J • GR-26J Part No. 227656

Revision Date Section Procedure / Schematic Page / Description

REFERENCE EXAMPLES:

Section 3_Maintenance, B-3.

Section 4_Repair Procedure, 4-2.

Section 5_Diagnostic Codes, All charts.

Section 6_Schematics, Legends diagrams and

schematics.

Electronic Version

Click on any procedure or page number

highlighted in blue to view the update.

REVISION HISTORY, CONTINUED

September 2016

Part No. 227656 GR-20J • GR-26J

INTRODUCTION

Serial Number Legend

Model:

Serial number:

Electrical schematic number:

Year of manufacture:

Machine unladen weight:

GRJL-1234

2016

GRJ L - 1234

Maximum allowable inclination of the chassis:

Gradeability:

Rated work load (including occupants):

Model:

Serial number:

Model year:

Electrical schematic number:

Manufacture date:

Machine unladen weight:

Maximum allowable inclination of the chassis:

GRJ16L-1234

1/2/16 2016

Gradeability:

Rated work load (including occupants):

GRJ 16 L - 1234

234

To August 31, 2016

1 Model

2 Model year

3 Facility code

4 Sequence number

5 Serial label

6 Serial number (stamped on chassis)

From September 1, 2016

1 Model

2 Facility code

3 Sequence number

4 Serial label

5 Serial number (stamped on chassis)

September 2016

GR-20J • GR-26J Part No. 227656

Section 1 • 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.

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.

Safety Rules

September 2016

Part No. 227656 GR-20J • GR-26J

Workplace Safety

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.

SAFETY RULES

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 an 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 minor 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.

vii

Section 1 • Safety Rules

September 2016

GR-20J • GR-26J Part No. 227656

viii

Table of Contents

Introduction

Important Information .........................................................................................

Revision History ................................................................................................

iii

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

Section 1 Safety Rules

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

Section 2 Specifications

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

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

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

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

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

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

Section 3 Scheduled Maintenance Procedures

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

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

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

Checklist A Procedures

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

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

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

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

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

September 2016

Part No. 227656 GR-20J • GR-26J

TABLE OF CONTENTS

Section 3 Scheduled Maintenance Procedures, continued

Checklist B Procedures

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Checklist C Procedures

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

C-2 Replace the Hydraulic Tank Breather Cap -

Models with Optional Hydraulic Oil ................................................... 3 - 25

Checklist D Procedures

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

Checklist E Procedure

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

September 2016

GR-20J • GR-26J Part No. 227656

TABLE OF CONTENTS

Section 4 Repair Procedures

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

Platform Controls

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

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

Platform Components

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

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

Jib Components

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

Mast Components

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

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

Ground Controls

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

Hydraulic Pump

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

Function Manifold

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

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

Steer Axle Components

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

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