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Genie GR-26J Service Manual Download Page 72

Section 4 • Repair Procedures

4 - 26

GR-20J • GR-26J

Part No. 227656

September 2016

Ground Controls

5-1
Level Sensor

The tilt alarm sounds when the incline of the
chassis exceeds 2° to the side, front or rear.

How to Install and Calibrate the
Level Sensor

Tip-over hazard. Failure to install
or calibrate the level sensor as
instructed will compromise
machine stability and cause the
machine to tip over, resulting in
death or serious injury. Do not
install or calibrate the level sensor
other than specified in this
procedure.

Note: Perform this procedure with the machine on
a firm, level surface that is free of obstructions, and
the machine in stowed position.

1 Open the turntable cover at the ground control

side of the machine.

2 Locate the level sensor which is mounted on

the turntable base below the battery charger.

3 Tag and disconnect the level sensor pigtail from

the machine wire harness.

4 After noting the orientation of level sensor

assembly, remove the fasteners securing the
base of level sensor assembly to the chassis.

5 Install the new level sensor onto the machine.

Install and securely tighten the fasteners. Do
not over tighten.

6 Securely install the level sensor pigtail into the

machine wire harness, disconnected in step 3.

7 Remove the plastic cap from the end of the

level sensor calibration wire.

8 Using a length of wire approximately

40 inches / 1 m long, connect the level sensor
calibration wire to the negative post of the
battery.

Result: The green LED underneath the level

sensor flashes several times and stops. The
level sensor calibration is complete.

Result: The green LED underneath the level

sensor does not flash. Check the calibration
wire connection. Contact Genie Industries
Service Department.

Note: The green LED is on during normal machine
operation and it only goes out when the tilt angle of
the machine exceeds 2°.

9 After the green LED stops flashing, disconnect

the calibration wire from the battery, and
securely install the plastic cap removed in
step 7.

Summary of Contents for GR-26J

Page 1: ...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 ...

Page 2: ...68 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 fo...

Page 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 SerialNumberLedgend 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...

Page 4: ...ption 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 iv REVISION HISTORY CONTINUED ...

Page 5: ...upants 4 5 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 1 2 3 4 5 6 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...

Page 6: ...entified 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 to...

Page 7: ... 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...

Page 8: ...lic 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 Perfor...

Page 9: ... 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 ...

Page 10: ...orm 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 ...

Page 11: ...e Components 11 1 Drive Motors 4 44 11 2 Drive Brake 4 46 Section 5 Fault Codes Introduction 5 1 Fault Code Chart 5 3 Section 6 Schematics Introduction 6 1 Electrical Component and Wire Color Legend 6 2 ECM Pin out legend 6 3 Limit Switch and Sensor Legend 6 4 Electrical Symbols Legend 6 5 Electrical Schematics ANSI Models GR 26J 6 6 Electrical Schematics CE Models GR 20J and GR 26J 6 8 Hydraulic ...

Page 12: ...September2016 GR 20J GR 26J Part No 227656 This page intentionally left blank ...

Page 13: ...ons 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 Tires and wheels Tire size solid rubber 16 x 5 x 11 in 40 6 x 12 7 x 28 cm Castle nut torque dry non steer end 89 ft lbs 120 Nm Castle nut torque lubricated non steer end 66 ft lbs 90 Nm Lug bolt torque dry steer end 132 ft lbs 180 Nm Lug bolt torque lubricated steer...

Page 14: ...for the approved optional fluids Consult the Genie Industries Service Department before use Functionpump Type Gear Displacement per revolution 0 256 cu in 4 2 cc Functionmanifold System relief valve pressure maximum 2030 psi 140 bar Lift relief valve pressure 930 psi 64 bar Filter cap torque 37 ft lbs 50 Nm SPECIFICATIONS Performance Specifications Drive speed maximum Platform stowed 2 8 mph 40 ft...

Page 15: ... 2 50 in lbs 6 Nm SAE No 4 13 ft lbs 18 Nm SAE No 6 18 ft lbs 24 Nm SAE No 8 50 ft lbs 68 Nm SAE No 10 55 ft lbs 75 Nm SAE No 12 75 ft lbs 102 Nm Torque specifications Brake mounting fasteners dry 75 ft lbs 102 Nm Brake mounting fasteners lubricated 56 ft lbs 76 Nm Grease Specification RETINAX HDX2 grease NLGI lithium based or equivalent ...

Page 16: ...4 8 3 4 16 1 10 7 8 14 1 12 11 16 12 1 16 15 16 12 1 20 1 5 8 12 1 24 1 7 8 12 1 SAE O ring Boss Port tube fitting installed into Aluminum all types SAE Dash size Torque 4 14 ft lbs 19 Nm 6 23 ft lbs 31 2 Nm 8 36 ft lbs 54 2 Nm 10 62 ft lbs 84 Nm 12 84 ft lbs 114 Nm 16 125 ft lbs 169 5 Nm 20 151 ft lbs 204 7 Nm 24 184 ft lbs 249 5 Nm SAE O ring Boss Port tube fitting installed into Steel SAE Dash ...

Page 17: ...tube flare hex nut against the nose of the fitting body body hex fitting and tighten the hex nut to the body hex fitting to hand tight approximately 30 in lbs 3 4 Nm 2 Make a reference mark on one of the flats of the hex nut and continue it on to the body hex fitting with a permanent ink marker Refer to Figure 1 Figure1 a hex nut b referencemark c body hex fitting 3 Working clockwise on the body h...

Page 18: ... 2670 3620 3560 4826 3000 4067 5 16 3 8 7 16 1 2 1 1 2 9 16 5 8 3 4 7 8 1 1 1 8 1 1 4 LUBED 1 4 LUBED DRY LUBED DRY LUBED DRY LUBED SAE FASTENER TORQUE CHART Grade 5 DRY LUBED Thischart is to beused as a guideonlyunless noted elsewhere in this manual A574 High Strength Black Oxide Bolts Grade 8 Size mm in lbs Nm in lbs Nm in lbs Nm in lbs Nm in lbs Nm in lbs Nm in lbs Nm in lbs Nm 5 16 1 8 21 2 4 ...

Page 19: ...tform in the stowed position Key switch in the off position with the key removed The red Emergency Stop button in the off position at both ground and platform controls Wheels chocked All external AC power supply disconnected from the machine About This Section This section contains detailed procedures for each scheduled maintenance inspection Each procedure includes a description safety warnings a...

Page 20: ...aration report to use for each inspection Store completed forms as required Maintenance Schedule There are five types of maintenance inspections that must be performed according to a schedule daily quarterly semi annually annually and two year The Scheduled Maintenance Procedures Section and the Maintenance Inspection Report have been divided into five subsections A B C D and E Use the following c...

Page 21: ...ce a check in the appropriate box after each part is completed Follow the instructions in the operator s manual If any inspection receives an N remove the machine from service repair and reinspect it After repair place a check in the R box Legend Y yes completed N no unable to complete R repaired Comments Fundamentals It is the responsibility of the dealer to perform the Pre delivery Preparation T...

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Page 23: ... Function tests Perform after 40 hours A 4 30 day service Perform every 100 hours A 5 Hydraulic suction strainer Instructions Make copies of this report to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hours Inspection A Quarterly or 250 hours Inspection A B Semi annually or 500 hours Inspection A B C Annually or 1000 hours Inspect...

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Page 25: ...operating conditions 1 Check to make sure that the operator s and safety manuals are present and complete in the storage container on the platform 2 Examine the pages of each manual to be sure that they are legible and in good condition Result The operator s manual is appropriate for the machine and all manuals are legible and in good condition Result The operator s manual is not appropriate for t...

Page 26: ...the operator prior to each work shift The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The Pre operation Inspection also serves to determine if routine maintenance procedures are required Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual...

Page 27: ...over and fasteners to the side 4 Tag and disconnect the wire harness connectors from the function manifold 5 Tag and disconnect the cables from the motor 6 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 ...

Page 28: ...er 1 Open the turntable covers of the machine 2 Confirm that the battery cable connections are tight and free of corrosion Note Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables 3 Locate the bolts between the battery pack and the counterweight Confirm that the head of each bolt is firmly in contact with the battery pac...

Page 29: ...e 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 CHECKLIST B PROCEDURES B 2 Inspect the Electrical Wiring Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining electrical wiring ...

Page 30: ...n the machine B 3 Inspect the Tires and Wheels Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the tires and wheels in good condition including proper castle nut torque is essential to safe operation and good performance Tire and or wheel failure could result in a machine tip over Component damage may also result if probl...

Page 31: ...atform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 5 Push the red Emergency Stop button at the platform controls to the off position 6 Check the machine functions from the platform controls Result The machine functions should not operate Note The red Emergency Stop button at the ground controls will stop all machine operations even...

Page 32: ...to platform control and pull out the red Emergency stop button to the on position at both the ground and platform controls 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 2 Check the machine functions from the ground controls Result The m...

Page 33: ... red Emergency Stop button to the on position at both the ground and platform controls 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 3 Lower the platform to the stowed position 4 Press the drive function select button a drive function s...

Page 34: ...ever comes first Proper drive functions are essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range Note Perform this procedure with the machine on a firm level surface that is free of obstructions 1 Create start ...

Page 35: ...his procedure be performed every 250 hours or quarterly whichever comes first Proper drive functions are essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range Note Perform this procedure with the machine on a fi...

Page 36: ...on at both the ground and platform controls 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 2 Activate any machine function from the ground control as indicated on the ground control box Result The beacon should flash 3 Turn the key switc...

Page 37: ...left position and then release it Press and hold the thumb rocker switch for a moment to the right position and then release it Result The motion alarm will sound when the rocker switch is moved off center in either direction B 11 Test the Motion Alarm Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Alarm is used to alert operators a...

Page 38: ...ace the Hydraulic Oil B 13 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 dusty conditions exist A free breathing hydraulic tank cap is essential for good machine performance and service life A dirty or clogged cap may cause the machine to perform poorly Extremely dirty c...

Page 39: ...e top of the ground control box 4 Move the free wheel selector switch to the right to set the machine to free wheel condition Result The parking brakes will release and the horn will sound softly 5 Remove the wheel chocks and using a fork lift or similar device apply force to the machine Result The machine will move freely Component damage hazard The machine can be damaged if it breaks free from t...

Page 40: ...sition at both the ground and platform controls 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 2 Raise the jib boom to a horizontal position 3 Raise the mast head approximately 8 inches 20 cm CHECKLIST B PROCEDURES 4 Using a suitable tor...

Page 41: ...o the platform 3 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 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 a number 1 mast b plumb line 4 R...

Page 42: ...ondition Machine stability could be compromised resulting in the machine tipping over The platform overload system is designed to prevent machine operation in the event the platform is overloaded Models equipped with the platform overload option are provided with two overload pressure sensors Models equipped with the platform overload option are provided with additional machine components an adjus...

Page 43: ...hydraulic tank is a vented type tank The breather cap has an internal air filter that can become clogged or over time can deteriorate If the breather cap is faulty or improperly installed impurities can enter the hydraulic system which may cause component damage Extremely dirty conditions may require that the cap be inspected more often 1 Remove breather cap from the hydraulic tank Discard the bre...

Page 44: ...de locate the filter cap of the function manifold Clean the area around the filter cap 3 Remove the filter cap from the function manifold Set it to the side 4 Remove the oil filter placed underneath the filter cap 5 Apply a thin layer of oil to the new oil filter gasket a filter cap 6 Install the new filter into the function manifold and securely tighten 7 Install the filter cap onto the function ...

Page 45: ...tches and other jewelry 3 Remove the fasteners securing the chassis side cover next to the tank to the chassis Remove the side cover Lay the side cover and fasteners to the side 4 Place a suitable container under the hydraulic tank Refer to Section 2 Specifications 5 Locate and remove the hydraulic tank filler cap Set the filler cap to the side 6 Remove the drain plug and drain all of the oil into...

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Page 47: ...oth ground and platform controls Wheels chocked All external AC power supply disconnected from the machine 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 Perform disassembly procedures to the point where repairs can be compl...

Page 48: ...the platform control box Carefully remove the top plate assembly from the box to expose the circuit boards 3 Tag and disconnect the wire harness connectors from the platform controls circuit board Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Component damage hazard Electrostatic discharge ESD...

Page 49: ...ition at both the ground and platform controls 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 2 Simultaneously press and hold all three function buttons for 3 seconds Result A beep sounds and three function indicator lights will flash on...

Page 50: ... flash one after another 3 Simultaneously press and hold the drive function and lift function buttons for 3 seconds Result All three function indicator lights will stop flashing 4 Briefly press and release the lift function button to turn the flashing beacon on or off Result The lift indicator light will be on if the flashing beacon is activated It will be off if the flashing beacon is deactivated...

Page 51: ...the drive function and jib boom function buttons for 3 seconds Result All three function indicator lights will stop flashing 4 Using the illustration as a guide move the joystick fully to the left then return the joystick to the neutral position Note Do not squeeze or activate the joystick function enable switch No machine function should operate while performing the joystick calibration procedure...

Page 52: ...pply The red Emergency Stop button returns automatically to the out or on position 7 Simultaneously press and hold all three function select buttons for 3 seconds Result A beep sounds and three function indicator lights will flash one after another a joystick function enable switch b thumb rocker switch c joystick d jib boom function button BN97 e lift function and turntable rotate function button...

Page 53: ...m the joystick 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 7 Remove the fasteners securing the outlet mounting plate to the platform Set the mounting plate assembly and fasteners to the side 8 Attach a lifting strap of suitable capacity from an overhead crane to ...

Page 54: ...rews of both the overload sensors Do not over tighten 4 Using a suitable lifting device place a 440 lbs 200 Kg test weight in the center of the platform Secure the weight to the platform 5 Tighten the overload spring adjustment screw just until the screw and lock nut will rotate freely and the clearance between the lock nut and sensor mounting bracket is minimal a adjusting screw b overload sensor...

Page 55: ...he overload indicator lights are off at the ground and platform controls and the alarm does not sound continuously Repeat the procedure beginning with step 9 10 Test all machine functions from the platform controls Result All platform control functions should not operate 11 Turn the key switch to the ground control 12 Test all machine functions from the ground controls Result All ground control fu...

Page 56: ...ht and place blocks under the platform for support Lower the jib boom until the platform is resting on the blocks 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 a jib boom b jib cylinder c platform 4 Tag disconnect and plug the jib cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury ha...

Page 57: ... and the machine in stowed position 1 Check the condition of the wear pads Refer to Maintenance Procedure B 16 Inspect the Mast Wear Pads 2 Using Illustration 1 as a guide create a safety steel plate using the dimensions specified 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 Open and remove the turnta...

Page 58: ... side 11 Raise the mast head jib boom and platform assembly and move the assembly approximately 20 inches 50 cm towards the non steer end of the machine Crushing hazard The mast head jib boom and platform assembly could become unbalanced and fall when removed from the machine Component damage hazard Cables and hose can be damaged if they are kinked or pinched Note During removal the mast head jib ...

Page 59: ...ace closest to the platform with the mark P on the number 1 mast Refer to Illustration 3 17 Remove the mast assembly from the machine while carefully pulling the cables and hydraulic hose from the mast With the P mark facing upwards place the mast assembly on a level workbench capable of supporting it Crushing hazard The mast assembly could become unbalanced and fall if not properly supported when...

Page 60: ...16 Illustration 1 1 number 1 mast 2 shims 3 wear pads 4 fasteners 5 stops 6 number 2 mast 7 number 3 mast 8 number 4 mast 9 cover plate MAST COMPONENTS P Steer End Power Unit Side Platform Non Steer End Ground Controls Side Illustration 2 1 3 5 4 2 6 7 8 9 TOP BOTTOM P P P P ...

Page 61: ...number 2 3 and 4 mast sections corresponding to the P mark on mast 1 Refer to Illustration 3 4 Working from the top of the mast assembly push the number 2 3 and 4 mast sections fully into the number 1 mast 5 Remove the fasteners securing the safety steel plate to the mast assembly Remove the safety steel plate Set the fasteners and safety steel plate to the side Illustration 3 a number 1 mast b nu...

Page 62: ...ing stops to the inside of the number 2 mast Remove the stops Set the fasteners and stops to the side 14 Working from the bottom of the number 2 mast pull the number 3 mast half way out 15 Attach a lifting strap from an overhead crane to the number 3 mast section Remove the number 3 mast while carefully pulling the it out from the bottom of the number 2 mast With the P mark facing upwards place th...

Page 63: ...de tag and remove the inner wear pads from the top of the number 2 mast section Set the shims to the side Discard the wear pads 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 21 Using Illustration 1 as a guide tag and remove the outer wear pads and shims fro...

Page 64: ...ections 1 2 and 3 5 Using Illustration 2 as a guide apply grease onto the inner faces of the mast sections 1 2 and 3 Grease Specification RETINAX HDX2 grease NLGI lithium based or equivalent MAST COMPONENTS How to Assemble the Mast GR 26J Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and ...

Page 65: ... 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 a b Illustration 3 a grease b mast section mast 4 shown ...

Page 66: ... Part No 227656 September2016 MAST COMPONENTS Illustration 1 1 number 1 mast 2 stops 3 shims 4 wear pads 5 number 2 mast 6 cover plate P Steer End Power Unit Side Platform Non Steer End Ground Controls Side Illustration 2 1 5 2 4 3 6 TOP BOTTOM P P ...

Page 67: ...mber 2 mast section corresponding to the P mark on mast 1 Refer to Illustration 3 4 Remove the fasteners securing the safety steel plate to the mast assembly Remove the safety steel plate Set the fasteners and safety steel plate to the side 5 Remove the fasteners securing stops to the inside of the number 1 mast Remove the stops Set the fasteners and stops to the side 6 Working from the bottom of ...

Page 68: ...ry to gently loosen the wear pads from the mast 10 Using Illustration 1 as a guide tag and remove the inner wear pads and shims from the top of the number 1 mast section Set the shims to the side Discard the wear pads 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 th...

Page 69: ...ads and the corresponding shims removed in the mast disassembly process onto the top mast section 1 5 Using Illustration 2 as a guide apply the grease onto the inner faces of the mast section 1 Grease Specification RETINAX HDX2 grease NLGI lithium based or equivalent Illustration 2 a grease b mast section mast 1 shown 6 Using Illustration 3 as a guide apply grease onto the outer faces of the mast ...

Page 70: ... Open and remove the turntable covers of the machine 3 Center a lifting jack under the drive chassis at the steer end of the machine 4 Raise the steer end of the machine approximately 10 inches 25 cm to access the nut at the bottom of the 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 a m...

Page 71: ...s securing the mast head to the mast assembly Set the fasteners to the side MAST COMPONENTS 13 Raise the mast head jib boom and platform assembly and move the assembly approximately 20 inches 50 cm towards the non steer end of the machine Crushing hazard The mast head jib boom and platform assembly could become unbalanced and fall when removed from the machine Component damage hazard Cables and ho...

Page 72: ... After noting the orientation of level sensor assembly remove the fasteners securing the base of level sensor assembly to the chassis 5 Install the new level sensor onto the machine Install and securely tighten the fasteners Do not over tighten 6 Securely install the level sensor pigtail into the machine wire harness disconnected in step 3 7 Remove the plastic cap from the end of the level sensor ...

Page 73: ...or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications Note Perform this procedure with the machine in stowed position 1 Disconnect the battery pack from the machine 2 Open and remove the turntable cover at the hydraulic power unit side of the machine 3 Tag and disconnect the wire harness connectors fro...

Page 74: ...amp securing the hydraulic power unit to the chassis Set the clamp to the side 9 Carefully remove the hydraulic power unit from the tank and place it on a clean work bench Note If necessary loosen the bottom connector of auxiliary pump to more easily remove the hydraulic power unit Illustration 2 a function pump b hydraulic tank 10 Remove the fasteners securing the function pump to the function ma...

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Page 76: ... pump 29 ft lbs 40 Nm 4 Solenoid valve 2 position 2 way D Platform up 18 ft lbs 25 Nm 5 Solenoid valve 2 position 4 way C Turntable rotate left right 18 ft lbs 25 Nm 6 Solenoid valve 2 position 2 way E Platform down and jib down 18 ft lbs 25 Nm 7 Relief valve 930 psi 64 bar G Platform up 18 ft lbs 25 Nm 8 Solenoid valve 2 position 4 way A Steer left right 18 ft lbs 25 Nm 9 Relief valve 2030 psi 14...

Page 77: ... notes on the hydraulic schematic Note alpha callouts refer to corresponding notes on the hydraulic schematic Note alpha numeric callouts refer to corresponding notes on the electrical schematic Note alpha numeric callouts refer to corresponding notes on the electrical schematic 6 E 7 G 8 A 9 F H 1 2 4 5 C B D Y117 Y21 Y118 Y22 Y116 3 I ...

Page 78: ...lamp 5 Remove the clamp securing the hydraulic power unit to the chassis Set the clamp to the side 6 Rotate the function manifold and locate the system relief valve on the 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 a system relief valve 8 Turn the key switch to ground control and pull out the red Emergency St...

Page 79: ... clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap Tip over hazard Failure to adjust the relief valves to specification could result in the machine tipping over causing death or serious injury Do not adjust the relief valve pressures higher than specifications 14 Turn the key switch to the ground controls 15 Repeat this procedure beginning...

Page 80: ...ches 30 cm Result The platform should lift the weight Proceed to step 12 Result The platform does not lift the weight Proceed to step 7 Component damage hazard Do not continue to operate the machine if the hydraulic pump is cavitating 7 Turn the key switch to the off position 8 Hold the lift relief valve with a wrench and remove the cap schematic item G b a a lift relief valve b system relief valv...

Page 81: ...an penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Hydraulic Tank 7 Place a suitable container under the hydraulic tank Refer to Section 2 Specifications 8 Locate and remove the hydraulic tank filler cap Set the filler cap to the side 9 Remove the drain plug and drain all of the oil into a suitabl...

Page 82: ...y 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 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 a turntable rotation motor b faste...

Page 83: ...rn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 8 Remove fasteners securing the turntable rotation motor to the chassis Set the fasteners to the side 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 f...

Page 84: ...Emergency Stop button to the off position at both the ground and platform controls 2 Open and remove the turntable covers 3 Tag and disconnect the cables connected to the ground terminal of the battery 4 Tag and disconnect the cables connected to the positive terminal of the battery 5 Locate the bolts between the battery pack and the counterweight Loosen the bolts holding the battery pack in posit...

Page 85: ... charger wires from the battery 5 Tag and disconnect the power cable from the battery charger 6 Locate the LED at the bottom of the bulkhead Tag and disconnect the LED wire harness connector 7 Tag and disconnect the charger cutout harness connector a power cable b charger cutout harness connector c LED d charger to battery wires 8 Locate and remove the nut holding the ground control box closed and...

Page 86: ...oximately 6 inches 15 cm Place blocks under the chassis for support Lower the chassis onto blocks Crushing hazard The chassis could fall if not properly supported 5 Remove the bolts from the wheel at the steer end of the machine Remove the wheel from the machine 6 Support and secure the yoke assembly to an appropriate lifting device 7 Remove the top cir clip from the pin at the steering rod 8 Remo...

Page 87: ... button to the off position at both the ground and platform controls 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 6 Center a lifting jack under the drive chassis at the steer end of the machine 7 Raise the machine approximately 6 inches 15 cm Place blocks under the chassis for support Crushing ha...

Page 88: ...ct the steer angle sensor wire harness from the machine wire harness 4 Remove the plastic cap above the steer yoke pivot Set the cap to the side 5 Carefully remove the sensor activator pin from the steer yoke pivot Set the pin to the side Note Inspect the sensor activator pin to confirm it is not broken or twisted If the sensor activator pin is broken or twisted it must be replaced Note the instal...

Page 89: ...eter until a reading of 4K 0 2 ohms is obtained 11 Install the bottom plate and it s fasteners on the steer yoke pivot 12 Install the sensor activator pin on to the steer yoke pivot Note Be sure the sensor activator pin is engaged into the sensor 13 Install the plate along with potentiometer on the steer yoke pivot and securely tighten the potentiometer stem with the screw Do not over tighten 14 I...

Page 90: ...s automatically to the out or on position 3 Raise the jib boom to the maximum height 4 Turn the key switch to off position and push in the red Emergency Stop button to the off position at the ground control 5 Open the turntable cover at the ground control side of the machine Non steer Axle Components a cable guard b right drive motor assembly c left drive motor assembly d fasteners e chassis 6 Tag...

Page 91: ...assis could fall if not properly supported 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 NON STEER AXLE COMPONENTS 16 Place a 2 x 4 x 6 inch 5 x 10 x 15 cm long wood block under the left drive motor Note The wood block will support to the drive motor...

Page 92: ...ontrol side of the machine 6 Tag and disconnect the cables from the ground terminal of the battery 7 Remove the fasteners securing the rear chassis cover to the chassis at the non steer end of the machine Remove the chassis cover Lay the cover and fasteners to the side 8 Tag and disconnect the two wire harness connectors at the steel bar a b c d e a drive brake b drive motor assembly c speed reduc...

Page 93: ...ury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Fault Codes Observe and Obey Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service a damaged or malfuncti...

Page 94: ...problem still exists Inspect and test LED Diagnostic Readout The diagnostic readout displays numerical codes that provide the information about the machine operating status and malfunctions FAULT CODES a b c a Error Source First two digits indicates the affected machine area or component 01 Controller interface board 02 Controller logic board 08 Platform controls circuit board 16 Diagnostic displa...

Page 95: ... The controller has asked the base board to activate the output for the drive or the pump but the interface does not identify a command or an operating state where the drive or pump must be allowed Check whether the software versions installed on the two consoles are correct If so there must be an internal fault 05 EEPROM There is a fault in the management verification of the internal EEPROM It is...

Page 96: ... the fault may be due to an internal fault of the controller then replace it Check whether there is contact or low impedance between pin A12 and the battery Otherwise the circuit is damaged 33 Eb Drv Shorted The electric cable of the brake is in short circuit Check whether there is a short circuit or low impedance between pin A10 and the battery 34 Driver shorted The main conductor of the driver i...

Page 97: ...erence Check the condition of the overload sensors or change the controller 55 Overcharge Overload fault Check the condition of the overload sensors or change the controller 56 Battery low Low battery voltage If the alarm is triggered when the battery is fully charged change the controller 57 No CAN signal The interface board has not received the CAN signal Check the BUSCAN connection between the ...

Page 98: ...r differs by more than 20 from the nominal battery voltage Check the battery type parameter 64 Charge in progress The platform has been started up with the battery charger in operation If the alarm appears with the charger disconnected from the mains there may be a problem with the connection of terminal A17 Otherwise it is an internal fault of the controller 65 Value of angle sensor incorrect The...

Page 99: ...ring valve There is a problem on one or other of the following outputs terminal A34 terminal A26 Check the condition of the valves and their connections Otherwise it is an internal fault of the controller 84 Aux Valve There is a problem on one or other of the following outputs FLASHING LIGHT and TILT LAMP Repair or replace the option 86 Brake coil open The main driver coil is not connected to pin ...

Page 100: ... controller 11 Thermal sensor faulty The thermal sensor is not functioning correctly its output voltage is outside the acceptable range It is an internal fault Replace the controller 12 Stand by motor right The right armature current sensor detects a current other than zero when the right motor is not running It is an internal fault Replace the controller 13 Stand by motor left The left armature c...

Page 101: ...arallel with the capacitor and reduces the current of the recharge circuit thereby preventing the capacitors from charging 2 There is a problem with the charging circuit and the controller must be replaced When the key is connected the controller tries to charge the power capacitors via a resistor and checks whether the capacitors are charged If they do not charge an alarm is generated The main dr...

Page 102: ...ump VMN high The VMN voltage of the pump is high when it should be low This alarm appears while the pump is working Check internal pump connections Electric cable connections leakage from the pump to the framework of the platform If everything is OK the controller has an internal fault 26 VMN right low The VMN voltage of the right motor is low when it should be high This alarm only appears when th...

Page 103: ...f everything is OK the controller has an internal fault 30 Driver closed Before activating the power relay the controller checks whether the driver is closed If the test is not conclusive this alarm appears Check the contacts of the power relay Replace the power relay if necessary 31 Driver open The power relay is controlled by the controller but this will not close The power relay is probably not...

Page 104: ...er board detects a problem in its own control circuit this alarm appears It is an internal fault Replace the controller 44 Driver1 The interface and logic board performs a counter check of signals for the steering choice If the logic detects a problem in its own control circuit field conductor circuit this alarm appears It is an internal fault Replace the controller 46 No ground current Although t...

Page 105: ...60 High temperatures The power section of the fuse has reached the temperature limit the maximum current is automatically reduced The alarm disappears as soon as the cutout cools down If this does not happen there is a problem with the internal temperature sensor 65 Value of angle sensor incorrect The value read by the potentiometer is different from the programmed value Check that the angle senso...

Page 106: ...tput CNE 10 Check the wiring If the wiring is correct and the alarm persists there is an internal fault 73 SV2 incorrect There is a problem short circuit to ground or to positive on output CNE 5 Check the wiring If the wiring is correct and the alarm persists there is an internal fault 74 SV3 4 incorrect There is a problem short circuit to negative or to positive on output CNE 1 or CNE 3 Check the...

Page 107: ...tools and test equipment are available and ready for use About This Section There are two groups of schematics in this section An illustration legend precedes each group of drawings Electrical Schematics Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Hydraulic Schematics Bodily injury hazard Sp...

Page 108: ...0 Drive select Fuse F F6 Fuse 250A F9 Fuse 5A Flashing beacon Hour meter Battery charge indicator Fault code display Ground Horn or Alarm H H1 Horn H2 Automotive style horn Joystick controller Key switch LED or Indicator light L L4 Platform overload L17 Drive select L48 Machine level L68 Platform overload L79 Out of level L81 Mast up down turntable rotate L82 Jib Limit switch LS LS11 Jib boom LS18...

Page 109: ...Section 6 Schematics Part No 227656 GR 20J GR 26J 6 3 September2016 ECM Pin out Legend ...

Page 110: ... 6 Schematics 6 4 GR 20J GR 26J Part No 227656 September2016 Limit Switch and Sensor Legend Limit and Sensor Legend a Platform overload LS31 b Mast down LS18 c Steer angle S21 d Tilt sensor S7 e Jib down LS11 ...

Page 111: ...g no connection Diode Connection no terminal Connector Flashing Beacon LED Fuse Switch or Button Toggle Switch Emergency Stop Button Key Switch Horn or Alarm Sensor hydraulic oil temperature Motor Battery Charger Battery Control Relay Level Sensor Solenoid Valve Parking Brake Electric Motor Joystick Controller ...

Page 112: ...9 17 2 3 11 10 H2 OR BR BL BK 2 1 3 C A B 1 2 2 1 BK RD 1 2 1 2 1 2 3 1 2 3 F6 250A F9 5A RD 7 PP 22 PP 5 PP 4 PP 3 PP 2 PP 1 RD 23 BR 1 BL 4 GR YL 2 RD 3 OR 14 OR 15 OR 16 Y 9 Y 8 Y 7 Y 6 Y 5 BL 13 BL 10 RD 11 RD 12 B9 12 2V GR YL 2 1 BR OR GR BL RD BK WH GR YL RD 2 BL 2 1 2 V J BR GR WH 1 2 2 1 PP 22 PP 7 PP 5 PP 3 PP 4 PP 2 PP 1 RD 6 RD 6 RD 6 RD 6 RD 6 RD 6 GND 24V dc OUTPUT REF U9 AC INPUT P1...

Page 113: ... 5 10 6 7 8 14 1 5 6 10 1 3 4 6 1 BL 2 RD 2 BR GR YL WH BK RD BL GR OR 8 5 10 3 4 9 11 1 2 12 C D A B E F BR 10 Y 2 GY 9 GR 7 BK Y 14 Y 13 Y 12 Y 15 OR 6 4 BK BL 3 BK OR BK 8 BK BK 20 1 BK 19 RD 16 GR YL 2 BK 23 BK 22 BK 21 P2 RD RD 1 2 GR YL Y102 Y101 U3A LS11 LS18 L68 L17 L1 BK BK BK BK L48 L81 L82 SW5 SW6L SW6R U10 JC1 4 1 2 BK RD RD LS31 BK BK BK PLATFORM CONTROLLER ES0525C L30 NOTE DASHED LIN...

Page 114: ...12 29 17 2 3 11 10 H2 OR BR BL BK 2 1 3 C A B 1 2 2 1 BK RD 1 2 1 2 1 2 3 1 2 3 F6 250A F9 5A RD 7 PP 22 PP 5 PP 4 PP 3 PP 2 PP 1 RD 23 BR 1 BL 4 GR YL 2 RD 3 OR 14 OR 15 OR 16 Y 9 Y 8 Y 7 Y 6 Y 5 BL 13 BL 10 RD 11 RD 12 B9 12 2V GR YL 2 1 BR OR GR BL RD BK WH GR YL RD 2 BL 2 1 2 V J BR GR WH 1 2 2 1 PP 22 PP 7 PP 5 PP 3 PP 4 PP 2 PP 1 RD 6 RD 6 RD 6 RD 6 RD 6 RD 6 GND 24V dc OUTPUT REF U9 AC INPU...

Page 115: ...10 6 7 8 14 1 5 6 10 1 3 4 6 1 BL 2 RD 2 BR GR YL WH BK RD BL GR OR 8 5 10 3 4 9 11 1 2 12 C D A B E F BR 10 Y 2 GY 9 GR 7 BK Y 14 Y 13 Y 12 Y 15 OR 6 4 BK BL 3 BK OR BK 8 BK BK 20 1 BK 19 RD 16 GR YL 2 BK 23 BK 22 BK 21 J1 1 8 14 7 P2 4 1 2 BK RD RD RD RD 1 2 GR YL Y102 Y101 LS31 U3A LS11 LS18 L68 L17 L1 BK BK BK BK BK BK BK L48 L81 L82 SW5 SW6L SW6R U3B U10 JC1 ES0525C L30 PLATFORM CONTROLLER NO...

Page 116: ...f valve Bi directional motor Solenoid operated 2 position 2 way directional valve Solenoid operated 2 position 2 way directional valve Solenoid operated 2 position 2 way directional valve Solenoid operated 2 position 4 way directional valve Solenoid operated 2 position 2 way directional valve Solenoid operated 2 position 4 way directional valve Hose reel Fucntion pump and manifold E G A F H C B D ...

Page 117: ... down P Jib up down flow control Q Check valve STEER RIGHT TURNTABLE ROTATE RIGHT STEER LEFT TURNTABLE ROTATE LEFT MAST CYLINDER RAISE MAST CYLINDER LOWER JIB CYLINDER RAISE JIB CYLINDER LOWER Y21 Y22 Y101 Y102 Y116 Y117 Y118 Y121 FUNCTION VALVE ACTIVATION FUNCTION MANIFOLD HYDRAULIC TANK M POWER UNIT T1 2030 psi 140 bar P2 P3 STEER CYLINDER P5 P6 TURNTABLE ROTATE 1450 psi 100 bar A DR B T2 TP HOS...

Page 118: ...Section 6 Schematics 6 12 GR 20J GR 26J Part No 227656 September2016 This page intentionally left blank ...

Page 119: ...1 53852570 86 21 53852569 65 98 480 775 65 67 533 544 81 3 3453 6082 81 3 3453 6083 82 25 587 267 82 25 583 910 55 11 41 665 755 55 11 41 665 754 31 183 581 102 31 183 581 566 Genie Scandinavia Genie France Genie Iberica Genie Germany Genie U K Genie Mexico City Phone Fax Phone Fax Phone Fax Phone Fax Phone Fax Phone Fax 46 31 575100 33 0 2 37 26 09 99 33 0 2 37 26 09 98 34 93 579 5042 34 93 579 5...

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