Genie GR-20J User manual

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
ii
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.
Contact Us:
www.genielift.com
e-mail: [email protected]
Copyright © 2011 by Terex Corporation
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.
iv
REVISION HISTORY, CONTINUED

September 2016
Part No. 227656 GR-20J • GR-26J
v
INTRODUCTION
Serial Number Legend
Model:
Serial number:
Electrical schematic number:
Year of manufacture:
Machine unladen weight:
GRJL-1234
2016
GRJ L - 1234
1
23
Maximum allowable inclination of the chassis:
Gradeability:
Rated work load (including occupants):
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
234
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 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
vi
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 ......................................................................................... ii
Revision History ................................................................................................ iii
Serial Number Legend ...................................................................................... v
Section 1 Safety Rules
General Safety Rules ........................................................................................ vi
Section 2 Specifications
Machine Specifications ................................................................................ 2 - 1
Performance Specifications ......................................................................... 2 - 2
Hydraulic Specifications ............................................................................... 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
ix

September 2016
GR-20J • GR-26J Part No. 227656
x
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

September 2016
Part No. 227656 GR-20J • GR-26J
Section 4 Repair Procedures, continued
Turntable Components
9-1 Turntable Rotation Motor .................................................................. 4 - 36
9-2 Battery ............................................................................................. 4 - 38
9-3 Battery Charger ................................................................................ 4 - 39
Steer Axle Components
10-1 Yoke ................................................................................................. 4 - 40
10-2 Steer Cylinder .................................................................................. 4 - 41
10-3 Steering Rod .................................................................................... 4 - 42
10-4 Steer Angle Sensor .......................................................................... 4 - 42
Non-steer Axle 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 Schematic
Component Reference and Hydraulic Symbols Legend ............................. 6 - 10
GR-20J and GR-26J .................................................................................. 6 - 11
TABLE OF CONTENTS
xi

September 2016
GR-20J • GR-26J Part No. 227656
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Section 2 • SpecificationsSeptember 2016
Part No. 227656 GR-20J • GR-26J 2 - 1
Machine Specifications
Battery, Standard
Voltage 2V DC
Group C5
Quantity 12
Battery capacity, maximum ANSI - 280 AH
CE - 250 AH
Fluid capacities
Hydraulic tank 5.8 gallons
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 end) 96 ft-lbs
130 Nm
Specifications

Section 2 • Specifications September 2016
2 - 2 GR-20J • GR-26J Part No. 227656
Hydraulic Specifications
Hydraulic Oil Specifications
Hydraulic oil type Shell PW 46
Viscosity grade Multi-viscosity
Viscosity index 152
Cleanliness level, minimum 15/13
Water content, maximum 200 ppm
Genie specifications require hydraulic oils which are
designed to give maximum protection to hydraulic
systems, have the ability to perform over a wide
temperature range, and the viscosity index should
exceed 140. They should provide excellent antiwear,
oxidation, corrosion inhibition, seal conditioning, and
foam and aeration suppression properties.
Optional fluids
Biodegradable Texaco Hydra 46
Shell Naturelle HF-E 46
Note: Genie specifications require additional
equipment and special installation instructions for
the approved optional fluids. Consult the Genie
Industries Service Department before use.
Function pump
Type Gear
Displacement per revolution 0.256 cu in
4.2 cc
Function manifold
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 / 9.8 sec
4.5 km/h
12.2 m / 9.8 sec
Platform raised 0.4 mph
40 ft / 54.8 sec
0.65 km/h
12.2 m / 54.8 sec
Braking distance, maximum
High range on paved surface 60 in
152 cm
Gradeability 25%
Airborne noise emissions
Sound pressure level at ground workstation <70 dBA
Sound pressure level at platform workstation <70 dBA
Function speed, maximum
GR-20J
Platform up 24 to 26 seconds
Platform down 19 to 21 seconds
GR-26J
Platform up 54 to 56 seconds
Platform down 40 to 42 seconds
Rated work load at full height, maximum
Platform, ANSI (GR-20J) 500 lbs
227 kg
Platform, CE (GR-20J & GR-26J) 440 lbs
200 kg

Section 2 • SpecificationsSeptember 2016
Part No. 227656 GR-20J • GR-26J 2 - 3
SPECIFICATIONS
Manifold Component
Specifications
Plug torque
SAE No. 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

Section 2 • Specifications September 2016
2 - 4 GR-20J • GR-26J Part No. 227656
SPECIFICATIONS
Hydraulic Hose and Fitting Torque
Specifications
Your machine is equipped with Parker Seal-Lok™
ORFS or 37° JIC fittings and hose ends.
Genie specifications require that fittings and hose
ends be torqued to specification when they are
removed and installed or when new hoses or
fittings are installed.
Seal-Lok™Fittings
(hose end - ORFS)
SAE Dash size Torque
-4 10 ft-lbs / 13.6 Nm
-6 30 ft-lbs / 40.7 Nm
-8 40 ft-lbs / 54.2 Nm
-10 60 ft-lbs / 81.3 Nm
-12 85 ft-lbs / 115 Nm
-16 110 ft-lbs / 150 Nm
-20 140 ft-lbs / 190 Nm
-24 180 ft-lbs / 245 Nm
JIC 37° Fittings
(swivel nut or hose connection)
SAE Dash size Thread Size Flats
-4 7/16-20 2
-6 9/16-18 1 1/4
-8 3/4-16 1
-10 7/8-14 1
-12 1 1/16-12 1
-16 1 5/16-12 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 size Torque
-4 ORFS / 37° (Adj) 15 ft-lbs / 20.3 Nm
ORFS (Non-adj) 26 ft-lbs / 35.3 Nm
37°(Non-adj) 22 ft-lbs / 30 Nm
-6 ORFS (Adj / Non-adj) 35 ft-lbs / 47.5 Nm
37° (Adj / Non-adj) 29 ft-lbs / 39.3 Nm
-8 ORFS (Adj / Non-adj) 60 ft-lbs / 81.3 Nm
37° (Adj / Non-adj) 52 ft-lbs / 70.5 Nm
-10 ORFS (Adj / Non-adj) 100 ft-lbs / 135.6 Nm
37° (Adj / Non-adj) 85 ft-lbs / 115.3 Nm
-12 (All types) 135 ft-lbs / 183 Nm
-16 (All types) 200 ft-lbs / 271.2 Nm
-20 (All types) 250 ft-lbs / 339 Nm
-24 (All types) 305 ft-lbs / 413.5 Nm
Adjustable
fitting (Adj)
Non-adjustable
fitting (Non-
adj)
Jamb nut

Section 2 • SpecificationsSeptember 2016
Part No. 227656 GR-20J • GR-26J 2 - 5
Torque Procedure
Seal-Lok™ fittings
1 Replace the O-ring. The O-ring must be
replaced anytime the seal has been broken.
The O-ring cannot be re-used if the fitting or
hose end has been tightened beyond finger
tight.
Note: The O-rings used in the Parker Seal Lok™
fittings and hose ends are custom-size O-rings.
They are not standard SAE size O-rings. They are
available in the O-ring field service kit (Genie part
number 49612).
2 Lubricate the O-ring before installation.
3 Be sure that the face seal O-ring is seated and
retained properly.
4 Position the tube and nut squarely on the face
seal end of the fitting and tighten the nut finger
tight.
5 Tighten the nut or fitting to the appropriate
torque per given size as shown in the table.
6 Operate all machine functions and inspect the
hoses and fittings and related components to
confirm that there are no leaks.
JIC 37° fittings
1 Align the 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.
Figure 1
a hex nut
b reference mark
c body hex fitting
3 Working clockwise on the body hex fitting,
make a second mark with a permanent ink
marker to indicate the proper tightening
position. Refer to Figure 2.
Note: Use the JIC 37° Fittings table on the
previous page to determine the correct number of
flats for the proper tightening position.
Note: The marks indicate that the correct
tightening positions have been determined. Use
the second mark on the body hex fitting to
properly tighten the joint after it has been
loosened.
Figure 2
a body hex fitting
b reference mark
c second mark
4 Tighten the hex nut until the mark on the hex
nut is aligned with the second mark on the
body hex fitting.
5 Operate all machine functions and inspect the
hoses and fittings and related components to
confirm that there are no leaks.
a
b
c
a
b
c
b
SPECIFICATIONS

Section 2 • Specifications September 2016
2 - 6 GR-20J • GR-26J Part No. 227656
SPECIFICATIONS
SIZE THREAD
in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm
20 80 9 100 11.3 110 12.4 140 15.8 130 14.7
28 90 10.1 120 13.5 120 13.5 160 18 140 15.8
ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm
18 13 17.6 17 23 18 24 25 33.9 21 28.4
2
4
14 19 19 25.7 20 27.1 27 36.6 24 32.5
16 23 31.2 31 42 33 44.7 44 59.6 38 51.5
2
4
26 35.2 3
5
47.4 37 50.1 49 66.4 43 58.3
1
4
37 50.1 49 66.4 50 67.8 70 94.7 61 82.7
20 41 55.5 5
5
74.5 60 81.3 80 108.4 68 92.1
13 57 77.3 7
5
101.6 80 108.4 110 149 93 126
20 64 86.7 8
5
115 90 122 120 162 105 142
12 80 108.4 110 149 120 162 150 203 130 176
18 90 12
2
120 162 130 176 170 230 140 189
11 110 149 150 203 160 217 210 284 180 244
18 130 176 170 230 180 244 240 325 200 271
10 200 271 270 366 280 379 380 515 320 433
16 220 298 300 406 310 420 420 569 350 474
9320 433 430 583 450 610 610 827 510 691
1
4
350 474 470 637 500 678 670 908 560 759
8480 650 640 867 680 922 910 1233 770 1044
12 530 718 710 962 750 1016 990 1342 840 1139
7590 800 790 1071 970 1315 1290 1749 1090 1477
12 670 908 890 1206 1080 1464 1440 1952 1220 1654
7840 1138 1120 1518 1360 1844 1820 2467 1530 2074
12 930 1260 1240 1681 1510 2047 2010 2725 1700 2304
6
1460 1979 1950 2643 2370 3213 3160 4284 2670 3620
12 1640 2223 2190 2969 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
LUBEDDRYLUBED
SAE FASTENER TORQUE CHART
Grade 5
DRYLUBED
• Thischart is to beused as aguideonlyunlessnotedelsewhereinthismanual •
A574 High Strength
Black Oxide Bolts
Grade 8
Size
(mm) in-lbs Nm in-lbs N
m
in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs N
m
516 1.8 21 2.4 41 4.63 54 6.18 58 6.63 78 8.84 68 7.75 91 10.3
619 3.05 36 4.07 69 7.87 93 10.5 100 11.3 132 15 116 13.2 15
5
17.6
745 5.12 60 6.83 116 13.2 155 17.6 167 18.9 223 25.2 1.95 22.1 260 29.4
ft-lbsNmft-lbsNmft-lbsNmft-lbsNmft-lbsNmft-lbsNmft-lbsNmft-lbsNm
85.4 7.41 7.2 9.88 14 19.1 18.8 25.5 20.1 27.3 26.9 36.5 23.6 32 31.4 42.6
10 10.8 14.7 14.4 19.6 27.9 37.8 37.2 50.5 39.9 54.1 53.2 72.2 46.7 63.3 62.3 84.4
12 18.9 25.6 25.1 34.1 48.6 66 64.9 88 69.7 94.5 92.2 12
5
81 110 108 147
14 30.1 40.8 40 54.3 77.4 105 103 140 110 150 147 200 129 17
5
17
2
234
16 46.9 63.6 62.5 84.8 125 170 166 226 173 235 230 313 202 274 269 36
5
18 64.5 87.5 86.2 117 171 233 229 311 238 323 317 430 278 377 371 503
20 91 124 121 165 243 330 325 441 337 458 450 610 394 53
5
52
5
713
22 124 169 166 225 331 450 442 600 458 622 612 830 536 727 71
5
970
24 157 214 210 285 420 570 562 762 583 791 778 1055 682 92
5
909 1233
LUBED DRY LUBED DRYLUBED DRY LUBED DRY
LUBEDDRYLUBED
Class 12.9Class 4.6
DRYLUBED
METRIC FASTENER TORQUE CHART
• Thischartis tobeused as aguideonlyunlessnotedelsewhereinthismanual •
LUBED DRY
Class 10.9Class 8.8
DRY

Section 3 • Scheduled Maintenance Procedures
Part No. 227656 GR-20J • GR-26J 3 - 1
September 2016
Scheduled Maintenance Procedures
Observe and Obey:
Maintenance inspections shall be completed
by a person trained and qualified on the
maintenance of this machine.
Scheduled maintenance inspections shall be
completed daily, quarterly, semi-annually,
annually and every 2 years as specified on the
Maintenance Inspection Report.
Failure to properly complete each
inspection when required may
cause death, serious injury or
substantial machine damage.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating the machine.
Use only Genie approved replacement parts.
Machines that have been out of service for a
period longer than 3 months must complete the
quarterly inspection.
Unless otherwise specified, perform each
procedure with the machine in the following
configuration:
• Machine parked on a firm, level surface
• Platform 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 and step-by-step instructions.
Symbols Legend
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.
Indicates that a specific result is expected after
performing a series of steps.
Indicates that an incorrect result has occurred
after performing a series of steps.

Section 3 • Scheduled Maintenance Procedures
3 - 2 GR-20J • GR-26J Part No. 227656
September 2016
SCHEDULED MAINTENANCE PROCEDURES
Maintenance Symbols Legend
Note: The following symbols have been used in
this manual to help communicate the intent of the
instructions. When one or more of the symbols
appears at the beginning of a maintenance
procedure, it conveys the meaning below.
Indicates that tools will be required to
perform this procedure.
Indicates that new parts will be required
to perform this procedure.
Indicates that a cold motor or pump will
be required to perform this procedure.
Indicates that dealer service will be
required to perform this procedure.
Pre-delivery Preparation Report
The pre-delivery preparation report contains
checklists for each type of scheduled inspection.
Make copies of the Pre-delivery Preparation 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 chart to determine
which group(s) of procedures are required to
perform a scheduled inspection.
Inspection Checklist
Daily or every 8 hours A
Quarterly or every 250 hours A + B
Semi-annually or every 500 hours A + B + C
Annually or every 1000 hours A + B + C + D
Two year or every 2000 hours A + B + C + D + E
Maintenance Inspection Report
The maintenance inspection report contains
checklists for each type of scheduled inspection.
Make copies of the Maintenance Inspection Report
to use for each inspection. Maintain completed
forms for a minimum of 4 years or in compliance
with employer, jobsite and governmental
regulations and requirements.