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GS-2032 Service Manual

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1. ui LLI gud T gt lt o A6 UP COIL BB czom RED BPO Os a DI A5 LEVEL 011 LEVEL SENSOR WHT a DK DATA LINK YEL 191 DOWN AH DATA LINK BLK B1 COIL 1 GROUND FROM JOYSTICK GRN 2 R EMERGENCY STOP TO JOYSTICK WHT 188 gt 542 HE d DK gt Hi JUMPER 610 4 5 gt 11 SWITCH A11 BH UPLIMTSW gi DA u 47 REVERSE 25 23 COIL 5 Oz oOE gt OLN ALN 390 e B10 POTHOLE SW B DK 2 O gt m B7 LEFT COIL 41 gt 54 z a JUMPER A10 B9 MULTIFUNCTION ALARM nest DA C7 C7 COIL Zee PLUG Nes 3 PLUG a3 p A PLUG A1 osse C12 DOWN LIMIT C12 DA BRAKE ___ C9 C9 SOIL LET C2 EMERGENCY STOP C2 4 BI2 UP DOWN SW UP 812 g SDE A12 UP DOWN SW DOWN A12 A US A8 MOTOR 8 c T M GOD 4 A9 MOTOR CONTROLLER A9 lt 5 TERMINAL 3 gt 2 B8 OPT SERVICE HORN B8__ GROUND 5 265 AN imo 252 ogo x Ek i E lt O UB gt
2. B M3 He LIMIT SWITCHES ud sO Q O 510251 _ EJE 4 E iie rm UPPER CHASSIS Mu El A6 BI ECM 0000 0000 HYDRAULIC POWER UNIT MOTOR Part No 46326 Genie GS 2032 6 5 Section 6 Schematics Service Manual First Edition SS SS SS SSS SO Electrical Symbols Legend m T 5 Circuit breaker d e i 4 3 Wire with description Ground supression circuit Solenoid Toggle switch SPDT 0 O ACOX S5 ko Horn Solenoid valve Pothole switch 5 Light T d p Alarm PLAT JB 28F 44D q T circuits connect at terminal A s CHASSIS NC T Y Down limit switch Key switch normally closed T circuits connect lo Re 87A 87 Ts es 510 Rela Connection HORN y no terminal Curtis motor So US controller Horn button normally open Fuse Circuits crossing 1KO POT no connection Connector 51 Emergency Stop 1K Ohm Diode button Potentiometer 7 normally closed 0 2 HOUR T qu GS
3. GS 2032 Steer End Non steer End Number 4 pivot pin steer end Number 3 center pivot pin Lift cylinder rod end pivot pin Number 3 inner arm Number 3 pivot pin steer end Number 2 center pivot pins 2 pins Number 2 inner arm Number 2 pivot pin steer end Number 1 center pivot pin NO O gt 10 Number 1 inner arm 11 Number 1 pivot pins steer end 2 pins 12 Number 4 pivot pin non steer end 13 Number 3 outer arm 14 Number 3 pivot pin non steer end 15 Number 2 outer arm 16 Number 2 pivot pin non steer end 17 Lift cylinder barrel end pivot pin 18 Number 1 outer arm Genie GS 2032 Part No 46326 Service Manual First Edition Section 7 Repair Procedures 3 1 Scissor Assembly How to Disassemble the Scissor Assembly GS 2032 Models This procedure requires specific AWARNING repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools may result in death or serious injury and significant component damage Dealer service is required 1 Remove the platform See 2 1 How to Remove the Platform 2 Remove the cables from the side of the number 3 outer arm index 13 at the ground controls side CAUTION Component damage hazard Cables can be damaged if they are kinked or pinched 3 Attach a lifting
4. 35 40 ft lbs 47 54 Nm Diagnostic nipple Buen Testing ecrit 10 12 ft lbs 14 16 Nm 3 Flow Regulator 0 75 gpm 2 83 L min Steer 35 40 ft lbs 47 54 Nm 4 Orifice Washer 0 040 inch 1 mm D Steering circuit 5 Relief valve 1500 psi 103 4 bar E Steering 25 30 ft lbs 34 41 Nm 6 Relief valve 3700 psi 255 1 bar E sss System 25 30 ft Ibs 34 41 Nm 7 3 position 4 way solenoid valve CREE Steer left right 18 20 ft lbs 24 27 Nm 8 2 position 4 way solenoid valve Eun Platform A RAY 23 25 ft lbs 31 34 Nm 9 2 position 2 way solenoid valve ee Brake circult anie 18 20 ft lbs 24 27 Nm 10 2 position 4 way solenoid valve ee Drive speed select circuit 25 30 ft lbs 34 41 Nm 11 3 position 4 way solenoid valve Kasai Drive forward reverse 18 20 ft lbs 24 27 Nm 12 Relief valve 130 psi 9 bar Back pressure 25 30 ft Ibs 34 41 Nm Plug Torque Specifications Description Hex Size Torque Description Hex Size Torque SAE No 2 1 8 50 in Ibs 6 Nm SAE No 8 5 16 50 ft lbs 68 Nm SAE No
5. or Brake 8 10 ft Ibs 11 14 Nm Hand BUMP uiis Pads Manual brake release 25 30 ft lbs 34 41 Nm O Plug Torque Specifications Description Hex Size Torque Description Hex Size Torque SAE No 2 1 8 50 in lbs 6 Nm SAE No 8 5 16 50 ft lbs 68 Nm SAE No 4 3 16 13 ft lbs 18 Nm SAE No 10 9 16 55 ft lbs 75 Nm SAE No 6 1 4 18 ft lbs 24 Nm SAE No 12 5 8 75 ft lbs 102 Nm 7 30 Genie GS 2032 Part No 46326 Distributed By Genie North America Phone 425 881 1800 Toll Free in USA 800 536 1800 Toll Free in Canada 800 426 8089 Fax 425 883 3475 Genie UK Limited Phone 44 1636 605030 Fax 44 1636 611090 Genie China Phone 86 21 62483040 Fax 86 21 62588180 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Australia Pty Ltd Phone 61 07 3375 1660 Fax 61 07 3375 1002 Genie France Phone 33 237 260 999 Fax 33 237 260 998 Genie Holland Phone 31 7051 78836 Fax 31 7051 13993 Genie Latin America Phone 561 994 0380 Fax 561 997 5877
6. 1 6 2 Genie GS 2032 Part No 46326 Service Manual First Edition Section 6 Schematics m This page intentionally left blank Part No 46326 Genie GS 2032 6 3 Section 6 Schematics Service Manual First Edition Module Tray Legend before serial number 6901 390 218 No T FONCTION MANIFOLD 54 153 152 O NU MI POTHOLE sO Q LIMIT SWITCHES 20 43G TEREE alt rm TO UPPER CHASSIS C6 m i i B77 ECM HOLOW Ldd HOLOVLNOO 000 00000 92 HYDRAULIC POWER UNIT MOTOR CONTROLLER 6 4 Genie GS 2032 Part No 46326 Service Manual First Edition Section 6 Schematics Module Tray Legend after serial number 6900 390 218 bean 6 Ne Ne FUNCTION MANIFOLD HP LS3 152
7. 4 12 B 6 Test the Service aaa ASP dec E RR da ene 4 12 B Test the Drive Brakes 4 13 B 8 Test the Drive Speed Stowed Position 4 15 B 9 Test the Drive Speed Raised Position 4 15 B 10 Perform Hydraulic Oil 4 16 B 11 Check the Electrical Contactor before serial number 6901 4 16 B 12 Replace the Hydraulic Return Filter 2 4 17 C 1 Check the Module Tray Latch Components 4 18 D 1 Testor Replace the Hydraulic Oil 2 0 022 2 0 0 00 4 19 viii Genie GS 2032 Part No 46326 Service Manual First Edition _______________________________ Section Five Chart Number ON Oa R m k 10A 12 13 14 TABLE OF CONTENTS Troubleshooting Flow Charts and Fault Codes Chart Title Page WTOC POSTRONNE ACE 5 1 Fault Code Chart Before Serial Number 17408 5 3 Normal Operation Code Chart Before Serial Number 17408 5 6 Fault Code Chart After Serial Number 17407 5 8 All Functions Will Not aera 5 9 Pump Motor Will Not Operate citis cineri OJ Ada EPA AAA 5 1
8. vao 2882 9 2 E Tz6 amp 5 z m uz I a E m ai ZO gt 290 e gt O 9 1 2 9 gt 5 in SEG 0283 110VAC AP1 F1 275 AMP FUSE 4 6V BATTERY G1 Part No 46326 Genie GS 2032 6 9 Service Manual Section 6 Schematics Electrical Schematic from serial number 6901 to 8931 M L RED A 2 RED WHT C 2 BLK GRN B 2 WHT BLK D2 BLU E GRN PINOUT FOR THE CONTROLLER a 5 C9 PLUG PLATGROUND BLUE PIN B PLUG ESTOP FROM PLAT WHITE PIN A LEVEL SENSOR POWER UP COIL REVERSE COIL MOTOR CONTACTOR MOTOR CONTROLLER JUMPER TO B4 KEY SWITCH TO PLAT DOWN PLAT DATA BLACK PIN D ESTOP TO PLAT WHITE PIN C GROUND JUMPER TO A10 PLUG DOWN COIL LEFT COIL HORN OPTION ALARM POTHOLE LIMIT SWITCH PLUG UP PLAT DATA YELLOW PIN E CHASSIS ESTOP PLUG PLUG JUMPER TO C10 FORWARD COIL RIGHT COIL PLUG BRAKE COIL C10 JUMPER TO C5 C11 LEVEL SENSOR SIGNAL C12 DOWN LIMIT SWITCH
9. 4 m v3 gt 4 1500 PSI 103 4 a 0 040 1mm X 130 PSI X cee u D Hopes D B M vs _ A A T3 d 0 75 28L mn ROA 3700 PSI Fan G sa bar E D EZ E uu t PRESSURE POWER UNIT k M 25 PSI 1 7 bar Nac Part No 46326 Genie GS 2032 6 20 Service Manual Section 6 Schematics ee Hydraulic Schematic after serial number 17481 Service Manual First Edition Section 7 Repair Procedures Observe and Obey Repair procedures shall be completed by a person trained and qualified on the repair of this machine M Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Repairs Start MI Read understand and obey the safety rules and operating instructions in the Genie GS 2032 amp Genie GS 2046 amp Genie GS 2646 amp Genie GS 3246 Operator s Manual Be sure that all necessary tools and parts are available and ready for use Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a flat level su
10. Raise the platform approximately 3 feet 0 9 m and drive yes machine Does the machine drive at a reduced speed no Consult the Genie Industries Service Department Repair open in the wht wire 39C pothole sw from S5 to the multi function alarm to the key switch Adjust the limit switch S5 so the pothole arm activates the switch OR replace the limit switch contact OR replace the limit switch S5 Repair open in the wht wire jumper 21B pothole jumper from the output side of S5 to the input side of S6 Adjust limit switch S6 so the pothole arm activates the switch OR replace the limit switch contact OR replace the limit switch S6 Raise the platform more than 6 feet 1 8 m and drive the machine If the machine does not drive and an alarm sounds the machine is operating normally Check the pothole guards for obstructions OR test the pothole guard limit switches see Repair section Genie GS 2032 Part No 46326 Service Manual First Edition Section 5 Troubleshooting Flow Charts Repair open in the wht wire B10 pothole switch from the output side of S6 to the ECM OR replace the ECM Continued from the previous page Chock both sides of the front drive wheels Install a 0 to 5000 psi 0 to 345 bar pressure gauge to the test port on the function manifold and drive the machine in either the forward or reverse direction Chock the wheels at the non
11. Stowed maximum 2 2 mph 40 ft 12 4 sec 3 5 km h 12 2 m 12 4 sec Platform raised maximum 0 5 mph 40 ft 54 5 sec Gradeability Function speed maximum from platform controls Platform up Platform down 0 8 km h 12 2 m 54 5 sec 3076 29 to 31 seconds 25 to 27 seconds Service Manual First Edition jn Z Se Hydraulic Specifications Hydraulic fluid Dexron equivalent Lift pump Type gear Displacement 244 cu in per revolution 4 cc Displacement 4 gpm 2500 psi 172 bar 15 L min Hydraulic tank return line filter Function manifold 10 micron with 25 psi 1 7 bar bypass System relief valve pressure 3500 psi 241 3 bar Steer relief valve pressure 1000 psi 69 bar Genie GS 2032 Part No 46326 Service Manual First Edition Section 2 Specifications z SPECIFICATIONS Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with either 37 flared fittings and hose ends OR Parker Seal Loke fittings and hose ends Machines that utilize Parker Seal Lok hoses and fittings require that the fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed Machines equipped with 37 flared fittings and hose ends do not need to be torqued to these specifications Hydraulic Hose and Fitting Torque Specifications SAE O ring Boss Port tube fitting SAE Da
12. raimove tha pin Steering Bellcrank Note the quantity and location of 1 Remove the steering cylinder See 7 2 How to the spacers when removing the Remove the Steering Cylinder rod end pivot pin m 2 Remove the retaining fastener from the center 5 Remove the steering cylinder from the of the bellcrank machine Note the quantity and the location of the spacers on the bellcrank 3 Remove the retaining fasteners from the steer links at each end of the bellcrank Remove the bellcrank from the machine Note the quantity and the location of the spacers in between the bellcrank and the steer links 7 28 Genie GS 2032 Part No 46326 Service Manual First Edition Section 7 Repair Procedures Non steering Axle Components 8 1 Drive Brake How to Remove a Drive Brake When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Support and secure the entry ladder to an appropriate lifting device Then remove the entry ladder mounting fasteners Remove the entry ladder from the machine Crushing hazard The entry ladder ACAUTION may become unbalanced and fall if not properly supported and secured to the lifting device 2 Block the steer wheels and center a lifting jack under the drive chassis at the non steer end 3 Remove the cotter pi
13. 0 BLK GRN B WHT BLK D BLU YEL E GRN PINOUT FOR THE CONTROLLER N FQQOQOQOOOOOOO 0 AMOOOOOOOOUO 1 C9 C10 C11 C12 PLUG PLATGROUND BLUE PIN B PLUG ESTOP FROM PLAT WHITE PIN A LEVEL SENSOR POWER UP COIL REVERSE COIL MOTOR CONTACTOR MOTOR CONTROLLER JUMPER TO B4 KEY SWITCH TO PLAT DOWN PLAT DATA BLACK PIN D ESTOP TO PLAT WHITE PIN C GROUND JUMPER TO A10 PLUG DOWN COIL LEFT COIL HORN OPTION ALARM POTHOLE LIMIT SWITCH PLUG UP PLAT DATA YELLOW PIN E CHASSIS ESTOP PLUG PLUG JUMPER TO C10 FORWARD COIL RIGHT COIL PLUG BRAKE COIL JUMPER TO C5 LEVEL SENSOR SIGNAL DOWN LIMIT SWITCH H G F E D C B A PLATFORM CONTROL BOX ENCODER 9 CONDUCTOR RIBBON 8 0 7 ro6 O5 I O4 NC i i I BLUE IDENTIFICATION LINE rot NO S9 EMERGENCY HIGH SPEED eee STOP SWITCH S8 NC NC ESTOP BLK WIRE 23 ESTOP RED WIRE 22 gt NO NO LED RED WIRE 21 PWR LED BD BLK WIRE 20 o BAT LED CARD LED BD YEL WIRE 19 O FLT EX LIFT DRIVE LED BD WHT WIRE 18 ON Ld S1 0 SWITCH S7 U3 HO
14. Perform this test from the ground with the platform controls Do not stand in the platform 1 Fully lower the platform 2 Place a 2x4 block or similar piece of wood under both wheels on one side and drive the machine up onto them 3 Raise the platform O Result When the platform is raised 7 feet 2 1 meters from the ground an alarm should sound 4 Lower the platform and remove both pieces of wood 4 6 Genie GS 2032 Part No 46326 Service Manual First Edition Section 4 Scheduled Maintenance Procedures A 9 Test the Pothole Guards The pothole guards should automatically deploy when the platform is raised The pothole guards activate two limit switches which control the machine drive speed If the pothole guards do not deploy and the platform is raised above 6 feet 1 8 meters an alarm sounds and the machine will not drive 1 Raise the platform Result When the platform is raised 4 feet 1 2 meters from the ground the pothole guards should deploy 2 Press on the pothole guards on one side and then the other Result The pothole guards should not move 3 Lower the platform Result The pothole guards should return to the stowed position 4 Place a 2x4 block or similar piece of wood under the pothole guard Raise the platform Result When the platform is raised above 6 feet 1 8 meters an alarm should sound and the drive function should not work 5 Lower the platform
15. 39 10010100 40 10100100 41 11000100 42 10011100 e 43 10101100 44 11001100 45 10110100 46 11010100 47 11100100 48 10111100 49 11011100 e 50 11101100 51 11110100 52 11111100 53 10011000 54 10101000 55 11001000 56 10111000 57 11011000 e 58 11101000 ele 59 11111000 60 10110000 o 61 11010000 62 11110000 63 11100000 PLATFORM CONTROLS DIP Switch Function Definitions Motion Beacon The motion beacon option flashes only when operating a function Motion Alarm The motion alarm will beep when operating any function Lift Drive Cut Out This cuts out lift and drive functions when the machine goes out of level Required for Europe and Australia Overload This cuts out lift when the cylinder is overloaded Required for France Descent Delay This option halts descent for 4 seconds at approximately 6 feet 2 m Required for Europe hazard Do not adjust the 14215 DIP switch settings to other than what is specified in this procedure Exceeding specifications will cause death or serious injury If replacing the circuit board note the toggle positions on the DIP switches Set the DIP switches on the n
16. 4 3 4 Part No 46326 Genie GS 2032 vii Service Manual First Edition TABLE OF CONTENTS Section Four Scheduled Maintenance Procedures 4 1 A 1 Inspect the Operator s and Safety Manuals 4 2 2 Inspect the Decals and 4 2 Inspect for Damage and Loose or Missing Parts 4 3 4 Check the Hydraulic Oil Level 2 4 4 A 5 Check forHydraulic Leaks aaa hikes edi 4 4 6 Testthe Platform and Ground 4 5 7 Testthe Manual Platform Lowering Operation 4 6 A 8 Testthe Tilt SOMSOM uii E a Erbe 4 6 9 Testthe Pothole Guards citer eid Feed e b naa da 4 7 A 10 Test the Lift Drive Select Switch before serial number 17408 4 7 A 11 Perform 30 Day Service aaa nnne nnns 4 8 B 1 Check the Batteries aaa a dA rni eap FER Dna ssa MERE RR En 4 9 2 Inspect the Electrical Wiring aa A A retener tainen eoi 4 10 B 3 Inspect the Tires and Wheels including castle nut torque 4 11 B 4 Test the Key 4 11 B 5 Test the Emergency Stop
17. 5 o D E IT 5 a S m EL m 9i U gt 9 a Cage 25 B 20 lt O Sapa pzy i t 5 i as 9 E CE gt XI QF m O lt AP1 4 AP1 275 AMP FUSE F1 G1 4 6V BATTERY Part No 46326 Genie GS 2032 6 13 Service Manual Section 6 Schematics Electrical Schematic after serial number 17407 N M L H G F E D C B A DIP SWITCHES sj 1 1 POWER OUT RED 2 REA gt 20K POTENTIOMETER 2 POWER IN BLACK J 1 J6 RIGHT TURN CHASSIS T 3 GROUND WHITE PIOS a gt 2 J7 ENABLE 536 t 4 DATA BLUE oPo4 2 5 gt DATA YELLOW 538 T r J8 LEFT TURN 2 539 POUTI o GH 01 POWER LED 3 POUT2 ea D2 FAULT LED POUT3 o 767 9 D3 HIGH TORQUE LED POUT4 GH D4 BATTERY LEVEL 1 5 E 105 BATTERY LEVEL 2 POUT6 mW D6 BATTERY LEVEL 3 POUT7 239 Ge D7 BATTERY LEVEL 4 POUT8 5 1D8 BATTERY LEVEL 5 4 POUT9 zd GH D9 DRIVE LED POUT10 4 D10 LIFT LED PINI o 31 J2 HIGH TORQUE J
18. 6 A6 COIL N pud 4 RED 1 LL e gt 19 g ANKA U B A5 LEVEL SENSOR RED 5 OUT C11 LEVEL SENSOR WHITE C11 IN C1 DATA LINK C1 IN B1 DATA LINK BIIN x A2 GROUND FROM JOYSTICK A2 IN DOWN M bl B2 EMERGENCY STOP TO JOYSTICK B2 our 007186 B6 COIL Ea 4 EMERGENCY STOP FROM JOYSTICK A4 IN A11 KEY SWITCH Atilin a gt K ce FORWARD ri j d B10 POTHOLE SWITCH B10 IN A 10 LI T LI Ir OUT a7 REVERSE d AP pe AT COIL Wi O O C12 DOWN LIMIT gt WSL 12 C12 IN ee ES OUTIBZ B7 coil A 3 gt pM RUNG UE B9 ALARM _ BIG gt lt pm p C7 COIL d b e LL Zz J OVERLOAD SENSOR OPTION A10 IN gt actA C2 EMERGENCY STOP C2 IN e DA 83 B12 UP SWITCH Bi2lIN OUT C9 C9 d 0 2 COIL 2 AT2 DOWN SWITCH At2lN g CONTROLLER ENABLE A8 OUT 54 MOTOR CONTROLLER PARALLEL m0 A9 TERMINAL 3 NE A GC B8 OPTION HORN B8 OUT 1 OUT QUTjB3 GROUND 28 28 Yzel Pn od i o Ry Szz U Hb X nm a QR
19. B10 5 gt lt L B7 LEFT COIL 9 gt 4 lt lt L JUMPER gt B9 MULTIFUNCTION ALARM Bg DK 7 7 4 COIL E PLUG 1 C3 4 5 CEZ PLUG 9 POEMA PLUG 1 E C12 C p C12 DOWN LIMI si DA C2 EMERGENCY STOP c2 PER Le B12 UP DOWN SW UP B12 Zz 9 A12 UP DOWN SW DOWN A12 gt lt 2 55 j 8 6 a ret os A9 MOTOR CONTROLLER A9 29 TERMINAL 3 gt gt B8 OPT SERVICE HORN B8__ GROUND 5 2 55 ZTN 280 z z R 626 B lii gt lt LO 2 Ro CZAJE SMG EG ZG GE o Eri DX Te m ii m T 5 Xo 0 0 9 lt o lt 5 a Ha g 9X gt S 5 LLI peg i T a z RE 5E c gt 2 2 a M 8 Sk wa 25 lt T SEE MOG 5 cee Lr 24F gt 3o gli G zz o Oka gt pog 55 lt WE lt n Zy sE kop 544 N gt E 46326 Genie 05 2032 6 7 Service Manual Section 6 Schematics Electrical Schematic before serial number 6901 N M L RED A 2 RED
20. Check voltage at the output side of the contact Check voltage at the center terminal of the platform up down toggle switch S3 at the ground controls Test or replace the platform up down toggle switch 53 See Repair Section OR repair open in the wht wire from the toggle switch to the ECM B12 up switch OR repair open in the wht wire from the toggle switch to the ECM A12 down switch OR consult the Genie Industries Service Department 24V or more Chart 4 Repair open in the wht wire jumper from the platform control contact to the ground control contact at the key switch Check if the key switch Replace the key switch internal cam is activating contact for ground the ground control controls contact Replace the key switch Repair open in the wht wire jumper from the key switch to the center terminal on toggle switch Part No 46326 Genie GS 2032 5 15 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 5 Platform Controls inoperative Ground Controls Operate Normally Be sure if the Error Indicator light is on at the platform controls you refer to the specific chart that relates to the error code that is displayed on the ECM Be sure the circuit breaker and fuse are not tripped or blown Be sure the batteries are properly connected Be sure the batteries are fully charged Turn the key switch to platform control and make su
21. Complete step by step instructions for each scheduled maintenance procedure are provided in section 4 Scheduled Maintenance Procedures 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 Store completed forms for three years Part No 46326 Genie GS 2032 3 1 Section 3 Scheduled Maintenance Inspections Service Manual First Edition Maintenance Tables Table A Tools are New parts 2 required required suggested A 1 Inspect the Operators and Safety Manuals A 2 Inspect the Decals and Placards A 3 Inspect for Damage and Loose or Missing Parts A 4 Check the Hydraulic Oil Level 5 Check for Hydraulic Leaks A 6 Test the Platform and Ground Controls A 7 Test the Manual Platform Lowering Operation A 8 Test the Tilt Sensor A 9 Test the Pothole Guards ra ra A 10 Test the Lift Drive Select Switch A 11 Perform 30 Day Service gt Table 1 Check the Batteries B 2 Inspect the Electrical Wiring B 3 Inspect the Tires and Wheels including castle nut torque ra Pa ra 3 2 Genie GS 2032 Part No 46326 Service Manual First Edition Table B continued Section 3 Scheduled Maintenance Inspections a Tools are required New parts requi
22. Down Limit Switch O Hour meter ev Limit switch Battery normally closed 6 6 Genie GS 2032 Part No 46326 Service Manual Section 6 Schematics Electrical Schematic before serial number 6901 o gt 2 Rz 10 1 B WHT dk i A6 UP COIL okZzyj NEC RED oS gt NORDEA LLI A5 LEVEL SENSOR RED A5 C11 LEVEL SENSOR WHT 11 DA DATA LINK YEL C1 _DOWN DATA LINK BLK 5i 56 B6 COIL TT 1 GROUND FROM JOYSTICK GRN 2 Es EMERGENCY STOP TO JOYSTICK WHT B2 gt EMERGENCY STOP FROM JOYSTICK RED A4 Ba FORWARD C6 SL C6 JUMPER C10 COIL 4 5 gt A11 KEY SWITCH 11 BH UPLIMTSW lpi gt lt ul A7 a7 REVERSE_ i 85 og COIL La gt 5 gt 0 nan 39C m 21B 11 B10 POTHOLE SW
23. EE Z Solenoid operated 2 pos 3 way directional valve mlx hs Solenoid operated 3 pos 4 way directional valve 001 Check valve pilot to open lt O gt Shuttle valve Genie GS 2032 Part No 46326 TP POWER UNIT Service Manual Section 6 Schematics ZZ ZZO OO OH Hydraulic Schematic before serial number 17482 L K J G F E D B A mm 1 LIFT LEFT 1 RIGHT CYLINDER BRAKE BRAKE Z Ek mim HAND PUMP L 1 03 CU IN LEFT lt O gt 4 DRIVE MOTOR DRIVE MOTOR 2 R STEER STEER Q LEFT RIGHT p x X 0 046 A GO 3 amm 5 ee WE The lift cylinder orifice is 3 located underneath the S1 S2 fitting on the lift cylinder LIFT BRAKE HP M1 M3 M2 M4 a ee ee ee 0 060 4 2 AD 5 L4 s H e 1000 PSI 4 82 7 ee 0 040 0 025 e c D 5 PSI ve Y5 V 0 3 bar W 6 0 5 GP
24. H F E D C B A PLATFORM CONTROL BOX NOCT E E 1 ENCODER 9 CONDUCTOR RIBBON 8 56 ro5 04 NC rog BLUE IDENTIFICATION LINE O 1 NO 2 S9 EMERGENCY HIGH SPEED o gt E STOP SWITCH S8 NC Nc ESTOP BLK WIRE 23 d LED BD RED LED BD BLK WIRE 20 LED CARD LED BD YEL WIRE 19 FLT CN LIFT DRIVE LED BD WHT WIRE 1 ON ORA HORN WHT WIRES 510 SWITCH 57 US 3 HORN ORG WIRE 16 HORN DRIVE BRAKE Vou MET V ENCODERBOARD 112435 8 TOGGLE WHT WIRE Baa SER se sie ccu 7 TOGGLE YEL WIRE 12 6 TOGGLE BLK WIRE 11 5 JS WHT POS 4 WIRE 10 4 JS YEL POS 2 WIRE 9 3 JS RED POS 3 WIRE 8 2 JS BLK POS 5 WIRE 7 4 1 JS ORG POS 1 WIRE 6 5 LEGEND 5 DES COMPONENT DES COMPONENT AP1 ANDERSON PLUG S8 HIGH SPEED SWITCH B1 MULTIFUNCTION ALARM S9 PLATFORM EMERGENCY STOP F1 275 AMP FUSE S10 HORN BUTTON F2 7ACIRCUIT BREAKER U1 CHASSIS CONTROLLER 7 Gi BATTERIES 4 6 VOLT U2 MOTOR CONTROLLER G2 BATTERY CHARGER U3 DRIVE BRAKE ENCODER BOARD H1 OPTIONAL HOUR METER Y1 PARALLEL COIL P2 LEVEL SENSOR Y2 BRAKE COIL 81 CHSSIS EMERGENCY STOP Y3 RIGHT TURN COIL S2 CHASSIS KEY SWITCH Y4 LEFT TURN COIL 3 CHASSIS UP DOWN SWITCH Y5 REVERSE COIIL 8 S4 DOWN LIMIT SWITCH Y6 FORWARD COIL S5 POTHOLE SWITCH Y7 DOWN COIL S6 POTHOLE SWITCH Y8 UPCOIL S7 DRIVE LIFT SELE
25. 11185000 000000000000 7 10 cB Sel E H 7 16 Ground Controls 4 1 Manual Platform Lowering 7 18 4 2 Toggle Switches See 1 3 Toggle Switches sess 7 6 Hydraulic Pump 5 iPydraulicPutrip zwa W tad ise iP 7 19 Manifolds 6 1 Function Manifold Components before serial number 11501 7 20 6 2 Function Manifold Components after serial number 11500 7 22 6 3 Valve Adjustment Function 7 24 Part No 46326 Genie GS 2032 xi Service Manual First Edition TABLE OF CONTENTS Section Seven Repair Procedures continued Steering Axle Components 74 YOKE and Drive MOOI esta eet ec ote tuu cde e dart 7 26 7 2 Steering Cylinder 7 27 7 3 SteeringBellGrank iret Enea TREE 7 28 Non steering Axle Components 8 1 Drive wan cS 7 29 Brake Release Hand Pump Components 9 1 Brake Release Hand Pump Components 7 30 xii Genie GS 2032 Part No 46326 Service Manual First Edition Section 2 Specifications Machine Specifications Stowed dimensions Specifications Tires and wheels Length 96 in 2
26. LHM pO wg GO adH 111 OOOOOO I J uj F HE SNOO ONCO S7 0 0 0 S10 59 Lift Drive Select SME af m Ow Oo Oe O 9 Ow O 9 OPWR ON ONO 0 O O PLATFORM CONTROL BOX 16 Genie GS 2032 Part No 46326 Service Manual First Edition Section 6 Schematics Platform Controls Legend after serial number 17407 EMERGENCY STOP BUTTON 524 Q ENS BLACK pol RED 5 RED w amp LE ALARM Saas a W AL T RED BLACK Part No 46326 Genie GS 2032 Section 6 Schematics Service Manual First Edition Hydraulic Symbols Legend Pressure gauge Filter Fixed displacement pump a Bi directional motor 8 Pump prime mover engine or motor Double acting cylinder 0 035 Orifice with size sa Check valve Relief valve Priority flow divider AOL Solenoid operated dump valve
27. Part No 46326 Service Manual First Edition Power Source The Genie GS 2032 machines are powered by four six volt 225 AH batteries The four batteries are wired in series to produce 24 volts Hydraulic System All machine functions are performed by the hydraulic system The hydraulic system is powered by a single section gear pump When the pump is activated it supplies hydraulic fluid under pressure to the function manifold where the control valves are located To protect from over pressurization of the hydraulic system the pump is provided with a pressure relief valve Activating a machine function is accomplished by actuating or moving a switch and or control handle which sends voltage to the ECM The ECM then sends the signal to the appropriate directional control valve The directional valve determines which direction the hydraulic fluid will travel Computer software determines the volume of fluid in relation to the proportional valve input voltage Electrical System Limit switches are found in various locations on the machine The function of a limit switch is to communicate the operating position of the machine to the ECM Electronic Control Module When a change in signal is received from a limit switch the ECM responds by limiting the drive speed to 0 5 miles per hour 0 8 km h according to the default settings in the ECM software Machine Controls Theory of Operation The GS 2032 machines are equ
28. index 8 25 Use a soft metal drift to remove the number 2 pivot pin index 8 Remove the number 2 inner arm index 7 from the machine Bodily injury hazard The number ACAUTION 2 inner arm index 7 may become unbalanced and fall if not properly supported when it is removed from the machine 26 Remove the safety arm from the number 2 inner arm index 7 that was just removed 27 Attach the strap from the overhead crane to the number 1 inner arm index 10 28 Raise the number 1 inner arm index 10 approximately 2 feet 0 6 m and insert the safety arm between the number 1 inner arm index 10 and the number 1 outer arm index 18 Bodily injury hazard Keep hands ACAUTION clear of moving parts when inserting the safety arm 29 Disconnect and plug the hydraulic hose on the lift cylinder Cap the fitting on the cylinder Bodily injury hazard Spraying AWARNING 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 7 12 Genie GS 2032 Part No 46326 Service Manual First Edition Section 7 Repair Procedures 30 Tag and disconnect the wires from the solenoid valve on the cylinder 31 Attach the strap from an overhead crane to the lug on the rod end of the lift cylinder 32 Remove the pin retaining fasteners from the cylinder barrel end pin index 17 Use a soft metal drift t
29. the manifold to the battery module tray OR replace the ECM OR consult the Genie Industries Service Department Replace the drive forward directional valve coil item J 5 28 Genie GS 2032 Part No 46326 Service Manual First Edition Section 5 Troubleshooting Flow Charts Drive Reverse Function inoperative Be sure all other functions operate normally Be sure the circuit breaker and fuse are not tripped or blown Be sure the batteries are properly connected Be sure the batteries are fully charged With the key switch in platform position and the Emergency Stop buttons pulled out to the on position at both the light is ground and platform on controls activate the drive controller in the reverse direction and check to see if the error indicator light at the platform controls is on light is not on Replace the drive forward reverse valve cartridge item J OR consult the Genie Industries Service Department Connect the positive lead from a volt meter to the drive reverse directional valve coil item J wire terminal without disconnecting the wire and the negative lead of the volt meter to the brown ground wire on the function manifold Activate drive in the reverse direction and check the voltage Disconnect the wires from the drive reverse directional valve coil item J and check the resistance See Repair Section Repair or replace
30. A A5 LEVEL SENSOR POWER A6 UP COIL A7 REVERSE COIL A8 MOTOR CONTACTOR A9 MOTOR CONTROLLER A10 JUMPER TO B4 A11 KEY SWITCH TO PLAT A12 DOWN B1 PLAT DATA BLACK PIN D B2 ESTOP TO PLAT WHITE PIN C B3 GROUND B4 JUMPER TO A10 B5 PLUG B6 DOWN COIL B7 LEFT COIL B8 HORN OPTION B9 ALARM B10 POTHOLE LIMIT SWITCH B11 PLUG B12 UP C1 PLAT DATA YELLOW PIN E C2 CHASSIS ESTOP C3 PLUG C4 PLUG C5 JUMPER TO C10 C6 FORWARD COIL C7 RIGHT COIL C8 PLUG C9 BRAKE COIL C10 JUMPER TO C5 C11 LEVEL SENSOR SIGNAL C12 DOWN LIMIT SWITCH G F E D C B A PLATFORM CONTROL BOX 1 9 CONDUCTOR RIBBON 5 ENCODER 2 Nc BLUE IDENTIFICATION LINE P NO S9 EMERGENCY HIGHSPEED STOP SWITCH S8 NC NC ESTOP BLK WIRE o 3 ESTOP WHT BLK WIRE NO LED BD RED WIRE LED CARD one LED BD WHT RED WIRE O BAT LED BD YEL WIRE O FLT a LIFT DRIVE LED BD WHT YEL WIRE O ON L 810 SWITCH 57 HORN VIOLET WIRE HORN WHT VIOLET WIRE HORN DRIVE BRAKE TOGGLE HS WHT GRAY WIRE ENCODERBOARD 6 911087 4 TOGGLE L D BLUE WIRE Ek 12222 TOGGLE L D WHT BLUE WIRE TOGGLE L D GREEN JS
31. Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 2 Turn the key switch to platform control and pull out the Emergency Stop button to the on position at both the ground and platform controls Lower the platform to the stowed position Move the drive select toggle switch down for normal drive operation OR press the drive speed selector button until the indicator light is OFF 5 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 6 Bring the machine to maximum drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 7 Continue at full speed and note the time when the machine reference point passes over the finish line Return the control handle to center Drive speed Stowed position 40 12 4 12 2 m 12 4 sec TABLE PROCEDURES B 9 Test the Drive Speed Raised Position 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 Select a test area that is firm level and free of obstructions 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 2 Turn the key switch to
32. PSI 103 4 bar after serial number 3405 Schematic item C was deleted after serial number 8798 Schematic item J was deleted after serial number 8798 Schematic item A changed to 0 75 GPM 2 8 L min after serial number 11500 Schematic item K changed to 200 PSI 13 8 bar after serial number 16893 Plug Torque Specifications Torque 35 40 ft lbs 47 54 Nm 10 12 ft lbs 14 16 Nm 25 30 ft lbs 34 41 Nm 25 30 ft lbs 34 41 Nm 18 20 ft lbs 24 27 Nm 23 25 ft lbs 31 34 Nm 18 20 ft lbs 24 27 Nm 35 40 ft lbs 47 54 Nm 25 30 ft lbs 34 41 Nm 18 20 ft lbs 24 27 Nm Description Hex Size Torque Description Hex Size Torque SAE No 2 1 8 50 in lbs 6 Nm SAE No 8 5 16 50 ft lbs 68 Nm SAE No 4 3 16 13 ft lbs 18 Nm SAE No 10 9 16 55 ft lbs 75 Nm SAE No 6 1 4 18 ft lbs 24 Nm SAE No 12 5 8 75 ft lbs 102 Nm 7 20 Genie GS 2032 Part No 46326 Service Manual First Edition Section 7 Repair Procedures FUNCTION MANIFOLD Part No 46326 Genie GS 2032 7 21 Section 7 Repair Procedures Service Manual First Edition E FUNCTION MANIFOLD 6 2 Function Manifold Components after serial number 17481 The function manifold is mounted inside the hydraulic power unit module Index Schematic No Description Item Function Torque 1 Check Steer
33. Service Manual First Edition Section 6 Schematics Observe and Obey M 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 damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Troubleshooting Read understand and obey the safety rules and operating instructions printed in the Genie GS 2032 amp Genie GS 2046 amp Genie GS 2646 amp Genie GS 3246 Operator s Manual Be sure that all necessary tools and test equipment are available and ready for use Schematics About This Section There are two groups of schematics in this section An illustration legend precedes each group of drawings Electrical Schematics AWARNING Electrocution hazard Contact with electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry Hydraulic Schematics Bodily injury hazard Spraying AWARNING 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 General Repair Process Malfunction Identify Troubleshoot discovered symptoms problem still exists Perform repair Return to service problem solved
34. WHT GRN POS10 JS ORANGE POS 9 GROUND JS WHT ORG POS 8 JS WHITE POS 7 JS WHT BRN POS 6 5 LEGEND 6 DES COMPONENT DES COMPONENT AP1 ANDERSON PLUG S8 HIGH SPEED SWITCH B1 MULTIFUNCTION ALARM S9 PLATFORM EMERG STOP F1 275 AMP FUSE S10 HORN BUTTON F2 7 AMP CIRCUIT BREAKER U1 CHASSIS CONTROLLER 7 G1 BATTERIES 4 6 VOLT 02 MOTOR CONTROLLER G2 BATTERY CHARGER US DRIVE BRAKE ENCODER BOARD H1 OPTIONAL HOUR METER Y1 PARALLEL COIL P2 LEVEL SENSOR Y2 BRAKE COIL 51 CHASSIS EMERGENCY STOP RIGHT TURN COIL 52 CHASSIS KEY SWITCH Y4 LEFT TURN COIL S3 CHASSIS UP DOWN SWITCH Y5 REVERSE COIIL 8 54 DOWN LIMIT SWITCH Y6 FORWARD COIL S5 POTHOLE SWITCH Y7 DOWN COIL S6 POTHOLE SWITCH Y8 UP COIL 57 LIFT DRIVE SELECTOR SWITCH Part No 46326 Genie GS 2032 6 12 Service Manual Section 6 Schematics p Electrical Schematic from serial number 8932 to 17407 Service Manual after serial number 17407 Electrical Schematic Section 6 Schematics 5 9 z ACE o S ee UP gt 5 WHT 7 OUT
35. and remove the block of wood TABLE A PROCEDURES A 10 Test the Lift Drive Select Switch before serial number 17408 A properly functioning Lift Drive Select Switch is essential for safe machine operation An improperly operating Lift Drive Select Switch will fail to activate the appropriate platform control which may result in a hazardous situation 1 Turn the key switch to platform control and pull out the Emergency Stop button to the on position at both the platform and ground controls Move the lift drive select switch to the LIFT position Press and hold the function enable switch Result The green power light should come on Slowly move the control handle off center Result The platform should raise or lower A Move the lift drive select switch to the DRIVE position Press and hold the function enable switch Result The green power light should come on Slowly move the control handle off center Result drive steer functions should operate Part No 46326 Genie GS 2032 4 7 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE A PROCEDURES A 11 Perform 30 Day Service The 30 day maintenance procedure is a one time sequence of procedures to be performed after the first 30 days or 50 hours of usage After this interval refer to the maintenance tables for continued scheduled maintenance 1 Perform the following maint
36. at the platform controls Check voltage at output Replace contact on side of platform Emergency Stop switch Emergency Stop switch OR replace Emergency Stop switch Check voltage at Before serial number terminal 5 on the main 6091 replace the main circuit board at the circuit board platform controls After serial number 6900 repair open in the wire from terminal 22 to terminal 5 on the main control board Check voltage at Replace control cable terminal A4 at the ECM from the ECM to the platform controls Replace the ECM OR consult the Genie Industries Service Department Part No 46326 Genie GS 2032 5 17 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 6 Platform Up Function inoperative Be sure all other functions operate normally Be sure the circuit breaker and fuse are not tripped or blown Be sure the batteries are properly connected Be sure the batteries are fully charged With the key switch in paron position and oth Emergency Stop buttons pulled out to the ON position and the lift light is drive selector switchin on the lift position activate the controller in the UP direction and check to see if the error indicator light at the platform controls is on light is not on Install a 0 to 3500 PSI 3000 pressure gauge at the PSI or quick disconnect more coupling on the function manifold and activate the platform up function
37. external snap ring from the lift cylinder rod end pivot pin Then use a soft metal drift to remove the pin AWARNING 10 Lower the cylinder Crushing hazard The lift cylinder will fall if not properly supported Genie GS 2032 Part No 46326 Service Manual First Edition Section 7 Repair Procedures Component damage hazard Be careful not to damage the level sensor box limit switch or level sensor while lowering the cylinder CAUTION 11 Support and secure the entry ladder to an appropriate lifting device 12 Remove the mounting fasteners from the entry ladder and remove the entry ladder from the machine Crushing hazard The entry ladder ACAUTION may become unbalanced and fall if not properly supported and secured to the lifting device 13 Support the barrel end of the lift cylinder with a lifting device 14 Remove the external snap ring from the lift cylinder barrel end pivot pin Then use a soft metal drift to remove the pin Crushing hazard The lift cylinder AWARNING may become unbalanced and fall if not properly supported 15 Carefully pull the cylinder out the non steer end of the machine through the scissor arms CAUTION Component damage hazard Be careful not to damage the valve or fittings on the cylinder while removing it from the machine SCISSOR COMPONENTS How to Check the Resistance of a Lowering Valve Coil 1 Turn the key switch to the position and disconnect th
38. m 5 Lift the safety arm move to the center of the scissor arm and rotate down to a vertical position Crushing hazard Keep hands AWARNING 4 clear of the safety arm when lowering the platform 6 Lower the platform onto the safety arm 7 Mark the mounting position of the level sensor box on the drive chassis 8 Remove the fasteners from the level sensor box and slide it towards the non steer end of the machine until it contacts the level sensor 9 Secure the ends of the scissor arms together at both ends of the machine with a tie down strap or other appropriate device 10 Remove the pin retaining fasteners from the number 1 inner arm pivot pins at the steer end of the machine Use a slide hammer to remove the pins 11 Attach a strap from an overhead crane to the steer end of the scissor arms 12 Carefully slide the forks from a forklift under the scissor arms at the non steer end of the machine 13 Raise the scissor arms up until the number 1 inner arm will clear the level sensor box CAUTION Component damage hazard Be careful not to damage the level sensor box limit switch or level sensor while moving the scissor assembly 14 Move the scissor assembly towards the non steer end of the machine slightly and to one side of the machine until one of the scissor arm wear pads is accessible Do not allow both wear pads to slide out of the drive chassis 7 The scissor assembly will fall if ADANGER both w
39. other manuals Please write to the technical publications team in care of Genie Industries PO Box 97030 Redmond WA 98073 9730 USA If you have any questions please call Genie Industries Genie North America Telephone 425 881 1800 Toll Free in U S A 800 536 1800 Toll Free in Canada 800 426 8089 Fax 425 882 9260 E mail techpub genieind com http www genielift com Genie Europe Office Telephone 44 01636 605030 Office Fax 44 01636 611090 Parts Telephone 44 01636 605002 Parts Fax 44 01636 611091 Genie Industries Copyright 1997 by Genie Industries First Edition First Printing August 1997 Second Printing March 1999 Third Printing October 1999 Genie is a registered trademark of Genie Industries in the U S A and many other countries GS is a trademark of Genie Industries These machines comply with ANSI SIA 92 6 1990 6 Printed on recycled paper Printed in U S A ii Genie GS 2032 Part No 46326 Service Manual First Edition Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the Genie GS 2032 amp Genie GS 2046 amp Genie GS 2646 amp Genie GS 3246 Operator s Manual 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 M You are trained and qualified to p
40. platform should lower The descent alarm should sound while the platform is lowering CE models When lowering the platform the platform should stop when it is 6 feet 1 8 m from the ground Be sure the area below the platform is clear of personnel and obstructions before continuing To continue lowering release the control handle wait 4 6 seconds then move the control handle again 11 Push in the Emergency Stop button to the oFF position Result No function should operate The machine should stop As a safety feature selecting and operating the ground controls will override the platform controls except the Emergency Stop button Part No 46326 Genie GS 2032 4 5 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE A PROCEDURES A 7 Test the Manual Platform Lowering Operation Detection of Manual Platform Lowering system malfunctions is essential for safe machine operation An unsafe working condition exists if the Manual Platform Lowering function does not operate in the event of a main power loss 1 Turn the key switch to ground control and pull out the Emergency Stop button to the on position at both the platform and ground controls 2 Raise the platform approximately 2 feet 0 6 m 3 Pull the Manual Platform Lowering handle located next to the ground controls O Result The platform should lower The descent alarm will not sound A 8 Test the Tilt Sensor
41. serial number 11500 Coil 20V function manifold items G I 26 28W Coil 20V function manifold items H J K 18 20W Part No 46326 Genie GS 2032 Section 7 Repair Procedures Service Manual First Edition Steering Axle Components 7 1 Yoke and Drive Motor How to Remove the Yoke and Drive Motor When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Block the non steering wheels and then center a lifting jack under the drive chassis at the steer end of the machine 2 Remove the cotter pin from the wheel castle nut Always replace the cotter pin with a new one when removing the castle nut 3 Loosen the wheel castle nut Do not remove it Raise the machine approximately 14 inches 36 cm and place blocks under the drive chassis for support Crushing hazard The chassis will AWARNING fall if it is not properly supported 5 Remove the castle nut then remove the wheel 6 Tag disconnect and plug the hoses on the drive motor Cap the fittings on the motor Bodily injury hazard Spraying AWARNING 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 7 Support and secure the yoke assembly to a
42. steer end Jack the steer end of machine up approximately 4 inches 10 cm and place jack stands under the machine for support With the lift drive selector switch in the drive position move the joystick controller to the full speed forward or reverse position See Chart 10A Brake Release Function Inoperative CHART 13 Reset the relief valve pressure OR replace the relief valve OR rebuild or replace the drive motors OR the function manifold may have an internal defect Consult the Genie Industries Service Department Repair or replace drive motor s OR consult the Genie Industries Service Department Part No 46326 Genie GS 2032 5 31 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 14 Machine With the key switch in ight is Consult ha Genie latform position and the not on Drives At Stop buttons ora pulled out to the ON Full Speed position at both the With Platform ground and platform b controls and the Raised platform in the stowed position drive the machine in either direction Is the error indicator light on at the Be sure the circuit platform controls breaker and fuse are not tripped or blown See Chart 13 OR Be sure the remove the obstruction batteries are the yrer guard R consult the Genie properly connected Industries Service Be sure the Department batteries are fully charged 5 32 Genie GS 2032 Part No 46326
43. strap from an overhead crane to the number 3 outer arm index 13 4 Remove the external snap rings from the number 3 center pivot pin index 2 5 Use a soft metal drift to remove the number 3 center pivot pin index 2 6 Remove the external snap rings from the number 3 pivot pin index 14 SCISSOR COMPONENTS 7 Use a soft metal drift to remove the number 3 pivot pin index 14 Remove the number 3 outer arm index 13 from the machine Bodily injury hazard The number ACAUTION 3 outer arm index 13 may become unbalanced and fall if not properly supported when it is removed from the machine 8 Remove the cable clamps from the number 3 inner arm index 4 9 Remove the mounting fasteners from the cable tray support at the steer end 10 Remove the external snap rings from the number 2 center pivot pin index 6 at the ground controls side Do not remove the pin 11 Slide the cable tray towards the battery pack side of the machine and remove it from the machine and lay it off to the side CAUTION Component damage hazard Cables can be damaged if they are kinked or pinched 12 Attach a lifting strap from an overhead crane to lug on the rod end of the lift cylinder 13 Remove the pin retaining fasteners from the cylinder rod end pivot pin index 3 Use a soft metal drift to remove the pin Bodily injury hazard The cylinder ACAUTION may fall if not properly supported when the pin is removed 14 L
44. the drive reverse directional valve item J OR consult the Genie Industries Service Department Chart 12 Repair open in the wht wire from the drive reverse directional valve coil A7 reverse coil to the ECM OR repair open in the brown ground wire circuit from the manifold to the battery module tray OR replace the ECM OR consult the Genie Industries Service Department Replace the drive reverse directional valve coil item J Part No 46326 Genie GS 2032 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 13 Machine Will Not Drive At Full Speed Be sure the circuit breaker and fuse are not tripped or blown Be sure the batteries are properly connected Be sure the batteries are fully charged With the key switch in platform position and the light is Emergency Stop buttons noton pulled out to the ON position at both the ground and platform controls and the platform in the stowed position drive the machine in either direction Is the error indicator light on at the platform controls light is on Check voltage at the wht 1 39C pothole sw at 5 24V Raise the platform approximately 3 feet 0 9 m and check the voltage at the output side of S5 24V Check voltage at the wht wire 21B pothole sw on the input side of S6 24V Check voltage on the oV output side of S6 24V Continued on the next page
45. the machine to aid in troubleshooting If the Part No 46326 Genie GS 2032 Service Manual First Edition ee ee THEORY OF OPERATION machine malfunctions a fault code will be shown in the display window Washing electronic components is not suggested Instead use compressed air to remove debris from these components Component damage hazard ACAUTION Avoid shock or impact to the ECM Internal damage may not be visible from the outside vi Genie GS 2032 Part No 46326 Service Manual First Edition Introduction Section One Section Two Section Three Table of Contents Important ii Safety Rules General Safety Rules eeee ue e aaa aaa aaa nenne nennen enn iii Theory of V Specifications Machine 2 1 Performance Specifications 2 2 Ilydraulic Specifications cd viet ccc Ded aaa coa 2 2 Hydraulic Hose and Fitting Torque Specifications 2 3 Scheduled Maintenance Inspections Introdu tOM M 3 1 Ay 3 2 21215 x IET 3 3 3 3 3 3 Maintenance Inspection
46. 2 All Functions Inoperative Power Unit Starts and 5 14 Ground Controls Inoperative Platform Controls Operate Normally 5 15 Platform Controls Inoperative Ground Controls Operate Normally 5 16 Platform Up Function Inoperative 5 18 Platform Down Function 2 nns 5 19 Steer Left Function Inoperative 5 21 Steer Right Function Inoperative 11 1 10 aaa aaa 5 23 All Drive Functions Inoperative All Other Functions Operate Normally 5 25 Brake Release Function Inoperative 4 4804044 5 27 Drive Forward Function eee 5 28 Drive Reverse Function 5 29 Machine Will Not Drive At Full Speed 044000000 5 30 Machine Drives At Full Speed With Platform Raised 5 32 Part No 46326 Genie GS 2032 ix Service Manual First Edition TABLE OF CONTENTS Section Six Schematics p RE ERP 6 1 Electrical C mBpOonEMIS 6 2 Module Tray Legend before serial number 6901 6 4 Module Tray Legend after serial number 6900 6 5 Electrical Symbols Legend ei o ee ie aa 6 6 Elec
47. 3 HORN 5 PINS gt J4 DRIVE ENABLE J5 LIFT ENABLE 6 PIN8 PIN9 PIN10 In B1 ALARM CN EMERGENCY STOP T J9 EMERGENCY STOP LEG E N D EMERGENCY STOP 8 BUTON Jj ALARM os PLATFORM CONTROLLER d LED j CONNECTOR Part No 46326 Genie GS 2032 6 14 Service Manual Section 6 Schematics Electrical Schematic after serial number 17407 Service Manual First Edition Section 6 Schematics Ground Controls and Level Sensor Box Legend E 11 KEY SWITCH 1 52 53 51 O poer LC 25F O H1 oop H FO LOH lt NCO TET U A12 B12 24F m _ 42F 23F C2 IN i j GROUND CONTROL BOX ND C 2 O la 3 7 S4 B9 c 5 zd lt TILT SENSOR BAL gt 29 23F C12 WHT 210 11 RED gt l C 2 y J LEVEL SENSOR BOX Part No 46326 Genie GS 2032 6 15 Section 6 Schematics Service Manual First Edition Platform Controls Legend before serial number 17408 J 2 O NYD 2 O
48. 4 3 16 13 ft lbs 18 Nm SAE No 10 9 16 55 ft lbs 75 Nm SAE No 6 1 4 18 ft lbs 24 Nm SAE No 12 5 8 75 ft lbs 102 Nm 7 22 Genie GS 2032 Part No 46326 Service Manual First Edition Section 7 Repair Procedures FUNCTION MANIFOLD Part No 46326 Genie GS 2032 7 23 Section 7 Repair Procedures Service Manual First Edition FUNCTION MANIFOLD 6 3 Valve Adjustments Function Manifold Be sure that the hydraulic oil level is between the FULL and ADD marks on the oil level indicator decal How to Adjust the System Relief Valve 1 Open the hydraulic power unit module tray and locate the system relief valve on the function manifold 2 Place maximum rated load onto the platform Secure the load to the platform Maximum Capacity GS 2032 1000 Ibs 454 kg 3 Turn the key switch to ground control and pull out the Emergency Stop button to the on position at both the ground and platform controls 4 Hold the system relief valve with a wrench and remove the cap item 6 function manifold 5 While activating the platform up function adjust the internal hex socket clockwise to increase lift capacity or counterclockwise to decrease lift capacity Adjust the relief valve until the platform just begins to raise 6 Fully lower the platform 7 Add an additional 100 pounds 45 4 kg to the platform Secure the additional weight 8 Activate the platform up functio
49. 43 8 cm Tire size solid rubber 15 x 5 in 38 1 x 12 7 x 28 5 cm Length platform extended 1351 2 in 344 2 cm Load range 2 400 Ibs 1 089 kg Width 32 in 81 3 cm Tire contact area 8 sq in 20 3 sq Height stowed maximum Rails up CE 827 8 210 3 cm Overall tire diameter 15 in 38 1 cm Height stowed maximum Wheel diameter 111 4in 28 5 cm Rails up ANSI 781 2 in 199 1 cm Wheel width 5 in 12 7 cm Height stowed maximum Rails lowered 761 2 in 193 8 cm Castle nut torque 300 ft lbs 406 7 Nm Height stowed maximum Platform dimensions rails removed 39 in 99 cm Length 89 in 226 1 cm Height guard rail level 39 in 99 1 cm 9 Weight 3438 Ibs 1559 kg Width 311 4 in 65 cm Ground clearance 4 0 in 10 2 cm Extension length 29 2 in 79 4 cm Ground clearance Maximum load capacity 800 Ibs 363 kg Pothole guards deployed 7 8 in 2 2 cm Fluid Capacities Operational dimensions Hydraulic tank capacity 5 5 gallons 20 8 liters Maximum platform height 20 ft 5 8 m Hydraulic system capacit 6 gallons 22 7 lit Maximum platform includit Un PX 9 working height 25 1 ft 6 1m Maximum platform extension 39 in im Continuous improvement of our products is a Genie policy Product specifications are subject to Wheelbase 73 in 185 cm change without notice Turning raduis outside 92 in 233 7 cm Turning raduis inside 0 in 0 cm Part No 46326 Genie GS 2032 Section 2 Specifications SPECIFICATIONS Performance Specifications Drive speeds maximum
50. 5 Pull the wiring through the platform tube If your machine is equipped with an air line to platform option the air line must be disconnected from the platform before removal 6 Support the platform with a forklift at the non steer end Do not lift it 7 Attach a strap from the platform railings to the carriage on the forklift to help support the platform 8 Remove the retaining fasteners from the Scissor platform pivot pins at the steer end of the machine 9 Use a slide hammer to remove the pins Crushing hazard The platform will AWARNING fall if it is not properly supported 10 Remove the plugs from the access holes in the side of the platform 11 Lift the steer end of the platform slightly to clear the scissor arms and slide the platform towards the non steer end of the machine until the non steer end platform pivot pins are visible through the access holes in the side of the platform 12 Remove the retaining fasteners from the scissor platform pivot pins at the non steer end of the machine 13 Use a slide hammer to remove the pins Crushing hazard The platform will AWARNING fall if it is not properly supported 14 Carefully lift the platform off of the machine and place it on a structure capable of supporting it Note the position of the wear pads before the platform is removed so when the platform is installed they will be in the correct position Genie GS 2032 Part No 46326 Service Manual Fi
51. 6 4 mm 7 To adjust loosen the upper lock nut on the cable mounting bracket Turn the lower lock nut clockwise to decrease the distance or counterclockwise to increase the distance 8 Tighten the upper lock nut and re measure the distance between the end of the lowering cable and the end of the lowering valve Re adjust if needed 9 Install the cable mounting nut onto the lowering valve 10 Raise the platform and rotate the safety arm to the storage position 11 Pull the manual lowering handle at the ground controls 2 to 3 times to ensure it is functioning correctly Cable distance 3 16 to 1 4 inch 4 7 to 6 4 mm a manualloweringcable sheath upper lock nut cable mounting bracket lowerlock nut e cablemounting nut f T end ofthe lowering cable g manuallowering valve 4 2 Toggle Switches See 1 3 Toggle Switches Genie GS 2032 Part No 46326 Service Manual First Edition Section 7 Repair Procedures 5 1 Hydraulic Pump The hydraulic pump is attached to the motor which makes up the Hydraulic Power Unit How to Test the Hydraulic Pump When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Disconnect and plug the high pressure hydraulic hose from the hydraulic pump Bodily injury ha
52. 75A to Anderson plug Before serial number 6901 repair open in 24V supply cable from Anderson plug to motor contactor K1 After serial number 6900 repair open in 24V supply cable from Anderson plug to terminal B on the motor controller Part No 46326 Genie GS 2032 Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 1 Check voltage at input side of 7A circuit oV breaker F2 Continued from the previous page 24V Check voltage at wht wire at input side of ov Stop Switch 1 24V Check voltage at input side of each contact at the key switch S2 24V Turn key switch to oV ground control position and check output side of contact 24V Continued on the next page Before serial number 6900 Repair open in wht wire from input side of motor contactor to input side of 7A circuit breaker 24f circuit breaker to relay After serial number 6901 repair open in wire from motor controller to 7A circuit breaker Repair open in wht wire from output side of 7A circuit breaker OR reset or replace 7A circuit breaker Repair open in wht wire from Emergency Stop Switch to key switch OR repair open in wht wire jumper to each contact OR replace contact on Emergency Stop Switch OR replace Emergency Stop Switch Check cam on key bad Repair or replace key switch switch good Replace contact OR refer to Ground Con
53. CTOR SWITCH Part No 46326 Genie GS 2032 6 10 Service Manual Section 6 Schematics p Electrical Schematic from serial number 6901 to 8931 Service Manual Section 6 Schematics Electrical Schematic from serial number 8932 to 17407 5 ug sli v z E A6 1 Ae UP CO or 5 7 Lu lt EFK xl roza RED BRN OSI 9 A5 LEVEL SENSOR RED 5 C11 LEVEL SENSOR WHITE zu DATA LINK lc gt K DATA LINK B6 DOWN TT 1 5 GROUND FROM JOYSTICK o ________ EMERGENCY STOP TO JOYSTICK gt ________ EMERGENCY STOP FROM JOYSTICK A4 5j C amp COL ARD ir JUMPER C5 4 11 SWITCH At gt LLI LLI DA a7 REVERSE _ AT COIL LET ip s 00 4 Oo Nan gt d 21B d B10 POTHOLE SWITCH 10 B4 B7 B7 LEFT COIL 9 JUMPER 10 1 4 z B9 SMALL HORN _ B9 c C7 8 RIGH
54. GS 2032 m G Technical Publications muc before serial number 17408 o EON CL coy nc 22 c is amp o c o 5 LLI LL Tj Introduction Service Manual First Edition Genie GS 2032 Important Read understand and obey the safety rules and operating instructions in the Genie GS 2032 amp Genie GS 2046 amp Genie GS 2646 amp Genie GS 3246 Operators Manual before attempting any maintenance or repair 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 Genie Industries 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
55. M 1 9 L min G 3700 5 ran G RE Y8 Es m 0 7 PRESSURE o LLL 222 IMPORTANT NOTES 25 PSI CHANGED TO 1500 PSI 103 4 bar AFTER SERIAL NUMBER 3405 INE a 1 7 bar H DELETED AFTER SERIAL NUMBER 8798 8 8 E DELETED AFTER SERIAL NUMBER 8798 TT A CHANGED TO 0 75 GPM 2 8 L min AFTER SERIAL NUMBER 11500 K CHANGED TO 200 PSI 13 8 bar AFTER SERIAL NUMBER 16893 Part No 46326 Genie GS 2032 6 19 Service Manual Section 6 Schematics ed Hydraulic Schematic before serial number 17482 Service Manual Section 6 Schematics mcg Hydraulic Schematic after serial number 17481 M L K J H G F E D C B A LIFT LEFT r4 RIGHT CYLINDER BRAKE BRAKE a HAND PUMP pees 1 IN LEFT SS R ORAZ see Co P DRIVE MOTOR DRIVE MOTOR STEER STEER R MN zl z z LEFT RIGHT x 4 9 Q ___ 1 MANUAL 1 17 RELEASE S ______ Er un The lift cylinder orifice is located underneath the S1 S2 fitting on the lift cylinder LIFT BRAKE HP M1 M3 M2 M4 pm T MAGN RK E E
56. M Electronic Control Module contains programming for all configurations of the GS 2032 The platform controls can be adjusted to a different configuration by changing the combination of the DIP switch settings The DIP switch is located on the circuit board inside the platform control box DIP switches have two positions on or When reading the DIP switch code in the DIP Switch Codes Chart on page 7 5 the on and are represented by the numbers 1 on and O oFF Select a test area that is firm level and free of obstructions Machines manufactured before serial number 17408 were not adjustable If your ECM has been replaced or if the machine serial number is after 17407 you can verify the revision level of the ECM by using the following procedure How to Determine the Revision Level 1 Remove the platform controls from the platform 2 the key switch to platform control and pull out the Emergency Stop buttons to the on position at both the ground and platform controls PLATFORM CONTROLS Press and hold the lift enable button and the function enable switch Move the joystick handle to the up position to raise the platform Observe the code shown in the LED display window located on the battery pack side of the machine Result The configuration code of the DIP switch will appear in the LED display window Press and hold the lift enable button and the function enable switch Move the joystic
57. NG Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 9 Locate the drive forward reverse valve on the function manifold Refer to Illustrations 2 and 3 a drive forward reserve valve Part No 46326 Genie GS 2032 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE B PROCEDURES 10 Tag the forward and the reverse valve coils Remove the coils from the valve The forward valve coil has white and brown wires attached The reverse valve coil has white black and brown wires attached For reassembly it will be helpful to leave the wire harness attached to the valve coils 11 Remove the drive forward reverse valve from the function manifold Cap the open port of the manifold 12 Carefully inspect the hex portion of the valve for an identification stamp Result SV10 4727 is stamped on the hex portion of the drive forward reverse valve This indicates the machine is equipped with a dynamic brake valve Proceed to step 13 X Result SV10 4727 is not stamped on the hex portion of the drive forward reverse valve This indicates the machine is not equipped with a dynamic brake valve Proceed to step 18 13 Install the drive forward reverse valve removed in step 11 into the function manifold and securely tighten Torque to 25 ft lbs 34 Nm 14 In order install the revers
58. Part No 46326 Genie GS 2032 6 1 Section 6 Schematics Service Manual First Edition nm es Electrical Components Item Description Genie Manufacturer Manufacturer Qty Part Number Part Number Anderson connector 19436 Anderson 6325 G1 2 izy Alarm steady tone 39540 Floyd Bell Inc UC 09628 Q 1 cowania Alarm intermittent 18963 Floyd Bell Inc XB 09 630 Q 1 uM Fuse 275 amp 40833 BUS ANN 275 1 pp Circuit breaker 47811 ETA a 45 700 IG1 P10 2 Flashing beacon 39676 ECCO Electronic Controls 62204 2 Oi Battery 225AH 6V DC 62201 Allied Battery Co T 105 dry 8 bl aussen Hour meter 56100424 Curtis Instruments 17305666 me 1 Relay 180 amp 19550 Curtis Instruments 13220544 1 Level sensor Dual Axis 40836 Power Comp of Midwest L36 1 R
59. RN WHT WIRE 17 HORN ORG WIRE H16 HORN DRIVE BRAKE TOGGLE RED WIRE TOGGLE BLK WIRE 14 ENCODER BOARD 12143 8 TOGGLE WHT WIRE amp 13 ede MA enl 7 TOGGLE YEL WIRE 12 6 TOGGLE BLK WIRE 11 5 JS WHT POS 4 WIRE 10 4 JS YEL POS 2 WIRE 9 3 JS RED POS 3 WIRE 8 2 JS BLK POS 5 WIRE 7 1 JS ORG POS 1 WIRE 6 LEGEND DES COMPONENT DES COMPONENT AP1 ANDERSON PLUG 58 HIGH SPEED SWITCH B1 MULTIFUNCTION ALARM 59 PLATFORM EMERGENCY STOP F1 275 AMP FUSE S10 HORN BUTTON F2 7A CIRCUIT BREAKER U1 CHASSIS CONTROLLER Gi BATTERIES 4 6 VOLT u2 MOTOR CONTROLLER G2 BATTERY CHARGER u3 DRIVE BRAKE ENCODER BOARD H1 OPTIONAL HOUR METER Y1 PARALLEL COIL P2 LEVEL SENSOR Y2 BRAKE COIL 51 CHSSIS EMERGENCY STOP Y3 RIGHT TURN COIL 52 CHASSIS KEY SWITCH Y4 LEFT TURN COIL 53 CHASSIS UP DOWN SWITCH Y5 REVERSE COIIL S4 DOWN LIMIT SWITCH Y6 FORWARD COIL S5 POTHOLE SWITCH Y7 DOWN COIL S6 POTHOLE SWITCH Y8 UP COIL S7 DRIVE LIFT SELECTOR SWITCH Part No 46326 Genie GS 2032 6 8 Service Manual Section 6 Schematics Electrical Schematic before serial number 6901 Service Manual from serial number 6901 to 8931 Section 6 Schematics Electrical Schematic
60. S 2032 7 19 Section 7 Repair Procedures Service Manual First Edition Function Manifold 6 1 Function Manifold Components before serial number 17482 The function manifold is mounted inside the hydraulic power unit module Index Schematic No Description Item Function 1 Flow Regulator 0 5 1 9 L min Ai Steer 2 Diagnostic nipple Bass TESNO ep 3 Orifice Plug 0 025 in 0 6 mm Brake circuit 4 Orifice Washer 0 040 inch 1 mm D Steering circuit 5 Relief valve 1500 psi 103 4 bar E Steering 6 Relief valve 3700 psi 255 1 bar E sss System 7 3 position 4 way solenoid valve CREE Steer left right 8 2 position 4 way solenoid valve Eus Platform UD uie 9 2 position 2 way solenoid valve IRA Brake circuit 10 Orifice Washer 0 060 1 5 mm J Brake circuit 11 Check valve entes Brake circuit 4 422 12 2 position 4 way solenoid valve APA Drive speed select circuit 13 3 position 4 way solenoid valve Drive forward reverse Important notes Schematic item E changed to 1500
61. T 0 4 2 COIL 1 C12 DOWN LIMIT C12 TEL gt lt C2 EMERGENCY STOP T _ cg BRAKE d bu z9 E B12 UP SWITCH Bo COIL 1 4 e A A12 DOWN SWITCH _____ 2 gt GE A amp MOTOR COL _ A8 puer az MOTOR CONTROLLER C8 p a 0 A9 TERMINAL 3 con P B8 OPTION HORN B8 gt GROUND i 788 l Q SRA 1 IO t og 1 Oz A 74 252 A1 g 5 9 NS mm A GS RZ Z EX ao m E 23 5 lt 65 z 3 5 5 c uo bm la x 1 z t20 S1 EMERGENCY STOP BREAKER 1KO POT G2 BATTERY CHARGER G1 4 6V BATTERY AC INPUT 110 VAC AP1 Part No 46326 Genie GS 2032 6 11 RED BLK A4 E STOP FROM JOYSTICK Service Manual Section 6 Schematics Electrical Schematic from serial number 8932 to 17407 B2 E STOP TO JOYSTICK BLUE B1 DATA LINK GREEN C1 DATA LINK WHT A2 GROUND FROM JOYSTICK gt PINOUT FOR THE CONTROLLER R r Fo eaOOOCOOCOOC 1 QODOOOCOOCO0O I A1 PLUG 2 PLATGROUND BLUE PIN A3 PLUG 4 ESTOP FROM PLAT WHITE PIN
62. any battery cell displays a specific gravity of less than 1 098 the battery must be replaced Part No 46326 Genie GS 2032 4 9 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE B PROCEDURES B 2 Inspect the Electrical Wiring Maintaining electrical wiring in good condition is essential to safe operation and good machine performance Failure to find and replace burnt chafed corroded or pinched wires could result in unsafe operating conditions and may cause component damage Electrocution hazard Contact AWARNING with hot or live circuits may result in death or serious injury Remove all rings watches and other jewelry 1 Inspectthe following areas for burnt chafed corroded and loose wires Ground control panel Hydraulic power unit module tray Battery pack module tray Scissor arms Platform controls 2 Turn the key switch to ground control and pull out the Emergency Stop button to the on position 3 Raise the platform approximately 8 feet 2 4 m from the ground 4 Lift the safety arm move to the center of the scissor arm and rotate down to a vertical position 5 Lower the platform onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 6 Inspect the center chassis area and scissor arms for burnt chafed and pinched cables 7 Inspect the following areas for burnt chafed corroded pinched and lo
63. c chart that relates to the error code that is displayed on the ECM Be sure the circuit breaker and fuse are not tripped or blown Be sure the batteries are properly connected Be sure the batteries are fully charged Fill with Dexron II equivalent hydraulic fluid Check the hydraulic fluid level Check for a positive connection between the coupling OR replace the electric motor and pump OR replace the pump by removing the motor pump from the motor leaving all hoses connected Visually check the coupling connection Replace the pump Replace the pump Consult the Genie Industries Service Department 5 14 Genie GS 2032 Service Manual First Edition Part No 46326 Service Manual First Edition Section 5 Troubleshooting Flow Charts Ground Controls inoperative Platform Controls Operate Normally Be sure if the Error Indicator light is on at the platform controls you refer to the specific chart that relates to the error code that is displayed on the ECM Be sure the circuit breaker and fuse are not tripped or blown Be sure the batteries are properly connected Be sure the batteries are fully charged With the key switch in ground position and the Emergency Stop buttons pulled out to the ON position at both the ground and platform controls check voltage on the contact at the input side of the key switch at the ground controls S2
64. check voltage at terminal 1 on the motor controller 24V Activate lift function and check voltage at terminal 3 on controller Activate lift function and check voltage at M terminal on controller Replace pump motor OR consult the Genie Industries Service Department less than 24V no continuity no continuity less than 24V 24V Service Manual First Edition Replace positive battery cable from pump to B terminal on motor controller Replace negative cable from B terminal on controller to the Anderson plug Replace ground cable on pump motor Before serial number 6901 Repair open in wht wire A8 motor from K1 contact to controller After serial number 6900 Repair open in wht wire A8 motor from ECM Before serial number 8932 Repair open in wht wire A9 mtr cont terminal 3 from ECM to controller OR replace ECM OR consult Genie Industries Service Department After serial number 8931 Repair open in wht wire A9 mtr cont terminal 3 OR relpace 1k ohm potentiometer on controller Replace controller or contact Genie Industries Service Department 5 12 Genie GS 2032 Part No 46326 Service Manual First Edition Continued from the previous page Activate lift function and 24V or check voltage on the more output side of motor controller relay K1 less than 24V Activate lift function and 24V or check voltage o
65. e the drive controller handle Part No 46326 Genie GS 2032 Section 5 Troubleshooting Flow Charts Service Manual First Edition RZEZI CEEP CHART 9 Install a 0 to 2000 psi Check for mechanical pressure gauge at the restrictions keeping the quick disconnect steer right function from coupling on the function moving OR repair or manifold and activate replace the steer the steer right function cylinder OR consult the Genie Industries Service Department Continued from the previous page Repair or replace the steer cylinder OR replace the steer left right valve cartridge OR the function manifold could have an internal defect Consult the Genie Industries Service Department 5 24 Genie GS 2032 Part No 46326 Service Manual First Edition Section 5 Troubleshooting Flow Charts All Drive Functions Inoperative All Other Functions Operate Normally Be sure if the Error Indicator light is on at the platform controls you refer to the specific chart that relates to the error code that is displayed on the ECM Be sure the circuit breaker and fuse are not tripped or blown Be sure the batteries are properly connected Be sure the batteries are fully charged With the key switch in platform position and the Emergency Stop buttons pulled out to the ON position at both the light is ground and platform flashing controls activate drive forward and drive reverse functi
66. e functions Each function should operate smoothly and be free of hesitation jerking and unusual noise 1 M Turn the key switch to ground control and pull out the Emergency Stop button to the on position at both the platform and ground controls Activate the platform up function Result The platform should raise Activate the platform down function Result The platform should lower The descent alarm should sound while the platform is lowering Push in the ground controls Emergency Stop button to the orr position Result No function should operate Turn the key switch to platform control and pull out the Emergency Stop button to the on position at both the ground and the platform controls Press and hold the lift function enable button OR move the lift drive selector switch to the lift position Section 4 Scheduled Maintenance Procedures TABLE A PROCEDURES 7 Press and hold the function enable switch on the control handle Result The green power light should come on OR the light below the lift selector button should come on 8 Slowly move the control handle in the direction indicated by the blue arrow Result The platform should raise The pothole guards should deploy 9 Release the control handle Result The platform should stop raising 10 Press and hold the function enable switch Slowly move the control handle in the direction indicated by the yellow arrow Result The
67. e oil is necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test Perform this procedure with the platform in the stowed position 1 Disconnect the battery pack from the machine 2 Open the power unit compartment and place a drain pan or other suitable container under the hydraulic tank Table D Procedure 3 Remove the drain plug from the hydraulic tank AWARNING pd injury hazard Spraying ydraulic 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 4 Completely drain the tank into a suitable container See capacity specifications listed at right 5 Remove the return filter mounting bracket fasteners from the manifold Push the filter and accumulator out of the way 6 Remove the motor controller mounting bracket retaining fasteners and move the motor controller to the side 7 Remove the hydraulic tank from the machine 8 Remove the suction strainer and clean it using a mild solvent 9 Clean the inside of the hydraulic tank using a mild solvent 10 Install the suction strainer using thread sealer on the threads 11 Install the drain plug using thread sealer on the threads Part No 46326 Genie GS 2032 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE D PROCEDURE 12 Instal
68. e valve coil with white black and brown wires spacer washer and the forward valve coil with white and brown wires onto the valve For the machine to function correctly the reverse valve coil must be closest to the manifold 15 Install the coil nut onto the valve and tighten Torque to 60 in lbs 7 Nm 16 Connect the battery pack to the machine 17 Replace the brakes and repeat this procedure beginning with step 1 Refer to Repair Procedure 8 1 How to Remove a Drive Brake 18 Contact the Genie Industries Service Parts Department and order kit part number 105457 19 Install the new valve received in the kit and mark the new valve with a white paint pen to identify new valve installation 20 Repeat this procedure beginning with step 1 If the machine fails to stop within the specified stopping distance after installing new brakes please contact the Genie Industries Scissors Service Department 1 800 536 1800 Ext 8710 Genie GS 2032 Part No 46326 Service Manual First Edition Section 4 Scheduled Maintenance Procedures B 8 Test the Drive Speed Stowed Position 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 Select a test area that is firm level and free of obstructions 1
69. e wires from the valve coil to be tested 2 Connect the positive lead from the ohmmeter to the valve coil terminal then connect the negative lead from the ohmmeter to the internal ring of the valve coil Platform lowering valve coil specifications 2 position 2 way N C solenoid valve 20V 23 25W hydraulic schematic item R Part No 46326 Genie GS 2032 7 17 Section 7 Repair Procedures Service Manual First Edition Ground Controls 4 1 Manual Platform Lowering Cable The manual platform lowering cable lowers the platform in the event of a main power failure The manual platform lowering cable is attached to the barrel end of the lift cylinder and is activated next to the ground controls How to Adjust the Manual Platform Lowering Cable 1 Raise the platform approximately 7 to 8 feet 2 1 to 2 4 m 2 Lift the safety arm move to the center of the scissor arm and rotate down to a vertical position 3 Lower the platform onto the safety arm Crushing hazard Keep hands AWARNING clear of the safety arm when lowering the platform 4 Push the handle on the manual platform lowering cable all the way in 5 Disconnect the cable mounting nut from the lowering valve at the barrel end of the lift cylinder 6 Pull the cable tight and measure the distance between the end of the lowering cable and the end of the lowering valve Result The measurement should be 3 16 to 1 4 inch 4 7 to
70. ear pads are allowed to slide out of the drive chassis 15 Remove the old wear pad Note the position of the wear pad before it is removed so when the new one is installed it will be in the correct position 16 Install the new wear pad Genie GS 2032 Part No 46326 Service Manual First Edition Section 7 Repair Procedures 17 Move the scissor assembly towards the other side of the machine until the other scissor arm wear pad is accessible y The scissor assembly will fall if A DANGER both wear pads are allowed to slide out of the drive chassis 18 Remove the old wear pad Note the position of the wear pad before it is removed so when the new one is installed it will be in the correct position 19 Install the new wear pad 20 Slide the scissor assembly back into the drive chassis 21 Lower the scissor assembly into position and install the pivot pins Component damage hazard Be CAUTION careful not to damage the level sensor box limit switch or level sensor while installing the scissor assembly Part No 46326 Genie GS 2032 7 15 Section 7 Repair Procedures Service Manual First Edition SCISSOR COMPONENTS 3 2 Lift Cylinder How to Remove the Lift Cylinder This procedure requires specific AWARNING repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools may result in death or serious injury and significant componen
71. effort wheels do not turn wheels turn Chart 10A Turn the brake release wheels valve item N clockwise turn all the way and try to rotate the wheels wheels do not turn Attempt to drive the machine in either wheels direction and have an turn assistant try to rotate the non steer wheels This will require 2 people wheels do not turn Plumb a 0 to 500 psi 200 to 34 5 bar gauge into the 300 psi hose from the function manifold to the brake Attempt to drive the machine in either direction and read the pressure on the gauge ess than 200 psi Replace the shuttle valve item O OR the 0 025 orifice item E may be plugged OR replace the brake release valve item N OR the function manifold or brake release manifold may have an internal defect OR consult the Genie Industries Service Department Rebuild or replace the brakes OR replace the brake release valve item N OR consult the Genie Industries Service Department If machine still does not drive at full speed with the platform in the stowed position replace the joystick controller OR replace the main circuit board at the platform controls OR replace the ECM OR consult the Genie Industries Service Department Pressure is good Replace the brakes OR consult the Genie Industries Service Department Part No 46326 Genie GS 2032 5 27 Section 5 Troubleshooting Flow Charts Serv
72. elated components to be sure that there are no leaks Part No 46326 Genie GS 2032 4 17 Section 4 Scheduled Maintenance Procedures Service Manual First Edition Table C Procedure C 1 Check the Module Tray Latch Components Maintaining the module tray latch components in good condition is essential to good performance and service life Failure to detect worn out latch components may result in module trays opening unexpectedly creating an unsafe operating condition Perform this procedure with the platform in the stowed position 1 Lubricate each module tray latch Using light oil apply a few drops to the side of the latch pin 2 Inspect each module tray latch pad if equipped Replace any worn pad before the latch will fail to securely hold the module tray closed 4 18 Genie GS 2032 Part No 46326 Service Manual First Edition Section 4 Scheduled Maintenance Procedures D 1 Test or Replace the Hydraulic Oil Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil and suction strainer may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more often This machine uses Dexron equivalent hydraulic oil Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing th
73. enance procedures B 3 Inspect Tires and Wheels B 12 Replace the Hydraulic Return Filter 4 8 Genie GS 2032 Part No 46326 Service Manual First Edition Section 4 Scheduled Maintenance Procedures Table B Procedures B 1 5 Check the battery acid level of each battery If needed replenish with distilled water to the Check the Batteries bottom of the battery fill tube Do not overfill Proper battery condition is essential to good 6 Install the battery vent caps machine performance and operational safety Improper fluid levels or damaged cables and 7 Check each battery pack and verify that the connections can result in component damage and batteries are wired correctly hazardous conditions Bodily injury hazard Batteries AWARNING contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 275A Fuse D Electrocution hazard Contact AWARNING with hot or live circuits may result in death or serious injury Remove all rings watches and other jewelry Perform this test after fully charging the batteries 1 Put on protective clothing and eye wear 2 Be sure that the battery cable connections are free of corrosion 3 Be sure that the battery hold downs and cable connections are tight 4 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Result If
74. end and remove it from the machine Bodily injury hazard The number ACAUTION 1 outer arm index 18 may become unbalanced and fall if not properly supported when removing it from the machine Note the position of the wear pads before the arm is removed so when the scissor is assembled they will be in the correct position 40 Attach the strap from an overhead crane to the number 1 inner arm index 10 Do not lift it 41 Remove the pin retaining fasteners from both of the number 1 pivot pins index 10 Use a slide hammer to remove the pins 42 Remove the number 1 inner arm index 10 from the machine ACAUTION Bodily injury hazard The number 1 inner arm index 10 may become unbalanced and fall if not properly supported when removed from the machine Part No 46326 Genie GS 2032 7 13 Section 7 Repair Procedures Service Manual First Edition SCISSOR COMPONENTS How to Replace the Scissor Arm Wear Pads 1 Remove the platform See 2 1 How to Remove the Platform 2 Remove the mounting fasteners from the stationary wear pads on the platform Note the position of the wear pads before they are removed so when the new ones are installed they will be in the correct position 3 Support and secure the entry ladder to an appropriate lifting device Then remove the entry ladder mounting fasteners Remove the entry ladder from the machine 4 Raise the platform approximately 7 to 8 feet 2 1 to 2 4
75. enie Industries Service Department Replace the steer left right micro switch inside the drive controller handle Part No 46326 Genie GS 2032 Section 5 Troubleshooting Flow Charts Service Manual First Edition RZEZI SS CHART 8 Install a 0 to 2000 psi Check for mechanical pressure gauge at the restrictions keeping the quick disconnect steer left function from coupling on the function moving OR repair or manifold and activate replace the steer the steer left function cylinder OR consult the Genie Industries Service Department Continued from the previous page less than 1200 psi Reset the steer relief valve pressure item C on the function manifold to 1200 psi OR replace the relief valve Repair or replace the steer cylinder OR replace the steer left right valve cartridge OR the function manifold could have an internal defect Consult the Genie Industries Service Department 5 22 Genie GS 2032 Part No 46326 Service Manual First Edition Section 5 Troubleshooting Flow Charts Steer Right Function Inoperative Be sure all other functions operate normally Be sure the circuit breaker and fuse are not tripped or blown Be sure the batteries are properly connected Be sure the batteries are fully charged With the key switch in platform position and both Emergency Stop buttons pulled out to the light is ON position activate the on steer rock
76. er switch in the LEFT direction and check to see if the error indicator light at the platform controls is on light is not on Activate the steer right function Does the motor turn on yes Continued on the next page Connect the positive lead from a volt meter to the steer right directional valve coil item F wire terminal without disconnecting the wire and the negative lead of the volt meter to the brown ground wire on the function manifold Activate the steer rocker switch in the RIGHT direction and check the voltage 24V Disconnect the wires 0 or from the steer right infinite 9 ohms directional valve coil on the function manifold item F and check the resistance of the valve coil See Repair Section 26 to 28 ohms Check continuity of the bad steer microswitch good Check for wire continuity from the steer microswitch to the main circuit board OR replace main circuit board at the platform controls Chart 9 Repair open in the wht wire wire C7 rt coil from the steer right directional valve coil item F to the ECM OR repair open in brown ground wire circuit from the manifold to the battery module tray OR replace the ECM OR consult the Genie Industries Service Department Replace the coil Repair or replace the steer directional valve item F OR consult the Genie Industries Service Department Replace the steer left right micro switch insid
77. erform maintenance on this machine M You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations M You have the appropriate tools lifting equipment and a suitable workshop Part No 46326 Genie GS 2032 lii Service Manual First Edition 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 Red used to indicate the ADANGER presence of an imminently hazardous situation which if not avoided will result in death or serious injury Orange used to indicate the AWARNING presence of a potentially hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert symbol ACAUTION used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation w
78. esistor 75 Ohm 51590 RS 10 38 75 Ohm 1 Contacts as uno 33020 Square D eris 1863 pr 1 Sess Contact keyswitch 45081 Telemecanique ZB2 BE101 1 SS scenes Toggle switch SPDT 3 position momentary 13097 42 Microswitch Control Inc TNT AES aute 1 54 S5 S6 Contact limit switch 19491 Telemecanique XESP2051 3 Toggle switch 2 position maintained 44987 ITT Schadow 220530 1 59 Contact N C 44990 Telemecanique ZA2 BZ1026 1 SIO Contact 44989 Telemecanique ZA2 BZ1016 1 U2 Motor controller 48V 275 amp 39472 Curtis Instruments 1204 036 1 Y2 4 Coil 20V DC with diode 39347 Hydra Power Systems 6309757 isses 3 Y5 Y6 Coil 20V DC with diode 44176 Hydra Power Systems 6359752 50000 3 YT ien Coil 20V DC 44787 Hydra Power Systems 10166 25
79. ew circuit board to the same configuration of the old one If replacing the circuit board use dielectric grease on all plug in connectors Part No 46326 Genie GS 2032 Section 7 Repair Procedures PLATFORM CONTROLS 1 3 Toggle Switches Toggle switches used for single function switching are single pole double throw SPDT switches Dual function switching requires a double pole double throw DPDT switch How to Test a Toggle Switch Continuity is the equivalent of O to 3 ohms A simple continuity tester may not accurately test the switch This procedure covers fundamental switch testing and does not specifically apply to all varieties of toggle switches 1 Turn the key switch to the orr position Tag and disconnect all wiring from the toggle switch to be tested The toggle switch at the platform controls requires that the wires are unplugged from the main circuit board before testing 2 Connect the leads of an ohmmeter to the switch terminals in the following combinations listed below to check for continuity Center Right Saepe 000 EE 01019 21210 01019 21210 SPDT Double pole double throw DPDT Service Manual First Edition gt Test Left position Desired result terminal 1 to 2 3 4 5 amp 6 no continuity infinite Q terminal 2 to 3 continuity zero Q terminal 2 to 4 5 amp 6 no continuity terminal 3 t
80. foreTroubleshooting Read understand and obey the safety rules and operating instructions printed in the Genie GS 2032 amp Genie GS 2046 amp Genie GS 2646 amp Genie GS 3246 Operator s Manual Be sure that all necessary tools and test equipment are available and ready for use Read each appropiate flow chart thoroughly Attempting shortcuts may produce hazardous conditions Be aware of the following hazards and follow generally accepted safe workshop practices Crushing hazard When testing or replacing any hydraulic component always support the structure and secure it from movement Electrocution hazard Contact ADANGER with electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry Bodily injury hazard Spraying AWARNING 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 Perform all troubleshooting on a firm level surface Two persons will be required to safely perform some troubleshooting procedures Part No 46326 Genie GS 2032 5 1 Section 5 Troubleshooting Flow Charts Service Manual First Edition TROUBLESHOOTING FLOW CHARTS About This Section When a malfunction is discovered the flow charts in this section will help a service professional pinpoint the cause of the problem To use th
81. function is selected Key switch to platform control Ground control and platform Emergency Stop buttons pulled out to the on position Function enable switch pressed 40 flashing Horn is being pressed Note Horn will operate without code 40 flashing if function enable switch is not pressed in 5 6 Genie GS 2032 Part No 46326 Service Manual First Edition Section 5 Troubleshooting Flow Charts _ gt w ZZ This page intentionally left blank Part No 46326 Genie GS 2032 5 7 Section 5 Troubleshooting Flow Charts Service Manual First Edition Fault Code Chart After Serial Number 17407 m NN Machine will not op rste ECM EPROM not programmed Replace ECM cannot be reset Defective control cable OR Troubleshoot cable OR 02 Platform ECM error platform controls platform controls Undefined platio switch DIP switch settings incorrect Correct DIP switch settings settings Wine Malfunctioning up down switch Troubleshoot up down switch Malfunctioning pothole switch Pothole guard failure OR obstruction in pothole guard linkage 42 Platform left turn switch closed Malfunctioning steer left Troubleshoot steer left at start up microswitch microswitch 43 Platform right turn switch Malfunctioning steer right Troubleshoot steer right closed at start up microswitch microswitch 45 Platform lift enable switch Malfunctioning lift enable Troubleshoot lif
82. fuse are not tripped or blown Be sure the batteries are properly connected Be sure the batteries are fully charged Be sure both Emergency Stop switches are pulled out to the on position Turn key switch to platform control and press and hold the light is on function enable switch Visually inspect the power on LED light is not on Check voltage on input less than side of 275A Ft fuse 24V inside battery module tray 24V or more Check voltage on output ov side of 275A fuse inside the battery module tray 24V Check continuity from B terminal on motor controller to the negative battery cable at the Anderson plug full continuity no continuit Before serial number 6901 Check voltage on the input side of the motor contactor K1 oV After serial number 6900 check voltage on terminal B on the motor controller 24V Continued on the next page Chart 1 Troubleshoot ground and platform control systems separately OR consult the Genie Industries Service Department Charge batteries OR check battery condition and replace bad batteries OR check for short circuits OR check battery cables OR check for open in negative battery cable from batteries to ground point on module tray Replace 275A fuse Repair open in negative battery cable from B terminal on motor controller to Anderson plug Repair open in 24V supply cable from 2
83. ght then continue holding the switch while observing the pressure reading on the pressure gauge Note the pressure 4 Press and hold the steer thumb rocker switch to the left Allow the wheels to completely turn to the left then continue holding the switch while observing the pressure reading on the pressure gauge 5 Turn the machine off Hold the steering relief valve and remove the cap item 5 function manifold 6 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the relief valve cap Tip over hazard Do not adjust AWARNING the relief valves higher than specified 7 Repeat steps 3 and 4 to confirm the steering relief pressure Steering relief valve specification Pressure 1500 psi 103 4 bar FUNCTION MANIFOLD How to Check the Resistance of a Valve Coil 1 Turn the key switch to the orr position and disconnect the wires from the valve coil to be tested 2 Coils with 2 terminals Connect the leads from the ohmmeter to the valve coil terminals Coils with 1 terminal Connect the positive lead from the ohmmeter to the valve coil terminal then connect the negative lead from the ohmmeter to the internal ring of the valve coil Valve coil specifications Before serial number 11501 Coil 20V function manifold items G J 26 28W Coil 20V function manifold items H L M 18 20W Valve coil specifications After
84. hich if not avoided may result in property damage CAUTION Green used to indicate operation or maintenance information Be sure to wear protective eye wear and other G protective clothing if the situation warrants it Be aware of potential crushing hazards such as moving parts and free swinging or Bl unsecured components when lifting or placing loads Always wear approved steel toed shoes Workplace Safety Be sure to keep sparks flames and lighted tobacco away from flammable and W combustible materials such as 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 IW Keep work surfaces clean and free of debris that could get into machine components and cause damage Be sure that your workshop or work area ama 5 properly ventilated and well lit Be sure any forklift overhead crane or other lifting or supporting device is fully capable of d 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 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 9 iv Genie GS 2032
85. ic tank through the sight gauge in the side of the power unit module Result The hydraulic oil level should be within the FULL and ADD marks on the oil level indicator decal 2 Add oil if necessary Do not overfill Hydraulic Oil Specifications Hydraulic oil type Dexron equivalent A 5 Check for Hydraulic Leaks Detecting hydraulic fluid leaks is essential to operational safety and good machine performance Undiscovered leaks can develop into hazardous situations impair machine functions and damage machine components 1 Inspect for hydraulic oil puddles dripping or residue on or around the following areas Hydraulic tank return filter fittings and hoses Hydraulic power unit fittings and hoses Hydraulic lift cylinder and manual lowering valve Function manifold The underside of the drive chassis Drive motors Drive brakes Ground area under the machine Hydraulic tank capacity 5 5 gallons 20 8 liters Hydraulic system 6 gallons including tank 22 7 liters 4 4 Genie GS 2032 Part No 46326 Service Manual First Edition F Ja 2 2 A 6 Test the Platform and Ground Controls Testing the machine functions and the Emergency Stop buttons for malfunctions is essential for safe machine operation An unsafe working condition exists if any function fails to operate properly or either Emergency Stop button fails to stop all the machin
86. ical cables Hydraulic power unit tank hoses fittings cylinders and manifolds Battery pack and connections Drive motors Wear pads Tires and wheels Limit switches alarms and horn Nut bolts and other fasteners Platform entry chain or gate Beacons and alarms if equipped Brake release components Safety arm Pothole guards Platform extension Scissor pins and retaining fasteners Platform control joystick Inverter if equipped TABLE A PROCEDURES Check the entire machine for Cracks in welds or structural components Dents or damage to machine Be sure that all structural and other critical components are present and all associated fasteners and pins are in place and properly tightened Side rails installed and bolts are fastened Be sure that the chassis trays are in place latched and properly connected Part No 46326 Genie GS 2032 4 3 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE A PROCEDURES A 4 Check the Hydraulic Oil Level Maintaining the hydraulic oil at the proper level is essential to machine operation Improper hydraulic oil levels can damage hydraulic components Daily checks allow the inspector to identify changes in oil level that might indicate the presence of hydraulic system problems Perform this procedure with the platform in the stowed position 1 Visually inspect the oil level in the hydraul
87. ice Manual First Edition Chart 11 Drive Forward Function Inoperative Be sure all other functions operate normally Be sure the circuit breaker and fuse are not tripped or blown Be sure the batteries are properly connected Be sure the batteries are fully charged With the key switch in Connect the positive platform position and the lead from a volt meter to Emergency Stop buttons the drive forward pulled out to the on directional valve coil position at both the light is item J wire terminal ground and platform on without disconnecting controls activate drive the wire and the controller in the forward negative lead of the volt direction and check to meter to the brown see if the error indicator ground wire on the light at the platform manifold Activate drive controls is on in the forward direction and check the voltage 0 or infinite ohms Disconnect the wires from the drive forward light is not on directional valve coil item J and check the resistance See Repair Section Replace the drive forward reverse valve cartridge item J OR 18 to 20 consult the Genie ohms Industries Service Department Repair or replace the drive forward directional valve item J OR consult the Genie Industries Service Department Repair open in the wht wire C6 forward coil from the drive forward directional valve coil to the ECM OR repair open in the brown ground wire circuit from
88. ies if replacement manuals are needed A 2 Inspect the Decals and Placards Maintaining all of the safety and instructional decals and placards in good condition is mandatory for safe machine operation Decals alert operators and personnel to the many possible hazards associated with using this machine They also provide users with operation and maintenance information An illegible decal will fail to alert personnel of a procedure or hazard and could result in unsafe operating conditions 1 Refer to the Decals section in the Genie GS 2032 amp Genie GS 2046 amp Genie GS 2646 A Genie GS 3246 Operator s Manual and use the decal list and illustrations to determine that all decals and placards are in place 2 Inspect all decals for legibility and damage Replace any damaged or illegible decal immediately Contact your authorized Genie distributor or Genie Industries if replacement decals are needed 4 2 Genie GS 2032 Part No 46326 Service Manual First Edition Section 4 Scheduled Maintenance Procedures A 3 Inspect for Damage and Loose or Missing Parts Daily machine condition inspections are essential to safe machine operation and good machine performance Failure to locate and repair damage and discover loose or missing parts may result in an unsafe operating condition 1 Inspect the entire machine for damage and improperly installed or missing parts including Electrical components wiring and electr
89. ill appear If function enable button is released first code 36 flashing will remain until another function is selected Key switch to platform control Ground control and platform Emergency Stop buttons pulled out to the on position Lift drive switch to lift position 37 flashing Down function selected Note if joystick controller is returned to center position before function enable button is released code 31 flashing will appear If function enable button is released first code 37 flashing will remain until another function is selected Key switch to platform control Ground control and platform Emergency Stop buttons pulled out to the on position Lift drive switch to drive position 38 flashing Drive in blue direction function selected Note if joystick controller is returned to center position before function enable button is released code 31 flashing will appear If function enable button is released first code 38 flashing will remain until another function is selected Key switch to platform control Ground control and platform Emergency Stop buttons pulled out to the on position Lift drive switch to drive position 39 flashing Drive in yellow direction function selected Note if joystick controller is returned to center position before function enable button is released code 31 flashing will appear If function enable button is released first code 39 flashing will remain until another
90. intenance Inspections 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 annually and every 2 years as specified on the Maintenance Inspection Report Failure to properly complete each AWARNING inspection when required may cause death serious injury or substantial machine damage Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating machine Keep records on all inspections for three years Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection About This Section The Schedule There are four types of maintenance inspections that must be performed according to a schedule daily quarterly annual and two year To account for repeated procedures the Maintenance Tables and the Maintenance Inspection Report have been divided into four subsections A B C D Use the following chart to determine which group s of procedures are required to perform a scheduled inspection Inspection Table or Checklist Daily A Quarterly A B Annual A B C Two year A B C D Maintenance Tables The maintenance tables contained in this section provide summary information on the specific physical requirements for each inspection
91. ipped with operational controls which are found in two locations the ground controls located on the hydraulic tank side of the machine and the platform controls located in the platform All lift and drive functions are available at the platform controls Only platform up down functions are available at the ground controls The ECM uses input from the ground or platform controls to activate the various machine functions The ECM has predetermined settings for the various machine functions The joystick is fitted with a 5000 ohm potentiometer With the joystick in the neutral position the potentiometer will measure 2730 ohms These signals are sent to the multiplex card then down to the ECM to control the voltage supplied to the proportional valve Two microswitches mounted on the joystick tell the ECM the drive direction desired A thumb rocker switch on the top of the joystick is used for steering Mounted on the platform control box lid of machines before serial number 17408 are buttons and a switch that when activated sends a signal to the ECM through the multiplex card On machines after serial number 17407 the platform control box lid has a decal membrane pad This is a touch activated pad incorporating wiring switches and LEDs that are resistant to the environment Activating any of the buttons on the pad will send a signal to the ECM through the multiplex card A diagnostic display is located at the battery pack side of
92. is section basic hand tools and certain pieces of test equipment required voltmeter ohmmeter and pressure gauges The location of terminals mentioned in this section can be found on the appropriate electrical or hydraulic schematics provided in Section 6 Schematics Since various degrees of a particular function loss may occur selecting the appropriate flow chart may be troublesome When a function will not operate with the same speed or power as a machine in good working condition refer to the flow chart which most closely describes the problem General Repair Process Identify symptoms Malfunction discovered Troubleshoot Y problem still exists Y Return to Perform Service lt problem repair solved LED Diagnostic Readout The diagnostic readout displays numerical codes that provide information about the machine operating status and about malfunctions The dot to the right of the numbers will blink during normal operation codes and remain on with fault codes The codes listed in the Operation Code Chart are common operational status codes and malfunction codes that can be cleared easily The codes listed in the Fault Code Chart describe malfunctions and can aid in troubleshooting the machine by pinpointing the area or component affected Genie GS 2032 Part No 46326 Service Manual First Edition Section 5 Troublesho
93. is machine Scheduled maintenance inspections shall be completed daily quarterly annually and every 2 years as specified on the Maintenance Inspection Report Failure to properly complete each AWARNING inspection when required may cause death serious injury or substantial machine damage Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating machine Keep records on all inspections for three years Unless otherwise specified perform each procedure with the machine in the following configuration Machine parked on a flat level surface Platform in the stowed position Key switch in the position with the key removed Wheels chocked 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 A 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 Red used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury Orange used to indicate the AWARNING presence of a potentially hazardous situation which if not avoided could result in death or serious injury Yellow w
94. ith safety alert symbol ACAUTION used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Green used to indicate operation or maintenance information Indicates that a specific result is expected after performing a series of steps Part No 46326 Genie GS 2032 4 1 Section 4 Scheduled Maintenance Procedures Service Manual First Edition Table A Procedures A 1 Inspect the Operator s and Safety Manuals Maintaining the operator s and safety manuals in good condition is essential to safe machine operation Manuals are included with each machine and should be stored in the container provided in the platform An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition 1 Check to be sure the storage container is present and in good condition 2 Check to make sure that the operator s responsibilities and safety manuals are present and complete in the storage container in the platform 3 Examine the pages of each manual to be sure that they are legible and in good condition 4 Always return the manuals to the storage container after use Contact your authorized Genie distributor or Genie Industr
95. k handle to the pown position to lower the platform Observe the code shown in the LED display window located on the battery pack side of the machine Result The software revision level will appear in the LED display window If revision level bO or later appears in the display window the following procedures will apply If revision level AO is displayed the following procedures will not apply Push in the Emergency Stop button to the position at both the ground and platform controls and turn the key switch the position Part No 46326 Genie GS 2032 7 3 Section 7 Repair Procedures Service Manual First Edition PLATFORM CONTROLS How to Set the DIP Switch Codes Tip over hazard Do not adjust the ADANGER DIP switch settings to other than what is specified in this procedure Exceeding specifications will cause death or serious injury If replacing the circuit board note the individual switch positions on the DIP switch Set the DIP switch on the new circuit board to the same configuration as the old one If replacing the circuit board use dielectric grease on all plug in connectors 1 Push the Emergency Stop button to the position at the ground and platform controls Turn the key switch to the orr position W 7 1 ZANE DIP switch Emergency stop button Circuit boards Joys
96. l other functions operate normally Be sure the circuit breaker and fuse are not tripped or blown Be sure the batteries are properly connected Be sure the batteries are fully charged light is not on Activate the steer left function Does the motor turn on yes Continued on the next page Connect the positive lead from a volt meter to the steer left directional valve coil item F wire terminal without disconnecting the wire and the negative lead of the volt meter to the brown ground wire on the manifold Activate the steer rocker switch in the LEFT direction and check the voltage 24V Disconnect the wires A from the coil on the ohms steer left directional valve on the function manifold item F and check the resistance of the valve coil See Repair Section 26 to 28 ohms Check continuity ofthe bad steer microswitch good Check for wire continuity from the steer microswitch to the terminal strip OR replace the main circuit board at the platform controls Chart 8 Repair open in the wht wire B7 left coil from the coil on the steer left directional valve item F to the ECM OR repair open in the brown ground wire circuit from the manifold to the battery module tray OR replace the ECM R consult the Genie Industries Service Department Replace the coil Repair or replace the steer directional valve cartridge item F OR consult the G
97. l the hydraulic filter bracket and the motor controller bracket AWARNING Electrocution hazard The connectors on the motor controller will short out to ground if the motor controller mounting bracket is not installed before the battery pack is connected 13 Install the hydraulic tank 14 Fill the tank with hydraulic oil until the fluid is within the FULL and ADD marks on the oil level indicator decal Do not overfill 15 Clean up any oil that may have spilled Properly dispose of the oil 16 Operate all machine functions through a full cycle and check for leaks Hydraulic oil type Dexron equivalent Hydraulic tank capacity 5 5 gallons 20 8 liters Hydraulic system 6 gallons including tank 22 7 liters 4 20 Genie GS 2032 Part No 46326 Service Manual First Edition Section 5 Troubleshooting Flow Charts Troubleshooting Flow Charts Observe and Obey M Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine M Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a flat level surface Platform in stowed position Key switch in the orr position with the key removed Wheels chocked Be
98. less than 3000 PSI Adjust the relief valve OR repair or replace the platform lift cylinder OR the platform lowering valve may be stuck open OR the function manifold could have an internal defect Consult the Genie Industries Service Department Connect the positive lead from a volt meter to the coil on the platform up directional valve item G wire terminal without disconnecting the wire and the negative lead of the volt meter to the ground point on the manifold Activate the controller in the UP direction and check the voltage 24V Disconnect the wire from the platform up directional valve coil on the function manifold item G and check the resistance See Repair Section 18 20 ohms Repair or replace the platform up directional valve cartridge item G OR consult the Genie Industries Service Department Check for mechanical restrictions keeping platform up function from moving OR repair or replace platform lift cylinder OR consult the Genie Industries Service Department Repair open in the wht wire A6 up coil from the platform up directional valve coil to the ECM see Repair Section OR replace ECM OR consult the Genie Industries Service Department Replace the platform up directional valve coil item G 5 18 Genie GS 2032 Part No 46326 Service Manual First Edition Section 5 Troubleshooting Flow Charts Platform Down Function inoperative Be s
99. n 9 The power unit should not be able to lift the platform If the power unit lifts the platform adjust the internal hex socket counterclockwise until the platform will not raise Tip over hazard Do not adjust the ADANGER relief valve to allow the power unit to lift more than maximum rated load 10 Install the relief valve cap 11 Remove the weight from the platform 12 Bleed the hydraulic system Raise the platform to full height and then lower it to the stowed position through two complete cycles Result If the pump cavitates or platform fails to reach full height add hydraulic oil until the pump is functioning correctly Do not overfill the hydraulic reservoir Re test the system by performing steps 8 through 11 CAUTION Component damage hazard Do not continue to operate the machine if the hydraulic pump is cavitating If the pump is still cavitating see 5 1 How to Test the Hydraulic Pump Genie GS 2032 Part No 46326 Service Manual First Edition Section 7 Repair Procedures How to Adjust the Steering Relief Valve 1 Connect a 0 to 5000 psi 0 to 345 bar pressure gauge to the test port on the function manifold item 2 function manifold 2 Turn the key switch to the ground controls and pull out the Emergency Stop button to the on position at both the ground and platform controls 3 Press and hold the steer thumb rocker switch to the right Allow the wheels to completely turn to the ri
100. n appropriate lifting device 8 Remove the retaining fastener from the steer link at the yoke assembly Note the quantity and location of the spacers when disconnecting the steer link from the yoke assembly 9 Remove the retaining fastener from the top of the yoke pivot shaft 10 Lower the yoke assembly out of the chassis while guiding the bellcrank pivot shaft out of the bellcrank Bodily injury hazard The yoke ACAUTION motor assembly may fall if not properly supported when it is removed from the chassis During re assembly be sure that the spacers are installed onto the steer link Torque specifications Castle nut 300 ft lbs 406 7 Nm Genie GS 2032 Part No 46326 Service Manual First Edition Section 7 Repair Procedures How to Remove a Drive Motor 1 Block the non steering wheels and then center a lifting jack under the drive chassis at the steer end of the machine 2 Remove the cotter pin on the wheel lug nut of the motor to be removed Always replace the cotter pin with a new one when removing the castle nut 3 Loosen the wheel castle nut Do not remove it 4 Raise the machine approximately 2 inches 5 cm and place blocks under the drive chassis for support 5 Remove the wheel castle nut then remove the wheel 6 Tag disconnect and plug the hoses on the drive motor Cap the fittings on the motor Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and b
101. n on the wheel castle nut Always replace the cotter pin with a new one when removing the castle nut 4 Loosen the wheel castle nut Do not remove it Raise the machine approximately 2 inches 5 cm and place blocks under the drive chassis for support 6 Remove the wheel castle nut then remove the wheel 7 Tag disconnect and plug the hose on the brake Cap the fittings on the brake Bodily injury hazard Sprayin AWARNING A 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 8 Place a lifting jack under the brake for support 9 Remove the brake mounting fasteners from the drive chassis Remove the brake Crushing hazard The brake may ACAUTION become unbalanced and fall if it is not properly supported when the mounting fasteners are removed Torque specifications Castle nut 300 ft lbs 406 7 Nm Part No 46326 Genie GS 2032 7 29 Section 7 Repair Procedures Service Manual First Edition Brake Release Hand Pump Components 9 1 Brake Release Hand Pump Components The brake release hand pump manifold is mounted behind the entry ladder next to the battery charger Index Schematic No Description Item Function Torque 1 Check valve pilot operated NSE Manual brake release 25 30 ft lbs 34 41 Nm 2 Shuttle valve
102. n the more input side of motor controller relay ov Check voltage on the output side of the 275A fuse Replace positive battery cables from output side of 275A fuse to Anderson plug AP1 OR replace positive battery cables from Anderson plug to K1 OR Consult Genie Industries Service Department Section 5 Troubleshooting Flow Charts Md Replace positive cable from K1 to the motor controller U2 OR replace the positive cable from the motor controller to the pump motor Activate lift function and check voltage on the wht wire on the coil of the motor controller relay 24V Check continuity on the continuity brown ground wire on the coil of the motor controller relay to the ground point on the chassis no continuity Repair open in brn ground wire from K1 to the ground point on chassis Replace 275A fuse OR replace positive cable from 275A fuse to battery switch OR consult Genie Industries Service Department CHART 2 Repair open in wht wire A8 motor from the ECM to the motor controller relay OR replace the ECM OR conult the Genie Industries Service Department Repair or replace the motor controller relay Part No 46326 Genie GS 2032 5 13 Section 5 Troubleshooting Flow Charts Chart 3 All Functions inoperative Power Unit Starts and Runs Be sure if the Error Indicator light is on at the platform controls you refer to the specifi
103. ncy Stop button to the on position at both the ground and platform controls 4 Push down the Emergency Stop button at the platform controls to the position Result No machine functions should operate The ground control Emergency Stop button will stop all machine operation even if the key switch is switched to platform control B 6 Test the Horn A functioning horn is essential to safe machine operation The horn is activated at the platform controls and sounds at the ground as a warning to ground personnel An improperly functioning horn will prevent the operator from alerting ground personnel of hazards or unsafe conditions 1 Turn the key switch to platform control and pull out the Emergency Stop button to the ON position at both the ground and platform controls 2 Push down the horn button at the platform controls Result The horn should sound The standard machine uses the multifunction alarm to emit the horn sound The optional horn will sound like an automotive type horn Genie GS 2032 Part No 46326 Service Manual First Edition Section 4 Scheduled Maintenance Procedures B 7 Test the Drive Brakes Proper brake action is essential to safe machine operation The drive brake function should operate smoothly free of hesitation jerking and unusual noise Hydraulically released individual wheel brakes can appear to operate normally when not fully operational Perform this procedu
104. o 4 5 amp 6 no continuity terminal 4 to 5 amp 6 no continuity terminal 5 to 6 Center position continuity There are no terminal combinations that will produce continuity infinite Q Right position terminal 1 to 2 continuity zero Q terminal 1 to 3 4 5 amp 6 no continuity infinite Q terminal 2 to 3 4 54 6 no continuity terminal 3 to 4 5 amp 6 no continuity terminal 4 to 5 continuity terminal 4 to 6 no continuity terminal 5 to 6 no continuity 7 6 Genie GS 2032 Part No 46326 Service Manual First Edition Section 7 Repair Procedures ARR LCL LL ERZE ZZL AZ ZL This page intentionally left blank Part No 46326 Genie GS 2032 7 7 Section 7 Repair Procedures Service Manual First Edition Platform Components 2 1 Platform How to Remove the Platform Perform this procedure with the platform extension fully retracted and locked in position 1 Lower the platform to the stowed position 2 Remove the retaining fastener that holds the platform controls quick disconnect plug to the bottom of the platform 3 Twist to disconnect the plug from the platform controls 4 Remove the cover to the AC outlet Label and disconnect the wiring from the outlet Electrocution hazard Contact with AWARNING electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry
105. o remove the pin Remove the cylinder from the machine Crushing hazard If the overhead AWARNING crane is not properly attached the cylinder may become unbalanced and fall when it is removed from the machine Component damage hazard Be careful not to damage the valve or fittings on the cylinder while removing it from the machine CAUTION 33 Place a 4 x 4 x 32 inch 10 x 10 x 80 cm long block across both sides of the chassis under the number 1 center pivot pin index number 9 34 Attach the strap from the overhead crane to the number 1 inner arm index 10 Raise the inner arm slightly and remove the safety arm Lower the arms on to the block Bodily injury hazard Keep hands ACAUTION clear of moving parts when lowering the arms onto the block 35 Remove the cables from the number 1 inner arm index 10 and lay them off to the side CAUTION Component damage hazard Cables can be damaged if they are kinked or pinched SCISSOR COMPONENTS 36 Attach the strap from the overhead crane to the number 1 outer arm index 18 Do not lift it 37 Remove the external snap rings from the number 1 center pivot pin index 9 38 Use a soft metal drift to remove the number 1 center pivot pin index 9 Bodily injury hazard The number ACAUTION 1 outer arm index 18 may become unbalanced and fall if not properly supported when the pin is removed 39 Slide the number 1 outer arm index 18 to the non steer
106. ol panel could cause a hazardous operating situation 1 Pull out the Emergency Stop button to the on position at both the ground and platform controls 2 Turn the key switch to platform control 3 Check the platform up down function from the ground controls Result The machine functions should not operate 4 Turn the key switch to ground control 5 Check the machine functions from the platform controls Result The machine functions should not operate 6 Turn the key switch to the position Result No function should operate Part No 46326 Genie GS 2032 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE B PROCEDURES B 5 Test the Emergency Stop Buttons Properly functioning Emergency Stop buttons are essential for safe machine operation An improperly operating Emergency Stop button will fail to shut off power and stop all machine functions resulting in a hazardous situation As a Safety feature selecting and operating the ground controls will override the platform controls except the platform Emergency Stop button 1 Turn the key switch to ground control and pull out the Emergency Stop button to the on position at both the ground and platform controls 2 Push in the Emergency Stop button at the ground controls to the position Result No functions should operate 3 Turn the key switch to platform control and pull out the Emerge
107. ons Check to see if the green indicator light is flashing at the platform controls light is not flashing Is the error indicator light on at the platform controls no Does the power unit no run yes Continued on the next page Reset the ECM by pushing in the platform Emergency Stop button to the OFF position switch the lift drive selector switch to the drive position and pull the Emergency Stop button up to the ON position Check the lights at the platform controls green light is flashing Test the lift drive toggle switch 57 see Repair Section Is switch good good Replace the main circuit board OR replace the ECM OR Consult the Genie Industries Service Department Refer to chart s that are related to the error code that is displayed on the ECM OR consult the Genie Industries Service Department Replace the joystick controller OR replace the main circuit board OR replace the ECM OR consult the Genie Industries Service Department Chart 10 error Refer to the 5 that are related to the error on code that is displayed on the ECM OR consult the Genie Industries Service Department bad Replace lift drive toggle switch Part No 46326 Genie GS 2032 Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 10 See Chart 3 Is the Replace or repair coupler between the coupler motor and or mot
108. or and pump in good pump condition Continued from the previous page Chock both sides of the 3000 PS See Chart 10A Brake front drive wheels Release Function Connect a 0 to 5000 psi Inoperative 0 to 345 bar pressure gauge to the test port on the function manitold and drive the machine in either the forward or reverse direction less than 3000 psi Repair or replace the drive forward reverse valve cartridge OR rebuild or replace the drive motors OR the manifold may have an internal defect Consult the Genie Industries Service Department 5 26 Genie GS 2032 Part No 46326 Service Manual First Edition Section 5 Troubleshooting Flow Charts Brake Release Function Inoperative Be sure if the Error Indicator light is on at the platform controls you refer to the specific chart that relates to the error code that is displayed on the ECM Be sure the circuit breaker and fuse are not tripped or blown Be sure the batteries are properly connected Be sure the batteries are fully charged Chock the wheels at the steer end Jack the non steer end of the machine up approximately 4 inches 10 cm and place jack stands under the machine for support Turn the brake release knob item N counterclockwise all the way and pump the hand pump fully 13 15 times or until much resistance is felt Turn each wheel by hand Each wheel should turn freely without much
109. or mounted above the hydraulic power unit 2 Visually inspect the contact points of each contactor for the following items Excessive burns Excessive arcs Excessive pitting Replace the contactor if any damage is found 4 16 Genie GS 2032 Part No 46326 Service Manual First Edition Section 4 Scheduled Maintenance Procedures _ 2 2 TABLE B PROCEDURES B 12 Replace the Hydraulic Return Filter Replacement of the hydraulic filter is essential for good machine performance and service life A dirty or clogged filter may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter be replaced more often Beware of hot oil Contact with ACAUTION hot oil may cause severe burns The hydraulic filter is mounted on the function manifold next to the hydraulic power unit 1 Clean the area around the oil filter then remove the filter with an oil filter wrench 2 Apply a thin layer of oil to the new oil filter gasket 3 Install the new filter Genie part number 55616 and tighten it securely by hand Clean up any oil that may have spilled during the replacement procedure 4 Turn the key switch to ground control and pull out the Emergency Stop button to the on position at both the ground and platform controls Activate and hold the platform up toggle switch 5 Inspect the filter and r
110. or replace the lift cylinder OR consult the Genie Industries Service Department 0 or infinite ohms platform lowers Chart 7 Repair open in the wht wire B6 down coil from the platform lowering valve coil item R to the ECM OR repair open in the brown ground wire circuit from the coil to the battery module tray OR replace the ECM OR consult the Genie Industries Service Department Replace platform lowering valve coil item R Repair or replace the platform lowering valve cartridge item R Part No 46326 Genie GS 2032 5 19 Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 7 switch bad Label and disconnect the wires from the lift drive toggle switch at the platform controls and troubleshoot the toggle switch see Repair Section Replace the lift drive Continued from the toggle switch previous page Replace the platform controls OR replace the ECM OR consult the Genie Industries Service Department 5 20 Genie GS 2032 Part No 46326 Service Manual First Edition Section 5 Troubleshooting Flow Charts Steer Left With the key switch in platform position and Function un Emergency Stop uttons pulled out to the light is Inoperative ON position activate the on steer rocker switch in the LEFT direction and check to see if the error indicator light at the platform controls is on Be sure al
111. ose wires ECM to platform controls Power to platform wiring 8 Raise the platform and return the safety arm to the stowed position 9 Lower the platform to the stowed position and turn the machine off 4 10 Genie GS 2032 Part No 46326 Service Manual First Edition Section 4 Scheduled Maintenance Procedures B 3 Inspect the Tires and Wheels including castle nut torque Maintaining the tires and wheels in good condition 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 problems are not discovered and repaired in a timely fashion 1 Check the tire surface and sidewalls for cuts cracks or unusual wear 2 Check each wheel for damage bends and cracks 3 Remove the cotter pin and check each castle nut for proper torque 4 Install a new cotter pin Always replace the cotter pin with a new one when removing the castle nut or when checking the torque of the castle nut Tires and wheels Castle nut torque dry 300 ft lbs 406 7 Nm Castle nut torque lubricated 225 ft lbs 305 Nm TABLE B PROCEDURES B 4 Test the Key Switch Proper key switch action and response is essential to safe machine operation The machine can be operated from the ground or platform controls and the activation of one or the other is accomplished with the key switch Failure of the key switch to activate the appropriate contr
112. oting Flow Charts Fault Code Chart Before Serial Number 17408 Fault Code Problem Possible Causes Reset the ECM If problem 012 Alarm sounds continuously Remove obstruction to pothole Error indicator light on at the Pothole guard may be blocked guard OR check pothole limit platform controls when function pothole limit switches may switch wiring for open enable switch is engaged not be activating or there isa connections OR check pothole Machine will not drive Machine bad wire connection limit switch for proper is not level adjustment and activation Alarm sounds continuously Remove obstruction to pothole Error indicator light on at the Pothole guard may be blocked guard OR check pothole limit platform controls when function pothole limit switches may switch wiring for open enable switch is engaged not be activating or there isa connections OR check pothole Machine will not drive Machine bad wire connection limit switch for proper is level adjustment and activation Release the function enable Machine will not operate Error Joystick initialization OK but OR check the switch for indicator light on at the platform function enable switch is tied continuity in the joystick controls controller box see Repair Section Machine unit will not operate Error indicator light on at the platform controls Machine unit will not operate Error indicator light on at the platfo
113. ower the cylinder onto the number 1 center pivot pin index 9 Part No 46326 Genie GS 2032 7 11 Section 7 Repair Procedures Service Manual First Edition SCISSOR COMPONENTS 15 Attach a lifting strap from an overhead crane to the number 3 inner arm index 4 16 Remove the external snap rings from the number 3 pivot pin index 5 17 Use a soft metal drift to remove the number 3 pivot pin index 5 Remove the number 3 inner arm index 4 from the machine Bodily injury hazard The ACAUTION number 3 inner arm index 4 may become unbalanced and fall if not properly supported when it is removed from the machine 18 Attach a strap from an overhead crane to the number 2 outer arm index 15 19 Remove the external snap rings from the number 2 center pivot pin index 6 at the battery pack side 20 Use a soft metal drift to remove both of the number 2 center pivot pins index 6 21 Remove the external snap rings from the number 2 pivot pin index 16 22 Use a soft metal drift to remove the number 2 pivot pin index 16 Remove the number 2 outer arm index 15 from the machine Bodily injury hazard The ACAUTION number 2 outer arm index 15 may become unbalanced and fall if not properly supported when it is removed from the machine 23 Attach a lifting strap from an overhead crane to the number 2 inner arm index 7 24 Remove the external snap rings from the number 2 pivot pin
114. platform control and pull out the Emergency Stop button to the oN position at both the ground and platform controls Raise the platform approximately 6 feet 2 m 4 Move the drive select toggle switch down for normal drive operation OR press the drive speed selector button until the indicator light is OFF 5 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 6 Bring the machine to maximum drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 7 Continue at full speed and note the time when the machine reference point passes over the finish line Return the control handle to center Drive speed maximum Platform raised 40 ft 54 5 sec 12 2 m 54 5 sec Part No 46326 Genie GS 2032 Section 4 Scheduled Maintenance Procedures Service Manual First Edition s nun TABLE B PROCEDURES B 10 B 11 Perform Hydraulic Oil Analysis Check the Electrical Contactor See D 1 Test or Replace the Hydraulic Oil before serial number 6901 Maintaining the electrical contactor in good condition is essential to safe machine operation Failure to locate a worn or damaged contactor could result in an unsafe working condition and component damage 1 Open the hydraulic power unit module and locate the electrical contact
115. re both oV Emergency Stop buttons are pulled out to the ON position at both the ground and platform controls Check voltage at the input side of the platform controls contact on the key switch S2 24V or more Check voltage at the output side of contact 24V Check voltage at terminal A11 at the ECM U1 24V Check voltage at ov terminal B2 at the ECM 24V Turn the key switch to platform controls and Before serial number 6902 check voltage at terminal 4 on the main circuit board at the platform controls After serial number 6900 check voltage at the input side of the Emergency Stop button S9 24V Continued on the next page Repair open in the wht wire jumper from the Emergency Stop contact to the platform control contact at the key switch S2 Check if the key switch internal cam is activating platform control contact yes no Replace the key switch Repair open in wht wire A11 key sw from the key switch to terminal 11 at the ECM Replace the ECM Replace contro cable from the ECM to the platform controls Replace the key switch contact for platform controls 5 16 Genie GS 2032 Part No 46326 Service Manual First Edition Section 5 Troubleshooting Flow Charts CHART 5 Before serial number Replace the main circuit ee 2n the 6091 Check voltage at P page the input side of the Emergency Stop switch
116. re with the machine on a firm level surface that is free of obstructions Be sure the platform extension deck is fully retracted and the platform is in the stowed position 1 Mark a test line on the ground for reference 2 Turn the key switch to platform control and pull out the Emergency Stop button to the on position at both the ground and platform controls 3 Lower the platform to the stowed position 4 Move the drive select toggle switch down for normal drive operation OR press the drive speed selector button until the indicator light is OFF 5 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the test line 6 Bring the machine to full drive speed before reaching the test line Release the function enable switch or the joystick on the platform controls when your reference point on the machine crosses the test line TABLE B PROCEDURES 7 Measure the distance between the test line and your machine reference point Braking paved surface Stopping distance 2 ft 0 6 m Result The machine stops within the specified braking distance No action required Result The machine does not stop within the specified braking distance Proceed to step 8 and determine if the machine is equipped with a dynamic braking valve The brakes must be able to hold the machine on any slope it is able to climb 8 Disconnect the battery pack from the machine AWARNI
117. red MAINTENANCE TABLES Dealer service suggested B 4 Test the Key Switch B 5 Test the Emergency Stop Buttons B 6 Test the Horn B 7 Test the Drive Brakes B 8 Test the Drive Speed Stowed Position B 9 Test the Drive Speed Raised Position B 10 Perform Hydraulic Oil Analysis See D 1 Test or Replace the Hydraulic Oil ra ra Pa ra B 11 Check the Electrical Contactor before serial number 6901 Every 250 hours perform the following engine maintenance procedure B 12 Replace the Hydraulic Return Filter Table C A C 1 Check the Module Tray latch Components Table D D 1 Test or Replace the Hydraulic Oil Part No 46326 Genie GS 2032 Section 3 Scheduled Maintenance Inspections Service Manual First Edition Maintenance Inspection Report Model Serial number Date Hour meter Machine owner Inspected by print Inspector signature Inspector title Inspector company Instructions Make copies of this page to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily Inspection A Quarterly Inspection A B Annual Inspection A B C 2 Year Inspection A B C D Place a check in the appropriate box after each inspection procedure is completed Use the maintenance tables in this section and the step by step procedures in section 4 to learn how to perform these inspections If any in
118. rface Platform in the stowed position Key switch in the position with the key removed Wheels chocked Repair Procedures 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 completed Then to re assemble perform the disassembly steps in reverse order 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 Red used to indicate the ADANGER presence of an imminently hazardous situation which if not avoided will result in death or serious injury Orange used to indicate the AWARNING 275 presence of a potentially hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert symbol ACAUTION used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Green used to indicate operation or maintenance information Indicates that a specific result is e
119. rm controls Replace joystick controller box main circuit board OR replace the coil cord ECM does not recognize the platform controls ECM does not recognize the joystick controller box platform controls main circuit board Only the platform down function operates no other functions operate Error No power output from ECM to indicator light on at the platform the motor contactor controls when the function enable switch is engaged Check wiring and terminal at motor contactor ckt A9 Curtis terminal 3 OR check wiring and terminal at control ECM pin A9 ckt A9 Curtis terminal 3 Continued on next page Part No 46326 Genie GS 2032 5 3 Section 5 Troubleshooting Flow Charts Service Manual First Edition FAULT CODE CHART BEFORE SERIAL NUMBER 17408 Fault Code Problem Machine will not drive forward Pump motor starts Error 52 indicator light on at the platform controls when the function enable switch is engaged Machine will not drive in reverse Pump motor starts 53 Error indicator light on at the platform controls when the function enable switch is engaged Platform will not raise Pump motor starts Error indicator 54 light on at the platform controls when the function enable switch is engaged Platform will not lower Error 55 indicator light on at the platform controls when the function enable switch is engaged Machine will not steer right Pump motor starts Er
120. rm controls is on 23 flashing Key switch to ground control Ground control Emergency Stop button pulled out to the on position Platform control Emergency Stop button pushed in to the off position Platform extended less than 6 feet 24 flashing Turn key switch to platform control To clear this code be sure joystick is properly connected or pull the platform Emergency Stop button out to the on position Key switch to ground control Ground control and platform Emergency Stop buttons pulled 25 out to the on position flashing Error indicator light at platform controls is on Platform extended less than 6 feet Turn key switch to platform control Key switch to platform control 31 Ground control and platform Emergency Stop buttons pulled out flashing to the on position Key switch to platform control Ground control Emergency Stop button pulled out to the on 32 position flashing Platform control Emergency Stop button pushed in to the off position Key switch to platform control Ground control and platform Emergency Stop buttons pulled out to the on position Lift drive switch to lift position 36 flashing Normal operation To clear this code be sure joystick is properly connected or pull the platform Emergency Stop button out to the on position Up function selected Note if joystick controller is returned to center position before function enable button is released code 31 flashing w
121. ror indicator light on at the platform controls when the function enable switch is engaged Machine will not steer left Pump motor starts Error indicator light on at the platform controls when the function enable switch is engaged Possible Causes No power output from ECM to the drive forward coil No power output from ECM to the drive reverse coil No power output from ECM to the platform up coil No power output from ECM to the platform lowering coil No power output from ECM to steer right coil No power output from ECM to steer left coil Check wiring and terminal at the forward coil ckt C6 Forward coil OR check wiring and terminal at control ECM pin C6 ckt C6 Forward coil Check wiring and terminal at the reverse coil ckt A7 Reverse coil OR check wiring and terminal at ECM pin A7 ckt A7 Reverse coil Check wiring and terminal at the platform up coil ckt A6 Up coil OR check wiring and terminal at ECM pin A6 ckt A6 Up coil Check wiring and terminal at the platform lowering coil ckt B6 Down coil OR check wiring and terminal at ECM pin B6 ckt B6 Down coil Check wiring and terminal at the steer right coil ckt C7 Right coil OR check wiring and terminal at ECM pin C7 C7 Right coil Check wiring and terminal at the steer left coil ckt B7 Left coil OR check wiring and terminal at ECM pin B7 B7 Left coil Continued on next page Genie GS 2032 Part No 46326 Service Man
122. rst Edition Section 7 Repair Procedures G PLATFORM COMPONENTS 2 2 How to Replace the Platform Platform Extension Extension Wear Pads 1 Remove the Platform Extension See 2 2 How How to Remove the to Remove the Platform Extension Platform Extension 2 Drill out the rivets which hold the wear pads in 1 Lower the platform to the stowed position place 2 Extend the platform approximately 3 feet 1 m 3 Install the new wear pad using new rivets 3 Remove the platform controls from the platform When installing new rivets make and lay them off to the side of the machine sure the rivet heads are not above the surface of the wear pad 4 Support the platform extension with a forklift at the steer end Do not lift it 5 Attach a strap from the platform extension railings to the carriage on the forklift to help support the platform extension 6 Remove the mounting fasteners from the platform extension roller support on both sides of the machine at the non steer end of the platform extension Remove the roller supports 7 Carefully slide the platform extension out from the platform and place it on a structure capable of supporting it Part No 46326 Genie GS 2032 7 9 Section 7 Repair Procedures Service Manual First Edition Scissor Com ponents machines before serial number 632 2 2 2
123. sh SAE Dash steel 16 217 6 27 3 6 6 23 312 8 40 5422 8 35 475 8 Aluminum 450 542 2 90 142 Aluminum 69 936 mes 1 1424 190 Stee 20 2847 260 3525 see _____ ts Torque Procedure 1 Replace the O ring The O ring must be 3 Be sure that the face seal O ring is seated and replaced anytime the seal has been broken retained properly gt Pe cannot be oe Ie Hung us 4 Position the tube and nut squarely on the face ose end has been tightened beyond finger me tight i end of the fitting and tighten the nut finger The O rings used in the Parker we Seal Lok fittings and hose ends Tighten the nut or fitting to the appropriate are a custom size O ring They torque per given size as shown in the table are not a standard SAE size above O ring They are available in the 6 Operate all machine functions and inspect the O ring field service kit Genie part hoses and fittings and related components to number 49612 be sure that there are no leaks 2 Lubricate the O ring before installation Part No 46326 Genie GS 2032 2 3 Section 2 Specifications Service Manual First Edition EE 00 This page intentionally left blank 2 4 Genie GS 2032 Part No 46326 Service Manual First Edition Section 3 Scheduled Maintenance Inspections Scheduled Ma
124. shing LED at the platform supply voltage is 18 5V DC or aval lable controls while function enable less Switch is activated Charge batteries Notes Continued on next page Part No 46326 Genie GS 2032 5 5 Section 5 Troubleshooting Flow Charts Service Manual First Edition Normal Operation Code Chart Before Serial Number 17408 Code Condition Key switch to platform control Platform extended above 6 feet Ground control and platform Emergency Stop buttons pulled out to the on position 20 flashing Key switch to platform control Platform extended above 6 feet Ground control and platform Emergency Stop buttons pulled out to the on position 21 flashing Explanation Machine was operating normally then the platform Emergency Stop button was pushed in and the key switch was turned to ground control Alarm will go off until key switch is turned to platform control or the platform Emergency Stop button is pulled out Normal operation Key switch to ground control Ground control Emergency Stop button pulled out to the on 22 position flashing Platform control Emergency Stop button pushed in to the off position To clear this code be sure joystick is properly connected or pull the platform Emergency Stop button out to the on position Key switch to ground control Ground control and platform Emergency Stop buttons pulled out to the on position Error indicator light at platfo
125. spection receives an N tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable remove from service R repaired Comments Checklist A Checklist C Y N R Referto Table A Refer to Table C A 1 Operator s and C 1 Latch components Safety manuals A 2 Decals and placards A 3 Damage and loose or missing parts A 4 Hydraulic oil level A 5 Hydraulic leaks A 6 Platform and ground controls A 7 Manual Platform Lowering A 8 Tilt sensor A 9 Pothole Guards A 10 Lift drive Select Switch A 11 30 Day Service Checklist B Refer to Table B B 1 Batteries B 2 Electrical wiring B 3 Tires and wheels B 4 Key Switch B 5 Emergency Stop B 6 Horn B 7 Drive Brakes B 8 Drive speed stowed B 9 Drive speed raised B 10 Hydraulic oil analysis B 11 Electrical contactor before serial number 6901 Perform every 250 hours B 12 B 12 Hydraulic Return Fiter Return Filter Checklist D Refer to Table D D 1 Hydraulic oil IT Genie GS 2032 Part No 46326 Service Manual First Edition Section 4 Scheduled Maintenance Procedures Scheduled Maintenance Procedures Observe and Obey MI Maintenance inspections shall be completed by a person trained and qualified on the maintenance of th
126. t damage Dealer service is strongly recommended When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Raise the platform approximately 7 to 8 feet 2 1 to 2 4 m 2 Lift the safety arm move to the center of the scissor arm and rotate down to a vertical position 3 Lowerthe platform onto the safety arm Crushing hazard Keep hands AWARNING clear of the safety arm when lowering the platform 4 Tag and disconnect the wiring from the solenoid valve at the barrel end of the lift cylinder 5 Disconnect the manual lowering cable from the solenoid During assembly the manual platform lowering cable needs to be properly adjusted Refer to 4 1 How to Adjust the Manual Platform Lowering Cable 6 Remove the mounting fasteners from the manual lowering cable mounting bracket Remove the bracket from the cylinder 7 Disconnect and plug the hydraulic hose from the lift cylinder Cap the fitting on the cylinder Bodily injury hazard Spraying AWARNING 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 8 Attach a strap from an overhead crane or similar lifting device to the rod end of the lift cylinder for support 9 Remove the
127. t enable switch closed at start up switch 46 Platform drive enable switch Malfunctioning drive enable Troubleshoot drive enable closed at start up switch switch 47 Platform joystick off neutral at Joystick potentiometer not Verify potentiometer setting start up centered Malfuctioning coil OR wire Troubleshoot coil OR inspect 52 Forward coil error disconnected from coil wire connection Malfuctioning coil OR wire Troubleshoot coil OR inspect 53 Reverse coil error 5 disconnected from coil wire connection Malfuctioning OR wire Troubleshoot coil OR inspect 54 Up coil error disconnected from coil wire connection Malfuctioning coil OR wire Troubleshoot coil OR inspect 55 Down coil error disconnected from coil wire connection Malfuctioning coil OR wire Troubleshoot coil OR inspect 56 Right coil error disconnected from coil wire connection Malfuctioning coil OR wire Troubleshoot coil OR inspect 57 Left coil error disconnected from coil wire connection Malfuctioning coil OR wire Troubleshoot coil OR inspect 58 Brake coil error disconnected from coil wire connection 68 Low Voltage Batteries discharged Charge batteries Troubleshoot pothole switch OR remove obstruction 5 8 Genie GS 2032 Part No 46326 Service Manual First Edition Section 5 Troubleshooting Flow Charts All Functions Will Not Operate Be sure the circuit breaker and
128. tick controller Controller box Enlarged view of DIP switch oOaQ 070M 2 Remove the fasteners securing the top of the controller to the controller case Rotate the platform controller box to the position shown to correctly identify the configuration of the DIP switch settings Open the controller box lid and locate the DIP switch on the circuit board Move the DIP switch settings to correspond with the configuration of the machine options indicated in the DIP Switch Code Chart Confirm the settings See 1 3 How to Determine the Revision Level Cover the DIP switch with dielectric grease Close the lid and install the fasteners Push in the Emergency Stop button to the position at both the ground and platform controls and turn the key switch 10 the position Any change in DIP settings will not take effect until the key switch is turned to the position 7 4 Genie GS 2032 Part No 46326 Service Manual First Edition Section 7 Repair Procedures DIP Switch Code Chart A mark in the column indicate that the machine configuration includes this option 515 s R 75 5 5 Diagnostic Switch 5 4 Display Code Code 2 8 S SIl 8 8 9 O Q 32 10000000 33 10000100 34 10001000 35 10010000 36 10100000 37 11000000 38 10001100 o
129. trical Schematic before serial number 6901 6 7 Electrical Schematic from serial number 6901 to 8931 44442222 1 6 9 Electrical Schematic from serial number 8932 to 17407 6 11 Electrical Schematic after serial number 17407 6 13 Ground Controls and Level Sensor Box Legend 6 15 Platform Controls Legend before serial number 17408 6 16 Platform Controls Legend after serial number 17407 6 17 Hydraulic Symbols Legend neck LA AA paene ne ERE auae 6 18 Hydraulic Schematic before serial number 17482 6 19 Hydraulic Schematic after serial number 17481 sse 6 20 Genie GS 2032 Part No 46326 Service Manual First Edition a Ss Section Seven TABLE OF CONTENTS Repair Procedures fore wzw O ES 7 1 Platform Controls 1 1 Platform Controller nennen nennen nennen 7 2 1 2 Software Configuration aaa nennen nns 7 3 153 Toggle Switches aaa Aa 7 6 Platform Components 24 7 8 2 2 Platon EONS ass ice EU 7 9 Scissor Components 3 1 Scissor Assembly GS 2032 00 22
130. trols Inoperative Chart 5 OR consult Genie Industries Service Department 5 10 Genie GS 2032 Part No 46326 Service Manual First Edition Section 5 Troubleshooting Flow Charts CHART 1 Turn key switch to platform control position and check output side of each contact Repair or replace key Check cam on key switch switch Continued from the previous page Replace bad contact OR refer to Platform Controls Inoperative Chart 6 OR consult the Genie Industries Service Department Refer to Chart 2 Pump Motor Will Not Operate OR repair open in wht wire C2 estop chassis OR consult the Genie Industries Service Department Part No 46326 Genie GS 2032 5 11 Section 5 Troubleshooting Flow Charts Chart 2 Pump Motor Will Not Operate Activate lift function from the ground controls and check voltage at positive terminal on pump motor M1 Be sure the circuit breaker and fuse are not tripped or blown Be sure the batteries are properly connected Be sure the batteries are fully charged less than 24V Continued on the next page Check voltage on B terminal on motor controller U2 24V Check continuity on ground cable from pump motor to M terminal on motor controller continuity Check continuity from B terminal on controller to the negative battery cable at the Anderson plug AP1 continuity Activate lift function and
131. ual First Edition Section 5 Troubleshooting Flow Charts FAULT CODE CHART BEFORE SERIAL NUMBER 17408 Fault Code Problem Possible Causes Machine will not drive but No power output from ECM to platform will still raise the brake orifice coil Check wiring and terminal at the orifice coil ckt C9 orifice coil OR check wiring and terminal at ECM pin C9 C9 orifice coil OR replace Coil Machine will not operate Error Lift drive switch is turned off Check switch position OR indicator light on at the platform or in neutral position Replace switch Lift drive switch turned from lift Machine will not operate Release function enable switch to drive or drive to lift while the Flashing green LED at the and move lift drive switch to function enable switch is 3 platform controls either lift or drive engaged Machine will not op rate ECM EPROM not programmed Replace ECM cannot be reset Release function enable switch Function enable switch held for OR check he tunetian enable no code Green flashing LED at the microswitch for continuity in more than 10 seconds without 1 platform controls the joystick controller box available activating any function ene ann fault code 33 at power up Machine drive speed reduces to off limit drive speed OR Low Voltage Cut Back LVCB no code platform raises slowly Red is activated because battery 1 fla
132. ure all other functions operate normally Be sure the circuit breaker and fuse are not tripped or blown Be sure the batteries are properly connected Be sure the batteries are fully charged With the key switch in the platform position and the platform raised slightly and the Emergency Stop buttons pulled out to the on position at both the ground and platform controls and the lift drive switch in the lift position activate the controller in the DOWN direction and check to see if the error indicator light is on light is not on Continued on the next page light is on With the platform raised and the safety arm installed connect the leads of a volt meter to the wires on the platform lowering coil on the cylinder without removing the wires With the key switch in the platform position and the lift drive toggle switch in the lift position activate the controller in the DOWN direction and check the voltage 24V Label and disconnect the wires from the coil on the platform lowering valve item R at the platform lift cylinder and check the resistance See Repair Section 23 to 25 ohms With the platform raised and the safety arm removed pull the manual platform lowering handle at the ground controls platform does not lower Check for mechanical restrictions keeping the platform from lowering OR repair or replace the platform lowering valve cartridge item R OR repair
133. urn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 7 Remove the drive motor mounting fasteners then remove the motor Torque specifications Castle nut 300 ft lbs 406 7 Nm STEERING AXLE COMPONENTS 7 2 Steering Cylinder How to Remove the Steering Cylinder When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Block the non steer wheels 2 Tag disconnect and plug the hydraulic hoses from the steering cylinder Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING 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 3 Remove the pin retaining fasteners from the barrel end pivot pin Use a soft metal drift to remove the pivot pin Note the quantity and location of the spacers when removing the barrel end pivot pin Part No 46326 Genie GS 2032 Section 7 Repair Procedures Service Manual First Edition p s STEERING AXLE COMPONENTS 4 Remove the pin retaining fasteners from the 7 3 rod end pivot pin Use a soft metal drift to
134. xpected after performing a series of steps Part No 46326 Genie GS 2032 7 1 Section 7 Repair Procedures Service Manual First Edition Platform Controls 1 1 Platform Controller The platform controller is controlled by an ECM Electronic Control Module located in the power unit module tray The ECM aids in troubleshooting by recognizing machine malfunctions and displaying fault codes on an LED screen on the ECM See the Troubleshooting section of this manual for a list of fault codes and additional information The ECM is not user serviceable The joystick controller is calibrated at the factory and does not need to be adjusted For further information or assistance consult the Genie Industries Service Department Platform Controller before serial number 17408 muj 00 gt Main circuit board Lift drive selector toggle switch Horn button Emergency stop button LED circuit board Joystick controller Platform Controller after serial number 17407 Bro a Maincircuit board b Emergency stop button c Joystick controller Alarm 7 2 Genie GS 2032 Part No 46326 Service Manual First Edition Section 7 Repair Procedures 1 2 Software Configuration The EC
135. zard Spraying AWARNING 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 2 Connect a O to 5000 psi 0 to 345 bar pressure gauge to the high pressure port on the pump 3 Turn the key switch to ground control and pull out the Emergency Stop button to the on position at both the ground and platform controls Hydraulic Pump Activate the platform up function from the ground controls Result If the pressure gauge reads 3000 psi 207 bar immediately stop The pump is good Result If pressure fails to reach 3000 psi 207 bar the pump is bad and will need to be serviced or replaced Remove the pressure gauge and reconnect the hydraulic hose How to Remove the Hydraulic Pump When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Tag disconnect and plug the hoses on the pump Cap the fittings on the pump Bodily injury hazard Sprayin AWARNING 09 PAra 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 2 Remove the pump mounting bolts Carefully remove the pump Part No 46326 Genie G

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