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PN 97385

1. 004 RD RD 4 WH WH 3 4 4 m 1 1 30 6 456 y a CR48 4 i 4 POWER 4 RELAY TOUS Bl 1 pu vi ava 85 E STOP Lo de 4 4 4 08 KS1 4 OR BK DRIVE ENABLE GS 3232 ONLY 8 R24 25 OHM i MOTOR CONT MC ENABLE OUT RD BK DOWN LIM 156 eee 52 PLATFORM OVERLOAD PRESSURE SWITCH _ N C H O DOWN 52 BN GROUND P d LIMIT bg v SWITCH o 1 8 4 1 gt gt 1 m g CR27A 27 CR27C 5 OVERLOAD OVERLOAD OVERLOAD MOTOR CONT LOAD SENSE DOWN COIL i 30 gt 30 86 30 86 N C niv i Joe p 1 eee 5
2. April 2008 Section 6 Schematics Electrical Schematic REVB CE Models GS 2032 2632 from serial number GS3207 83651 to GS3207 84866 GS 2046 2646 3246 from serial number GS4607 82536 to GS4607 84839 NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF RD RD 4 4 WH WH 3 34 CR28 86 af 2 6 8 BL 1 C 1 ES ec 87A 85 87 85 E STOP OR o S 54 24 25 OHM NC 4 D4 PS2 PLATFORM OVERLOAD 156 4 PRESSURE SWITCH wv d SWITCH N O H C 5 CR27A CR27B CR27C oron conn OvER AD pope pr 4 30 86 30 86 30 86 238 87 85 87A 85 87 85 LS5 NO SENSOR UP BOARD C57 Simon OO zi 5 www x 5 mz De Row m 35 34 CR27D 55958 9 OVERLOAD 2 Oo 5 DOWN DELAY g UE 9 P 8 2 2 5 2 mE e agp 4 1 A9 A6 A
3. QD4 1 4 4 3 3 i WH rd BL 1 1 1 j DEI BK 2 2 1 1 1 1 1 f 1 ES 4 4 1 4 4 4 MC THROTTLE us 6 56 30 4 56 CR48 r3 UU MEN cn Rn tee fi xs BK MC ENABLE IN 4 4 POWER NEN UEM REEL 4 BK 24V 4 RELAY TO 05 ava 85 E STOP L 4 4 4 4 4 4 OR KS1 4 F OR BK DRIVE ENABLE 4 gt 65 3232 ONLY CR28 R24 GROUND CUT OUT 25 OHM 6 L MOTOR CONT EN in Hid DEAE 2 MC ENABLE OUT 4 NC 4 ge DOWN LIM LS6 rege PLATFORM OVERLOAD 6 PS2 PRESSURE SWITCH N C H O DOWN po 2 250
4. POSITION WITH THE POWER OFF RD RD 4 4 WH WH 3 34 CR28 86 2 46 8 BL 1 6 1 cutout 4 4 E POWER BK 2 2 MOTOR CONT w _ fof Eso 8 824 25 NC 4 D4 PS2 PLATFORM OVERLOAD LS6 7 4 PRESSURE SWITCH N C H O DOWN LIMIT SWITCH 4 gt 6 2 CR27A CR27B CR27C OVERLOAD OVERLOAD ovcROAD MOTOR CONT LOAD SENSE DOWN COIL t NO 30 486 30 86 304 3 486 N C 4 saa 1 EAT TE G 2 1 LEVEL 1 87 85 87A 85 87 85 4 1 SENSOR 1 LS5 N O CIRCUIT MEE i BOARD E 1 C5 SWITCH go go E 22556545 S7 gt gt O LEVEL c 2 2 85 22228 SENSOR Tes 3 9 5 2 po i i 25 5 59 5 3 BK 4 CR27D B252 5 OVERLOAD 0 3 DOWN DELAY m X A 9 2 8 E ME 5 3 98 02 Bii A9 A6 10 B6 C12 A4 2 Bi
5. CE Models REV A GS 1530 32 8 1930 32 from serial number GS3010A 99456 to GS301 1A 109999 GS 1530 32 amp 1930 32 from serial number GS3010C 2190 to GS3011C 5059 e ces eec Da ue De ede E 1 8 ____ ________________________ i 3 1 gU EMERGENCY EN Pd CN S 8 S N or i CB2 2 CIRCUIT 2 T BREAKER 51 1 key PLATFORM gt H5 SWITCH CONTROL i 4 ALARM B1 24 1 ii 3 1 N NCHO i N GROUND 2 CONTROL m LS7 TS66 POTHOLE SERRE SRR Sang tn Grea sins sae ne ane ees bog PLATFORM R30 T UP DOWN 1 1 w NOTE RD 4 We 4 N CHO MACHINE SHOWN IN THE Lo 0 2 STOWED POSITION WITH 5 U27 5 158 THE POWER OFF bog 47 mH INDUCTOR NOISE SUPPRESSION POTHOLE d GUARD pog SWITCH x 2 g AE Q i 5 8 e 3 8 5 5 Ti IR L2 ape 228 5 C WORK LIGHT o 9 d m IATA OPTION 5 E
6. GS 2032 2632 3232 after serial number GS3207 84866 and from GS3208C 101 REV D GS 2046 2646 3246 after serial number GS4607 84839 and from GS4609C 101 LET OYLINDER 1 LEFT j RIGHT OVERLOAD CE MODELS __ BRAKE __ 370 to 450 psi i lan 1 N 26 to 31 bar MANUAL el pi m Y7 on r y BRAKE 774 s Hn RELEASE 059 i THE ORIFICE IS LOCATED C iim MANIFOLD UNDERNEATH THE HOSE peu sce FITTING ON THE LIFT CYLINDER 4 B1 EFT RIGHT r 4 75 CU IN DRIVE a UPPER LIFT CYLINDER 78 65 3232 GS 3246 MODELS 2 2 g 5 5 Y9 5 M 51 52 HP B AC M1 2 4 Momm J m 1 A mm 77 2 4 1 X 1 m oer va N M vs gt 48 THE ORIFICE IS LOCATED UNDERNEATH THE PLUG KI OPPOSITE THE HOSE INLET OF THE LIFT CYLINDER O LN Y1 5 0 25 Y5 0 95 L min t m i e Al aa 7 UL 6 23u x EE g
7. GROUND BN 5 256 ROLL 928 5 1 SBG PITCH BL POWER b WH a sic lt 1 5 5 SEF E 9 2 gt 5 GN WH E 4 E lt lt 5 lt lt 4 A E I 5 2 o 1 Ber No YA 52 DATA LOW 08 1 Ora 345 D obs 6 POWER TO PLAT RDB 55 BLWH gt E 5 8 S 5 GROUND TO PLAT 4 BL 8 I3 ze 8 TIT Ors 5 E pesi k GN 5 ul e in 5 5 NENNEN 5 ir 98 1 p MC ENABLE 6 82 a 89 ORMH NTT lz 9 4 pee MC ENABLE 1 8 2 0 E Opa Ei sone B 9
8. EMERGENCY 2f STOP NAT B PAIN 2 4 KS1 key PLATFORM 1 SWITCH CONTROL Bi 4 NOTE i H5 N ALARM MACHINE SHOWN IN THE 2 3 STOWED POSITION WITH Sg THE POWER OFF CONTROL 7 1577 TS66 POTHOLE GUARD PLATFORM SWITCH UP DOWN N C H O CB2 c 9 7A 9 CIRCUIT gt BREAKER 4 LS8 U27 P GUARD 47 mH INDUCTOR NOISE SUPPRESSION SWITCH X s 5 8 8 9 5 2 i 2227 P i o e BLACK AND WHITE WIRES CUT POWER f z 92 TO MOTOR CONTROLLER WHEN THE 130 g 5 CHARGER IS PLUGGED IN OPTION X gt NA OPTION i QD1 9 LZ TN E wi onem F6 275A FUSE 2 2 2 BK Iz lI qp 696 12 B12 11 9 B10 Sigur IN IN OUT IN OUT 9 10 F CHARGER U5 ELECTRONIC CONTROL MODULE OUT OUT B8 B3 B5 4 AC INPUT 9 NINE MOTOR CONTROLLER 2 Li p PUE RES CONNECTED MOTOR 4 CRS ICONTROLLER P HORNRELAY 1 CUT OFF POWER H2 OPTION pr U13 OPTION _ _ _
9. POSITION WITH THE POWER OFF RD RD 4 4 WH WH 3 34 CR28 86 af 2 6 8 BL 1 C 1 cutout 4 4 E POWER BK 2 2 MOTOR CONT w _ fe fe Eso 8 T 824 25 NC 4 D4 PS2 PLATFORM OVERLOAD LS6 7 4 PRESSURE SWITCH N C H O DOWN LIMIT 7 SWITCH N O H C gt 6 2 CR27A CR27B CR27C 804 OVERLOAD OVERLOAD 4 MOTOR CONT LOAD SENSE DOWN COIL t NO 30 86 30 86 30 86 4 1 1 Sak oul P EE G LEVEL 1 87 85 87A 85 87 85 4 1 SENSOR 1 LS5 CIRCUIT MEE i BOARD E 1 C5 SWITCH 5 89 85 57 309 5 4 2 5 0 SS 53 2 2 LEVEL 5 5 23822 8 8 SENSOR Tes 3 2 07 i 5 5 20 2 8 BK 2 a 1 CR27D 8 A 28 OVERLOAD z DOWN DELAY 9 9 2 8 5 3 2298 2 c xL A4 AQ 10 B6 C12 C2 A2 B1 5 IN OUT IN Us ELECTRONIC CONTROL MODULE OUT OUT OUT OUT OUT C8 C7 B7 A7 C6
10. REVE ANSI CSA and Australia Models GS 2032 2632 from serial number GS3205 75407 to GS3206 79991 GS 2046 2646 3246 from serial number GS4605 75438 to GS4606 78915 NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF QD4 RD RD 4 4 4 WH WH 3 30 86 CR48 BL 1 4 1 MESI gr 95 5 OR ese a N O HCC 4 156 DOWN LIMIT SWITCH z E BOARD nS g 9 4 4 57 SE z 5 9955 LEVEL SEE S255 8 5 5 7 2 o 9 5 58 55 3 5 5 d lt 9 8 3 zumo um d I2 Lue m C2 11 C12 A10 4 A2 B1 A5 IN IN IN IN IN IN IN IN OUT U5 ELECTRONIC CONTROL MODULE OUT OUT OUT OUT OUT OUT OUT C8 B7 AT 6 B6 A6 OMS eco ee UR ONUS TU 2 8 P E 2 8 2 Ej 9 E Y1 Y4 Y5 Y6 Y9 Y7 Y8 PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM RIGHT LEFT REVERSE FORWARD DOWN DOWN UP GS 3246 SPX ap GND ES0141H Genie Part No 97385 GS 30 GS 32 6 6 31 Section 6 Schematics April 2008
11. Section 6 Schematics April 2008 Electrical Schematic CE Models REVE GS 2032 2632 from serial number GS3205 75407 to GS3205 77290 GS 2046 2646 3246 from serial number GS4605 75438 to GS4605 76734 P2 QD3 EMERGENCY 4 4 BK POWER PLATFORM p 3 3 RD POWER TO GROUND 1 1 WH crounn __ 1 2 2 BL DATALINK HIGH 5 5 OR DATALINK LOW U3 D7 si PLATFORM CONTROLS VOLTAGE PRINTED CIRCUIT BOARD REGULATOR HALL EFFECT a NN RTE GN SW5 SW6 6 Pp FUNCTION ENABLE T Mari PLATFORM CONTROLS MEMBRANE DECAL POUT1 0 gt LIFT LED 116 POUT2 4 DRIVE LED L17 POUT3 O 4 HIGH TORQUE LED L21 G8 POUT4 DIAGNOSTIC DISPLAY PIN1 HIGH TORQUE BN6 PIN2 HORN BN5 PIN3 DRIVE ENABLE BN8 4 POUT11 PLATFORM BK M LU CONTROLLER ES0142G Genie GS 30 GS 32 GS 46 Part No 97385 April 2008 Section 6 Schematics m This page intentionally left blank Genie Part No 97385 GS 30 GS 32 6 6 89 Section 6 Schematics April 2008 eee Electrical Schematic CE Models REV D GS 2032 2632 from serial number GS3205 77291 to GS3206 79991 GS 2046 2646 3246 from serial number GS4605 7
12. QD4 i RD RD 4 4 8 8 WH WH E 1 Fd DEI BK 2 2 1 1 1 OR 5 5 i ot Se SS 3d E aul Gay 16 4 4 1 4 4 4 MC THROTTLE 4 CR48 on eee a es eee eee l BK MC ENABLE IN 4 4 LO Tr cR ONE 1 BK 24V RELAY TO 05 n ava 85 E STOP L d 4 4 4 4 OR KS1 4 4 4 p OR BK DRIVE ENABLE 4 gt 65 3232 ONLY CR28 R24 GROUND CUT OUT 25 OHM MOTOR CONT EN in Hid DEAE 2 MC ENABLE OUT 4 NC 4 ge DOWN LIM LS6 rege PLATFORM OVERLOAD __ 56 PS2 PRESSURE SWITCH N C H O DOWN BN GROUND 16 LL EN v j SWITCH BE E 9 N 8 4 4 8 4 1 1 1 4 eee 2 5 o CR27A CR27B CR27C 88 lt OVERLOAD OVERLOAD OVERLOAD Hi sar
13. REV ANSI CSA and Australia Models GS 2032 2632 from serial number GS3207 83651 to GS3207 84866 GS 2046 2646 3246 from serial number GS4607 82536 to GS4607 84839 NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF RD RD 4 4 4 WH WH 34 04 4 CR48 POWER BK 2 2 RELAY US 95 5 N O H C 4 OF LS6 DOWN LIMIT SWITCH 5 E SENSOR Soar 5 5 E 9 i 3 5 z 5 lt lt g LEVEL 3 d 5 9 2524255 SENSOR 2 5 5 a 7 4 9 8 2 3 5 89 8 E a GL ILI E qp LL A4 1 C12 A10 C2 A2 B1 C1 C11 A5 IN IN IN IN IN IN IN IN OUT U5 ELECTRONIC CONTROL MODULE OUT OUT OUT OUT OUT OUT C8 B7 AT 6 B6 A6 ee oS oe ee a ee TEES TU 000 y Y3 Y4 Y5 Y6 Y9 Y7 Y8 PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM RIGHT LEFT REVERSE FORWARD DOWN DOWN UP GS 3246 aX APX APX APX GND ES0141M Genie Part No 97385 GS 30 GS 32 6 6 39 Section 6 Schematics April 2008 Electrical Schematic ANSI CSA and Australia Models GS 2032 2632 from serial number GS3207 83651 to GS3207
14. GREEN MTG2 RED 2 2 9 e 9 yn 9 3 15 2 iem To Illustration 6 18 Open the PSoC Programmer on a PC or laptop Part No 97385 October 2009 Section 4 Repair Procedures eee REV J PLATFORM CONTROLS 19 Select MINIProg1 048E47470618 from the Result All the boxes in the lower right corner of Port drop down menu the PSoC Programmer window should have a green background and show as being Connected Psoc Programmer BAX Programming Utilities View Help Device Family Device 20 34 CV8C20234 12LKX v INIProal J618 Device CY8C20234 12LKX a Device Family set to 20x34 at 1 V PSoC Programmer Programming Utilities View Load 8 2 Checksum 2 Read Port Device Family Device Connect 20x34 cvac202341 2LKX Toggle Device Power Programming Mode 421 PowerCycde Successful port connection for Open MiniProgrammer at 14 31 19 MINI Version 1 71 Device set to CY8C20234 12LKX a Device Family set to 20x34 at 1 For Help press F1 Green Backgrounds For Help press F1 Not Powered Idle Connected Genie Part No 973
15. enie GS 30 GS 32 6 T P Lg T UP COIL n Bill 195 tee ace a 25 13 2 UP IN BBK amp lt 1 2 5 8 5 cp ee 41 COZRE 958 rug 1252 4 6 5 1 Po WH 8 9 5 i x 1 1818 RD HEE i IG 58855 8 pu Oo 5 i un ii lg 5 E 5 FO bog 1 3 J o5 28 ME QUE OPP Sar LVL SNSR RED 23 12 E 8 5 gt 5 184 bg LVL SNSR WHT 52 ESI lir ud 128 58 pone i h DATA LINK LOW oZ P 5
16. ES0141V enie 6 27 GS 30 GS 32 GS 46 Part No 97385 REVA February 2012 GS 1530 1532 1930 1 932 from serial number GS3010A 99456 to GS301 1A 109999 Electrical Schematic ANSI CSA and Australia Models Section 6 Schematics 8 GROUND BN co 229 ROLL 252 1 2 j 8 PITCH BL 4 1 E POWER WH 4 d EE 1 ul 55 1 21 1 rir Oui 1 IE 1 E g 2 2 Sal 2 EEG Need 8 jg cec DATA HIGH 4 ei E E 8 DATA 1 E z c AT i f gee POWER TO 1 80 8 EB 2m n VE o5 is 5 z I pr GROUND TO PLAT i 8L X8 E 1 NE 8 lee u Qtr E
17. CE Models REV C GS 2032 2632 from serial number GS3206 79992 to GS3207 83650 GS 2046 2646 3246 from serial number GS4606 78916 to GS4607 82535 P1 egi RS EMERGENCY Ex Pd H 2 8 1 N oR 227 2 KS1 key PLATFORM 1 SWITCH CONTROL 4 NOTE j m ALARM MACHINE SHOWN IN THE 243 STOWED POSITION WITH Sg E 4 THE POWER OFF NA 7 1577 7566 POTHOLE PLATFORM SNCH UP DOWN N C H O CB2 S 3 0 BREAKER LS8 U27 P GUARD 47 mH INDUCTOR NOISE SUPPRESSION SWITOH S 5 4 2 5 3 3 E 2 227 5 BLACK AND WHITE WIRES CUT POWER 2 E TO MOTOR CONTROLLER WHEN THE ky 0 S CHARGER IS PLUGGED IN OPTION 7 WORK 5 2 90169 Sa RAE 5 F6 275 FUSE 8 BK f WH A12 B12 11 B9 B10 aler OUT IN uo A8 OUT BATTERY 1 OUT CHARGER U5 ELECTRONIC CONTROL MODULE OUT B8 B3 B5 E CE xu 0 7 7 BATTERY AG INPUT 9 2 NINE MOTOR CONTROLLER 7 1 NOT CONNECTED A CR5 E V HORN RELAY CUT OFF POWER ITN E H2 OPTION 86 l us pene ge ci DC AC INVERTER FLASHING 85 OPTION BEACONS SS XE LU OPTION H2 G6 AUTO S
18. Section 6 Schematics April 2008 Electrical Schematic CE Models REV D GS 2032 2632 from serial number GS3205 77291 to GS3206 79991 GS 2046 2646 3246 from serial number GS4605 76735 to GS4606 78915 P2 QD3 EMERGENCY 4 4 POWER PLATFORM 74 3 3 RD POWER TO GROUND 1 1 WH ioro 1 2 2 BL DATALINK HIGH 5 5 OR DATA LINK LOW 1 D7 PLATFORM CONTROLS VOLTAGE PRINTED CIRCUIT BOARD REGULATOR T HALL EFFECT GENERATOR JOYSTICK CONTROLLER GN SW5 E PP FUNCTION ENABLE T STEER 1 LEFT RIGHT PLATFORM CONTROLS MEMBRANE DECAL LIFT LED 116 DRIVE LED L17 HIGH TORQUE LED L21 POUT4 C DIAGNOSTIC T DISPLAY PIN1 HIGH TORQUE BN6 PIN2 HORN BN5 PIN3 DRIVE ENABLE BN8 PIN4 LIFT ENABLE BN9 POUT11 PLATFORM BK 7 CONTROLLER ES0142J Genie GS 30 GS 32 GS 46 Part No 97385 April 2008 Section 6 Schematics m This page intentionally left blank Genie Part No 97385 GS 30 GS 32 6 6 93 Section 6 Schematics April 2008 eee Electrical Schematic
19. d GROUND BN 256 ROLL H OR 500 5 PITCH BL de ye ee vse oe all POWER 4 a 6 7 stra 5 E eos a m zu 5 5 5h omm 5E Nri 8 DATA HIGH owe 4 5 5 5 8 oee DATA LOW cin Ope Sg A X SYE POWER TO PLAT i RD 2 Bo BAM E 5 4 o5 8 000 GROUND TO PLAT 1 24 NE 5 Q tz BOTAIP MC THROTTLE r GN 3 589 T2 gt _ cu 3 5 MC ENABLE 5 25 ORME ATT LO 4 i MC ENABLE 8 5 me bd H 1 p KEYSWITCH L 08 8 59 EN e 512 ENABLE H ORIBK 15 2 z TES 5 Lid BN pae ee BK 48 Oo 4 rt o 1 N Oz 14 E gt 1 Tz H ERTE Jo i 29 gt x ae aS 14 NENNT NES 5 89 MEM E E i 5 WOES cbe OW 1 r
20. d d NC ag ee 297 Tte EE 1 pq oH 1 TERES Mae e e i i 11 iii 1 M bg Ld uud bar d I ped V A al tii 1 1 13 4 amp 0 1 5 ts 1 98 ey 5 FEIJES 2 5 2 59 1 2 52208 985255 5 ee ae a i 1 1 Jt 1 ES0141P Part No 97385 GS 30 GS 32 GS 46 6 44 February 2012 Section 6 Schematics Electrical Schematic REV D ANSI CSA and Australia Models GS 2032 2632 3232 from serial number GS3207A 84867 to GS3210A 94974 GS 2046 2646 3246 from serial number GS4607A 84840 to GS4610A 95454 P2 EMERGENCY NOTE BK POWER TO PLATFORM RD POWER TO GROUND MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF BL DATA LINK HIGH lan VS VY 4 3 1 WH GROUND 2 5 OR DATA LINK LOW Do Re PLATFORM CONTROLS VOLTAGE PRINTED CIRCUIT BOARD REGULATOR 1
21. SW5 SW6 pp FUNCTION ENABLE T STEER LEFT RIGHT PLATFORM CONTROLS 9 MEMBRANE DECAL POUTI O 4 LIFT LED L16 POUT2 i E DRIVE LED L17 POUT3 O 4 HIGH TORQUE LED 121 M G8 DIAGNOSTIC DISPLAY POUT4 PIN1 HIGH TORQUE BN6 PIN2 HORN BN5 PIN3 DRIVE ENABLE BN8 PIN4 LIFT ENABLE BN9 flu PLATFORM CONTROLLER POUT11 ES0141V Genie GS 30 GS 32 GS 46 Part No 97385 Section 6 Schematics April 2008 eee Electrical Schematic ANSI CSA and Australia Models REVE GS 2032 2632 from serial number GS3205 75407 to GS3206 79991 GS 2046 2646 3246 from serial number GS4605 75438 to GS4606 78915 egi P1 x ES EMERGENCY Ex 2f N STOP FAS OR 22 2 1 key PLATFORM 1 SWITCH CONTROL 4 NOTE H5 ALARM MACHINE SHOWN IN THE 243 STOWED POSITION WITH 7 CONTROL 7 THE POWER OFF 1875
22. LLL 4 Y1 Y4 Y5 Y6 Y9 Y7 Y8 PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM RIGHT LEFT REVERSE FORWARD DOWN pow UP ___ ___ GS 3232 GS 3246 2 e 4 e 74 GND ES0142T Genie Part No 97385 GS 30 GS 32 GS 46 6 107 REVA February 2012 GS 2032 2632 3232 from serial number GS3210A 94975 to GS321 1A 97903 and GS3210C 379 to GS3212C 1386 GS 2046 2646 3246 from serial number GS4610A 95455 to GS461 1A 97982 and GS4610C 119 to GS4612C 1385 Electrical Schematic CE Models Section 6 Schematics CE Models GROUND BN 256 ROLL 9242 5 1 SG PITCH POWER b WH a POT sic lt 1 5 5 298 5 Sal 27 6 tM eS E lt lt 5 lt lt 4 A E I 5 4 2 5 1 Ber No YA 52 DATA LOW
23. 2 1 5 95 3232 ONLY 5 QD1 eje c E 3 gt 9054 gi Contactor p 2 _ IN OUT 25 _ 275 wa 5 0 _ Low WH OUT U5 U9 ELECTRONIC BATTERY CONTROL CHARGER out MODULE out B5 Ll B8 B3 r RD ov U6 11 9 g BATTERY Nd MOTOR 3 Note 2 Dog CONTROLLER Diodes added at AC INPUT serial numbers o GS3011A 102860 F S 5 GS3211A 96875 m i S A HORN RELAY GS46114 97260 Dw 30 2 485 cr U13 v 2 DC AC INVERTER 62 m te 85 OPTION Mt J BEACONS GS3011C 1484 T rere OPTION H2 GS3212C 1483 G6 A AUTO STYLE 9946120 1517 HOUR HORN QD1 QD54 METER L 1 OPTION GND BM ES0142T Genie 6 78 GS 30 GS 32 6 97385 February 2012 Section 6 Schematics Electrical Schematic REVA CE Models GS 1530 32 amp 1930 32 from serial number GS3010A 99456 to GS301 1A 109999 GS 1530 32 amp 1930 32 from serial number GS3010C 2190 to GS301 1C 5059
24. 1 uj j MIT PITCH BL 5 POWER b WH a 0 o 2 2 a 5 a 9 DATA HIGH K z f ir 5 4 2 o 6 o DATA LOW Se A m POWER TO PLAT 5 gt ui wb 6 S 5 GROUND PLAT ie 8 i2 B 109 5 5 2 210 10 MC ENABLE lez a Jz MC ENABLE 85 gt E KEYSWITCH 9 2 o VS e 2 amp ul a W 5 9 lez 5 9 ul 5 sz o 2 2 5 5 15 c 2 m lt L E 5 Ez 5 IP E E z m l 2 d on 1 aM Fu 2 2 2 5 jigs aaa Tope po EE pr M BL BK in gt 4 d 6666 RXR 11 5 5 bog bg
25. 6 3 6 4 Outrigger ECM Pin out 6 5 Wiring Diagram Ground Controls and Level Sensor Harness 6 6 Wiring Diagram Platform Control and Outrigger Control Pad 6 7 Limit Switch 6 8 Electrical Symbols Legend esses eene enne 6 9 Electrical Schematics ANSI CSA and Australia Models GS 1530 1532 1930 1932 from serial number GS3005A 76000 to GS3006A 83067 from serial number GS3005B 76000 to GS3006B 79659 6 10 GS 1530 1532 1930 1932 from serial number GS3006A 83068 to GS3007A 87490 from serial number GS3006B 79660 to GS3007B 825493 6 14 GS 1530 1532 1930 1932 from serial number GS3007A 87491 to GS3007A 89537 from serial number GS3007B 82544 to GS3007B 84599 6 18 GS 1530 1532 1930 1932 from serial number GS3007A 89538 to GS3010A 99455 Part No 97385 from serial number GS3007B 84600 to GS3009B 98941 6 22 GS 1530 1532 1930 1932 from serial number GS3010A 99456 to GS30114 109999 6 26 GS 2032 2632 from serial number GS3205 75407 to GS3206 79991 GS 2046 2646 3246 from serial number GS4605 75438 to GS4606 78915 6 30 Genie GS 30
26. 5 gt sed 34 FUNCTION Joystick Section 6 Schematics April 2008 eee Electrical Schematic ANSI CSA and Australia Models REVE GS 1530 1532 1930 1932 from serial number GS3005A 76000 to GS3006A 83067 GS 1530 1532 1930 1 932 from serial number GS3005B 76000 to GS3006B 79659 Bi md EN EMERGENCY Ex 2f STOP 2 e H B PON 22 2 i KS1 key PLATFORM 1 SWITCH CONTROL 1 B 4 NOTE H5 MACHINE SHOWN IN THE x 3 STOWED POSITION WITH Sg NCHO THE POWER OFF CONTROL 7 1874 7566 POTHOLE GUARD PLATFORM SWITCH UP DOWN CB2 g 7 CIRCUIT 2 BREAKER LS8 POTHOLE GUARD SWITCH c 5 SAE 8 2 5 gt 2 2 3 9 e BLACK AND WHITE WIRES CUT POWER f z 9 TO MOTOR CONTROLLER WHEN THE NA L30 g 5 CHARGER IS PLUGGED IN OPTION X 2 OPTION E QD1 9 LAT N 3 F6 275 FUSE P 8 BK i GN A12 B12 11 9 B10 PI a9 OUT N OUT IN BK A8 O
27. 4 4 1 3 Software Configuration 4 9 1 4 Outrigger EC Mhita te a a a t de eee ett 4 14 1 5 Outrigger Controls Software Update 4 17 Platform Components XE dcn 4 34 2 2 Platform Extension uere ntt sah aed 4 35 Scissor Components 3 1 Scissor Assembly GS 1530 and 95 1532 4 36 3 2 Scissor Assembly GS 1930 and 95 1932 4 42 3 3 Scissor Assembly GS 2032 and 95 2046 4 50 3 4 Scissor Assembly GS 2632 and 035 2646 ssseneseeeenneneeerne eneee 4 56 3 5 Scissor Assembly GS 3232 GS 3246 4 64 3 6 Lift 4 72 3 7 Platform Overload 4 77 Ground Controls 4 1 Manual Platform Lowering Cable 4 79 4 2 LevelSensors edi eed e et 4 80 Hydraulic Pump 5 1 Function PUMP 0 4 4 86 Genie Part No 97385 GS 30 GS 32 GS 46 ix February 2012 TABLE OF CONTENTS Section 4 Rev Repair Procedures continued F Manifolds 6 1 Function Manifold Components GS 1530 95 1532 95 1930 95 1932 4 88 6 2 Function Manifold Components GS 2032 GS 2632 95 3232 GS 2046 GS 2646 GS 3246 0 6 3 Out
28. 1 E 8 RDWH t LR 4 21 1 DRIVE ENABLE 15 8 z o 8 0 2 0 Me Mes he Wh hs o o8 2001 2 2 QC ob Sia t Sa Se gt ii Q tet Dx 84 9 E Qziiiii 05580 2 4 B lima 6912 lez 1 o o 5 9 m 2E DESEE i T O PUDE Oz 3 atv DOWN LIM RD BK Em u TE eroe 5 5 qe pit i 5 GNIBK 4 1 1 1 1 I N m 1 p UP IN eusk 82 0 58 2 REGEN COIL N A ON 3232 x 1 pe FORWARD WH i 2 0 2 EE lE Pob oj 8K 1 qoo ow sg 1 050 d d Es fe 1292 24V MAIN gt E BK See APT REVERSE WH BK 2 29 gk 1 rot UP COIL BL BK 25 1 2 VERUM Tn fud qutt We e oo BN e GND qe I 8 A 2 0 EMEN NM ECCE 2
29. 2 7 Scheduled Maintenance Procedures 3 1 Pre delivery Preparation 3 3 3 5 Maintenance Inspection Report Checklist A Procedures A 1 Inspect the Manuals and 3 6 2 Perform Pre operation 3 7 A 3 Perform Function 3 7 4 Perform 30 Day 3 8 5 Grease the Steer 3 8 Genie Part No 97385 GS 30 GS 32 GS 46 Vii February 2012 ______________________________________________________________________________ TABLE OF CONTENTS Section 3 Rev Scheduled Maintenance Procedures continued J Checklist B Procedures B 1 Inspect the 3 9 B 2 Inspect the Electrical 3 12 B 3 Inspect the Electrical Contactor 3 13 B 4 Inspect the Tires Wheels and Castle Nut Torque 3 13 B 5 Test the Emergency 2 0 4000 3 14 B 6 Test the Key 20420 0 0 3 14 B 7 Test the Automotive style Horn if 3 15 B 8 Test the Drive 3 16 B 9 Test the Drive Speed Stowed Position 3
30. ES F6 275A FUSE 2 2 2 BK u zc WH A12 B12 11 B9 B10 pecie OUT 09 EN A8 OUT roce WH BATTERY A1 OUT CHARGER U5 ELECTRONIC CONTROL MODULE OUT OUT B8 B3 7 CM MOTOR CONTROLLER 2 5 ee CONNECTED _ UR MOTOR 1 CRS CONTROLLER P HORNRELAY o CUT OFF POWER 4 H2 OPTION ___ pg 1 i d HM 55 FLASHING OPTION BEACONS OPTION H2 AUTO STYLE G6 HORN nie i OPTION E 4 ES0142D Genie 6 54 GS 30 GS 32 6 Part No 97385 April 2008 Section 6 Schematics Electrical Schematic REVE CE Models GS 1530 1532 1930 1932 from serial number GS3005A 76000 to GS3005A 76388 GS 1530 1532 1930 1932 from serial number GS3005B 76000 to GS3005B 760
31. a Tag UP COIL 7 4 2 5 REVERSE WEUDK 1o one erre Greer tue re een Bui 51 FORWARDER WIT e eU 29 Daz 01 06 lt lec 1 24 26115 5 00255 Fog gm 5 5 6 5 roy WH 42 11151 18 x 1 11 S x 9 RD 95 Y 1158 2295 ce a 5 5 15806559 859 8 ps 1 1 1 waa eee 2 5 I 1 a 1 E aet ERN E 1 1 a ute shed epus o5 2 91 ME 504 E 1 LVL SNSR RED RD 22 ZA E 28560 t S 1801 DE og gt LVL SNSR WHT onoz 152 _ ME MM 1 1291 6 RE z MM TIT DATA LINK LOW 5 DATA LINK HIGH BKd 2 2 BEN 1 1 i GND FROM JOYSTICK az 9 5 1 e ECM POWER wH 8 2 8 1 1 1 ZEN U bod og 1 i TEE 1 i ek 226 gt 8 p ra 111 po E 8 314 a
32. 08 1 Ora Se bt 6 POWER TO PLAT RDB 55 BLWH gt E 5 8 S 5 GROUND TO PLAT 4 BL 8 Td z E E pesi k GN 5 ul e in 5 5 NENNEN 5 ir 98 1 p MC ENABLE 6 82 a 89 ORMH NTT dg pri ddd 5 pee MC ENABLE 1 8 2 1 o E Opa Ei sone B 9 1 E 8 RDWH t LR 4 21 1 DRIVE ENABLE ORIBK 5 2 z o 1851111 1 4 0 2 0 Me Mes he Wh hs o o8 2001 2 2 lla QC t Sa Se gt ii Q tet Dx 84 9 E Qziiiii 05580 2 4 5 6912 lez 1 1 o o 5 9 m 2E DESEE i T O PUDE Oz 3 atv DOWN LIM RD BK Em u TE eroe 5 5 qe pit i 5 GNIBK 4 1 1 1 1 I
33. DATA LINK HIGH sk 52 5 8 T GND FROM JOYSTICK gz s z 1 e ECM POWER wH 2 x 8 el 1 a OIZ 1 1 i 1 cet bog gt 8 1 1 pod bog lt 6 i a m 1 pq 11 gseeedeseesceeseeee 1 5 it 5 58 WH i oe 5 gt 2T 558 2 gt 3 OPI 6 el T le ss 50 1 e 5 ST g o gE OVERLOAD POWER BL BK 2 gt 87 1 gt lt o e DWN LIMIT 2 1 o 58 sd 69555 xc 1 5 0 655 uii 2 4878 gt i 1 29 rS GS 3232 ONLY UP LIMIT SWITCH onek 5 541 em ee jes ee oz UP LIMIT SWITCH GS 3232 ONLY 28 89 i S z Do Tr d DRIVER POWER 2 SHS MEN PEE ME TES de POTHOLE LIMIT SWITCH RD 2 1 ad 0 o 0858 305 5 1 TSE 7 5 28 j GNBK o 5835 9 igs z 2 97 xi 1 TEE 10 5
34. ES0141V Part No 97385 enie GS 30 GS 32 GS 46 6 48 February 2012 Section 6 Schematics REVA Electrical Schematic ANSI CSA and Australia Models GS 2032 2632 3232 from serial number GS3210A 94975 to GS321 1A 97903 GS 2046 2646 3246 from serial number GS4610A 95455 to GS461 1A 97982 P2 EMERGENCY STOP NOTE MACHINE SHOWN IN THE STOWED 4 7 4 POWER TO PLATFORM 3 gt 3 RD POWER GROUND 1 5 1 WH GROUND N 2 2 BL DATA LINK HIGH H 5 5 OR DATA LINK LOW POSITION WITH THE POWER OFF U3 PLATFORM CONTROLS VOLTAGE PRINTED CIRCUIT BOARD REGULATOR NOTE ES0141 Rev V applies to machines with kit number 232534 installed HALL EFFECT JC1 GENERATOR JOYSTICK CONTROLLER SW5 SW6 FUNCTION ENABLE T STEER LEFT RIGHT PLATFORM CONTROLS POUTI O POUT2 O MEMBRANE DECAL A a LIFT LED L16 POUT3 O E DRIVE LED L17 HIGH TORQUE LED 1 POUT4 M G8 DIAGNOSTIC DISPLAY PIN1 HIGH TORQUE BN6 PIN2 PIN3 HORN BN5 PIN4 DRIVE EN
35. MI For Help press 1 Device Family 29x66 m 21 Read Device CY8C29666 768 FLASH bytes NI Version 1 71 Red Background Powered Green Backgrounds Ll Pass Idle Connected Genie GS 30 GS 32 6 Part No 97385 October 2009 Section 4 Repair Procedures REV J 27 Click the Toggle Device Power button to power down the printed circuit board Result All the boxes in the lower right hand corner of the PSoC Programmer window should have a green background and should indicate Not Powered PLATFORM CONTROLS 28 Carefully disconnect the MiniProg cable from the printed circuit board Component damage hazard Electrostatic discharge ESD can damage printed circuit board components Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap Note Repeat this procedure beginning with step 16 if updates are required of the outrigger ECM AND the outrigger control pad C Documents and Settings EllisT My DocumentsProjects 3232 Outriggers PSoC in progress Jeg Programming Utilities View Help a gt File Load Program 2 Checksum MINIProg 70482 47470618 Programming Mode Reset C PowerCycle Programming Requested at 14 38 29 Device Family set to 29x66 at 1 Active HEX file set to C Do
36. P I i J x Note 4 1 Diodes added at AC INPUT 0 serial numbers ste cg 0 653011 102860 INST CONNECTED 1 5 GS3211A 96875 amp 2 1 HORN RELAY GS4611A 97260 _ _ i i I Cor OFF POWER N 39 2 86 TIE a 2 1 FLASHING M 85 OPTION BEACONS OPTION 4 H2 5 oe G6 AUTO STYLE HORN HOUR QD1 QD54 METER L 1 OPTION GND BN ES0141V Genie 6 46 GS 30 GS 32 6 Part No 97385 6 47 Section 6 Schematics Electrical Schematic ANSI CSA and Australia Models GS 2032 2632 3232 from serial number GS3210A 94975 to GS321 1A 97903 GS 2046 2646 3246 from serial number GS4610A 95455 to GS461 1A 97982 February 2012 REVA GND enie GS 30 GS 32 6 ES0141V T TT T UP COIL
37. Section 6 Schematics April 2008 Electrical Schematic CE Models REVE GS 1530 1532 1930 1 932 from serial number GS3005A 76000 to GS3005A 76388 GS 1530 1532 1930 1 932 from serial number GS3005B 76000 to GS3005B 76030 2 003 EMERGENCY 2 ES 2 BL DATALINK HIGH 5 5 OR DATA LINK LOW U3 du T HALL EFFECT GENERATOR JOYSTICK CONTROLLER GN 5 i SW5 SW6 FUNCTION ENABLE 22 ELS PIN9 1 2 BK 4 PIN8 PLATFORM CONTROLS MEMBRANE DECAL 2 POUT4 POUTI La LIFT LED 6 POUT2 A DRIVE LED L17 4 HIGH TORQUE LED 121 G8 PIN1 DIAGNOSTIC DISPLAY HIGH TORQUE BN6 PIN2 C PIN3 HORN BN5 PIN4 DRIVE ENABLE BN8 POUT11 LIFT ENABLE BN9 PIN11 PLATFORM CONTROLLER ES0142D Genie GS 30 GS 32 25 46 Part No 97385 April 2008 Section 6 Schematics m This page intentionally left blank Genie Part No 97385 GS 30 GS 32 6 6 57 Section 6 Schematics April 2008 eee Electrical Schematic CE Models REVE GS 1530 1532 1930 1932 from serial number GS3005A 76389 to GS3005A 79394 GS 1530 1532 1930 1932 from serial number GS3005B 76031 to GS3005B 76920
38. TERMINAL 1 4 66 6 PIN NEUE WH BK HOUR METER ECM PIN B12 J1 TS66 PLATFORM UP DOWN ECM PIN A12 J1 DOWN TOGGLE SWITCH TERMINAL 30 22 ECM PIN A1 J1 98 1 5 EMERGENCY STOP WH NC e MN RP DET ANSI AND CSA MODELS H5 LS6 MULTI FUNCTION ALARM S7 DOWN LIMIT SWITCH 1 0 SHOWN IN STOWED POSITION e ECM PIN B9 LEVEL SENSOR 2 048 TERMINAL 87 13 14 3 WH Bk CR48 TERMINAL 87 Z N RD BK BK 4e 4 ECM PIN C12 RD WH L 5 Y oN ECM PIN C11 e BN GROUND le RD ECM PIN A5 9 NOTUSED L CE MODELS ANSI CSA MODELS WITH PLATFORM OVERLOAD H5 LS6 MULTI FUNCTION ALARM LA S7 DOWN LIMIT SWITCH 1 Br SHOWN IN STOWED POSITION e ECM PIN B9 LEVEL SENSOR 2 _ TERMINAL 87 13 14 3 re CR48 TERMINAL 87 RD BK 2 2 2 NCHO BK 4e RDBK _ C12 5 ECM PIN C11 e _ GROUND le RD ECM PIN A5 L NOT USED n Em CR27D TERMINALS 85 87 AND 87A BK ECM PIN B6 Genie GS 30 GS 32 6 Part No 97385 2007 REV Platform Control Box and Outrigger Control Pad 69 CONTROLS 7 GEN 5 1 CONT
39. PLATFORM CONTROLS MEMBRANE DECAL 2 POUT4 POUTI La LIFT LED 6 POUT2 A DRIVE LED L17 4 HIGH TORQUE LED 121 G8 DIAGNOSTIC DISPLAY PIN1 PIN2 C HIGH TORQUE BN6 PIN3 HORN BN5 PIN4 DRIVE ENABLE BN8 POUT11 LIFT ENABLE BN9 PIN11 PLATFORM CONTROLLER ES0142J Genie GS 30 GS 32 6 Part No 97385 April 2008 Section 6 Schematics m This page intentionally left blank Genie Part No 97385 GS 30 GS 32 6 6 65 Section 6 Schematics April 2008 Electrical Schematic CE Models REV GS 1530 1532 1930 1932 from serial number GS3006A 83068 to GS3007A 87490 GS 1530 1532 1930 1932 from serial number GS3006B 79660 to GS3007B 82543 P1 egi RS EMERGENCY Ex 7 7 H 2 8 1 N oR PCS N 2 KS1 key PLATFORM SWITCH CONTROL NOTE H5 N ALARM MACHINE SHOWN IN THE 243 STOWED POSITION WITH Sg E 4 THE POWER OFF NA m 15
40. 5 1 85 85 85 LEVEL RA 155 SENSOR CIRCUIT Lora dea 52 1 LIMIT TETES 1 1 4700 uF SWITCH Q 1 nooo tz i i 5 5 486 5 5 5 S7 bd i 5 33 55 22 LEVEL 65 3232 B S 1 gt Wi SENSOR Dat 5 Wes a ONLY 5 9 85 2 i2 Pa di 1 2 B3 t CR27D 222 36 E 26 2 OVERLOAD EE 8 2 _ DOWN DELAY 5 1 2529 i 1 22 w o 5 o 5 z 5 o D 7 2 9 5 20 ee 1 4 11 9 10 66 C12 C2 2 B1 5 i IN IN OUT OUT IN OUT IN IN IN OUT md i NOT CONNECTED 08 222 i 05 ELECTRONIC CONTROL MODULE NorcowECTED ON GS 3232 1 1 C8 C7 B7 AT C a eee l M 1 he T TT 1 2 5 5 o o 1 5 ES A p aM J 65 3232 ONLY 4 4222 27 4 4 4 PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM RIGHT LEFT REVERSE FORWARD DOWN
41. 9 Genie Part No 97385 GS 30 GS 32 GS 46 4 91 Section 4 Repair Procedures February 2009 MANIFOLDS REV F 6 3 Outrigger Function Manifold Components GS 3232 The outrigger function manifold is mounted behind an inspection door on the battery side of the machine Index Schematic No Description Item Function Torque sachet ree 4 5 ft lbs 5 7 Nm 1 Solenoid valve 3 position 4 way BA Outrigger extend retract 25 ft lbs 34 Nm 2 Relief valve 3500 psi 241 bar maximum Outrigger circuit 20 ft lbs 27 Nm INSIDE 5 COIL E OUTSIDE Y39 COIL 2 BB Note alpha numeric callouts refer to corresponding notes on the electrical schematic BA 2 How to Install a Valve Cartridge 1 Dip the cartridge in clean oil to lube the O rings 2 Screw the cartridge in by hand until the top O ring is met then torque to specification 3 If required install the valve coil s onto the 1 Note alpha callouts refer valve stem Install the coil nut onto the valve 4 stem and torque to specification the hydraulic schematic Genie 4 92 GS 30 GS 32 6 Part No 97385 February 2009 REV F 6 4 Outrigger Cylinder Manifold Components GS 3232 Section 4 Repair Procedures
42. ES0142U Genie 6 82 GS 30 GS 32 6 97385 February 2012 Section 6 Schematics REVA Electrical Schematic CE Models GS 1530 32 8 1930 32 from serial number GS3012C 5060 to GS3012C 531 1 4 3 1 2 i IT am le 1113042 CBAR 1 P 1 4 4 4 4 4 MC THROTTLE 1 30 30 1 CR48 MC ENABLE IN POWER RELAY TO US 87A 85 87 5 sop 000000 Leo pe per gq KS1 i4 4 4 oa a esce OR BK DRIVE ENABLE 65 3232 ONLY CR28 R24 lt GROUND CUT OUT 25 OHM MOTOR CONT OE el PLATFORM OVERLOAD LS6 1 PS2 DOWN i BN GROUND Ld gaad M j SWITCH aj 4 pad N
43. MANIFOLDS The front outrigger cylinders are located behind the inspection doors at the battery side and at the ground control side of the machine The rear outrigger cylinders are located inside the outrigger enclosures at the rear of the machine Index Schematic No Description Item Function Torque Coil nut item CB CC CD 00000 4 5 ft lbs 5 7 Nm 1 Solenoid valve 2 position 2 way CA CB CC CD Outrigger extend retract 25 ft lbs 34 Nm 2 Orifice plug 0 037 inch 0 94 MM Outrigger retract Check valve pilot operated GE flow control 20 ft lbs 27 1 Nm 4 Pressure Transducer Outrigger autolevel 16 ft lbs 21 7 Nm F F 6 5 CG ES 4 SA 7 CE 2 2 gt 2 D 0 FRONT gt REAR OUTRIGGERS OUTRIGGERS CA and CB O How to Install a Valve Cartridge 1 Dip the cartridge in clean oil to lube the O rings 2 Screw the cartridge in by hand until the top O ring is met then torque to specification 3 If required install the valve coil s onto the valve stem Install the coil nut onto the valve stem and torque to specification Genie Part No 97385 NU Note alpha numeric callouts refer to correspond
44. Tes 3 9 5 2 p i i 25 5 59 5 3 BK 4 CR27D B252 5 OVERLOAD 3 DOWN DELAY m X A 9 2 8 E ME 5 3 98 IL LEG ee ee ee Sk cle 02 AQ 10 B6 C12 A4 A2 Bi Cii AS IN OUT OUT IN OUT IN IN IN IN OUT Us ELECTRONIC CONTROL MODULE OUT OUT OUT OUT OUT C8 C7 B7 A7 C6 vc ce es um eo c m mE mee 8 A Y1 Y3 Y4 Y5 Y6 Y9 Y7 Y8 PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM RIGHT LEFT REVERSE FORWARD DOWN DOWN UP GS 3246 4 4 4 4 4 Le Le GND DE ES0142J Genie Part No 97385 GS 30 GS 32 GS 46 6 63 Section 6 Schematics April 2008 Electrical Schematic CE Models REV D GS 1530 1532 1930 1932 from serial number GS3005A 79395 to GS3006A 83067 GS 1530 1532 1930 1932 from serial number GS3005B 76921 to GS3006B 79659 P2 QD3 EMERGENCY 2 ES 2 BL DATALINK HIGH 5 5 OR DATA LINK LOW 1 U3 D7 T HALL EFFECT GENERATOR JOYSTICK CONTROLLER GN Z i SW5 E FUNCTION ENABLE 22 2 PINS 1 BK 4 PIN8
45. OUT CHARGER U5 ELECTRONIC CONTROL MODULE T OUT OUT B8 B3 H Eoo plo po ee I IIl AC INPUT 9 2 MOTOR 9 CONTROLLER E CONNECTED 3 CR5 i eni HORN RELAY U13 POWER H2 OPTION 1 DC AC INVERTER 5 Yer 55 OPTION 5 H2 ETE OPTION G6 AUTO STYLE HOUR HORN METER 1 OPTION 1 ES0141K Genie GS 30 GS 32 GS 46 Part No 97385 April 2008 Section 6 Schematics Electrical Schematic REV ANSI CSA and Australia Models GS 2032 2632 from serial number GS3206 79992 to GS3207 83650 GS 2046 2646 3246 from serial number GS4606 78916 to GS4607 82535 NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF QD4 RD RD 4 4 4 WH WH 3 30 86 CR48 BL 1 4 1 MESI ma uh gr 95 5 OR ese a N O HCC 4 156 DOWN LIMIT SWITCH z E BOARD 5 9 4 4 57 SE z 5 ao lt lt LEVEL 2 5 5822545 SENSOR 5 EG 5 d
46. lt 9 8 3 zumo um d I2 Lue m C2 11 C12 A10 4 A2 B1 A5 IN IN IN IN IN IN IN IN OUT U5 ELECTRONIC CONTROL MODULE OUT OUT OUT OUT OUT OUT OUT C8 B7 AT 6 B6 A6 OMS eco ee UR ONUS TU 2 8 P E 2 E E Ej 9 E Y1 Y4 Y5 Y6 Y9 Y7 Y8 PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM RIGHT LEFT REVERSE FORWARD DOWN UP 4 ES0141K Genie Part No 97385 GS 30 GS 32 6 6 35 Section 6 Schematics April 2008 Electrical Schematic ANSI CSA and Australia Models GS 2032 2632 from serial number GS3206 79992 to GS3207 83650 GS 2046 2646 3246 from serial number GS4606 78916 to GS4607 82535 REV P2 EMERGENCY 4 4 BK POWER PLATFORM 21 3 3 RD POWER GROUND 1 1 4 GROUND 2 2 BL DATA LINK HIGH H 5 5 OR DATA LINK LOW U3 PLATFORM CONTROLS PRINTED CIRCUIT BOARD LJ D7 5V DC VOLTAGE REGULATOR T HALL EFFECT N GENERATOR wv GN JOYSTICK CONTROLLER WH PIN9 BK 6 BL
47. 1 dog 1 1 bg bod RES 3d 2 28 HWH o gt 25 5 1 1 tc 1 5 o g d EE 52 WHEk e gt 2 gt T 1 m 5 o ful OVERLOAD POWER 8 02 8 tb o gt O DWN LIMIT ul GE gt 5 if 5 3232 8 Zy 1961 1 5 1 4 UP LIMIT SWITCH 65 3232 ONLY EE 9 98K 55 DRIVER POWER 2 5 ES0141P enie 6 43 09 30 GS 32 GS 46 Part 97385 REV February 2012 GS 2032 2632 3232 from serial number GS3207A 84867 to GS3210A 94974 GS 2046 2646 3246 from serial number GS4607A 84840 to GS4610A 95454 Electrical Schematic ANSI CSA and Australia Models Section 6 Schematics
48. AME PEt dy Ql it 5 cope Westone lop ud DT 5 RD BK Dog i pog p l 1 2 69011 125 E 6 60 8 5 EE Fd 5 oo eee ae i rr i 1 SEBS S age p pC Sas 122 3 i Qiii E g pm PRESS B i NT 1 1 1 65 T 3 fof bee 8086 coo sees coop cons cie Tos porcus ie pop aeg pou p a NEN 1 4 Ro dde ccce toc i 0 1 0 EE road S oe LIRE uae ESTAS TEE NE b Y d od Log oq 1 M pog 1 er 1 i bala ii x E iig NES bg iii iii Lii 2 ul NE 58 igo 25 5 Eo ES r2iiu 5 06 n a Sj 9 558956 5 5 tort d 1 1 1 1 1 Lito ijt ES0142U Part No 97385 GS 30 GS 32 GS 46 6 112 February 2012 Section 6 Schematics Electrical Schematic REVA CE Models GS 2032 2632 3232 from serial number GS3211A 97904 to GS3212A 109999 and GS3212C 1387 to GS3212C 9999 GS 2046 2646 3246 from serial number GS4611A 97983 to GS4612A 109999 and
49. BK gt po d r E t 2 24V MAIN 1 REVERSE WHEK 2 zu oak ME 1 1 1 E supe mE gt oh 8 2 g BN GND deeem ecce POOR X pod 5 5 be Pry i D Doa prod dd z 222 fe ME pog 1 Ie AD Ss t eta Tog 1 198 8 5 6 5 1 i dg 1j E I EN T COMPRESE n i A se 55555 1 5 85 8 8 8 1 di 00307175 X gt gt pg 9 0 DS E eh o UU soe irTTH 1 i 1 4 1 1 1 1 1 5 7 22 BLBK E pees 118 ME yd py vos rog q ok box 1 N TIT ME Kon ctum Say dua ect oa eee zaza ere 1 1 pi 1 1 iii 1 Vier ay pog 4 Tog NE Ws es o Mp ot t Tul qp 21 arg Lr x ul 1 1 1 1 1 1 1 1 ii i 181 ullli acl oel te zi aos Gay i 02 tL 28 1
50. 0 9 mm PRESSURE B2 B1 R3 R1 R2 PRESSURE SENSE PORT SENSE PORT 6 5 OUTRIGGER 69 MANIFOLD WT TET Y39 Y40 peus From Pump 0 25 3700 psi 0 95 L mim 6 255 bar IN To Function Manifold PORT am 3500 psi maximum L 241 bar maximum i P r LR OUTRIGGER RR OUTRIGGER CYLINDER con CYLINDER TP Ot S O 0087 in 0 037 in gt 0 94 0 94 mm vas Y34 Y 0 035 in 69 0 035 in 0 9 mm RETRACT RETRACT 0 9 mm PRESSURE PRESSURE SENSE PORT SENSE PORT ABBREVIATION LEGEND cont Description Right front outrigger extend retract Left front outrigger extend retract CC Right rear outrigger extend retract CD Left rear outrigger extend retract CE Orifice plug outrigger retract Check valve pilot operated Pressure transducer Hand pump manual brake release Needle valve manual brake release Platform lowering valve Orifice platform down circuit Accumulator Relief valve platform down Pressure switch platform overload HS0040B Genie Part No 97385 GS 30 GS 32 6 6 1 Section 6 Sc
51. 1 T UP COIL a LZ ida REVERSE c a aE FORWARD WH ace a as eon 9 5 Las UP IN nnn IES 8321 Z3 We 000 E gt i 1 1 8 266 9 2 WH 1 n verano lif it zi ig 7 TH i 58 1 8 x x e 1 1 m RD 5985 uf 2 ce 5 AWS 1 2 a 01158855 8 8 250 4 8 r1 gt 6 gt ehe rri 5 5 o i foU s jm LVL SNSR RED 23 129 E 8 5 gt 5 t 1881 gt lt NIE E EN LVL SNSR WHT 52 ESI E MT 0 ED E s 28 1 1 cae DATA LINK LOW 52 P Es 4 _ i DATA LINK HIGH sk GND FROM JOYSTICK gz 5 1 e ECM POWER Z 3I Dx 1 1 9 1 1 puc a e pe t 11 I Zo 1 1 RES QUE 6 tt Eon I bog 4 1 n xe m 11 i 2 i Q 58 Hwi o 525 gt 5 L
52. 156 DOWN LIMIT SWITCH 8 prx sl NO LEVEL SENSOR CIRCUIT 1 BOARD 9 5 5 2 52555 lt 57 2 m gt gt LEVEL v p m m mmu 9 5 o 28 2 SENSOR 5 o gt pu T God Uu paca ec 1 9 5 9 5 55 2 8 3 295228 I 5 d 5 45 9 8 5 5 8 2 283 2 5 o 59 2 liL d 02 C12 A10 A4 2 B1 C11 AS IN IN IN IN OUT ELECTRONIC CONTROL MODULE OUT OUT OUT OUT OUT OUT OUT C8 C7 B7 A7 C6 B6 AG ee cc necdum 2 m 5 E 5 2 I 5 5 5 5 A PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM RIGHT LEFT REVERSE FORWARD DOWN DOWN UP GS 3246 4 4 L_ L_ L_ 4 GND 4 4 ES0141H Genie Part No 97385 GS 30 GS 32 6 6 11 Section 6 Schematics April 2008 Electrical Schematic ANSI CSA and Australia Models REVE GS 1530 1532 1930 1932 from serial number GS3005A 76000 to GS3006A 83067 GS 1530 1532 1930 1932 from serial number GS3005B 76000 to GS3006B 79659 D P2 QD3 EMERGENCY
53. 4 87 Section 4 Repair Procedures February 2009 Manifolds 6 1 Function Manifold Components GS 1530 GS 1532 GS 1930 and GS 1932 The function manifold is mounted under the machine between the module trays Index Schematic No Description Item Function Coilinut items E ard 1 Diagnostic nipple Testing 2 Check 00 nih teni tats Steer circuit Relief valve 1800 to 3700 psi 124 to 255 bar ta aded Lift relief 4 Check valve 10 psi 0 7 bar Drive 5 Solenoid valve 3 position 4 way Drive forward reverse 6 Solenoid valve 3 position 4 way Steer left right 7 Flow regulator and relief valve 0 75 gpm 2 8 L min 1500 psi 103 istituti Steer circuit 8 Solenoid valve 2 position 4 way Platform 9 Relief valve 3700 psi 255 bar maximum een System relief How to Install a Valve Cartridge 1 Dip the cartridge in clean oil to lube the O rings 2 Screw the cartridge in by hand until the top O
54. 5 5 A PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM RIGHT LEFT REVERSE FORWARD DOWN DOWN UP GS 3246 4 4 L_ L_ 4 GND 4 4 ESO141K Genie Part No 97385 GS 30 GS 32 6 6 15 Section 6 Schematics April 2008 Electrical Schematic ANSI CSA and Australia Models REV GS 1530 1532 1930 1932 from serial number GS3006A 83068 to GS3007A 87490 GS 1530 1532 1930 1932 from serial number GS3006B 79660 to GS3007B 82543 LES P2 QD3 EMERGENCY 2 2 BL DATALINK HIGH 5 5 OR DATA LINK LOW U3 du HALL EFFECT GENERATOR JOYSTICK x CONTROLLER GN i SW5 SW6 FUNCTION ENABLE 22 ELS PINS 1 BK 4 PIN8 POUT1 POUT2 PIN1 PIN3 PIN4 POUT11 PIN11 POUT4 C PIN2 C BK PLATFORM CONTROLS MEMBRANE DECAL 2 La LIFT LED 116 DRIVE LED 117 4 HIGH TORQUE LED 121 G8 DIAGNOSTIC DISPLAY HIGH TORQUE BN6 HORN BN5 DRIVE ENABLE BN8 LIFT ENABLE BN9 PLATFORM CONTROLLER 50141 Genie GS 30 GS 32 25 46 Part No
55. DRIVE ENABLE BN8 PIN4 LIFT ENABLE BN9 H1 PLATFORM BK ALARM c CONTROLLER POUT11 5 ES0141W Genie Part No 97385 GS 30 GS 32 GS 46 6 53 Section 6 Schematics April 2008 eee Electrical Schematic CE Models REVE GS 1530 1532 1930 1932 from serial number GS3005A 76000 to GS3005A 76388 GS 1530 1532 1930 1932 from serial number GS3005B 76000 to GS3005B 76030 EMERGENCY 2f STOP 2 e 8 2 227 2 4 KS1 key PLATFORM 1 SWITCH CONTROL Bi 4 1 NOTE iis ALARM MACHINE SHOWN IN THE STOWED POSITION WITH Sg THE POWER OFF CONTROL P 1577 POTHOLE TS66 GUARD PLATFORM SWITCH 4 UP DOWN CB2 9 7A CIRCUIT 2 BREAKER 4 LS8 POTHOLE 27 GUARD 47 mH INDUCTOR NOISE SUPPRESSION SWITCH c gt lt 5 3 3 5 5 5 a d m BLACK AND WHITE WIRES CUT POWER f z 92 TO MOTOR CONTROLLER WHEN THE 130 g 5 CHARGER IS PLUGGED IN OPTION X 2 o OPTION QD1 9 8
56. NE 8 E 065 oa 359 MC THROTTLE m uj 8g gt 2 5 gt 5 pe MC ENABLE gt 86 8 lt 1 1 i 1 c dz o i ti 1 1 rii 4 1 dope MC ENABLE 85 gt 1 ATE E 5 Gia KEYSWITCH r OR amp gt 1 g 1 1 I OL M dai 111 MEN DRIVE ENABLE 5 ROMH Pee re r1 re 5 He a 1 1 M eec 8 48 2 B 5 af 2 2 2 45 59 xk NO 5 FB Of GN 77777 T um Q Tij 0550 2 9 T 92 d 119 9e dm uw 5 1 4 r RD BK u o9 Ouma 5 og 1 lt 5 52247 ep cta L 15 5 Oa 88 5 58 58 5555 __ gt P 5 par db Gg gd RD BK Z 28 GNBK Iz TERETE 5 4 dd I UP IN L 2 Lio 7 5 ba i ee ae a 8 8 REGEN COIL N A ON 3232 7 RO pee FORWARD WH 45 Z Nerea Te Ld do geen tas edd
57. POUT1 POUT2 PIN1 PIN3 PIN4 POUT11 PIN11 POUT4 C PIN2 C BK PLATFORM CONTROLS MEMBRANE DECAL 2 La LIFT LED 116 DRIVE LED 117 4 HIGH TORQUE LED 121 G8 DIAGNOSTIC DISPLAY HIGH TORQUE BN6 HORN BN5 DRIVE ENABLE BN8 LIFT ENABLE BN9 PLATFORM CONTROLLER ES0141M Genie GS 30 GS 32 25 46 Part No 97385 April 2008 Section 6 Schematics m This page intentionally left blank Genie Part No 97385 GS 30 GS 32 6 6 21 Section 6 Schematics February 2012 Electrical Schematic ANSI CSA and Australia Models REV D GS 1530 1532 1930 1932 from serial number GS3007A 89538 to GS3010A 99455 GS 1530 1532 1930 1932 from serial number GS3007B 84600 to GS3009B 98941 l 2 8 w iol
58. 1 1 i 1 c dz o i ti 1 1 rii 4 1 dope MC ENABLE 85 gt i 1 ATE E 5 Gia KEYSWITCH r OR amp gt 1 g 1 1 I OL M dai 111 MEN DRIVE ENABLE 5 ROMH Pee re r1 re 5 He a 1 1 M eec 8 48 2 B etr tu 5 af 2 2 2 45 59 xk PE ERES NO 5 FB Of GN 77777 T um Q Tij 0550 2 9 T 92 d 119 9e dm uw 5 1 4 r RD BK u o9 Ouma 5 og 1 lt 5 52247 ep cta L 15 5 Oa 88 5 58 58 5555 __ gt P e par db Gg gd RD BK Z 28 GNBK Iz TERETE 5 4 dd I UP IN L 2 Lio 7 5 ba i ee ae a 8 8 REGEN COIL N A ON 3232 7 RO pee FORWARD WH 45 Z Nerea Te Ld do geen tas edd BK gt po d r E t 2 24V MAIN 1 REVERSE WHEK 2 zu oak ME 1 1 1 E supe mE gt oh
59. 2 Ore 8 o lt woke Or 9 8 5 4 zz NEU POWER 35 7 5 hates 5 1 N 8 000 GROUND TO PLAT 1 24 i 5 5 9 u Ore BOTAIP MC THROTTLE r GN 3 589 5 gt 2 4 lt 5 NI 7n gg MC ENABLE Le exa z 29 Ix od 98 0 o5 z 4 1 ot MC ENABLE 1 8 2 1 58 mick p KEYSWITCH on 18 9 g rd E 2 4 ENABLE ORIBK 2 2 9 TIT 5 pae ee BK 48 Oo 4 we 1 oz 3 14 E gt 1 Tz H qe o P 1 2o gt E 1 x E Ese e 5 89 0 5 5 T 4738 4986 rhe Ho RD BK 5 Ez 5 i 5z c 933 EN 8 p DOMNLIM RD BK E gt 45 Peep 1 6 DU 1 5l 1 d 8 28 gt ERST m 4 5 UP IN BUBK 5 d 8 8 58 REGEN COIL N A 3232 GN ee p qe FOR
60. 700 A12 812 11 9 B10 te IN IN OUT IN E A8 OUT 22 1 WH BATTERY A1 OUT CHARGER U5 ELECTRONIC CONTROL MODULE OUT OUT Gu AC INPUT soli 3 2 IE CNET OTOR y CONTROLLER 4 p Er SENE CONNECTED N _ MOTOR CRS ICONTROLLER HORN RELAY CUT OFF POWER H2 OPTION p U13 OPTION _ _ _ i DC AC INVERTER 87 85 OPTION 5 OPTION H2 AUTO STYLE G6 HORN HOUR OPTION PES ISS METER L 4 E 4 ES0142G Genie 6 86 GS 30 GS 32 6 Part No 97385 April 2008 Section 6 Schematics Electrical Schematic REVE CE Models GS 2032 2632 from serial number GS3205 75407 to GS3205 77290 GS 2046 2646 3246 from serial number GS4605 75438 to GS4605 76734 NOTE MACHINE SHOWN IN THE STOWED POSITIO
61. DEI 8 cg 87 85 87A 85 87 85 LS5 SENSOR UP BOARD C57 1 9 1 55 au 8 5 55 3 8 BK 2 1 CR27D 5298218 5 5 OVERLOAD Lo DOWN DELAY 9 A o o d 2 9 5 5 5 5 20025 x z 5 2 0 LL m e eL 02 A9 10 B6 C12 A4 2 B1 C11 AS IN OUT OUT IN OUT IN IN IN OUT Us ELECTRONIC CONTROL MODULE OUT OUT OUT OUT OUT C8 C7 B7 A7 C6 ce ect mE m ES Y1 Y3 Y4 Y5 Y6 Y9 Y7 Y8 PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM RIGHT LEFT REVERSE FORWARD DOWN DOWN UP GS 3246 D GND ES0142G Genie Part No 97385 GS 30 GS 32 6 Section 6 Schematics April 2008 Electrical Schematic CE Models REVE GS 1530 1532 1930 1932 from serial number GS3005A 76389 to GS3005A 79394 GS 1530 1532 1930 1932 from serial number GS3005B 76031 to GS3005B 76920 S P2 QD3 EMERGENCY 4 4 BK
62. Genie 4 6 GS 30 GS 32 GS 46 REV J O a joystick controller JC1 with thumb steering rocker SW6 horn button BN5 lift function select button BN9 diagnostic display G8 red Emergency Stop button P2 drive function select BN8 speed select button BN6 5 20 6 Press the drive function select button Result The diagnostic display will show the stowed drive speed percentage 7 Use the steering thumb rocker switch on the joystick to increase or decrease the stowed drive speed percentage Refer to Section 2 Specifications for drive speeds 8 Turn the key switch to the off position Note Any change in software settings will not take effect until the key switch is turned to the off position Part No 97385 October 2009 Section 4 Repair Procedures REV J How to Adjust the Raised Drive Speed Tip over hazard Do not adjust the 2 lift and or drive speed higher than specified in this procedure Setting the function speeds greater than specifications could cause the machine to tip over resulting in death or serious injury Tip over hazard This procedure must only be performed by a trained service professional Attempting this procedure without the necessary skills will result in death or serious injury On machines with software revision A4 and higher setting the raised drive speed percen
63. POTHOLE TS66 GUARD PLATFORM SWITCH UP DOWN 4 N CH O B2 58 cr CIRCUIT 2 BREAKER 4 LS8 POTHOLE GUARD SWITCH c C gt 2106 g e 5 5 5 3 ul 4 H BLACK AND WHITE WIRES CUT POWER 5 9 TO MOTOR CONTROLLER WHEN THE NA L30 g 5 CHARGER IS PLUGGED IN OPTION OPTION E QD1 9 LAT N 3 ON es 8 F6 275A FUSE P BK i GN A12 B12 11 B9 B10 PI a9 OUT N OUT IN A8 OUT LM pcdes WH 1 OUT CHARGER U5 ELECTRONIC CONTROL MODULE OUT B5 0 E BATTERY AC INPUT 9 5 uA E MOTOR 80 P CONTROLLER 2 w m CONTROLLER 2 HORNRELAY 2 OPTION OFF POWER pi i D D U13 OPTION _ _ _ i DC AC INVERTER FLASHING 87 85 OPTION BEACONS H2 SS uH OPTION AUTO STYLE 56 HORN itl METER OPTION 1 lt ES0141H Genie 6 30 GS 30 GS 32 6 Part No 97385 April 2008 Section 6 Schematics Electrical Schematic
64. SWITCH CONTROL 4 ALARM 4 4 A amp 1 N 2 3 N NCHO GROUND gif CONTROL LS7 1 POTHOLE Eee E _ 1866 830 UP DOWN Fd 200 ohm 10 NOTE Ro ro 3 Ior MACHINE SHOWN IN THE xz 2 STOWED POSITION WITH EN U27 5 158 THE POWER OFF 47 mH INDUCTOR NOISE SUPPRESSION POTHOLE GUARD ae E SWITCH R o 01 B I I g T4 L30 gt 2 5 1 C WORK LIGHT 2 2 d m BK od 5 5s 5 sec EA 65 3232 1 QD1 3 T 1 1 i 1 2 1 md T o 3 ed m 7 atts IN IN OUT IN F6 aM BK fas OUT NOT CONNECTED FUSE BK 100 JE A Ub XLI ON GS 3232 275A WH Ws TIENE m T 05 Ug ELECTRONIC BATTERY CONTROL CHARGER out MODULE out B5 Ll B8 B3 r RD gev UG 1 9 g BATTERY 3 J D CONTROLLER INPUT b NN 5 VAY 1 5 Ur S HORN RELAY ITS 30 H2OPTION 38 U13 a DC AC INVERTER FLASHING 87 85 OPTION Mt J BEACONS ee H2 G6 a AUTO STYLE HORN METER L G OPTION 5
65. 5 IN OUT OUT IN IN IN OUT Us ELECTRONIC CONTROL MODULE OUT OUT OUT OUT OUT C8 C7 B7 A7 C6 vc ce es um eo c m mE mee 8 Y1 Y3 Y4 Y5 Y6 Y9 Y7 Y8 PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM RIGHT LEFT REVERSE FORWARD DOWN DOWN 05 3246 4 4 E LH 4 Le Le L_ GND di 50142 Genie Part No 97385 GS 30 GS 32 6 6 67 Section 6 Schematics April 2008 Electrical Schematic CE Models REV GS 1530 1532 1930 1932 from serial number GS3006A 83068 to GS3007A 87490 GS 1530 1532 1930 1932 from serial number GS3006B 79660 to GS3007B 82543 P2 QD3 EMERGENCY 2 ES 2 BL DATALINK HIGH 5 5 OR DATA LINK LOW U3 du T HALL EFFECT GENERATOR JOYSTICK CONTROLLER GN Z i SW5 SW6 FUNCTION ENABLE 22 ELS PIN9 On 1 m 2 J 9 PIN8 PLATFORM CONTROLS MEMBRANE DECAL 2 POUT4 POUTI La LIFT LED 6 POUT2 A DRIVE LED L17 4 HIGH TORQUE LED 121 G8 PIN1 DIAGNOSTIC DISPLAY HIGH TORQUE BN6
66. 7 a WD ijt 5 _ dd o Rug GNE ae 1 I p obo eem QUEE MIN MM MEO M s i2 11 fgg ig fans bpd E rey nee Pd EE 41202311 AR ea PEEP na Eu 12 uU lg rot t a 1 e 08 2 8 5 221 5 2 56 1 551185 8 255956 2859285 L TETEE d 1 1 1 1 1 ES0142T enie GS 30 GS 32 GS 46 Part No 97385 6 80 February 2012 Section 6 Schematics Electrical Schematic REV CE Models GS 1530 32 amp 1930 32 from serial number GS3010A 99456 to GS301 1A 109999 GS 1530 32 amp 1930 32 from serial number GS3010C 2190 to GS301 1C 5059 P2 4 4 L BK POWER TO PLATFORM 3 RD POWER TO GROUND _ MACHINE SHOWN IN THE STOWED 1 1 wH GROUND POSITION WITH THE POWER OFF NI 2 2 BL DATALINK HIGH H 5 5 OR DATA LINK LOW US PLATFORM CONTROLS VOLTAGE PRINTED CIRCUIT BOARD REGULATOR HALL EFFECT JC1 JOYSTICK CONTROLLER SW5 SW6 FUNCTION ENABLE
67. Electrical Schematic ANSI CSA and Australia Models GS 2032 2632 from serial number GS3205 75407 to GS3206 79991 GS 2046 2646 3246 from serial number GS4605 75438 to GS4606 78915 REV E P2 EMERGENCY 4 4 BK POWER PLATFORM 21 3 3 RD POWER GROUND 1 1 4 GROUND 2 2 BL DATA LINK HIGH H 5 5 OR DATA LINK LOW U3 PLATFORM CONTROLS PRINTED CIRCUIT BOARD LJ D7 5V DC VOLTAGE REGULATOR T HALL EFFECT N GENERATOR wv GN JOYSTICK CONTROLLER WH PIN9 BK 6 BL SW5 SW6 FUNCTION ENABLE T STEER 1 LEFT RIGHT OR J PIN8 1 POUT1 POUT2 PIN1 PIN3 PIN4 POUT11 PIN11 POUT4 C PIN2 C BK 2 PLATFORM CONTROLS MEMBRANE DECAL LIFT LED L16 ty 4 Ca Im G8 DIAGNOSTIC DISPLAY DRIVE LED 117 HIGH TORQUE LED 121 HIGH TORQUE BN6 HORN BN5 DRIVE ENABLE BN8 LIFT ENABLE BN9 PLATFORM CONTROLLER ES0141H Genie GS 30 GS 32 GS 46 Part No 97385 April 2008 Section 6 Schematics
68. GROUND B NE Y N 4 EN S ode AP 79 9 24 22 2 5 CR27A 27 CR27C a 2218 lt OVERLOAD OVERLOAD OVERLOAD Hi sar LOAD SENSE DOWN COIL NO 1 304 486 30 86 30 86 N C 4 prer Lo 2 zi a y a 4 1253 1 cen eie I 1 gt 1 LEVEL 51 E 5 87 85 87 85 87 85 155 SENSOR ia 5 CIRCUIT 2 4 vtr S BOARD ar 1 N 1 S site o g mo ie 1 11 5 92 5 5 57 t di 5 8 48 55 lt lt y yl LEVEL p pi 1 2 Zi GS 3232 i 2622 9 8 SENSOR 7 eza Tes E d ME d a 2585 3 8 BK 1 m 282 7 CR27D 422 49 0 2 6 5 OVERLOAD E L 149 2 DOWN DELAY 9 pog 1 io 0000 R 57 i 2 2 a 2 e 1 Er 9 5 9 eg i A4 A9 10 B6 C12 C2 2 B1 C1 C11 5 N ON OUT OUT IN OUT IN IN IN IN IN OUT M I9 NOT CONNECTED ONGS 3282 Ub L LLL ELECTRONIC CONTROL MODULE NOT
69. PIN2 C PIN3 HORN BN5 PIN4 DRIVE ENABLE BN8 POUT11 LIFT ENABLE BN9 PIN11 PLATFORM CONTROLLER 50142 Genie GS 30 GS 32 25 46 Part No 97385 April 2008 Section 6 Schematics m This page intentionally left blank Genie Part No 97385 GS 30 GS 32 6 6 69 Section 6 Schematics E J Electrical Schematic CE Models April 2008 gt BLACK AND WHITE WIRES CUT POWER TO MOTOR CONTROLLER WHEN THE CHARGER IS PLUGGED IN OPTION REV B GS 1530 1532 1930 1932 from serial number GS3007A 87491 to GS3007A 89537 GS 1530 1532 1930 1932 from serial number GS3007B 82544 to GS3007B 84599 P1 2 m A EMERGENCY CN aN SIE 2 ae 1 Non NEN 2 key PLATFORM SWITCH CONTROL 4 1 NOTE 5 MACHINE SHOWN IN THE p 3 STOWED POSITION WITH e NCHO THE POWER OFF ONTROL M d 7707 157 1566 POTHOLE PLATFORM suites 4 UP DOWN CB2 gt 2 N CH O 7A 2 B
70. Repeat this procedure beginning with step 4 Raise the platform and rotate the safety arm to the stowed position Pull the manual lowering handle at the ground controls 2 to 3 times to ensure it is functioning correctly Genie GS 30 GS 32 GS 46 Section 4 Repair Procedures March 2007 GROUND CONTROLS 4 2 Level Sensors The Electronic Control Module ECM is programmed to deactivate the lift and drive functions and activate an alarm when a signal is received from the level sensor The tilt alarm sounds when the incline of the chassis exceeds 1 5 to the side and 3 to the front or rear How to Install and Calibrate the 1 5 Level Sensor 71 Tip over hazard Failure to install calibrate the level sensor as instructed will compromise machine stability and cause the machine to tip over resulting in death or serious injury Do not install or calibrate the level sensor other than specified in this procedure 1 Move the machine to an area that has a firm level surface and is free of obstructions 2 Remove the platform controls from the platform 3 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 4 Raise the platform 7 to 8 feet 2 1 to 2 4 m Genie GS 30 GS 32 GS 46 REV D 5 Lift the safety arm move it to the center of the scissor arm and rotate down to a ver
71. CONT LOAD SENSE DOWN COIL Km NO 1 30 86 30 2 86 30 3 86 N C z 3 BEEN OT Dur LEVEL RA c 87 85 87A 85 87 85 155 SENSOR 4 ies CIRCUIT BOARD 22 1 N 1 S site o 1 go Ibe She al aa i Ge 3 533 2 9 i i uwanee 22 LEVEL 5 232 gis 9822 8 9 SENSOR ONL eza Tes E d ME d a 2585 3 8 BK 1 m 282 7 CR27D 422 49 0 2 6 5 OVERLOAD E L 149 2 DOWN DELAY 9 pog 3 1 11 3 F A 57 EE E i 2 2 a 2 e 1 Er 9 5 9 eg i A4 A9 10 B6 C12 C2 2 B1 C1 C11 5 N ON OUT OUT IN IN IN OUT ETETEN NOT CONNECTED 668 3232 U5 5 ELECTRONIC CONTROL MODULE NOT CONNECTED 2 z SS 1 OUT OUT OUT OUT OUT C8 B7 7 6 3 ee a I i 9 2 m 5 2 e T 1 o 1 X A m Pu 95 3232 ONLY
72. Check the battery acid level If needed replenish with distilled water to 1 8 inch 3 mm below the bottom of the battery fill tube Do not overfill 12 Install the vent caps and neutralize any electrolyte that may have spilled 3 10 GS 30 GS 32 6 Genie REV K batteries 5 275A fuse F6 quick disconnect QD1 Part No 97385 February 2012 Section 3 Scheduled Maintenance Procedures t REVK All models 13 Check each battery pack and verify that the batteries are wired correctly 14 Inspect the battery charger plug and pigtail for damage or excessive insulation wear Replace as required 15 Connect the battery charger to a properly grounded 115V 60Hz or 230V 60Hz single phase AC power supply Result The charger should operate and begin charging the batteries Wi If simultaneously the charger alarm sounds and the LEDs blink one time correct the charger connections at the fuse and battery The charger will then operate correctly and begin charging the batteries If simultaneously the charger alarm sounds and the LEDs blink two times the input voltage is too low or too high Correct the voltage issue The charger will then operate correctly and begin charging the batteries If simultaneously the charger alarm sounds and the LEDs blink three times the charger is overheated Allow the charger to cool The charger will then operate correctly an
73. SWITCH N O H C lt 6 2 CR27A CR27B CR27C o OVERLOAD OVERLOAD OVERLOAD eases 1 MOTOR CONT LOAD SENSE DOWN COIL t NO 30 486 30 86 304 3 486 N C 4 saa 1 Sak uM LEVEL 87 85 87A 85 87 85 4 1 SENSOR 1 LS5 N O CIRCUIT BOARD E 1 C5 SWITCH BI je 52555 57 2i aS lt lt LEVEL seed 5 5 2 2 3 2 2 5 SENSOR ge fe tas 3 9 2 Qs Up SSeS E 25 5 59 5 3 BK 4 CR27D B252 5 5 OVERLOAD Lo DOWN DELAY Q A 9 2 8 E ME 5 3 98 44 02 AQ 10 B6 C12 A4 2 B1 C11 AS IN OUT OUT IN OUT IN IN IN OUT Us ELECTRONIC CONTROL MODULE OUT OUT OUT OUT OUT C8 C7 B7 A7 C6 8 gt Y1 Y3 Y4 Y5 Y6 Y9 Y7 Y8 PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM RIGHT LEFT REVERSE FORWARD DOWN DOWN UP GS 3246 4 4 4 LH 4 Le Le GND di ES0142J Genie Part No 97385 GS 30 GS 32 GS 46 6 91
74. pz ii Qt 3 r GN g 2 259 1 Lo 5 2 OR WH _ u 98 f Lg Ja z sil OR WH 252555 E 9 7 _ 8 5 T pog j kb E Ei KeyswitcH 88 9 953 EMEN per potty E 58 2 EL Nes r DRIVE ENABLE OR BK 45 2 9 181111111 8 4 Eg 1 o LLL ELE Emo ERE eg g lt S 2 5 6 k Ort tt tit 4 8 N te D Uz Q 08 1 og E i5 Lo 1 4 555 4 now 22 22 T 053 0053 xz 2 9280 INT A E om 5 gt ___ 5 TITITd cr gz 6 0 LIM RD BK m 5 I E g GNIBK 14 x d oj a o9 1 9 o UP IN BUBK 8 5 umen L E EN a sel REGEN COIL N A ON 3232 x pe Sa oak bop td 208 BK a SAY MAIN nm 7 passes a 1 REVER
75. 4 Connect the negative lead to the other terminal on the coil Note If testing a single terminal coil connect the negative lead to the internal metallic ring at either end of the coil 4 100 Genie GS 30 GS 32 GS 46 MEM HRS e 100 RESISTOR multimeter 9V DC battery 10Q resistor coil ao oo Note Dotted lines in illustration indicate a reversed connection as specified in step 6 5 Momentarily connect the positive lead from the multimeter to the positive terminal on the 9V battery Note and record the current reading 6 At the battery coil terminals reverse the connections Note and record the current reading Result Both current readings are greater than 0 mA and are different by a minimum of 20 The coil is good Result If one or both of the current readings are 0 mA or if the two current readings do not differ by a minimum of 2096 the coil and or its internal diode are faulty and the coil should be replaced Part No 97385 April 2008 Section 4 Repair Procedures REV B 7 1 Hydraulic Tank The primary functions of the hydraulic tank are to cool and deaerate the hydraulic fluid during operation It utilizes internal suction strainers for the pump supply lines and has an external return line filter How to Remove the Hydraulic Tank Component damage hazard The work area and surfaces where this procedure will be perfo
76. EE i DC AC INVERTER FLASHING 87 85 OPTION 5 BEACONS H OPTION H2 G6 n HOUR OPTION L 3 E 4 ES0142G Genie 6 58 GS 30 GS 32 6 Part No 97385 April 2008 Section 6 Schematics Electrical Schematic REVE CE Models GS 1530 1532 1930 1932 from serial number GS3005A 76389 to GS3005A 79394 GS 1530 1532 1930 1932 from serial number GS3005B 76031 to GS3005B 76920 NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF RD RD 4 4 WH WH 3 34 3 486 CR48 BL MESES gr 95 5 OR 822 2294 824 25 4 D PS2 PLATFORM OVERLOAD 156 PRESSURE SWITCH pone T SWITCH N O H C 5 CR27A CR27B CR27C OVERLOAD OVERLOAD OVERLOAD eae oa aia MOTOR CONT LOAD SENSE DOWN COIL N O 30 9 6 30 86 30 86 N C 4
77. HALL EFFECT GeNeRaTOR JOYSTICK Ay CONTROLLER PI FUNCTION ENABLE STEER LEFT RIGHT SW5 SW6 OR 1331 BK BK PLATFORM CONTROLS a MEMBRANE DECAL POUTI LIFT LED 6 POUT2 DRIVE LED L17 POUT3 O 4 HIGH TORQUE LED 121 M G8 DIAGNOSTIC DISPLAY POUT4 PIN1 HIGH TORQUE BN6 PIN2 HORN BN5 PIN3 DRIVE ENABLE BN8 PIN4 LIFT ENABLE BN9 H1 PLATFORM BK ALARM CONTROLLER POUT11 O ES0141P Genie Part No 97385 GS 30 GS 32 GS 46 6 45 Section 6 Schematics February 2012 1 Electrical Schematic ANSI CSA and Australia Models REVA GS 2032 2632 3232 from serial number GS3210A 94975 to 953211 97903 GS 2046 2646 3246 from serial number GS4610A 95455 to GS4611A 97982 MM vn g ER VEL 267 P1 ry EMERGENCY a STOP
78. L d 4 OR KS1 4 E 4 F 4 OR BK DRIVE ENABLE 4 gt 65 3232 ONLY CR28 R24 GROUND CUT OUT 25 OHM L MOTOR CONT in cid 2 MC ENABLE OUT 4 NC 4 ge DOWN LIM LS6 rege PLATFORM OVERLOAD 6 PS2 PRESSURE SWITCH N C H O DOWN po 2 250 me BN GROUND B NE 1 5 v 24 SWITCH BE E N P bg S ode AP 79 2 5 CR27A 27 CR27C a 2218 lt OVERLOAD OVERLOAD OVERLOAD Hi sar LOAD SENSE DOWN COIL NO 1 30 186 30 86 30 86 N C 4 prer Lo 2 eU a a y zd 4 1253 1 cen eie I LEVEL ELE S A 87 85 87 85 87 85 155 SENSOR ia 5 CIRCUIT LIMIT cs TOR N 1 T 1 5 2 95 55 57 t 1 2 U gt gt oli i i E 2 2 LEVEL 7166 3232 gis 856 22 8 SENSOR ONL eza Tes E d ME d a 2585 3 8 BK 1 m 284 1 CR27D 655 E
79. Schematics AboutThis Section There are two groups of schematics in this section An illustration legend precedes each group of drawings Electrical Schematics AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Hydraulic Schematics Bodily injury hazard 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 Be sure that all necessary tools and test equipment are available and ready for use Malfuncion troubleshoot discovered symptoms problem still exists Retum to Perform service problem 7 repair solved Genie Part No 97385 GS 30 GS 32 6 6 1 Section 6 Schematics Electrical Component Legend ELECTRICAL COMPONENT LEGEND Item Description B5 Battery BN Button 5 Horn BN6 High torque 8 Drive select 9 Lift select BN105 Outrigger extend GS 3232 BN106 Outrigger function enable GS 3232 BN107 Outrigger retract GS 3232 C5 Capacitor 4700 uF CB2 Circuit breaker 7A CR Control relay CR48 Power relay to 05 e stop 5 Horn relay with H2 option CR27A Overload motor controller option CR27B Overload load se
80. We RD NOTE JE MACHINE SHOWN IN THE 2 STOWED POSITION WITH 5 THE POWER OFF e p i go N 214 BLACK AND WHITE WIRES 1 5 i f CUT POWER TO MOTOR a CONTROLLER WHEN THE EN d 130 5 5 CHARGER IS PLUGGED IN LX 2 HOPTION gt 1 o g E BK 5 2 1 QD1 9 0 Plum p mi d GN Ao our A12 812 11 IN 8 68 3232 ONLY A 2 F6 BK 7 NOT CONNECTED ruse 2 Se i WH A1 OUT U5 ELECTRONIC CONTROL L 4 MODULE B8 Le es BS 17 6 4 6V 9 INOT CONNECTED RN CR5 WITH MOTOR A HORN RELAY IGUT Orr POWER NA 7 2 OPTION 488 OPTION fei FB Il L 2 DC AC INVERTER 4 FLASHING M 85 OPTION BEACONS 1 OPTION 2 H2 G6 AUTO STYLE HORN HOUR METER L 1 OPTION 4 BN ES0141W Genie 6 50 GS 30 GS 32 6 Part No 97385 6 51 Section 6 Schematics Electrical Schematic ANSI CSA and Australia Models GS 2032 2632 3232 from serial number GS3211A 97904 to GS3212A 109999 GS 2046 2646 3246 from serial number GS461 1A 97983 to GS4612A 109999 February 2012 REVA GND
81. 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 2 Hydraulic Hose and Fitting Torque Specifications Steer End 1 Chock the wheels at the non steer end of the machine 2 With a suitable floor jack lift the steer end of the machine to a height that will allow the outrigger cylinder to be removed 3 Open the access door at the battery side and or at the hydraulic tank side of the machine 4 Tag and disconnect the wire harness from the outrigger cylinder solenoid valve and the pressure transducer 5 Tag and disconnect the pressure transducer from the outrigger cylinder Plug the fitting on the cylinder 6 Tag disconnect and plug the hydraulic hoses from the outrigger cylinder Cap the fittings on the cylinder AWARNING sd 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 Part No 97385 Genie GS 30 GS 32 GS 46 suitable lifting device 8 Remove the outrigger cylinder mounting fasteners 9 Remove the outrigger cylinder from the machine Crushing hazard The outrigger ACAUTION cylinder may become unbalanced and fall if not properly supported when it is removed from the machine Note After installing a new cylinder or pressure tr
82. gt LIFT LED L16 POUT2 A lt DRIVE LED L17 POUT3 5 HIGH TORQUE LED L21 G8 POUT4 DIAGNOSTIC DISPLAY PIN1 HIGH TORQUE BN6 PIN2 HORN BN5 PIN3 DRIVE ENABLE BN8 4 LIFT ENABLE POUT11 H1 PLATFORM BK ALARM CONTROLLER 50142 Genie 6 100 GS 30 GS 32 GS 46 Part No 97385 April 2008 Section 6 Schematics m This page intentionally left blank Genie Part No 97385 GS 30 GS 32 6 6 101 Section 6 Schematics p ________ _ Electrical Schematic CE Models CE Models February 2012 REV GS 2032 2632 3232 from serial numberGS3207 84867 to GS3210A 94974 and GS3208C 101 to GS3210C 378 GS 2046 2646 3246 from serial number GS4607 84840 to GS4610A 95454 and GS4609C 101 to GS4610C 118 MIRI P Jo LS 8 I I jme oL c c lt lt lt CM c EIL lt lt oS 2 1 77 Ux EMERGENCY STOP WH B 1 i 7 e KS1 i
83. lt i Auf 1 E 3 P1 ER a EMERGENCY ge STOP WH WH B oe CB2 d CIRCUIT a Y 2 BREAKER i i key PLATFORM 1 gt SWITCH CONTROL H5 ALARM 4 E 1 1 T X s 3 N NCHO i N GROUND 2 CONTROL 1 1 4 157 TS66 P GUARD peer a a EET PLATFOR SWITCH R30 UP DOWN 1 NOTE 4 200 ohm 10w 2 e RD WW RD MACHINE SHOWN IN THE 1 e STOWED POSITION WITH E U27 5 158 THE POWER OFF we d 47 mH INDUCTOR NOISE SUPPRESSION POTHOLE og GUARD edt SWITCH 1 E S SAE 8 iN L30 2 8 lt C WORK LIGHT 5 2 5 UE A SN 2 E 5 5 ONLY 7 E 65 3232 5 E E QD1 69 7 E sir Contactor i no A12 812 11 9 B10 OUT Em tms mm Em 1 i A BK 13148 our CONNECTED _ FUSE BK WH OUT U5 273A U9 4 ELECTRONIC BATTERY CONTR
84. n lt lt lt lt lt lt lt 3 lt lt 192 2 10101 I oz e m d me FORWARD WH ace a as eon cen 9 IER 15 4 UP IN EER iu 5 2 Roe ee i 00555 206 278 Mag 3 6 5 8 1 18 19 oy 1 1 2 1 o litrai 5 1 TA EP gt RD 5295 i aise 4888 L S55 5 1 A 1 1 i te bg 5 M m 1 1 Oa 1 1 d FREE SEN RN J es 128 E z 4 LVL SNSR RED 22 2 NEN 5 gt 5 80 I LO od bg LVL SNSR WHT GN 5 2 ME BENE Ip t 198 58 ewBk DATA LINK LOW 52 5 TERE gt 65 A E EL DATA LINK HIGH sk 2 5 i GND FROM JOYSTICK lz s z 1 e ECM POWER wH 2 x i 4314111 1 Pid i 9 Pe W a aot 1 lt 1 1 59 01 tot a PLETI E eee reece 4 5 d 5
85. 0 LAN M OPTION 5 9 2 i F6 275a BN 8852 B PS NR rw GN OUT 12 812 B9 B10 ERR 68 3232 ONLY LIN IN OUT iN 11 BK TS ug B WH A1 OUT CHARGER U5 p 4 ELECTRONIC CONTROL MODULE OUT B5 53 46V 4 m BATTERY AGINPUT C 3 2 pd MOTOR 30 CONTROLLER 2 b 3 NOT CONNECTED CR5 1 I CONTROLLER 7 HORN RELAY CUT OFF POWER 39 2 86 PaE DC AC INVERTER FLASHING M 85 OPTION BEACONS scene OPTION H2 G6 AUTO STYLE E E orion ES0141P Genie 6 42 GS 30 GS 32 GS 46 Part No 97385 Section 6 Schematics Electrical Schematic ANSI CSA and Australia Models GS 2032 2632 3232 from serial number GS3207A 84867 to GS3210A 94974 GS 2046 2646 3246 from serial number GS4607A 84840 to GS4610A 95454 February 2012 REV D GND
86. 1 1 Circuit Boards How to Remove the Platform Controls Circuit Board 1 Push in the red Emergency Stop button to the off position at both the ground and platform controls 2 Remove the fasteners securing the platform control box together Open the control box 3 Locate the circuit board mounted to the top half of the platform control box AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Component damage hazard Electrostatic discharge ESD can damage printed circuit board components Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap 4 Remove the alarm and the red Emergency Stop button assemblies from the control box 5 Carefully disconnect the wire harness connectors from the circuit board 6 Carefully remove the circuit board retaining fasteners and remove the circuit board from the control box Part No 97385 October 2009 Section 4 Repair Procedures REV J PLATFORM CONTROLS The outrigger control pad is used to operate the How to Remove the Outrigger outriggers from the platform or while standing on the ground and can also be used to calibrate the Pad Circuit Board outrigger ECM and the outrigger level sensor Push in the red Emergency Stop button to the off position
87. 8 2 g BN GND deeem ecce POOR X pod 5 5 be Pry i D Doa prod dd z 222 fe ME pog 1 Ie AD Ss t eta Tog 1 198 8 5 6 5 1 i dg 1j E I EN T COMPRESE n i A se 55555 1 5 85 8 8 8 1 di 00307175 X gt gt pg 9 0 DS E eh o EUI eee H i 1 4 1 1 1 1 1 5 7 22 BLBK E pees 118 ME yd py vos rog q ok box 1 N DNI EHE HUE or p ect oa eee zaza ere 1 1 pi 1 1 iii 1 Vier ay pog 4 Tog NE Ws es o Mp ot t Tul qp 21 arg Lr x ul 1 1 1 1 1 1 1 1 ii i 181 ullli acl oel te zi aos Gay i 02 tL 28 189 Eu eel 22509 jo 00 5 9 gt lt gt bo Pos a Pg 1 1 M 1 1 1 a
88. 9 h 3 Remove the fasteners from the entry ladder and remove the entry ladder from the machine 5 Disconnect the number 5 cable bridge from the ACAUTION Crushing hazard The entry ladder number 5 outer arm index 17 and remove may become unbalanced and fall the cable bridge from the machine if not properly supported and 6 Remove the retaining fasteners from the secured to the lifting device number 6 pivot pin index 1 4 Remove the cables from the number 5 cable 7 Use a soft metal drift to remove the number 6 bridge and lay them off to the side pivot pin index 1 Remove the platform Component damage hazard mount bracket from the machine Cables can be damaged if they 8 Attach a lifting strap from an overhead crane to are kinked or pinched the number 5 outer arm at the ground control side index 17 Genie Part No 97385 GS 30 GS 32 GS 46 4 65 Section 4 Repair Procedures March 2007 SCISSOR COMPONENTS 9 Remove the retaining fasteners from the number 5 center pivot pin index 2 at the ground control side 10 Place a rod through the number 5 center pivot pin at the ground control side index 2 and twist to remove the pin 11 Remove the retaining fasteners from the number 5 pivot pin index 18 at the non steer end 12 Use a soft metal drift to remove the number 5 pivot pin index 18 from the non steer end of the machine Remove the number 5 outer arm at the ground control side index 17
89. Fasteners Before Securing Into Place Part No 97385 March 2007 Section 4 Repair Procedures Non steer Axle Components 9 1 9 Tag disconnect and plug the hydraulic hose Drive Brake How to Remove a Drive Brake When removing a hose assembly or fitting the fitting and or hose end must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Support and secure the entry ladder to an appropriate lifting device 2 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 itis not properly supported and secured to the lifting device 3 Block the steer wheels 4 Remove the cotter pin from the wheel castle nut Note Always replace the cotter pin with a new one when removing the castle nut 5 Loosen the wheel castle nut Do not remove it 6 Center a lifting jack under the drive chassis at the non steer end 7 Raisethe machine approximately 2 inches 5 cm Place blocks under the chassis for support Crushing hazard The chassis AWARNING could fall if not properly supported 8 Remove the wheel castle nut Remove the wheel Part No 97385 Genie GS 30 GS 32 GS 46 from the brake Cap the fitting on the brake AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connectio
90. GS 32 GS 46 xi February 2012 TABLE OF CONTENTS Section 6 Rev Schematics continued GS 2032 2632 from serial number GS3206 79992 to GS3207 83650 GS 2046 2646 3246 from serial number GS4606 78916 0354607 82595 6 34 GS 2032 2632 from serial number GS3207 83651 to GS3207 84866 GS 2046 2646 3246 from serial number GS4607 82536 to 654607 84839 6 38 GS 2032 2632 3232 from serial number GS3207A 84867 to GS3210A 94974 GS 2046 2646 3246 from serial number GS4607A 84840 to GS46104A 95454 6 42 GS 2032 2632 3232 from serial number GS3210A 94975 to GS3211A 97903 GS 2046 2646 3246 from serial number GS4610A 95455 to GS46114A 97982 6 46 GS 2032 2632 3232 from serial number GS3211A 97904 to GS3212A 109999 GS 2046 2646 3246 from serial number GS4611A 97983 to GS4612A 109999 6 50 Electrical Schematics CE Models GS 1530 1532 1930 1932 from serial number GS3005A 76000 to GS3005A 76388 from serial number GS3005B 76000 to GS3005B 76030 6 54 GS 1530 1532 1930 1932 from serial number GS3005A 76389 to GS3005A 79394 from serial number GS3005B 76031 to GS3005B 76920 6 58 GS 1530 1532 1930 1932 from serial number GS3005A 79395 to GS3006A 83067 from serial number GS3005B 76921 to AS3006B 79659 0sseesseessn 6 62 GS 1530 1
91. Genie A TEREX BRAND Service Manual GS 1530 32 GS 1930 32 GS 2032 GS 2632 GS 3232 GS 2046 GS 2646 GS 3246 Serial Number Range from GS3005A 76000 to GS3011A 109999 from GS3005B 76000 to GS3009B 98941 from GS3008C 101 to GS3011C 9999 from GS3205 75407 to GS3209 94602 from GS3209A 94603 to GS3212A 109999 from GS3205B 76000 to GS3209B 98941 from GS3208C 101 to GS3212C 9999 from GS4605 75438 to GS4609 95192 from GS4609A 95193 to GS4611A 109999 from GS4608C 101 to GS4612C 9999 Part No 97385 Rev E10 February 2012 February 2012 Introduction Important Read understand and obey the safety rules and operating instructions in the appropriate Operator s Manual on your machine before attempting any maintenance procedure Basic mechanical hydraulic and electrical skills are required to perform most procedures However several procedures require specialized skills tools lifting equipment and a suitable workshop In these instances we strongly recommend that maintenance and repair be performed at an authorized Genie dealer service center Compliance Machine Classification Group A Type 3 as defined by ISO 16368 Machine Design Life Unrestricted with proper operation inspection and scheduled maintenance Technical Publications Genie has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie poli
92. Machine Function Code at Diagnostic Display Motion Lift Drive Platform Descent Genie 4 42 GS 30 GS 32 6 Part No 97385 October 2009 Ewe Uns c 2 REV J How to Activate the Battery Drain Alarm Option 1 9 Note To deactivate the battery drain alarm option Pull out the red Emergency Stop button to the on position at the ground controls Push in the red Emergency Stop button to the off position at the platform controls Turn the key switch to platform control At the platform controls press and hold the lift function select and speed select buttons and pull out the red Emergency Stop button to the on position Result The diagnostic display at the platform controls and the ECM will show SC Release the lift function select and speed select buttons Result The diagnostic display will show the current configuration Press the speed select button Result The 65 digit setting will be activated and the current ones setting will flash in the diagnostic display Press the horn button Result A dot located at the lower right of the diagnostic display window will become illuminated This indicates that the battery drain alarm option has been activated Press and hold the speed select button for a minimum of 3 seconds or until the ones setting stops flashing Turn the key switch to the off position on a machine whi
93. Malfunctioning control cable OR malfunctioning platform controls Troubleshoot control cable OR troubleshoot platform controls Undefined platform DIP switch settings DIP switch settings incorrect Correct DIP switch settings Chassis up down toggle closed at start up Pothole guard failure Malfunctioning up down switch Malfunctioning pothole switch OR obstruction in pothole guard linkage Troubleshoot up down switch Troubleshoot pothole switch OR remove obstruction 42 Limit switch failure Platform left turn switch fault Platform right turn switch fault Malfunctioning limit switch OR wire disconnected from limit switch Malfunctioning steer left microswitch Malfunctioning steer right microswitch Troubleshoot limit switch OR inspect wire connection Troubleshoot steer left microswitch Troubleshoot steer right microswitch Platform drive enable switch fault Malfunctioning drive enable switch Troubleshoot drive enable switch 52 53 54 Platform joystick fault Forward coil fault Reverse coil fault Up coil fault Not used on GS 3232 Down coil fault Joystick potentiometer not centered Malfunctioning coil OR wire disconnected from coil Malfunctioning coil OR wire disconnected from coil Malfunctioning coil OR wire disconnected from coil Malfunctioning coil OR wire disconnected from coil Verify potentiometer
94. REV 2 From serial numbers GS3003A 60000 to GS3006A 85006 and from GS3005B 76000 to GS3006B 80468 Measure the distance between the number one outer arm cross tube and the chassis deck at the battery pack side of the non steer end of the machine Refer to illustration 1 After serial numbers GS3006A 85006 GS3006B 80468 and GS3008C 101 Measure the distance between the number one inner arm cross tube and the chassis deck at the battery pack side of the non steer end of the machine Refer to illustration 2 Result The measurement is 0 90 inch 22 9 mm or more Proceed to step 3 Result The measurement is less than 0 90 inch 22 9 mm Replace both wear pads Refer to Repair Procedure 3 1 or 3 2 How to Replace the Scissor Arm Wear Pads 3 Apply a thin layer of dry film lubricant to the area of the chassis where the scissor arm wear pads make contact Cross tube to chassis specification CHECKLIST D PROCEDURES Measurement minimum 0 90 inch 22 9 mm Part No 97385 Illustration 1 b outer arm cross tube 0 chassis deck Te 0 b Illustration 2 b inner arm cross tube 0 chassis deck Section 3 Scheduled Mai
95. bog WH E e MH B para 2 5 BE B 7A 1 2 X CIRCUIT 00 OP od T BREAKER KS1 KEY PLATFORM SWITCH CONTROL 1 EE og d B1 4 S E ES0141 Rev V applies to i for machines with kit number 3 installed N 4 232534 0 GROUND 7 CONTROL T d 5 TS66 E QNUM er PLATFORM Fa a bod R30 UP DOWN 4 200 ohm 10w RD RD NOTE 8 MACHINE SHOWN IN THE 5 STOWED POSITION WITH 5 THE POWER OFF e p m S I a iu 8 BEP BLACK AND WHITE WIRES 1 gt 7 CUT POWER TO MOTOR 1 i c CONTROLLER WHEN THE rot 1 L30 S 38 z CHARGER IS PLUGGED IN WORK LIGHT 9 OPTION OPTION 2 D 1 2 N o zi nien ee T 4 g BK 1 g u o QD1 tele 0ps 8 9 9954 Contactor 9 po E ue N O H C on SN N N REED S GS 3232 ONLY p PSE DETE F6 9 BK 7 our NOT CONNECTED FUSE ON 065 3232 e TIE i SS PISA pes US U9 ELECTRONIC CONTROL BATTERY 17 MODULE CHARGER SNI B8 B5 Lum 4 6V ig S BATTERY
96. pt 5 EMERGENCY a y gt B e Non 5 0 ed 2 KS1 key PLATFORM SWITCH CONTROL 7 B1 H5 ALARM 3 A UM NC E NCHO EN x OF 9 7 poo E000 MM TS66 POTHOLE a MI M 1 4 PLATFORM ree 1 UP DOWN 1 9 CB2 pups 58 MACHINE SHOWN IN THE 4 BREAKER Nn STOWED POSITION WITH pod GUARD THE POWER OFF SWITCH c gt E Wt 5 8 PU 52 5 BLACK AND WHITE WIRES CUT POWER M 803 9 MOTOR CONTROLLER WHEN THE by L30 5 2 5 CHARGER IS PLUGGED IN OPTION ec wore 5 g QD1 0 LAN M OPTION 9 2 i F6 275a BN 8852 BK 2 rw GN our 12 812 B9 B10 es 65 3232 ONLY BETIS LIN IN OUT N uo pe ee BATTERY WH aou 7 7 quz CHARGER U5 ELECTRONIC CONTROL MODULE 5 0 4 6V SAY 9 E BATTERY AGINPUT C 3 2 pd MOTOR 30 CONTROLLER 2 b 3 NOT CONNECTED CR5 IGONTROLLER 7 HORN RELAY 1 CUT OFF POWER 3 2 86 p U13 _ _ 12 bee 2j DC AC INVERTER FLASHING M 85 OPTION BEACONS Y eie Sue T OPTIO
97. 0 037 incn 0 94 mm UM Orifice with size PS2 Platform overload pressure switch WX Solenoid operated 2 position 2 way valve normally closed JP Variable speed motor E Fixed displacement pump C3 Bi directional motor Priority flow regulator Filter 6 114 Brake o Shuttle valve S Solenoid operated 2 position 4 way directional valve Accumulator Check valve Genie REV B Pilot operated check valve with needle valve INY n Solenoid operated 3 position 4 way directional valve il X M Ye I Y5 Solenoid operated 3 position 4 way directional valve Solenoid operated 3 position 5 way directional valve GS 30 GS 32 GS 46 Part No 97385 2007 Section 6 Schematics Component Reference and REV Hydraulic Symbols Legend Function manifold GS 1530 GS 1532 GS 1930 and GS 1932 Outrigger manifold GS 3232 ier and CB Front outrigger cylinder Function manifold GS 2032 GS 2632 GS 3232 GS 2046 GS 2646 and GS 3246 Brake release manifold all models GS 3232 Rear outrigger cylinder GS 3232 Genie Part No 9738
98. 172 bar maximum 7 THE ORIFICE IS LOCATED UNDERNEATH va X THE FITTING ON THE LIFT CYLINDER AE m m YI KAN AD 10 psi l _ _ A Qrber 0 040in ve IN xl M vs 1 Ty 9 Mem al 4 1 2 0 75 NI 2 8 Limin 1 130 psi Er aS Sas 522 4 9 bar e ES HR boe Y8 ND FUNCTION MANIFOLD 5 124 241 ll ABBREVIATION LEGEND 241 bar maximum 1 Item Description MM rct AA Test port AB Relief valve system 1 AC Steer left right AD Check valve steer circuit C AE Drive speed F AF Relief valve brake release atop AG Drive forward reverse e LEES aed AH Flow regulator relief valve Al Platform up AJ Relief valve lift HYDRAULIC TANK L Hand pump manual brake release M Needle valve manual brake release N Platform lowering valve Orifice platform down circuit Relief valve platform down HS0036H R Pressure switch platform overload Genie 6 118 GS 30 GS 32 6 97385 2007 Section 6 Schematics REVA Hydraulic Schematic GS 2032 2632 from serial number GS3206
99. 637 500 678 670 908 560 759 480 650 640 867 680 922 910 1255 770 1044 12 530 718 no 965 750 1016 800 31342 s0 mo 2 gt 9 lt N o o s 312 908 860 1206 1080 1464 1440 1962 1220 1054 31681 1240 1260 930 2047 200 2725 1700 2504 1460 1950 2643 2370 3218 3160 4284 2670 3620 2 312 1640 2223 2190 2969 2670 3620 3960 4826 3000 4067 METRIC FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual DRY DRY U 1 EB c 1 A 99 84 68 775 51 103 52 DRY Nm ios Nm 2 125 8i 110 147 200 Peto 304 535 525 713 622 612 778 1055 682 925 909 1233 N gt Po N co el Co e mE zo 4 E O O1 ojo Go gt 00 E A A A c B zi oj NI A 0 42 jw n ges E E e c 8 A A A n 91 n A oP BAIN Ol
100. 97385 April 2008 Section 6 Schematics m This page intentionally left blank Genie Part No 97385 GS 30 GS 32 6 6 17 Section 6 Schematics Electrical Schematic April 2008 ANSI CSA and Australia Models REVB GS 1530 1532 1930 1932 from serial number GS3007A 87491 to GS3007A 89537 GS 1530 1532 1930 1932 from serial number GS3007B 82544 to GS3007B 84599 P1 egi RS Pd H 2 8 1 N oR t1 2 2 KS1 key PLATFORM 1 SWITCH CONTROL 4 1 NOTE L H5 MACHINE SHOWN IN THE k ds STOWED POSITION WITH Sg NCHO THE POWER OFF NA P LS7 TS66 POTHOLE PLATFORM 4 UP DOWN 4 BREAKER 4 7 POTHOLE GUARD SWITCH t 55956 8 BLACK AND WHITE WIRES CUT POWER 5 E TO MOTOR CONTROLLER WHEN THE ky 130 S CHARGER IS PLUGGED IN OPTION 3 worker 3 i QD1 d I A 3 F6 275A FUSE 8 BK ee t ol WoW BS 09 A8 OUT y A1 OUT CHARGER U5 ELECTRONIC CONTRO
101. SW5 SW6 FUNCTION ENABLE T STEER 1 LEFT RIGHT OR J PIN8 1 POUT1 POUT2 PIN1 PIN3 PIN4 POUT11 PIN11 POUT4 C PIN2 C BK 2 PLATFORM CONTROLS MEMBRANE DECAL LIFT LED L16 ty 4 Ca Im G8 DIAGNOSTIC DISPLAY DRIVE LED 117 HIGH TORQUE LED 121 HIGH TORQUE BN6 HORN BN5 DRIVE ENABLE BN8 LIFT ENABLE BN9 PLATFORM CONTROLLER 50141 Genie GS 30 GS 32 GS 46 Part No 97385 April 2008 Section 6 Schematics m This page intentionally left blank Genie Part No 97385 GS 30 GS 32 6 6 37 Section 6 Schematics _______________ Electrical Schematic April 2008 ANSI CSA and Australia Models REV B GS 2032 2632 from serial number GS3207 83651 to GS3207 84866 GS 2046 2646 3246 from serial number GS4607 82536 to GS4607 84839 P1 egi RS Pd H 2 8 1 N oR 22 2 2 KS1 key PLATFORM
102. The lift cylinder may become unbalanced and fall when it is removed from the machine if not properly attached to the overhead crane Component damage hazard Be careful not to damage the valve or fittings on the cylinder while removing it from the machine 63 Place a 4 4 x 48 inch 10 cm x 10 cm x 1 2m SCISSOR COMPONENTS 64 Attach a lifting strap from an overhead crane to the number 1 inner arm index 10 at the non steer end Raise the number 1 inner arm and remove the safety arm Lower the number 1 inner arm index 10 onto the block that was placed across the chassis Bodily injury hazard Keep hands A CAUTION clear of moving parts when lowering the arms onto the block 65 Remove the cables from the number 1 cable bridge and lay them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched 66 Support and secure the entry ladder to an appropriate lifting device 67 Remove the 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 68 Attach a lifting strap from an overhead crane to the number 1 outer arm index 22 Do not apply any lifting pressure 69 Remove the external snap rings and retaining fasteners from the number 1 center pivot pins index 11 70 Remove the number 1 cable bridge from t
103. XI EN 25585 0 y 1 FER ie 5 5 5 5 1 tr a I 888865 gt gt 28 E do 5 5 4 1 ig nee 5 E Ed 1 1 2 eS N 1 eee EE OS NES S oi 1 1 1 1 1 Oo p 1 1 0 d E ron pd 1 7 rop 4 zw 1 LN ME SP d 1 15 1 0 urs TET 5 EUIS gt eg 95158 28 8 c 558 6 5 5 EE db b go dad bd 1 1 1 1 1 ES0141V Part No 97385 GS 30 GS 32 GS 46 6 28 February 2012 Section 6 Schematics Electrical Schematic ANSI CSA and Australia Models GS 1530 1532 1930 1 932 from serial number GS301 0A 99456 to GS301 1A 109999 REVA P2 EMERGENCY QD3 4 4 BK POWER TO PLATFORM 3 RD POWER TO GROUND _ MACHINE SHOWN IN THE STOWED 1 1 wH GROUND POSITION WITH THE POWER OFF N 2 2 BL DATA LINK HIGH H 5 5 OR DATA LINK LOW 15V DC m e md PRINTED CIRCUIT BOARD REGULATOR NOTE ES0141 Rev V applies to machines with kit number 232534 installed HALL EFFECT JC1 GENERATOR JOYSTICK CONTROLLER
104. at the battery pack side of the machine 31 Use a soft metal drift to tap the number 3 pivot pin index 17 in the other direction Remove the number 3 outer arm index 16 from the battery pack side of the machine Bodily injury hazard The number ACAUTION 3 outer arm at the battery pack side may become unbalanced and fall if not properly supported when removed from the machine 32 Remove the number 3 pivot pin index 17 from the non steer end of the machine Part No 97385 Genie GS 30 GS 32 GS 46 SCISSOR COMPONENTS 33 Attach a lifting strap from an overhead crane to the lug on the rod end of the lift cylinder for support Do not apply any lifting pressure 34 Remove the pin retaining fasteners from the lift cylinder rod end pivot pin index 5 Use a soft metal drift to remove the pin Bodily injury hazard The cylinder ACAUTION may fall when the rod end pivot pin is removed if not properly supported 35 Lower the cylinder onto the number 1 inner arm index 9 Component damage hazard Cables can be damaged if they are kinked or pinched 36 Attach a lifting strap from an overhead crane to the number 3 inner arm index 15 37 Remove the retaining fasteners from the number 3 pivot pin index 6 at the steer end 38 Use a soft metal drift to remove the number 3 pivot pin index 6 Remove the number 3 inner arm index 15 from the machine Bodily injury hazard The number ACAUTION 3
105. conditions exist A free breathing hydraulic tank cap is essential for good machine performance and service life A dirty or clogged cap may cause the machine to perform poorly Extremely dirty conditions may require that the cap be inspected more often 1 Remove the breather cap from the hydraulic tank 2 Check for proper venting Result Air passes through the breather cap Result If air does not pass through the cap clean or replace the cap Proceed to step 3 Note When checking for positive tank cap venting air should pass freely through the cap 3 Using a mild solvent carefully wash the cap venting system Dry using low pressure compressed air Repeat step 2 4 Install the breather cap onto the hydraulic tank Part No 97385 February 2012 Section 3 Scheduled Maintenance Procedures REV K B 14 Check the Module Tray Latch Components Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first 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 1 Inspect each module tray rotary latch and related components for wear Tighten any loose fasteners 2 Lubricate each module tray rotary latch Using light oil apply a few drops to each of the springs and
106. er 1 i bala ii x E iig NES bg iii iii 1 2 ul NE 58 igo 25 5 Eo ES r2iiu 5 06 n a Sj 9 558956 5 5 d 1 I 1 1 1 1 tops ES0142T Part No 97385 GS 30 GS 32 GS 46 6 108 February 2012 Section 6 Schematics Electrical Schematic REVA CE Models GS 2032 2632 3232 from serial number GS3210A 94975 to GS321 1A 97903 and GS3210C 379 to GS3212C 1386 GS 2046 2646 3246 from serial number GS4610A 95455 to GS46114 97982 and GS4610C 119to GS4612C 1385 P2 EMERGENCY QD3 4 4 BK POWER TO PLATFORM 3 RD POWER TO GROUND 1 MACHINE SHOWN IN THE STOWED 1 1 wH GROUND POSITION WITH THE POWER OFF NI 2 2 BL DATA LINK HIGH H 5 5 OR DATA LINK LOW U3 07 PLATFORM CONTROLS VOLTAGE PRINTED CIRCUIT BOARD REGULATOR HALL EFFECT JC1 JOYSTICK CONTROLLER SW5 SW6 pp FUNCTION ENABLE T STEER gt ii LEFT RIGHT PLATFORM CONTROLS 9 MEMBRANE DECAL POUTI 4 LIFT LED L16 POUT2 O E DRIVE LED L17
107. from the machine Crushing hazard The number 5 ACAUTION outer arm at the ground control side index 17 may become unbalanced and fall if not properly supported when removed from the machine 13 Attach a lifting strap from an overhead crane to the number 5 outer arm at the battery side index 17 14 Remove the retaining fasteners from the number 5 center pivot pin index 2 at the battery side 15 Place a rod through the number 5 center pivot pin at the battery side index 2 and twist to remove the pin 16 Remove the number 5 outer arm index 17 from the machine Crushing hazard The number 5 ACAUTION outer arm index 17 may become unbalanced and fall if not properly supported when removed from the machine 17 Attach a lifting strap from an overhead crane to the number 5 inner arm index 16 Raise the arm to a vertical position Genie GS 30 GS 32 GS 46 REV 18 Remove the retaining fasteners from the number 5 pivot pin at the steer end of the machine index 4 19 Use a soft metal drift to remove the number 5 pivot pin index 18 from the steer end of the machine Remove the number 5 inner arm index 16 from the machine Crushing hazard The number 5 ACAUTION inner arm index 16 may become unbalanced and fall if not properly supported when removed from the machine 20 Tag disconnect and plug the hydraulic hose on the upper lift cylinder Cap the fittings on the cylinder
108. lt 6 cnc 2 5 o CR27A CR27B CR27C 2228 OVERLOAD OVERLOAD OVERLOAD 4 4 1 1 1 MOTOR CONT LOAD SENSE DOWN COIL NOS i P A 282 p lisse cid End 1 LEVEL 25 Ts LS5 SENSOR 5 M CIRCUIT 0 BOARD prd 1 ii 1 1 5 switch 2 4700 uF 4 86 5 55 55 S7 idet 5 2 5 0 gt gt LEVEL 9 83 55 22 65 32 2 gis R 2822 8 5 SENSOR OnLy 7 gt 9 87 85 1 J 6 5 7526 BK SEE 1 CR27D 285 45 2 6 5 OVERLOAD 2 a _ DOWN DELAY Q WE Ex 1 77 99 ME o ME 4 9 9 5 it xp d i ei eS 7 0 NE A4 A9 10 B6 C12 C2 2 B1 C1 C11 5 ME IN OUT OUT IN OUT IN IN IN IN IN OUT NN Fd ee WE NOT CONNECTED EN ONGS 3292 E 1 1 U5 e ELECTRONIC CONTROL MODULE EN ON GS 32
109. perform each repair procedure with the machine in the following configuration Machine parked on a firm level surface Platform in the stowed position Key switch in the off position with the key removed The red Emergency Stop button in the off position at both ground and platform controls Wheels chocked All external AC power supply disconnected from the machine Part No 97385 Genie GS 30 GS 32 GS 46 4 1 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 ray Indicates an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous ACAUTION situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may r
110. 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 red 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 Genie Part No 97385 GS 30 GS 32 GS 46 3 15 Section 3 Scheduled Maintenance Procedures February 2012 CHECKLIST B PROCEDURES B 8 Test the Drive Brakes Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first 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 procedure with the machine on a firm level surface that is free of obstructions with the platform extension deck fully retracted and the platform 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 red Emergency Stop button to the on position at both the ground and platform controls 3 Lower the platform to the stowed position 4 Press the drive function select button Refer to Illustration 1 6 8799 Illustra
111. roll S8 input A9 Outrigger data link high input A10 Outrigger data link lo input A11 Power for platform controller output A12 Ground for platform controller output B1 Outrigger ECM ground input B2 Plug B3 Plu B4 Motor controller throttle output B5 Motor controller enable input B6 Height limit signal input B7 Down limit switch LS66 input B8 Key switch KS1 input B9 Up signal from Gen 5 ECM U5 input B10 Drive reverse Y5 input B11 Drive forward Y6 input B12 24V A C1 24V B C2 Plu C3 Outrigger retract Y39 output C4 Outrigger extend Y40 output C5 Left front outrigger Y35 output Right front outrigger 36 output C7 Left rear outrigger Y33 output C8 Right rear outrigger Y34 output C9 Motor controller enable output C10 Outrigger transducer 2 axis tilt level sensor S8 and up limit switch LS5A power output C12 C11 Platform up Y8 output Drive enable Section 6 Schematics February 2009 Wiring Diagram Ground Controls and Level Sensor Harness REV B GROUNDCONTROLS MOTOR CONTROLLER TERMINAL B s MOTOR CONTROLLER KS1 2 KEY SWITCH 3 WH 1 BREAKER B1
112. serious injury and significant component damage Dealer service is required 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 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform See 2 1 How to Remove the Platform 2 Support and secure the entry ladder to an appropriate lifting device 3 Remove the 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 4 Remove the cables from the number 3 cable bridge and lay them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched Part No 97385 Genie GS 30 GS 32 GS 46 SCISSOR COMPONENTS 99 2046 Cable bridge legend cable bridge 3 cable bridge 2A cable bridge 2B cable bridge 1 ao om 5 Disconnect the number cable bridge from the number 3 outer arm index 11 and remove the cable bridge from the machine 6 Remove the retaining fasteners from the number 4 pivot pin index 1 7 Use a soft metal drift to remove the number 4 pivot pin index 1 Remove the platform mount bracket from the machine 8 Attach a lifting strap from an overhead crane to the number 3 outer arm at the ground control side in
113. t 6 6 8 MEN m 58885 EE DN bp od ox J i 1 1 T M ot P ES0142U enie GS 30 GS 32 GS 46 Part No 97385 6 4 February 2012 Section 6 Schematics Electrical Schematic CE Models GS 1530 32 8 1930 32 from serial number GS3012C 5060 to GS3012C 531 1 REVA P2 EMERGENCY L_ U3 07 502 PLATFORM CONTROLS VOLTAGE PRINTED CIRCUIT BOARD REGULATOR HALL EFFECT JC1 JOYSTICK CONTROLLER pP FUNCTION ENABLE pen SW5 SW6 STEER LEFT RIGHT POUT4 POUTI E POUT2 6 E DRIVE LED L17 POUT3 HIGH TORQUE LED 121 M G8 PIN1 DIAGNOSTIC DISPLAY PLATFORM CONTROLS md LIFT LED 6 MEMBRANE DECAL PIN2 HIGH TORQUE BN6 PIN3 HORN BN5 5 DRIVE ENABLE BN8 POUT11 LIFT ENABLE BN9 ES0142U H1 PLATFORM CONTROLLER Part No 97385 Genie QD3 4 4 BK POWER TO PLATFORM 3 RD POWER TO GROUND _ MACHINE SHOWN
114. the steer end of the machine with a strap or other suitable device 93 Secure the ends of the scissor arms together at the non steer end of the machine with a strap or other suitable device 94 Remove the retaining fasteners securing the chassis mount bracket to the chassis 95 Remove the linkset from the machine Bodily injury hazard The number ACAUTION 1 inner and outer arms index 14 and 29 may become unbalanced and fall if not properly supported when removed from the machine Component damage hazard Be sure not to damage the limit switch or level sensor box components when the number 1 inner and outer arms index 14 and 29 is removed from the machine Part No 97385 2007 Section 4 Repair Procedures REV How to Replace the Scissor Arm Wear Pads 1 Remove the platform See 2 1 How to Remove the Platform 2 Support and secure the entry ladder to an appropriate lifting device 3 Remove the 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 4 Secure the ends of the scissor arms together at the steer end of the machine with a strap or other suitable device 5 Secure the ends of the scissor arms together at the non steer end of the machine with a strap or other suitable device 6 Remove the retaining fasteners securi
115. vc ce es um eo c m mE mee 8 A Y1 Y3 Y4 Y5 Y6 Y9 Y7 Y8 PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM RIGHT LEFT REVERSE FORWARD DOWN DOWN UP GS 3246 4 4 E LH 4 Le Le GND di ES0142M Genie Part No 97385 GS 30 GS 32 6 6 71 Section 6 Schematics April 2008 Electrical Schematic CE Models REV B GS 1530 1532 1930 1932 from serial number GS3007A 87491 to GS3007A 89537 GS 1530 1532 1930 1932 from serial number GS3007B 82544 to GS3007B 84599 2 QD3 EMERGENCY 4 4 BK POWER PLATFORM 3 3 RD POWER TO GROUND 1 1 crounn ___ iopo 2 gt 2 BL DATA LINK HIGH H5 5 OR DATA LINK LOW U3 PLATFORM CONTROLS VOLTAGE PRINTED CIRCUIT BOARD REGULATOR GY db M COD o GN 5 BL SW5 pd pp FUNCTION ENABLE lt STEER 5 T 1 LEFT RIGHT o 4 5 e 0 8 PLATFORM CONTROLS E MEMBRANE DECAL POUT1 0 gt LIFT LED L16 POUT2 0 4G lt 7 4 DRIVE LED L17 POUT3 lt 4 HIGH TORQUE LED L21 G8 POUT4 DIA
116. 1 STEER ii LEFT RIGHT PLATFORM CONTROLS 9 MEMBRANE DECAL POUT1 5 E LIFT LED L16 POUT2 i E DRIVE LED L17 POUT3 O 4 HIGH TORQUE LED 121 M POUT4 DIAGNOSTIC DISPLAY PIN1 HIGH TORQUE BN6 PIN2 HORN BN5 DRIVE ENABLE BN8 PIN4 LIFT ENABLE BN9 H1 PLATFORM BK ALARM 75 CONTROLLER POUT11 ES0142T Genie Part No 97385 GS 30 GS 32 GS 46 6 81 Section 6 Schematics cac Electrical Schematic February 2012 CE Models REVA GS 1530 32 amp 1930 32 from serial number GS3012C 5060 to GS3012C 5311 UU UM MIR 0 8 EN ae 8 777 1 lax EMERGENCY EN WH B para CB2 LA CIRCUIT 2 T BREAKER 51 key PLATFORM 1 gt H5
117. 1932 Raise the platform approximately 1 5 m Part No 97385 Genie GS 30 GS 32 GS 46 SCISSOR COMPONENTS 6 Using a suitable lifting device place a test weight corresponding to the maximum load as indicated on the capacity indicator decal in the center of the platform floor Secure the weight to the platform Refer to the chart below GS 1532 484 kg GS 1932 435 kg GS 2032 693 kg GS 2632 479 kg GS 3232 498 kg GS 2046 985 kg GS 2646 798 kg GS 3246 649 kg 7 Apply a piece of tape onto the side of the platform at a point which corresponds to the maximum load position of the capacity indicator decal on the side of the platform 8 Raise the platform until the position indicator corresponds to the maximum load position of the capacity indicator decal on the platform Release the toggle switch Tip over hazard Raising the platform with maximum load above the maximum load position as shown on the capacity indicator decal on the side of the platform could result in the machine tipping over resulting in death or serious injury Do not raise the platform above the maximum load position of the capacity indicator decal on the side of the platform Note To perform this step the lift relief valve will need to be adjusted 9 Lift the safety arm move it to the center of the scissor arm and rotate down to a vertical position Section 4 Repair Procedures March 2007 SCISSOR
118. 2 2 BL DATALINK HIGH 5 5 OR DATA LINK LOW U3 du T HALL EFFECT GENERATOR JOYSTICK x CONTROLLER Nay GN SW5 SW6 FUNCTION ENABLE 22 ELS PIN9 On 1 m 2 BK J g l PIN8 POUT1 POUT2 PIN1 PIN3 PIN4 POUT11 PIN11 POUT4 C PIN2 C BK PLATFORM CONTROLS MEMBRANE DECAL 2 La LIFT LED 116 DRIVE LED 117 4 HIGH TORQUE LED 121 G8 DIAGNOSTIC DISPLAY HIGH TORQUE BN6 HORN BN5 DRIVE ENABLE BN8 LIFT ENABLE BN9 PLATFORM CONTROLLER ES0141H Genie GS 30 GS 32 25 46 Part No 97385 April 2008 Section 6 Schematics m This page intentionally left blank Genie Part No 97385 GS 30 GS 32 6 6 13 Section 6 Schematics IE ____ __ ______________ scc Electrical Schematic TO MOTOR CONTROLLER WHEN THE CHARGER IS PLUGGED IN OPTION April 2008 ANSI CSA and Australia Models REV GS 1530 1532 1930 1932 from seria
119. 2 m 5 0 gt gt LEVEL OG S rug 2 5 gt gt 0 SENSOR 2 gt 5 9 2 22 n z v m m 6 BK 5 85349 2 5 5 9 8 2g 3 gt 8 9 9 8 2 lL A4 B11 C12 A10 C2 A2 B1 C11 5 IN IN IN IN ELECTRONIC CONTROL MODULE OUT OUT OUT OUT OUT OUT 8 C7 B7 A7 C6 B6 AG DE c EN HIE LC 2 2 g 2 E 5 A PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM RIGHT LEFT REVERSE FORWARD DOWN DOWN UP GS 3246 _ 4 4 L_ LH L_ L_ 4 Le GND 4 4 ES0141M Genie Part No 97385 GS 30 GS 32 6 6 19 Section 6 Schematics April 2008 Electrical Schematic ANSI CSA and Australia Models REVB GS 1530 1532 1930 1 932 from serial number GS3007A 87491 to GS3007A 89537 GS 1530 1532 1930 1 932 from serial number GS3007B 82544 to GS3007B 84599 D P2 QD3 EMERGENCY 2 2 BL DATALINK HIGH 5 5 OR DATA LINK LOW U3 du T HALL EFFECT GENERATOR JOYSTICK x CONTROLLER Nay GN SW5 SW6 FUNCTION ENABLE 22 ELS PIN9 On 1 m 2 BK J g l PIN8
120. 2646 3246 from serial number GS4606 78916 to GS4607 82535 P2 QD3 EMERGENCY 4 4 POWER PLATFORM 74 3 3 RD POWER TO GROUND 1 1 WH ioro 1 2 2 BL DATALINK HIGH 5 5 OR DATA LINK LOW 1 D7 PLATFORM CONTROLS VOLTAGE PRINTED CIRCUIT BOARD REGULATOR T HALL EFFECT GENERATOR JOYSTICK CONTROLLER GN SW5 E PP FUNCTION ENABLE T STEER 1 LEFT RIGHT PLATFORM CONTROLS MEMBRANE DECAL LIFT LED 116 DRIVE LED L17 HIGH TORQUE LED L21 POUT4 C DIAGNOSTIC T DISPLAY PIN1 HIGH TORQUE BN6 PIN2 HORN BN5 PIN3 DRIVE ENABLE BN8 PIN4 LIFT ENABLE BN9 POUT11 PLATFORM BK 7 CONTROLLER ES0142K Genie GS 30 GS 32 GS 46 Part No 97385 April 2008 Section 6 Schematics m This page intentionally left blank Genie Part No 97385 GS 30 GS 32 6 6 97 Section 6 Schematics April 2008 eee Electrical Schematic CE Models REV B GS 2032 2632 from serial number GS3207 83651 to GS3207 84866 GS 2046 2646 3246 from serial number GS4607 82536 to GS4607 84
121. 3 outer arm 17 Number 3 pivot pin non steer end 18 Number 2 inner arm 19 Number 2 outer arm 20 Number 2 pivot pin non steer end 21 Lift cylinder barrel end pivot pin 22 Number 1 outer arm Part No 97385 2007 Section 4 Repair Procedures REV 3 2 Scissor Assembly GS 1930 and GS 1932 How to Disassemble the Scissor Assembly GS 1930 and GS 1932 AWARNING Podily injury hazard The procedures in this section require specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is required 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 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform See 2 1 How to Remove the Platform 2 Remove the cables from the number 4 outer arm index 13 at the ground controls side Component damage hazard Cables can be damaged if they are kinked or pinched 3 Remove the cables from the number 4 cable bridge and lay them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched Part No 97385 Genie GS 30 GS 32 GS 46 SCISSOR COMPONENTS GS 1930 _ 65 1932 Cable bridge legend a cable bridge
122. 4 b cable bridge 3 C cable bridge 2 d cable bridge 1 Models with dual number 4 outer arms 4 Attach a lifting strap from an overhead crane to the number 4 outer arm at the ground controls side of the machine index 13 5 Remove the external snap rings and retaining fasteners from the number 4 center pivot pin at the ground control side of the machine index 2 6 Use a soft metal drift to remove the number 4 center pivot pin at the ground control side of the machine index 2 7 Remove the retaining fasteners from the number 4 pivot pin index 14 at the non steer end of the machine Section 4 Repair Procedures March 2007 SCISSOR COMPONENTS 8 Use a soft metal drift to remove the number 4 pivot pin index 14 from the non steer end of the machine Remove the number 4 outer arm at the ground control side index 13 from the machine AWARNING Crushing hazard The number 3 outer arm may become unbalanced and fall if not properly supported when removed from the machine 9 Attach a lifting strap from an overhead crane to the number 4 outer arm at the battery pack side of the machine index 13 10 Remove the external snap rings and retaining fasteners from the number 4 center pivot pin at the battery pack side of the machine index 2 11 Use a soft metal drift to remove the number 4 center pivot pin at the battery pack side of the machine index 2 12 Remove the number 4 outer arm at the battery
123. 75437 96316 Copyright 2011 by Terex Corporation 97385 RevE March 2007 Fifth Edition Second Printing Genie is a registered trademark of Terex South Dakota in the U S A and many other countries GS is a trademark of Terex South Dakota Inc Printed on recycled paper Printed in U S A ii GS 30 GS 32 GS 46 February 2012 INTRODUCTION Serial Number Legend Genie A TEREX BRAND Model GS 1930 Serial number GS3005A 12345 Model year 2011 Manufacture date 04 12 2005 Electrical schematic number ES0141 Machine unladen weight 2748 Ibs 1246 kg Rated work load including occupants 500 Ibs 227 kg Maximum allowable inclination of the chassis 1 5 Side 3 Front 3 Rear GS30 05 8 a 12345 Outriggers retracted N A Outriggers deployed Wandal did Model Sequence Gradeability 30 16 796 number Outdoor rating Model year Maximum allowable side force N A Maximum wind speed N A Maximum number of platform occupants N A Indoor rating Maximum allowable side force 100 Ibs 445 N Maximum wind speed 28 mph 12 5 m s in multiple facilities Maximum number of platform occupants 2 Nominal Power Country of manufacture Manufacturer European Representative Terex South Dakota Inc Genie UK LTD 500 Oak Wood Drive The Maltings 1150 Wharf Road Grantham Lin Watertown SD 57201 NG31 6BH United Kingdom USA This machine
124. 9 Solenoid valve 2 position 4 way PETERE RUNE Platform up 25 ft lbs 34 Nm 10 Relief valve 1800 to 3700 psi 124 to 255 bar Ad cce test Lift 20 ft lbs 27 Nm How to Install a Valve Cartridge 1 Dip the cartridge in clean oil to lube the O rings 2 Screw the cartridge in by hand until the top O ring is met then torque to specification 3 If required install the valve coil s onto the valve stem Install the coil nut onto the valve stem and torque to specification Genie 4 90 GS 30 GS 32 95 46 Part No 97385 February 2009 Section 4 Repair Procedures REV F MANIFOLDS Note alpha callouts refer to corresponding notes on the hydraulic schematic Note alpha numeric callouts refer to corresponding notes on the electrical schematic Inside Coil closest to manifold Before serial number GS3206 80132 drive forward coil Y6 Before serial number GS4606 79028 drive forward coil Y6 After serial number GS3206 80131 drive reverse coil Y5 After serial number GS4606 79027 drive reverse coil Y5 Outside Coil furthest from manifold Before serial number GS3206 80132 drive reverse coil Y5 Before serial number GS4606 79028 drive reverse coil Y5 After serial number GS3206 80131 drive forward coil Y6 After serial number GS4606 79027 drive forward coil Y6
125. 9205 gt LI _ dgittag rc RD BK 4 o9 2 55 L 5z 68 5 8 DOWN LIM RD BK ui SE e 00208 0 807 He 1 b i o E E E 1 5Z 28r GN BK 1 4 5 4 8 8 59 5 1 po UP IN pue que L 2 a sel REGEN COIL 3232 x Pp pe FORWARD WH j5 Z 8K gt 0 i 2 24V MAIN pe X P 1 E p ReERSE WHBK 52 zg Bek bd l gt rop Lor TUUPCOL BUBK 5 5 d 1 TODO os d wk 01 E M 1 e o 2 1 20 23295 ME N 1 12 ENT SORTEM 21 1 i 1 RD BK 1 1 E 1 55 2 4 1 22 06 ms it Fd 0 TA 55 oo eee ae i ce i 1 ud BEERS C 3 01 p foe xX Q 2 1 1 5 5 5 1 9 1 it Hof wees RR a a E WH BK 2 001
126. AWARNING iud 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 21 Tag and disconnect the wire harness from the solenoid valve on the cylinder 22 Remove the cables from the number 4A and 4B cable bridges and lay them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched 23 Disconnect the number 4A and 4B cable bridges from the scissor linkset and remove both cable bridges from the machine 24 Attach a lifting strap from an overhead crane to the lug of the rod end of the upper lift cylinder 25 Remove the retaining fasteners from the upper lift cylinder rod end pivot pin index 3 Part No 97385 2007 Section 4 Repair Procedures REV 26 Use a soft metal drift to remove the upper lift cylinder rod end pivot pin index 3 from the machine Crushing hazard The lift cylinder ACAUTION may become unbalanced and fall if not properly supported when the pivot pin is removed 27 Lower the cylinder onto the linkset 28 Attach a lifting strap from an overhead crane to the number 4 outer arm at the ground control side index 20 29 Remove the retaining fasteners from the number 4 center pivot pin index 5 at the ground control side 30 Place a rod through the number 4 center pivot pin at the ground control sid
127. Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the test port on the function manifold schematic item A or AA 3 Chock both sides of the wheels at the steer end of the machine 4 Remove the platform controls from the platform 5 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls GS 1530 32 and GS 1930 32 a test port b system relief valve Part No 97385 Genie GS 30 GS 32 GS 46 MANIFOLDS 6 Press and hold the function enable switch 7 Move and hold the joystick fully in either direction while observing the pressure reading on the pressure gauge Note the pressure Refer to Section 2 Specifications 8 Turn the machine off Hold the system relief valve with a wrench and remove the cap schematic item or AB 9 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure J Tip over hazard Failure to adjust the relief valves to specification could result in the machine tipping over causing death or serious injury Do not adjust the relief valve pressures higher than specifications 10 Install the relief valve cap 11 Repeat steps 5 through 7 to confirm the relief valve pressure GS 32 and GS 46 a b 0 0 test port system relief valve steer relief valve lift relief valve Section 4 Repair Procedures
128. February 2009 MANIFOLDS REV F How to Adjust the 7 Move and hold the joystick fully in either direction while observing the pressure reading Platform Lift Relief Valve on the pressure gauge Note the pressure Perform this test from the ground with the platform Refer to Section 2 Specifications controls Do not stand in the platform 8 Turn the machine off Hold the system relief valve with a wrench and remove the cap Be sure that the hydraulic oil level is at the FULL hydraulic schematic item or AB mark on the hydraulic tank 9 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure 1 Locate the system relief valve on the function manifold item 2 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the test port on the function manifold schematic item A or AA DANGE 1 Tip over hazard Failure to adjust Eoo the relief valves to specification could result in the machine tipping 3 Chock both sides of the wheels at the steer end over causing death or serious of the machine injury Do not adjust the relief valve pressures higher than 4 Remove the platform controls from the platform specifications 5 Turn the key switch to platform control and pull 10 Install the relief valve cap out the red Emergency Stop button to the on position at both the ground and platform 11 Repeat steps 4 through 7 to confirm the relief controls valve pres
129. GS 1930 Place 8 0 64 6 6 inch 16 2 mm 15 cm 15 cm thick steel block under both wheels at the ground controls side of the machine GS 1532 GS 1932 Place a 0 68 x 6 6 inch 17 2 mm 15 cm x 15 cm thick steel block under both wheels at the ground controls side of the machine GS 2032 GS 2632 and GS 3232 Place a 0 66 x 6 x 6 inch 16 8 mm x 15 cm x 15 cm thick steel block under both wheels at the REVD 25 Lower the platform to the stowed position 26 Raise the machine approximately 2 inches 5 cm 27 Remove the blocks from under both wheels 28 Lower the machine and remove the jack 29 Center a lifting jack under the drive chassis at the battery pack side of the machine 30 Raise the machine approximately 2 inches 5 cm ground controls side of the machine 31 GS 1530 and GS 1930 Place a 0 77 6 6 GS 2046 GS 2646 and GS 3246 Place a 1 x 6 en dos um x 6 inch 25 4 mm x 15 cm x 15 cm thick steel block under both wheels at the battery pack block under both wheels at the ground controls side of the machine side of the machine GS 1532 and GS 1932 Place a 0 83 x 6x 6 23 Lower the machine onto the blocks inch 21 1 mm x 15 cm x 15 cm thick steel block under both wheels at the battery pack 24 Raise the platform 7 to 8 feet 2 1 to 2 4 m side of the machine O Result The level sensor alarm should not GS 2032 GS 2632 and GS 3232 Place a sound 0 8 x 6 x 6
130. IN THE STOWED 1 1 wH GROUND POSITION WITH THE POWER OFF NI 2 2 BL DATA LINK HIGH H 5 5 OR DATA LINK LOW GS 30 GS 32 GS 46 Section 6 Schematics April 2008 Electrical Schematic CE Models REVE GS 2032 2632 from serial number GS3205 75407 to GS3205 77290 GS 2046 2646 3246 from serial number GS4605 75438 to GS4605 76734 P1 x EMERGENCY ae STOP 4 eH B 5 2 4 KS1 E key PLATFORM 1 SWITCH CONTROL Bi 4 5 5 ALARM MACHINE SHOWN IN THE AE STOWED POSITION WITH A NCHO THE POWER OFF CONTROL 7 LS7 TS66 POTHOLE GUARD PLATFORM SWITCH UP DOWN N C H O CB2 c 9 7A m CIRCUIT gt BREAKER 4 LS8 U27 P GUARD 47 mH INDUCTOR NOISE SUPPRESSION 558 8 gt 2 J A 2227 P o BLACK AND WHITE WIRES CUT POWER f z 9 E TO MOTOR CONTROLLER WHEN THE Ses L30 g 5 CHARGER IS PLUGGED IN OPTION Y 2 NA OPTION QD1 9 LATAN F6 275 FUSE 2 2 2 BK lll
131. POUT3 ie HIGH TORQUE LED 1 G8 POUT4 DIAGNOSTIC DISPLAY PIN1 HIGH TORQUE BN6 PIN2 HORN BN5 PIN3 DRIVE ENABLE BN8 5 LIFT ENABLE BN9 fui PLATFORM CONTROLLER POUT11 ES0142T Genie Part No 97385 GS 30 GS 32 GS 46 6 109 Section 6 Schematics February 2012 Electrical Schematic CE Models CE Models REV A GS 2032 2632 3232 from serial number GS3211A 97904 to GS3212A 109999 and GS3212C 1387 to GS3212C 9999 GS 2046 2646 3246 from serial number GS4611A 97983 to GS4612A 109999 and GS4612C 1386 to GS4612C 9999 ROGERUS MEETUPS NE 181 1 1 E i P1 52 T 74 pU a EMERGENCY N 9 Ne WH B oe CB2 um 2 8 CIRCUIT 1 BREAKER 4 PLATFORM SWITCH CONTROL H5 4 ALARM 1 1 1 3
132. POWER PLATFORM p 3 3 RD POWER TO GROUND 1 1 eroun f iopo 2 2 BL DATALINK HIGH I 5 5 OR DATA LINK LOW U3 PLATFORM CONTROLS VOLTAGE PRINTED CIRCUIT BOARD REGULATOR p 1 ar 0 GN 5 WH 0 BL SW5 E pp FUNCTION ENABLE T STEER 5 T 7 LEFT RIGHT PIN9 C oR 5 pns o 4 0 8 PLATFORM CONTROLS MEMBRANE DECAL POUT1 0 gt LIFT LED 116 POUT2 6 d A DRIVE LED L17 POUTS lt 4 HIGH TORQUE LED 121 G8 POUT4 DIAGNOSTIC 1 DISPLAY HIGH TORQUE 6 PIN2 HORN BN5 PINS DRIVE ENABLE BN8 PIN4 LIFT ENABLE BN9 POUTM Hi PLATFORM BK CONTROLLER ES0142G Genie GS 30 GS 32 GS 46 Part No 97385 April 2008 Section 6 Schematics m This page intentionally left blank Genie Part No 97385 GS 30 GS 32 6 6 61 Section 6 Schematics April 2008 Electrical Schematic CE Models REV D GS 1530 1532 1930 1 932 from serial number GS3005A 79395 to GS3006A 83067 GS 1530 1532 1930 1932 from serial number GS3005B 76921 to GS3006B 79659 P1 egi RS EMERGENCY Ex Pd STOP WH
133. Part No 97385 2007 Section 3 Scheduled Maintenance Procedures REV A 2 Perform Pre operation Inspection Completing a Pre operation Inspection is essential to safe machine operation The Pre operation Inspection is a visual inspection performed by the operator prior to each work shift The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The Pre operation Inspection also serves to determine if routine maintenance procedures are required Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine Part No 97385 Genie GS 30 GS 32 GS 46 CHECKLIST A PROCEDURES A 3 Perform Function Tests Completing the function tests is essential to safe machine operation Function tests are designed to discover any malfunctions before the machine is put into service A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from service Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine Section 3 Scheduled Maintenance Procedures March 2007 CHECKLIST A PROCEDURES A 4 Perform 30 Day Service The 30 day maintenance procedure is a one time procedure to be performed after the f
134. Power Device set to 8 29666 at 14 3 32768 FLASH bytes Device Family set to 29x66 at 1 Active HEX file set to C Docum Successful port connection for Open MiniProgrammer at 14 31 19 MINI Version 1 71 Device set to CY8C20234 12LKX a Device Family set to 20x34 at 1 Green Backgrounds For Help press F1 Not Powered Pass Idle Connected 2 Genie Part No 97385 GS 30 GS 32 GS 46 4 27 Section 4 Repair Procedures October 2009 PLATFORM CONTROLS 25 Click the Toggle Device Power button Result A portion of the lower right hand corner in the PSoC Programmer window should now be red and show as being Powered Result The red light labeled Target Power on the MiniProg cable should be on REV J 26 Click the Program button to update the firmware of either the ECM or the control pad Result The main PSoC Programmer window will indicate a successful program C Documents and Settings EllisT My Documents Projects 3232 Outriggers PSoC in progress Jeg Programming Utilities View Help Checksum Port MINIProg1 048E47470618 Programming Mode Reset Connect C PowerCycle Actions Device set to CY8C29666 at 14 3 Device Family set to 29x66 at 1 Active HEX file set to C Docun Successful port connection for Open MiniProgrammer at 14 31 19 Device set to CY8C20234 12LKX a Device Family set to 20x34 at 1
135. Refer to Section 2 Specifications for capacity information AWARNING td 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 7 Clean up any oil that may have spilled Properly discard the used oil 8 Clean the inside of the hydraulic tank using a mild solvent Allow the tank to dry completely 9 Install the hydraulic tank and install and tighten the hydraulic tank retaining fasteners Torque to AWARNING Electrocution burn hazard Contact specification with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 2 Open the power unit module tray Torque specifications Hydraulic tank retaining fasteners dry 35 4 Nm Hydraulic tank retaining fasteners lubricated 26 in Ibs 2 9 Nm 3 36 GS 30 GS 32 GS 46 Part No 97385 April 2008 Section 3 Scheduled Maintenance Procedures SS Ss REV CHECKLIST E PROCEDURE 10 Install the hydraulic pump inlet hard line into the tank Install the fitting onto the pump and torque to specification Refer to Section 2 Specifications 11 Install the hydraulic pump return hard line into the tank Install the fitting onto the hydraulic filter head and torque to specification Refer to Section 2 Specifications 12 Fill the tank with hydraulic oil
136. a trained service professional Attempting this procedure without the necessary skills will result in death or serious injury Note Select a test area that is firm level and free of obstructions How to Determine the Software Revision Level 1 Remove the platform controls from the platform 2 Place the platform controls close to the diagnostic display on the power unit side of the machine Genie 4 4 GS 30 GS 32 GS 46 REV J 3 Turn key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 296 CI joystick controller JC1 lift function select button BN9 red Emergency Stop button P2 yellow arrow ao oo 4 Press the lift function select button 5 Slowly move the joystick in the direction indicated by the yellow arrow Result The software revision level will appear in the diagnostic display 6 Pushin the red Emergency Stop button to the off position at both the ground and platform controls and turn the key switch to the off position Part No 97385 October 2009 Section 4 Repair Procedures REV J How to Adjust the Lift Speed PATT 173 Tip over hazard Do not adjust the lift and or drive speed higher than specified in this procedure Setting the function speeds greater than specifications could cause the machine to tip over r
137. arm at the battery pack side index 11 from the machine AWARNING Crushing hazard The number 3 outer arm may become unbalanced and fall if not properly supported when removed from the machine Models with a single number 3 outer arm assembly 13 Attach a lifting strap from an overhead crane to the number 3 outer arm index 11 14 Remove the external snap rings and retaining fasteners from the number 3 center pivot pins index 2 15 Use a soft metal drift to remove the number 3 center pivot pins index 2 16 Remove the retaining fasteners from the number 3 pivot pin index 12 at the non steer end of the machine 17 Use a soft metal drift to remove the number 3 pivot pin index 12 from the non steer end of the machine Remove the number 3 outer arm index 11 from the machine AWARNING Crushing hazard The number 3 outer arm may become unbalanced and fall if not properly supported when removed from the machine All models 18 Remove the number 3 cable bridge mounting fasteners and remove the cable bridge from the machine 19 Attach a lifting strap from an overhead crane to the lug on the rod end of the lift cylinder for support Do not apply any lifting pressure 4 38 Genie GS 30 GS 32 GS 46 REV 20 Remove the pin retaining fasteners from the lift cylinder rod end pivot pin index 3 Use a soft metal drift to remove the pin ACAUTION Bodily injury hazard The cylinder may
138. at both the ground and platform Activating buttons on the outrigger control pad controls sends a signal to the outrigger Electronic Control Module ECM When the outrigger ECM receives Remove the fasteners securing the outrigger control pad to the outrigger control pad bracket a signal it enables the outrigger control pad to Set the fasteners to the side extend retract or autolevel the outriggers When calibrating the outrigger ECM and the outrigger 3 Carefully remove the top half of the control pad level sensor the outrigger control pad buttons are and set to the side used in a specific sequence to achieve calibration 4 Locate the circuit board mounted to the bottom The outrigger control pad consist of an electronic half of the outrigger control pad circuit board membrane decal buttons and LEDs au AWARNING Flectrocution burn hazard Contac For further information or assistance consult the with electrically charged circuits Genie Service Department could result in death or serious injury Remove all rings watches and other jewelry use O hazard CONTROL Electrostatic discharge ESD can O damage printed circuit board components Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap 5
139. at the non steer end of the machine 31 Use a soft metal drift to tap the number 2 pivot pin index 15 halfway out at the non steer end of the machine Remove the number 2 outer arm index 14 from the ground controls side of the machine Bodily injury hazard The number ACAUTION 2 outer arm at the ground controls side may become unbalanced and fall if not properly supported when removed from the machine 32 Attach a lifting strap from an overhead crane to the number 2 outer arm index 14 at the battery pack side 33 Remove the external snap rings and retaining fasteners from the number 2 center pivot pin index 5 at the battery pack side 34 Use a soft metal drift to remove the number 2 center pivot pin index 5 at the battery pack side Bodily injury hazard The number ACAUTION 2 outer arm at the battery pack side may become unbalanced and fall if not properly supported when removed from the machine 35 Use a soft metal drift to tap the number 2 pivot pin index 15 in the other direction at the non steer end Remove the number 2 outer arm index 14 from the battery pack side of the machine Bodily injury hazard The number ACAUTION 2 outer arm at the battery pack side may become unbalanced and fall if not properly supported when removed from the machine 36 Attach a lifting strap from an overhead crane to the number 2 inner arm index 13 37 Remove the retaining fasteners from the number 2 pivot
140. battery side Genie GS 30 GS 32 GS 46 REV 15 Place a rod through the number 4 center pivot pin at the battery side index 2 and twist to remove the pin 16 Remove the number 4 outer arm index 13 from the machine Crushing hazard The number 4 ACAUTION outer arm index 13 may become unbalanced and fall if not properly supported when removed from the machine 17 Attach a lifting strap from an overhead crane to the number 4 inner arm index 12 Raise the arm to a vertical position 18 Remove the retaining fasteners from the number 4 pivot pin at the steer end of the machine index 3 19 Use a soft metal drift to remove the number 4 pivot pin index 3 from the steer end of the machine Remove the number 4 inner arm index 12 from the machine Crushing hazard The number 4 ACAUTION inner arm index 12 may become unbalanced and fall if not properly supported when removed from the machine 20 Remove the cables from the number 3A and 3B cable bridge and lay them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched 21 Disconnect the number 3A and 3B cable bridges from the scissor linkset and remove both cable bridges from the machine Part No 97385 2007 Section 4 Repair Procedures REV 22 Attach a lifting strap from an overhead crane to the number 3 outer arm at the ground control side index 16 23 Remove the ret
141. en E MC THROTTLE 5 989 c ca ME gt in 9 5 iiiI E p MC ENABLE gt 86 8 2 8 sr OR WH 45 i pm If 7 MC ENABLE 85 gt nies a 2 1 r KEYSWITCH Lon 55 Q 1 1 E 1 5 8 RD WH RIVE ENABLE 8 5 o 5 pO pen BK 18 B 1 N oz xz lt ONG amp lt lt I a x 84 7 EO IOa o 093 0023 lez i o o 1 23 5 gt r RD BK 5 m ei S own uM E SEP T oorom JS z 5 uo PT 1 p 1 lt 5 4 L gt 5a o 34 REGEN COIL ON 3232 x eae Ry Vee ge D QU NOE CO OE BK gt NM cm ct 24V MAIN 77 2 BK lt lt lt gt zal GND 1 4 OR E 5 1 1 2 1 1 OR BK 2 22 2 0 4 2 DOE o 1 22226 DOES 07 RD BK zd E
142. end of the machine Remove the number 4 inner arm index 19 from the machine Crushing hazard The number 4 ACAUTION inner arm index 19 may become unbalanced and fall if not properly supported when removed from the machine 40 Remove the cables from the number 3A and 3B cable bridges and lay them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched 41 Disconnect the number 3A and 3B cable bridges from the scissor linkset and remove both cable bridges from the machine 42 Attach a lifting strap from an overhead crane to the number 3 outer arm at the ground control side index 7 43 Remove the retaining fasteners from the number 3 center pivot pin index 8 at the ground control side 44 Place a rod through the number 3 center pivot pin at the ground control side index 8 and twist to remove the pin 45 Remove the retaining fasteners from the number 3 pivot pin index 24 at the non steer end 4 67 Section 4 Repair Procedures March 2007 SCISSOR COMPONENTS 46 Use a soft metal drift to remove the number 3 pivot pin index 24 from the non steer end of the machine Remove the number 3 outer arm at the ground control side index 7 from the machine Crushing hazard The number 3 ACAUTION outer arm at the ground control side index 7 may become unbalanced and fall if not properly supported when removed from the machine 47 Attach a lifting strap f
143. fault pressure transducer times Right front Right front Ground short OR wire Inspect wire connection outrigger light outrigger pressure disconnected from blinks red 3 transducer fault pressure transducer times Right rear Right rear Ground short OR wire Inspect wire connection outrigger light outrigger pressure disconnected from blinks red 3 transducer fault pressure transducer times Left rear Left rear outrigger Ground short OR wire Inspect wire connection outrigger light pressure disconnected from blinks red 3 transducer fault pressure transducer times Left front Left front outrigger Short to power Troubleshoot the harness to outrigger light pressure the pressure transducer OR blinks red 4 transducer fault replace the harness times Right front Right front Short to power Troubleshoot the harness to outrigger light outrigger pressure the pressure transducer OR blinks red 4 transducer fault replace the harness times Outrigger fault code chart continued on next page Part No 97385 Genie GS 30 GS 32 GS 46 Section 5 Fault Codes November 2007 OUTRIGGER FAULT CODES cont REV B Outrigger lights blink red alternating left to right Outrigger level sensor fault Fault Code Problem Possible Causes Solution Right rear outrigger light Right rear Short to power Troubleshoot the blinks red 4 times outrigger harness to the pressure pressure transducer t
144. from serial number GS4610A 95455 to GS4611A 97982 Electrical Schematic ANSI CSA and Australia Models Section 6 Schematics 8 GROUND BN 256 ROLL H DERE 5 E o 8 PITCH BL 4 E POWER WH 4 d EE id i ul 1 et 8 8 a eer gt ae lt 4 ot 8 8 poene DATA Ever 4 Qt 5 5 5 DATA LOW z 3 olx pee hee DL NEUE ee m bog 1 AT it POWER TO 1780 08 55 BLWH T lt aile re BEN o5 is 5 z pe GROUND TO PLAT i 8L X8 NE 8 E 065 oa 359 MC THROTTLE m uj 8g gt 2 5 gt 5 pe MC ENABLE gt 86 8 lt
145. gradually Do not allow oil to squirt or spray 2 Connect 8 1 5000 psi 0 to 350 bar pressure gauge to the high pressure port on the pump 3 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls Genie GS 30 GS 32 GS 46 REV B 4 Activate the platform up function from the ground controls Result If the pressure gauge reads 3200 psi 221 bar immediately stop The pump is good Result If pressure fails to reach 3200 psi 221 bar the pump is bad and will need to be serviced or replaced Component damage hazard There is no relief valve in the hydraulic pump and the pump can be damaged if the pressure is allowed to exceed 3200 psi 221 bar When testing the pump activate the pump in one second intervals until 3200 psi 221 bar is confirmed Do not over pressurize the pump 5 Remove the pressure gauge and reconnect the hydraulic hose Torque to specification AWARNING indi 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 Part No 97385 April 2008 Section 4 Repair Procedures REV B 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 specificatio
146. i key PLATFORM SWITCH CONTROL l B1 4 E H5 ALARM 43 d S N CH O 1 GROUND 7 a CONTROL 2 7 dT LS7 POTHOLE TS66 GUARD te Ee ee PLATFORM SWITCH UP DOWN I CB2 E N C H O 7A 2 MACHINE SHOWN IN THE circuit 5 158 STOWED POSITION WITH 7 T POTHOLE 027 GUARD THE POWER OFF 47 mH INDUCTOR NOISE SUPPRESSION SWITCH gt E I m c 0 B 8 3 E 1 5 525 a ol o o d m BLACK AND WHITE WIRES CUT POWER 59 MOTOR CONTROLLER WHEN THE 0 g CHARGER IS PLUGGED IN OPTION C WORK LIGHT 2 2 OPTION 5 QD1 9 H S 8 ETE Nes F6 275 FUSE BK rp a a uc WH 8 ae ns AM m ae GS 3232 ONLY 524 Nou 2 BK 4 As OUT NOT CONNECTED U9 Ed meme ep ONGSG232 BATTERY WH A1 OUT CHARGER U5 ELECTRONIC CONTROL MODULE OUT OUT B8 B3 B5 M M i BATERY AC INPUT EE C j 9 2 MOTOR ITA CONTROLLER 21 B 104 34 1 Bed CONNECTED MOTOR b on CONTROLLER itl f CUT OFF POWER 39 H2 86 po U13 LORTION FB i DC AC INVERTER
147. if not properly supported when removed from the machine Component damage hazard Be sure not to damage the limit switch or level sensor box components when the number 1 inner arm is removed from the machine Part No 97385 2007 REV How to Replace the Scissor Arm Wear Pads 1 Remove the platform See 2 1 How to Remove the Platform Support and secure the entry ladder to an appropriate lifting device Remove the fasteners from the entry ladder and remove the entry ladder from the machine ACAUTION Crushing hazard The entry ladder may become unbalanced and fall if not properly supported and secured to the lifting device Secure the ends of the scissor arms together at the steer end of the machine with a strap or other suitable device Secure the ends of the scissor arms together at the non steer end of the machine with a strap or other suitable device Remove the retaining fasteners securing the chassis mount bracket to the chassis at the steer end of the machine Attach a lifting strap from an overhead crane to the scissor arm assembly Raise the scissor arm assembly at the steer end with the overhead crane until the chassis mount bracket will clear the level sensor Part No 97385 Genie GS 30 GS 32 GS 46 4 41 Section 4 Repair Procedures SCISSOR COMPONENTS 9 Remove the scissor assembly from the machine just enough to access both wear pads Crushing
148. inch 20 8 mm x 15 cm x 15 cm Result The level sensor alarm does sound and athe fault code LL appears in the diagnostic display Adjust the level sensor retaining fasteners just GS 2046 GS 2646 and GS 3246 Place a until the level sensor alarm does not sound 1 22 x 6 x 6 inch 31 mm x 15 cm x 15 cm thick steel block under both wheels at the battery pack side of the machine Genie 4 82 GS 30 GS 32 GS 46 Part No 97385 March 2007 Section 4 Repair Procedures er REV D GROUND CONTROLS 32 Lower the machine onto the blocks 33 Raise the platform 7 to 8 feet 2 1 to 2 4 m Result The platform should stop an alarm should sound and fault code LL appears in the diagnostic display Result The platform does not stop or the level sensor alarm does not sound Adjust the level sensor until the alarm just begins to sound OR the down limit switch may need to be adjusted 34 Lift the safety arm move it to the center of the scissor arm and rotate down to a vertical position 35 Lower the scissor arms onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 36 Raise the platform 7 to 8 feet 2 1 to 2 4 m 37 Return the safety arm to the stowed position 38 Lower the platform to the stowed position 39 Raise the machine approximately 2 inches 5 cm 40 Remove the blocks from under both wheels 41 Lower the machine and remove the
149. index 25 Raise the arm to a vertical position 74 Remove the retaining fasteners from the number 2 pivot pin at the steer end of the machine index 12 75 Use a soft metal drift to remove the number 2 pivot pin index 12 from the steer end of the machine Remove the number 2 inner arm index 25 from the machine Crushing hazard The number 2 ACAUTION inner arm index 25 may become unbalanced and fall if not properly supported when the pivot pin is removed 76 Attach a lifting strap from an overhead crane to the number 1 inner arm index 14 77 Raise the number 1 inner arm index 14 approximately 2 feet 60 cm 78 Place 4 4 48 inch 10 cm 10 cm 1 2 m long block across both sides of the chassis under the number 1 center pivot pin index 13 79 Lower the scissor arms onto the block that was placed across the chassis Bodily injury hazard Keep hands ACAUTION clear of moving parts when lowering the scissor arms 80 Attach a lifting strap from an overhead crane to the lug of the rod end of the lower lift cylinder Section 4 Repair Procedures March 2007 SCISSOR COMPONENTS 81 Tag disconnect and plug the hydraulic hose on the lower lift cylinder Cap the fittings on the cylinder AWARNING 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 t
150. it 3 5g e p o o9 Vi 5 gt 2T 558 gt lt 1 1 as Orri i x 9 iG 8 8 Ne 29 7 O 5 i S ou 8 WH BK 1 621 OVERLOAD POWER LO 8 lt S228 1 5 e DWN LIMIT 2 1 58 BE 20 BEE E GP x 1 o 1 d 4675 gt 1 E E 1 TEAM 2 91 gt mes GS 3232 ONLY UP LIMIT SWITCH 52 541 ee 1 EAE PEIE o re 2999 ONLY _______ 4 loz UP LIMIT SWITCH GS 3232 ONLY 12 1 55 RD BK E b c 54 EE DRIVER POWER 2 SHS MEME ES i Ub 1 de 00 4 POTHOLE LIMIT SWITCH RD 2 BEEN o odd od mak 20 Make E q 5 2 o 5835 9 igs 829 2 lt gt 5 NE M Iz E lt ALARM 25 88 MEME Part No 97385 REVA February 2012 GS 2032 2632 3232 from serial number GS3210A 94975 to GS3211A 97903 GS 2046 2646 3246
151. lifting strap from an overhead crane to the number 2 outer arm at the ground control side index 14 28 Remove the retaining fasteners from the number 2 center pivot pin index 5 at the ground control side 29 Place a rod through the number 2 center pivot pin at the ground control side index 5 and twist to remove the pin Part No 97385 2007 Section 4 Repair Procedures REV 30 Remove the retaining fasteners from the number 2 pivot pin index 15 at the non steer end 31 Use a soft metal drift to remove the number 2 pivot pin index 15 from the non steer end of the machine Remove the number 2 outer arm at the ground control side index 14 from the machine Crushing hazard The number 2 ACAUTION outer arm at the ground control side index 14 may become unbalanced and fall if not properly supported when the pivot pin is removed 32 Attach a lifting strap from an overhead crane to the number 2 outer arm at the battery side index 14 33 Remove the retaining fasteners from the number 2 center pivot pin index 5 at the battery side 34 Place a rod through the number 2 center pivot pin at the battery side index 5 and twist to remove the pin Crushing hazard The number 2 ACAUTION outer arm index 14 may become unbalanced and fall if not properly supported when the pivot pin is removed 35 Remove the number 2 outer arm index 14 from the machine Crushing hazard T
152. m This page intentionally left blank Genie Part No 97385 GS 30 GS 32 6 6 33 Section 6 Schematics po gt gt Electrical Schematic ANSI CSA and Australia Models TO MOTOR CONTROLLER WHEN THE CHARGER IS PLUGGED IN OPTION April 2008 REV GS 2032 2632 from serial number GS3206 79992 to GS3207 83650 GS 2046 2646 3246 from serial number GS4606 78916 to GS4607 82535 1 2d EMERGENCY CN 7 li e H e on 2 KS1 key PLATFORM SWITCH CONTROL 4 1 NOTE x H5 MACHINE SHOWN IN THE x 7 STOWED POSITION WITH E 4 THE POWER OFF ONTROL 7 21 7707 157 1566 POTHOLE PLATFORM SWITCH 4 UP DOWN N C HO S 3 0 BREAKER 2 LS8 POTHOLE GUARD SWITCH 2227 P BLACK AND WHITE WIRES CUT POWER 2 89 E 130 S 5 5 g QD1 0 A OPTION 3 fe ete F6 275 FUSE 8 a eo U9 2K 48 our j
153. on before any function can be resumed Required for CE models Descent Delay This option halts descent for 4 to 6 seconds All controls must be released and re engaged before descent is re enabled Required for CE models Battery Drain Alarm When the machine is turned on and in the stowed position and no function is activated for 2 minutes an alarm will sound once every 3 seconds When this option is configured a dot in the diagnostic display window will remain continuously illuminated when the ECM is in the SC mode OR when the platform up function is activated Part No 97385 GS 30 GS 32 GS 46 4 9 Section 4 Repair Procedures October 2009 PLATFORM CONTROLS REV J How to Change the Software Configuration t 1 Pull out the red Emergency Stop button to the position at the ground controls b mas 2 Pushin the red Emergency Stop button to the off position at the platform controls 3 Turn the key switch to platform control 4 Atthe platform controls press and hold the lift function select and speed select buttons and pull out the red Emergency Stop button to the on position w joystick controller JC1 with thumb steering rocker SW6 lift function select button BN9 diagnostic display red Emergency Stop button P2 drive function select button BN8 speed select button BN6 Result The diagnostic display at the platform controls and th
154. operating the machine Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a firm level surface Platform in the stowed position Key switch in the off position with the key removed The red Emergency Stop button in the off position at both ground and platform controls Wheels chocked All external AC power supply disconnected from the machine Part No 97385 or replacing any hydraulic component always support the structure and secure it from movement AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray GS 30 GS 32 6 5 1 Section 5 Fault Codes February 2012 FAULT CODES About This Section When a malfunction is discovered the fault code charts in this section will help a service professional pinpoint the cause of the problem To use this section basic hand tools and certain pieces of test equipment are required voltmeter ohmmeter pressure gauges General Repair Process Malfunction Identify tt Troubleshoot discovered symptoms prob
155. pack side index 13 from the machine AWARNING Crushing hazard The number 4 outer arm may become unbalanced and fall if not properly supported when removed from the machine Models with a single number 4 outer arm assembly 13 Attach a lifting strap from an overhead crane to the number 4 outer arm index 13 14 Remove the external snap rings and retaining fasteners from the number 4 center pivot pins index 2 15 Use a soft metal drift to remove the number 4 center pivot pins index 2 Genie GS 30 GS 32 GS 46 REV 16 Remove the retaining fasteners from the number 4 pivot pin index 14 at the non steer end of the machine 17 Use a soft metal drift to remove the number 4 pivot pin index 14 from the non steer end of the machine Remove the number 4 outer arm index 13 from the machine AWARNING Crushing hazard The number 4 outer arm may become unbalanced and fall if not properly supported when removed from the machine All models 18 Remove the number 4 cable bridge mounting fasteners and remove the cable bridge from the machine 19 Attach a lifting strap from an overhead crane to the number 4 inner arm index 12 20 Remove the retaining fasteners from the number 4 pivot pin index 3 21 Use a soft metal drift to remove the number 4 pivot pin index 3 at the steer end Remove the number 4 inner arm index 12 from the machine Crushing hazard The number 4 ACAUTION inne
156. pin index 6 at the steer end of the machine Part No 97385 Genie GS 30 GS 32 GS 46 SCISSOR COMPONENTS 38 Use a soft metal drift to remove the number 2 pivot pin index 6 Remove the number 2 inner arm index 13 from the machine Bodily injury hazard The number ACAUTION 2 inner arm may become unbalanced and fall if not properly supported when removed from the machine 39 Remove the safety arm from the number 2 inner arm index 13 that was just removed 40 Attach a lifting strap from an overhead crane to the number 1 inner arm index 8 41 Raise the number 1 inner arm index 8 approximately 2 feet 60 cm and install the safety arm between the number 1 inner arm index 8 and the number 1 outer arm index 17 Lower the scissor arms onto the safety arm Bodily injury hazard Keep hands ACAUTION clear of moving parts when lowering the scissor arms onto the safety arm 42 Attach a lifting strap from an overhead crane to the lug on the rod end of the lift cylinder index 3 Raise the lift cylinder approximately 3 ft 1m 43 Tag disconnect and plug the hydraulic hoses on the lift cylinder Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 44 Tag and disconnect the wires and manual lowering c
157. portion of the drive forward reverse valve This indicates the machine is equipped with a dynamic brake valve Proceed to step 23 Result SV10 5905 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 28 23 Install the drive forward reverse valve removed in step 21 into the function manifold and torque to 25 ft lbs 34 Nm 24 In order install the reverse valve coil with white black and brown wires spacer washer and the forward valve coil with white and brown wires onto the valve Note For the machine to function correctly the reverse valve coil must be closest to the manifold Genie GS 30 GS 32 GS 46 REV K 25 Install the coil nut onto the valve and torque to 60 in Ibs 7 Nm 26 Connect the battery pack to the machine 27 Replace the brakes and repeat this procedure beginning with step 1 Refer to Repair Procedure 9 1 How to Remove a Drive Brake Repeat this procedure beginning with step 1 28 Contact the Genie Service Parts Department and order kit part number 105458 29 Install the new valve received in the kit and mark the new valve with a white paint pen to identify new valve installation 30 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 Service Department 1 800 536 18
158. ring is met then torque to specification 3 Ifrequired install the valve coil s onto the valve stem Install the coil nut onto the valve stem and torque to specification Genie REV F Torque 4 5 ft lbs 5 7 Nm 5 7 ft lbs 7 9 Nm 18 ft lbs 24 Nm 20 ft lbs 27 Nm 20 ft lbs 27 Nm 25 ft lbs 34 Nm 25 ft lbs 34 Nm 26 ft lbs 35 Nm 25 ft lbs 34 Nm 20 ft lbs 27 Nm 4 88 GS 30 GS 32 95 46 Part 97385 February 2009 Section 4 Repair Procedures REV F MANIFOLDS o e Before serial number GS3005A 76492 drive reverse coil Y5 Before serial number GS3005B 76085 drive reverse coil Y5 After serial number GS3005A 76491 drive forward coil Y6 After serial number GS3005B 76084 drive forward coil Y6 Note alpha callouts refer to corresponding notes on the hydraulic schematic Before serial number GS3005A 76492 drive forward coil Y6 Before serial number GS3005B 76085 drive forward coil Y6 After serial number GS3005A 76491 drive reverse coil Y5 After serial number GS3005B 76084 drive reverse coil Y5 Note alpha numeric callouts refer to corresponding notes on the electrical schematic Genie Part No 97385 GS 30 GS 32 GS 46 4 89 Section 4 Repair Procedures February 2009 MANIFOLDS 6 2 Function Manifold Components GS 203
159. setting Troubleshoot coil OR inspect wire connection Troubleshoot coil OR inspect wire connection Troubleshoot coil OR inspect wire connection Troubleshoot coil OR inspect wire connection Steer right coil fault Malfunctioning coil OR wire disconnected from coil Troubleshoot coil OR inspect wire connection Steer left coil fault Malfunctioning coil OR wire disconnected from coil Troubleshoot coil OR inspect wire connection Brake coil fault Malfunctioning coil OR wire disconnected from coil Troubleshoot coil OR inspect wire connection Series parallel coil fault DIP switch settings are incorrect Troubleshoot and correct DIP switch settings LL Low battery voltage Off level fault Batteries discharged Tilt of chassis exceeds level sensor setting Charge batteries Reduce chassis angle OL Overload cutout fault Too much weight in platform Remove weight Part No 97385 Genie GS 30 GS 32 GS 46 Section 5 Fault Codes November 2007 Ml FAULT CODES REV B Outrigger Control Pad The outrigger control pad displays solid red or blinking red lights as well as a audible alarm that provide information about the outrigger operating status and about malfunctions The codes listed in the Outrigger Fault Code Chart describe malfunctions and can aid in troubleshooting the machine by pinpointing the area
160. spray Drive motor mounting fasteners dry 75 ft lbs Component damage hazard 101 7 Nm Hoses can be damaged if they are kinked or pinched Drive motor mounting fasteners lubricated 56 ft lbs 76 3 Nm Genie Part No 97385 GS 30 GS 32 GS 46 4 103 Section 4 Repair Procedures November 2008 STEER AXLE COMPONENTS 8 3 Steer Bellcrank How to Remove the Steer Bellcrank 1 Remove the steer cylinder See 8 2 How to Remove the Steer Cylinder 2 Remove the retaining fasteners from the steer links at each end of the bellcrank Note While removing the retaining fasteners take note of the quantity and location of the spacers between the bellcrank and the steer links 3 Center a lifting jack under the drive chassis at the steer end 4 Raise the machine approximately 14 inches 36 cm Place blocks under the chassis for support AWARNING Crushing hazard The chassis could fall if not properly supported 5 Turn the yokes to the side so the bellcrank can be removed 4 104 Genie GS 30 GS 32 GS 46 REV B 6 Remove the bellcrank from the machine Note While removing the bellcrank from the machine take note of the quantity and location of the spacers between the bellcrank and the steer links Note Before re installing the steer bellcrank onto the machine apply a small amount of Loctite onto the threads of the fasteners Torque the fasteners to 31 ft lbs 42 Nm Apply Loctite
161. the Device drop down menu select CY8C29666 if the outrigger ECM firmware is being updated OR select CY8C29466 if the outrigger control pad firmware is being updated V C Documents and Settings EllisT My Documents Projects 3232 Outriggers PSoC in progress 3 Programming Utilities View Help GF Fie Load Progam 2 Checksum Port Device Family C Device gt 1 048E 47470618 gt Connect 29 66 CY8C29466 Programming Mode jg Reset Powe Detect LYSL29bbb CY8C29556 24LFXI Actions Resuts CYBC29866 Device Family set to 29x66 at 1 Active HEX file set to C Docun Successful port connection for Open MiniProgrammer at 14 31 19 MINI Version 1 71 Device set to CY8C20234 12LKX a Device Family set to 20x34 at 1 All Green Backgrounds 2 For Help press F1 Not Powered Pass Idle Connected Genie 4 26 GS 30 GS 32 6 Part No 97385 October 2009 Section 4 Repair Procedures REV J PLATFORM CONTROLS 24 At Programming Mode select the Reset bullet C Documents and Settings VEllisTWMy Documents Projects 3232 Outriggers PSoC in progress Programming Utilities View File Load Program 2 Port Device Family Device 1 048 47470518 29 66 CY8C29666 E Dete Toggle Device
162. the umber 30086 101 machine configuration code in the left column A mark in the four right columns indicates the includes this feature machine configuration code in the left column 65 1530 65 1532 GS 1930 65 1932 includes this feature ECMs with software revisins to A4 GS 1530 GS 1532 GS 1930 2 ECMs with software revisions A5 and higher Machine Function Code at Diagnostic Display Machine Function Code at Diagnostic Display Motion Lift Drive Platform Descent Alarm Cut Out Overload Motion Lift Drive Platform Descent Genie Part No 97385 GS 30 GS 32 GS 46 4 11 Section 4 Repair Procedures October 2009 PLATFORM CONTROLS REV J Machine Configuration Code Chart Machine Configuration Code Chart before serial numbers after serial numbers GS3207 85152 GS3207 85153 and GS4607 84772 and GS4607 84771 ndi TT from serial numbers GS3208C 101 and mark in the four right columns indicates that the GS4609C 101 machine configuration code in the left column includes this feature A mark in the four right columns indicates that the GS 2032 2 machine configuration code in the left column GS 2046 GS 2646 GS 3246 includes this feature ECMs with software revisins to A4 GS 2032 GS 2632 GS 3232 GS 2046 GS 2646 GS 3246 ECMs with software revisions A5 and higher Machine Function Code at Diagnostic Display
163. to be calibrated Refer to Repair Procedure 3 7 Calibrate the Platform Overload System if equipped Note To determine the software revision level refer to Repair Procedure 1 2 How to Determine the Revision Level 10 Lower the platform to the stowed position Part No 97385 2007 Section 3 Scheduled Maintenance Procedures 1 REV CHECKLIST PROCEDURES C 2 Replace the Hydraulic Tank Breather Cap Models with Optional Hydraulic Oil Genie requires that this procedure be performed every 500 hours or semi annually whichever comes first The hydraulic tank is a vented type tank The breather cap has an internal air filter that can become clogged or over time can deteriorate If the breather cap is faulty or improperly installed impurities can enter the hydraulic system which may cause component damage Extremely dirty conditions may require that the cap be inspected more often 1 Remove and discard the hydraulic tank breather cap 2 Install a new cap onto the tank Genie Part No 97385 GS 30 GS 32 GS 46 3 31 Section 3 Scheduled Maintenance Procedures June 2009 Checklist D Procedures D 1 Check the Scissor Arm Wear Pads Genie requires that this procedure be performed every 1000 hours or annually whichever comes first Maintaining the condition of the scissor arm wearpads is essential to safe machine operation Continued use of worn out wear pads may re
164. to the on position at the ground controls 3 Push in the red Emergency Stop button to the off position at the platform controls 4 Atthe platform controls press and hold the lift function select and speed select buttons and pull out the red Emergency Stop button to the on position Result The diagnostic display at the platform controls and the ECM will show SC PLATFORM CONTROLS 999 lift function select button BN9 diagnostic display red Emergency Stop button P2 speed select button BN6 ao oo Release the lift function select and speed select buttons Result The diagnostic display will show the current configuration Push in the red Emergency Stop button to the off position at both the ground and platform controls and turn the key switch to the off position Machine Option Feature Definitions Motion Alarm The motion alarm will sound when operating any function Lift Drive Cut Out In addition to an alarm sounding lift and drive functions are disabled when the platform is raised above the down limit switch and the incline of the chassis exceeds the rating on the serial plate Configured on all machines Platform Overload When the platform overload limit switch is tripped signaling an overload condition in the platform all machine functions are disabled The additional weight must be removed from the platform and the power cycled from off to
165. to the machine may only be made by a qualified service technician according to the manufacturer s specifications Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual Genie A TEREX BRAND Terex South Dakota Inc USA 500 Oak Wood Road PO Box 1150 Genie UK The Maltings Wharf Road Grantham Lincolnshire Watertown SD 57201 6150 NG31 6BH England 605 882 4000 44 3 Copyright 2011 Terex Corporation Genie is a registered trademark of Terex South Dakota Inc 133192 RevD Instructions Use the operator s manual on your machine The Pre delivery Preparation consists of completing the Pre operation Inspection the Maintenance items and the Function Tests Use this form to record the results Place a check in the appropriate box after each part is completed Follow the instructions in the operator s manual If any inspection receives an N remove the machine from service repair and reinspect it After repair place a check in the R box Legend Y yes completed N no unable to complete R repaired Comments Pre Delivery Preparation Y N R Pre operation inspection completed Maintenance items completed Function tests completed Model Serial number Date Machine owner Inspected by print Inspector signature Inspector title Inspector
166. types of maintenance inspections that must be performed according to a schedule daily quarterly semi annually annually and two year The Scheduled Maintenance Procedures Section and the Maintenance Inspection Report have been divided into five subsections A B C D and E Use the following chart to determine which group s of procedures are required to perform a scheduled inspection Inspection Checklist Daily or every 8 hours A Quarterly or every 250 hours A B Semi annually or every 500 hours A B C Annually or every 1000 hours A B C D Two year or every 2000 hours A B C D E Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection Make copies of the Maintenance Inspection Report to use for each inspection Maintain completed forms for a minimum of 4 years or in compliance with your employer jobsite and governmental regulations and requirements Part No 97385 Pre Delivery Preparation Fundamentals It is the responsibility of the dealer to perform the Pre delivery Preparation The Pre delivery Preparation is performed prior to each delivery The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service A damaged or modified machine must never be used If damage or any variation from factory delivered condition is discovered the machine must be tagged and removed from service Repairs
167. until the fluid is at the FULL indicator on the hydraulic tank Do not overfill 13 Activate the pump to fill the hydraulic system with oil and bleed the system of air Component damage hazard The pump can be damaged if operated without oil Be careful not to empty the hydraulic tank while in the process of filling the hydraulic system Do not allow the pump to cavitate 14 Repeat steps 12 through 13 until the hydraulic system and tank are both full Part No 97385 GS 30 GS 32 GS 46 3 37 Section 3 Scheduled Maintenance Procedures April 2008 This page intentionally left blank Genie 3 38 GS 30 GS 32 GS 46 Part No 97385 2007 Section 4 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 Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necessary tools and parts are available and ready for use Use only Genie approved replacement parts Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Unless otherwise specified
168. when your reference point on the machine passes over the finish line Refer to Section 2 Specifications Section 3 Scheduled Maintenance Procedures February 2012 CHECKLIST B PROCEDURES B 10 Test the Drive Speed Raised Position Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Proper drive functions are essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range Perform this procedure with the machine on a firm level surface that is 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 platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 3 Press the lift function select button REVK Press and hold the function enable switch on the joystick Raise the platform approximately 4 feet 1 2 m from the ground Press the drive function select button 7 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 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machi
169. yoke assembly to an appropriate lifting device 9 Remove the retaining fastener from the steer link at the yoke assembly Note While removing the retaining fasteners take note of the quantity and location of the spacers when disconnecting the steer link from the yoke assembly 10 Remove the retaining fastener from the top of the yoke pivot shaft Note The pivot shaft retaining fastener is located above the main deck 11 Lower the yoke assembly out of the chassis Bodily injury hazard The yoke ACAUTION motor assembly may fall if not properly supported when it is removed from the chassis Part No 97385 November 2008 Section 4 Repair Procedures REV B How to Remove a Drive Motor 1 Block the non steer wheels 2 Remove the cotter pin from the wheel castle nut of the motor to be removed Note 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 Center a lifting jack under the drive chassis at the steer end of the machine 5 Raise the machine approximately 2 inches 5 cm Place blocks under the chassis for support AWARNING Crushing hazard The chassis could fall if not properly supported 6 Remove the wheel castle nut Remove the wheel 7 Tag disconnect and plug the hydraulic hoses on the drive motor Cap the fittings on the drive motor AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn
170. 0 GS 1532 GS 2032 GS 2046 and GS 2646 30 Airborne noise emissions lt 70 dB Maximum sound level at normal operation workstations A weighted Genie GS 30 GS 32 6 REVG Function speed maximum from platform controls with 1 person in platform GS 1530 and GS 1532 15 to 17 seconds 16 to 18 seconds Platform up Platform down GS 1930 and GS 1932 15 to 17 seconds 22 to 24 seconds Platform up Platform down GS 2032 and GS 2046 28 to 32 seconds 26 to 30 seconds Platform up Platform down GS 2632 and GS 2646 28 to 32 seconds 22 to 26 seconds Platform up Platform down GS 3232 and GS 3246 55 to 59 seconds 38 to 42 seconds Platform up Platform down Rated work load at full height maximum GS 1530 and GS 1532 600 Ibs 272 kg GS 1930 GS 1932 GS 2632 and GS 3232 500 Ibs 227 kg GS 2032 800 Ibs 363 kg GS 2046 1200 5 544 kg GS 2646 1000 5 454 kg GS 3246 700 Ibs 317 kg GS 3232 Outrigger leveling capacity maximum Side to side 5 Front to rear 3 Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Part No 97385 February 2009 Section 2 Specifications REVG Hydraulic Specifications Hydraulic Oil Specifications Hydraulic oil type Viscosity grade Chevron Rando HD equivalent Multi viscosity Viscosity index 200 Cleanliness level minimum
171. 00 Ext 8710 Part No 97385 February 2012 Section 3 Scheduled Maintenance Procedures REV K B 9 Test the Drive Speed Stowed Position Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Proper drive functions are essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range 5 Perform this procedure with the machine on a firm level surface that is 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 platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 3 Lower the platform to the stowed position Press the drive function select button a drive function select button BN8 Part No 97385 Genie GS 30 GS 32 GS 46 CHECKLIST B PROCEDURES 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 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line Continue at full speed and note the time
172. 1 SWITCH CONTROL 4 1 H5 MACHINE SHOWN IN THE k 7 STOWED POSITION WITH Sg E NCHO THE POWER OFF NA m LS7 TS66 CB2 E N CHO 58 BREAKER 158 POTHOLE GUARD SWITCH i ale eR 5 8 2 8 552 5 gQez BLACK AND WHITE WIRES CUT POWER f z 9 TO MOTOR CONTROLLER WHEN THE ky 130 S CHARGER IS PLUGGED IN OPTION X 5 2 QD1 0 A OPTION 3 eM ra g F6 275A FUSE 8 BK ra 0 oe 09 A8 OUT y 1 OUT U5 CHARGER ELECTRONIC CONTROL MODULE OUT OUT B5 211 BATTERY AGIBPUF 9 2 MOTOR SOT E R CONTROLLER A NOT CONNECTED CR5 ICONTROLLER V HORNRELAY pi i D 3 qun POWER PIN 7 H2 OPTION 7 po DC AC INVERTER E 85 OPTION BEACONS Oei OPTION H2 6 AUTO STYLE HOUR HORN E METER a E OPTION jl ES0141M Genie GS 30 GS 32 GS 46 Part No 97385 April 2008 Section 6 Schematics Electrical Schematic
173. 1 277 0 007 The battery is fully charged Proceed to step 11 Result One or more battery cells display specific gravity of 1 217 or below Proceed to step 8 8 Perform an equalizing charge OR fully charge the batteries and allow the batteries to rest at least 6 hours 9 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results Section 3 Scheduled Maintenance Procedures February 2012 CHECKLIST B PROCEDURES 10 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows Add 0 004 to the reading of each cell for every 10 5 5 C above 80 26 7 C e Subtract 0 004 from the reading of each cell for every 10 5 5 C below 80 26 7 C Result All battery cells display a specific gravity of 1 277 0 007 The battery is fully charged Proceed to step 11 Result One or more battery cells display specific gravity from 1 269 to 1 218 The battery is still usable but at a lower performance so will need to be recharged more often Proceed to step 11 Result One or more battery cells display specific gravity from 1 217 to 1 173 The battery is approaching the end of its life Proceed to step 11 Result The difference in specific gravity readings between cells is greater than 0 1 OR the specific gravity of one or more cells is 1 172 or less Replace the battery i
174. 10 B6 C12 C2 A2 B1 C1 C11 A5 IN OUT OUT IN OUT IN IN IN IN OUT Us ELECTRONIC CONTROL MODULE OUT OUT OUT OUT OUT C8 B7 AT 6 1 2 mE m ES Y1 Y3 Y4 Y5 Y6 Y9 Y7 Y8 PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM RIGHT LEFT REVERSE FORWARD DOWN DOWN UP GS 3246 GND ES0142M Genie Part No 97385 GS 30 GS 32 6 Section 6 Schematics April 2008 Electrical Schematic CE Models REV B GS 2032 2632 from serial number GS3207 83651 to GS3207 84866 GS 2046 2646 3246 from serial number GS4607 82536 to GS4607 84839 2 QD3 EMERGENCY 4 4 BK POWER PLATFORM 8 3 RD POWER TO GROUND 1 1 WH crounn ___ 1 2 gt 2 BL DATA LINK HIGH I 5 5 OR DATALINK LOW U3 07 9 PLATFORM CONTROLS VOLTAGE PRINTED CIRCUIT BOARD REGULATOR JOYSTICK 5 GY CONTROLLER MN 0 GN i i SWS SW6 pp FUNCTION ENABLE T STEER 1 LEFT RIGHT 5 ok PLATFORM CONTROLS MEMBRANE DECAL POUT1 0
175. 15 13 Water content maximum 200 ppm Chevron Rando HD oil is fully compatible and mixable with Shell Donax TG Dexron Ill oils Genie specifications require hydraulic oils which are designed to give maximum protection to hydraulic systems have the ability to perform over a wide temperature range and the viscosity index should exceed 140 They should provide excellent antiwear oxidation corrosion inhibition seal conditioning and foam and aeration suppression properties Optional fluids Petro Canada Environ MV 46 Statoil Hydra Way Bio SE 32 BP Biohyd SE S Biodegradable UCON Hydrolube HP 5046 Quintolubric 822 Fire resistant Shell Tellus T32 Shell Tellus T46 Chevron Aviation A Mineral based Continued use of Chevron Aviation A hydraulic fluid when ambient temperatures are consistently above 32 F 0 C may result in component damage Note Use Chevron Aviation A hydraulic fluid when ambient temperatures consistently below O F 17 C Note Use Shell Tellus T46 hydraulic oil when oil temperatures consistently exceed 205 F 96 Note Genie specifications require additional equipment and special installation instructions for the approved optional fluids Consult the Genie Service Department before use Part No 97385 Genie GS 30 GS 32 6 SPECIFICATIONS Function pump Type Gear Displacement per revolution 0 244 cu in 4 cc Flow rate 2500 psi 172 bar 4 gpm
176. 15L min 10 micron with 25 psi 1 7 bar bypass Hydraulic tank return filter Function manifold System relief valve pressure maximum 3700 psi 255 bar Lift relief valve pressure 1800 to 3700 psi 124 to 241 bar Steer relief valve pressure 1500 psi 103 bar Outrigger manifold Relief valve pressure maximum 3500 psi 241 bar Check valve manifold GS 1530 GS 1532 GS 1930 GS 1932 Check valve pressure maximum 200 psi 13 8 bar Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Section 2 Specifications February 2009 SPECIFICATIONS Manifold Component Specifications Plug torque SAE No 2 50 in Ibs 6 Nm SAE No 4 13 ft lbs 18 Nm SAE No 6 18 ft lbs 24 Nm SAE No 8 50 ft lbs 68 Nm SAE No 10 55 ft lbs 75 Nm SAE No 12 75 ft lbs 102 Nm 2 4 Genie REVG Valve Coil Resistance Note The following coil resistance specifications are at an ambient temperature of 68 F 20 C As valve coil resistance is sensitive to changes in air temperature the coil resistance will typically increase or decrease by 4 for each 18 F 7 7 C that your air temperature increases or decreases from 68 F 20 C Description Specification Solenoid valve 3 position 4 way 27 20 20V DC with diode schematic items F and AC Solenoid valve 3 position 4 way 190 20V with diode sche
177. 19 B 10 Test the Drive Speed Raised Position 3 20 B 11 Test the Slow Drive 3 21 B 12 Perform Hydraulic Oil 3 22 B 13 Inspect the Hydraulic Tank Cap Venting System 3 22 B 14 Check the Module Tray Latch 3 23 B 15 Inspect the Voltage Inverter if equipped 3 24 B 16 Test the Down Limit Switch and the Pothole Limit Switches 3 25 B 17 Test the Up Limit Switch if equipped and the Outrigger Limit Switches if equipped 3 28 Checklist Procedures C 1 Test the Platform Overload System if equipped 3 29 C 2 Replace the Hydraulic Tank Breather Cap Models with Optional Hydraulic 3 31 E Checklist D Procedures D 1 Check the Scissor Arm Wear Pads 3 32 D 2 Replace the Hydraulic Tank Return Filter Element 3 35 C Checklist E Procedure E 1 Testor Replace the Hydraulic Oil 3 36 Genie viii GS 30 GS 32 6 February 2012 Section 4 Rev TABLE OF CONTENTS Repair Procedures Introduction ire te hei cette et hec 4 1 Platform Controls 1 1 Circuit 4 2 1 2 Controller
178. 2 GS 2632 GS 3232 GS 2046 GS 2646 and GS 3246 REV F The function manifold is mounted behind an inspection door on the ground control side of the machine Index Schematic No Description Item Function Torque Coibnu t ilemrAG cit tacere et iis 4 5 ft lbs 5 7 Nm Coil nut items AE AG ang iiano ein e ae 5 7 ft lbs 7 9 Nm Diagnostic nipple Testing 2 Relief valve 3700 psi 255 bar maximum System relief 20 ft Ibs 27 Nm 3 Solenoid valve 3 position 4 way Steer left right 25 ft lbs 34 Nm 4 Check dise RR AD iiie Steer circuit 18 ft Ibs 24 Nm 5 Solenoid valve 2 position 4 way AE xu Drive speed select circuit 25 ft lbs 34 Nm 6 Relief valve Before serial number GS3206 80132 and GS4606 79028 130 psi 9 bar After serial number GS3206 80131 and GS4606 79027 50 psi 3 4 bar AR Brake release 20 ft lbs 27 Nm Solenoid valve 3 position 5 way Drive forward reverse 25 ft lbs 34 Nm 8 Flow regulator and relief valve 0 75 gpm 2 8 L min 1500 psi 103 esp Steer circuit 26 ft Ibs 35 Nm
179. 2 6 5 OVERLOAD E L 149 8 DOWN DELAY Q 259 1 11 Pop o 57 i 2 2 g o 8 1 Er 9 5 9 eg 2 5 gt S 4 A9 10 B6 C12 C2 2 B1 C1 C11 5 N ON OUT OUT IN IN IN OUT NOT CONNECTED ONGS 3292 U5 L LLL ELECTRONIC CONTROL MODULE NOT CONNECTED ON 65 3232 z SS 1 OUT OUT OUT OUT OUT C8 C7 B7 A7 C6 L uu i 6 TT 1 9 2 m 5 5 9 I X A m Pu 95 3232 ONLY LLL 4 Y1 Y4 Y5 Y6 Y9 Y7 Y8 PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM RIGHT LEFT REVERSE FORWARD DOWN Down UPR ssf GS 3232 GS 3246 2 e 4 e 74 GND ES0142U Genie Part No 97385 GS 30 GS 32 6 6 111 REVA February 2012 GS 2032 2632 3232 from serial number GS321 1A 97904 to GS3212A 109999 and GS3212C 1387 to GS3212C 9999 GS 2046 2646 3246 from serial number GS461 1A 97983 to GS4612A 109999 and GS4612C 1386 to GS4612C 9999 Electrical Schematic CE Models Section 6 Schematics CE Models
180. 26 1 12 1 1 16 12 1 16 139 ft Ibs 188 5 Nm 16 1 5 16 12 1 20 172 ft lbs 233 2 Nm 20 1 5 e 12 1 24 208 ft lbs 282 Nm 24 1 2 1 SAE O ring Boss Port tube fitting installed into Steel SAE Dash size Torque 4 16 ft lbs 21 7 Nm 6 35 ft lbs 47 5 Nm 8 60 ft lbs 81 3 Nm 10 105 ft lbs 142 4 Nm 12 140 ft lbs 190 Nm 16 210 ft lbs 284 7 Nm 20 260 ft lbs 352 5 Nm 24 315 ft lbs 427 1 Nm Genie Part No 97385 GS 30 GS 32 6 2 5 Section 2 Specifications February 2009 SPECIFICATIONS Torque Procedure JIC 37 fittings 1 Align the tube flare hex nut against the nose of the fitting body body hex fitting and tighten the hex nut to the body hex fitting to hand tight approximately 30 in Ibs 3 4 Nm 2 Make reference mark on one of the flats of the hex nut and continue it on to the body hex fitting with a permanent ink marker Refer to Figure 1 Figure 1 hydraulic hose hex nut reference mark body hex fitting Genie GS 30 GS 32 6 REVG 3 Working clockwise on the body hex fitting make a second mark with a permanent ink marker to indicate the proper tightening position Refer to Figure 2 Note Use the JIC 37 Fittings table on the previous page to determine the correct number of flats for the proper tightening position Note The marks indicate that the correct tightening positions have been dete
181. 3 5 1 1 0 cree 1 1 1 1 TN xc I 1 1 1 1 1 1 1 ee MEE eiae ael ts ce Sa BLONDES rf tod gy row od LUE C bd dg usd Pu 1 Fori 1g 5 8 wilt 1 5 x T 83 84 5 5 8 a gt a gt g 8 2859085 2022098 POE E d 1 1 1 d re a ES0142P Part No 97385 GS 30 GS 32 GS 46 6 104 February 2012 Section 6 Schematics Electrical Schematic REV CE Models GS 2032 2632 3232 from serial numberGS3207 84867 to GS3210A 94974 and GS3208C 101 to GS3210C 378 GS 2046 2646 3246 from serial number GS4607 84840 to GS4610A 95454 and GS4609C 101 to GS4610C 118 P2 EMERGENCY QD3 4 4 Bk POWER PLATFORM NOTE 3 q RD POWER TO GROUND 1t MACHINE SHOWN IN THE STOWED 1 1 WH GROUND POSITION WITH THE POWER OFF N 2 2 BL DATA LINK HIGH 5 5 OR DATA LINK LOW U3 D7 PLATFORM CONTROLS VOLTAGE PRINTED CIRCUIT BOARD REGU
182. 30 NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF RD RD 4 4 4 WH WH 3 34 3 1 CR48 BL 144 MESES o gr 95 5 OR 8 2 lt N C PS2 PLATFORM OVERLOAD 156 PRESSURE SWITCH INC DOWN 7 SWITCH N O H C lt 5 CR27A CR27B CR27C OVERLOAD OVERLOAD OVERLOAD eee ca ia MOTOR CONT LOAD SENSE DOWN COIL N O 30 9 6 30 86 30 9 86 4 za 87 85 85 87 85 LS5 SENSOR UP BOARD C57 7 Wireh 2 Ps rox 1 seen 58058 CR27D 34223509 558 OVERLOAD a Lo 3 DOWN DELAY m A m o 2 9 d 5 5 5 2002 x z A 5 2 0 Lo 1 02 9 A10 B6 C12 A4 2 B1 C11 AS IN OUT OUT IN OUT IN IN IN OUT Us ELECTRONIC CONTROL MODULE OUT OUT OUT OUT OUT C8 C7 B7 A7 C6 cx em Ie MEMMIUS Y1 Y3 Y4 Y5 Y6 Y9 Y7 Y8 PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM RIGHT LEFT REVERSE FORWARD DOWN DOWN UP GS 3246 ACOX SPX APX GND ES0142D Genie Part No 97385 GS 30 GS 32 6
183. 30 1932 from serial number GS3006A 83068 to GS3007A 87490 GS 1530 1532 1930 1932 from serial number GS3006B 79660 to GS3007B 82543 NOTE MACHINE SHOWN IN THE STOWED RD RD 4 4 4 WH WH 3 a CR48 BL 1 6 1 E POWER BK 2 2 RELAY TO US gr 95 5 p 98 T 5 C 5d 4 156 DOWN LIMIT SWITCH 8 prx sl NO LEVEL SENSOR CIRCUIT 1 BOARD 5 5 2 SSS lt 57 2 m gt gt LEVEL ps p m m 2 9 5 o 28 2 SENSOR 5 gt pu T God Uu ecu 1 5 5 2222 15 8 3 295228 IS 5 45 9 8 5 8 2 5 2 5 o 59 2 a liL d 02 C12 A10 A4 2 B1 C11 AS IN IN IN IN OUT ELECTRONIC CONTROL MODULE OUT OUT OUT OUT OUT OUT OUT C8 C7 B7 A7 C6 B6 AG ee cc necdum 2 m 5 E 5 2 I 5 5
184. 32 z it OUT OUT OUT OUT OUT EN C8 C7 B7 A7 C6 2 EN ee Rw ew pe eR a I TE w 1 2 5 EE 111 d 6 3232 ONLY E 21 Y1 Y4 Y5 Y6 Y9 Y7 Y8 PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM RIGHT LEFT REVERSE FORWARD DOWN DOWN UP GS 3232 GS 3246 e 4 e 74 GND ES0142U Genie Part No 97385 GS 30 GS 32 6 February 2012 Section 6 Schematics Electrical Schematic CE Models REVA GS 1530 32 amp 1930 32 from serial number GS3012C 5060 to GS3012C 5311 GROUND ots 209 ROLL PITCH 0 POWER L52 FR OUTRIGGER lt lt 154 169 ENABLE T d d RR OUTRIGGER ALARM H8 FL OUTRIGGER L51 4 153 RL OUTRIGGER 2 3 RETRACT gt BN105 FUNCTION ENABLE EXTEND OUTRIGGER a 1 1 1 25 5 10 WATT R24 GS 3232 ONLY MC ENABLE 24 gt 7 1 1 EN eL li 1 DRI
185. 32P FIRMWARE FILE 125131 hex REV A1 DATE CODE SERIAL 125320 A FIRMWARE FILE NUMBER Genie Genie A TEREX COMPANY PCON P N 105627 REV A DESCRIPTION PCON O R CONTROLS GS3232P FIRMWARE FILE 125132 hex REV A1 DATE CODE SERIAL 125321 A FIRMWARE FILE NUMBER Part No 97385 GS 30 GS 32 6 4 23 Section 4 Repair Procedures October 2009 PLATFORM CONTROLS REV J 22 With the background of all boxes in the lower right corner of the PSoc Programmer window green in color locate the Device Family drop down menu and select 29x66 V C Documents and Settings EllisT My Documents Projects 3232 Outriggers PSoC in progress CES Programming Utilities View Help Load d Program 2 Checksum Port Device 1 048E 47470618 gt Connect CY8C20234 12LKX Programming Mode Reset PowerCycle er Dete j Toggle Device Power Active HEX file set to C Docum lt 9 9 Successful port connection for Open MiniProgrammer at 14 31 19 MINI Version 1 71 Device set to CY8C20234 12LKX a Device Family set to 20x34 at 1 PENAS For Help press F1 Not Powered Connected Genie 4 24 GS 30 GS 32 6 Part No 97385 October 2009 Section 4 Repair Procedures REV J Note The ECM printed circuit board will be labeled with Genie part number 105368 and wi
186. 46 Part No 97385 2007 Section 4 Repair Procedures REV 3 4 Scissor Assembly GS 2632 and GS 2646 How to Disassemble the Scissor Assembly GS 2632 and GS 2646 AWARNING Podily injury hazard The procedures in this section require specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is required 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 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform See 2 1 How to Remove the Platform 2 Support and secure the entry ladder to an appropriate lifting device 3 Remove the 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 Part No 97385 Genie SCISSOR COMPONENTS GS 2632 GS 2646 Cable bridge legend cable bridge 4 cable bridge 3A cable bridge 3B cable bridge 2A cable bridge 2B cable bridge 1 Remove cables from number 4 cable bridge and lay them off to the side Component damage hazard Cables can be damaged if they
187. 5 RDK 9322 5 OE 93 2 p ne GS 3232 ONLY 19 4 ad 291 2 1961 E 1 L 4 UP LIMIT SWITCH 65 3232 ONLY EE 9 98K 3 lt DRIVER POWER 2 5 i Part No 97385 ES0141P REV February 2012 GS 1530 1532 1930 1 932 from serial number GS3007A 89538 to GS3010A 99455 GS 1530 1532 1930 1 932 from serial number GS3007B 84600 to GS3009B 98941 Electrical Schematic ANSI CSA and Australia Models Section 6 Schematics E GROUND 256 ROLL H OR E 59 8 ant PITCH BL i POWER 4 iE i u 8 5 8 E oa 2 2 88 24 yp p DATA HIGH pos 4 5 E s 5 3 YD DATA LOW
188. 5 GS 30 GS 32 6 6 115 Section 6 Schematics 2007 Hydraulic Schematic GS 1530 1532 1930 1932 from serial number GS3005A 76000 to GS3005A 76491 REV GS 1530 1532 1930 1932 from serial number GS3005B 76000 to GS3005B 76084 1 LEFT dj RIGHT LIFT CYLINDER L ALL MODELS BRAKE RELEASE BRAKE PRESSURE _ 370 to 450 psi 7 26 to 31 b MANUAL RELEASE PLATFORM 2 OVERLOAD EM HAND 5 WoO 7 n HAND 4 a eal IN BRAKE PS2 RELEASE gt 0 059 inch _ CL ms 02 147mm IMANIFOLD Em MR 0 1 THE ORIFICE IS LOCATED RIGHT UNDERNEATH THE FITTING STEER STEER LEFT ON THE LIFT CYLINDER LEFT RIGHT P 1 03 DRIVE MOTOR Ee 168 MOTOR 5 FORWARD REVERSE S on E lt 11500 psi 42103bar L 4 n y JK Ol 10 psi 8 L min fe 0 7 bar SS E Ex lt Y8 MN FUNCTION MANIFOLD 1800 to 3500 psi 1 12416 241 bar 4 1 1 3500 psi maximum 1 241 bar maximum ABBREVIATION L
189. 532 1930 1932 from serial number GS3006A 83068 to GS3007A 87490 from serial number GS3006B 79660 to GS3007B 825493 6 66 GS 1530 1532 1930 1932 from serial number GS3007A 87491 to GS3007A 89537 from serial number GS3007B 82544 to GS3007B 84599 6 70 GS 1530 1532 1930 1932 from serial number GS3007A 89538 to GS3010A 99455 from serial number GS3007B 84600 to GS3009B 98941 from serial number GS3008C 101 to GS3010C 2189 6 74 Genie Xii GS 30 GS 32 GS 46 February 2012 Section 6 Rev TABLE OF CONTENTS Schematics continued GS 1530 1532 1930 1932 from serial number GS3010A 99456 to GS30114 109999 from serial number GS3010C 2190 to GS3011C 5059 GS 1530 1532 1930 1932 from serial number GS3012C 5060 to GS3012C 5311 GS 2032 2632 from serial number GS3205 75407 to GS3205 77290 GS 2046 2646 3246 from serial number GS4605 75438 to GS4605 76734 GS 2032 2632 from serial number GS3205 77291 to GS3206 79991 GS 2046 2646 3246 from serial number GS4605 76735 to 354606 78915 GS 2032 2632 from serial number GS3206 79992 to GS32007 83650 GS 2046 2646 3246 from serial number GS4606 78916 to GS4607 82535 GS 2032 2632 from serial number GS3207 83651 to GS32007 84866 GS 2046 2646 3246 from serial number GS4607 82536 10 GS4607 84
190. 61210295 TT o gt 8 8 lea r gt 5 5 5 i 1 Ua 1 1 29 NE 6 TE NE DN E LVL SNSR RED 128 od gt 0 BOE 188 5 N LVL SNSR WHT GN 5 2 152 1 Liga a 1 GNBK DATA LINK LOW 52 TES 5 DATA LINK HIGH 13 ES BEN 5 E i GND FROM JOYSTICK gz 8 e 1 t I ECM POWER 8 2 o 8 1 1 1 225 d gt 8 285 5 8 1 1 1 1 1 1 1 1 FIOR POET I 1 1 1 AT Sea ae 28 HWH 31 Once eres 4 o 25 gt 5 i i 5 2 425 ome 25 WH BK OPE 2 TIT gt 1 a gt 9 5 gt SR m 5 o ay OVERLOAD POWER 6 8 02 1 5 o gt 2 9 DWN LIMIT 55 E JEE 5 2
191. 6735 to GS4606 78915 P1 di EMERGENCY Ex 2f N STOP 2 WH 8 2 4 KS1 key PLATFORM 1 SWITCH CONTROL 4 NOTE i H5 N ALARM MACHINE SHOWN IN THE 2 3 STOWED POSITION WITH Sg THE POWER OFF CONTROL 7 1577 1566 POTHOLE GUARD PLATFORM SWITCH UP DOWN N C H O CB2 9 7A CIRCUIT 2 BREAKER 4 LS8 U27 P GUARD 47 mH INDUCTOR NOISE SUPPRESSION SWITCH s 5 8 8 gt 9 5 2 i 2227 P i o e BLACK AND WHITE WIRES CUT POWER f z 92 TO MOTOR CONTROLLER WHEN THE 130 g 5 CHARGER IS PLUGGED IN OPTION X 2 OPTION 3 QD1 9 IAT Pe F6 275 FUSE 2 2 2 BK Iz lI 77777 A12 B12 11 B9 B10 zu acu ym IN OUT IN EN A8 OUT 22 p WH BATTERY CHARGER U5 ELECTRONIC CONTROL MODULE OUT OUT B8 B3 Bs d BATTERY 30144 M MOTOR CONTROLLER 2 Li CONNECTED MOTOR 4 CRS mu CONTR
192. 71 TS66 POTHOLE PLATFORM EH 4 UP DOWN N CHO BREAKER 158 927 P GUARD 47 mH INDUCTOR NOISE SUPPRESSION BLACK AND WHITE WIRES CUT POWER 2 TO MOTOR CONTROLLER WHEN THE ky 0 S CHARGER IS PLUGGED IN OPTION 7 WORK 2 2 QD1 5 IAT OPTION E zar REEL 9 F6 275 FUSE 8 m WH 12 812 11 9 B10 IN IN OUT ues ag our us BATTERY A1 OUT U5 CHARGER ELECTRONIC CONTROL MODULE OUT OUT 83 5 f BATTERY AGINPUT 2 MOTOR CONTROLLER E 1 NOT CONNECTED A CR5 1 CONTROLLER ND HORN RELAY CUT OFF POWER ITN 39 OPTION 86 __ OPTION l FB 2 DC AC INVERTER FLASHING 85 OPTION lo H2 G6 AUTO STYLE fl HOUR OPTION METER 1 4 0142 Genie GS 30 GS 32 GS 46 Part No 97385 April 2008 Section 6 Schematics Electrical Schematic REV CE Models GS 1530 1532 1930 1932 from serial number GS3006A 83068 to GS3007A 87490 GS 1530 1532 1930 1932 from serial number GS3006B 79660 to GS3007B 82543 NOTE MACHINE SHOWN IN THE STOWED
193. 80132 to GS3207 84866 GS 2046 2646 3246 from serial number GS4606 79028 to GS4607 84839 WE 1 LIFT CYLINDER PEET RIGHT OVERLOAD ALL MODELS BRAKE RELEASE BRAKE CE PRESSURE 370 to 450 psi n 1 26 to 31 bar MANUAL zu m N VI RELEASE _ 0 037 2 0 94 t T 8 W gt 4 t 2 5 Wy BRAKE PE PER RELEASE a THE ORIFICE IS LOCATED we 1 5mm MANIFOLD UNDERNEATH THE HOSE 0 FITTING ON THE LIFT CYLINDER RIGHT fae 4 75 CU IN DRIVE 1 78 MOTOR MOTOR UPPER LIFT CYLINDER GS 3246 MODELS 2 2 a 9 gt 9 2 v 51 52 HP B AC M1 M3 M2 M4 0 037 inch 1 0 94 mm WKN ac 0 1 7 ii X LJ 2500 psi maximum AN Ah ES 172 bar maximum 0 1 M THE ORIFICE IS LOCATED UNDERNEATH THE PLUG OPPOSITE THE HOSE INLET OF T
194. 839 GS 2032 2632 GS 3232 from serial number GS3207 84867 to GS3210A 94974 from serial number GS3208C 101 to GS3210C 378 GS 2046 2646 3246 from serial number GS4607 84840 to GS4610A 95454 from serial number GS4609C 101 to 3546100 118 GS 2032 2632 GS 3232 from serial number GS3210A 94975 to GS3211A 97903 from serial number GS3210C 379 to GS3212C 1386 GS 2046 2646 3246 from serial number GS4610A 95455 to GS4611A 97982 from serial number GS4610C 119 to 35461202 13859 GS 2032 2632 GS 3232 from serial number GS32114A 97904 to GS3212A 109999 from serial number GS3212C 1387 to GS3212C 9999 GS 2046 2646 3246 from serial number GS461 1A 97983 to GS4612A 109999 from serial number GS4612C 1386 to GS4612C 9999 Genie Part No 97385 GS 30 GS 32 GS 46 Xiii February 2012 ______________________________________________________________________________ TABLE OF CONTENTS Hydraulic Schematics B Component Reference and Hydraulic Symbols 6 114 GS 1530 1532 1930 1932 from serial number GS3005A 76000 to 76491 from serial number GS3005B 76000 to 76084 6 116 D GS 1530 1532 1930 1932 after serial number GS3005A 76491 after serial number GS3005B 76084 from serial number 553008 101 6 117 D GS 2032 2632 from serial number GS3205 75407 to GS3206 80131
195. 839 P1 2 m A EMERGENCY CON 7 d 4 WH 2 45 41 NOR CES N 2 KS1 ul KEY PLATFORM SWITCH CONTROL 4 n MACHINE SHOWN IN THE 2 3 STOWED POSITION WITH 4 THE POWER OFF ONTROL 7 7 TS66 POTHOLE PLATFORM 4 UP DOWN CB2 3 N C H O E E Of BREAKER 158 927 GUARD 47 mH INDUCTOR NOISE SUPPRESSION SWITCH B 3 22 BLACK AND WHITE WIRES CUT POWER 2 E TO MOTOR CONTROLLER WHEN THE V 130 S 5 CHARGER IS PLUGGED IN OPTION 7 WORK LIGHT 5 2 QD1 OPTION F6 275 FUSE 8 3 ak s WH 12 812 11 9 B10 ghee IN IN OUT U9 48 our 1 OUT CHARGER U5 ELECTRONIC CONTROL MODULE OUT B8 B3 3 dob eR AE AC INPUT 9 5 MOTOR CONTROLLER E T NOT CONNECTED CR5 1 CONTROLLER J HORN RELAY OFF POWER A 30 H2OPTION 486 cr 3 option 1 A 2 DC AC INVERTER FLASHING 85 OPTION EE PS RA E 0 G6 AUTO STYLE BR d HOUR OPTION METER L 1 ES0142M Genie 6 98 GS 30 GS 32 6 97385
196. 84866 GS 2046 2646 3246 from serial number GS4607 82536 to GS4607 84839 REV B P2 EMERGENCY 4 4 BK POWER PLATFORM 21 3 3 RD POWER GROUND 1 1 4 GROUND 2 2 BL DATA LINK HIGH H 5 5 OR DATA LINK LOW U3 PLATFORM CONTROLS PRINTED CIRCUIT BOARD LJ D7 5V DC VOLTAGE REGULATOR T HALL EFFECT N GENERATOR wv GN JOYSTICK CONTROLLER WH PIN9 BK 6 BL SW5 SW6 FUNCTION ENABLE T STEER 1 LEFT RIGHT OR J PIN8 1 POUT1 POUT2 PIN1 PIN3 PIN4 POUT11 PIN11 POUT4 C PIN2 C BK 2 PLATFORM CONTROLS MEMBRANE DECAL LIFT LED L16 ty 4 Ca Im G8 DIAGNOSTIC DISPLAY DRIVE LED 117 HIGH TORQUE LED 121 HIGH TORQUE BN6 HORN BN5 DRIVE ENABLE BN8 LIFT ENABLE BN9 PLATFORM CONTROLLER ES0141M Genie GS 30 GS 32 GS 46 Part No 97385 April 2008 Section 6 Schematics m This page intentionally left blank Genie Part No 97385 GS 30 GS 32 6 6 41 Section 6 Sc
197. 85 GS 30 GS 32 GS 46 4 21 Section 4 Repair Procedures October 2009 PLATFORM CONTROLS REV J 20 Click the File Load button Psoc Programmer Device Family Device Connect 20 34 20234 2LKX Programming Mode Reset PowerCycle Power Det Toggle Device Power Successful port connection for Open MiniProgrammer at 14 31 19 MINI Version 1 71 Device set to CY8C20234 12LKX a Device Family set to 20x34 at 1 Green Backgrounds For Help press Fi Not Powered Connected Genie 4 22 GS 30 GS 32 6 Part No 97385 October 2009 Section 4 Repair Procedures REV J 21 Browse the folder containing the appropriate hex file select the file and click Open Result All the boxes in the lower right hand corner of the PSoC Programmer window should have a green background PLATFORM CONTROLS Note To ensure the correct file is selected for either the ECM or control pad update refer to the decals located in Illustrations 2 and 5 An example of the firmware file number and revision level can be found on the decals as shown below Open 4 om File name _125131_a0 hex Files of type Hex Files Look in output Eg Open Cancel Genie A TEREX COMPANY ECU P N 109954 REV A DESCRIPTION ECU O R CONTROLS GS32
198. 89 Eu eel 22509 jo 9 gt i 2528986 285925 ees pee bo Pos a Pg 1 1 M 1 1 1 1 a MEE E ES0141W Part No 97385 enie GS 30 GS 32 GS 46 6 52 February 2012 Section 6 Schematics Electrical Schematic REVA ANSI CSA and Australia Models GS 2032 2632 3232 from serial number GS3211A 97904 to GS3212A 109999 GS 2046 2646 3246 from serial number GS4611A 97983 to GS4612A 109999 P2 8 4 4 L BK POWER TO PLATFORM 3 RD POWER TO GROUND _ MACHINE SHOWN IN THE STOWED 1 1 wH GROUND POSITION WITH THE POWER OFF N 2 2 BL DATALINK HIGH H 5 5 OR DATA LINK LOW U3 PLATFORM CONTROLS VOLTAGE PRINTED CIRCUIT BOARD REGULATOR HALL EFFECT JC1 GENERATOR JOYSTICK CONTROLLER SW5 SW6 FUNCTION ENABLE gt STEER LEFT RIGHT PLATFORM CONTROLS 9 MEMBRANE DECAL POUTI O 4 LIFT LED L16 POUT2 i E DRIVE LED L17 POUT3 O 4 HIGH TORQUE LED 121 M G8 POUT4 DIAGNOSTIC DISPLAY PIN1 HIGH TORQUE BN6 PIN2 HORN BN5
199. ABLE BN8 POUT11 LIFT ENABLE BN9 ES0141V BK ALARM a c CONTROLLER H1 PLATFORM Genie Part No 97385 GS 30 GS 32 6 6 49 Section 6 Schematics February 2012 Electrical Schematic ANSI CSA and Australia Models REVA GS 2032 2632 3232 from serial number GS321 1A 97904 to GS3212A 109999 GS 2046 2646 3246 from serial number GS461 1A 97983 to GS4612A 109999 PIENE RIDES PEE OE RUSE SESE RINE 9 l CLE 1 mE 0 amp 2 P1 P dog 1 EE ry EMERGENCY E STOP Odd e WH para 2 4 7 2 CIRCUIT oi T BREAKER KS1 d d KEY PLATFORM SWITCH CONTROL 1 4 B1 4 _ 3 11 oe GROUND 7 CONTROL T d gt NM MEME i TS66 recur MET RNC C DE E ag PLATFORM bod R30 UP DOWN 200 ohm 10w RD
200. B li LIT 2 1 key PLATFORM SWITCH CONTROL 4 NOTE oe 5 iis N ALARM MACHINE SHOWN IN THE 2 3 STOWED POSITION WITH Sg THE POWER OFF NA 67 TS66 PLATFORM SWITCH 4 UP DOWN CB2 E 7 8 BREAKER 58 927 PCGUARD 47 mH INDUCTOR NOISE SUPPRESSION SWITOH S BLACK AND WHITE WIRES CUT POWER 2 5 MOTOR CONTROLLER WHEN THE 0 5 g CHARGER IS PLUGGED IN OPTION wonkuenrl 2 g QD1 69 Laren 1 5 Pe 9 F6 275 FUSE 63 Emu ze l l A12 812 B9 B10 S IN OUT IN A8 OUT uy l F E A1 OUT CHARGER U5 ELECTRONIC CONTROL MODULE B8 B3 B5 alode ee TRE BATTERY AG INPUT 9 2 NINE MOTOR CONTROLLER 2 1 NOT CONNECTED A CR5 CONTROLLER E WP HORN RELAY 39 H2 OPTION U13 77 pg oo 2 coe 4 FLASHING ter 5 lb OPTION H2 G6 AUTO STYLE ir HOUR OPTION METER L J Aa ES0142J Genie 6 62 GS 30 GS 32 6 97385 April 2008 Section 6 Schematics Electrical Schematic REV D CE Models GS 1530 1532 1930 1932 from serial number GS3005A 79395 to GS3006A 83067 GS 1530 1532 1930 1932 from serial number GS3005
201. B 76921 to GS3006B 79659 NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF RD RD 4 4 WH WH 3 34 CR28 86 2 46 8 BL 1 C 1 cutout 4 4 2 2 MOTOR CONT 824 25 NC 4 D4 PS2 PLATFORM OVERLOAD LS6 7 4 PRESSURE SWITCH N C H O DOWN LIMIT SWITCH N O H C lt lt gt 6 2 CR27A CR27B CR27C o OVERLOAD OVERLOAD OvERLOAD 1 MOTOR CONT LOAD SENSE DOWN COIL t NO 30 486 30 86 304 3 486 N C 4 saa 1 2988 Sl G 2 1 LEVEL 1 87 85 87A 85 87 85 4 1 SENSOR 1 LS5 N O CIRCUIT MEE i BOARD E 1 65 SWITCH go go E 22556545 S7 gt gt O LEVEL c TJ EC 8 2 85 22228 SENSOR
202. COMPONENTS 10 Models with round pressure switch Remove the retaining ring securing the cover to the pressure switch and remove the cover Using a flat blade turn the slotted switch adjustment screw of the platform overload pressure switch into the hydraulic line in 90 increments until the overload alarm does not sound Models with box shaped pressure switch Remove the fasteners securing the cover to the pressure switch and remove the cover Using a wrench turn the nut of the platform overload pressure switch into the hydraulic line in 90 increments until the overload alarm does not sound Note To allow the platform overload system to reset the red Emergency Stop button must be cycled after each quarter turn of the nut or slotted switch adjustment screw Note Turning the nut or slotted switch adjustment screw into the hydraulic line will deactivate the alarm turning the nut or slotted switch adjustment screw out of the hydraulic line will activate the alarm 11 Slowly turn the nut or adjustment screw of the platform overload pressure switch out of the hydraulic line just until the overload alarm sounds Note To allow for the platform overload system delay wait 3 seconds between each quarter turn of the nut or adjustment screw 12 Turn the nut or adjustment screw one quarter turn into the hydraulic line 13 Return the safety arm to the stowed position 14 Using the manual lowering knob lower the platform to the
203. CONNECTED ON GS 3232 z SS 1 OUT OUT OUT OUT OUT B7 6 L uu i 6 TT 1 9 2 m 5 5 9 I 1 X A m Pu 95 3232 ONLY LLL 4 Y1 Y4 Y5 Y6 Y9 Y7 Y8 PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM RIGHT LEFT REVERSE FORWARD DOWN DOWN uP ___ GS 3232 GS 3246 2 e 4 e 74 50142 Genie Part No 97385 GS 30 GS 32 6 6 79 February 2012 Section 6 Schematics Electrical Schematic CE Models REVA GS 1530 32 8 1930 32 from serial number GS3010A 99456 to GS301 1A 109999 GS 1530 32 8 1930 32 from serial number GS3010C 2190 to GS3011C 5059 POWER XDCR wat c10 our y IN OUT Ls 2_ 12 2 Bi L REGEN COIL N A ON 3232 BK 24V MAIN ES BK ery NEE E GROUND BN 259 ROLL
204. Carefully disconnect the wire harness connectors from the circuit board 6 Carefully remove the circuit board retaining fasteners and remove the circuit board from the Outrigger Control Pad control pad a liftenable L69 solid green light b lifterror L70 flashing red or solid red light c right front outrigger L52 solid green or solid red light d left front outrigger 151 solid green or solid red light e right rear outrigger L54 solid green or solid red light f left rear outrigger L53 solid green or solid red light outrigger extend BN105 function enable BN106 outrigger retract BN107 outrigger control circuit board U36 Genie Part No 97385 GS 30 GS 32 GS 46 4 3 Section 4 Repair Procedures October 2009 PLATFORM CONTROLS 1 2 Controller Adjustments Platform lift speed stowed drive speed raised drive speed and high torque drive speed are adjustable to compensate for wear in the hydraulic pump and drive motors The function speeds are determined by the percentage of total controller output For further information or assistance consult the Genie Service Department 73 Tip over hazard Do not adjust the lift and or drive speed higher than specified in this procedure Setting the function speeds greater than specifications could cause the machine to tip over resulting in death or serious injury 11 3 Tip over hazard This procedure lt must only be performed by
205. DOWN up 0 GS 3232 GS 3246 2 e 4 4 4 4 4 4 GND ES0142P Genie Part No 97385 GS 30 GS 32 6 6 75 REVG February 2012 GS 1530 32 amp 1930 32 from serial number GS3007A 89538 to GS3010A 99455 and GS3007B 84600 to GS3009B 98941 and GS3008C 101 to GS3010C 2189 Electrical Schematic Section 6 Schematics CE Models F GROUND L BN 256 ROLL b OR eo xu 5 EARN 1 o PITCH Se Se POWER H WH 4 8 1 1 1 c m E cc i m 9 DATA HIGH WH 2z M mu 8 DATA LOW i GN 42 10 D pu ce eS ATA COW eae 5 Fg V RE c TT RES POWER PLAT 3 5 BUWH 47 a Nort p 1 1 8 NZ 5 E Pope GROUND TO PLAT 1 BL 4 8
206. EGEND P T Item Description cas A Test port 200 psi s Check valve steer circuit ASB Relief valve lift Check valve brake circuit Drive forward reverse Steer left right Flow regulator relief valve Platform up Relief valve system HYDRAULIC TANK Hand pump manual brake release Needle valve manual brake release Platform lowering valve Orifice platform down circuit Accumulator Pressure switch platform overload Check valve drive circuit 10 MICRON WITH 4 gpm 2500 psi 25psi 1 7 bar POWER UNIT 15 L min 172 bar BYPASS 5 Ee c oD v ozz HS0035F Genie 6 116 GS 30 GS 32 GS 46 Part No 97385 June 2009 Section 6 Schematics Hydraulic Schematic REV D GS 1530 1532 1930 1932 after serial number GS3005A 76491 GS 1530 1532 1930 1932 after serial number GS3005B 76084 GS 1530 1532 1930 1932 from serial number GS3008C 101 LIFT CYLINDER
207. ER OFF 47 mH INDUCTOR NOISE SUPPRESSION SWITOH 5 5 8 5 8 lt gt 5 2 29 P BLACK AND WHITE WIRES CUT POWER 1 1 2 5 TO MOTOR CONTROLLER WHEN L30 CHARGER IS PLUGGED IN OPTION WORK LIGHT 2 2 OPTION 5 QD1 69 HZT d f rese F6 275A 2 2 BK rp a uc 77777777775 i A12 B12 11 B9 B10 8 05 3232 ONLY BK PS Pe ug WH A1 OUT CHARGER U5 ELECTRONIC CONTROL MODULE B8 B3 B5 E IL 4 6V NAR p BATTERY AC INPUT C 9 9 MOTOR 30 ITA CONTROLLER 21 B 104 34 gt on GUT OFF POWER N 30 H2OPTION 426 erae U13 _ _ _ LS 2 DC AC INVERTER MZ 85 2 mashing 4 OPTION H2 AUTO STYLE G6 HORN HOUR L OPTION METER ES0142P Genie GS 30 GS 32 GS 46 Part No 97385 February 2012 Section 6 Schematics Electrical Schematic REVG CE Models GS 1530 32 amp 1930 32 from serial number GS3007A 89538 to GS3010A 99455 and
208. FLASHING 87 85 OPTION yf BEACONS 54 H2 G AUTO STYLE 6 HORN HOUR 1 OPTION zi METER ES0142P Genie 6 102 GS 30 GS 32 GS 46 Part No 97385 February 2012 Section 6 Schematics Electrical Schematic REV CE Models GS 2032 2632 3232 from serial numberGS3207 84867 to GS3210A 94974 and GS3208C 101 to GS3210C 378 GS 2046 2646 3246 from serial number GS4607 84840 to GS4610A 95454 and GS4609C 101 to GS4610C 118 hus T pesos 1 1 30 12 i JA POWER 85 87 85 us I 1 CR28 GS 3232 ONLY Cms Read EE M i MOTOR CONT MC ENABLE OUT 4 RD BK DOWN LIM 15 p D PS2 PLATFORM OVERLOAD 6 L PRESSURE SWITCH
209. GNOSTIC 1 DISPLAY PIN1 HIGH TORQUE 6 PIN2 HORN BN5 PIN3 4 DRIVE ENABLE BN8 PIN4 LIFT ENABLE BN9 POUTM m PLATFORM BK p CONTROLLER ES0142M Genie GS 30 GS 32 GS 46 Part No 97385 April 2008 Section 6 Schematics m This page intentionally left blank Genie Part No 97385 GS 30 GS 32 6 6 73 Section 6 Schematics Electrical Schemat ic February 2012 CE Models REV G GS 1530 32 amp 1930 32 from serial number GS3007A 89538 to GS3010A 99455 and GS3007B 84600 to GS3009B 98941 and GS3008C 101 to GS3010C 2189 1 2 5 po E P1 i 7 EMERGENCY a f 6 STOP NAT NB i 2 KS1 key PLATFORM SWITCH CONTROL 4 l B1 5 ALARM eed N NCHO 1 GROUND 7 contro Ma 1 77 57 TS66 POTHOLE ia aa CM CR PLATFORM aires 1 UP DOWN i N CH O CB2 S 8 MACHINE SHOWN IN THE circuit 5 158 STOWED POSITION WITH t ma POTHOLE THE POW
210. GS 2046 2646 3246 from serial number GS4605 75438 to 4606 79027 6 118 A GS 2032 2632 from serial number GS3206 80132 to GS3207 84866 GS 2046 2646 3246 form serial number GS4606 79028 to GS4607 84839 6 119 D GS 2032 2632 3232 after serial number GS3207 84866 and from GS3208C 101 GS 2046 2646 3246 after serial number GS4607 84839 and from 354609 101 6 120 D GS 3232 from serial number GS3207 84867 from serial number 553208 10 6 121 Genie Xiv GS 30 GS 32 GS 46 February 2009 Section 2 Specifications REVG Machine Specifications Batteries Standard Voltage 6V DC Group GC2 Type T 105 Quantity 4 Battery capacity maximum 225AH Reserve capacity 25A rate 447 minutes Weight each 62 Ibs 28 kg Batteries Maintenance free option Voltage 6V DC Group GC2 Type 6V AGM Quantity 4 Battery capacity maximum 200AH Reserve capacity 25A rate 380 minutes Weight each 62 Ibs 28 kg Fluid capacities Hydraulic tank 3 75 gallons Allmodels 14 2 Hydraulic system including tank 5gallons GS 3232 and GS 3246 19 liters Hydraulic system including tank 4 5gallons All other models 18 liters For operational specifications refer to the Operator s Manual Part No 97385 Genie GS 30 GS 32 6 2 1 Specifications Tires and wheels GS 1530 GS 1532 G
211. GS 30 GS 32 GS 46 4 31 Section 4 Repair Procedures October 2009 eee PLATFORM CONTROLS REV J 37 Using the fasteners removed in step 12 How to Finish the Outrigger securely install the ECM assembly onto the ECM bracket Do not over tighten Refer to Illustration 9 Controls Software Update 40 Connect the battery pack to the machine AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 41 Calibrate the outrigger level sensor See 1 4 How to Calibrate the Outrigger Level Sensor 42 Calibrate the outrigger pressure transducers See 1 4 How to Calibrate the Outrigger Pressure Transducers 43 Perform the function tests Refer to the Operator s Manual on your machine 44 Return the machine to service If you have any further questions regarding these instructions or need assistance please contact the Genie Service Department 1 800 536 1800 Ext 8710 Illustration 9 a assembly b ECM bracket 38 Connect the ECM harness to the ECM 39 Close the access door and secure in place Genie 4 32 GS 30 GS 32 GS 46 Part No 97385 October 2009 Section 4 Repair Procedures p wr This page intentionally left blank Genie Part No 97385 GS 30 GS 32 GS 46 4 33 Section 4 Repair Procedures A
212. GS4612C 1386 to GS4612C 9999 P2 EMERGENCY QD3 4 4 BK POWER TO PLATFORM 3 RD POWER TO GROUND _ MACHINE SHOWN IN THE STOWED 1 1 wH GROUND POSITION WITH THE POWER OFF NI 2 2 BL DATA LINK HIGH H 5 5 OR DATA LINK LOW U3 07 PLATFORM CONTROLS VOLTAGE PRINTED CIRCUIT BOARD REGULATOR HALL EFFECT JC1 JOYSTICK CONTROLLER SW5 SW6 pp FUNCTION ENABLE T STEER gt ii LEFT RIGHT PLATFORM CONTROLS 9 MEMBRANE DECAL POUTI 4 LIFT LED L16 POUT2 O E DRIVE LED L17 POUT3 ie HIGH TORQUE LED 1 G8 POUT4 DIAGNOSTIC DISPLAY PIN1 HIGH TORQUE BN6 PIN2 HORN BN5 PIN3 DRIVE ENABLE BN8 5 LIFT ENABLE BN9 flu PLATFORM CONTROLLER POUT11 ES0142U Genie Part No 97385 GS 30 GS 32 GS 46 6 113 Section 6 Schematics March 2007 Component Reference and Hydraulic Symbols Legend Hydraulic cylinder Relief valve 7 Solenoid operated 2 position 2 way directional valve normally closed
213. HE LIFT CYLINDER 3 Yi 1 E ee Ed ve IN ws AG 11500 23 2108 bar Q 0 75 m d 2 8 L min AH TP 1 150 psi 1 3 4 bar 6 gt Nec vbi FUNCTION MANIFOLD 1800 to 3500 psi H 124 241 12 1 3500 psi maximum ABBREVIATION LEGEND Rar maximum 1 Item Description AA Test port AB Relief valve system 1 1 Steer left right AD Check valve steer circuit C Drive speed F AF Relief valve brake release POWER UNIT 10 MICRON WITH Drivef 4gpm 2500 psi 25 psi 1 7 bar rive 7 J AH Flow regulator relief valve Al Platform up AJ Relief valve lift HYDRAULIC TANK L Hand pump manual brake release M Needle valve manual brake release N Platform lowering valve Orifice platform down circuit Accumulator Q Relief valve platform down HS0036L R Pressure switch platform overload Genie Part No 97385 GS 30 GS 32 GS 46 6 119 Section 6 Schematics Hydraulic Schematic June 2009
214. He 5 58 ou 1 az 5 5 2 ONIE gt lt Gi 5 8 WH BK 1 OVERLOAD POWER BUBK 2 gt 4 2 gt gt 5 i 1 gt lt e DWN LIMIT RD BK 52 1 ed 05 58 ZO 330 17 5 45 gt 4 2 291 mes 5 3232 ONLY UP LIMIT SWITCH ont 1 amp z 541 65 ESI gt K BEES EOE A a EE E LEE ET L 10200500 3939 ONLY loz d UP LIMIT SWITCH GS 3232 ONLY 28 55 1 1 i nd DRIVER POWER BK 2 us IM x gt 88 iur d IM ES de iu ca POTHOLE LIMIT SWITCH RD FZ D 5 o oo uai 858 ONPE be EE o Egz 6 28 NE EOS o 4 MEM z z 2 TE 95 T lt Tz IN P i BL 0 49 38 bon PEE 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
215. L MODULE OUT OUT 55 2 eee iE 4 6 1 w BATTERY AC INPUT 9 2 MOTOR SOT E R CONTROLLER A T NOT CONNECTED CR5 4 HORN RELAY 3 Ta POWER ZTN 2 H2 OPTION i genes pe cc wh s DC AC INVERTER E 85 OPTION BEACONS OPTION G6 AUTO STYLE HOUR HORN E METER a E OPTION jl ES0141M Genie GS 30 GS 32 GS 46 Part No 97385 April 2008 Section 6 Schematics Electrical Schematic REV ANSI CSA and Australia Models GS 1530 1532 1930 1932 from serial number GS3007A 87491 to GS3007A 89537 GS 1530 1532 1930 1932 from serial number GS3007B 82544 to GS3007B 84599 NOTE MACHINE SHOWN IN THE STOWED RD RD 4 4 4 WH WH 34 BL 1 1 CR48 C 4 POWER BK s EE RELAY TO US 95 5 5 SSA N O H C 4 156 DOWN LIMIT SWITCH 8 NO LEVEL SENSOR CIRCUIT 1 BOARD 5 5 e 85 8 57
216. LATOR 1 HALL EFFECT JC1 Jovsnck CONTROLLER SW5 SW6 FUNCTION ENABLE STEER LEFT RIGHT PLATFORM CONTROLS La MEMBRANE DECAL POUTI O a 2 lt 4 LIFT LED 6 POUT2 0 E DRIVE LED L17 POUT3 6 HIGH TORQUE LED 121 G8 POUT4 DIAGNOSTIC DISPLAY PIN1 HIGH TORQUE BN6 PIN2 5 HORN BN5 PIN3 DRIVE ENABLE BN8 PIN4 LIFT ENABLE BN9 FA PLATFORM CONTROLLER 11 O ES0142P Genie Part No 97385 GS 30 GS 32 GS 46 6 105 Section 6 Schematics February 2012 Electrical Schematic CE Models CE Models REV GS 2032 2632 3232 from serial number GS3210A 94975 to GS321 1A 97903 and GS3210C 379 to GS3212C 1386 GS 2046 2646 3246 from serial number GS4610A 95455 to GS461 1A 97982 and GS4610C 119 to GS4612C 1385 Vita 1 i 2
217. LERT RIGHT ALL MODELS BRAKE RELEASE BRAKE PRESSURE 370 10 450 5 7 26 to 31 bar MANUAL N 0 037 inch N E OVERLOAD 0 94 mm 1 CE MODELS 7 0 met 1 U RELEASE Ol E 0 THE ORIFICE IS LOCATED RIGHT UNDERNEATH THE STEER STEER LEFT DRIVE am MOTOR 2 L 51 52 Hp B AC 1 M4 1 Ya X M BY 025 gpm 1 ve Il vs 95 L min 11500 psi 5 0 H WW 2 1076 10 psi E 2 8 L min 6 p 0 7 bar T qu 8 w FUNCTION MANIFOLD 025 gpm s700 psi ABBREVIATION LEGEND preg ee DU PTT Item Description ge A Test port s B Check valve steer circuit 200 psi fastar S C Relief valve lift D Check valve brake circuit Drive forward reverse F Steer left right dame 8 Flow regulator relief valve POWER UNIT 15 L min 172 bar BYPASS 1 atform L Relief valve system HYDRAULIC TANK L Hand pump manual brake release M Needle valve manual brake release N Platform lowering valve Orifice platform down circuit P Accumulator R Pressure switch
218. Lid Lid Lad amp No ts 5 a 1 58 851624 Eu 5 2 59 1 881188 122206 995958 8 5 We ee 1 i 1 1 1 ES0141P Part No 97385 enie GS 30 GS 32 GS 46 6 24 February 2012 Section 6 Schematics Electrical Schematic REV D ANSI CSA and Australia Models GS 1530 1532 1930 1 932 from serial number GS3007A 89538 to GS3010A 99455 GS 1530 1532 1930 1932 from serial number GS3007B 84600 to GS3009B 98941 P2 EMERGENCY NOTE BK POWER TO PLATFORM RD POWER TO GROUND MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF 1 WH GROUND 2 2 BL DATA LINK HIGH 5 5 OR DATA LINK LOW amp U3 D7 PLATFORM CONTROLS VOLTAGE PRINTED CIRCUIT BOARD REGULATOR 1 HALL EFFECT JC1 Jovsnck 17 CONTROLLER SW5 SW6 FUNCTION ENABLE STEER LEFT RIGHT OR Bm 2 PINS BK 5 PLATFORM CONTROLS 9 MEMBRANE DECAL POUT1 ZA LIFT LED 6 POUT2 DRI
219. Lift the steer end of the platform slightly to clear the platform mount and slide the platform towards the non steer end of the machine until the platform slide blocks at the non steer end of the machine are visible through the access holes in the bottom of the platform 1 All other models Lift the steer end of the platform slightly to clear the platform mount and slide the platform towards the steer end of the machine until the platform slide blocks at the non steer end of the machine are visible through the access holes in the bottom of the platform AWARNING Crushing hazard The platform will fall if not properly supported 12 Carefully lift the platform off of the machine and place it on a structure capable of supporting it Note Take notice of the wear pad position before the platform is removed so when the platform is installed they will be in the correct position Part No 97385 April 2008 REV B 2 2 Platform Extension How to Remove the Platform Extension 1 2 3 Lower the platform to the stowed position Extend the platform approximately feet 1 m Remove the platform controls from the platform and lay them off to the side of the machine Support the platform extension with a forklift at the steer end of the machine Do not apply any lifting pressure Attach a strap from the platform extension railings to the carriage on the forklift to help support the platform extension Remove
220. Limit Switch if equipped and 6 while raising the platform from the ground the Outrigger Limit Switches if equipped Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the limit switches is essential to safe operation and good machine performance Operating the machine with a faulty limit switch controls and working with the outrigger limit switch at the battery side of the machine push the arm of the outrigger limit switch towards the steer end of the machine to activate the limit switch Result The platform stops raising The machine is functioning properly W Result The platform continues to raise Adjust or replace the outrigger limit switch Note Repeat this procedure for the outrigger limit Switch at ground controls side of the machine could result in reduced machine performance and 7 Return the safety arm to the stowed position a potentially unsafe operating condition Perform these procedures with the machine on a firm level surface that is free of obstructions Up Limit Switch if equipped 8 Lowerthe platform to the stowed position and turn off the machine 1 Turn the key switch to ground control and raise the platform approximately 8 feet 2 4 m from the ground 2 Rotate the safety arm away from the machine and let it hang down 3 Lower the platform onto the safety arm AWARNING Crushing hazard Keep hands clear of the safet
221. N NCHO 1 GROUND 4 CONTROL p E Ws LS71 POTHOLE E _ 1866 SWITCH R30 UP DOWN 200 ohm 10w RD 4 N CH O MACHINE SHOWN IN THE Lo 0 2 STOWED POSITION WITH 027 5 158 THE POWER OFF 47 mH INDUCTOR NOISE SUPPRESSION POTHOLE Pod GUARD ae SWITCH gi 1 84 S 1 5 5 5 8 T ST E NE 2 292 5 2 C WORK 2 2 d m BK A gt 75 5 x 2 65 3232 1 QD1 1 1 5 age Contactor LL i A12 B12 11 B9 B10 IN OUT F6 La hejas our NOT CONNECTED FUSE BK See ee 0 4 2 ane WH OUT U5 U9 CONTROL LE CHARGER out MODULE our B8 B3 B5 r RD 1 4 6V U6 8 2 3 m N MOTOR NS Note 6 ol Diodes added at INPUT serial numbers 1 1 GS3011A 102860 dr NA 5 GS3211A 96875 47 5 C A HORN RELAY G846114 97260 STTS 59 H2OPTION 455 U13 J a i DC AC INVERTER FLASHING d 2 OPTION Mt J BEACONS GS3212C 1483 OPTION H2 GS4612C 1517 G6 AUTO STYLE HO
222. N H2 1 2 G6 AUTO STYLE E E orion ESO141P Genie 6 22 GS 30 GS 32 GS 46 Part No 97385 6 23 Section 6 Schematics Electrical Schematic ANSI CSA and Australia Models GS 1530 1532 1930 1 932 from serial number GS3007A 89538 to GS3010A 99455 GS 1530 1532 1930 1 932 from serial number GS3007B 84600 to GS3009B 98941 February 2012 REV D GND G GS 30 GS 32 6 UP COIL lt lt 4 i 1 b 1 tear 18 gt MEME Ri fail EVERSE WH BK T 1 bee FORWARD pace cea as eee arcs 06 IES LUIS qz UP IN 9 252 85 LIS 8 5 7787 os Bo _ gt 5 9 95 Leis bd 5 WH uz Se 1289 T Te ta 1 8i MEC 2 1 1 gt ah uosc 1 IA Wl 2
223. N WITH THE POWER OFF RD RD 4 4 WH WH 3 34 3 486 CR48 BL MESES 87 7 5 OR 822 2294 824 25 D4 PS2 PLATFORM OVERLOAD 156 i PRESSURE SWITCH DOWN T SWITCH 5 CR27A CR27B CR27C OVERLOAD OVERLOAD OVERLOAD MOTOR CONT LOAD SENSE DOWN COIL NO 30 9 6 30 86 30 86 N C 4 555 87 85 87A 85 87 85 LS5 SENSOR UP BOARD C57 Samen 9 1 g 5 Ts 85 5 8 8 2 3 INE on 25 5 5 58 3 8 BK CR27D 22859 558 OVERLOAD a 3 DOWN DELAY m A e 2 9 5 5 5 5 20025 x z 5 lt 2 a 02 B11 A9 A6 10 B6 C12 A4 2 Bi 5 IN OUT IN IN IN OUT Us ELECTRONIC CONTROL MODULE OUT OUT OUT OUT OUT C8 C7 B7 A7 C6 ce ect mE m ES Y1 Y3 Y4 Y5 Y6 Y9 Y7 Y8 PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM RIGHT LEFT REVERSE FORWARD DOWN DOWN 05 3246 ACOX APX APX APX GND ES0142G Genie Part No 97385 GS 30 GS 32 6
224. N m 1 p UP IN eusk 82 Boi 2 58 REGEN COIL N A ON 3232 x i 8 i pe FORWARD WH i 2 0 2 EE lE Pob oj 8K 1 qoo ow sg 1 050 d d Es fe 1292 24V MAIN gt E BK ZI APT REVERSE WH BK 2 29 gk 1 rot UP COIL BL BK 25 1 x 2 VERUM Tn fud qutt We e oo BN e GND qe I 8 A 2 0 EMEN NM ECCE 2 TE ee 5 3 5 8 8 i 125 V ee RDBK ae a ary el bg 1165 p ok arz 1 585 E 6 60 8 5 EE Fd 5 oo eee ae i rr i 1 BEN 55555 gt pC Sas 122 3 i Qiii E g pm 0 PRESS B 1 NT 1 1 1 5 T 3 fof bee 8086 coo sees coop cons cie ie 1 11 Ro dde ccce toc 0 1 0 S oe LIRE uae ESTAS TEE NE b Y d od Log oq 1 M pog 1
225. NO 029 N O o 2 gt Po E 4 2x a A N N A A o a cel A o E a EN A N 17 00 rol AYO Oy AYO OJN O oj gt AININ Copco Oyo A 2 o M A N gt a 5 0 A N 5 A On A NIN N 85 56 N 62 583 Genie Part No 97385 GS 30 GS 32 6 2 7 Section 2 Specifications February 2009 m This page intentionally left blank Genie 2 8 GS 30 GS 32 GS 46 Part No 97385 April 2008 Section 3 Scheduled Maintenance Procedures Scheduled Maintenance Procedures Observe and Obey Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine Scheduled maintenance inspections shall be completed daily quarterly semi annually annually and every 2 years as specified on the Maintenance Inspection Report The frequency and extent of periodic examinations and tests may also depend on national regulations AWARNING Failu
226. OL CHARGER out MODULE out A B8 B3 B5 r RD 9 9 06 4 6 BATTERY MOTOR 9 A Not prc 3 ote f CONTROLLER TN Diodes added at AC INPUT serial numbers GS3011A 102860 NA 5 GS3211A 96875 C A HORN RELAY 954611 97260 5 Dw 30 2 48 U13 2j DC AC INVERTER 4 BUE ts 2 OPTION Mt E BEACONS 4 GS3212C 1483 OPTION H2 GS4612C 1517 3 te G6 AUTO STYLE 1 HORN os HOUR OPTION E QD1 9054 METER 4 oo GND BN ES0142T Genie 6 106 GS 30 GS 32 6 97385 February 2012 Section 6 Schematics Electrical Schematic REVA CE Models GS 2032 2632 3232 from serial number GS3210A 94975 to GS321 1A 97903 and GS3210C 379 to GS3212C 1386 GS 2046 2646 3246 from serial number GS4610A 95455 to GS461 1A 97982 and GS4610C 119 to GS4612C 1385
227. OL MODULE NorcowECTED ON GS 3232 1 1 OUT OUT OUT OUT C8 C7 B7 AT C a eee l M i o 2 w e EF i o o 1 5 ES A a N00 El GS 3232 ONLY 4 MM LL LL 4 PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM RIGHT LEFT REVERSE FORWARD DOWN DOWN up GS 3232 GS 3246 e 4 4 4 3 4 4 GND ES0142P Genie Part No 97385 GS 30 GS 32 6 6 103 REVG February 2012 GS 2032 2632 3232 from serial numberGS3207 84867 to GS3210A 94974 and GS3208C 101 to GS3210C 378 GS 2046 2646 3246 from serial number GS4607 84840 to GS4610A 95454 and GS4609C 101 to GS4610C 118 Electrical Schematic CE Models Section 6 Schematics CE Models F GROUND BN 256 OR eoe Quas D 5 E e 8 PITCH H BL lt lt lt lt lt lt 4 3 5
228. OLLER P HORNRELAY o 1 CUT OFF POWER H2 OPTION pr 013 OPTION ____ ue DC AC INVERTER 85 OPTION BEACONS ET OPTION H2 1 AUTO STYLE G6 HORN ng HOUR OPTION METER m 4 4 4 4 ES0142J Genie 6 90 GS 30 GS 32 6 Part No 97385 April 2008 Section 6 Schematics Electrical Schematic REV D CE Models GS 2032 2632 from serial number GS3205 77291 to GS3206 79991 GS 2046 2646 3246 from serial number GS4605 76735 to GS4606 78915 NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF RD RD 4 4 WH WH 3 34 CR28 86 2 46 8 BL 1 6 1 cutout 4 4 2 2 MOTOR CONT 824 25 NC 4 D4 PS2 PLATFORM OVERLOAD LS6 4 PRESSURE SWITCH N C H O DOWN LIMIT
229. POWEROFF 1 1 m BACK ANE WAITE WIRES CUT POWER MOTOR a CONTROLLER WHEN THE 4 L9 0 CHARGER IS PLUGGED IN 2 OPTION 1 RE 2 2 4 E BK g s QD1 9 _ 8 Contactor 2 r E N O H C 8 fN REED S GS 3232 ONLY amp Ru ME ee ey F6 o z As our NOT CONNECTED Ase dinem ro E g l ON GS 3232 ni ipee f E U9 ELECTRONIC CONTROL BATTERY 17 MODULE CHARGER OUT B 5 4 6V ig 4 9 H A Note pl 3 653011 102860 SAY CR5 GS3211A 96875 8 5 HORN RELAY 0 ti i CUT OFF POWER N H2 OPTION 486 013 _ _ FB 1 2 2 DC AC INVERTER 85 OPTION FLASHING SS N OPTION H2 AUTO STYLE OPTION QD1 0054 GND BN ES0141V 6 26 GS 30 GS 32 6 Part No 97385 Section 6 Schematics February 2012 Electrical Schematic ANSI CSA and Australia Models GS 1530 1532 1930 1 932 from serial number GS3010A 99456 to GS301 1A 109999 REVA 1 1 1 1 1 1
230. REAKER 158 U27 47 mH INDUCTOR NOISE SUPPRESSION ors 5 5 8 8 2 8 2 5 gt 1 5 VA 0 S 5 2 g QD1 0 A OPTION 3 EAT F6 275A FUSE 8 BK ee l WH 12 B12 11 B9 B10 MED IN IN OUT IN U9 BK EO AS E 1 OUT U5 CHARGER ELECTRONIC CONTROL MODULE 1 OUT OUT B8 B3 5 qoM AC INPUT 9 9 MOTOR 3 CONTROLLER 2 NOT CONNECTED CR5 zs 02 HORNRELAY OFF POWER VA H2 OPTION U13 1 1 i DC AC INVERTER 85 aL ur 24 OPTION H2 Ge 1 OPTION ES0142M Genie GS 30 GS 32 GS 46 Part No 97385 April 2008 Section 6 Schematics Electrical Schematic REV B CE Models GS 1530 1532 1930 1932 from serial number GS3007A 87491 to GS3007A 89537 GS 1530 1532 1930 1932 from serial number GS3007B 82544 to GS3007B 84599 NOTE MACHINE SHOWN IN THE STOWED
231. REV K Illustration 3 a drive forward reverse valve 10 Tag the forward and the reverse valve coils Remove the coils from the valve Note The forward valve coil has white and brown wires attached Note The reverse valve coil has white black and brown wires attached Note For reassembly it will be helpful to leave the wire harness attached to the valve coils For GS 1530 GS 1532 GS 1930 and GS 1932 all models proceed to step 11 For GS 2032 and GS 2632 before serial number GS3204 51608 proceed to step 11 For GS 2046 GS 2646 and GS 3246 before serial number GS4604 60000 proceed to step 11 For GS 2032 and GS 2632 after serial number GS3204 51607 and from GS3208C 101 proceed to step 21 For GS 2046 GS 2646 and GS 3246 after serial number GS4604 59999 and from GS4609 101 proceed to step 21 11 Remove the drive forward reverse valve from the function manifold Plug the open port of the manifold Part No 97385 Genie GS 30 GS 32 GS 46 CHECKLIST B PROCEDURES 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 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 Pro
232. RN METER 1 OPTION ES0142U Genie 6 110 GS 30 GS 32 6 97385 February 2012 Section 6 Schematics REVA Electrical Schematic CE Models GS 2032 2632 3232 from serial number GS321 1A 97904 to GS3212A 109999 and GS3212C 1387 to GS3212C 9999 GS 2046 2646 3246 from serial number GS461 1A 97983 to GS4612A 109999 and GS4612C 1386 to GS4612C 9999 QD4 i RD RD 4 4 i WH WH 3 3 vod BL 1 1 1 prid BK 2 2 1 1 Hitt OR T1 5 5 EE oro bod SS ee ca b 4 4 4 4 4 4 4 GN MC THROTTLE us 6 56 30 4 56 CR48 r3 UU MEN cn Rn tee fi xs BK MC ENABLE IN 4 4 EN BIEN r NEN UEM REEL 4 BK 24V 4 RELAY TO 05 85 E STOP
233. ROLLER 6 TO COIL CORD E als 9 C9 5 c3 E T T C Section 6 Schematics Wiring Diagram p OUTRIGGER CONTROL PAD GS 3232 Part No 97385 Leo amp LIFTENABLE 2 L70 U36 qu OUTRIGGER PLATFORM CONTROL CIRCUIT BOARD 151 152 LF OUTRIGGER RF OUTRIGGER 153 154 LR OUTRIGGER RR OUTRIGGER BN107 BN106 BN105 OUTRIGGER FUNCTION OUTRIGGER RETRACT ENABLE EXTEND oe TO COIL CORD Genie GS 30 GS 32 6 Section 6 Schematics 2007 Limit Switch Legend REV GS 2032 b a GS 2632 GS 3232 GS 2046 GS 2646 GS 1530 GS 3246 GS 1532 GS 1930 GS 1932 ALL MODELS Limit Switch Legend a b 0 0 maximum height limit switch LS5 CE models down limit switch LS6 pothole switches LS7 LS8 22 ft 6 7 m maximum drive height when outriggers not deployed LS5A GS 3232 Genie 6 8 GS 30 GS 32 GS 46 Part No 97385 February 2012 Section 6 Schematics REV H 1NOO HOLOW Wire with description Circuits crossing no connection v Diode Circuits conn
234. S 1930 GS 1932 Tire size solid rubber 12x4 5in 30 5 x 11 4 Tire contact area 9 sqin 58 cm2 Castle nut torque dry 300 ft lbs 406 7 Nm Castle nut torque lubricated 225 ft lbs 305 Nm GS 2032 GS 2632 GS 3232 GS 2046 GS 2646 GS 3246 Tire size solid rubber 15 5 38 1 x 12 7 cm Tire contact area 15 96 7 cm Castle nut torque dry 300 ft lbs 406 7 Nm Castle nut torque lubricated 225 ft lbs 305 Nm Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Section 2 Specifications February 2009 SPECIFICATIONS Performance Specifications Drive speed maximum GS 1530 GS 1532 GS 1930 and GS 1932 Platform stowed fast 2 5mph 40 ft 10 7 sec 4km h 12 2 10 7 sec Platform stowed slow 1 1 mph 40 ft 24 8 sec 1 8 km h 12 2 24 8 sec Platform raised 0 5mph 40 ft 55 sec 0 8 km h 12 2 m 55 sec GS 2032 GS 2632 GS 3232 GS 2046 GS 2646 and GS 3246 Platform stowed fast 2 2 mph 40 ft 12 4 sec 3 5 km h 12 2 m 12 4 sec Platform stowed slow 1 1 mph 40 ft 24 8 sec 1 8 km h 12 2 24 8 sec Platform raised 0 5 mph 40 ft 55 sec 0 8 km h 12 2 m 55 sec Braking distance maximum 24 in 12 in 61 30 cm High range on paved surface Gradeability GS 1930 GS 1932 GS 2632 GS 3232 and GS 3246 25 GS 153
235. S 46 REV K 4 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 5 Raise the platform approximately 8 feet 2 4 from the ground 6 Rotate the safety arm away from the machine and let it hang down 7 Lowerthe platform onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 8 Inspect the center chassis area and scissor arms for burnt chafed and pinched cables 9 Inspect the following areas for burnt chafed corroded pinched and loose wires Scissor arms ECM to platform controls Power to platform wiring 10 Inspect for a liberal coating of dielectric grease in all connections between the ECM and the platform controls 11 Raise the platform and return the safety arm to the stowed position 12 Lower the platform to the stowed position and turn the machine off Part No 97385 February 2012 Section 3 Scheduled Maintenance Procedures REV K B 3 Inspect the Electrical Contactor Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first 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 the ground controls turn the key switch to the off posit
236. SE 2 4 E E pip 140b g les ME gt 1 qOUBCOECCCBUPK S 5 BN GND 4 eet seca TODO os d wk 01 E d sae am SB e d 2 MEM typ pot bd MEN p e3225 ME N 25 i EE HD BKOSS ee een DEUM od bg 1165 arz 1 11 6 6 8 5 1 55 8 lt lt lt lt lt 255 3555 222 i i 1 dix 21 666 3 oo Dp 5 8 8 wd III NE p UE oo E Eon LIIS ap 6 1 1 1 51 boh oq i 1 Dd IH 11 ig bg Eo i NENNEN 6225 MENS LLL Suan cE quce 1 1 1 n bree Hr y TE 0 x bg 8 u lg T A gt gt a 1 BSi ea m ieee JE IEG IUS 8 a a gt 8 2859085 2022098 POE E d 1 1 d 501420 Part No 97385 enie GS 30 GS 32 GS 46 6 76 February 2012 Section 6 Sc
237. TYLE tt 1 HOUR OPTION METER L 4 ES0142K Genie 6 94 GS 30 GS 32 GS 46 Part No 97385 April 2008 Section 6 Schematics Electrical Schematic REV CE Models GS 2032 2632 from serial number GS3206 79992 to GS3207 83650 GS 2046 2646 3246 from serial number GS4606 78916 to GS4607 82535 NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF RD RD 4 4 WH WH 3 34 CR28 86 2 46 8 BL 1 6 1 cutout 4 4 E POWER BK 2 2 MOTOR CONT w _ fof Eso a 824 25 NC 4 D4 PS2 PLATFORM OVERLOAD LS6 4 PRESSURE SWITCH N C H O DOWN LIMIT SWITCH 4 6 2 CR27A CR27B CR27C 5 5 OVERLOAD OVERLOAD OVERLOAD MOTOR CONT LOAD SENSE DOWN COIL t NO 30 86 30 86 30 86 4 1 1 932 s
238. UT ug 1 MB 2 ml BATTERY 1 CHARGER U5 ELECTRONIC CONTROL MODULE OUT OUT 5 0 B8 B3 E D RA 4 6V BATTERY AC INPUT n 9 9 MOTOR 5 l CONTROLLER 2 CONNECTED x _ WITH MOTOR 1 CRS m CONTROLLER P HORNRELAY pi i D U13 ICUT OFF POWER 2 OPTION option L Pane DC AC INVERTER E 85 OPTION BEACONS T o I ue OPTION G6 AUTO STYLE HOUR HORN 11 METER E 3 OPTION E lt ES0141H Genie 6 10 GS 30 GS 32 6 Part No 97385 April 2008 Section 6 Schematics Electrical Schematic REVE ANSI CSA and Australia Models GS 1530 1532 1930 1932 from serial number GS3005A 76000 to GS3006A 83067 GS 1530 1532 1930 1932 from serial number GS3005B 76000 to GS3006B 79659 NOTE MACHINE SHOWN IN THE STOWED RD RD 4 4 4 WH WH 3 a CR48 BL 1 6 1 E POWER BK 2 2 RELAY TO US gr 95 5 p 98 T 5 C 5d 4
239. VE ENABLE L GROUND 81 1 d 4 4 1 CEDE i 1 i ij 1 1 I ip cuin REVERSE 4 L UP COIL L FORWARD 5 2 1 a dae dom icc a o 1 tea 9 e i MES gt 1 A 5 z 9 7 lt Ne t 2z Ora ki OES 5 gt r 58 gO BLWH OEE 1 55 8 955 8 5 gt 4 dz 8 5 4 5 55 gt 1 lors p 9 uo m E 58 5 ct 2 4 oz 1 a 1 2 1 5 2 gt ii E Bf O 4 wu i 1 o9 5 ec SE 5 28 0086 1 oT Es 2 8 58 oo REGEN COIL N A ON 3232 x 1 m N 1 z Bp Bk gt 24V MAIN i m 2 9 BK 25 g BN GND 1 5 22 2 9 2x2 5 vee
240. VE LED L17 POUT3 O 4 HIGH TORQUE LED 121 M G8 DIAGNOSTIC DISPLAY POUT4 PIN1 HIGH TORQUE BN6 PIN2 HORN BN5 PIN3 DRIVE ENABLE BN8 PIN4 LIFT ENABLE BN9 Ht PLATFORM BK ALARM S cup c CONTROLLER POUT11 O 50141 Genie Part No 97385 GS 30 GS 32 GS 46 6 25 Section 6 Schematics Electrical Schematic February 2012 ANSI CSA and Australia Models REVA GS 1530 1532 1930 1932 from serial number GS3010A 99456 to GS301 1A 109999 181 penn nnn E A I l 101 74 kc ovi _ 1 7 EMERGENCY FON STOP 7 Seer jv d WH b CB2 ME NE 7A 2 CIRCUIT 2 BREAKER A IN odd ail ES0141 Rev V applies to machines with kit number 3 101 232534 installed 7 0 7566 CQ MDC MDC PLATFORM R30 UP DOWN 200 ohm 10 RD We NOTE 55 MACHINE SHOWN IN THE STOWED POSITION WITH THE
241. WARD WH 2 Mi gt 11222211 x a un S 8 EA 29 bog bod iol 1 1 5 gt Pop de dese 2 SUP COIE SBEBK zd BN GND pd ee AL 4 5 1 1 Aog 8 NE ME t OR BK 5 MEE IY eg usa 23225 NE 5 cee aie oco ete E bd IS RD BK o 5 6911 iige l 6 6 8 Dd D RE o i 1 1 7 ae 5 5 5 ors sl MEL S ecce cree ce sc PNE o 1 ug 8 8 1 a WH 2222258 vB 5 5 8 E MEN E EU hides opee c TT 7 1 T bod d D x Scr mes 81 86 9 ee he ue i rd j hos f Passos 1 1 1 1 ata 2205 20400 n EE St he pii y d TEC 1 1 1 1 1 moe 1 m T Dol TE iii Lii
242. _ N C H O DOWN 52 BN GROUND P d LIMIT bg SWITCH rg bag 1 S 1 8 4 5 a 2 5 59085 o 2 CR27B CR27C 5 5285 OVERLOAD OVERLOAD 4 EA MOTOR CONT LOAD SENSE DOWN COIL t 71 304 486 30 86 30 56 N C E D 5 a Ws 1 o 7125778 Mia NE 1 Om 1 5 E g feo sut 85 155 SENSOR an LI jj S CIRCUIT a 5 1 1 E n ms x BOARD PS 1 pe pe al C5 Q 1 OO 1 i i 5 S EO E 5 55 754 m ems id 5 1 1 ONLY 9 5 eza 85 3 250 m BK EN 6 8 2 t 1 6270 5 2 240 5 6 5 OVERLOAD 411 2 DOWN DELAY 1 Q it 5 ld 5 2 2 1 w o 5 o 5 z 5 o D 2 A I Ez A oU AD H rp ed 4 9 6 10 66 C12 C2 2 B1 5 i IN IN OUT OUT IN OUT IN IN IN OUT 1 Ed ee 1 NOT CONNECTED 68 3232_ _ U5 EE 1 ELECTRONIC CONTR
243. a d RD BK 5 xps A i T gt tr ez 5 68 p DOWNLIM RD BK m SG 45 Peep 1 DU 1 5 8 28 x d T 2 4 1 uod BL BK P E d 5 8 58 REGEN COIL N A 3232 pop pope FORWARD WH 45 2 gt lt 5 poo REVERSE WH B Er Z9 Bk Soc 1 pog bod pes eec ee 9 d d 1 1 1 2 PEP 88 LL 1 OR Phiri dt 8 t OR BK 5 5 5 5 rod c 323225 N rg i 15 REP bai p pee cl 1 i 1 1 155 RD BK o 5 691 i29 amp tg qo M 55555 Ld 5 0058 dg ve 282858 g 5 5 8 oem opee c 1 T pog ot MEE 1 B 1
244. able from the solenoid valve on the cylinder 45 Models with platform overload option Tag and disconnect the wire harness from the platform overload switch Section 4 Repair Procedures March 2007 SCISSOR COMPONENTS 46 Raise the lift cylinder to a vertical position 47 Remove the pin retaining fasteners from the lift cylinder barrel end pin index 16 Use a soft metal drift to remove the pin Remove the lift cylinder from the machine AWARNING Crushing hazard The lift cylinder could become unbalanced and fall when it is removed from the machine if not properly attached to the overhead crane Component damage hazard Be careful not to damage the valve or fittings on the cylinder while removing it from the machine 48 Place a 4 x 4 48 inch 10 cm x 10 cm x 1 2m long block across both sides of the chassis under the number 1 center pivot pin index 7 49 Attach a lifting strap from an overhead crane to the number 1 inner arm index 8 at the non steer end Raise the number 1 inner arm and remove the safety arm Lower the number 1 inner arm index 8 onto the block that was placed across the chassis ACAUTION Bodily injury hazard Keep hands clear of moving parts when lowering the arms onto the block 50 Remove the cables from the number 1 cable bridge and lay them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched 51 Support and secure the entry
245. ack and side to side while the outriggers are deployed For further information or assistance consult the Genie Service Department How to Calibrate the Outrigger Level Sensor 1 Move the machine to a firm level surface that is free of obstructions Use a digital level to confirm 2 Turn the key switch to platform control 3 Pull out the red Emergency Stop button to the on position at the ground controls 4 Pushin the red Emergency Stop button to the off position at the platform controls 5 Press and hold the function enable extend and retract buttons on the outrigger control pad and pull out the red Emergency Stop button to the on position at the platform controls Result The lift error light turns red on the outrigger control pad Genie GS 30 GS 32 GS 46 REV J 6 Continue to hold the function enable outrigger extend and outrigger retract buttons Result After approximately 3 seconds at the outrigger control pad the right rear outrigger and left front outrigger lights turn red The right front outrigger and left rear outrigger lights turn green and the lift error light remains red 7 Continue to hold the outrigger extend and outrigger retract buttons Release the function enable button Result After approximately 5 seconds at the outrigger control pad the lift enable right rear outrigger and left front outrigger lights turn green The right front outrigger and left rear outrigger light
246. aining fasteners from the number 3 center pivot pin index 4 at the ground control side 24 Place a rod through the number 3 center pivot pin at the ground control side index 4 and twist to remove the pin 25 Remove the retaining fasteners from the number 3 pivot pin index 17 at the non steer end 26 Use a soft metal drift to remove the number 3 pivot pin index 17 from the non steer end of the machine Remove the number 3 outer arm at the ground control side index 16 from the machine Crushing hazard The number 3 ACAUTION outer arm at the ground control side index 16 may become unbalanced and fall if not properly supported when removed from the machine 27 Attach a lifting strap from an overhead crane to the number 3 outer arm at the battery side index 16 28 Remove the retaining fasteners from the number 3 center pivot pin index 4 at the battery side 29 Place a rod through the number 3 center pivot pin at the battery side index 4 and twist to remove the pin Part No 97385 Genie GS 30 GS 32 GS 46 SCISSOR COMPONENTS 30 Remove the number 3 outer arm index 16 from the machine Crushing hazard The number 3 ACAUTION outer arm index 16 may become unbalanced and fall if not properly supported when removed from the machine 31 Attach a lifting strap from an overhead crane to the lug of the rod end of the lift cylinder 32 Remove the retaining fasteners from the lift cy
247. all if not properly supported when the pivot pin is removed 57 Place a 2 x 4x 10 inch 10 x 10 x 25 cm block onto the number 1 inner arm cylinder plate index 14 58 Lower the cylinder onto the block Bodily injury hazard Keep hands ACAUTION clear of moving parts when lowering the cylinder 59 Attach a lifting strap from an overhead crane to the number 3 inner arm index 23 Raise the arm to a vertical position 60 Remove the retaining fasteners from the number 3 pivot pin at the steer end of the machine index 10 61 Use a soft metal drift to remove the number 3 pivot pin index 10 from the steer end of the machine Remove the number 3 inner arm index 23 from the machine Crushing hazard The number 3 ACAUTION inner arm index 23 may become unbalanced and fall if not properly supported when the pivot pin is removed 62 Remove the cables from the number 2A and 2B cable bridges and lay them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched Part No 97385 2007 Section 4 Repair Procedures REV 63 Disconnect the number 2A and 2B cable bridges from the scissor linkset and remove both cable bridges from the machine 64 Attach a lifting strap from an overhead crane to the number 2 outer arm at the ground control side index 26 65 Remove the retaining fasteners from the number 2 center pivot pin index 11 at the ground contr
248. ansducer the pressure transducers on the machine must be calibrated Refer to Section 1 4 How to Calibrate the Outrigger Pressure Transducers CF CA and CB fA Y35 E LULU Y36 Steer End Outrigger a pressure transducer b orifice 0 valve coil d outrigger cylinder e check valve 4 107 Section 4 Repair Procedures March 2007 OUTRIGGER COMPONENTS Non steer End 1 Chock the wheels at the steer end of the machine 2 With a suitable floor jack lift the non steer end of the machine to a height that will allow the outrigger cylinder to be removed 3 Remove the fasteners securing the cover to the rear outrigger enclosure Set the fasteners to the side and remove the cover 4 Tag and disconnect the wire harness from the outrigger cylinder solenoid valve and the pressure transducer 5 Tag and disconnect the pressure transducer from the outrigger cylinder Plug the fitting on the cylinder 6 Tag disconnect and plug the hydraulic hoses from the outrigger cylinder Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 7 Support and secure the outrigger cylinder to a suitable lifting device 8 Remove the outrigger cylinder mounting fasteners 9 Remove the outrigger cylinder from t
249. are kinked or pinched Disconnect the number 4 cable bridge from the number 4 outer arm index 13 and remove the cable bridge from the machine Remove the retaining fasteners from the number 5 pivot pin index 1 GS 30 GS 32 6 4 57 Section 4 Repair Procedures March 2007 SCISSOR COMPONENTS 7 Usea soft metal drift to remove the number 5 pivot pin index 1 Remove the platform mount bracket from the machine 8 Attach a lifting strap from an overhead crane to the number 4 outer arm at the ground control side index 13 9 Remove the retaining fasteners from the number 4 center pivot pin index 2 at the ground control side 10 Place a rod through the number 4 center pivot pin at the ground control side index 2 and twist to remove the pin 11 Remove the retaining fasteners from the number 4 pivot pin index 15 at the non steer end 12 Use a soft metal drift to remove the number 4 pivot pin index 14 from the non steer end of the machine Remove the number 4 outer arm at the ground control side index 13 from the machine Crushing hazard The number 4 ACAUTION outer arm at the ground control side index 13 may become unbalanced and fall if not properly supported when removed from the machine 13 Attach a lifting strap from an overhead crane to the number 4 outer arm at the battery side index 13 14 Remove the retaining fasteners from the number 4 center pivot pin index 2 at the
250. areas other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted Use only chains or straps that are in good condition and of ample capacity Be sure any forklift overhead crane or Be sure i fasteners intended for one time use i e cotter pins and self locking nuts are not reused These components may fail if they are used a second time P Be sure to properly dispose of old oil or other fluids Use an approved container Please be environmentally safe Be sure that your workshop or work area is properly ventilated and well lit vi GS 30 GS 32 6 February 2012 Introduction Section 1 Section 2 Rev G Section 3 Rev Table of Contents Important Information essersi ertet eee deer li Serial Number li Serial Number iii Safety Rules General Safety Specifications Machine 2 1 Performance 2 2 2 3 Manifold Component Specifications 2 4 Hydraulic Hose and Fitting Torque Specifications 2 5 SAE and Metric Fasteners Torque Charts
251. arm 6 Number 2 pivot pin steer end 15 Number 2 pivot pin non steer end 7 Number 1 center pivot pin 2 pins 16 Lift cylinder barrel end pivot pin 8 Number 1 inner arm 17 Number 1 outer arm 9 Number 1 pivot pin Genie 4 36 GS 30 GS 32 6 Part No 97385 March 2007 Section 4 Repair Procedures REV SCISSOR COMPONENTS 3 1 Scissor Assembly GS 1530 and GS 1532 How to Disassemble the Scissor Assembly GS 1530 and GS 1532 AWARNING Podily injury hazard The procedures in this section require specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is required 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 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform See 2 1 How to Remove the Platform 2 Remove the cables from the number 3 outer arm index 11 at the ground controls side Component damage hazard Cables can be damaged if they are kinked or pinched 3 Remove the cables from the number 3 cable bridge and lay them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched Models with dual number 3 outer arms 4 Attach a lifting strap from an overhead c
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253. bs P EE G LEVEL 1 87 85 87A 85 87 85 4 1 SENSOR 1 LS5 N O CIRCUIT BOARD E C5 SWITCH 6 2 S7 80 5 486 z gt 0 Pest gt 9 By LEVEL 5 5 2822 9 SENSOR fe tas 3 9 2 QU E i 25 5 59 5 3 BK 4 CR27D B252 5 OVERLOAD 0 3 DOWN DELAY m A 9 2 8 E ME 5 3 98 44 02 Bii A9 A6 10 B6 C12 A4 2 Bi 5 IN OUT OUT IN IN IN OUT Us ELECTRONIC CONTROL MODULE OUT OUT OUT OUT OUT C8 C7 B7 A7 C6 vc ce es um eo c m mE mee 8 Y1 Y3 Y4 Y5 Y6 Y9 Y7 Y8 PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM RIGHT LEFT REVERSE FORWARD DOWN DOWN 05 3246 4 4 E LH 4 Le Le L_ GND mS 50142 Genie Part No 97385 GS 30 GS 32 6 6 95 Section 6 Schematics April 2008 Electrical Schematic CE Models REV GS 2032 2632 from serial number GS3206 79992 to GS3207 83650 GS 2046
254. ceed to step 18 13 Install the drive forward reverse valve removed in step 11 into the function manifold and torque to 25 ft Ibs 34 Nm 14 In order install the reverse valve coil with white black and brown wires spacer washer and the forward valve coil with white and brown wires onto the valve Note 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 torque to 60 in Ibs 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 9 1 How to Remove a Drive Brake Repeat this procedure beginning with step 1 18 Contact the Genie 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 Service Department 1 800 536 1800 Ext 8710 Section 3 Scheduled Maintenance Procedures February 2012 CHECKLIST B PROCEDURES 21 Remove the drive forward reverse valve from the function manifold Plug the open port of the manifold 22 Carefully inspect the hex portion of the valve for an identification stamp Result SV10 5905 is stamped on the hex
255. ch has the option activated repeat this procedure When the ECM is in the SC mode and the option is deactivated there will not be an illuminated dot in the diagnostic display window Part No 97385 Genie GS 30 GS 32 GS 46 Section 4 Repair Procedures PLATFORM CONTROLS How to Determine the Battery Voltage The diagnostic display on the platform controls is used to indicate the battery voltage at all times when the machine is in normal operation Limp Mode If the battery level falls to less than 17 8V DC the single bar in the diagnostic display will be flashing and machine drive speed is limited to that of the raised drive speed Refer to Section 2 Specifications the battery level is 22 6V DC or higher the battery level is 21 6 to 22 5V DC the battery level is 20 7 to 21 5V DC the battery level is 19 7 to 20 6V DC the battery level is 17 8 to 19 6V DC the battery level is less than 17 8V DC O W Ww th Section 4 Repair Procedures October 2009 PLATFORM CONTROLS 1 4 Outrigger ECM The Electronic Control Module ECM is programmed to deactivate the drive and steer functions while the outriggers are deployed and activate an alarm when a signal is received from the outrigger level sensor indicating the outriggers are not deployed or the machine is out of level The ECM is also used to calibrate the outrigger level sensor to achieve a levelness of 0 0 5 front to b
256. company Section 3 Scheduled Maintenance Procedures April 2008 This page intentionally left blank Genie 3 4 GS 30 GS 32 GS 46 Part No 97385 February 2012 Section 3 Scheduled Maintenance Procedures Maintenance Inspection Report Model Checklist A Rev C Y NR Checklist B Rev K Y NR serialnumber 1 Inspect the manuals B 1 Batteries and decals B 2 Electrical wiring Date 2 Pre operation B 3 Electrical contactor B 4 Tires and wheels Hour meter A 3 Function tests Perform after 40 hours A 4 30 day service Perform every 100 hours A 5 Grease steer yokes Machine owner Inspected by print Inspector signature Inspector title Inspector company Instructions Make copies of this report to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hours Inspection A Quarterly or 250 hours Inspection Semi annually or 500 hours Inspection A B C Annually or 1000 hours Inspection A B C D Two year or 2000 hours Inspection A B C D E Place a check in the appropriate box after each inspection procedure is B 5 Emergency stop B 6 Key switch B 7 Horn if equipped B 8 Drive brakes B 9 Drive speed stowed B 10 Drive speed raised B 11 Drive speed slow B 12 Hydraulic oil analysis B 13 Tank venting
257. complies with ANSI A92 6 354 2 YR P N 77055 Facility code used only for model manufactured I STR Serial number stamped on chassis Serial number stamped on chassis Genie Part No 97385 GS 30 GS 32 GS 46 lii February 2012 This page intentionally left blank Genie iv GS 30 GS 32 GS 46 February 2012 Section 1 Safety Rules Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the appropriate Operator s Manual on your machine will result in death or serious injury Many of the hazards identified in the operator s manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless M You are trained and qualified to perform maintenance on this machine You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations You have the appropriate tools lifting equipment and a suitable workshop Genie Part No 97385 GS 30 GS 32 GS 46 v Section 1 Safety Rules February 2012 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 pri
258. cun Successful port connection for Open MiniProgrammer at 14 31 19 Device set to CY8C20234 12LKX a Device Family set to 20x34 at 1 For Help press F1 2 Read Port Device Family Connect 29x66 Programming Succeeded at 14 39 25 Doing Checksum Doing Protect Verify succeeded Verify starting Programming succeeded Programming starting Erase succeeded Silicon 2C Family Die 11 Major Rev Device set to CY8C29666 at 14 3 32768 FLASH bytes MINI Version 1 71 Device Cvac2s666 All Green Backgrounds Not Powered Pass Connected Genie Part No 97385 GS 30 GS 32 6 4 29 Section 4 Repair Procedures October 2009 PLATFORM CONTROLS REV J How to Assemble and Install the 33 Install the control pad onto the control pad bracket and secure using the fasteners Outrigger Control Pad removed in step 4 Do not over tighten the 30 Carefully connect the control pad coil cord to fasteners Refer to Illustration 1 the control pad printed circuit board Refer to Illustration 2 31 Install the button caps removed in step 7 onto the buttons of the control pad printed circuit board Refer to Illustration 2 Component damage hazard Electrostatic discharge ESD can damage printed circuit board components Maintain firm contact with a metal part of the machine that is grounded at all times when hand
259. cy Therefore product specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in suggestions for improvement All communications will be carefully considered for future printings of this and all other manuals Contact Us www genielift com e mail techpub terex com Genie Serial Number Information Genie offers the following Service Manuals for these models Title Part No Genie GS 1530 and GS 1930 Service Manual First Edition before serial number 17408 39528 Genie GS 1530 and GS 1930 Service Manual Second Edition from serial number 17408 to 59999 72876 Genie GS 1530 and GS 1930 Service Manual Third Edition from serial number 60000 to 75999 96316 Genie GS 2032 Service Manual First Edition before serial number 17408 46326 Genie GS 2032 and GS 2632 Service Manual Second Edition from serial number 17408 to 59999 72963 Genie GS 2032 and GS 2632 Service Manual Third Edition from serial number 60000 to 75406 96316 Genie GS 2046 GS 2646 and GS 3246 Service Manual First Edition before serial number 17408 48339 Genie GS 2046 GS 2646 and GS 3246 Service Manual Second Edition from serial number 17408 to 59999 72972 Genie GS 2046 GS 2646 and GS 3246 Service Manual Third Edition from serial number 60000 to
260. d begin charging the batteries Note For best results use an extension of adequate size with a length no longer than 50 feet 15 m Note If you have any further questions regarding the battery charger operation please contact the Genie Service Department Genie Part No 97385 GS 30 GS 32 GS 46 3 11 Section 3 Scheduled Maintenance Procedures February 2012 CHECKLIST B PROCEDURES B 2 Inspect the Electrical Wiring Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first 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 burn hazard Contact AWARNING with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Inspect the underside of the chassis for damaged or missing ground strap s 2 Inspect the 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 3 Inspect for a liberal coating of dielectric grease in the following locations Between the ECM and platform controls All wire harness connectors Level sensor Genie GS 30 GS 32 G
261. der AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 45 Tag and disconnect the wire harness from the solenoid valve on the cylinder Section 4 Repair Procedures March 2007 SCISSOR COMPONENTS 46 Tag and disconnect the wires and manual lowering cable from the solenoid valve on the cylinder 47 Models with platform overload option Tag and disconnect the wire harness from the platform overload switch 48 Raise the lift cylinder to a vertical position 49 Remove the pin retaining fasteners from the lift cylinder barrel end pivot pin index 16 Use a soft metal drift to remove the pin Remove the lift cylinder from the machine Crushing hazard The lift cylinder ACAUTION will fall if not properly supported when the pivot pin is removed Component damage hazard Be careful not to damage the valve or fittings on the cylinder while removing it from the machine 50 Remove the cables from the number 1 cable bridge and lay them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched 51 Disconnect the number 1 cable bridge from the number 1 outer arm index 17 and remove the cable bridge from the machine 52 Attach a lifting strap from an overhead crane to the number 1 inner arm index 8 53 Raise the arm s
262. dex 11 9 Remove the retaining fasteners from the number 3 center pivot pin index 2 at the ground control side 10 Place a rod through the number 3 center pivot pin at the ground control side index 2 and twist to remove the pin 11 Remove the retaining fasteners from the number 3 pivot pin index 12 at the non steer end 4 51 Section 4 Repair Procedures March 2007 SCISSOR COMPONENTS 12 Use a soft metal drift to remove the number 3 pivot pin index 12 from the non steer end of the machine Remove the number 3 outer arm at the ground control side index 11 from the machine Crushing hazard The number 3 ACAUTION outer arm at the ground control side index 11 may become unbalanced and fall if not properly supported when removed from the machine 13 Attach a lifting strap from an overhead crane to the number 3 outer arm at the battery side index 11 14 Remove the retaining fasteners from the number 3 center pivot pin index 2 at the battery side 15 Place a rod through the number 3 center pivot pin at the battery side index 2 and twist to remove the pin 16 Remove the number 3 outer arm index 11 from the machine Crushing hazard The number 3 ACAUTION outer arm index 11 may become unbalanced and fall if not properly supported when removed from the machine 17 Attach a lifting strap from an overhead crane to the lug of the rod end of the lift cylinder 18 Remove the reta
263. e index 5 and twist to remove the pin 31 Remove the retaining fasteners from the number 4 pivot pin index 21 at the non steer end 32 Use a soft metal drift to remove the number 4 pivot pin index 21 from the non steer end of the machine Remove the number 4 outer arm at the ground control side index 20 from the machine Crushing hazard The number 4 ACAUTION outer arm at the ground control side index 20 may become unbalanced and fall if not properly supported when removed from the machine 33 Attach a lifting strap from an overhead crane to the number 4 outer arm at the battery side index 20 34 Remove the retaining fasteners from the number 4 center pivot pin index 5 at the battery side 35 Place a rod through the number 4 center pivot pin at the battery side index 5 and twist to remove the pin Part No 97385 Genie GS 30 GS 32 GS 46 SCISSOR COMPONENTS 36 Remove the number 4 outer arm index 20 from the machine Crushing hazard The number 4 ACAUTION outer arm index 20 may become unbalanced and fall if not properly supported when removed from the machine 37 Attach a lifting strap from an overhead crane to the number 4 inner arm index 19 Raise the arm to a vertical position 38 Remove the retaining fasteners from the number 4 pivot pin at the steer end of the machine index 6 39 Use a soft metal drift to remove the number 4 pivot pin index 6 from the steer
264. e operation and good machine performance Operating the machine with a faulty limit switch could result in reduced machine performance and a potentially unsafe operating condition Perform these procedures with the machine firm level surface that is free of obstructions Down Limit Switch 1 Remove the platform controls from the platform 2 Raise the platform 7 to 8 feet 2 1 to 2 4 m 3 Liftthe safety arm move it to the center of the Scissor arm and rotate down to a vertical position 4 Lower the platform onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 5 Turn the key switch to the off position 6 Tag and disconnect the platform control box at the platform Part No 97385 Genie GS 30 GS 32 GS 46 CHECKLIST B PROCEDURES 7 GS 1530 32 and GS 1930 32 Follow the platform control cable down the scissor stack to the alarm bracket on the chassis deck Tag and disconnect the platform control cable from the ECM cable at the 6 pin Deutsch connector GS 2032 GS 2632 GS 3232 GS 2046 GS 2646 and GS 3246 Follow the platform control cable down the scissor stack to the underside of the chassis deck Tag and disconnect the platform cable from the ECM cable at the 6 pin Deutsch connector under the chassis deck 8 Securely install the platform control box harness plug into the 6 pin Deutsch connector of the ECM cable 9 Disable the down l
265. e ECM will show SC 5 Release the lift function select and speed select 8 Press the speed select button buttons Result The ones digit setting will be activated Result The diagnostic display will show the and the current ones setting will flash in the rocker switch on the joystick to increase or 6 Press the lift function select button decrease the value See 1 3 Machine Result The tens digit setting will be activated Configuration Code Chart for configuration and the current tens setting will flash in the settings diagnostic display Use the steering thumb 9 Press and hold the speed select button for a rocker switch on the joystick to increase or minimum of 3 seconds to set the ones value decrease the value See 1 3 Machine 0 Configuration Code Chart for configuration 10 Turn the key switch to the off position settings Note Any change in software settings will not take 7 Press and hold the lift function select button for effect until the key switch is turned to the off a minimum of 3 seconds to set the tens value position Genie 4 10 GS 30 GS 32 6 Part No 97385 October 2009 Section 4 Repair Procedures M REV J PLATFORM CONTROLS Machine Configuration Code Chart Machine Configuration Code Chart before serial numbers GS3007A 89468 after serial numbers GS3007A 89467 and GS3007B 84527 and GS3007B 84526 from serial number 101 A mark in the four right columns indicates
266. e all rings watches and other jewelry 2 Push in the red Emergency Stop button to the off position at both the ground and platform controls 3 Tag and disconnect the outrigger controls coil cord from the outrigger controls cable Part No 97385 Genie GS 30 GS 32 GS 46 PLATFORM CONTROLS 4 Remove the fasteners securing the outrigger control pad to the outrigger control pad bracket Set the fasteners to the side Refer to Illustration 1 Component damage hazard After removing the fasteners securing the control pad assembly to the control pad bracket the control pad assembly may slide away from the bracket Use caution when removing the fasteners Illustration 1 a control pad b control pad bracket c washer d screw 5 Carefully remove the outrigger control pad from the outrigger control pad bracket Refer to Illustration 1 Section 4 Repair Procedures October 2009 eee PLATFORM CONTROLS REV J 6 Remove the top enclosure of the control pad 8 Using a set of pliers grasp the connector of the and set to the side Refer to Illustration 2 coil cord and slowly pull the coil cord away from the printed circuit board Refer to Illustration 3 Component damage hazard Electrostatic discharge ESD can Component damage hazard damage printed circuit board Attempting to disconnect the coil components Mai
267. e lifting device 15 Remove the lift cylinder through the scissor arms at the steer end of the machine Crushing hazard The lift cylinder ACAUTION may become unbalanced and fall if not properly supported and secured to the lifting device Component damage hazard Be careful not to damage the valve or fittings on the cylinder while removing it from the machine Torque specification Solenoid valve 2 position 2 way N C 20 ft lbs to remove the pin schematic item N 27 Nm AWARNING Crushing hazard The lift cylinder Coil nut 5 ft lbs will fall if not properly supported 7Nm 11 Lower the cylinder onto the number 1 inner arm cylinder plate Bodily injury hazard Keep hands ACAUTION clear of moving parts when lowering the cylinder Genie GS 30 GS 32 GS 46 Part No 97385 2007 Section 4 Repair Procedures REV GS 3232 and GS 3246 1 Raise the platform 7 to 8 feet 2 1 to 2 4 m 2 Liftthe safety arm move it to the center of the Scissor arm and rotate down to a vertical position 3 Lower the platform onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 4 Tag and disconnect the wiring from the solenoid valve coil at the barrel end of the lift cylinder Skip to step 9 if removing the upper cylinder Lower Lift Cylinder lift cylinder orifice fitting schematic item O connector fitting hydraulic
268. e nut 4 Install a new cotter pin Bend the cotter pin to lock it in place Section 3 Scheduled Maintenance Procedures February 2012 CHECKLIST B PROCEDURES B 5 Test the Emergency Stop Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first A properly functioning Emergency Stop is essential for safe machine operation An improperly operating red 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 red Emergency Stop button 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Pushin red Emergency Stop button at the ground controls to the off position Result No machine functions should operate 3 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 4 Push down the red Emergency Stop button at the platform controls to the off position Result No machine functions should operate Note The red Emergency Stop button at the ground controls will stop all machine operation even if the key switch is switched to platform control Genie GS 30 GS 32 GS 46 REV K B 6 Test the Ke
269. e speeds 9 Turn the key switch to the off position Note Any change in software settings will not take effect until the key switch is turned to the off position Section 4 Repair Procedures October 2009 PLATFORM CONTROLS How to Adjust the Slow or High Torque Drive Speed 77177177 hazard Do not adjust the 2 lift and or drive speed higher than specified in this procedure Setting the function speeds greater than specifications could cause the machine to tip over resulting in death or serious injury 777777177 Tip over hazard This procedure I must only be performed by a trained service professional Attempting this procedure without the necessary skills will result in death or serious injury On machines with software revision A4 and higher setting the raised drive speed percentage to zero will result in the steer function being disabled when the platform is above the down limit switch Refer to 1 2 How to Determine the Software Revision Level 1 Pull out the red Emergency Stop button to the on position at the ground controls 2 Pushin the red Emergency Stop button to the off position at the platform controls 3 Turn the key switch to platform control 4 Atthe platform controls press and hold the lift function select and horn buttons and pull out the red Emergency Stop button to the on position Result The diagnostic display will show PS 5 Release the lift function sel
270. e the ends of the scissor arms together at the steer end of the machine with a strap or other suitable device 5 Secure the ends of the scissor arms together at the non steer end of the machine with a strap or other suitable device 6 Remove the retaining fasteners securing the chassis mount bracket to the chassis at the steer end of the machine 7 Attach a lifting strap from an overhead crane to the scissor arm assembly 8 Raise the scissor arm assembly at the steer end with the overhead crane until the chassis mount bracket will clear the level sensor Part No 97385 Genie GS 30 GS 32 GS 46 SCISSOR COMPONENTS 9 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 Component damage hazard Be careful not to damage the level sensor or limit switch while moving the scissor assembly 10 Remove the old wear pad 11 Install the new wear pad 12 Rotate the scissor assembly towards the other side of the machine until the other scissor arm wear pad is accessible Do not allow both wear pads to slide out of the drive chassis TTJ Crushing hazard The scissor 4 assembly will fall if both wear pads are allowed to slide out of the drive chassis Component damage hazard Be careful not to damage the level sensor or limit switch while moving the sci
271. econd 9 Press and hold the function enable and outrigger retract buttons until the outriggers are fully retracted Push in the red Emergency Stop button to the off position at the platform controls The pressure transducers are now calibrated Note After installing a new cylinder or pressure transducer the pressure transducers on the machine must be calibrated N Q f 16 m IA l e 0 7 Outrigger Control lift enable lift error right front outrigger right rear outrigger outrigger extend function enable outrigger retract left rear outrigger left front outrigger Genie REV J How to Activate the Outrigger Motion Alarm Option 1 Turn the key switch to platform control 3 Pull out the red Emergency Stop button to the on position at the ground controls 4 Pushin the red Emergency Stop button to the off position at the platform controls 5 Press and hold the outrigger extend button and pull out the red Emergency Stop button to the on position at the platform controls Result After approximately 5 seconds the outrigger controls alarm will sound twice The outrigger motion alarm is now activated How to Deactivate the Outrigger Motion Alarm Option 1 Turn the key switch to platform control 3 Pull out the red Emergency Stop button to the on position at the ground controls 4 Pushin the red Emergency S
272. ect and horn buttons Result The diagnostic display will show the maximum lift speed percentage Genie GS 30 GS 32 GS 46 REV J O a joystick controller JC1 with thumb steering rocker SW6 horn button BN5 lift function select button BN9 diagnostic display G8 red Emergency Stop button P2 drive function select BN8 speed select button BN6 6 Press the drive function select button Result The diagnostic display will show the stowed drive speed percentage 7 Press and hold the speed select button Result The diagnostic display will show the stowed high torque drive speed percentage 8 Use the steering thumb rocker switch on the joystick to increase or decrease the stowed high torque drive speed percentage 9 Turn the key switch to the off position Note Any change in software settings will not take effect until the key switch is turned to the off position Part No 97385 October 2009 Section 4 Repair Procedures REV J 1 3 Software Configuration The Electronic Control Module ECM contains programming for all configurations of the Genie GS 30 GS 32 and GS 46 The machine can be adjusted to a different configuration using the buttons at the platform controls How to Determine the Software Configuration 1 Remove the platform controls from the platform 2 Pull out the red Emergency Stop button
273. ection Y Connector Hour meter bad Light or flashing beacon Inductor noise suppression 200 0 We Resistor Pressure switch normally open N C N O 4 none 4 0 Of Limit switch CN Button or switch Toggle switch g Emergency stop button CB2 gt Circuit breaker 30 86 87 85 Control relay Fuse Horn or alarm 47 LED Genie Part No 97385 GS 30 GS 32 6 Electrical Symbols Legend 1 Motor controller 57 LEVEL SENSOR Level sensor M5 Solenoid valve TIT Battery charger Solenoid valve with diode telje 1 6V DC Battery Contactor F Capacitor P xu ER M 7 4 WH By eel ge 52 1 PLATFORM SWITCH CONTROL 4 1 j 7 N 3 7 GROUND CONTROL Key switch 5552222225 5 202 HALL JC1 GENERATOR JOYSTICK CONTROLLER
274. empt to raise the platform approximately 8 feet 2 4 m Result The pothole guard contacts the block and does not fully deploy the diagnostic display shows code 18 an alarm sounds and the platform will lift to 8 feet 2 4 m or beyond The machine is functioning properly W Result The pothole guard contacts the block and does not fully deploy the diagnostic display does not show code 18 the alarm does not sound and the machine will continue to lift the platform after the pothole guards are deployed Adjust or replace the pothole limit switch 33 Press the drive function select button Attempt to steer or drive the machine Result The diagnostic display shows code 18 an alarm sounds and the machine will not steer or drive The machine is functioning properly W Result The diagnostic display does not show code 18 the alarm does not sound and the steer and drive functions operate Adjust or replace the down limit switch 34 Lower the platform to the stowed position and remove the block under the right pothole guard 35 Repeat this procedure beginning with step 31 for the left pothole guard 36 Lower the platform to the stowed position remove the block under the left pothole guard 37 Turn off the machine Section 3 Scheduled Maintenance Procedures February 2012 CHECKLIST B PROCEDURES B 17 Test the REV K Outrigger Limit Switches if equipped 5 Lower the platform onto the safety arm Up
275. ency Stop button to the off position at the platform controls 5 Press and hold the outrigger extend and retract buttons and pull out the red Emergency Stop button to the on position at the platform controls Result The lift error light turns red at the outrigger control pad 6 Continue to hold the outrigger extend and retract buttons Result After approximately 3 seconds at the outrigger control pad the right front outrigger right rear outrigger left rear outrigger and left front outrigger lights turn red The lift error light remains red 7 Continue to hold the outrigger retract button and release the outrigger extend button Result After approximately 5 seconds at the outrigger control pad the lift enable light turns green The right front outrigger right rear outrigger left rear outrigger and left front outrigger lights remain red Part No 97385 Genie GS 30 GS 32 GS 46 4 15 Section 4 Repair Procedures October 2009 PLATFORM CONTROLS 8 Press and hold the function enable and outrigger extend buttons until the outriggers are fully extended Continue to hold the outrigger extend button and release the function enable button Result After approximately 5 seconds at the outrigger control pad the right front outrigger right rear outrigger left rear outrigger and left front outrigger lights turn green Result The outrigger controls alarm will sound for approximately 1 s
276. es AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Note If the machine has been in operation allow the coil to cool at least 3 hours before performing this test 1 Tag and disconnect the wiring from the coil to be tested 2 the coil resistance using a multimeter set to resistance Q Refer to the Valve Coil Resistance Specification table W Result If the resistance is not within the adjusted specification plus or minus 1096 replace the coil Part No 97385 Genie GS 30 GS 32 GS 46 MANIFOLDS Valve Coil Resistance Specification Note The following coil resistance specifications are at an ambient temperature of 68 F 20 C As valve coil resistance is sensitive to changes in air temperature the coil resistance will typically increase or decrease by 4 for each 18 F 7 7 C that your air temperature increases or decreases from 68 F 20 C Valve Coil Resistance Specifications Description Specification Solenoid valve 3 position 4 way 27 20 20V with diode schematic items F Solenoid valve 3 position 4 way 190 20V DC with diode schematic item E Solenoid valve 2 position 4 way 190 20V DC with diode schematic item H and AI Solenoid valve 2 position 2 way N C 25Q 20V DC with diode schematic item N Solenoid valve 2 pos
277. esult in property damage Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of steps Section 4 Repair Procedures October 2009 Platform Controls The platform controls used to operate the machine from the platform or while standing on the ground can also be used to tune the performance of the machine Moving the joystick or activating a button sends a signal to the Electronic Control Module ECM When the ECM is in the function mode the platform controls are used to operate the various machine functions When the ECM is in the programming mode PS is shown in the diagnostic display window the platform controls are used to adjust the function speed parameters The platform controls consist of an electronic circuit board joystick membrane decal buttons LEDs and a diagnostic display For further information or assistance consult the Genie Service Department Fg 3 JC1 JOYSTICK CONTROLLER E 0 LARM 6 o S PLATFORM CONTROLS CIRCUIT BOARD oo oo d EMERGENCY NE STOP a joystick controller JC1 b alarm H1 c platform controls circuit board U3 d red Emergency Stop button P2 Genie 4 2 GS 30 GS 32 GS 46 REV J
278. esulting in death or serious injury Tip over hazard This procedure must only be performed by a trained service professional Attempting this procedure without the necessary skills will result in death or serious injury 1 Pull out the red Emergency Stop button to the on position at the ground controls 2 Push in the red Emergency Stop button to the off position at the platform controls 3 Turn the key switch to platform control 4 Atthe platform controls press and hold the lift function select and horn buttons and pull out the red Emergency Stop button to the on position Result The diagnostic display will show PS 5 Release the lift function select and horn buttons Result The diagnostic display will show the maximum lift speed percentage 6 Press the lift function select button Part No 97385 Genie GS 30 GS 32 GS 46 4 5 PLATFORM CONTROLS 5 E joystick controller JC1 with thumb steering rocker SW6 horn button BN5 lift function select button BN9 diagnostic display G8 red Emergency Stop button P2 drive function select BN8 speed select button BN6 5 20 7 Use the steering thumb rocker switch on the joystick to increase or decrease the maximum lift speed percentage Refer to Section 2 Specifications for function speeds 8 Turn the key switch to the off position Note Any change in software se
279. fall when the rod end pivot pin is removed if not properly supported 21 Lower the cylinder onto the number 1 inner arm index 8 Component damage hazard Cables can be damaged if they are kinked or pinched 22 Attach a lifting strap from an overhead crane to the number 3 inner arm index 10 23 Remove the retaining fasteners from the number 3 pivot pin index 4 at the steer end 24 Use a soft metal drift to remove the number 3 pivot pin index 4 Remove the number 3 inner arm index 10 from the machine AWARNING Bodily injury hazard The number 3 inner arm may become unbalanced and fall if not properly supported when removed from the machine 25 Remove the cables from the number 2 cable bridge and lay them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched 26 Remove the external snap rings and retaining fasteners from the number 2 center pivot pin index 5 at the ground controls side 27 Remove the number 2 cable bridge mounting fasteners and remove the cable bridge from the machine 28 Attach a lifting strap from an overhead crane to the number 2 outer arm index 14 at the ground controls side 29 Use a soft metal drift to remove the number 2 center pivot pin index 5 at the ground controls side Part No 97385 2007 Section 4 Repair Procedures REV 30 Remove the retaining fasteners from the number 2 pivot pin index 15
280. g fasteners dry Hydraulic tank retaining fasteners lubricated 26 in Ibs 2 9 Nm 4 101 Section 4 Repair Procedures November 2008 Steer Axle Components 8 1 Yoke and Drive Motor How to Remove the Yoke and Drive Motor Assembly When removing a hose assembly or fitting the fitting and or hose end must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Block the non steer wheels 2 Remove the cotter pin from the wheel castle nut Note 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 Center a lifting jack under the drive chassis at the steer end of the machine 5 Raise the machine approximately 6 inches 15 cm Place blocks under the chassis for support AWARNING Crushing hazard The chassis could fall if not properly supported 6 Remove the wheel castle nut Remove the wheel 4 102 Genie GS 30 GS 32 GS 46 REV B 7 Tag disconnect and plug the hydraulic hoses on the drive motor Cap the fittings on the drive motor AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Component damage hazard Hoses can be damaged if they are kinked or pinched 8 Support and secure the
281. gt MEIN E 5 MEN 5 1 ALARM 35 E 6 28 Len MEN o9 MEN ESO141W Part No 97385 REVA February 2012 GS 2032 2632 3232 from serial number GS321 1A 97904 to GS3212A 109999 GS 2046 2646 3246 from serial number GS461 1A 97983 to GS4612A 109999 Electrical Schematic ANSI CSA and Australia Models Section 6 Schematics 8 GROUND BN 256 ROLL H DERE 5 E o 8 PITCH BL 4 E POWER WH 4 d EE i ul 1 et 8 8 a eer gt ae lt 4 ot 8 8 poene DATA Ever 4 Qt 5 5 5 DATA LOW z 3 olx pee hee DL NEUE m bog 1 AT it POWER TO 1780 08 55 BLWH T lt aile re BEN o5 is 5 z pe GROUND TO PLAT i 8L X8
282. hazard The scissor eio assembly will fall if not properly supported when removed from the drive chassis Component damage hazard Be careful not to damage the level sensor or limit switch while moving the scissor assembly 10 Remove both old wear pads 11 Install two new wear pads 12 Slide the scissor assembly back into the drive chassis 13 Lower the scissor assembly into position and install the chassis mount bracket onto the chassis Securely install and tighten the fasteners Do not overtighten Component damage hazard Be careful not to damage the level sensor or limit switch while moving the scissor assembly Section 4 Repair Procedures March 2007 SC ISSOR COMPONENTS O REV C 9 9 96 0 6 Steer End EHC Non steer End 9 10 11 Number 5 pivot pin Number 4 center pivot pin 2 pins Number 4 pivot pin steer end Number 3 center pivot pin 2 pins Lift cylinder rod end pivot pin Number 3 pivot pin steer end Number 2 center pivot pin 2 pins Number 2 pivot pin steer end Number 1 center pivot pin 2 pins Number 1 inner arm Number 1 pivot pin Genie GS 30 GS 32 GS 46 12 Number 4 inner arm 13 Number 4 outer arm 14 Number 4 pivot pin non steer end 15 Number 3 inner arm 16 Number
283. he machine 71 Use a soft metal drift to remove the number 1 center pivot pins index 9 Bodily injury hazard The number long block across both sides of the chassis ACAUTION 1 outer arm may become under the number 1 center pivot pin unbalanced and fall if not properly index 11 supported when the pin is removed Genie Part No 97385 GS 30 GS 32 GS 46 Section 4 Repair Procedures March 2007 72 Slide the number 1 outer arm index 22 to the non steer end and remove it from the machine Bodily injury hazard The number ACAUTION 1 outer arm may become unbalanced and fall if not properly supported when removed from the machine 73 Attach the strap from an overhead crane to the number 1 inner arm index 10 Do not lift it 74 Remove the upper fasteners securing the number 1 inner arm pivot bracket to the end of the chassis Loosen the lower fasteners 75 Remove the number 1 inner arm index 10 from the machine Bodily injury hazard The number ACAUTION 1 inner arm may become unbalanced and fall if not properly supported when removed from the machine Component damage hazard Be sure not to damage the limit switch or level sensor box components when the number 1 inner arm is removed from the machine Genie GS 30 GS 32 GS 46 REV How to Replace the Scissor Arm Wear Pads 1 Remove the platform See 2 1 How to Remove the Platform 2 Support and secure the entry ladder to a
284. he machine Crushing hazard The outrigger ACAUTION cylinder may become unbalanced and fall if not properly supported when it is removed from the machine Note After installing a new cylinder or pressure transducer the pressure transducers on the machine must be calibrated Refer to Section 1 4 How to Calibrate the Outrigger Pressure Transducers 4 108 Genie GS 30 GS 32 GS 46 REVA e CF EZ CC and CD Y33 xL Y34 Non steer End Outrigger orifice pressure transducer valve coil outrigger cylinder check valve 97385 2007 Section 5 Fault Codes Fault Codes Before Troubleshooting Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necessary tools and test equipment are available and ready for use Observe and Obey Read each appropriate fault code thoroughly Attempting short cuts may produce hazardous conditions Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine Be aware of the following hazards and follow Immediately tag and remove from service generally accepted safe workshop practices damaged or malfunctioning machine TUTTA Crushing hazard When testing Repair any machine damage or malfunction before
285. he number 2 ACAUTION outer arm index 14 may become unbalanced and fall if not properly supported when removed from the machine 36 Attach a lifting strap from an overhead crane to the number 2 inner arm index 13 Raise the arm to a vertical position Part No 97385 Genie GS 30 GS 32 GS 46 SCISSOR COMPONENTS 37 Remove the retaining fasteners from the number 2 pivot pin at the steer end of the machine index 6 38 Use a soft metal drift to remove the number 2 pivot pin index 6 from the steer end of the machine Remove the number 2 inner arm index 13 from the machine Crushing hazard The number 2 ACAUTION inner arm index 13 may become unbalanced and fall if not properly supported when the pivot pin is removed 39 Attach a lifting strap from an overhead crane to the number 1 inner arm index 8 40 Raise the number 1 inner arm index 8 approximately 2 feet 60 cm 41 Place 4 x 4 x 48 inch 10 cm x 10 cm x 1 2 long block across both sides of the chassis under the number 1 center pivot pin index 7 42 Lower the scissor arms onto the block that was placed across the chassis Bodily injury hazard Keep hands ACAUTION clear of moving parts when lowering the scissor arms 43 Attach a lifting strap from an overhead crane to the lug of the rod end of the lower lift cylinder 44 Tag disconnect and plug the hydraulic hose on the lower lift cylinder Cap the fittings on the cylin
286. hematics 2007 1 Genie 6 122 GS 30 GS 32 6 Part No 97385 Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 61 7 3375 1002 Genie Scandinavia Phone 46 31 575100 Fax 46 31 579020 Genie China Phone 86 21 53852570 Fax 86 21 53852569 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Malaysia Phone 65 98 480 775 Fax 65 67 533 544 Genie Iberica Phone 34 93 579 5042 Fax 34 93 579 5059 Genie Germany Phone 49 0 4202 88520 Fax 49 0 4202 8852 20 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Korea Phone 82 25 587 267 Fax 82 25 583 910 Genie U K Phone 44 0 1476 584333 Fax 44 0 1476 584334 Genie Brasil Phone 55 11 41 665 755 Fax 55 11 41 665 754 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Genie Holland Phone 31 183 581 102 Fax 31 183 581 6 Service Manual GS 30 GS 32 GS 46 from serial number GS3005A 7600 from serial number GS3005B 7600 from serial number GS3205 75407 from serial number GS4605 75438 Part No 97385 Rev E10 G A TEREX BRAND
287. hematics Electrical Schematic REVG CE Models GS 1530 32 amp 1930 32 from serial number GS3007A 89538 to GS3010A 99455 and GS3007B 84600 to GS3009B 98941 and P2 EMERGENCY NOTE BK POWER TO PLATFORM MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF 4 3 RD POWER GROUND 1 WH GROUND 2 2 BL DATALINK HIGH m PIAS 5 5 OR DATA LINK LOW U3 PLATFORM CONTROLS VOLTAG PRINTED CIRCUIT BOARD REGULATOI HALL EFFECT J GeNERATOR JOYSTICK 7 CONTROLLER SW5 SW6 FUNCTION ENABLE STEER LEFT RIGHT OR I BK PLATFORM CONTROLS 24 MEMBRANE DECAL POUT1 ZA LIFT LED 6 POUT2 4 DRIVE LED L17 POUT3 4 HIGH TORQUE LED 121 M G8 POUT4 DIAGNOSTIC DISPLAY PIN1 HIGH TORQUE BN6 PIN2 HORN BN5 PIN3 DRIVE ENABLE BN8 PIN4 LIFT ENABLE BN9 H1 PLATFORM BK ALARM CONTROLLER POUT11 O ES0142P Genie Part No 97385 GS 30 GS 32 GS 46 6 77 Section 6 Schematics S E EEEN Electrical Schematic February 2012
288. hematics February 2012 Electrical Schematic ANSI CSA and Australia Models REV D GS 2032 2632 3232 from serial number GS3207A 84867 to GS3210A 94974 GS 2046 2646 3246 from serial number GS4607A 84840 to GS4610A 95454 MR RSA SPR SERIE l bo deeem 1 505050805 i EN pt 5 EMERGENCY a y Te ep B po 1 2 KS1 at key PLATFORM 1 d SWITCH CONTROL 11 4 1 7 B1 H5 ALARM 3 A UM NC E NCHO AM Of CB 157 2 TS66 POTHOLE Eod PLATFORM ree 1 UP DOWN 1 CB2 8 N C H O y f OF MACHINE SHOWN IN THE 2 LS8 STOWED POSITION WITH P GUARD THE POWER OFF SWITCH c gt j 585 52 5 BLACK AND WHITE WIRES CUT POWER pod 2 MOTOR CONTROLLER WHEN THE Lo DS L30 5 5 CHARGER IS PLUGGED IN OPTION LIGHT 5 2 QD1
289. hose manual lowering cable solenoid valve schematic item N cable mount bracket 750 0 om Note At the lower lift cylinder install the orifice fitting with the small opening of the orifice fitting closest to the supply hose Part No 97385 Genie GS 30 GS 32 GS 46 SCISSOR COMPONENTS 5 Models with platform overload option Tag and disconnect the wiring from the platform overload switch 6 Loosen the adjustment nuts on the solenoid valve and disconnect the manual lowering cable from the valve Note During assembly the manual platform lowering cable needs to be properly adjusted See 4 1 How to Adjust the Manual Platform Lowering Cable 7 Remove the fasteners securing the manual lowering cable mount bracket to the cylinder Remove the bracket from the cylinder 8 Tag disconnect and plug the hydraulic hoses on the lift cylinder Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 9 Attach a lifting strap from an overhead crane to the rod end of the lift cylinder for support 10 Remove the retaining fasteners from the lift cylinder rod end pivot pin Use a soft metal drift to remove the pin AWARNING Crushing hazard The lift cylinder will fall if not properly supported 11 Lower the cylinder to a horizon
290. ight add hydraulic oil until the pump is functioning correctly Do not overfill the hydraulic tank Component damage hazard Do not continue to operate the machine if the hydraulic pump is cavitating MANIFOLDS Genie Part No 97385 GS 30 GS 32 GS 46 4 97 Section 4 Repair Procedures February 2009 MANIFOLDS How to Adjust the Steer Relief Valve Perform this test from the ground with the platform controls Do not stand in the platform Be sure that the hydraulic oil level is at the FULL mark on the hydraulic tank 1 Locate the steer relief valve on the function manifold schematic item G or AH 2 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the test port schematic item A or AA on the function manifold Remove the platform controls from the platform 4 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls GS 1530 32 GS 1930 32 a test port b Steer relief valve 5 REVF Activate the function enable switch and press and hold the steer thumb rocker switch to the right Allow the wheels to completely turn to the right Continue holding the switch while observing the pressure reading on the pressure gauge Note the pressure Refer to Section 2 Specifications Press and hold the steer thumb rocker switch to the left Allow the wheels to completely turn to the lef
291. ilure 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 2 3 Raise the platform 7 to 8 feet 2 1 to 2 4 m Lift the safety arm move it to the center of the Scissor arm and rotate down to a vertical position Lower the platform onto the safety arm AWARNING Cushing hazard Keep hands clear of the safety arm when lowering the platform Pull the handle of the manual platform lowering cable out until considerable resistance is felt Release the handle Measure the distance between the base of the handle and cable mounting nut Result The measurement should be no greater than 1 8 inch 3 mm Platform manual lowering cable specification Gap lowering handle to mounting nut 0 to 1 8 inch 0 to 3 mm Part No 97385 Ground Controls Skip to step 8 if the measurement is correct 6 To adjust loosen the upper lock nut on the cable mounting bracket at the cylinder Turn the lower lock nut clockwise to decrease the distance or counterclockwise to increase the distance Tighten the upper lock nut mtm ee COC manual lowering cable sheath upper lock nut cable mounting bracket lower lock nut cable mounting nut end of the lowering cable manual lowering valve hydraulic schematic item N
292. imit switch Loosen the fastener securing the roller arm to the limit switch and rotate the roller arm 90 degrees in a downwards direction Do not activate the switch contacts 10 Turn the key switch to platform control 11 Raise the platform and return the safety arm to the stowed position 12 Working at the platform controls press the lift function select button Lower the platform to the stowed position Result The diagnostic display will show code 18 an alarm sounds and the lift function should operate The machine is functioning properly Result The diagnostic display does not show code 18 the alarm does not sound and the lift function should not operate Replace the down limit switch Section 3 Scheduled Maintenance Procedures February 2012 CHECKLIST B PROCEDURES 13 Press the drive function select button Attempt to drive the machine Result The diagnostic display will show code 18 an alarm sounds and the steer and drive functions should not operate The machine is functioning properly Result The diagnostic display does not show code 18 the alarm does not sound and the steer and drive functions operate Replace the down limit switch 14 Press the lift function select button Raise the platform approximately 12 inches 0 3 m Result The diagnostic display will show code 18 and an alarm sounds The machine is functioning properly W Result The diagnostic display does not sh
293. ing notes on the electrical schematic Note alpha callouts refer to corresponding notes on the hydraulic schematic GS 30 GS 32 GS 46 Section 4 Repair Procedures February 2009 MANIFOLDS 6 5 Check Valve Manifold Components GS 1530 GS 1532 GS 1930 and GS 1932 The check valve manifold is mounted on the function manifold Index Schematic No Description Item Function 1 Check valve 200 psi 13 8 REM Drive circuit Note alpha callouts refer to corresponding notes on the hydraulic schematic How to Install a Valve Cartridge 1 Dip the cartridge in clean oil to lube the O rings 2 Screw the cartridge in by hand until the top O ring is met then torque to specification 3 If required install the valve coil s onto the valve stem Install the coil nut onto the valve stem and torque to specification Genie REV F Torque 20 ft lbs 27 Nm 4 94 GS 30 GS 32 95 46 Part 97385 February 2009 Section 4 Repair Procedures REV F 6 6 Valve Adjustments Function Manifold How to Adjust the System Relief Valve Perform this test from the ground with the platform controls Do not stand in the platform Be sure that the hydraulic oil level is at the FULL mark on the hydraulic tank 1 Locate the system relief valve on the function manifold schematic item or AB 2
294. ining fasteners from the lift cylinder rod end pivot pin index 3 19 Use a soft metal drift to remove the lift cylinder rod end pivot pin index 3 from the machine Crushing hazard The lift cylinder ACAUTION will fall if not properly supported when the pivot pin is removed 20 Place a 2 x 4 x 10 inch 10 x 10 x 25 cm block onto the number 1 inner arm cylinder plate index 8 4 52 Genie GS 30 GS 32 GS 46 REV 21 Lower the cylinder onto the block Bodily injury hazard Keep hands ACAUTION clear of moving parts when lowering the cylinder onto the block 22 Attach a lifting strap from an overhead crane to the number 3 inner arm index 10 Raise the arm to a vertical position 23 Remove the retaining fasteners from the number 3 pivot pin at the steer end of the machine index 4 24 Use a soft metal drift to remove the number 3 pivot pin index 4 from the steer end of the machine Remove the number 3 inner arm index 10 from the machine Crushing hazard The number 3 ACAUTION inner arm index 10 may become unbalanced and fall if not properly supported when the pivot pin is removed 25 Remove the cables from the number 2A and 2B cable bridge and lay them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched 26 Disconnect the number 2A and 2B cable bridges from the scissor linkset and remove both cable bridges from the machine 27 Attach a
295. inner arm may become unbalanced and fall if not properly supported when removed from the machine 39 Remove the cables from the number 2 cable bridge and lay them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched 40 Remove the external snap rings and retaining fasteners from the number 2 center pivot pin index 7 at the ground controls side Section 4 Repair Procedures March 2007 SCISSOR COMPONENTS 41 Remove the number 2 cable bridge mounting fasteners and remove the cable bridge from the machine 42 Attach a lifting strap from an overhead crane to the number 2 outer arm index 19 at the ground controls side 43 Use a soft metal drift to remove the number 2 center pivot pin index 7 at the ground controls side 44 Remove the retaining fasteners from the number 2 pivot pin index 20 at the non steer end of the machine 45 Use a soft metal drift to tap the number 2 pivot pin index 20 halfway out at the non steer end of the machine Remove the number 2 outer arm index 19 from the ground controls side of the machine Bodily injury hazard The number ACAUTION 2 outer arm at the ground controls side may become unbalanced and fall if not properly supported when removed from the machine 46 Attach a lifting strap from an overhead crane to the number 2 outer arm index 19 at the battery pack side 47 Remove the external snap rings and retaining fas
296. ion 2 Push in the red Emergency Stop button at the ground controls to the off position 3 Open the battery tray and disconnect the Anderson connector 4 Locate the electrical contactor mounted on the fuse bracket 5 Visually inspect the contact points of the contactor for the following items Excessive burns Excessive arcs Excessive pitting AWARNING Electrocution burn hazard Contact with hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry Note Replace the contactor if any damage is found Part No 97385 Genie GS 30 GS 32 GS 46 CHECKLIST B PROCEDURES B 4 Inspect the Tires and Wheels including castle nut torque Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the tires and wheels in good condition is essential to safe operation and good performance Tire and or wheel failure could result 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 punctures and unusual wear 2 Check each wheel for damage bends and cracks 3 Remove the cotter pin and check each castle nut for proper torque Refer to Section 2 Specifications Note Always replace the cotter pin with a new one when removing the castle nut or when checking the torque of the castl
297. irst 30 days or 40 hours of usage After this interval refer to the maintenance tables for continued scheduled maintenance 1 Perform the following maintenance procedures 3 Inspect the Tires Wheels and Castle Nut Torque D 2 Replace the Hydraulic Tank Return Filter Element Genie GS 30 GS 32 GS 46 REV A 5 Grease the Steer Yokes Genie specifications require that this procedure be performed every 100 hours of operation Regular application of lubrication to the steer yokes is essential to good machine performance and service life Continued use of an insufficiently greased steer yoke will result in component damage 1 Locate the grease fitting on the top of the steer yoke 2 Pump multipurpose grease into the steer yoke until the steer yoke is full and grease is being forced past the bearings Repeat this step for the other steer yoke Grease Specification Chevron Ultra duty grease EP NLGI 1 lithium based or equivalent Part No 97385 February 2012 Section 3 Scheduled Maintenance Procedures Checklist B Procedures REV K B 1 Inspect the Batteries Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Proper battery condition is essential to good machine performance and operational safety Improper fluid levels or damaged cables and connections can result in component damage and hazardous conditions AWARNING Electrocuti
298. ition 4 way 190 20V DC with diode schematic items AE Solenoid valve 3 position 5 way 190 20V DC with diode schematic item AG Solenoid valve 2 position 2 way 27 20 20V DC with diode schematic item CA and CD Solenoid valve 3 position 4 way 19Q 20V DC with diode schematic item BA 4 99 Section 4 Repair Procedures February 2009 MANIFOLDS REV F How to Test a Coil Diode Genie incorporates spike suppressing diodes in all COIL of its coils Properly functioning coil diodes protect A MULTI the electrical circuit by suppressing voltage spikes Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil Faulty diodes can fail to protect the electrical system resulting in a tripped circuit breaker or component damage AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 the coil for resistance See 6 7 How to Test a Coil 2 Connect a 100 resistor to the negative terminal of a known good 9V DC battery Connect the other end of the resistor to a terminal on the coil Note The battery should read 9V DC or more when measured across the terminals Resistor 10Q Genie part number 27287 Seta multimeter to read DC amperage Note The multimeter when set to read DC amperage should be capable of reading up to 800 mA
299. jack Genie Part No 97385 GS 30 GS 32 GS 46 4 83 Section 4 Repair Procedures March 2007 GROUND CONTROLS How to Install the Outrigger Level Sensor REV D Place the new outrigger level sensor onto the outrigger level sensor base with the flat side of the outrigger level sensor closest to the battery side access door Refer to Illustration 1 ADAN SER Tip over hazard Failure to install 7 the outrigger level sensor as instructed will compromise e A JJ machine stability and cause the Yoo machine to tip over resulting in 1 4 death or serious injury Do not 9 install the outrigger level sensor other than specified in this H procedure 9 o o sf 1 Move the machine to an area that has a firm Lool d level surface and is free of obstructions Bes A n SOS 2 key switch to off position and push in the red Emergency Stop button to the off Outrigger position at both the ground and platform p Sensor controls Illustration 1 3 Open the access door at the battery side of the machine 7 Secure the outrigger level sensor onto the base with the retaining fasteners removed in step 5 4 Tag and disconnect the outrigger level sensor 9 P wire har
300. l drift to remove the pin AWARNING Crushing hazard The lift cylinder will fall if not properly supported when the pin is removed 14 Support and secure the lift cylinder to an appropriate lifting device 15 Remove the lift cylinder through the scissor arms at the steer end of the machine Crushing hazard The lift cylinder ACAUTION may become unbalanced and fall if not properly supported and secured to the lifting device Component damage hazard Be careful not to damage the valve or SCISSOR COMPONENTS GS 2032 GS 2632 GS 2046 and GS 2646 Raise the platform 7 to 8 feet 2 1 to 2 4 m Lift the safety arm move it to the center of the scissor arm and rotate down to a vertical position Lower the platform onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 4 Tag and disconnect the wiring from the solenoid valve coil at the barrel end of the lift cylinder fittings on the cylinder while a lift cylinder removing it from the machine b orifice schematic item c connector fitting d hydraulic hose Torque specification e manuallowering cable m f solenoid valve schematic item N Solenoid valve 2 position 2 way N C 20 ft Ibs g mount bracket schematic item N 27 Nm FE 5 Models with platform overload option Tag cue and disconnect the wiring from the platform 7 Nm overload
301. l number GS3006A 83068 to GS3007A 87490 GS 1530 1532 1930 1932 from serial number GS3006B 79660 to GS3007B 82543 P1 2 m A EMERGENCY CN 7 pi 4 WH 2 8 1 Non 2 KS1 key PLATFORM SWITCH CONTROL 4 1 NOTE x H5 MACHINE SHOWN IN THE x 7 STOWED POSITION WITH 4 THE POWER OFF ONTROL 7 21 7707 157 TS66 P GUARD PLATFORM SWITCH 4 UP DOWN CB2 N C HO 7 E Of BREAKER 2 LS8 POTHOLE GUARD SWITCH Wee eo c A Uu 1 S35 3 52 5 BLACK AND WHITE WIRES CUT POWER 5 9 130 S 5 2 2 QD1 0 A OPTION 3 fe ete F6 275 FUSE 8 BK a eo U9 2K 48 our j OUT U5 CHARGER ELECTRONIC CONTROL MODULE T B8 B3 o Jo l AC INPUT 9 2 MOTOR 9 CONTROLLER E CONNECTED gt CR5 i eni T HORN RELAY tC T DC AC INVERTER Sor 5 Yer 55 OPTION 5 H2 SS eos OPTION 56 AUTO STYLE METER jl ES0141K Genie GS 30 GS 32 GS 46 Part No 97385 April 2008 Section 6 Schematics Electrical Schematic REV ANSI CSA and Australia Models GS 1530 1532 19
302. ladder to an appropriate lifting device 52 Remove the 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 Genie GS 30 GS 32 GS 46 REV 53 Attach a lifting strap from an overhead crane to the number 1 outer arm index 17 Do not apply any lifting pressure 54 Remove the external snap rings and retaining fasteners from the number 1 center pivot pins index 7 55 Remove the number 1 cable bridge from the machine 56 Use a soft metal drift to remove the number 1 center pivot pins index 7 Bodily injury hazard The number ACAUTION 1 outer arm may become unbalanced and fall if not properly supported when the pin is removed 57 Slide the number 1 outer arm index 17 to the non steer end and remove it from the machine Bodily injury hazard The number ACAUTION 1 outer arm may become unbalanced and fall if not properly supported when removed from the machine 58 Attach the strap from an overhead crane to the number 1 inner arm index 8 Do not lift it 59 Remove the upper fasteners securing the number 1 inner arm pivot bracket to the end of the chassis Loosen the lower fasteners 60 Remove the number 1 inner arm index 8 from the machine Bodily injury hazard The number ACAUTION 1 inner arm may become unbalanced and fall
303. ld wire harness disconnected from the limit switch wire harness in step 2 4 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls Genie GS 30 GS 32 GS 46 REV 5 Fully raise the platform Release the toggle Switch Result The alarm should sound Result The alarm does not sound Calibrate the platform overload system Refer to Repair Procedure 3 7 Calibrate the Platform Overload System if equipped 6 Using the manual lowering knob lower the platform to the stowed position 7 Disconnect the two blue black wires of the manifold wire harness at the lift valve coil on the manifold 8 Securely connect the black and white wires of the up limit switch wire harness to the two blue black wires of the manifold wire harness at the lift valve coil on the manifold 9 Fully raise the platform Release the toggle switch Result models with software revision AO and A1 The alarm should not sound and fault code 54 should be present in the diagnostic display The system is functioning correctly O Result models with software revision A2 and higher The alarm should not sound The system is functioning correctly W Result all models The alarm sounds The system is not functioning correctly Troubleshoot the limit switch limit switch wire harness or limit switch mount bracket OR the platform overload system needs
304. lem still exists Return to Perform service 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 remain on when a fault code is displayed The codes listed in the Fault Code Chart describe malfunctions and can aid in troubleshooting the machine by pinpointing the area or component affected Fault Code Note If the machine will not drive or lift but the readout is powered and no fault code is displayed the electrical contactor could have failed If this condition is present measure the resistance across the positive and negative signal terminals Do not measure resistance at the power terminals The resistance should measure 47 ohms If the resistance measures lower than 47 ohms replace the electrical contactor Refer to the illustration below Power Terminals Positive T Negative Signal Signal Terminals Terminals Electrical Contactor 5 2 GS 30 GS 32 6 Part No 97385 March 2007 Section 5 Fault Codes Fault Code Chart Fault Code Problem Possible Causes Solution 01 Internal ECM error EPROM not programmed Replace ECM ECM Platform communication error
305. lightly and remove the block 4 54 Genie GS 30 GS 32 GS 46 REV 54 Lower the arm to the stowed position Bodily injury hazard Keep hands ACAUTION clear of moving parts when lowering the scissor arms 55 Secure the ends of the scissor arms together at the steer end of the machine with a strap or other suitable device 56 Secure the ends of the scissor arms together at the non steer end of the machine with a strap or other suitable device 57 Remove the retaining fasteners securing the chassis mount bracket to the chassis 58 Remove the linkset from the machine Bodily injury hazard The number ACAUTION 1 inner and outer arms index 8 and 17 may become unbalanced and fall if not properly supported when removed from the machine Component damage hazard Be sure not to damage the limit switch or level sensor box components when the number 1 inner and outer arms index 8 and 17 is removed from the machine Part No 97385 2007 Section 4 Repair Procedures REV How to Replace the Scissor Arm Wear Pads 1 Remove the platform See 2 1 How to Remove the Platform 2 Support and secure the entry ladder to an appropriate lifting device 3 Remove the 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 4 Secur
306. linder rod end pivot pin index 5 33 Use a soft metal drift to remove the lift cylinder rod end pivot pin index 5 from the machine Crushing hazard The lift cylinder ACAUTION will fall if not properly supported when the pivot pin is removed 34 Place a 2 x 4x 10 inch 10 x 10 x 25 cm block onto the number 1 inner arm cylinder plate index 10 35 Lower the cylinder onto the block Bodily injury hazard Keep hands ACAUTION clear of moving parts when lowering the cylinder onto the block 36 Attach a lifting strap from an overhead crane to the number 3 inner arm index 15 Raise the arm to a vertical position 37 Remove the retaining fasteners from the number 3 pivot pin at the steer end of the machine index 6 Section 4 Repair Procedures March 2007 SCISSOR COMPONENTS 38 Use a soft metal drift to remove the number 3 pivot pin index 6 from the steer end of the machine Remove the number 3 inner arm index 15 from the machine Crushing hazard The number 3 ACAUTION inner arm index 15 may become unbalanced and fall if not properly supported when the pivot pin is removed 39 Remove the cables from the number 2A and 2B cable bridge and lay them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched 40 Disconnect the number 2A and 2B cable bridges from the scissor linkset and remove both cable bridges from the machine 41 Attach a lifting strap f
307. ling printed circuit boards OR use a grounded wrist strap 32 Install the control pad top enclosure onto the control pad bottom enclosure Refer to Illustration 2 Illustration 2 Illustration 1 a control pad b control pad bracket washer d screw 34 Connect the outrigger controls coil cord to the top enclosure coil cord outrigger controls cable bottom enclosure printed circuit board control pad decal hidden from view button cap 20 Genie 4 30 GS 30 GS 32 GS 46 Part No 97385 October 2009 Section 4 Repair Procedures REV J How to Assemble and Install the Outrigger ECM 35 Insert the ECM printed circuit board into the ECM enclosure Refer to Illustration 5 Component damage hazard Electrostatic discharge ESD can damage printed circuit board components Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap 36 Using the fasteners removed in step 13 securely install the ECM bottom cover to the ECM enclosure Do not over tighten Refer to Illustration 5 Genie PLATFORM CONTROLS NS SEN Illustration 5 a b 0 0 f ECM enclosure printed circuit board torx screw bottom cover mounting bracket ECM decal Part No 97385
308. ll serve as the identifier when for selecting 29x66 from the Device Family drop down menu Refer to Illustration 7 105368 8 ca cfe 8 lt 6 R98 101 ca PCB P N 105367 REV A M ECM erum 5 49 PRINTED CIRCUIT BOARD pers 8 Illustration 7 Part No 97385 Genie GS 30 GS 32 GS 46 PLATFORM CONTROLS Note The control pad printed circuit board will be labeled with Genie part number 105370 and will serve as the identifier when for selecting 29x66 from the Device Family drop down menu Refer to Illustration 8 G Qn Q A TEREX COMPANY MTG1 PCB 105369 REV A LIFT cg 9 9 2 CONTROL PAD PRINTED CIRCUIT BOARD Illustration 8 Section 4 Repair Procedures October 2009 PLATFORM CONTROLS REV J 23 At
309. ll the tilt level sensor as instructed could result in the machine tipping over causing death or serious injury 13 Install the level sensor retaining fasteners through the level sensor and springs and into the mount bracket Tighten the fasteners and measure the distance between the level sensor and the level sensor mount bracket Result The measurement should be approximately 3 8 inch 10 mm 14 Connect the chassis wire harness to the level sensor wire harness 15 Turn the key switch to the ground control and pull out the red Emergency Stop button to the on position at the ground controls 16 Adjust the level sensor retaining fasteners until the bubble in the top of the level sensor is centered in the circles Result The tilt sensor alarm should not sound Part No 97385 Genie GS 30 GS 32 GS 46 A 0 Non steer end limit switch level sensor mount bracket level sensor S7 alarm H5 level sensor retaining fastener scissor chassis 17 Raise the platform slightly 18 Return the safety arm to the stowed position 19 Lower the platform to the stowed position 20 Center a lifting jack under the drive chassis at the ground controls side of the machine 21 Raise the machine approximately 2 inches 5 cm 4 81 Section 4 Repair Procedures March 2007 GROUND CONTROLS 22 GS 1530 and
310. matic item Solenoid valve 2 position 4 way 190 20V DC with diode schematic item H and AI Solenoid valve 2 position 2 way N C 250 20V DC with diode schematic item Solenoid valve 2 position 4 way 190 20V DC with diode schematic items AE Solenoid valve 3 position 5 way 190 20V DC with diode schematic item AG Solenoid valve 2 position 2 way 27 20 20V DC with diode schematic item CA CB CC and CD Solenoid valve 3 position 4 way 190 20V DC with diode schematic item BA Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice GS 30 GS 32 GS 46 Part No 97385 February 2009 Section 2 Specifications REV SPECIFICATIONS Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with JIC 37 flared fittings and hose ends Genie specifications require that fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed SAE O ring Boss Port JIC 37 Fittings tube fitting installed into Aluminum swivel nut or hose connection SAE Dash size Torque SAE Dash size Thread Size Flats 4 11 ft lbs 14 9 Nm 4 7 16 20 2 6 23 ft lbs 31 2 Nm 6 9 16 18 1 1 4 8 40 ft lbs 54 2 Nm 8 3 4 16 1 10 69 ft lbs 93 6 Nm 10 74 1 12 93 ft lbs 1
311. me unbalanced and fall if not properly supported when removed from the machine Part No 97385 2007 Section 4 Repair Procedures REV 50 Attach a lifting strap from an overhead crane to the number 2 inner arm index 18 Raise the arm to a vertical position 51 Remove the retaining fasteners from the number 2 pivot pin at the steer end of the machine index 8 52 Use a soft metal drift to remove the number 2 pivot pin index 8 from the steer end of the machine Remove the number 2 inner arm index 18 from the machine Crushing hazard The number 2 ACAUTION inner arm index 18 may become unbalanced and fall if not properly supported when the pivot pin is removed 53 Attach a lifting strap from an overhead crane to the number 1 inner arm index 10 54 Raise the number 1 inner arm index 10 approximately 2 feet 60 cm 55 Place 4 4 48 inch 10 cm x 10 cm 1 2 m long block across both sides of the chassis under the number 1 center pivot pin index 9 56 Lower the scissor arms onto the block that was placed across the chassis Bodily injury hazard Keep hands ACAUTION clear of moving parts when lowering the scissor arms 57 Attach a lifting strap from an overhead crane to the lug of the rod end of the lower lift cylinder Part No 97385 Genie GS 30 GS 32 GS 46 SCISSOR COMPONENTS 58 Tag disconnect and plug the hydraulic hose on the lower lift c
312. move the old wear pad 14 Install the new wear pad 15 Slide the scissor assembly back into the drive chassis 16 Lower the scissor assembly into position and install the chassis mount bracket onto the chassis Securely install and tighten the fasteners Do not overtighten Component damage hazard Be careful not to damage the level sensor or limit switch while moving the scissor assembly Genie Part No 97385 GS 30 GS 32 GS 46 4 63 Section 4 Repair Procedures March 2007 SCISSOR COMPONENTS REV e QD 5 amp 9 9 9 5 OAOA OOO 988 0909 8 9 9 2 9 GS 3232 D Steer end GS 3246 Non steer end Number 6 pivot pin Number 5 center pivot pin 2 pins Upper lift cylinder rod end pivot pin Number 5 pivot pin steer end Number 4 center pivot pin 2 pins Number 4 pivot pin steer end Number 3 outer arm Number 3 center pivot pin 2 pins 9 Lower lift cylinder rod end pivot pin 10 Number 3 pivot pin steer end 11 Number 2 center pivot pin 2 pins 12 Number 2 pivot pin steer end 13 Number 1 center pivot pin 2 pins 14 Number 1 inner arm o 4 16 Number 5 inner arm 17 Number 5 outer arm 18 Number 5 pivot pin non steer end 19 Number 4 inner arm 20 Number 4 outer arm 21 Numbe
313. n appropriate lifting device 3 Remove the 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 4 Secure the ends of the scissor arms together at the steer end of the machine with a strap or other suitable device 5 Secure the ends of the scissor arms together at the non steer end of the machine with a strap or other suitable device 6 Remove the retaining fasteners securing the chassis mount bracket to the chassis at the steer end of the machine 7 Attach a lifting strap from an overhead crane to the scissor arm assembly 8 Raise the scissor arm assembly at the steer end with the overhead crane until the chassis mount bracket will clear the level sensor Part No 97385 March 2007 Section 4 Repair Procedures REV 9 Remove the scissor assembly from the machine just enough to access both wear pads TJ Crushing hazard The scissor assembly will fall if not properly supported when removed from the drive chassis Component damage hazard Be careful not to damage the level sensor or limit switch while moving the scissor assembly 10 Remove both old wear pads 11 Install two new wear pads 12 Slide the scissor assembly back into the drive chassis 13 Lower the scissor assembly into position and install the chassis mount bracket onto the cha
314. n during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Disconnect the battery pack from the machine AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 2 Tag and disconnect the hydraulic power unit cables at the motor controller 3 Disconnect the filter head from the filter head mounting bracket Rotate the filter out and away from the hydraulic power unit 4 Remove the hydraulic power unit retaining fasteners 5 Tag disconnect and plug the hydraulic hard line from the pump Cap the fitting on the pump Part No 97385 Genie GS 30 GS 32 GS 46 HYDRAULIC PUMP 6 Tag disconnect and plug the high pressure hose at the pump Cap the fitting on the pump AWARNING ae 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 7 Remove the hydraulic power unit from the machine 8 Remove the pump mounting bolts Carefully remove the pump 7117 Tip over hazard After replacing the hydraulic pump it is critical to return the function speed settings to original factory specifications Failure to restore the machine to original factory specifications could cause the machine to tip over resulting in death or serious injury
315. nded period of time Reduce the power draw The inverter will then operate correctly and begin supplying AC power If the right fault LED 123 blinks two times the Ground Fault Interrupt has been activated A short circuit or partial short exists between the AC hot and ground in the tool or outlet Check the tool for burnt chafed corroded and loose wires and inspect the tool for internal moisture Correct the short circuit or moisture issue OR inspect the wiring in the power to platform box The inverter will then operate correctly and begin supplying AC power If right fault LED 123 blinks three times the inverter is overheated Allow the inverter to cool The inverter will then operate correctly and begin supplying AC power If the battery 25 volt fault LED 25V blinks one time the battery voltage is over 30V Operate the machine to lower the voltage level The inverter will then operate correctly and begin supplying AC power If the battery 21 volt fault LED 21V blinks one time the battery voltage is less than 20V DC The inverter will continue to operate until the battery voltage falls to 17 8V DC Part No 97385 February 2012 Section 3 Scheduled Maintenance Procedures REV K B 16 Test the Down Limit Switch and the Pothole Limit Switches Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the limit switches is essential to saf
316. ne crosses the start line Continue at full speed and note the time when your reference point on the machine passes over the finish line Refer to Section 2 Specifications a lift function select button BN9 b drive function select button BN8 Genie 3 20 GS 30 GS 32 GS 46 Part No 97385 February 2012 Section 3 Scheduled Maintenance Procedures REV K B 11 5 Test the Slow Drive Speed 6 Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first 7 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 Perform this procedure with the machine on a firm level surface that is 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 platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 3 Lower the platform to the stowed position 4 Press the slow speed select button a slow speed select button BN6 Part No 97385 GS 30 GS 32 Genie CHECKLIST B PROCEDURES Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and fini
317. ne operation in the event the platform is overloaded Models equipped with the platform overload option are provided with two additional machine control components the overload pressure switch and a maximum height limit switch The overload pressure switch which is adjustable and located at the barrel end of the lift cylinder is used to determine when the hydraulic lift cylinder requires too much pressure to support the load inside the platform When this occurs the pressure switch will send a signal to the ECM which will not allow the machine to function until the extra weight is removed from the platform Genie ices overload pressure switch maximum height limit switch Part No 97385 GS 30 GS 32 GS 46 Section 3 Scheduled Maintenance Procedures March 2007 CHECKLIST C PROCEDURES 1 Locate the lift valve coil on the function manifold GS 1532 GS 1932 gt GS 2032 GS 2632 GS 2046 GS 2646 GS 3246 a test port b lift valve coil 2 Tagand disconnect the black and white wires of the up limit switch wire harness from the blue black wires of the manifold wire harness at the lift valve coil on the manifold 3 Securely connect together the terminals of the two blue black wires of the manifo
318. ness from the outrigger level sensor 8 Adjust the outrigger level sensor retaining fasteners until the bubble in the top of the level i r retainin 5 Remove the outrigger level sensor retaining sensor is centered in the circles fasteners and remove the outrigger level sensor from the machine 9 Connect the outrigger level sensor wire harness to the new outrigger level sensor 10 Close the access door at the battery side of the machine 11 Calibrate the new outrigger level sensor Refer to Section 1 4 How to Calibrate the Outrigger Level Sensor Genie 4 84 GS 30 GS 32 GS 46 Part No 97385 2007 Section 4 Repair Procedures GROUND CONTROLS This page intentionally left blank Genie Part No 97385 GS 30 GS 32 GS 46 4 85 Section 4 Repair Procedures April 2008 Hydraulic Pump 5 1 Function 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 fitting and or hose end must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Tag disconnect and plug the high pressure hydraulic hose from the hydraulic pump AWARNING ed injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate
319. ng the chassis mount bracket to the chassis at the steer end of the machine 7 Attach a lifting strap from an overhead crane to the scissor arm assembly 8 Raise the scissor arm assembly at the steer end with the overhead crane until the chassis mount bracket will clear the level sensor 9 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 Component damage hazard Be careful not to damage the level sensor or limit switch while moving the scissor assembly Part No 97385 Genie GS 30 GS 32 GS 46 SCISSOR COMPONENTS 10 Remove the old wear pad 11 Install the new wear pad 12 Rotate the scissor assembly towards the other side of the machine until the other scissor arm wear pad is accessible Do not allow both wear pads to slide out of the drive chassis 711771111 Crushing hazard The scissor c assembly will fall if both wear pads are allowed to slide out of the drive chassis Component damage hazard Be careful not to damage the level sensor or limit switch while moving the scissor assembly 13 Remove the old wear pad 14 Install the new wear pad 15 Slide the scissor assembly back into the drive chassis 16 Lower the scissor assembly into position and install the chassis mount bracket onto the chassis Securely install and tighten
320. ns very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 10 Place a lifting jack under the brake for support 11 Remove the fasteners that attach the brake to the drive chassis Remove the brake Crushing hazard The brake will ACAUTION fall if not properly supported when the mounting fasteners are removed Torque specifications Brake mounting fasteners dry 75 ft lbs 102 Nm Brake mounting fasteners lubricated 56 ft lbs 76 Nm 4 105 Section 4 Repair Procedures March 2007 Brake Release Hand Pump Components REVA 10 1 Brake Release Hand Pump Components The brake release hand pump manifold is mounted behind the entry ladder Index Schematic No Description Item Function Torque 1 Hand E usus Manual brake release 30 ft lbs 41 Nm 2 Needle Manual brake release enable 45 50 in lbs 5 Nm Note alpha callouts refer to corresponding notes on the hydraulic schematic Genie 4 106 GS 30 GS 32 GS 46 Part No 97385 March 2007 Section 4 Repair Procedures 0 Outrigger Components 11 1 7 Support and secure the outrigger cylinder to a Outrigger Cylinder How to Remove an Outrigger Cylinder Perform this procedure with the platform in the stowed position and the outriggers fully retracted
321. nse option CR27C Overload down coil option CR27D Overload down delay option D7 Voltage regulator Platform controls circuit board F6 Fuse 275A FB Flashing beacons G Gauge G6 Hour meter G8 Diagnostic Display GND Ground H Horn or alarm H1 H2 Automotive style horn option 5 Multifunction alarm H8 Multifunction alarm outrigger control pad GS 3232 1 JC1 Joystick controller Key switch L LED or light L16 Lift L17 Drive L21 High torque L30 Work light option L51 LF outrigger GS 3232 L52 RF outrigger GS 3232 L53 LR outrigger GS 3232 L54 RR outrigger GS 3232 L69 Lift enable outrigger control pad GS 3232 L70 Lift error outrigger control pad GS 3232 LS Limit switch LS5 Platform up option LS5A Up Limit Switch GS 3232 1 55 Up Limit Switch GS 3232 LS6 Platform down LS7 Pothole LS8 Pothole 5 Hydraulic power unit Normally closed NCHO Normally closed held open NOHC Normally open held closed GS 30 GS 32 GS 46 enie March 2007 REV C ELECTRICAL COMPONENT LEGEND cont QD Item Description P Power switch P1 Emergency Stop button at ground controls P2 Emergency Stop button at platform controls PS2 Platform overload pressure switch option PT Pressure transducer PT4 Left rear outrigger GS 3232 PT1 Left fro
322. nt outrigger GS 3232 PT2 Right front outrigger GS 3232 PT3 Right rear outrigger GS 3232 Quick disconnect QD1 Battery quick disconnect QD3 Control cable to ground QD4 Control cable to platform 0020 Cable to outrigger control pad GS 3232 Resistor R24 25 ohm sw Switch SW5 Function enable SW6 Steer left right Sensor S7 Tilt level sensor 58 2 axis tilt level sensor GS 3232 TS66 Platform up down toggle switch Electronic component 3 Platform controls printed circuit board 5 Electronic control module 6 Motor controller 9 Battery charger 13 Voltage inverter option 27 47 mH inductor noise suppression 36 Outrigger control printed circuit board GS 3232 39 Outrigger control CPU GS 3232 40 Outrigger control power supply chip GS 3232 41 Outrigger control transmit receive chip GS 3232 42 Outrigger electronic control module GS 3232 Co eee Valve coil Y1 Parallel GS 2032 GS 2632 and all GS 46 Y3 Steer right Y4 Steer left Y5 Drive reverse Y6 Drive forward Y7 Platform down Y8 Platform up Y9 Platform down GS 3246 Y33 Left rear outrigger GS 3232 Y34 Right rear outrigger GS 3232 Y35 Left front outrigger GS 3232 Y36 Right front outrigger GS 3232 Y39 Outrigger retract GS 3232 Y40 Outrigger extend GS 3232 Part No 97385 2007 Section 6 Schematic
323. ntain firm contact cord from the printed circuit board with a metal part of the machine at the cord wires may result in the that is grounded at all times when cord wires pulling out of the handling printed circuit boards OR connector use a grounded wrist strap Y Illustration 2 6 5 5 9 2 4 OQ I gt 1D 4 6 L9 S coil cord coil cord connector printed circuit board 5 9 Proceed to step 16 to update the firmware top enclosure coil cord bottom enclosure printed circuit board control pad decal hidden from view button cap 7 Locate the printed circuit board mounted to the bottom enclosure of the outrigger control pad and remove the button caps Refer to Illustration 2 Genie 4 18 GS 30 GS 32 GS 46 Part No 97385 October 2009 Section 4 Repair Procedures REV J How to Remove and Disassemble the Outrigger ECM 10 At the battery pack side of the machine open the access door to the ECM Refer to Illustration 4 Illustration 4 a outrigger ECM 11 Tag and disconnect the wire harness from the Outrigger ECM 12 Remove the fasteners securing the outrigger ECM to the mounting bracket and remove the ECM from the machine Set the fasteners to the side 13 Remove the fasteners securing the bottom cover to the ECM enclosure Set the cover and the fasteners to the side Refer to Illustration 5 14 Caref
324. ntenance Procedures June 2009 CHECKLIST D PROCEDURES REV GS 2032 GS 2632 GS 3232 GS 2046 GS 2646 and GS 3246 1 Measure the distance between the number one outer arm cross tube and the fork lift tube at ground controls side of the non steer end of the machine Nn Result The measurement is 0 88 inch 22 4 mm or more Proceed to step 2 Result The measurement is less than 0 88 inch 22 4 mm Replace both wear pads Refer to Repair Procedure 3 3 3 4 or 3 5 How to Replace the Scissor Arm Wear Pads 2 Measure the distance between the number one outer arm cross tube and the fork lift tube at the battery pack side of the non steer end of the machine Result The measurement is 0 88 inch 22 4 mm or more Proceed to step 3 Result The measurement is less than 0 88 inch 22 4 mm Replace both wear pads Refer to Repair Procedure 3 3 3 4 or 3 5 How to Replace the Scissor Arm Wear Pads 3 Apply a thin layer of dry film lubricant to the area of the chassis where the scissor arm wear pads make contact Cross tube to chassis specification Measurement minimum 0 88 inch a outer arm cross tube 22 4 mm b fork lift tube wear pad 3 34 GS 30 GS 32 GS 46 Part No 97385 June 2009 Section 3 Scheduled Main
325. nual lowering cable solenoid valve schematic item N g cable mount bracket 6 Loosen the adjustment nuts on the solenoid valve and disconnect the manual lowering cable from the valve Note During assembly the manual platform lowering cable needs to be properly adjusted See 4 1 How to Adjust the Manual Platform Lowering Cable 7 Remove the fasteners securing the manual lowering cable mount bracket to the cylinder Remove the bracket from the cylinder 8 Tag disconnect and plug the hydraulic hoses on the lift cylinder Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Part No 97385 2007 Section 4 Repair Procedures REV 9 Attach a lifting strap from an overhead crane to the rod end of the lift cylinder for support 10 Remove the retaining fasteners from the lift cylinder rod end pivot pin Use a soft metal drift to remove the pin AWARNING Crushing hazard The lift cylinder will fall if not properly supported 11 Lower the cylinder onto the number 2 inner arm 12 Attach a lifting strap from an overhead crane or similar lifting device to the barrel end of the lift cylinder for support 13 Remove the retaining fasteners from the lift cylinder barrel end pivot pin Use a soft meta
326. o squirt or spray 82 Tag and disconnect the wire harness from the solenoid valve on the cylinder 83 Tag and disconnect the wires and manual lowering cable from the solenoid valve on the cylinder 84 Models with platform overload option Tag and disconnect the wire harness from the platform overload switch 85 Raise the lift cylinder to a vertical position 86 Remove the pin retaining fasteners from the lift cylinder barrel end pivot pin index 28 Use a soft metal drift to remove the pin Remove the lift cylinder from the machine Crushing hazard The lift cylinder ACAUTION will fall if not properly supported when the pivot pin is removed Component damage hazard Be careful not to damage the valve or fittings on the cylinder while removing it from the machine 87 Remove the cables from the number 1 cable bridge and lay them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched Genie GS 30 GS 32 GS 46 REV 88 Disconnect the number 1 cable bridge from the number 1 outer arm index 29 and remove the cable bridge from the machine 89 Attach a lifting strap from an overhead crane to the number 1 inner arm index 14 90 Raise the arm slightly and remove the block 91 Lower the arm to the stowed position Bodily injury hazard Keep hands ACAUTION clear of moving parts when lowering the scissor arms 92 Secure the ends of the scissor arms together at
327. ol side 66 Place a rod through the number 2 center pivot pin at the ground control side index 11 and twist to remove the pin 67 Remove the retaining fasteners from the number 2 pivot pin index 27 at the non steer end 68 Use a soft metal drift to remove the number 2 pivot pin index 27 from the non steer end of the machine Remove the number 2 outer arm at the ground control side index 26 from the machine Crushing hazard The number 2 ACAUTION outer arm at the ground control side index 26 may become unbalanced and fall if not properly supported when the pivot pin is removed 69 Attach a lifting strap from an overhead crane to the number 2 outer arm at the battery side index 26 70 Remove the retaining fasteners from the number 2 center pivot pin index 11 at the battery side 71 Place a rod through the number 2 center pivot pin at the battery side index 11 and twist to remove the pin Crushing hazard The number 2 ACAUTION outer arm index 26 may become unbalanced and fall if not properly supported when the pivot pin is removed Part No 97385 Genie GS 30 GS 32 GS 46 SCISSOR COMPONENTS 72 Remove the number 2 outer arm index 26 from the machine Crushing hazard The number 2 ACAUTION outer arm index 26 may become unbalanced and fall if not properly supported when removed from the machine 73 Attach a lifting strap from an overhead crane to the number 2 inner arm
328. on burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry AWARNING Bodily injury hazard Batteries contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 1 Put on protective clothing and eye wear 2 Release the battery pack latch and rotate the battery pack out and away from the chassis 3 Be sure that the battery cable connections are free of corrosion Note Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables 4 Be sure that the battery retainers and cable connections are tight 5 Fully charge the batteries Allow the batteries to rest 24 hours before performing this procedure to allow the battery cells to equalize Part No 97385 Genie GS 30 GS 32 GS 46 Models without maintenance free or sealed batteries 6 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results 7 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows Add 0 004 to the reading of each cell for every 10 5 5 C above 80 F 26 7 C Subtract 0 004 from the reading of each cell for every 10 5 5 C below 80 26 7 C O Result All battery cells display an adjusted specific gravity of
329. or component affected Bot M or 101 mF bb a P Outrigger Control Pad lift enable lift error right front outrigger right rear outrigger left rear outrigger left front outrigger Genie 5 4 GS 30 GS 32 GS 46 Part No 97385 November 2007 Section 5 Fault Codes Outrigger Fault Code Chart Fault Code Problem Possible Causes Solution Lift error light Up coil fault Malfunctioning coil OR Troubleshoot coil OR blinks red 2 wire disconnected from inspect wire connection times coil Left front Left front outrigger Malfunctioning coil OR Troubleshoot coil OR outrigger light coil fault wire disconnected from inspect wire connection blinks red 2 coil times Right front Right front Malfunctioning coil OR Troubleshoot coil OR outrigger light outrigger coil fault wire disconnected from inspect wire connection blinks red 2 coil times Right rear Right rear Malfunctioning coil OR Troubleshoot coil OR outrigger light outrigger coil fault wire disconnected from inspect wire connection blinks red 2 coil times Left rear Left rear outrigger Malfunctioning coil OR Troubleshoot coil OR outrigger light coil fault wire disconnected from inspect wire connection blinks red 2 coil times Left front Left front outrigger Ground short OR wire Inspect wire connection outrigger light pressure disconnected from blinks red 3 transducer
330. ority 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 ADANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous ACAUTION situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Be sure to wear protective eye wear and other protective clothing if the situation warrants it Be aware of potential crushing hazards 3il such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Genie Workplace Safety Be sure to keep sparks flames and lighted tobacco away from flammable and combustible materials like battery gases and engine fuels Always have an approved fire extinguisher within easy reach are properly maintained and ready for use Keep work surfaces clean and free of debris that could get into machine components and cause damage Be sure that all tools and working
331. ow code 18 and the alarm does not sound Replace the down limit switch 15 Raise the platform until the pothole guards are deployed Result The diagnostic display does not show code 18 and the alarm does not sound The machine is functioning properly Result The diagnostic display shows code 18 and an alarm sounds Replace the down limit switch 16 Raise the platform 7 to 8 feet 2 1 to 2 4 m 17 Lift the safety arm move it to the center of the scissor arm and rotate down to a vertical position 18 Lower the platform onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform Genie 3 26 GS 30 GS 32 GS 46 REV K 19 Turn the key switch to the off position 20 Disconnect the platform controls from the ECM cable 21 Securely install the connector of the ECM cable into the platform control cable 22 Working at the platform securely install the connector of the platform controls into the platform control cable 23 Enable the down limit switch Loosen the fastener securing the roller arm to the limit switch and rotate the roller arm 90 degrees in a upwards direction Do not activate the switch contacts 24 Turn the key switch to platform control 25 Raise the platform and return the safety arm to the stowed position 26 Lower the platform to the stowed position Part No 97385 February 2012 Section 3 Scheduled Maintenance Proced
332. 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 Check to make sure that the operator s and safety manuals are present and complete in the storage container on the platform 2 Examine the pages of each manual to be sure that they are legible and in good condition Result The operator s manual is appropriate for the machine and all manuals are legible and in good condition W Result The operator s manual is not appropriate for the machine or all manuals are not in good condition or is illegible Remove the machine from service until the manual is replaced Genie 3 6 GS 30 GS 32 6 REV 3 Open the operator s manual to the decals inspection section Carefully and thoroughly inspect all decals on the machine for legibility and damage Result The machine is equipped with all required decals and all decals are legible and in good condition W Result The machine is not equipped with all required decals or one or more decals are illegible or in poor condition Remove the machine from service until the decals are replaced 4 Always return the manuals to the storage container after use Note Contact your authorized Genie distributor or Genie if replacement manuals or decals are needed
333. platform overload HS0035J 5 Check valve drive circuit Part No 97385 Genie GS 30 GS 32 6 6 117 Section 6 Schematics 2007 Hydraulic Schematic GS 2032 2632 from serial number GS3205 75407 to GS3206 80131 REV D GS 2046 2646 3246 from serial number GS4605 75438 to GS4606 79027 at LIFT CYLINDER ALL MODELS Lo wens pase 370 to 450 psi P z N 26 to 31 bar M MANUAL 4 y p 0 GANDY 1 7 Ip 8 Pals j 4 RELEASE THE ORIFICE IS LOCATED 2 15mm MANIFOLD a Ol UNDERNEATH THE HOSE 0 1 FITTING ON THE LIFT CYLINDER 4 STEER STEER LEFT RIGHT RIGHT 103 CU IN DRIVE DRIVE pod HN MOTOR 2 3 5 i p 51 52 M1 2 M4 0 059 i Mr 2500 psi maximum I t
334. plug lubricated 30 in Ibs 3 4 Nm Section 3 Scheduled Maintenance Procedures April 2008 Checklist E Procedure E 1 Test or Replace the Hydraulic Oil Genie requires that this procedure be performed every 2000 hours or every two years whichever comes first Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil 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 Refer to Section 2 Specifications Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the 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 Note Perform this procedure with the platform in the stowed position 1 Disconnect the battery pack from the machine REV C 3 Tagand disconnect the hydraulic tank return hard line from the hydraulic filter head and remove the hard line from the tank Cap the fitting on the filter head 4 Tag and disconnect the hydraulic pump inlet hard line and remove the hard line from the tank Cap the fitting on the pump 5 Remove the hydraulic tank retaining fasteners and remove the hydraulic tank from the machine 6 Drain all of the oil into a suitable container
335. pril 2008 Platform Components 2 1 Platform How to Remove the Platform Perform this procedure with the platform extension fully retracted and locked in position 1 Raise the platform to approximately 3 ft 1 m 2 Remove the retaining fasteners securing the platform to the platform mount at the steer end of the machine Lower the platform to the stowed position 4 Disconnect the battery packs from the machine AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 5 Disconnect the platform controls from the control cable at the platform 6 Remove the cover from the AC outlet Tag and disconnect the wiring from the outlet AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 7 Disconnect the wiring from the platform and pull the wiring free of the platform 4 34 Genie GS 30 GS 32 GS 46 REV 8 Models with air line to platform option Disconnect the air line from the platform Pull the air line free of the platform 9 Support the platform with a forklift at the non steer end Do not apply any lifting pressure 10 Attach a strap from the lanyard anchorage point on the platform railings to the carriage on the forklift to help support the platform GS 1530 32 and GS 1930 32
336. r 4 pivot pin non steer end 22 Upper lift cylinder barrel end pivot pin 23 Number 3 inner arm 24 Number 3 pivot pin non steer end 25 Number 2 inner arm 26 Number 2 outer arm 27 Number 2 pivot pin non steer end 28 Lower lift cylinder barrel end pivot pin 29 Number 1 outer arm 15 Number 1 pivot pin steer end 2 pins Genie 4 64 GS 30 GS 32 GS 46 Part No 97385 March 2007 Section 4 Repair Procedures REV SCISSOR COMPONENTS 3 5 Scissor Assembly GS 3232 and GS 3246 How to Disassemble the Scissor Assembly GS 3232 and GS 3246 AWARNING Podily injury hazard The procedures in this section require specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is required When removing a hose assembly or fitting the 656 3232 O ring on the fitting and or hose end must be GS 3246 replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose rs Piin Cable bridge legend Fitting Torque Specifications cable bridge 2 cable bridge 2B cable bridge 1 appropriate lifting device a cable bridge 5 1 Remove the platform See 2 1 How to Remove b cable bridge 4A the Platform c cable bridge 4B d cable bridge 3A 2 Support and secure the entry ladder to an e cable bridge 3B
337. r arm may become unbalanced and fall if not properly supported when removed from the machine 22 Remove the cables from the number 3 cable bridge and lay them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched 23 Remove the number 3 cable bridge mounting fasteners and remove the cable bridge from the machine Part No 97385 2007 Section 4 Repair Procedures REV 24 Attach a lifting strap from an overhead crane to the number 3 outer arm index 4 at the ground controls side 25 Remove the external snap rings and retaining fasteners from the number 3 center pivot pins index 4 26 Use a soft metal drift to remove the number 3 center pivot pin index 4 at the ground control side 27 Remove the retaining fasteners from the number 3 pivot pin index 17 at the non steer end of the machine 28 Use a soft metal drift to tap the number 3 pivot pin index 17 halfway out at the non steer end of the machine Remove the number 3 outer arm index 16 at the ground controls side from the machine Bodily injury hazard The number ACAUTION 3 outer arm at the ground controls side may become unbalanced and fall if not properly supported when removed from the machine 29 Attach a lifting strap from an overhead crane to the number 3 outer arm index 16 at the battery pack side 30 Use a soft metal drift to remove the number 3 center pivot pin index 4
338. rane to the number 1 inner arm index 10 56 Raise the number 1 inner arm index 10 approximately 2 feet 60 cm and install the safety arm between the number 1 inner arm index 10 and the number 1 outer arm index 22 at the non steer end of the machine Lower the scissor arms onto the safety arm Bodily injury hazard Keep hands ACAUTION clear of moving parts when lowering the scissor arms onto the safety arm Genie Part No 97385 2007 Section 4 Repair Procedures REV 57 Attach a lifting strap from an overhead crane to the lug on the rod end of the lift cylinder index 5 Raise the lift cylinder approximately 3 ft 1m 58 Tag disconnect and plug the hydraulic hoses on the lift cylinder Cap the fittings on the cylinder AWARNING 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 59 Tag and disconnect the wires and manual lowering cable from the solenoid valve on the cylinder 60 Models with platform overload option Tag and disconnect the wire harness from the platform overload switch 61 Raise the lift cylinder to a vertical position 62 Remove the pin retaining fasteners from the lift cylinder barrel end pin index 21 Use a soft metal drift to remove the pin Remove the lift cylinder from the machine AWARNING Crushing hazard
339. rane to the number 3 outer arm at the ground controls side of the machine index 11 Part No 97385 Genie GS 30 GS 32 GS 46 GS 1532 Cable bridge legend a cable bridge 3 b cable bridge 2 C cable bridge 1 5 Remove the external snap rings and retaining fasteners from the number 3 center pivot pin at the ground control side of the machine index 2 6 Use a soft metal drift to remove the number 3 center pivot pin at the ground control side of the machine index 2 7 Remove the retaining fasteners from the number 3 pivot pin index 12 at the non steer end of the machine 8 Use a soft metal drift to remove the number 3 pivot pin index 12 from the non steer end of the machine Remove the number 3 outer arm at the ground control side index 11 from the machine AWARNING Crushing hazard The number 3 outer arm may become unbalanced and fall if not properly supported when removed from the machine 9 Attach a lifting strap from an overhead crane to the number 3 outer arm at the battery pack side of the machine index 11 4 37 Section 4 Repair Procedures March 2007 SCISSOR COMPONENTS 10 Remove the external snap rings and retaining fasteners from the number 3 center pivot pin at the battery pack side of the machine index 2 11 Use a soft metal drift to remove the number 3 center pivot pin at the battery pack side of the machine index 2 12 Remove the number 3 outer
340. range wire at platform controls c2 Power from platform controls to ECM input Red wire at platform controls Plug C4 Plug C5 Not used C6 Drive forward coil Y6 output C7 Steer right coil output C8 Parallel coil Y1 not available on GS 1530 32 and GS 1930 32 09 Work light L30 option C10 Not used C11 Level sensor signal S7 input C12 Down limit switch LS66 input CE 5 REV L1 91112222228 99990000 8200000000000 GS 30 GS 32 6 Part No 97385 2007 Section 6 Schematics REVA mmm 20300000000 000000 Machine ECM All Models Outrigger ECM GS 3232 Part No 97385 Genie GS 30 GS 32 GS 46 Outrigger ECM Pin out Legend OUTRIGGER ECM PIN OUT LEGEND Item Description A1 24V C A2 24 CC Right rear outrigger pressure transducer signal input A4 Right front outrigger pressure transducer signal input A5 Left rear outrigger pressure transducer signal input A6 Left front outrigger pressure transducer signal input A7 2 axis tilt level sensor pitch S8 input A8 2 axis tilt level sensor
341. ransducer OR replace the fault harness Left rear outrigger light Left rear Short to power Troubleshoot the blinks red 4 times outrigger harness to the pressure pressure transducer transducer OR replace the fault harness Outrigger lights blink red Outrigger level Ground short OR wire Inspect wire alternating front to rear sensor fault disconnected from level connection sensor Short to power Troubleshoot the harness to the outrigger sensor OR replace the harness Outrigger lights blink red Extend coil Malfunctioning coil OR Troubleshoot coil OR in a clockwise sequence fault wire disconnected from inspect wire coil connection Outrigger lights blink red Retract coil Malfunctioning coil OR Troubleshoot coil OR in a counter clockwise fault wire disconnected from inspect wire sequence coil connection All lights turn red on initial power up and the alarm sounds No calibration data Outrigger level sensor and pressure transducers not calibrated Calibrate the outrigger level sensor and pressure transducers During operation all lights turn red and all functions cut out After auto leveling the machine all lights turn red and the alarm sounds Motor controller fault Outrigger off level fault Motor controller throttle short Machine is out of level OR all outriggers are not in contact with the ground Troubleshoot the harness to the motor controller OR replace
342. re to properly complete each 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 the machine Use only Genie approved replacement parts Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection Unless otherwise specified perform each procedure with the machine in the following configuration Machine parked on a firm level surface Platform in the stowed position Key switch in the off position with the key removed The red Emergency Stop button in the off position at both ground and platform controls Wheels chocked All external AC power supply disconnected from the machine Part No 97385 Genie GS 30 GS 32 GS 46 3 1 About This Section This section contains detailed procedures for each scheduled maintenance inspection Each procedure includes a description safety warnings and step by step instructions Symbols Legend Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death ADANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Indicates a potentially hazardo
343. rigger Function Manifold Components 7 4 92 6 4 Outrigger Cylinder Manifold Components 0 4 93 6 5 Check Valve Manifold Components GS 1530 GS 1532 95 1930 and 95 1932 4 94 6 6 Valve Adjustments Function Manifold 4 95 6 7 NValVe CollS zie tee a et bu PEE ete 4 99 B Hydraulic Tank 451 Hydraul 4 101 B Steer Axle Components 8 1 Yoke and Drive 4 102 8 2 Steer Cylinder 00222 0 000 4 103 8 8 01 0 0 4 104 Non steer Axle Components 921 Drive ce ees du cde t t deed 4 105 A Brake Release Hand Pump Components 10 1 Brake Release Hand Pump 4 106 A Outrigger Components 11 1 Outrigger 4 107 Genie x GS 30 GS 32 6 February 2012 Section 5 Section 6 Rev Rev rYrdsDO 0 TABLE OF CONTENTS Fault Codes INthOGUCTION 5 1 Fault Code ere e 5 3 Outrigger Fault Code 5 5 Schematics INTRODUCTION E 6 1 Electrical Component Legend 0 240000 07 6 2 Wire Color
344. rm assembly at the steer ACAUTION Bodily injury hazard The number end with the overhead crane until the chassis 1 inner and outer arms index 10 mount bracket will clear the level sensor and 22 may become unbalanced 9 Move the scissor assembly towards the and fall if not properly supported non steer end of the machine slightly and to when removed from the machine one side of the machine until one of the scissor Component damage hazard Be arm wear pads is accessible Do not allow both sure not to damage the limit switch wear pads to slide out of the drive chassis or level sensor box components Component damage hazard Be when the number 1 inner and careful not to damage the level outer arms index 10 and 22 is sensor or limit switch while moving removed from the machine the scissor assembly Genie 4 62 GS 30 GS 32 GS 46 Part No 97385 March 2007 Section 4 Repair Procedures REV SCISSOR COMPONENTS 10 Remove the old wear pad 11 Install the new wear pad 12 Rotate the scissor assembly towards the other side of the machine until the other scissor arm wear pad is accessible Do not allow both wear pads to slide out of the drive chassis Crushing hazard scissor gt assembly will fall if both wear pads are allowed to slide out of the drive chassis Component damage hazard Be careful not to damage the level sensor or limit switch while moving the scissor assembly 13 Re
345. rmed must be clean and free of debris that could get into the hydraulic system When removing a hose assembly or fitting the fitting and or hose end must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications Perform this procedure with the platform in the stowed position 1 Disconnect the battery pack from the machine AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Part No 97385 Genie GS 30 GS 32 GS 46 Hydraulic Tank 2 Remove the drain plug from the hydraulic tank and allow all of the oil from the tank to drain into a suitable container Refer to Section 2 Specifications AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Tag and disconnect the hydraulic tank return hard line from the filter Remove the hard line from the machine Cap the fitting on the filter head 4 Tag and disconnect the hydraulic tank hard line from the pump Remove the hard line from the machine Cap the fitting on the pump 5 Remove the hydraulic tank retaining fasteners and remove the hydraulic tank from the machine Torque specifications 35 in lbs 4Nm Hydraulic tank retainin
346. rmined Use the second mark on the body hex fitting to properly tighten the joint after it has been loosened Figure 2 a body hex fitting b reference mark second mark 4 Tighten the hex nut until the mark on the hex nut is aligned with the second mark on the body hex fitting 5 Operate all machine functions and inspect the hoses and fittings and related components to confirm that there are no leaks Part No 97385 February 2009 Section 2 Specifications REVG SPECIFICATIONS SAE FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual A574 High Strength Grades 52 Grade8 525 Black Oxide Bolts DRY LUBED DRY LUBED Nm LUBED Nm ints Nm 9 1 1138 110 LUBED 13 23 14 257 23 22 26 274 37 66 4 11 745 3 92 1 5 75 1016 60 064 110 149 03 126 20 64 867 15 5 122 320 162 15 ane 12 580 1064 no 140 8 0 122 120 3162 1130 3176 230 271 5 2 244 180 230 176 8 sa 10 200 277 270 366 280 380 515 820 16 220 298 300 406 310 420 420 569 0 am 19 320 438 430 583 450 610 610 827 510 om 550 474 270
347. rom an overhead crane to the number 2 outer arm at the ground control side index 19 42 Remove the retaining fasteners from the number 2 center pivot pin index 7 at the ground control side 43 Place a rod through the number 2 center pivot pin at the ground control side index 7 and twist to remove the pin 44 Remove the retaining fasteners from the number 2 pivot pin index 20 at the non steer end Genie GS 30 GS 32 GS 46 REV 45 Use a soft metal drift to remove the number 2 pivot pin index 20 from the non steer end of the machine Remove the number 2 outer arm at the ground control side index 19 from the machine Crushing hazard The number 2 ACAUTION outer arm at the ground control side index 19 may become unbalanced and fall if not properly supported when the pivot pin is removed 46 Attach a lifting strap from an overhead crane to the number 2 outer arm at the battery side index 19 47 Remove the retaining fasteners from the number 2 center pivot pin index 7 at the battery side 48 Place a rod through the number 2 center pivot pin at the battery side index 7 and twist to remove the pin Crushing hazard The number 2 ACAUTION outer arm index 19 may become unbalanced and fall if not properly supported when the pivot pin is removed 49 Remove the number 2 outer arm index 19 from the machine Crushing hazard The number 2 ACAUTION outer arm index 19 may beco
348. rom an overhead crane to the number 3 outer arm at the battery side index 7 48 Remove the retaining fasteners from the number 3 center pivot pin index 8 at the battery side 49 Place a rod through the number 3 center pivot pin at the battery side index 8 and twist to remove the pin 50 Remove the number 3 outer arm index 7 from the machine Crushing hazard The number 3 ACAUTION outer arm index 7 may become unbalanced and fall if not properly supported when removed from the machine 51 Attach a lifting strap from an overhead crane to the lug of the rod end of the upper lift cylinder 52 Raise the lift cylinder to a vertical position 53 Remove the pin retaining fasteners from the lift cylinder barrel end pivot pin index 22 Remove the lift cylinder from the machine Crushing hazard The lift cylinder ACAUTION will fall if not properly supported when the pivot pin is removed Component damage hazard Be careful not to damage the valve or fittings on the cylinder while removing it from the machine Genie GS 30 GS 32 GS 46 REV 54 Attach a lifting strap from an overhead crane to the lug of the rod end of the lower lift cylinder 55 Remove the retaining fasteners from the lower lift cylinder rod end pivot pin index 9 56 Use a soft metal drift to remove the lower lift cylinder rod end pivot pin index 9 from the machine Crushing hazard The lower lift ACAUTION cylinder will f
349. s TT Wire Color Legend REV 5 WIRE COLOR LEGEND Color Description BK Black BL Blue BL BK Blue Black BL WH_ Blue White BN Brown GN Green GN BK Green Black GN WH Green White GY Gray OR Orange Orange Black OR WH Orange White Purple RD Red RD BK Red Black RD WH Red White WH White WH BK White Black Genie Part No 97385 GS 30 GS 32 GS 46 6 3 Section 6 Schematics April 2008 ECM Pin out Legend ECM PIN OUT LEGEND Item Description A1 Flashing beacon FB output A2 Ground from platform controls input White wire at platform controls AS Plug 4 Driver power input A5 Level sensor power S7 output A6 Platform up coil Y8 output 7 Drive reverse coil Y5 output A8 Motor controller U6 terminal 1 A9 Motor controller U6 terminal 3 A10 Overload sensor PS2 input A11 Key switch to platform control input A12 Platform down TS66 input B1 Platform data link high input Blue wire at platform controls B2 Plug B3 ECM ground output B4 Plug B5 Plug B6 Platform down coil Y7 output B7 Steer left coil Y4 output B8 Automotive style horn H2 option output B9 Multi function alarm H5 output B10 Pothole limit switch input B11 Drive enable power up limit switch input B12 Platform up TS66 input C1 Platform data link low input O
350. s remain green Result All lights turn red on the outrigger control pad and the alarm sounds continuously The outrigger level sensor is installed incorrectly OR the machine is not on a level surface Check the levelness of the surface and inspect the digital level sensor to ensure the bubble at the top of the level sensor is centered in the circles Repeat this procedure beginning with step 3 8 Push in the Red Emergency Stop button at the platform controls The outrigger level sensor is now calibrated Note After installing a new outrigger level sensor the new outrigger level sensor must be calibrated Part No 97385 October 2009 Section 4 Repair Procedures REV J PLATFORM CONTROLS How to Calibrate the Outrigger t 5 p LEES Pressure Transducers EIL Note For best performance calibrate the pressure transducers when the ambient temperature is 32 F 0 or above ton 1 NIA 1 Move the machine firm level surface that Outrigger Control Pad lift enable lift error right front outrigger right rear outrigger outrigger extend function enable outrigger retract left rear outrigger left front outrigger is free of obstructions Use a digital level to 2 key switch to platform control 9 lf us O confirm 3 Pull out the red Emergency Stop button to the on position at the ground controls 4 Pushin the red Emerg
351. sh lines Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line Continue at full speed and note the time when your reference point on the machine passes over the finish line Refer to Section 2 Specifications GS 46 3 21 Section 3 Scheduled Maintenance Procedures February 2012 CHECKLIST B PROCEDURES B 12 Perform Hydraulic Oil Analysis Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil 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 Refer to Section 2 Specifications Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the 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 See E 1 Test or Replace the Hydraulic Oil Genie 4 22 GS 30 05 32 GS 46 REV K B 13 Inspect the Hydraulic Tank Cap Venting System Genie requires that this procedure be performed quarterly or every 250 hours whichever comes first Perform this procedure more often if dusty
352. skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Component damage hazard Hoses can be damaged if they are kinked or pinched 8 Remove the drive motor mounting fasteners Remove the motor Torque specifications STEER AXLE COMPONENTS 8 2 Steer Cylinder How to Remove the Steer 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 Remove the pin retaining fasteners from the rod end pivot pin Remove the pivot pin Note While removing the pin retaining fasteners take note of the quantity and location of the spacers when removing the pivot pin 3 Remove the pin retaining fasteners from the barrel end pivot pin Remove the pin Note While removing the pin retaining fasteners take note of the quantity and location of the spacers when removing the pin 4 Remove the steer cylinder from the machine 5 Tag disconnect and plug the hydraulic hoses from the steer cylinder Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or
353. ssis Securely install and tighten the fasteners Do not over tighten Component damage hazard Be careful not to damage the level sensor or limit switch while moving the scissor assembly Genie Part No 97385 GS 30 GS 32 GS 46 4 49 Section 4 Repair Procedures March 2007 SCISSOR COMPONENTS REV 2 69 Se 2 van 05 2032 GS 2046 Steer end Non steer end 1 Number 4 pivot pin 10 Number 3 inner arm 2 Number 3 center pivot pin 2 pins 11 Number 3 outer arm 3 Lift cylinder rod end pivot pin 12 Number 3 pivot pin non steer end 4 Number 3 pivot pin steer end 13 Number 2 inner arm 5 Number 2 center pivot pin 2 pins 14 Number 2 outer arm 6 Number 2 pivot pin steer end 15 Number 2 pivot pin non steer end 7 Number 1 center pivot pin 2 pins 16 Lift cylinder barrel end pivot pin 8 Number 1 inner arm 17 Number 1 outer arm 9 Number 1 pivot pin Genie 4 50 GS 30 GS 32 6 Part No 97385 2007 Section 4 Repair Procedures REV 3 3 Scissor Assembly GS 2032 and GS 2046 How to Disassemble the Scissor Assembly GS 2032 and GS 2046 AWARNING Podily injury hazard The procedures in this section require specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or
354. ssor assembly 13 Remove the old wear pad 14 Install the new wear pad 15 Slide the scissor assembly back into the drive chassis 16 Lower the scissor assembly into position and install the chassis mount bracket onto the chassis Securely install and tighten the fasteners Do not overtighten Component damage hazard Be careful not to damage the level sensor or limit switch while moving the scissor assembly Section 4 Repair Procedures March 2007 SCISSOR COMPONENTS REV 1 0 amp 69 GGG 999 0 9 768 2632 i GS 2646 4 Steer end E Non steer end 1 Number 5 pivot pin 12 Number 4 inner arm 2 Number 4 center pivot pin 2 pins 13 Number 4 outer arm 3 Number 4 pivot pin steer end 14 Number 4 pivot pin non steer end 4 Number 3 center pivot pin 2 pins 15 Number 3 inner arm 5 Lift cylinder rod end pivot pin 16 Number 3 outer arm 6 Number 3 pivot pin steer end 17 Number 3 pivot pin non steer end 7 Number 2 center pivot pin 2 pins 18 Number 2 inner arm 8 Number 2 pivot pin steer end 19 Number 2 outer arm 9 Number 1 center pivot pin 2 pins 20 Number 2 pivot pin non steer end 10 Number 1 inner arm 21 Lift cylinder barrel end pivot pin 11 Number 1 pivot pin 22 Number 1 outer arm Genie 4 56 GS 30 GS 32 GS
355. stowed position and remove all test weight from the platform Genie GS 30 GS 32 GS 46 REV 15 Using a suitable lifting device place a test weight in the center of the platform floor Secure the weight to the platform Refer to the chart below GS 1532 272 kg GS 1932 227 kg GS 2032 363 kg GS 2632 227 kg GS 3232 227 kg GS 2046 544 kg GS 2646 454 kg GS 3246 317 kg 16 Raise the platform to 25 cm less than full height 17 Lift the safety arm move it to the center of the scissor arm and rotate down to a vertical position 18 Raise the platform in 5 cm increments until the overload alarm sounds Adjust the up limit switch until it actuates just before this point was reached 19 Install the cover onto the platform overload pressure switch and install and tighten the cover retaining fastener s Do not over tighten 20 Apply Sentry Seal to the fastener s securing the cover onto the platform overload pressure switch 21 Return the safety arm to the stowed position 22 Using the machine controls lower the platform to the stowed position and remove all test weight from the platform 23 Calibrate the lift relief valve See 6 6 How to Adjust the Platform Lift Relief Valve Part No 97385 2007 Section 4 Repair Procedures REV D 4 1 Manual Platform Lowering Cable The manual platform lowering cable lowers the platform in the event of a main power fa
356. sult in component damage and unsafe operating conditions Perform this procedure with the platform in the stowed position GS 1530 GS 1532 GS 1930 and GS 1932 1 From serial numbers GS3003A 60000 to GS3006A 85006 and from GS3005B 76000 to GS3006B 80468 Measure the distance between the number one outer arm cross tube and the chassis deck at the ground controls side of the non steer end of the machine Refer to illustration 1 REV E Illustration 1 a wear pad b outer arm cross tube chassis deck After serial numbers GS3006A 85006 GS3006B 80468 and GS3008C 101 Measure the distance between the number one inner arm cross tube and the chassis deck at the ground controls side of the non steer end of the machine Refer to illustration 2 Result The measurement is 0 90 inch 22 9 mm or more Proceed to step 2 Result The measurement is less than 0 90 inch 22 9 mm Replace both wear pads Refer to Repair Procedure 3 1 or 3 2 How to Replace the Scissor Arm Wear Pads GS 30 GS 32 GS 46 KN b Illustration 2 a b inner arm cross tube 0 chassis deck Part No 97385 June 2009 Section 3 Scheduled Maintenance Procedures
357. sure 6 Press and hold the function enable switch 12 Place maximum rated load into the platform Secure the load to the platform Refer to a 4 gt Section 2 Specifications SSE SG lt lt Se S GS 1530 32 and GS 1930 32 GS 32 and GS 46 a b 0 0 a test port b system relief valve c liftrelief valve test port system relief valve steer relief valve lift relief valve Genie 4 96 GS 30 GS 32 GS 46 Part No 97385 February 2009 Section 4 Repair Procedures REV F 13 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 14 Hold the lift relief valve with a wrench and remove the cap schematic item C or AJ 15 While activating the platform up function adjust the internal hex socket clockwise just until the platform fully raises 16 Fully lower the platform 17 Add an additional 50 pounds 22 7 kg to the platform Secure the additional weight 18 Attempt to raise the platform Result The power unit should not be able to lift the platform W Result If the power unit lifts the platform adjust the internal hex socket counterclockwise until the platform will not raise 19 Install the relief valve cap 20 Remove the weight from the platform 21 Bleed the hydraulic system by raising the platform to full height If the pump cavitates or the platform fails to reach full he
358. switch Genie Part No 97385 GS 30 GS 32 GS 46 Section 4 Repair Procedures March 2007 SCISSOR COMPONENTS 6 Loosen the adjustment nuts on the solenoid valve and disconnect the manual lowering cable from the valve Note During assembly the manual platform lowering cable needs to be properly adjusted See 4 1 How to Adjust the Manual Platform Lowering Cable 7 Remove the fasteners securing the manual lowering cable mount bracket to the cylinder Remove the bracket from the cylinder 8 Tag disconnect and plug the hydraulic hoses on the lift cylinder Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 9 Attach a lifting strap from an overhead crane to the rod end of the lift cylinder for support 10 Remove the retaining fasteners from the lift cylinder rod end pivot pin Use a soft metal drift REV 12 Attach a lifting strap from an overhead crane or similar lifting device to the barrel end of the lift cylinder for support 13 Remove the retaining fasteners from the lift cylinder barrel end pivot pin Use a soft metal drift to remove the pin AWARNING Crushing hazard The lift cylinder will fall if not properly supported when the pin is removed 14 Support and secure the lift cylinder to an appropriat
359. system B 14 Latch components B 15 Voltage inverter if equipped B 16 Test the down and pothole limit switches B 17 Test the up and outrigger limit switches if equipped ChecklistC RevC Y NR C 1 Platform overload if equipped C 2 Breather cap models with optional oil Checklist E Rev C Y NR ChecklistD RevE Y NR D 1 Scissor arm wear pads D 2 Hydraulic filter E 1 Hydraulic oil completed Use the step by step procedures in this section to learn how to perform these inspections Comments If any inspection receives an 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 no remove from service repaired Part No 97385 GS 30 GS 32 GS 46 Section 3 Scheduled Maintenance Procedures March 2007 Checklist A Procedures A 1 Inspect the Manuals and Decals 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 In addition maintaining all of the safety and instructional decals in good condition is mandatory for safe machine operation Decals alert operators and
360. t Continue holding the switch while observing the pressure reading on the pressure gauge Turn the machine off Hold the steer relief valve with a wrench and remove the cap schematic item G or AH Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Component damage hazard Do not adjust the relief valve pressures higher than specifications 9 Install the relief valve cap 10 Repeat steps 5 through 6 to confirm the relief valve pressure Genie GS 30 GS 32 GS 46 GS 32 and GS 46 test port system relief valve steer relief valve lift relief valve ao oo Part No 97385 February 2009 Section 4 Repair Procedures REV F 6 7 Valve Coils How to Test a Coil A properly functioning coil provides an electromagnetic force which operates the solenoid valve Critical to normal operation is continuity within the coil Zero resistance or infinite resistance indicates the coil has failed Since coil resistance is sensitive to temperature resistance values outside specification can produce erratic operation When coil resistance decreases below specification amperage increases As resistance rises above specification voltage increases While valves may operate when coil resistance is outside specification maintaining coils within specification will help ensure proper valve function over a wide range of operating temperatur
361. t lt pee k FUNCTION MANIFOLD 0 25 0 2 180010370 l J 0 95 L min 124 to 255 bar 1 L 10 25 gpm 3700 psi bees E NOT CONNECTED T ON GS 3232 ABBREVIATION LEGEND Description V e AA Test port BOWER uir Fj AB Relief valve system 4 gpm 2500 psi Steer left right Check valve steer circuit AE Drive speed AF Relief valve brake release HYDRAULIC TANK AG Drive forward reverse To Outrigger Manifold In Port GS 3232 Models AH Flow regulator relief valve To Outrigger Manifold Out Port GS 3232 Models Al Platform up AJ Relief valve lift BA 3position 4 way directional valve outrigger cylinder extend retract 50036 Relief valve outrigger circuit Genie 6 120 GS 30 GS 32 GS 46 Part No 97385 June 2009 Section 6 Schematics Hydraulic Schematic REV D GS 3232 from serial number GS3207 84867 from serial number GS3208C 101 LF OUTRIGGER 2 RF OUTRIGGER CYLINDER EXTEND EXTEND CYLINDER HO O 0 037 0 037 in 0 94 mm 0 94 Y35 N Y 0 035 in 0 035 in 0 9 mm
362. tage to zero will result in the steer function being disabled when the platform is above the down limit switch Refer to 1 2 How to Determine the Software Revision Level 1 Pull out the red Emergency Stop button to the on position at the ground controls 2 Push in the red Emergency Stop button to the off position at the platform controls 3 Turn the key switch to platform control 4 Atthe platform controls press and hold the lift function select and horn buttons and pull out the red Emergency Stop button to the on position Result The diagnostic display will show PS 5 Release the lift function select and horn buttons Result The diagnostic display will show the maximum lift speed percentage Part No 97385 Genie GS 30 GS 32 GS 46 PLATFORM CONTROLS 2 mi lt gt lae 6 4 joystick controller JC1 with thumb steering rocker SW6 horn button BN5 lift function select button BN9 diagnostic display G8 red Emergency Stop button P2 drive function select BN8 speed select button BN6 5 20 6 Press the drive function select button 7 Press and hold the horn button Result The diagnostic display will show the raised drive speed percentage 8 Use the steering thumb rocker switch on the joystick to increase or decrease the raised drive speed percentage Refer to Section 2 Specifications for driv
363. tal position Bodily injury hazard Keep hands ACAUTION clear of moving parts when lowering the cylinder Section 4 Repair Procedures March 2007 SCISSOR COMPONENTS Upper Lift Cylinder before serial GS4607 83692 a b 0 0 8 f 9 manifold plug orifice fitting schematic item O lift cylinder connector fitting hydraulic hose solenoid valve schematic item N relief valve schematic item Q Note Before serial number GS4607 83692 at the upper lift cylinder install the orifice fitting with the large opening of the orifice fitting closest to the manifold plug 12 Attach a lifting strap from an overhead crane or similar lifting device to the barrel end of the lift cylinder for support 13 Remove the retaining fasteners from the lift cylinder barrel end pivot pin Use a soft metal drift to remove the pin AWARNING Crushing hazard The lift cylinder will fall if not properly supported when the pin is removed 14 Support and secure the lift cylinder to an appropriate lifting device 15 Remove the lift cylinder through the scissor REV 209 Upper Lift Cylinder after serial GS4607 83691 lift cylinder orifice fitting schematic item O connector fitting hydraulic hose solenoid valve schematic item N relief valve schematic item Q Note After serial number GS4607 83691 and from GS4609 101 at the upper lift cylinder ins
364. tall the orifice fitting with the small opening of the orifice fitting closest to the supply hose Crushing hazard The lift cylinder ACAUTION may become unbalanced and fall if not properly supported and secured to the lifting device Component damage hazard Be careful not to damage the valve or fittings on the cylinder while removing it from the machine Torque specification Solenoid valve 2 position 2 way N C 20 ft lbs arms at the steer end of the machine schematic item N 27 Nm Relief Valve 20 ft lbs schematic item Q 27 Nm Coil nut 5 ft lbs 7Nm Genie GS 30 GS 32 GS 46 Part No 97385 2007 Section 4 Repair Procedures REV 3 7 Platform Overload System How to Calibrate the Platform Overload System if equipped Perform this procedure after confirming that the maximum height limit switch and the limit switch bracket are not damaged and are functioning correctly 1 Fully charge the batteries and check the hydraulic fluid level Note The hydraulic fluid level must be between the FULL and App marks on the hydraulic tank 2 Applyathin layer of dry film lubricant to the area of the chassis where the scissor arm wear pads make contact 3 Chock both sides of the wheels at the steer end of the machine 4 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 5 GS 1532 and GS
365. tenance Procedures REV D 2 Replace the Hydraulic Tank Return Filter Element Genie requires that this procedure be performed every 1000 hours or annually whichever comes first Replacement of the hydraulic tank return 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 Note The hydraulic tank return filter is mounted on the function manifold next to the hydraulic power unit 1 Clean the area around the oil filter Remove the filter with an oil filter wrench 2 Applyathin layer of oil to the new oil filter gasket 3 Install the new filter and tighten it securely by hand 4 Use a permanent ink marker to write the date and number of hours from the hour meter onto the filter Part No 97385 CHECKLIST D PROCEDURES 5 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 6 Activate and hold the platform up toggle switch 7 Inspect the filter and related components to be sure that there are no leaks 8 Clean up any oil that may have spilled Torque specifications Hydraulic tank drain plug dry 40 in Ibs 4 5 Nm Hydraulic tank drain
366. teners from the number 2 center pivot pin index 7 at the battery pack side 48 Use a soft metal drift to remove the number 2 center pivot pin index 7 at the battery pack side Bodily injury hazard The number ACAUTION 2 outer arm at the battery pack side may become unbalanced and fall if not properly supported when removed from the machine GS 30 GS 32 GS 46 REV 49 Use a soft metal drift to tap the number 2 pivot pin at the non steer end index 20 in the other direction Remove the number 2 outer arm index 19 from the battery pack side of the machine Bodily injury hazard The number ACAUTION 2 outer arm at the battery pack side may become unbalanced and fall if not properly supported when removed from the machine 50 Remove the number 3 pivot pin index 17 from the non steer end of the machine 51 Attach a lifting strap from an overhead crane to the number 2 inner arm index 18 52 Remove the retaining fasteners from the number 2 pivot pin index 8 at the steer end of the machine 53 Use a soft metal drift to remove the number 2 pivot pin index 8 Remove the number 2 inner arm index 18 from the machine Bodily injury hazard The number ACAUTION 2 inner arm may become unbalanced and fall if not properly supported when removed from the machine 54 Remove the safety arm from the number 2 inner arm index 18 that was just removed 55 Attach a lifting strap from an overhead c
367. the fasteners Do not over tighten Component damage hazard Be careful not to damage the level sensor or limit switch while moving the scissor assembly Section 4 Repair Procedures March 2007 SCISSOR COMPONENTS 3 6 Lift Cylinder How to Remove the Lift Cylinder AWARNING 20dily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended When removing a hose assembly or fitting the fitting and or hose end must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications GS 1530 GS 1532 GS 1930 and GS 1932 1 Raise the platform 7 to 8 feet 2 1 to 2 4 m 2 Lift the safety arm move it to the center of the scissor arm and rotate down to a vertical position 3 Lower the platform onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 4 Tag and disconnect the wiring from the solenoid valve coil at the barrel end of the lift cylinder 5 Models with platform overload option Tag and disconnect the wiring from the platform overload switch Genie GS 30 GS 32 GS 46 REV lift cylinder orifice schematic item O connector fitting hydraulic hose ma
368. the entry ladder to an number 1 outer arm index 22 and remove appropriate lifting device the cable bridge from the machine 3 Remove the fasteners from the entry ladder and 66 Attach a lifting strap from an overhead crane to remove the entry ladder from the machine the number 1 inner arm index 10 ACAUTION Crushing hazard The entry ladder 67 Raise the arm slightly and remove the block may become unbalanced and fall if not properly supported and 68 Lower the arm to the stowed position secured to the lifting device ACAUTION Bodily injury hazard Keep hands 4 Secure the ends of the scissor arms together at 1 i rts wh i i Ese SIE DIVIDI the steer end of the machine with a strap or lowering the scissor arms other suitable device 69 Secure the ends of the scissor arms togetherat 5 Secure the ends of the scissor arms together at the steer end of the machine with a strap or the non steer end of the machine with a strap or other suitable device other suitable device 70 Secure the ends of the scissor arms together at 6 Remove the retaining fasteners securing the the non steer end of the machine with a strap or chassis mount bracket to the chassis at the other suitable device steer end of the machine 71 Remove the retaining fasteners securing the 7 Attach a lifting strap from an overhead crane to chassis mount bracket to the chassis the scissor arm assembly 72 Remove the linkset from the machine 8 Raise the scissor a
369. the harness Relocate the machine OR redeploy the outriggers All lights turn red and the alarm sounds Only while calibrating the outrigger level sensor Outrigger level sensor fault Outrigger level sensor installed incorrectly OR the machine in not on level ground Troubleshoot outrigger level sensor All lights turn red and the alarm sounds Only while calibrating the outrigger pressure transducers Outrigger pressure transducer fault Pressure transducer installed incorrectly in improper position or faulty Make sure the pressure transducers are wired correctly and functioning properly Individual OR light turns solid red and the alarm sounds While auto leveling Outrigger has reached End of Stroke EOS 5 6 GS 30 Slope too steep to level machine Retract outriggers and repeat auto level procedure Genie GS 32 GS 46 Part No 97385 2007 Section 6 Schematics Observe and Obey Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service 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 in the appropriate operator s manual on your machine
370. the two retaining fasteners from each platform extension roller bracket assembly Remove each assembly from the machine Note Do not remove the platform roller bolt a roller bracket assembly b assembly retaining fastener c platform roller bolt Part No 97385 Genie Section 4 Repair Procedures PLATFORM COMPONENTS Remove the platform roller wheels from the machine Carefully slide the platform extension out from the platform and place it on a structure capable of supporting it How to Replace the Platform Extension Wear Pads Remove the Platform Extension See 2 2 How to Remove the Platform Extension 2 Drill out the rivets which hold the wear pads in place Install the new wear pads using new rivets When installing the new rivets make sure the rivet heads are not above the surface of the wear pad GS 30 GS 32 GS 46 Section 4 Repair Procedures March 2007 Scissor Components REV 6 6 O 0G OOG 771 68 1532 E Steer End ae 2 Non steer End 1 Number 4 pivot pin 10 Number 3 inner arm 2 Number 3 center pivot pin 2 pins 11 Number 3 outer arm 3 Lift cylinder rod end pivot pin 12 Number 3 pivot pin non steer end 4 Number 3 pivot pin steer end 13 Number 2 inner arm 5 Number 2 center pivot pin 2 pins 14 Number 2 outer
371. tical position 6 Lower the platform onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform If you are not installing a new level sensor proceed to step 15 7 Turn the key switch to the off position and push in the red Emergency Stop button to the off position at the ground controls 8 Tag and disconnect the level sensor wire harness from the chassis wire harness Note The wire harness connection is located next to the level sensor on top of the chassis at the steer end of the machine 9 Remove the level sensor retaining fasteners Remove the level sensor from the machine 10 Tag and disconnect the level sensor wires from the level sensor connector plug 11 Securely install the wires of the new level sensor into the level sensor connector plug Part No 97385 March 2007 Section 4 Repair Procedures REV D GROUND CONTROLS 12 Place the new level sensor onto the level Steer end sensor mount bracket with the X on the level sensor base closest to the long side of the level sensor mount and the Y on the level sensor base closest to the short side of the level sensor mount Tip over hazard The level sensor Ei must be installed with the the level sensor base closest to the long side of the tilt level sensor box and the Y on the level sensor base closest to the short side of the tilt level sensor box Failure to insta
372. tion 1 a drive function select button BN8 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 Genie GS 30 GS 32 GS 46 REV K 6 Bring the machine to top drive speed before reaching the test line Release the function enable switch or the joystick when your reference point on the machine crosses the test line Measure the distance between the test line and your machine reference point Refer to Section 2 Specifications 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 Note 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 Electrocution burn hazard Contact AWARNING 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 lt lt Now GS 1530 GS 1532 GS 1930 GS 1932 Illustration 2 a drive forward reserve valve GS 2032 GS 2632 GS 3232 GS 2046 GS 2646 GS 3246 Part No 97385 February 2012 Section 3 Scheduled Maintenance Procedures
373. to the sides of the rotary latch mechanism Part No 97385 GS 30 GS 32 GS 46 Genie CHECKLIST B PROCEDURES Section 3 Scheduled Maintenance Procedures February 2012 CHECKLIST B PROCEDURES B 15 3 Inspect the Voltage Inverter if equipped 2 Genie requires that this procedure be performed x every 250 hours or quarterly whichever comes first 1 Inspect the inverter plug and pigtail for damage or excessive insulation wear Replace as required 2 the key switch to the on position and pull x out the red Emergency Stop button to the on position at both the ground and platform controls x x a rightfault LED b leftfault LED c 25VLED d 21VLED x Genie GS 30 GS 32 GS 46 REV K Connect an appropriate power tool to the inverter Activate the tool Result The power tool should operate There may be a brief 0 5 second delay if the power tool has not been used in the previous 10 minutes If the left fault LED REV_POL is illuminated the inverter is connected to batteries with the incorrect polarity Correct the polarity issue with the red wire to battery positive and the black wire to battery negative The inverter will then operate correctly and begin supplying AC power If the right fault LED 123 blinks one time the power draw is too high The tool being used requires too much power to operate or is being used at or near the limit of the inverter for an exte
374. top button to the off position at the platform controls 5 Press and hold the outrigger extend button and pull out the red Emergency Stop button to the on position at the platform controls Result After approximately 5 seconds the outrigger controls alarm will sound twice The outrigger motion alarm is now deactivated 4 16 GS 30 GS 32 6 Part No 97385 October 2009 Section 4 Repair Procedures REV J 1 5 Outrigger Controls Software Update Periodically the outrigger controls system is updated to improve system performance When an update is available for the outrigger controls system the system can be updated with the latest software revision Updates to the outrigger controls system include updating the outrigger ECM and or the outrigger control pad Prior to updating the outrigger controls system the software programmer hardware and firmware must be acquired through the Genie Service Department Note Perform this procedure with the machine on a firm level surface Note Failure to update the firmware on the outrigger ECM and or the outrigger control pad when updating the outrigger controls system may result in abnormal operation of the outrigger controls system How to Remove and Disassemble the Outrigger Control Pad 1 Disconnect the battery pack from the machine Electrocution burn hazard Contact AWARNING with electrically charged circuits could result in death or serious injury Remov
375. ttings will not take effect until the key switch is turned to the off position Section 4 Repair Procedures October 2009 PLATFORM CONTROLS How to Adjust the Stowed Drive Speed A DANGER Tip over hazard Do not adjust the 2 4 lift and or drive speed higher than specified in this procedure Setting the function speeds greater than specifications could cause the machine to tip over resulting in death or serious injury 777777177 Tip over hazard This procedure must only be performed by a trained service professional Attempting this procedure without the necessary skills will result in death or serious injury On machines with software revision A4 and higher setting the raised drive speed percentage to zero will result in the steer function being disabled when the platform is above the down limit switch Refer to 1 2 How to Determine the Software Revision Level 1 Pull out the red Emergency Stop button to the on position at the ground controls 2 Pushin the red Emergency Stop button to the off position at the platform controls 3 Turn the key switch to platform control 4 Atthe platform controls press and hold the lift function select and horn buttons and pull out the red Emergency Stop button to the on position Result The diagnostic display will show PS 5 Release the lift function select and horn buttons Result The diagnostic display will show the maximum lift speed percentage
376. ully remove the printed circuit board from the ECM enclosure Refer to Illustration 5 Component damage hazard Electrostatic discharge ESD can damage printed circuit board components Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap 15 Proceed to step 16 to update the firmware Part No 97385 Genie GS 30 GS 32 GS 46 PLATFORM CONTROLS Illustration 5 a b 0 0 8 f ECM enclosure printed circuit board torx screw bottom cover mounting bracket ECM decal Section 4 Repair Procedures October 2009 PLATFORM CONTROLS How to Update the Firmware Note The PSoC Programmer Genie part number 125324 updated Hex files for the outrigger control pad Genie part number 125132 and the updated Hex files for the outrigger ECM Genie part number 125131 must be installed on a PC or laptop 16 Plug the USB end of the PSoC MiniProg cable into a PC or laptop Note A window may ask to find a driver for the PSoC MiniProg cable Click Yes until finished Genie GS 30 GS 32 GS 46 REV J 17 Plug the PSoc MiniProg cable into the printed circuit board of the ECM or the control pad making sure the VDD on the PSoC MiniProg cable line up with the on the printed circuit board Refer to Illustration 6
377. ures REV K Pothole Limit Switches 27 Move the machine onto a grade which exceeds the rating of the level sensor Refer to the serial label on the machine 28 Press the lift function select button Standing on the up hill side of the machine attempt to raise the platform to approximately 8 feet 2 4 m Result The diagnostic display shows code LL an alarm sounds and the machine stops lifting after the pothole guards are deployed The machine is functioning properly Result The diagnostic display does not show code LL the alarm does not sound and the machine will continue to lift the platform after the pothole guards are deployed Adjust or replace the pothole limit switch 29 Press the drive function select button Standing on the up hill side of the machine attempt to steer and drive the machine O Result The diagnostic display shows code LL an alarm sounds and the machine will not steer or drive The machine is functioning properly Result The diagnostic display does not show code LL the alarm does not sound and the steer and drive functions operate Adjust or replace the pothole limit switch 30 Lower the platform to the stowed position Move the machine onto a firm level surface 31 Place a wooden block approximately 2 inches 5 cm tall under the right pothole guard Part No 97385 Genie GS 30 GS 32 GS 46 CHECKLIST B PROCEDURES 32 Press the lift function select button Att
378. us situation which if not avoided could result in death or serious injury Indicates a potentially hazardous ACAUTION situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of steps Section 3 Scheduled Maintenance Procedures April 2008 SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend Note The following symbols have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appears at the beginning of a maintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Indicates that a cold motor or pump will be required to perform this procedure Indicates that dealer service will be required to perform this procedure Genie 3 2 GS 30 GS 32 GS 46 Pre delivery Preparation Report The pre delivery preparation report contains checklists for each type of scheduled inspection Make copies of the Pre delivery Preparation report to use for each inspection Store completed forms as required Maintenance Schedule There are five
379. y Switch Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first 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 control panel could cause a hazardous operating situation Perform this procedure from the ground using the platform controls Do not stand in the platform 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 the key switch to platform control 3 Checkthe platform up down function from the ground controls Result The machine functions should not operate 4 Turn the key switch to ground control 5 Checkthe machine functions from the platform controls Result The machine functions should not operate 6 Turn the key switch to the off position Result No function should operate Part No 97385 February 2012 Section 3 Scheduled Maintenance Procedures H Rrrt REVK CHECKLIST B PROCEDURES B 7 Test the Automotive style Horn if equipped Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first The horn is activated at the platform controls and sounds at the ground as a warning to ground
380. y arm when lowering the platform 4 While raising the platform from the ground controls push the arm of the up limit switch towards the steer end of the machine to activate the limit switch Result The platform stops raising The machine is functioning properly Result The platform continues to raise Adjust or replace the up limit switch 3 28 GS 30 Genie GS 32 GS 46 Part No 97385 2007 Section 3 Scheduled Maintenance Procedures Checklist Procedures C 1 The maximum height limit switch located in the Test the middle of the drive chassis under the scissor arms Platform Overload System is used to disable the lift valve coil when the platform is near maximum height When activated the limit switch keeps the lift cylinder from going if equipped over lift relief which would cause the pressure switch to falsely indicate an overload condition Genie specifications require that this procedure be performed every 500 hours or six months whichever comes first OR when the machine fails to lift the maximum rated load Testing the platform overload system regularly is essential to safe machine operation Continued use of an improperly operating platform overload system could result in the system not sensing an overloaded platform condition Machine stability could be compromised resulting in the machine tipping over The platform overload system is designed to prevent machi
381. ylinder Cap the fittings on the cylinder AWARNING 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 59 Tag and disconnect the wire harness from the solenoid valve on the cylinder 60 Tag and disconnect the wires and manual lowering cable from the solenoid valve on the cylinder 61 Models with platform overload option Tag and disconnect the wire harness from the platform overload switch 62 Raise the lift cylinder to a vertical position 63 Remove the pin retaining fasteners from the lift cylinder barrel end pivot pin index 21 Use a soft metal drift to remove the pin Remove the lift cylinder from the machine Crushing hazard The lift cylinder ACAUTION will fall if not properly supported when the pivot pin is removed Component damage hazard Be careful not to damage the valve or fittings on the cylinder while removing it from the machine 4 61 Section 4 Repair Procedures March 2007 SCISSOR COMPONENTS 64 Remove the cables from the number 1 cable bridge and lay them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched REV How to Replace the Scissor Arm Wear Pads 1 Remove the platform See 2 1 How to Remove the Platform 65 Disconnect the number 1 cable bridge from the 2 Support and secure

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