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Service Manual - Genie Industries

1. Electrical Schematic REV B from serial number 40926 to 48103 is 1 1 QD4 76F 78 KS1 2 WH A A S 1 f 7X KEY SWITCH CR48 e k BL B B gt y Es T RELAY 8747 85 BK D D a TO US CB2 P1 12 d up EMERGENCY 1 CIRCUIT STOP zm 2 BREAKER 7 PLATFORM e o o f CONTROL 39C NC 4 N O ae e i OF L_ D eh 156 5 52 7 157 i DOWN MULTI PLATFORM POTHOLE GROUND LIMIT FUNCTION OVERLOAD GUARD 218 7 CONTROL SWITCH ALARM PRESSURE SWITCH 1 4 SWITCH 3 1966 B SWITCH 158 74 POTHOLE M e GUARD SWITCH mE CR5 giz 5 gt gt g 9 e YE gt SENSOR a HORN RELAY Z 9 amp m d X oq 3 CIRCUIT 027 87 5 H2 OPTION 318 3 9 S 2 3 S BoE BOARD 4 0 034 OHM 2 9 d 82 2 El Q E Des 92259 INDUCTOR gc cw 5 38 0509
2. REV B i i Electrical Schematic from serial number 40926 to 48103 M L J H G F E D C B A BK POWER TO PLATFORM CONTROLS 1 A 2 RD POWER TO GROUND CONTROLS we 2 co B B WH GROUND X N LESS p BE DATA LINK HIGH soystick CONTROLLER DATA LINK LOW WH YL QD3 n 1 Ve 5000 6 SW25 POTENTIOMETER ck es DIP SWITCHES 2 SW5 FUNCTION VOLTAGE REGULATOR 3 POUT1 POWER LED L19 POUT2 O FAULT LED L25 POUT3 O HIGH TORQUE LED L21 POUT4 C BATTERY LEVEL 1 POUTS BATTERY LEVEL 2 POUT6 BATTERY LEVEL3 gt 37 POUT7 BATTERY LEVEL 4 POUT8 O BATTERY LEVEL 5 4 POUT9 DRIVE LED L17 POUT10 LIFT LED L16 U3 PRINTED CIRCUIT BOARD CONTROLS ABBREVIATION LEGEND ABBREVIATION LEGEND MEMBRANE DECAL PANEL Item Description Item Description B Battery N C Normally closed MIGH TORQUEBNG B5 Main power N C H O Normally closed held open HORN BN5 5 B7 Auxiliary down GS 3246 only N O Normally open BN Button P Power switch DRIVE ENABLE BN8 BNS5 Horn P1 Emergency Stop button at ground controls LIFT ENABLE BN9 BN6 High torque P2 Emergency Stop button at platform controls BNO Li
3. WH A A 1 EE WH K BL B lt B CN KEY SWITCH 1 BK D C D Lal i 390 OR CB2 P1 EMERGENCY Wi NC 4 N O NCHO CIRCUIT STOP za BREAKER PLATFORM 41 D CONTROL 1 2 i 156 H5 PS2 157 mE i DOWN MULTI PLATFORM POTHOLE 1 LIMIT SWITCH FUNCTION OVERLOAD GUARD 218 i PRESSURE SWITCH B SWITCH 1 9 OPTION N CHO i GROUND CONTROL PLATFORM UP DOWN POTHOLE 3 SWITCH GUARD SWITCH 80 i 1 Be EE 28 25 g E x x Bae gp Pepe oS P m Br m T dao SS i 4 5 o S 5 E 2 8 lt i t 2 2 m 3 5 5 5 9 m i 3 G 2 2 4 i lt ang ZZ PEE BE 2 uu z c a 5 5 2 co 2 6 2 o 4 gt 2 E c 9 lel z 8 m p A 2 3 DOSS SE 2 8 52 Q 4 9 2 o 9 55 x m 027 To a o 9 1 E 5 Y ad 3 P k E 5 d 47 mH S gs 3 85 S7 INDUCTOR 2 3 LEVEL NOISE E a 1 SENSOR SUPPRESSION 22 86 9 Lee Eee 2 D 5 85 D 275A FUSE HORN RELAY l 1 lI i m H2 OPTION B8 8 AQ A12
4. M L K J G F E D C B A 1 a j LIFT LEFT RIGHT CYLINDER PLATFORM DRIVE MOTOR DRIVE MOTOR OVERLOAD LEFT RIGHT ume Deme CL 7 zu N O Y7 71 F 2 2 COM __7 PUMP N C 1 03 CU IN D 16 9 i Been BRAKE E oon MANUAL RELEASE L J MANIFOLD c MO X 3 UU LIFT 51 52 M1 M3 M2 M4 tc cc ep 7 4 ALL AL LA es W M D e y CJ 10 1 T SO _ 0 7 e Y1 amp e x ee ird 2 NM a Y2 M 4 1500 psi an a 0 75 gpm 1 So 103 4 5 AS sg 2 8 L min i e mE 2 i M M CD ye SE De ca ve IW de On oe 4 4 30 6 N i 2bar Eise Se ea ee ee Ny PRESSURE TANK ABBREVIATION LEGEND ABBREVIATION LEGEND power MARET Description Description 7 UNIT m D Platform lowering valve CA Test port Bam ks E Orifice platform down circuit zm regulator steer circuit
5. ECM PIN OUT LEGEND From serial number 17408 to 21064 Item Description A1 Spare A2 Platform ground from joystick White wire at platform AS Spare A4 Emergency Stop from platform Red wire at platform 5 Level sensor power A6 Platform up valve coil 7 Drive reverse valve A8 Motor controller terminal 1 A9 Motor controller terminal 3 A10 Overload sensor A11 Key switch to platform A12 Platform down at ground controls B1 Platform data link Blue wire at platform B2 Emergency Stop to platform Black wire at platform B3 Ground for electronic control module B4 Spare B5 Spare B6 Platform down valve coil B7 Steer left valve coil B8 Automotive style horn option B9 Multifunction alarm B10 Pothole limit switch B11 Spare B12 Platform up at ground controls C1 Platform data link yellow wire at platform C2 Emergency Stop at ground controls main power C3 Spare C4 Spare C5 Spare C6 Drive forward valve coil C7 Steer right valve coil C8 Parallel coil C9 Brake release valve coil C10 Spare C11 Level sensor signal C12 Down limit switch CA BC CC a DADA S LT KE C ECM PIN OUT LEGEND From serial number 21065 to 25141 Item Description A1 Flashing beacon A2 Platform grou
6. Electrical Schematic REVA from serial number 49300 to 59999 A B C D E F G H J K L M B 1 76 78F 1 X WH WH RD 4 ot WH WH 3 gg CR48 id st WH BL 1 2 1 PLATFORM KS1 POWER WH BK 2 7A EMERGENCY CONTROL RELAY 87A 87 85 CIRCUIT STOP KEY SWITCH TO U5 WH OR 5 BREAKER B1 4 3 zen 2 Le 39C GROUND N C N O 87 CONTROL 156 H5 527 157 DOWN MULTI PLATFORM POTHOLE LIMIT FUNCTION OVERLOAD GUARD 218 s A SWITCH ALARM PRESSURE SWITCH TS66 SWITCH UP DOWN OPTION 3 SWITCH Pu ar c o lr ee CR 1 LS8 POTHOLE i i GUARD 4 x SWITCH Li CRS EIE E 2 a 9 g sn 5 HORN RELAY 615 6 pb SZ ip 2 m MP 4602 3 Wi CIRCUIT i U27 85 H2 OPTION 3 8 amp 9 2 2 2 S amp QS aZ EE BOARD 0 034 olg 3 2 9 i zo 2822 59 F i INDUCTOR mJ 2 3 d o 5 9 FT 2 Gi kl 4 NOISE 18 m a m 15 E g m a Z5 S7 SUPPRESSION R21 912 2 2 9 B 4 2 S E LEVEL CE MODELS ONLY 75 OHM o g 6 a di SENSOR Olm 2 E 2 2 2 3 BN am 3 4 NEE QD1 9 B8 9 A12 B12 AM C12 B9 A10 B10 Bi C2 M4 A2 BICI CH OUT OUT OUT IN N IN IN OUT IN IN IN IN IN IN IN IN IN OUT 5
7. 6 15 Genie GS 2032 and GS 2632 Part No 72963 REV B June 2004 Section 6 Schematics E REV B j j Electrical Schematic from serial number 25142 to 28936 M L J G F D jS CS rc 7 BK POWER TO PLATFORM CONTROLS STOP 3 gt RD POWER TO GROUND CONTROLS 1 amp B B WH GROUND 0 7 D BL DATALINK HIGH Joystick CONTROLLER DATA LINK LOW j WH YL QD3 pe 1 J YE 5000 OHM SW6steer POTENTIOMETER SW25 Shes DIP SWITCHES 2 SW5 FUNCTION ENABLE 24V DC D7 VOLTAGE U U REGULATOR 3 POUTI x POWER LED L19 POUT2 O Cat FAULT LED L25 POUT3 a HIGH TORQUE LED L21 POUT4 BATTERY LEVEL 1 POUTS O a BATTERY LEVEL 2 POUT6 O BATTERY LEVEL 3 G7 POUT7 BATTERY LEVEL4 POUT8 O BATTERY LEVEL 5 4 fA POUT9 O 2 4 DRIVE LED 117 POUT10 LIFT LED L16 U3 PRINTED CIRCUIT BOARD ABBREVIATION LEGEND ABBREVIATION LEGEND MEMBRANEDEGAEPANEL Item Description Item Description HIGH TORQUE BN6 B Battery N C Normally closed B5 Main power N C
8. 1 TESNO 10 ft lbs 14 Nm 3 Flow regulator 0 75 2 8 L min iss Steer rout 35 ft lbs 47 Nm 4 Orifice washer 0 040 in 1 mm AD saisis Steer circuit 5 Relief valve 1500 psi 103 4 bar ees Steering relief 20 ft Ibs 27 Nm 6 Relief valve 3500 psi 241 3 bar AE unis System 20 ft lbs 27 Nm 7 Solenoid valve 3 position 4 way AQ suus Steer left right 20 ft lbs 27 Nm 8 Solenoid valve 2 position 4 way Platform steric 25 ft lbs 34 Nm 9 Solenoid valve 2 position 2 way N O Aliases Brake circuit erre 20 ft Ibs 27 Nm 10 Solenoid valve 2 position 4 way Drive speed select circuit 25 ft lbs 34 Nm 11 Solenoid valve 3 position 4 way Drive forward reverse 25 ft lbs 34 Nm 12 Relief valve 130 psi 9 bar AL seis Brake cirount niisiis 20 ft Ibs 27 Nm 4 54 Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section 4 Repair Procedures REV MANIFOLDS lt SCH e a K ET t 3 9 e Le 7 WO 12 11
9. 3 3 Maintenance Inspection Report 3 5 Checklist A Procedures A 1 Perform Pre operation Inspection 3 6 2 Perform Function Tests adape 3 6 A 3 Perform 30 Day 3 7 4 Grease the Steer 2 0 0 044 16004000 00 3 7 Part No 72963 Genie GS 2032 and GS 2632 V September 2006 TABLE CONTENTS Section 3 Rev Scheduled Maintenance Procedures continued D Checklist B Procedures B 1 Inspect the Batteries etri cce sedente tune ceat 3 8 B 2 Inspect the Electrical 3 9 B 3 Inspect the Tires and Wheels including castle nut torque 3 10 BA Test the Emergency Stop 3 10 B 5 Test the Key Switch eei tee neds 3 11 6 Testthe Automotive style Horn if eouippedt 3 11 B 7 Testthe Drive Brakes i eire 3 12 B 8 Testthe Drive Speed Stowed Position 3 15 B 9 Testthe Drive Speed Raised Position 3 16 B 10 Perform Hydraulic Analysis see 3 17 B 11 Replace the Hydraulic Tank Return Filter 3 17 B 12 Check the Module Tray Latch Components eeeeeeeeeereeeeneen 3 1
10. 6 21 Electrical Schematic from serial number 49300 to 59999 6 23 Component Reference and Hydraulic Symbols Legend 6 25 B Hydraulic Schematic from serial number 174081036100 6 26 B Hydraulic Schematic from serial number 361011052788 6 27 A Hydraulic Schematic from serial number 52789 to 59999 6 28 B Hydraulic Schematic Models with Traction Control 6 29 x Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section 2 Specifications REVA Machine Specifications Specifications Performance Specifications Batteries Drive speed maximum Type 6V DC Platform stowed 2 2 mph 40 ft 12 4 sec Group T 105 3 5 km h Quantity 4 12 2 12 4 sec Platform raised 0 5 mph Battery capacity maximum 225AH 40 ft 55 sec Reserve capacity 25A rate 447 minutes 0 8 km h 12 2 m 55 sec Fluid capacities Braking distance maximum Hydraulic tank 5 gallons 18 9 liters High range on paved surface 2ft 61 cm Hydraulic system including tank 5 5 gallons 20 8 liters Function speed maximum from platform controls with 1 person in platform Tires and wheels Platform up 29 to 31 seconds Tire size solid rubber 15x5in Platform down 25 to 27 seconds 38 1 x 12 7 cm Gradeability
11. Joystick CONTROLLER DATA LINK LOW WHNL QD3 pw J uL 5000 OHM SWOsreen POTENTIOMETER re es DIP SWITCHES 2 SW5 FUNCTION ENABLE VOLTAGE REGULATOR 3 POUT1 O POWER LED L19 POUT2 FAULT LED L25 POUT3 HIGH TORQUE LED L21 POUT4 O BATTERY LEVEL 1 POUTS BATTERY LEVEL 2 POUT6 BATTERY LEVEL3 gt 37 POUT7 BATTERY LEVEL 4 POUT8 a BATTERY LEVEL5 4 POUT9 E DRIVE LED L17 POUT10 ES LIFT LED L16 U3 PLATFORM CONTROLS PRINTED CIRCUIT BOARD MERE ANDE PARET ABBREVIATION LEGEND ABBREVIATION LEGEND Item Description Item Description HIGH TORQUE BN6 B Battery N C Normally closed BORN BRS B5 Main power N C H O Normally closed held open 5 B7 Auxiliary down GS 3246 only N O Normally open DRIVE ENABLE BN8 BN Button P Power switch BN5 Horn P1 Emergency Stop button at ground controls HET ENABES BN6 High torque P2 Emergency Stop button at platform controls BNO Lift enable PS2 Platform overload pressure switch option BN23 Auxiliary down GS 3246 only QD Quick disconnect CB2 Circuit breaker 7A QD1 Battery quick disconnect CR Control relay QD3 Control cable to ground Horn with H2 option QD4 Control cable to platform CR48 Power to U5 R Resistor 6 D7 Voltage regulator R15 5000 ohm potentiometer F Fuse R21 75 ohm resistor POUT11 F6 275A S7 Tilt level sensor F8 50A with U13 option SW Switch FB Flashing beacons option SW5 Function enabl
12. 72963 Genie GS 2032 5 2632 4 55 Section Ae Repair Procedures June 2004 EE MANIFOLDS REV C 6 3 Function Manifold Components from serial number 36101 to 49245 The function manifold is mounted inside the hydraulic power unit module tray Index Schematic No Description Item Function Torque 1 Diagnostic nipple TOSUN ccce ree 10 ft lbs 14 Nm 2 Flow regulator valve 075 2 8 2 2 2 ne BB e Steer 35 ft Ibs 47 Nm 3 Relief valve 3000 to 3200 psi 207 to 221 BG eei Platform up eerte 20 ft lbs 27 Nm 4 Relief valve 3500 psi 241 3 bar BD ute System relief 20 ft Ibs 27 Nm 5 Orifice washer 0 040 in 1 mm 2 Steer circuit 6 Relief valve 1500 psi 103 4 bar BEES Steering relief 20 ft Ibs 27 Nm 7 Relief valve 130 psi 9 bar Brake relief 20 ft lbs 27 Nm 8 Solenoid valve 3 position 4 way Steer left right 20 ft lbs 27 Nm 9 Solenoid valve 2 position 4 way Bl Drive speed select circuit 25 ft lbs 34 Nm 10 Solenoid valve 3 position 4 way Drive forward rev
13. 1 2 1 SC 7 EMERGENCY 7 CIRCUIT STOP PLATFORM CONTROL Sec 2 J fr S N C 4 NO N CHO 4 d t e 3 56 H5 52 87 GROUND DOWN ALARM PLATFORM POTHOLE CONTROL LIMIT OVERLOAD GUARD Se 7866 SWITCH PRESSURE SWITCH SWITCH UP DOWN OPTION 3 SWITCH emen POTHOLE GUARD 8 SWITCH 1 i SS e g 9 SEB SBPTS me I Y mox Ka m ES cmd o zz x qma E e v pO gt EC 9 o o 5 S o v ee i 4 2 A I 2 m 5 o EI E 2 es E S 9 5 2 E gt 4 4 SS Sg Si o E o o o Ko 3 8 8 2 2 2 57 8 Bie 2 3 9 3 2 5 2 mi U27 2 5 E o gt 9 z E o Zo 5 47 mH m 2 E S7 INDUCTOR m 3 LEVEL QD1 NOISE e m 5 i SENSOR SUPPRESSION Ke SE 2 2 D 5 85 g CR5 4 HORN RELAY Ten H2 OPTION B8 A8 A9 12 B12 An C12 B9 A10 B10 B11 C2 A4 2 Bi Cii A5 OUT OUT OUT IN N IN IN OUT IN IN IN IN IN IN IN IN IN OUT 05 A1 OUT ELECTRONIC CONTROL MODULE OUT OUT OUT OUT OUT OUT OUT OUT OUT B3 C8 B7 AT c6 B6 A6 m AC INPUT SLY poo Pe ee MERE REENEN CS NS 0 o D gt D 2 3 gt o I D 2 es
14. PLATFORM CONTROLS Le h CIRCUIT BOARD JC1 T ig e ig E a O L le E a b J Platform controls with hall effect joystick a Emergency Stop button P2 b platform controls circuit board U3 c circuit board retaining fastener d circuit board voltage regulator alarm Hi f joystick controller JC1 g potentiometer h DIP switch SW25 4 2 Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section Ae Repair Procedures REV B 1 1 Circuit Boards How to Remove the Platform Controls Circuit Board 1 Push in the Emergency Stop button to the off position at both the ground and platform controls 2 Loosen the platform control box lid retaining fasteners Open the control box lid 3 Locate the circuit board mounted to the inside of the platform control box lid AWARNING Electrocution 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 CAUTION 4 Carefully disconnect the three wire harness connectors from the platform controls circuit board 5 Carefully remove the platform co
15. H 52F oa 58F O NC O stF A H Cas pia 12 2 HL a H J A from serial number 21065 to 40925 r 50F 49F 5 KS1 5 PLATFORM wi NO AA A11 A11 KEY SWITCH TS66 P1 o mO qv CB2 olo o DOWN 53F O NC O 51F 24 L 4sF L 42F d H er d before serial number 21065 6 8 Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section Ge Schematics Level Sensor Box Wiring Diagram REV B ts S7 B9 44D H5 T B11 39C RD BK WH Y Y A5 11 29 270 N 44D 75D LJ E Los 230 after serial number 21064 156 S7 B9 44D H5 MN B11 39C Lom 1 id RD BK WH AS 70D 11 75D 29F 27D N L 44D P 23F C12 before serial number 21065 WIRE COLOR LEGEND ABBREVIATION LEGEND Color Description Description BK Black H5 Multi function alarm RD Red LS6 Down limit switch WH White S7 Level sensor Part No 72963 Genie GS 2032 and GS 2632 Section 6 Schematics June 2004 Electrical Symbols
16. 20 ft Ibs 27 Nm 13 Flow divider combiner valve EM eener Drive slip limit 25 ft lbs 34 Nm 14 Solenoid valve 2 position 4 way Platform Up EE 25 ft lbs 34 Nm 15 Check valve 10 psi 0 7 bar Steer 20 ft lbs 27 Nm 4 60 Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section 4 e Repair Procedures REV MANIFOLDS T bs z Y 6 72963 Genie 95 2032 95 2632 4 61 Section Ae Repair Procedures June 2004 MANIFOLDS 6 6 Valve Adjustments Function Manifold How to Adjust the System Relief Valve before serial number 36101 1 Open the hydraulic power unit module tray and locate the system relief valve on the function manifold item AF 2 Place maximum rated load into the platform Secure the load to the platform Load capacity maximum GS 2032 800 Ibs 363 kg GS 2632 500 Ibs 227 kg A Ze MG AE os RNG Se 6 2 9 6 6 System relief valve b function manifold REV C 3 Turn the key switch to ground control and pull out the red Emergency Stop button to the position at both the ground and platform controls 4 Hold the system relief valve with a wrench and remove the cap it
17. Steer left right 20 ft lbs 27 Nm 8 Solenoid valve 2 position 4 way Platform up iie etes 25 ft lbs 34 Nm 9 Solenoid valve 2 position 2 way N O Brake 2 20 ft Ibs 27 10 Solenoid valve 2 position 4 way A ste Drive speed select circuit 25 ft lbs 34 Nm 11 Solenoid valve 3 position 4 way AK uses Drive forward reverse 25 ft lbs 27 Nm 12 Check valve 200 psi 13 8 bar AL Brake 25 ft lbs 34 Nm 4 52 Genie GS 2032 95 2632 72963 June 2004 Section 4 Repair Procedures REV MANIFOLDS lt w a K ET t 3 9 e Le 7 d Me 0 12 11 72963 Genie GS 2032 GS 2632 4 58 Section Ae Repair Procedures June 2004 EE MANIFOLDS REV C 6 2 Function Manifold Components from serial number 17482 to 36100 The function manifold is mounted inside the hydraulic power unit module tray Index Schematic No Description Item Function Torque 1 Check valve 30 psi 2 bar Steer 20 ft lbs 27 Nm 2 Diagnostic nipple
18. Part No 72963 June 2004 Section Ae Repair Procedures REV B 28 Use a soft metal drift to remove the number 3 pivot pin index 6 Remove the number 3 inner arm index 17 from the machine Bodily injury hazard The number ACAUTION 3 inner arm index 17 become unbalanced and fall if not properly supported when it is removed from the machine 29 Remove the cable clamps from the lower cable tray Lay the cables to the side Component damage hazard CAUTION Cables can be damaged if they are kinked or pinched 30 Remove the mounting fasteners from the lower cable tray supports 31 Remove the mounting fasteners from the lower cable tray mounting bracket on the number 2 center pivot pin index 7 at the ground controls side of the machine 32 Slide the cable tray towards the battery pack side of the machine and remove it from the machine 33 Attach a lifting strap from an overhead crane to the number 2 outer arm index 21 at the ground controls side 34 Remove the external snap rings from the number 2 center pivot pin index 7 at the ground controls side 35 Use a soft metal drift to remove the number 2 center pivot pin index 7 at the ground controls side SCISSOR COMPONENTS 36 Use a soft metal drift to tap the number 2 pivot pin index 22 halfway out at the non steer end of the machine Remove the number 2 outer arm index 21 from the ground controls side of the machine Bodily inj
19. i m 2 3 2 S 6 g X 4 929 D 027 5 m 5 6 d du 47 mH 3 gm 2 5 A aR 87 INDUCTOR 2 5 3 x LEVEL NOISE B a SENSOR QD1 9 SUPPRESSION 2 zi g iile Se D tu 2 5 275 HORN RELAY ur SSS SS SS m r H2 OPTION B8 12 12 C2 2 B9 A10 B11 10 B2 A4 A2 B1 C11 A5 OUT OUT OUT IN N IN IN IN OUT IN IN IN IN IN OUT nx a1 our U5 ELECTRONIC CONTROL MODULE OUT OUT OUT OUT OUT OUT OUT OUT OUT B3 C8 C9 C7 B7 AT C6 B6 e ope ee T 2 g g 9 d E g d 7 2 E 3 S 3 E A 9 J 2 5 2 5 F8 U6 Shy 8 2 E 8 g 8 8 9 50A FUSE 1 a E E CONTROLLER FB LIN ors 1013 G6 FB H2 Y1 Y2 Y3 Y4 Y5 Y6 Y7 Y8 HOUR FLASHING AUTOMOTIVE STYLE PARALLEL BRAKE STEER STEER DRIVE DRIVE PLATFORM PLATFORM DC AC INVERTER METER BEACONS HORN RELEASE RIGHT LEFT REVERSE FORWARD DOWN UP OPTION OPTION OPTION OPTION j n Sech 4 T I I I Le 6 13 Genie GS 2032 and GS 2632 Part No 72963 REV B June 2004 Section 6 Schematics E Electrical Schematic from serial number 21065 to 25141 L J H G rc BK POWER TO PLATFORM CONTROLS ve A A RD POW
20. 12 C2 C12 Bit B9 A10 B10 11 2 4 2 1 1 Cii Ap OUT OUT OUT IN N N IN OUT IN IN IN OUT IN IN IN IN IN OUT Y ELECTRONIC CONTROL MODULE OUT OUT OUT OUT OUT OUT OUT OUT OUT B3 C8 C9 B7 A7 B6 A6 AC INPUT i 7 OUTRE DOMNUS m 1 T 71 T ATA g g g 9 g 5 g g 5 D 3 3 m D i 5 5 5 8 8 5 8 SOAFUSE U6 motor NV z x 7 CONTROLLER FB bu G6 FB H2 Y1 Y2 Y4 Y5 Y6 Y7 Y8 HOUR FLASHING AUTOMOTIVE STYLE PARALLEL BRAKE STEER STEER DRIVE DRIVE PLATFORM PLATFORM DC AC INVERTER METER BEACONS HORN RELEASE RIGHT LEFT REVERSE FORWARD DOWN UP OPTION 5 4 e L_ Le L_ 8 GND GND 6 11 Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section 6 Schematics E REV B i i Electrical Schematic from serial number 17408 to 21064 M L J H G D C B A poc Ee e d C5 7 BK POWER TO PLATFORM CONTROLS E m RD POWER TO GROUND CONTROLS 1 V E B B WH GROUND Ve D BL
21. a steer relief valve b function manifold test port a system relief valve b function manifold C test port Models without traction control from serial number 49426 to 59999 KBB NS S BC Rr Ss i S BD BE oa Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section 4 e Repair Procedures lt MANIFOLDS 2 Turn the key switch to ground control and pull out the Emergency Stop button to the on position at both the ground and platform controls 3 Press and hold the steer thumb rocker switch to the right Allow the wheels to completely turn to the right then continue holding the switch while observing the pressure reading on the pressure gauge Note the pressure 4 Press and hold the steer thumb rocker switch to the left Allow the wheels to completely turn to the left then continue holding the switch while observing the pressure reading on the pressure gauge Note the pressure Refer to Section 2 Specifications 5 Turn the machine off Hold the steering relief valve with a wrench and remove the cap item BF or CF 6 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap ADANGER Tip over hazard Failure to adjust the relief valves to spe
22. eL a odit i E 1500 psi p 1 0 75 gpm 1 i f 5 5 2 8 neuen E e X E BO BG ve W vs BJ 3000 to 3200 psi A NC 1 e deg 2071 221 bar d We 130 psi 6 i 1 9 bar PRESSURE TANK ABBREVIATION LEGEND ABBREVIATION LEGEND E MESURER Item Description Item Descripton 7 9 SS D Platform lowering valve BA Test port POWER cu D E Orifice platform down circuit BB Flow regulator steer circuit UNIT 5 25 psi 1 7 bar F Accumulator BC Relief valve lift oe SIE J Shuttle valve brake release BD Relief valve system L 21 Orifice washer steer circuit J K Check valve manual brake release circuit BF Relief valve steer E E L Hand pump manual brake release circuit BG Relief valve brake circuit 100 MESH e M Platform lowering valve BH Steer left right 8 R Platform overload pressure switch Drive speed select BJ Drive forward reverse BK Brake circuit IMPORTANT NOTES E Pise un Item Description BM Check valve steer circuit BM Changed to 10 psi 0 7 bar after serial number 43739 Part No 72963 Genie GS 2032 and GS 2632 6 27 June 2004 Section 6 Schematics BEE Hydraulic Schematic from serial number 36101 to 52788 June 2004 Section Ge Schematics E
23. 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 Two Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform See 2 1 How to Remove the Platform 2 Remove the cables from the side of the number 4 outer arm index 15 at the ground controls side Component damage hazard CAUTION Cables can be damaged if they are kinked or pinched SCISSOR COMPONENTS 3 Attach a lifting strap from an overhead crane to the number 4 outer arm index 15 4 Remove the external snap rings from the number 4 center pivot pin index 2 5 Use a soft metal drift to remove the number 4 center pivot pin index 2 6 Remove the external snap ring from the number 4 pivot pin index 16 at the non steer end of the machine 7 Usea soft metal drift to remove the number 4 pivot pin index 16 from the non steer end of the machine Remove the number 4 outer arm index 15 from the machine Crushing hazard The number 4 ACAUTION outer arm index 15 may become unbalanced and fall if not properly supported when it is removed from the machine 8 Remove the cables from the upper cable tray and lay them off to the side Component damage hazard
24. Department Reset the ECM U5 by pushing in Emergency Stop button P2 to the OFF position Pull the Emergency Stop button P2 up to the ON position Check to see if the error indicator light is on at the platform controls Replace the platform controls OR consult the Genie Industries Service Department Replace the platform controls REVA Refer to the chart s that are related to the error code that is displayed on U5 OR consult the Genie Industries Service Department Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section 5 Troubleshooting Flow Charts REVA Brake Release Function Inoperative Be sure if the Error Indicator light is on at the platform controls you refer to the specific chart that relates to the error code that is displayed on the ECM Be sure the circuit breaker and fuse are not tripped or blown Be sure the batteries are fully charged and properly connected Chock the wheels at the wheels steer end of the turn machine Jack the non steer end of the machine up approximately 4 inches 10 cm and place jack stands under the machine for support Turn the brake release knob item A counterclockwise all the way and pump the hand pump item C fully 13 15 times or until much resistance is felt Turn each wheel by hand Each wheel should turn freely without much effort wheels do not turn Plumb a 0 to 500 psi 35 bar gau
25. F6 275A FUSE U5 ELECTRONIC CONTROL MODULE OUT 9 C8 C9 C7 B7 A7 C6 A6 B6 BATTERY Ka I t c See CHARGER x IB T T 6 2 2 g g 2 g 2 bd m m 2 2 d S 3 p 5 AC INPUT Vly 3 8 2 8 8 8 8 8 FB T E STN 4 res l 50A FUSE U6 motor NU 7 CONTROLLER ATN U4 G6 FB H2 Y1 Y2 Y3 Y4 Y5 Y6 Y8 Y7 U13 HOUR FLASHING AUTOMOTIVE STYLE PARALLEL BRAKE STEER STEER DRIVE DRIVE PLATFORM PLATFORM DC AC INVERTER METER BEACONS HORN RELEASE RIGHT LEFT REVERSE FORWARD UP DOWN OPTION OPTION 1 LH _ L_ Le GND GND 8 M 6 23 Genie GS 2032 GS 2632 Part No 72963 June 2004 Section 6 Schematics REVA j j Electrical Schematic from serial number 49300 to 59999 M L J G F D C B A jue ys 4 7 4 BK POWER TO PLATFORM CONTROLS STOP 3 3 RD POWER TO GROUND CONTROLS 1 D a w 1 1 WH GROUND 2 2 BL DATA LINK HIGH
26. OR consult the Genie Industries Service Department Check the connection at the ECM U5 OR replace the drive forward reverse valve cartridge item or BJ OR consult the Genie Industries Service Department 0 or infinite ohms REVA Repair open in the WH C6 fwd coil wire from the drive forward directional valve coil item AI or BJ to the ECM U5 OR repair open in the brown ground wire circuit from the coil to the wire harness OR replace U5 OR consult the Genie Industries Service Department Replace the drive forward directional valve coil item or BJ Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section 5 Troubleshooting Flow Charts REVA Drive Reverse Function Inoperative Be sure all other functions operate normally Be sure the circuit breaker and fuse are not tripped or blown Be sure the batteries are fully charged and properly connected With the key switch Connect the positive lead from a volt meter to the drive reverse directional valve coil item Al or BJ wire terminal without disconnecting the wire and the negative lead of the volt meter to the brown ground wire on the coil Activate drive in the REVERSE direction and check the voltage turned to platform controls and both Emergency Stop buttons pulled out to the ON position activate drive controller in the reverse direction and check to see if the error indicator light at the pl
27. Platform lift speed stowed drive speed raised drive speed and high torque drive speed are 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 Industries Service Department VT T3173 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 A DANGER Tip over hazard This procedure must only be performed by a trained service professional Attempting this procedure without the necessary skills will result in OR press the lift function select button Genie E yellow arrow joystick controller JC1 lift function select button BN9 Emergency Stop button P2 lift function enable button BN9 D 5 Slowly move the joystick in the direction death or serious injury indicated by the yellow arrow miar ees Result The software revision level will appear and free of obstructions in the diagnostic display How to Determine the Revision O Result If the software revision level does not Level appear in the diagnostic display turn the key Switch to ground control and repeat steps 4 and 1 Remove the platform controls from the platform
28. Replace the coil cord assembly OR replace the control cable from the platform to U5 REVA 5 28 Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section 5 Troubleshooting Flow Charts Chart 17 REV B Fault Code 59 With the key alg Check for continuity in Repair or replace the 1 turned to platform the WH 8 coil wire continuity WH C 8 coil wire Parallel Series controls from the ECM U5 to the from the ECM U5 to the 1 Emergency Stop buttons drive speed select coil drive speed select coil Coil Fault pulled out to the ON item AJ or Bl or CJ position and the machine on incline LED d activated check for continuity Be sure all other voltage on the positive functions operate terminal at the Drive Replace U5 OR consult normall speed select valve coil the Genie Industries y item AJ or BI or CJ Service Department Be sure the circuit breaker and fuse are not tripped or blown 20V or more Check for continuity in 10 Repair or replace the the brown ground wire ground wire circuit from Be sure the batteries circuit from the drive the drive speed select are fully charged and speed select valve coil coil to ground item AJ or Bl or CJ to properly connected ground continuity Disconnect the wires Consult the Genie from the drive speed Industries Service select valve coil item AJ Department or Bl or CJ and check resistance of the coil See Repair Section 0 or i
29. Tire contact area 10 sq 64 5 2 GS 2032 30 95 2632 25 Castle nut torque dry 300 ft lbs 406 7 Nm Airborne noise emissions gt 70 dB Maximum sound level at normal operation workstations Castle nut torque lubricated 225 ft lbs A weighted 305 Nm Continuous improvement of our products isa For operational specifications refer to the Genie policy Product specifications are subject Operator s Manual to change without notice Part No 72963 Genie GS 2032 and GS 2632 2 1 Section 2 Specifications June 2004 SPECIFICATIONS Hydraulic Specifications Hydraulic Oil Specifications Hydraulic oil type Chevron Rykon MV equivalent Approximate SAE grade 5W 20 Viscosity index rating 200 Chevron Rykon MV oil is fully compatible and mixable with Shell Donax TG Dexron lll 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 have a minimum viscosity index rating of 150 They should provide excellent antiwear oxidation corrosion inhibition seal conditioning and foam and aeration suppression properties Optional fluids Petro Canada Premium ECO 46 Statoil Hydra Way Bio Pa 32 BP Biohyd SE S Biodegradable Fire resistant UCON Hydrolube HP 5046 Quintolubric 822 Shell Tellus T32 Shell Tellus T46 Chevron Aviation A Mineral based Genie specifications require additional equi
30. VOLTAGE REGULATOR POUT1 5000 OHM POTENTIOMETER B Section 6 Schematics E Electrical Schematic A JC Joystick CONTROLLER WH YL SW5i FUNCTION POUT2 POUT4 POUTS POUT6 0 30 70 POUT7 POUT8 9 O POUT10 U3 PLATFORM CONTROLS PRINTED CIRCUIT BOARD PLATFORM CONTROLS MEMBRANE DECAL PANEL POWER LED L19 FAULT LED L25 HIGH TORQUE LED L21 BATTERY LEVEL 1 BATTERY LEVEL 2 BATTERY LEVEL3 gt 37 BATTERY LEVEL 4 BATTERY LEVELS DRIVE LED L17 LIFT LED L16 HIGH TORQUE BN6 HORN BN5 DRIVE ENABLE BN8 LIFT ENABLE BN9 PIN9 PIN10 POUT11 SW 6steer PIN11 WIRE COLOR LEGEND Color Description Color Description BL Blue RD Red BK Black WH White BN Brown YL Yellow GN Green WH BL White Blue GY Gray WH BK White Black OR Orange WH RD White Red PP Purple WH YL White Yellow PLATFORM CONTROLLER H1 aarm from serial number 28937 to 40925 Part No 72963 Genie GS 2032 and GS 2632 6 18 June 2004 Section 6 Schematics SS FSS SS Electrical Schematic from serial number 28937 to 40925 Section Ge Schematics EE June 2004
31. index 49 Remove the number 2 inner arm index 20 from the machine Bodily injury hazard The number ACAUTION 2 inner arm index 20 may become unbalanced and fall if not properly supported when it is removed from the machine 44 Remove the safety arm from the number 2 inner arm index 20 that was just removed 45 Attach a lifting strap from an overhead crane to the number 1 inner arm index 11 46 Raise the number 1 inner arm index 11 approximately 2 feet 60 cm and install the safety arm between the number 1 inner arm index 11 and the number 1 outer arm index 24 Lower the scissor arms onto the safety arm A CAUTION Bodily injury hazard Keep hands clear of moving parts when lowering the scissor arms onto the safety arm 47 Tag disconnect and plug the hydraulic hose on the lift cylinder Cap the fitting 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 REV B 48 Tag and disconnect the wires from the solenoid valve on the cylinder 49 Attach a lifting strap from an overhead crane to the lug on the rod end of the lift cylinder index 8 Raise the lift cylinder to a vertical position 50 Remove the pin retaining fasteners from the lift cylinder barrel end pin index 23 Use a soft metal drift to remove the pin Re
32. item AE or BF Department Part No 72963 Genie GS 2032 and GS 2632 5 15 Section 5 Troubleshooting Flow Charts June 2004 Chart 9 Steer Right Function Inoperative Be sure all other functions operate normally Be sure the circuit breaker and fuse are not tripped or blown Be sure the batteries are fully charged and properly connected With the key switch turned to platform controls and both Emergency Stop buttons pulled out to the ON light is position on From serial number 17408 to 21262 activate the function enable switch and activate the steer rocker switch in the RIGHT direction and check to see if the error indicator light at the platform controls is on After serial number 21262 press the drive function select button and activate the function enable switch and activate the steer rocker switch in the RIGHT direction and check to see if the error indicator light at the platform controls is on light is not on Activate the function enable switch and activate the steer right no function Does the motor turn on yes Continued on the next page Connect the positive lead from a volt meter to the WH B7 left coil wire terminal at the steer left directional valve coil item AF or BI without oV disconnecting the wire and the negative lead of the volt meter to the brown ground wire at the valve coil Activate the steer rocker switch in the
33. raised drive speed percentage 6 Use the steering thumb rocker switch on the joystick to increase or decrease the maximum lift speed percentage Refer to Section 2 Specifications 7 Turn the key switch to the off position Any change in software settings will not take effect until the key switch is turned to the off position A 1 Genie 95 2032 69 2632 Part No 72963 June 2004 Section Ae Repair Procedures REV B 1 4 Software Configuration The ECM Electronic Control Module contains programming for all configurations of the Genie GS 2032 and GS 2632 The machine can be adjusted to a different configuration by changing the toggle settings on the DIP switch The DIP Switch is located on the circuit board inside the platform control box Each of the eight toggles of the DIP switch have two positions on or off When reading the DIP switch code in the DIP Switch Code Chart the on and off are represented by the numbers 1 on and O off wes P d BUTTON E A st t GE CONTROLLER CONTROLS RCT E a ae d E 169 K before serial number a co A after serial number 48054 a b platform controls circuit board enlarged view of DIP switch SW25 joystick controller JC1 DIP switch SW25 PLATFORM CONTROLS How
34. 10 MICRON WITH valve II E lt gt 25 psi 1 7 bar E Accumulator brak CD Relief valve system L e ere UIUC valve Drake Orifice washer steer circuit J K Check valve manual brake release circuit CF Relief valve steer LL LI Hand pump manual brake release circuit Check valve brake circuit 100 MESH lt gt Platform lowering valve CH Steer left right 8 R Platform overload pressure switch Brake circuit CJ Drive speed select CK Drive forward reverse CL High speed bypass CM Flow divider combiner CN Platform up CO Check valve steer circuit Part No 72963 Genie GS 2032 and GS 2632 6 29 June 2004 Section 6 Schematics E Hydraulic Schematic Models with Traction Control Service Manual 659 2032 655 2632 Part No 12963 Rev C2 Genie Scandinavia Phone 46 31 575100 Fax 46 31 579020 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Iberica Phone 34 93 579 5042 Fax 34 93 579 5059 Genie Germany Phone 0800 180 9017 Phone 49 422 149 1818 Fax 49 422 149 1820 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 China Phone 86 21 53852570 Fax 86 21 53852569 Genie Malaysia Phone 65 98 480 775 Fax 465 67 533 544 Genie Ja
35. 5 The software revision level will appear in the 2 Place the platform controls close to the diagnostic display diagnostic display on the ground controls side 6 Push in the Emergency Stop button to the off of the machine position at both the ground and platform 3 Turn the key switch to platform control and pull 2 out the Emergency Stop buttons to the P position at both the ground and platform controls Part No 72963 Genie GS 2032 and GS 2632 4 5 Section Ae Repair Procedures June 2004 PLATFORM CONTROLS How to Adjust the Lift Speed ADANGER Tip over hazard Do not adjust the lift and or drive speed higher than specified in this procedure Setting the drive speed greater than specifications will cause death or serious injury ADANGER 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 Software revision AO and BO 1 Push the Emergency Stop button to the off position at the ground and platform controls Turn the key switch to the off position Pull out the Emergency Stop button to the on position at the ground and platform controls REV B 3 Press and hold the lift function enable and horn buttons and turn the key switch to platform controls Result The diagnostic display will show PS N Genie a function enable swi
36. CAUTION Cables can be damaged if they are kinked or pinched 9 Remove the mounting fasteners from the upper cable tray supports 10 Remove the upper cable tray from the scissor assembly 11 Attach a lifting strap from an overhead crane to the number 4 inner arm index 14 12 Remove the external snap rings from the number 4 pivot pin index 3 Part No 72963 Genie GS 2032 and GS 2632 Section Ae Repair Procedures June 2004 SCISSOR COMPONENTS 13 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 14 from the machine Crushing hazard The number 4 ACAUTION inner arm index 14 become unbalanced and fall if not properly supported when it is removed 14 Attach a lifting strap from an overhead crane to the number 3 outer arm index 4 at the ground controls side 15 Remove the external snap rings from the number 3 center pivot pin index 18 16 Use a soft metal drift to remove the number 3 center pivot pin index 18 17 Remove the external snap rings from the number 3 pivot pin index 19 at the non steer end of the machine Do not remove the pin 18 Use a soft metal drift to tap the number 3 pivot pin index 19 halfway out at the non steer end of the machine Remove the number 3 outer arm index 4 at the ground controls side from the machine Bodily injury hazard The number ACAUTION 3 outer arm index 4 at
37. D 3500 psi maximum L 241 bar maximum LEGEND Descripton 7 BA Test port PRESSURE E ABBREVIATION LEGEND z Tow regulator steer circuit a Description i BD Relief valve system y ks D Platform lowering valve BE Orifice washer steer circuit UNIT ae 25 psi 1 7 bar E Orifice platform down circuit BF Relief valve steer dt 1 er 2 BYPASS F Accumulator BG Relief valve brake circuit J Shuttle valve brake release Steer Ee 8 K Check valve manual brake release circuit BJ Drive forward raverse ees seg 21 L Hand pump manual brake release circuit BK Brake circuit M Platform lowering valve BL Platform up R Platform overload pressure switch BM Check valve steer circuit Part No 72963 Genie GS 2032 and GS 2632 6 28 June 2004 Section 6 Schematics Mp Hydraulic Schematic from serial number 52789 to 59999 June 2004 Section Ge Schematics E SE Hydraulic Schematic Models with Traction Control
38. END 8 121 High Torque Steer right Color Description Color Description L25 Fault Y4 Steer left Di BL Blue RD Red LS Limit switch Drive reverra BK Black WH White LS2 Platform up GS 3246 only Y6 Drive forward BN B YL Yell LS6 Platform down Y7 Platform down rown mE Y8 Platform GN Green WH BL White Blue LS7 Pothole p LS8 Pothole Y9 Platform down GS 3246 only GY Gray WH BK White Black 5 Hydraulic power unit Y10 Auxiliary down GS 3246 only OR Orange WH RD White Red Y11 Auxiliary down GS 3246 only PP Purple WH YL White Yellow Part No 72963 Genie GS 2032 and GS 2632 6 16 June 2004 Section 6 Schematics SS Electrical Schematic from serial number 25142 to 28936 Section 6 Schematics June 2004 Electrical Schematic REV B from serial number 28937 to 40925 76 78 WH A A 1 IKSi TE WH C 30 86 a KEY SWITCH CR48 4 ae BK D ge ON po QT RELAY 87 e D D TOUS m OR
39. H O Normally closed held open HORN BNG 5 B7 Auxiliary down GS 3246 only N O Normally open DRIVE ENABLE BN8 BN Button Power switch BN5 Horn P1 Emergency Stop button at ground controls LIET ENABLE BN6 High torque P2 Emergency Stop button at platform controls BNO Lift enable PS2 Platform overload pressure switch option BN23 Auxiliary down GS 3246 only QD Quick disconnect CB2 Circuit breaker 7A QD1 Battery quick disconnect CR Control relay QD3 Control cable to ground Horn with H2 option QD4 Control cable to platform CR48 Power to U5 R Resistor 6 D7 Voltage regulator R15 5000 ohm potentiometer F Fuse R21 75 ohm resistor POUT11 F6 275A S7 Tilt level sensor F8 50A with U13 option SW Switch FB Flashing beacons option SW5 Function enable PINTI G Gauge SW6 Steer left right G6 Hour meter SW25 DIP switch G7 Battery charge indicator TS66 Platform up down toggle switch GND Ground U Electronic component 7 H Horn or alarm U3 Encoder printed circuit board LAT FO H M C Q N T H L L E H H1 Horn 05 Electronic control module H2 Automotive style horn option U6 Motor controller H5 Multifunction alarm U9 Battery charger JC1 Joystick controller U13 Voltage inverter option KS1 Key switch U27 0 034 ohm inductor noise suppression L LED or light Y Valve coil L16 Lift Y1 Parallel L17 Drive Y1A High speed bypass option L19 Power Y2 Brake release WIRE COLOR LEG
40. No 72963 September 2006 Section 3 Scheduled Maintenance Procedures REV D B 8 Test the Drive Speed Stowed Position Proper drive functions are essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range 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 Emergency Stop button to the on position at both the ground and platform controls 3 Lower the platform to the stowed position 4 Models with drive function select button Press the drive function select button so Genie 100000 a drive function select button BN8 CHECKLIST B PROCEDURES 5 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 6 Bring the machine to maximum drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 7 Continue at full speed and note the time when the machine reference point passes over the finish line Refer to Section 2 Specifications Part No 72963 Genie GS 2032 and GS 2632 3
41. REV A Hydraulic Schematic from serial number 52789 to 59999 M L K J G F E D C B A PLATFORM LATI LIFT CYLINDER 71 5 5 LEFT RIGHT LEFT RIGHT 1 OVERLOAD LEFT RIGHT BRAKE BRAKE DRIVE DRIVE MODELS MOTOR MOTOR Ee e fitting on the lift cylinder 71 e Foo tC 2 PS2 CF 2 eil Wolf TN C Ew 221 1 08 CU IN Ss R e BRAKE i SAH PUMP 1 Y Ey RELEASE MANIFOLD L 0 046 1 17 _ II B1 3 LIFT V S1 S2 AC B HP M1 M4 FUNCTION MANIFOLD 1 Y4 MN M Y3 1 4 2 d b Yi M i 0 040 we M 1 Im 1 Sne Ke ye LT T Il 5 A yt M N 0 75 gpm AH i m 2 8 L min m NIS gt lt 4 6 I m AB Mess Y8 FUNCTION MANIFOLD Xe 1800 to 3500 psi pipi 124 to 241 bar
42. Remove the bracket from the cylinder 7 Before serial number 23568 Tag disconnect and plug the hydraulic hardline from the lift cylinder Cap the fitting on the cylinder After serial number 23567 Tag disconnect and plug the hydraulic hose from the lift cylinder Cap the fitting 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 8 Before serial number 23568 Remove the hardline retaining strap from the cylinder 9 Attach a lifting strap from an overhead crane or similar lifting device to the rod end of the lift cylinder for support SCISSOR COMPONENTS 10 Remove the external snap ring 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 when the pin is removed 11 Lower the cylinder CAUTION Component damage hazard Be careful not to damage the level sensor box limit switch or level sensor while lowering the cylinder 12 Support and secure the entry ladder to an appropriate lifting device 13 Remove the entry ladder mounting fasteners Remove the entry ladder from the machine Crushing hazard The entry ladder ACAUTION may become unbalanced and fall if not properly supported and secured to the lifting device 14 Attach
43. Se A gt A gt AJ 4 AG W Y1 al sS Nao Al amp ei t E 0 040 in 1300 pal D 5 125 d MES pe _ ve IN Ys A SEE AK AC T 078 opm j T all A Se 2 81 AL 200 AL 13 8 bar a F Y8 Sa i i H 3500 psi 241 3 bar oJ 7 EE a KEE ABBREVIATION LEGEND Description _ T in ABBREVIATION LEGEND AA Check valve steer circuit UNIT 10 MICRON WITH ION AB Test port 2 25 1 7 bar Item Description AC Flow regulator steer circuit 02 4 J BYPASS D Platform lowering valve AD Orifice washer steer circuit Orifice platform down circuit AE Relief valve steer 8 N F Accumulator AF Relief valve system lt gt 4 Shuttle valve brake release AS Seer left right K Check valve manual brake release circuit A Brake E NOTES L Hand pump manual brake release circuit AJ Drive speed select Item Description M Platform lowering valve AK Drive forward reverse AL Changed to 130 psi 9 bar relief valve after serial number 17481 H Platform overload pressure switch AL Check valve OR relief valve brake circuit Part No 72963 Genie G
44. Section 5 Troubleshooting Flow Charts June 2004 Chart 1 Functions Will Not Operate Be sure the circuit breaker and fuse are not tripped or blown Be sure both Emergency Stop switches are pulled out to the position Be sure the batteries are fully charged and properly connected Be sure the hydraulic tank is filled to the correct level With the key switch turned to platform control and both Emergency Stop buttons pulled out to the ON light is on position press and hold the function enable switch Visually inspect the power on LED light is not on After serial number bad 25141 Troubleshoot the CR48 power relay to U5 good Check voltage on the less than output side of the 275A 20V fuse F6 20V or more Check continuity from the B terminal on the motor controller U6 to the negative battery cable at QD1 continuity Check voltage at ov terminal D1 at the pump motor M6 20V or more Continued on the next page REVA Troubleshoot ground and platform control systems separately OR consult the Genie Industries Service Department Repair or replace the wire circuit from the platform controls to CR48 OR repair or replace the CR48 socket OR replace CR48 Replace F6 OR check for short circuits OR check battery cables OR check for open in negative battery cable from batteries to ground point on module tray Repair open in the ne
45. Sensor before serial number 47665 The tilt sensor sounds when the incline of the chassis exceeds the rating on the serial plate How to Install and Calibrate the 1 5 Level Sensor This procedure is for the following models GS 2032 ANSI and CSA models 777171777 Tip over hazard Failure to install A DANGER or calibrate the tilt 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 Perform this procedure with the machine on a firm level surface that is free of obstructions 1 Remove the platform controls from the platform 2 Turn the key switch to platform control and pull out the red Emergency Stop buttons to the position at both the ground and platform controls 3 Block the wheels at the non steer end of the machine REV C 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 6 Place a 1 27 x 6x6 inch 32 3 mm x 15 cm x 15 cm thick steel block under both wheels at the steer end of the machine N Lower the machine onto the blocks 8 Raise the platform 7 to 8 feet 2 1 to 2 4 m 9 Liftthe safety arm move it to the center of the Scissor arm and rotate down to a vertical position 10 Lower the scissor arms onto the safety arm AWARNING Crushing
46. THE PRESSURE SWITCH NUT INTO PRESSURE SWITCH OUT OF ADJUSTMENT THE HYDRAULIC LINE 1 4 TURN BATTERIES ARE NOT FULLY CHARGED CHARGE BATTERIES OVERLOAD SYSTEM NOT ADJUSTED PROPERLY REPEAT CALIBRATION PROCEDURE SLIDER CHANNEL NOT LUBRICATED PUT CORRECT RATED LOAD IN PLATFORM LUBRICATE SLIDER CHANNELS AT DOWN LIMIT THE PRESSURE SWITCH ALARM CONTINUES TO SOUND AFTER ADJUSTMENT TESTED SYSTEM NEEDS TO BE RESET DOWN LIMIT SWITCH OUT OF ADJUSTMENT RAISE THE DOWN LIMIT SWITCH WRONG RATED LOAD FOR HEIGHT BEING TURN OFF RED EMERGENCY STOP BUTTON WAIT THREE SECONDS AND TURN BACK ON PUT CORRECT RATED LOAD IN PLATFORM PROPERLY OVERLOAD SYSTEM NOT ADJUSTED TURN THE PRESSURE SWITCH NUT INTO THE HYDRAULIC LINE 1 4 TURN OR REPEAT CALIBRATION PROCEDURE Part No 72963 Genie GS 2032 and GS 2632 Section Ae Repair Procedures June 2004 Ground Controls 4 1 Manual Platform Lowering Cable The manual platform lowering cable lowers the platform in the event of a main power failure The manual platform lowering cable is attached to the barrel end of the lift cylinder and is activated next to the ground controls How to Adjust the Manual Platform Lowering Cable 1 Raise the platform 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 to a vertical position 3 Lower the platform onto the safety arm AWARNING C shing hazard Keep hands clear o
47. Tip over hazard The level sensor must be installed with the X on 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 install the tilt level sensor as instructed could result in the machine tipping over causing death or serious injury GROUND CONTROLS Steer end Non steer end limit switch level sensor mount bracket level sensor S7 alarm H5 level sensor retaining fastener scissor chassis rop Oo o 12 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 Part No 72963 Genie GS 2032 and GS 2632 Section Ae Repair Procedures June 2004 GROUND CONTROLS 13 Connect the chassis wire harness to the level sensor wire harness 14 Turn the key switch to the ground control and pull out the red Emergency Stop button to the on position at the ground controls 15 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 16 Raise the platform slightly 17 Return the safety arm to the stowed position
48. Valve after serial number 36100 Be sure that the hydraulic oil level is between the FULL and marks on the oil level indicator decal 1 Open the hydraulic power unit module tray and locate the system relief valve on the function manifold item BD or CD N Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the test port on the function manifold item BA or CA Models with traction control FM CB amp g e fe pr UE CD ae CE CD Sei 6 SS S CF System relief valve b function manifold C test port MANIFOLDS Models without traction control from serial number 36101 to 49425 6 S NA BL a system relief valve b function manifold C test port Models without traction control from serial number 49426 to 59999 BB 0 CD BF Q f SP Am Ne SS CB Part No 72963 Genie GS 2032 and GS 2632 Section Ae Repair Procedures June 2004 EE MANIFOLDS REV C 3 Chock both sides of the wheels at the steer end of the machine 4 Remove the platform controls from the platform Perform this test from the ground with the platform controls Do not stand in the platform 5 Turn the key switch to platform control and pull out the Emergency Stop button to the on position at both the ground and platform control
49. WH White U3 Platform controls circuit board YL Yellow Part No 72963 Genie GS 2032 and GS 2632 6 7 Section 6 Schematics June 2004 Ground Controls Wiring Diagram REV B AA Geer 8 H 11 A11 KEY SWITCH E SIF G6 TS66 1 ci B1 m CS E a eom Leo NCOL sir G7 4 2 Ur 4 Bi2 12 eh UTC 52F l 7 i i Z H from serial number 49012 to 59999 Laag KS1 PLATFORM N O O19 E A11 A11 KEY SWITCH 1 H TS66 06 48 P1 KSl CB2 GROUND v 25 N o N O 9 52F H IN E 53F O NC Ox 51F 4 HF H 45F B12 A12 Oa L N 76F l 2 E from serial number 40926 to 49011 49F 5 KS1 PLATFORM NO ECCL H Lat 11 KEY SWITCH 54 G6 K81 566 P1 3 GROUND 2 cl 25F NO NO mo de _29
50. a lifting strap from an overhead crane or similar lifting device to the barrel end of the lift cylinder for support 15 Remove the external snap ring 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 16 Support and secure the lift cylinder to an appropriate lifting device AWARNING Crushing hazard The lift cylinder may become unbalanced and fall if not properly supported and secured to the lifting device 17 Remove the lift cylinder through the scissor arms at the non steer end of the machine Component damage hazard Be CAUTION careful not to damage the valve or fittings on the cylinder while removing it from the machine Part No 72963 Genie GS 2032 and GS 2632 Section Ae Repair Procedures June 2006 SCISSOR COMPONENTS 3 4 Platform Overload System Calibrate the Platform Overload System if equipped On machines with platform overload systems proper calibration is essential to safe machine operation An improperly calibrated platform overload system could result in the system failing to sense an overloaded platform The stability of the machine is compromised and it could tip over Perform this procedure after fully charging the batteries Perform this procedure with toggle position 4 and 5 of DIP switch SW25 located in the platform control box set to
51. and secured to the lifting device 56 Attach a lifting strap from an overhead crane to the number 1 outer arm index 24 Do not lift it 57 Remove the external snap rings from the number 1 center pivot pin index 10 58 Use a soft metal drift to remove the number 1 center pivot pin index 10 Bodily injury hazard The number ACAUTION 1 outer arm index 424 may become unbalanced and fall if not properly supported when the pin is removed SCISSOR COMPONENTS 59 Slide the number 1 outer arm index 24 to the non steer end and remove it from the machine Bodily injury hazard The number ACAUTION 1 outer arm index 424 may become unbalanced and fall if not properly supported when it is removed from the machine Note the position of the wear pads before the arm is removed so when the scissor is assembled they will be in the correct position 60 Attach the strap from an overhead crane to the number 1 inner arm index 11 Do not lift it 61 Remove the pin retaining fasteners from both of the number 1 pivot pins index 12 at the steer end of the machine Use a slide hammer to remove the pins 62 Remove the number 1 inner arm index 11 from the machine Bodily injury hazard The number ACAUTION 1 inner arm index 11 may become unbalanced and fall if not properly supported when it is removed from the machine Component damage hazard Be sure not to damage the limit switch or level sensor box compo
52. 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 re inspect 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 company Section 3 Scheduled Maintenance Procedures June 2004 This page intentionally left blank 3 4 Genie GS 2032 and GS 2632 Part No 72963 June 2006 Section Scheduled Maintenance Procedures Maintenance Inspection Report Model Serial number Date Hour meter Machine owner Inspected by print Inspector signature Inspector title Inspector company Instructions Make copies of this report to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hours Inspection A Quarterly or 250 hours Inspection A B Semi annually or
53. inner arm index 12 16 Remove the external snap rings from the number 3 pivot pin index 4 17 Use a soft metal drift to remove the number 3 pivot pin index 4 Remove the number 3 inner arm index 12 from the machine Bodily injury hazard The number ACAUTION 3 inner arm index 12 may become unbalanced and fall if not properly supported when it is removed from the machine 18 Attach a lifting strap from an overhead crane to the number 2 outer arm index 16 19 Remove the external snap rings from the number 2 center pivot pin index 5 at the battery pack side of the machine 20 Use a soft metal drift to remove both of the number 2 center pivot pins index 5 21 Remove the external snap rings from the number 2 pivot pin index 17 at the non steer end REV 22 Use a soft metal drift to remove the number 2 pivot pin index 17 Remove the number 2 outer arm index 16 from the machine Bodily injury hazard The number ACAUTION 2 outer arm index 16 may become unbalanced and fall if not properly supported when it is removed from the machine 23 Attach a lifting strap from an overhead crane to the number 2 inner arm index 6 24 Remove the external snap rings from the number 2 pivot pin index 7 25 Use a soft metal drift to remove the number 2 pivot pin index 7 Remove the number 2 inner arm index 6 from the machine Bodily injury hazard The number ACAUTION 2 inner arm inde
54. 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 install the tilt level sensor as instructed could result in the machine tipping over causing death or serious injury 12 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 13 Connect the chassis wire harness to the level sensor wire harness 14 Turn the key switch to the ground control and pull out the red Emergency Stop button to the on position at the ground controls 15 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 REV Steer end MEM Non steer end limit switch level sensor mount bracket level sensor S7 alarm H5 level sensor retaining fastener scissor chassis 16 Raise the platform slightly 17 Return the safety arm to the stowed position 18 Lower the platform to the stowed position 19 Center a lifting jack under the drive chassis at the ground controls side of the machine Genie GS 2032 and GS 2632 Part No 72963 J
55. lifting jack under the drive chassis at the non steer end 5 Remove the cotter pin from the wheel castle nut Always replace the cotter pin with a new one when removing the castle nut 6 Loosen the wheel castle nut Do not remove it Non steer Axle Components 7 Raisethe machine approximately 2 inches 5 cm Place blocks under the chassis for support AWARNING Crushing hazard The chassis will fall if it is not properly supported 8 Remove the wheel castle nut Remove the wheel 9 Disconnect and plug the hydraulic hose from the brake Cap the fittings on the brake 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 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 itis not properly supported when the mounting fasteners are removed Torque specifications Brake mounting fasteners dry 75 ft lbs 101 7 Nm Brake mounting fasteners lubricated 56 ft lbs 76 3 Nm Part No 72963 Genie GS 2032 and GS 2632 Section Ae Repair Procedures June 2004 Brake Release Hand Pump Components REV B 10 1 Brake Release Hand Pump Components The brake release hand pump manifold is mounted behind the entry ladd
56. of How to Remove the gt T when removing the Steer Cylinder ib QU 5 Remove the steering cylinder from the machine When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Block the non steer wheels 2 Tag disconnect and plug the hydraulic hoses from the steering cylinder Cap the fittings on the cylinder 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 CAUTION Component damage hazard Hoses can be damaged if they are kinked or pinched 3 Remove the pin retaining fasteners from the barrel end pivot pin Remove the pivot pin Note the quantity and location of the spacers when removing the barrel end pivot pin Part No 72963 Genie GS 2032 and GS 2632 4 75 Section Ae Repair Procedures June 2004 EE STEER AXLE COMPONENTS REVA 8 3 5 Remove the bellcrank from the machine Steer Bellcrank Note the quantity and the location of the spacers in between the How to Remove the bellcrank and the steer links Steer Bellcrank Perform this procedure with the machine on a flat level surface 1 Remove the steering cylinder See 8 2 How to Remove the Steering Cylinder 2 Fro
57. off to the side 2 Tag disconnect and plug the hydraulic hoses on the pump Cap the fittings on the pump AWARNING dd 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 3 Remove the pump mounting bolts Carefully remove the pump Part No 72963 Genie GS 2032 and GS 2632 4 51 Section Ae Repair Procedures June 2004 Manifolds REV C 6 1 Function Manifold Components from serial number 17408 to 17481 The function manifold is mounted inside the hydraulic power unit module tray Index Schematic No Description Item Function Torque Check valve 30 psi 2 bar Steer 20 ft lbs 27 Nm 2 Diagnostic nipple AB su E 10 ft lbs 14 Nm 3 Flow regulator 0 75 2 8 L min Steer 35 ft lbs 47 4 Orifice washer 0 040 in 1 mm PADD Steer circuit 5 Relief valve 1500 psi 103 4 bar AE unes Steering relief 20 ft Ibs 27 Nm 6 Relief valve 3500 psi 241 3 bar System relief 20 ft Ibs 27 Nm 7 Solenoid valve 3 position 4 way
58. 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 REV B A 2 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 Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section Scheduled Maintenance Procedures REV B A 3 Perform 30 Day Service The 30 day maintenance procedure is a onetime procedure to be performed after the first 30 days or 40 hours of usage After this interval refer to the maintenance tables for continued scheduled maintenance 1 Perform the following m
59. properly connected REVA With the key switch turned to platform control and both DV Emergency Stop buttons pulled out to the ON Repair open in WH wire from KS1 to Emergency Stop button P1 OR repair open in the WH wire from P1 to circuit position check voltage breaker CB2 on the input side of the platform control contact on key switch KS1 20V or more Check if internal cam at KS1 is activating platform control contact Check voltage on output side of platform control es Replace contact for platform controls at KS1 contact at KS1 no 20V or more Replace KS1 Check voltage on terminal A11 at the Repair open in WH A11 keyswitch wire from KS1 U5 to terminal A11 at U5 20V or more Check voltage on OV terminal B2 at U5 Replace U5 20V or more Check voltage at the output side of the DV Emergency Stop button P2 Repair or replace P2 OR replace control cable from U5 to the platform controls 20V or more Check voltage on oV terminal A4 at U5 Replace control cable from U5 to the platform controls 20V or more Replace control cable from U5 to the platform controls OR replace the platform controls OR consult the Genie Industries Service Department Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section 5 Troubleshooting Flow Charts REVA Platform Up Function Inoperative Be sure all other functi
60. section Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section 5 Troubleshooting Flow Charts REVA Machine Drives At Full Speed With Platform Raised Be sure the circuit breaker and fuse are not tripped or blown Be sure the batteries are fully charged and properly connected With the key switch turned to platform controls and both Emergency Stop buttons pulled out to the ON position and the platform In the stowed position drive the machine in either direction Is the error indicator light on at the platform controls See Chart 13 OR remove the obstruction from the pothole guard OR consult the Genie Industries Service Department Check limit switch LS7 and 158 for correct adjustment Adjust LS7 or LS8 See Repair Section OR repair or replace limit switch wire circuit Chart 14 Check the controller adjustments See Repair Section OR replace the platform controls OR replace the ECM U5 OR consult the Genie Industries Service Department Part No 72963 Genie GS 2032 and GS 2632 Section 5 Troubleshooting Flow Charts June 2004 Chart 15 REVA Limit Switch With the key switch ZOV Or Adjust the pothole limit Function turned to platform m OR ee B controls and both pothole limit switc 1 Emergency Stop buttons Inoperative pulled out to the position and the platform the stowed position check voltage on the Be sure the circuit WH B10 pot
61. the ground controls side may become unbalanced and fall if not properly supported when it is removed from the machine 19 Attach a lifting strap from an overhead crane to the number 3 outer arm index 4 at the battery pack side REV B 20 Use a soft metal drift to tap the number 3 pivot pin index 19 in the other direction Remove the number 3 outer arm index 4 from the battery pack side of the machine Bodily injury hazard The number ACAUTION 3 outer arm index 4 at the battery pack side may become unbalanced and fall if not properly supported when it is removed from the machine 21 Remove the number 3 pivot pin index 19 from the non steer end of the machine 22 Attach a lifting strap from an overhead crane to the lug on the rod end of the lift cylinder for support Do not lift it 23 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 it is not properly supported 24 Lower the cylinder onto the number 1 center pivot pin index 10 25 Remove the cables from the number 3 inner arm index 17 and lay them to the side 26 Attach a lifting strap from an overhead crane to the number 3 inner arm index 17 27 Remove the external snap rings from the number 3 pivot pin index 6 at the steer end Genie GS 2032 and GS 2632
62. turned to platform controls and both Emergency Stop buttons pulled out to the on position and the platform raised slightly From serial number 17408 to 21262 press and hold the lift function light is enable button and on activate the controller in the DOWN direction and check to see if the error indicator light is on After serial number 21262 press the lift function select button and activate the controller in the DOWN direction and check to see if the error indicator light is on light is not on Replace the platform controls OR replace the ECM 05 OR consult the Genie Industries Service Department With the platform raised and the safety arm installed connect the leads of a volt meter to the wires on the platform lowering coil item D on the cylinder without removing the wires From serial number 17406 to 21262 Press and hold the lift function enable button and activate the controller in the DOWN direction and check the voltage After serial number 21262 Press the lift function select button and activate the controller in the DOWN direction and check the voltage 20V or more 0 or infinite ohms Label and disconnect the wires from the coil on the platform lowering valve item D at the platform lift cylinder and check the resistance See Repair Section 23 to 25 ohms With the platform raised platform and the safety arm lowers removed pull the manual platform lowe
63. vii June 2006 TABLE OF CONTENTS Section 4 Rev Repair Procedures continued C Function Manifold 631 Function Manifold Components from serial number 17408 to 17481 4 52 6 2 Function Manifold Components from serial number 17482 to 36100 4 54 6 3 Function Manifold Components from serial number 36101 to 49245 4 56 6 4 Function Manifold Components from serial number 49246 to 59999 4 58 6 5 Function Manifold Components Models with Traction Control 4 60 6 6 Valve Adjustments Function Manifold 4 62 67 E 4 70 Hydraulic Tank Fl Hydraulic Tank eb Crest 6 4 72 Steer Axle Components 8 1 Drive MOON erret ertet oet ee agde 4 73 82 0020 1 1 0000 4 75 8 3 Steer Bellcrank tere ues 4 76 Non steer Axle Components 91 Dive 4 77 Brake Release Hand Pump Components 10 1 Brake Release Hand Pump Components 4 78 Viii Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section 5 Rev FaultCodes INTOGUCTION 5 1 A Fault Code Chart after serial number 17407 5 3 Char
64. 15 Section 3 Scheduled Maintenance Procedures September 2006 CHECKLIST B PROCEDURES B 9 Test the Drive Speed Raised Position Proper drive functions are essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range 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 Emergency Stop button to the on position at both the ground and platform controls 3 Models with lift function enable button Press and hold the lift function enable button Models with drive function select button Press the lift function select button Genie ch Genie 2229294 lift function enable button BN9 lift function select button BN9 drive function select button BN8 REV D Press and hold the function enable switch on the joystick Raise the platform approximately 4 feet 1 2 m from the ground Models with lift function enable button Release the lift function enable button Models with drive function select button Press the drive function select button Choose point on the machine i e contact patch of a t
65. 18 Lower the platform to the stowed position 19 Center lifting jack under the drive chassis at the ground controls side of the machine 20 Raise the machine approximately 2 inches 5 cm 21 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 ground controls side of the machine 22 Lower the machine onto the blocks 23 Raise the platform 7 to 8 feet 2 1 to 2 4 m Result The level sensor alarm should not sound W Result The level sensor alarm does sound Adjust the level sensor retaining fasteners just until the level sensor alarm does not sound 24 Lower the platform to the stowed position 25 Raise the machine approximately 2 inches 5 cm REV C 26 Remove the blocks from under both wheels 27 Lower the machine and remove the jack 28 Center a lifting jack under the drive chassis at the battery pack side of the machine 29 Raise the machine approximately 2 inches 5 cm 30 Place a 0 8x 6x 6 inch 20 3 mm x 15 cm x 15 cm thick steel block under both wheels at the battery pack side of the machine 31 Lower the machine onto the blocks 32 Raise the platform 7 to 8 feet 2 1 to 2 4 m O Result The platform should stop and an alarm should sound 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 33 Lift the safety ar
66. 2 D 1 3 S 3 2 5 3 5 231 8 9 o 8 1 1 U6 M e 8 2 50A FUSE MOTOR 3 1 gt lt P 7 d CONTROLLER f FB m T 1013 G6 FB H2 Y1 Y2 Y4 Y5 Y6 Y7 Y8 HOUR FLASHING AUTOMOTIVE STYLE PARALLEL BRAKE STEER STEER DRIVE DRIVE PLATFORM PLATFORM d DC AC INVERTER METER BEACONS HORN RELEASE RIGHT LEFT REVERSE FORWARD DOWN UP 4 OPTION i 1 e L LHP NAE A L_ L_ Le L_ GND 8 6 17 Genie GS 2032 and GS 2632 Part No 72963 REV B June 2004 D C ee EMERGENCY STOP L J POWER TO PLATFORM CONTROLS RD POWER TO GROUND CONTROLS WH GROUND NER D BL DATA LINK HIGH E E DATA LINK LOW QD3 ee pov v 25 5 ABBREVIATION LEGEND ABBREVIATION LEGEND Item Description Item Description B Battery N C Normally closed B5 Main power N C H O Normally closed held open B7 Auxiliary down GS 3246 only N O Normally open BN Button P Power switch BN5 Horn P1 Emergency Stop button at ground controls BN6 High torque P2 Emergency Stop button at platform controls BNO Lift enable PS2 Platform overload pressure switch option BN23 Auxiliary down GS 3246 on
67. 21 7 2 Gi NOISE R21 18 D e x x E S 9 FI S7 SUPPRESSION 9012 9 z A 2 8 LEVEL CE MODELS ONLY 75 OHM x 2 g a 5 9 SENSOR AFTER SERIAL m 3 2 a 9 ed NUMBER 47940 ze 9 g E E L n eg B8 A8 A9 A12 B12 11 12 B9 A10 10 4 Bii C2 A2 Bi C11 A5 5 OUT OUT OUT IN N IN IN OUT IN IN IN IN IN IN IN IN IN OUT F6 275A FUSE U5 ELECTRONIC CONTROL MODULE OUT U9 OUT OUT OUT OUT OUT OUT OUT OUT OUT B3 C8 C9 B7 A7 C6 AG B6 1 BATTERY Kee E E 6 CHARGER 71 T T Jl 7 HARD WIRED AFTER SERIAL g 9 9 9 gt 9 NUMBER 46645 E E m E 2 amp S 5 8 S 8 8 8 9 8 8 8 FB F E x Leg 7 fe 50A FUSE U6 motor p CONTROLLER Y1A HIGH SPEED U1 G6 FB H2 Y1 BYPASS Y2 YS YA Y5 Y6 Y8 Y7 l U13 HOUR FLASHING AUTOMOTIVE STYLE PARALLEL OPTION BRAKE STEER STEER DRIVE DRIVE PLATFORM PLATFORM DC AC INVERTER METER BEACONS HORN RELEASE RIGHT LEFT REVERSE FORWARD UP DOWN 1 X EPX Woch 8 e L_ LA Le GND GND d 6 19 Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section Ge Schematics E
68. 3 mm Checklist D Procedure 2 Measure the thickness of the wear pad at the battery pack side of the non steer end of the machine O Result The measurement is 0 21 inch 5 3 mm or more Proceed to step 2 Ww Result The measurement is less than 0 21 inch 5 3 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 Wear pad specification Thickness minimum 0 21 inch 5 3 mm Part No 72963 Genie GS 2032 and GS 2632 Section Scheduled Maintenance Procedures June 2004 Checklist E Procedure E 1 Test or Replace the Hydraulic Oil Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil and a clogged suction strainer may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more often 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 Perform this procedure with the platform in the stowed position 1 Disconnect the battery pack from th
69. 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 completed Use the step by step procedures in this section to learn how to perform these inspections If any inspection receives tag and remove the machine from service repair and re inspect it After repair place a check in the box Legend Y yes acceptable no remove from service repaired Checklist A Rev B Y NR Checklist B RevD Y NR 1 Pre operation B 1 Batteries inspection B 2 Electrical wiring A 2 Function tests Perform after 40 hours A 3 30 day service 100 IT A 4 Grease steer yokes B 3 Tires and wheels B 4 Emergency stop B 5 Key switch B 6 Horn if equipped B 7 Drive brakes B 8 Drive speed stowed B 9 Drive speed raised B 10 Hydraulic oil analysis B 11 Hydraulic filter B 12 Latch components ChecklistC RevC NR C Rev C Y NR C 1 Platform overload if equipped Checklist D Rev D Y NR D 1 Scissor arm wear pads Checklist E Rev Y NR E 1 Hydraulic oil Comments Part No 72963 Genie GS 2032 and GS 2632 Section 3 Scheduled Maintenance Procedures June 2004 Checklist A Procedures A 1 Perform Pre
70. 8 C Checklist C Procedure C 1 Testthe Platform Overload System if equipped 3 19 D Checklist D Procedures D 1 Check the Scissor Arm Wear Pads 3 21 A Checklist E Procedure E 1 Testor Replace the Hydraulic 440 04 3 22 vi Genie GS 2032 and GS 2632 Part No 72963 June 2006 nm rg TABLE OF CONTENTS Section 4 Rev RepairProcedures INTOGUCTION 4 1 B Platform Controls 14 Circuit Board Sessi 4 2 1 2 Joystick Controller AAA 4 3 13 Controller Adjustments 2 244 4 5 1 4 Software Configuration ie inne diede Exe aide 4 13 B Platform Components Me Et un utei tuu 4 16 2 2 Platform Extension ceinture een Se 4 17 D Scissor Components 3 1 Scissor Assembly 25 2032 4 18 3 2 Scissor Assembly 495 2632 4 24 c ME deg 4 32 34 Platform Overload System A 4 34 C Ground Controls 4 1 Manual Platform Lowering Cable esee 4 36 42 Relays irn ecce ro e Pede d dr ee 4 37 4 3 Level Sensor before serial number 47665 4 38 4 4 Level Sensor after serial number 47664 4 44 A Hydraulic Pump 51 Function PUMP EE 4 50 Part No 72963 Genie GS 2032 and GS 2632
71. Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Tagand disconnect the wire harness from the coil to be tested 2 Testthe coil resistance Result The resistance should be within specification plus or minus 30 Result If the resistance is not within specification plus or minus 30 replace the Coil REV C Valve Coil Resistance Specifications Description Specification Solenoid valve 3 position 4 way 25 to 270 20V DC with diode schematic items AG BH and CH Solenoid valve 2 position 4 way 18 to 200 20V DC with diode schematic items AJ BI BL CJ and CN Solenoid valve 2 position 2 way N O 25 to 279 20V DC with diode schematic items BK CI and CL Solenoid valve 3 position 4 way 18 to 200 20V DC with diode schematic items AK BJ and CK Solenoid valve N C 23 to 250 2 position 2 way 20V DC with diode schematic item D after serial number 28936 Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section 4 Repair Procedures REV How to Test a Coil Diode Genie incorporates spike suppressing diodes in all of its coils Properly functioning coil diodes protect 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
72. Dash size Torque 4 16 ft lbs 21 7 Nm 6 35 ft lbs 47 5 Nm 8 60 ft Ibs 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 2 4 Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section 2 Specifications REVA SPECIFICATIONS Torq ue Procedure 3 Working clockwise on the body hex fitting make _ second mark with permanent ink marker to JIC 37 fittings indicate the proper tightening position Refer to Fi 2 1 Align the tube flare hex nut against the nose of can D the fitting body body hex fitting and tighten the Use the 37 Fittings table on hex nut to the body hex fitting to hand tight the previous page to determine the approximately 30 in Ibs 3 4 Nm correct number of flats for the tighteni ition 2 Make a reference mark on one of the flats of the pone ene eae hex nut and continue it on to the body hex The marks indicate that the correct fitting with a permanent ink marker Refer to tightening positions have been Figure 1 determined Use the second mark on the body hex fitting to properly tighten the joint after it has been loosened N di J N Figure 1 a hydraulic hose b hexnut reference mark d body hex fitting Figure 2 a body hex fitting b reference mark second mark 4 Tighten the hex nut until the mark on the hex nut is aligne
73. ER TO GROUND CONTROLS WH GROUND ve D D BL DATA LINK HIGH E E DATA LINK LOW n 1 YL ABBREVIATION LEGEND ABBREVIATION LEGEND SW25 DIP SWITCHES 24V Cat La e gt 6 eo as DC 5v DC VOLTA REGULAT U3 Drui GE OR POUT1 POUT2 POUT3 POUT4 POUTS POUT6 POUT7 POUT8 POUT9 POUT10 PLATFORM CONTROLS PRINTED CIRCUIT BOARD Item Description Item Description B Battery N C Normally closed B5 Main power N C H O Normally closed held open B7 Auxiliary down GS 3246 only N O Normally open BN Button Power switch BN5 Horn P1 Emergency Stop button at ground controls BN6 High torque P2 Emergency Stop button at platform controls BNO Lift enable PS2 Platform overload pressure switch option BN23 Auxiliary down GS 3246 only QD Quick disconnect CB2 Circuit breaker 7A QD1 Battery quick disconnect CR Control relay QD3 Control cable to ground Horn with H2 option QD4 Control cable to platform CR48 Power to U5 R Resistor D7 Voltage regulator R15 5000 ohm potentiometer F Fuse R21 75 ohm resistor F6 275A S7 Tilt level sensor F8 50A with U13 option SW Switch FB Flashing beacons o
74. Genie Service Manual Refer to inside cover for serial number information Part No 72963 September 2006 Rev C2 GS 2032 GS 2632 June 2004 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 atan authorized Genie dealer service center Technical Publications Genie Industries has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in suggestions for improvement All communications will be carefully considered for future printings of this and all other manuals Contact Us www genieindustries com e mail techsup genieind com Serial Number Information Genie Industries offers the following Service Manuals for these models Title Part No Genie GS 2032 Service Manual First Edition before serial number 17408 46326 Cop
75. H PRESSURE SWITCH 1966 SWITCH OPTION SWITCH N C HO POTHOLE GUARD SWITCH 1 2 g E nj I D c e S cmg oO dcc 2 S 9 5 S S amp 2 E 2 9 Hr FEES 2 o 2 3 9 E 2 o 3 5 2 11 o 2 J 5 9 o 5 a3 2 6 34 222 Z f 5 5 D R i g f 3 2 2 5 MER U27 2 3 3 g c gt 9 g 47 mH p S 3 1 3 E 87 INDUCTOR gt 3 x i LEVEL NOISE a 5 SENSOR SUPPRESSION L 2 E E D Wi 85 2 CR5 4 HORN RELAY _ _ m H2 OPTION B8 8 A9 A12 B12 C12 B9 A10 B10 Bt C2 A4 A2 Bi C11 5 OUT OUT OUT N IN IN IN OUT IN IN IN IN IN IN IN IN OUT 05 A1 OUT ELECTRONIC CONTROL MODULE OUT OUT OUT OUT OUT OUT OUT OUT OUT B3 C8 C9 C7 B7 A7 C6 B6 AG LL e zm u Se zs SSS f 3 T 30 A 0 o o D gt D 2 i n gt B E 3 m z 2 104 E A lt 2 5 H 8 E o 2 o 06 Pi 1 ems 9 9 2 9 CONTROLLER V G6 2 H2 Y1 Y2 Y3 Y4 Y5 Y6 Y8 HOUR FLASHING AUTOMOTIVE STYLE PARALLEL BRAKE STEER STEER DRIVE DRIVE PLATFORM PLATFORM METER BEACONS HORN RELEASE RIGHT LEFT REVERSE FORWARD DOWN UP OPTION OPTION OPTION i 4 Le _ LA _ GND
76. JC1 Joystick controller U13 Voltage inverter option KS1 Key switch U27 0 034 ohm inductor noise suppression L LED or light Y Valve coil L16 Lift Y1 Parallel L17 Drive Y1A High speed bypass option L19 Power Y2 Brake release WIRE COLOR LEG END 8 121 High Torque Y3 Steer right Color Description Color Description L25 Fault Y4 Steer left Di BL Blue RD Red LS Limit switch dei BK Black WH White LS2 Platform up GS 3246 only Y6 Drive forward BN B YL Yell LS6 Platform down Y7 Platform down rown mE LS7 Pothole Y8 Platform up GN Green WH BL White Blue LS8 Pothole Y9 Platform down GS 3246 only GY Gray WH BK White Black M5 Hydraulic power unit Y10 Auxiliary down GS 3246 only OR Orange WH RD White Red Y11 Auxiliary down GS 3246 only PP Purple WH YL White Yellow Part No 72963 Genie GS 2032 and GS 2632 6 22 June 2004 Section 6 Schematics E Electrical Schematic from serial number 48104 to 49299 Section 6 Schematics June 2004
77. JOYSTICK 5 5 OR DATA LINK LOW EUCH TOR CONTROLLER VOLTAGE QD3 REGULATOR SW6 STEER LEFT RIGHT 1 coles 2 2 H SW5 5 FUNCTION 6 7 8 3 POUT1 Ze POWER LED 119 POUT2 FAULT LED L25 POUTS E HIGH TORQUE LED L21 POUT4 BATTERY LEVEL 1 4 POUTS a BATTERY LEVEL 2 POUT6 BATTERY LEVEL 3 G7 POUT7 2 44 BATTERY LEVEL4 POUT8 BATTERY LEVEL 5 POUT9 O DRIVE LED 117 ABBREVIATION LEGEND ABBREVIATION LEGEND od LIFT LED L16 Item Description Item Description V B Battery N C Normally closed BLATEOBM CONTROLS PLATFORM CONTROLS B5 Main power N C H O Normally closed held open PRINTED CIRCUIT BOARD MEMBRANE DECAL PANEL 5 B7 Auxiliary down GS 3246 only N O Normally open BN Button Power switch PIN1 HIGH TORQUE BN6 BN5 Horn P1 Emergency Stop button at ground controls BN6 High torque P2 Emergency Stop button at platform controls RING HORN BNS BNO Lift enable 52 Platform overload pressure switch option DRIVE ENABLE BN8 BN23 Auxiliary down GS 3246 only QD Quick disconnect CB2 Circuit breaker 7A QD1 Battery quick disconnect 4 LIFT ENABLE CR Control relay QD3 Control cable to ground Horn with H2 option QD4 Control cable to platform CR48 Power to U5 R Resistor PING 6 D7 Voltage regulator R15 5000 ohm potentiometer O F Fuse R21 75 ohm resistor F6 275A S7 Tilt level sensor PINIO F8 50A with U13 option SW Switch FB Flashing beacons
78. LEFT direction and check the voltage 20V or more Disconnect the wires from the coil on the 25 to 27 steer right directional ohms valve on the function manifold item AF or BI and check the resistance of the valve coil See Repair Section 0 or infinite ohms Replace the steer right directional valve coil item AF or BI Check continuity of the steer left right microswitch SW6 inside the joystick controller handle JC1 good Repair or replace the wire circuit from SW6 to the platform controls circuit board U3 OR replace U3 OR consult the Genie Industries Service Department REVA Repair open in the WH C7 rt coil wire from the coil on the steer right directional valve item AF or Bl to the ECM U5 OR repair open in the brown ground wire circuit from the coil to the wire harness OR replace U5 OR consult the Genie Industries Service Department Repair or replace the steer directional valve cartridge item AF or Bl OR consult the Genie Industries Service Department bad Replace SW6 Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section 5 Troubleshooting Flow Charts REVA CHART 9 Install a 0 to 2000 psi Are there mechanical 138 bar pressure restrictions keeping the gauge at the quick steer left function from disconnect coupling on moving the function manifold and activate the steer right function Remove the mechanical restrictions Contin
79. Legend REV B NO 06 D 5 5 Pressure switch normally open 3 Motor controller 5 N C l N C H O i GROUND o 5 Key switch Wire with been Motor dese description y Abs 09 als 7 E Circuits crossing CN no connection Level sensor Switch Battery charger ll Diode X 6V battery Toggle switch Solenoid valve Horn or alarm Connection LA no terminal e e Emergency Stop button E X d Normally closed T inductor Solenoid valve CB2 noise suppression Connector N GS pp with diode Circuit breaker JC Joystick conTROLLER y 3 1 x cu D D D DC CE 1 Pi 5K 1 L 30 86 1 POTENTIOMETER 5 WH YL d e WI 87A e 85 one LEFT RIGHT our meter Pio RENE ES G6 Relay awe 8 B Lo FUNCTION eege mal II FB WHIBK N I uj Flashing beacons F se Joystick controller FB1 6 10 Genie GS 2032 and GS 2632 Part No 72963 Section 6 Schematics June 2004 M Electrical Schematic REV B from serial number 17408 to 21064
80. MIT FUNCTION OVERLOAD GUARD 21B 4 SWITCH ALARM PRESSURE SWITCH TS66 SWITCH 3 UP DOWN OPTION 4 N C H O SWITCH 158 i i E D GUARD 3i je SWITCH CR5 uiz E gt og 9 g 9 o si SENSOR E HORN RELAY 512 5 9 b 8 2 5 4233 Grou 027 Te 85 H2 OPTION 3 8 S gt 9 2 E 8 S E Sazze EI BOARD 4 0 034 OHM olg 2 9 2 2 3 9 i zo 12522 s gig 9 P239 g S Si gett eg 57 NOISE o 3 EI n T SUPPRESSION R21 9 4 2 2 3 2 g 8 5 8 om LEVEL CE MODELS ONLY 75 OHM 5 2 e 9 S E 9 gt 9 SENSOR 2 2 5 5 E 3 BN 3 1 L 4 NEES EE 5 A8 9 A12 B12 11 C12 B9 A10 B10 B11 C2 A4 A2 Bi Ci Cii A5 5 ke OUT OUT OUT IN N N IN IN IN IN IN OUT 6 275A FUSE U5 ELECTRONIC CONTROL MODULE OUT U9 1 OUT OUT OUT OUT OUT C9 C7 B7 A7 C6 A6 B6 1 BATTERY L CHARGER 71 6 A T T e D gt m 2 x T 1 gt 3 3 E m m i z E 2 g 2 o 5 AC INPUT g 9 8 9 8 8 8 FB F K E E Im IY v Dr T 7 cp 50A FUSE 06 d CONTROLLER FB 1 E l SEN 1 HIGH SPEED jd 109 G6 FB H2 Y1 BYPASS Y2 Y4 Y5 Y6 Y8 Y7 1 U13 H
81. ON LEGEND ABBREVIATION LEGEND Sas Ce Description Item Description B Battery N C Normally closed U3 PLATFORM CONTROLS B5 Main power N C H O Normally closed held open BITTER E BORED MEMBRANE DECAL PANEL 5 B7 Auxiliary down GS 3246 only N O Normally open BN Button Power switch PIN1 HIGH TORQUE BN6 BN5 Horn P1 Emergency Stop button at ground controls BN6 High torque P2 Emergency Stop button at platform controls ENS HORNBNS BN9 Lift enable PS2 Platform overload pressure switch option PIN3 DRIVE ENABLE BN8 BN23 Auxiliary down GS 3246 only QD Quick disconnect 2 Circuit breaker 7A Battery quick disconnect CR Control relay QD3 Control cable to ground 5 Horn with H2 option QD4 Control cable to platform CR48 Power to U5 R Resistor PIN9 6 D7 Voltage regulator R15 5000 ohm potentiometer F Fuse R21 75 ohm resistor FS F6 275A S7 Tilt level sensor PINIO O F8 50A with U13 option SW Switch FB Flashing beacons option 5 5 Function enable POUT11 G Gauge SW6 Steer left right G6 Hour meter SW25 DIP switch G7 Battery charge indicator TS66 Platform up down toggle switch 11 LAT FO H M GND Ground U Electronic component 7 H Horn or alarm 03 Encoder printed circuit board N T H L L E H H1 Horn 05 Electronic control module H2 Automotive style horn option U6 Motor controller H5 Multifunction alarm U9 Battery charger
82. OUR FLASHING AUTOMOTIVE STYLE PARALLEL OPTION BRAKE STEER STEER DRIVE DRIVE PLATFORM PLATFORM DC AC INVERTER METER BEACONS HORN RELEASE RIGHT LEFT REVERSE FORWARD UP DOWN OPTION OPTION 1 L Wee WA Woh 8 Le L_ gt _ Le Li GND GND e gt 6 21 Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section Ge Schematics E REV A Electrical Schematic from serial number 48104 to 49299 M L J G F E D C B A ec coc BK POWER TO PLATFORM CONTROLS T s X STOP 72 RD POWER TO GROUND CONTROLS 1 V Ce B B WH GROUND D D BL DATA LINK HALL JOYSTICK E E OR DATA LINK REDE CONTROLLER VOLTAGE QD3 REGULATOR ee SW6 STEER LEFT RIGHT 1 2 2 4 5 SW5 5 FUNCTION 6 7 SW25 DIP SWITCHES 3 POUT1 POWER LED L19 POUT2 FAULT LED L25 POUT3 HIGH TORQUE LED L21 POUT4 BATTERY LEVEL 1 POUTS BATTERY LEVEL 2 4 POUT6 BATTERY LEVEL3 gt 37 POUT7 O BATTERY LEVEL 4 POUT8 BATTERY LEVEL 5 POUT9 DRIVE LED L17 ABBREVIATI
83. R COMPONENTS 18 Remove the old wear pad Note the position of the wear pad before it is removed so when the new one is installed it will be in the correct position 19 Install the new wear pad 20 Move the scissor assembly towards the other side of the machine until the other scissor arm wear pad is accessible ADANGER Crushing hazard The scissor assembly will fall if both wear pads are allowed to slide out of the drive chassis 21 Remove the old wear pad Note the position of the wear pad before it is removed so when the new one is installed it will be in the correct position 22 Install the new wear pad 23 Slide the scissor assembly back into the drive chassis 24 Lower the scissor assembly into position and install the pivot pins Component damage hazard Be CAUTION careful not to damage the level sensor box limit switch or level sensor while installing the scissor assembly Part No 72963 Genie GS 2032 and GS 2632 4 31 Section Ae Repair Procedures June 2004 SCISSOR COMPONENTS 3 3 Lift Cylinder How to Remove the Lift Cylinder AWARNING P dily 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 O ring on the fi
84. RQUE LED 121 PU BATTERY LEVEL 1 BATTERY LEVEL2 BATTERY LEVEL 3 gt G7 lt 4 BATTERY LEVEL 4 BJ BATTERY LEVELS 4 DRIVE LED L17 LIFT LED L16 PLATFORM CONTROLS MEMBRANE DECAL PANEL HIGH TORQUE BN6 HORN BN5 5 DRIVE ENABLE BN8 LIFT ENABLE BN9 6 PLATFORM CONTROLLER 7 8 Part No 72963 Genie GS 2032 and GS 2632 6 14 June 2004 Section 6 Schematics E Electrical Schematic from serial number 21065 to 25141 Section 6 Schematics June 2004 Electrical Schematic from serial number 25142 to 28936 A B AC INPUT F8 50A FUSE U13 DC AC INVERTER OPTION 76F 78F ZA 3 WH KS1 CR48 30 86 Y i gt KEY SWITCH SE BL B B 4 i C 3 dr RELAY wo BK D D n ECC OS e TO 05 OR E C E 28D 7A EMERGENCY tee CIRCUIT STOP PLATFORM BHEAKER V CONTROL 9 1 I OT NC NO N C H O OF L 1 e 1 156 ue PS2 157 GROUND DOWN ALARM PLATFORM POTHOLE CONTROL LIMIT OVERLOAD GUARD 218 S ee Soi Del SWITC
85. Repair Procedures REV 4 2 Control Relays Relays used for single function switching are single pole double throw SPDT relays How to Test a Single Pole Double Throw Relay AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Label and then disconnect all the wiring from the relay to be tested 2 Connectthe leads from an ohmmeter or continuity tester to each terminal combination and check for continuity Terminals 85 and 86 represent the coil and should not be tested in any other combination Test Desired result terminal 85 to 86 with resistor 280 to 3300 terminal 87 to 87a and 30 no continuity infinite terminal 87a to 30 continuity zero Q GROUND CONTROLS 3 Connect 24V DC and a ground wire to terminals 85 and 86 then test the following terminal combinations Test Desired result terminal 87a to 87 and 30 no continuity infinite terminal 87 to 30 continuity zero 85 87 87 Relay schematic deactivated O 85 87 86 30 Relay schematic activated Terminal Number Legend terminal no 87a N C terminal no 85 ground terminal no 30 common terminal no 86 coil terminal no 87 N O Part No 72963 Genie GS 2032 and GS 2632 Section Ae Repair Procedures June 2004 GROUND CONTROLS 4 3 Level
86. S 2032 and GS 2632 6 26 June 2004 Section 6 Schematics Vie eoe LLL Hydraulic Schematic from serial number 17408 to 36100 June 2004 Section Ge Schematics E REV B Hydraulic Schematic from serial number 36101 to 52788 M L K J H G F E D C B A RIGHT 1 m LIFT BRAKE LEFT RIGHT YLINDER PLATFORM STEER UT DRIVE MOTOR DRIVE MOTOR OVERLOAD LEFT RIGHT 7 ll ve el ETGEN s AO e NO Y7 71 F 4 HAND 2 PUMP EM M Q AL 1 03 CU IN C B 169cc d ES S 046 i f MANUAL Q _ RELEASE 1 MANIFOLD we RS LI el mn Jess 3 l e se LIFT 81 52 HP M1 M3 M2 M4 gt SEENEN ibe 71 v4 E em SEE NOTE gs BH 4 5 lt M i gt BI AW s psi ES 0 3 bar 1 y1 E e x 1 BE S 7 i Qoae 2
87. Section Ge Schematics June 2004 mM LLL XJ Hydraulic Symbols Legend and Component Reference Section 6 Schematics June 2004 Hydraulic Symbols Legend and Component Reference gt Q K Check valve AL was replaced by relief valve AL at serial number 17482 M NA AG B o A O AH Ke E e Al Function manifold components from serial number 17408 to 36100 gy BB Function manifold components from serial number 49246 to 59999 BL Function manifold components from serial number 36101 to 49245 gy 6 Si ge 7 oa E D d Ba 4 Q A Function manifold components Models with Traction Control 6 25 Genie GS 2032 and GS 2632 Part No 72963 Spec S0 _CE m Lift cylinder components before serial number 23568 Lift cylinder components after serial number 23567 Filter O Fixed displacement pump Bi directional motor NM Variable speed motor Check valve d P dm 0 040 in 1 mm Orifice with size 5 s Relief valve Priority flow regulator ON ed Platform overload pressure switch 1 03 CU 16 9 cc Accumulator Dual acting cylinder EH Solenoid operated 2 position 2 way val
88. Steer circuit 6 Relief valve 1500 psi 103 4 bar BEES Steering relief 20 ft Ibs 27 Nm 7 Relief valve 130 psi 9 bar Brake relief 20 ft lbs 27 Nm 8 Solenoid valve 3 position 4 way Steer left right 20 ft lbs 27 Nm 9 Solenoid valve 2 position 4 way Bl Drive speed select circuit 25 ft lbs 34 Nm 10 Solenoid valve 3 position 4 way Drive forward reverse 25 ft lbs 34 Nm 11 Solenoid valve 2 position 2 way N O BK ice Brake 20 ft Ibs 27 Nm 12 Solenoid valve 2 position 4 way Bl ud Platform usines 25 ft lbs 34 Nm 13 Check valve 5 psi 0 3 Steer Circuit sssiiseiinorisecrossniss 20 ft lbs 27 Nm 4 58 Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section 4 e Repair Procedures REV MANIFOLDS g 1 D BB 5 Part No 72963 Genie GS 2032 and GS 2632 4 59 Section Ae Repair Procedures June 2004 EE MANIFOLDS REV C 6 5 Function Manifold Components Models with Traction Control The function manifold is mounted inside the hydraulic power unit module tray Index Schemat
89. ace contact OR refer to Ground Controls Inoperative Chart 5 OR consult the Genie Industries Service Department CHART 1 Repair or replace KS1 Repair or replace KS1 Part No 72963 Genie GS 2032 and GS 2632 Section 5 Troubleshooting Flow Charts June 2004 Chart 2 Pump Motor Will Not Operate Be sure the circuit breaker and fuse are not tripped or blown Be sure the batteries are fully charged and properly connected 20V or more With the key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position activate the lift function and check for voltage on the positive terminal D1 at pump motor M5 DV After serial number bad 25141 Troubleshoot the CR48 power relay to 05 good 20V or Check voltage on the B more terminal at motor controller U6 Check for continuity in the positive cable circuit from the B terminal at U6 through battery quick disconnect QD1 through the 275A fuse F6 to the battery B5 no continuity continuity Check for continuity in the ground cable circuit from terminal A1 at pump motor M5 to the M terminal at motor controller U6 continuity Continued on the next page Activate the lift function check voltage on terminal M at U6 20V or more Replace U6 OR consult the Genie Industries Service Department Repair or replace the wire circuit from the platfo
90. age place the volt meter negative lead on the purple wire Place the volt meter positive lead on the brown wire Electrocution hazard Contact with AWARNING electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry REV B Loosen the set screw on the potentiometer shaft just enough to let the shaft rotate With the joystick in the neutral position adjust the potentiometer to 2 05V DC at the potentiometer shaft Tighten the set screw Move the joystick full stroke in both directions several times Return the joystick to the neutral position Result The volt meter should read 2 05V DC Result If the volt meter does not read 2 05V DC repeat steps 5 through 7 8 Turn the key switch to the off position 9 Wait a few seconds and then turn the key Switch to platform controls Result The error light on the top of the platform control box should go out and Code 47 should not be present on the diagnostic display at the battery module side of the machine Result If the error indicator light is still on or if code 47 is present on the diagnostic display repeat steps 5 through 9 10 Turn the key switch to the off position 11 Close the lid and install the fasteners 4 4 Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section 4 e Repair Procedures REV B PLATFORM CONTROLS 1 3 4 Press and hold the lift function enable button Controller Adjustments
91. aintenance procedures B 3 Inspect the Tires and Wheels including castle nut torque B 10 Replace the Hydraulic Tank Return Filter CHECKLIST A PROCEDURES 4 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 type Multipurpose grease Part No 72963 Genie GS 2032 and GS 2632 Section 3 Scheduled Maintenance Procedures September 2006 Checklist B Procedures B 1 Inspect the Batteries 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 AWARNING Bodily injury hazard Batteries contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water Electrocution hazard Contact with hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry Per
92. ard The lift cylinder index 15 may become unbalanced and fall when it is removed from the machine if it is not properly attached to the overhead crane CAUTION Component damage hazard Be fittings on the cylinder while removing it from the machine 33 Place a 4 x 4 x 32 inch 10 x 10 x 80 cm long block across both sides of the chassis under the number 1 center pivot pin index 8 careful not to damage the valve or SCISSOR COMPONENTS 34 Attach a lifting strap from an overhead crane to the number 1 inner arm index 9 Raise the inner arm slightly and remove the safety arm Lower the arms onto the block Bodily injury hazard Keep hands ACAUTION clear of moving parts when lowering the arms onto the block 35 Remove the cables from the number 1 inner arm index 9 and lay them off to the side Component damage hazard CAUTION Cables can be damaged if they are kinked or pinched 36 Attach a lifting strap from an overhead crane to the number 1 outer arm index 19 Do not lift it 37 Remove the external snap rings from the number 1 center pivot pin index 8 38 Use a soft metal drift to remove the number 1 center pivot pin index 8 Bodily injury hazard The number ACAUTION 1 outer arm index 19 may become unbalanced and fall if not properly supported when the pin is removed Part No 72963 Genie GS 2032 and GS 2632 Section Ae Repair Procedures June 2004 SCISSOR COMPONENTS 39 Slide
93. atform controls is on light is on 20V or more Disconnect the wires from the drive reverse directional valve coil item Al or BJ and check resistance of the coil See Repair Section light is not on 18 to 20 ohms Repair or replace the drive reverse directional valve item Al or BJ OR consult the Genie Industries Service Department Check the connection at the ECM U5 OR replace the drive forward reverse valve cartridge item or BJ OR consult the Genie Industries Service Department 0 or infinite ohms Chart 12 Repair open in the WH A7 rev coil wire from the drive reverse directional valve coil item Al or BJ to the ECM U5 OR repair open in the brown ground wire circuit from the coil to the wire harness OR replace U5 OR consult the Genie Industries Service Department Replace the drive reverse directional valve coil item AI or BJ Part No 72963 Genie GS 2032 and GS 2632 Section 5 Troubleshooting Flow Charts June 2004 Chart 13 Machine Will Not Drive At Full Speed Be sure the circuit breaker and fuse are not tripped or blown Be sure the batteries are fully charged and properly connected With the key switch turned to platform controls and both Emergency Stop buttons pulled out to the ON position and the platform In the stowed position drive the machine in either direction Is the error indicator light on at the platform controls
94. atform up valve coil 7 Drive reverse valve A8 Motor controller terminal 1 A9 Motor controller terminal 3 A10 Overload sensor A11 Key switch to platform A12 Platform down from ground controls B1 Platform data link Black wire at platform B2 Spare B3 Ground for electronic control module B4 Spare B5 Spare B6 Platform down valve coil B7 Steer left valve coil B8 Automotive style horn option B9 Multifunction alarm B10 Pothole limit switch B11 Spare B12 Platform up from ground controls C1 Platform data link Yellow wire at platform C2 Emergency Stop at ground controls main power C4 Spare C5 Spare C6 Drive forward valve coil C7 Steer right valve coil C8 Parallel coil C9 Brake release valve coil C10 Spare C11 Level sensor signal C12 Down limit switch ECM PIN OUT LEGEND 4 SE BOULOT CLOCOT CC OC XC CC OCC COCOCX2 e C3 C3 ECM PIN OUT LEGEND After serial number 36100 Item Description A1 Flashing beacon A2 Platform ground from joystick Blue wire at platform A3 Spare 4 Emergency Stop from platform White wire at platform A5 Level sensor power A6 Platform up valve coil A7 Drive reverse valve coil A8 Motor controller terminal 1 A9 Motor controller terminal 3 A10 Overload sensor A11 Key swit
95. ch 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 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 Read each appropriate flow chart thoroughly Attempting shortcuts may produce hazardous conditions Be aware of the following hazards and follow generally accepted safe workshop practices A DANGER Crushing hazard When testing or replacing any hydraulic component always support the structure and secure it from movement AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry AWARNING GE 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 Two persons will be required to safely perform some troubleshooting procedures Part No 72963 Genie GS 2032 and GS 2632 5 1 Section 5 Troubleshooting Flow Charts June 2004 TROUBLESHOOTING FLOW CHARTS About This Section When a malfunction is discovered the fl
96. ch to platform A12 Platform down from ground controls B1 Platform data link Black wire at platform B2 Spare B3 Ground for electronic control module B4 Spare B5 Spare B6 Platform down valve coil B7 Steer left valve coil B8 Automotive style horn option B9 Multifunction alarm B10 Pothole limit switch B11 Spare B12 Platform up from ground controls C1 Platform data link Yellow wire at platform C2 Emergency Stop at ground controls main power C4 Spare C5 Spare Drive forward valve coil C7 Steer right valve coil C8 Parallel coil C9 Brake release valve coil C10 Spare C11 Level sensor signal C12 Down limit switch Part No 72963 Genie GS 2032 and GS 2632 Section 6 Schematics June 2004 Platform Controls Wiring Diagram models with potentiometer equipped joystick s DIP SWITCH San oo No m P2 EMERGENCY STOP BUTTON JC1 JOYSTICK CONTROLLER WH BK K zo gesch DD WH WH RD WH BL U3 PLATFORM CONTROLS CIRCUIT BOARD BK _ RD WH BI TO COIL CORD ASSEMBLY ABBREVIATION LEGEND Item Description H1 Alarm JC1 Joystick controller P2 Emergency Stop butt
97. cification could cause the machine to tip over resulting in death or serious injury Do not adjust the relief valve pressures higher than specifications 7 Repeat steps 3 and 4 to confirm the relief valve pressure Part No 72963 Genie GS 2032 and GS 2632 4 67 Section Ae Repair Procedures June 2004 MANIFOLDS How to Adjust the Platform Lift Relief Valve after serial number 36100 Be sure that the hydraulic oil level is between the FULL and app marks on the oil level indicator decal 1 Open the hydraulic power unit module tray and locate the system relief valve on the function manifold item BD or CD Models without traction control _ FL sl ein 61 266 X La Ze E BF CO BM 9 ia T ER Q i j 7 Sul BL BK lift relief valve System relief valve function manifold test port OC om Models without traction control from serial number 36101 to 49425 BB O Su gp b _ i SS y BG NS Cr SS EN BL lift relief valve System relief valve function manifold test port Oo CO om Models without traction control from serial number 49426 to 59999 _ BB Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section 4 Repair Procedures REV 2 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the t
98. circuit from SW6 to the platform controls circuit board U3 OR replace U3 OR consult the Genie Industries Service Department REVA Repair open in the WH B7 left coil wire from the coil on the steer left directional valve item AF or BI to the ECM U5 OR repair open in the brown ground wire circuit from the coil to the wire harness OR replace U5 OR consult the Genie Industries Service Department Repair or replace the steer directional valve cartridge item AF or Bl OR consult the Genie Industries Service Department bad Replace SW6 Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section 5 Troubleshooting Flow Charts REVA previous page Continued from the CHART 8 Remove the mechanical restrictions Install a 0 to 2000 psi Are there mechanical 138 bar pressure restrictions keeping the gauge at the quick steer left function from disconnect coupling on moving the function manifold and activate the steer left function Repair or replace the steer cylinder OR consult the Genie less than Industries Service 1500 PSI Department Reset the steer relief Repair or replace the valve pressure steer cylinder OR item AE or BF replace the steer left See Repair Section right valve cartridge item AF or BI OR the less than function manifold could 1500 PSI have an internal defect Consult the Genie Replace the steer relief Industries Service valve
99. d from the machine 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 To re assemble perform the disassembly steps in reverse order Symbols Legend Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Red used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury Orange used to indicate the AWARNING presence of a potentially hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert symbol ACAUTION used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Green used to indicate operation or maintenance information Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after perfor
100. d slide the platform towards the non steer end of the machine until the non steer end platform pivot pins are visible through the access holes in the side of the platform 13 Remove the platform pivot pin retaining fasteners from the platform pivot pins at the non steer end of the machine 14 Use a slide hammer to remove the pins AWARNING Crushing hazard The platform will fall if it is not properly supported 15 Carefully lift the platform off of the machine and place it on a structure capable of supporting it Note the position of the wear pads before the platform is removed so when the platform is installed they will be in the correct position Genie GS 2032 and GS 2632 Part No 72963 June 2004 EE 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 3 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 Do not lift it Attach a strap from the platform extension railings to the carriage on the forklift to help support the platform extension Remove the two retaining fasteners from each platform extension roller bracket assembly Remove each assembly from the machine Do not remove the platform roller bolt a roller bracket assembly b assembly retaining fastener c plat
101. d 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 72963 Genie GS 2032 and GS 2632 2 5 Section 2 e Specifications June 2004 _ cc M M REVA This page intentionally left blank 2 6 Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section 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 annually and every 2 years as specified on the Maintenance Inspection Report AWARNING Failure 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 Keep records on all inspections for three years Unless otherwise specified perform each procedure with the machine in the following configuration Machine parked on a firm level surface Platform in the stowed position Key switch in the off position with the key removed Wheels chocked All external AC power supply disconnected from the machine Abou
102. e G Gauge SW6 Steer left right G6 Hour meter SW25 DIP switch G7 Battery charge indicator TS66 Platform up down toggle switch GND Ground U Electronic component 7 H Horn or alarm Encoder printed circuit board P LAT FO H M C Q N T H L L E H H1 Horn 05 Electronic control module H2 Automotive style horn option U6 Motor controller H5 Multifunction alarm U9 Battery charger JC1 Joystick controller U13 Voltage inverter option KS1 Key switch U27 0 034 ohm inductor noise suppression L LED or light Y Valve coil L16 Lift Y1 Parallel L17 Drive Y1A High speed bypass option L19 Power Y2 Brake release WIRE COLOR LEG END 8 L21 High Torque Steer right Color Description Color Description L25 Fault Y4 Steer left aed BL Blue RD Red LS Limit switch dei BK Black WH White LS2 Platform up GS 3246 only Y6 Drive forward BN Brown YL Yellow LS6 Platform down Y7 Platform down 2 Y8 Platform GN Green WH BL White Blue LS7 Pothole p LS8 Pothole Y9 Platform down GS 3246 only GY Gray WH BK White Black M5 Hydraulic power unit Y10 Auxiliary down GS 3246 only OR Orange WH RD White Red Y11 Auxiliary down GS 3246 only PP Purple WH YL White Yellow Part No 72963 Genie GS 2032 and GS 2632 6 12 June 2004 Section 6 Schematics E Electrical Schematic from serial number 17408 to 21064 Section Ge Schematics I Electrical Schema
103. e ground and platform controls 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 5 GROUND CONTROLS 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 6 Turn the key switch to the off position and push in the red Emergency Stop button to the off position at the ground controls Tag and disconnect the level sensor wire harness from the chassis wire harness The wire harness connection is located next to the level sensor on top of the chassis at the steer end of the machine Remove the level sensor retaining fasteners Remove the level sensor from the machine Tag and disconnect the level sensor wires from the level sensor connector plug 10 Securely install the wires of the new level sensor into the level sensor connector plug Part No 72963 Genie GS 2032 and GS 2632 Section Ae Repair Procedures June 2004 GROUND CONTROLS 11 Place the new level sensor onto the level 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 ADANGER Tip over hazard The level sensor must be installed with the X on the
104. e machine 2 Open the power unit module tray Remove the drain plug from the hydraulic tank and allow all of the oil to drain into a suitable container Refer to Section 2 Specifications for capacity information 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 disconnect and cap the hydraulic hoses from the hydraulic tank 4 Remove the hydraulic tank mounting fasteners Remove the hydraulic tank from the machine REVA 5 Remove the suction strainer and clean it using a mild solvent 6 Clean the inside of the hydraulic tank using a mild solvent 7 Install the suction strainer using thread sealer on the threads 8 Install the drain plug using thread sealer on the threads Torque to specification Torque specifications Hydraulic tank drain plug dry 75 in lbs 8 5 Nm Hydraulic tank drain plug lubricated 56 in lbs 6 3 Nm 9 Install the hydraulic tank and install and tighten the hydraulic tank retaining fasteners Torque to specification Torque specifications 35 in Ibs 4 Nm Hydraulic tank retaining fasteners dry Hydraulic tank retaining fasteners lubricated 26 in lbs 2 9 Nm 10 Connect the hydraulic hoses to the hydraulic tank 11 Fill the tank with hydraulic oil until the fluid is within the FULL and app marks on
105. e stowed position 12 Lower the platform to the stowed position and turn the machine off Part No 72963 Genie GS 2032 and GS 2632 Section 3 Scheduled Maintenance Procedures September 2006 CHECKLIST B PROCEDURES B 3 Inspect the Tires and Wheels including castle nut torque Maintaining the tires and wheels in good condition is essential to safe operation and good performance Tire and or wheel failure could result in a machine tip over Component damage may also result if problems are not discovered and repaired in a timely fashion 1 Check the tire surface and sidewalls for cuts cracks or unusual wear 2 Check each wheel for damage bends cracks 3 Remove the cotter pin and check each castle nut for proper torque Refer to Section 2 Specifications Always replace the cotter pin with a new one when removing the castle nut or when checking the torque of the castle nut 4 Install a new cotter pin Bend the cotter pin to lock it in place REV D B 4 Test the Emergency Stop 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
106. e the platform extension deck is fully retracted and the platform is in the stowed position 1 Mark a test line on the ground for reference 2 Turn the key switch to platform control and pull out the Emergency Stop button to the on position at both the ground and platform controls 2 Lower the platform to the stowed position 3 Models with drive function select button Press the drive function select button Refer to Illustration 1 so Genie Illustration 1 drive function select button BN8 5 Choose a point the machine Le contact patch of a tire as a visual reference for use when crossing the test line REV D 6 Bring the machine to full drive speed before reaching the test line Release the function enable switch or the joystick on the platform controls when your reference point on the machine crosses the test line 7 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 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 AWARNING Electrocution hazard Contact with electrically charged circuits could
107. em AF 5 While activating the platform up function adjust the internal hex socket clockwise to increase lift capacity or counterclockwise to decrease lift capacity Adjust the relief valve until the platform just begins to raise 6 Fully lower the platform 7 Addan additional 50 pounds 22 7 kg to the platform Secure the additional weight 8 Activate the platform up function Result The power unit should not be able to lift the platform Result If the power unit lifts the platform adjust the internal hex socket counterclockwise until the platform will not raise ADANGER Tip over hazard Do not adjust the relief valve to allow the power unit to lift more than maximum rated load 9 Install the relief valve cap 10 Remove the weight from the platform 11 Bleed the hydraulic system Raise the platform to full height and then lower it to the stowed position through two complete cycles Result If the pump cavitates or platform fails to reach full height add hydraulic oil until the pump is functioning correctly and the platform reaches full height Do not overfill the hydraulic tank Component damage hazard Do CAUTION not continue to operate the machine if the hydraulic pump is cavitating If the pump is still cavitating see 5 1 How to Test the Hydraulic Pump Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section 4 Repair Procedures REV How to Adjust the System Relief
108. er next to the battery charger Index Schematic No Description Item Function Torque 1 Shuttle valve Brake release 45 50 in lbs 5 Nm 2 Check valve pilot operated I siue Manual brake release circuit 65 70 in Ibs 7 8 Nm 3 Hand p imp iei Lei Manual brake release 30 ft lbs 41 Nm 4 Needle valve Manual brake release enable 45 50 in lbs 5 Nm N GS 2032 GS 2632 before serial number GS 3204 52789 S 8 Note alpha callouts refer L to corresponding notes on the hydraulic schematic GS 2032 GS 2632 after serial number GS 3204 52788 4 78 Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section 5 Troubleshooting Flow Charts Troubleshooting Flow Charts 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 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 swit
109. erse 25 ft lbs 34 Nm 11 Solenoid valve 2 position 2 way N O BK ice Brake 20 ft Ibs 27 Nm 12 Solenoid valve 2 position 4 way Bl ud Platform usines 25 ft lbs 34 Nm 13 Check valve 5 psi 0 3 Steer Circuit sssiiseiinorisecrossniss 20 ft lbs 27 Nm 4 56 Genie 65 2032 95 2632 Part No 72963 June 2004 Section 4 e Repair Procedures REV MANIFOLDS ke Ra SE Part No 72963 Genie GS 2032 and GS 2632 4 57 Section Ae Repair Procedures June 2004 EE MANIFOLDS REV C 6 4 Function Manifold Components from serial number 49246 to 59999 The function manifold is mounted inside the hydraulic power unit module tray Index Schematic No Description Item Function Torque 1 Diagnostic nipple TOSUN ccce ree 10 ft lbs 14 Nm 2 Flow regulator valve 075 2 8 2 2 2 ne BB e Steer 35 ft Ibs 47 Nm 3 Relief valve 3000 to 3200 psi 207 to 221 BG eei Platform up eerte 20 ft lbs 27 Nm 4 Relief valve 3500 psi 241 3 bar BD ute System relief 20 ft Ibs 27 Nm 5 Orifice washer 0 040 in 1 mm 2
110. est port on the function manifold item BA or CA 3 Chock both sides of the wheels at the steer end of the machine 4 Remove the platform controls from the platform Perform this test from the ground with the platform controls Do not stand in the platform Confirm the System Relief Valve Pressure 5 Turn the key switch to platform control and pull out the Emergency Stop button to the position at both the ground and platform controls 6 Press and hold the function enable switch 7 Move and hold the joystick controller 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 item BD or CD 9 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure ADANGER Tip over hazard Failure to adjust the relief valves to specification could cause the machine to tip over resulting in 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 MANIFOLDS Confirm the Lift Relief Valve Pressure 12 Place the maximum rated load in the platform Secure the load to the platform Refer to Section 2 Specifications 13 Turn the key switch to ground control a
111. f the safety arm when lowering the platform 4 Push the handle on the manual platform lowering cable all the way in 5 Disconnect the cable mounting nut from the lowering valve at the barrel end of the lift cylinder 6 Pullthe cable tight and measure the distance between the end of the lowering cable and the end of the lowering valve Result The measurement should be 3 16 to 1 4 inch 4 7 to 6 4 mm Platform manual lowering cable specification 3 16 to 1 4 inch 4 7 to 6 4 mm Gap lowering cable to valve REV C Skip to step 10 if the measurement is correct 7 To adjust loosen the upper lock nut on the cable mounting bracket Turn the lower lock nut clockwise to decrease the distance or counterclockwise to increase the distance a Manual lowering cable sheath b Upper lock nut cable mounting bracket d Lower lock nut e Cable mounting nut f End of the lowering cable g Manual lowering valve schematic item D D D d 8 Tighten the upper lock nut 9 Measure the distance between the end of the lowering cable and the end of the lowering valve Adjust if needed 10 Install the cable mounting nut onto the lowering valve 11 Raise the platform and return the safety arm to the stowed position 12 Pull the manual lowering handle at the ground controls 2 to 3 times to ensure it is functioning correctly Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section Ae
112. ferent by a minimum of 20 The coil is good Result If one or both of the current readings are mA or if the two current readings do not differ by a minimum of 20 the coil and or its internal diode are faulty and the coil should be replaced Part No 72963 Genie GS 2032 and GS 2632 4 71 Section Ae Repair Procedures June 2004 ydraulic Tank 7 1 2 Open the power unit module tray Hydraulic Tank 3 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 The primary functions of the hydraulic tank are to Specifications cool clean and deaerate the hydraulic fluid during operation It utilizes internal suction strainers for the pump supply lines and has an external return line filter 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 How to Remove the Hydraulic Tank CAUTION Component damage hazard The work area and surfaces where this 4 Tag disconnect and plug the hydraulic tank procedure will be performed must return hose at the top of the hydraulic tank be 2 4 that 5 Remove the motor controller mounting bracket could get into the hydraulic retaining fasteners and move the motor system controller to the side When removing a hose assembly or fitti
113. form roller bolt Section Ae Repair Procedures PLATFORM COMPONENTS 7 Remove the platform roller wheels from the machine 8 Carefully slide the platform extension out from the platform and place it on a structure capable of supporting it AWARNING Crushing hazard The platform extension could become unbalanced and fall if not properly supported and secured to the forklift How to Replace the Platform Extension Wear Pads 1 Remove the Platform Extension See 2 2 How to Remove the Platform Extension Drill out the rivets which hold the wear pads in place Install the new wear pads using new rivets When installing new rivets make sure the rivet heads are not above the surface of the wear pad Part No 72963 Genie GS 2032 and GS 2632 Section Ae Repair Procedures June 2004 Scissor Components REV B 9 GG 9 9 Gi 65 2032 Sel Non steer End Steer End 1 Number 4 pivot pin steer end 11 Number 4 pivot pin non steer end 2 Number center pivot pin 12 Number 3 inner arm 3 Lift cylinder rod end pivot pin 13 Number 3 outer arm 4 Number 3 pivot pin steer end 14 Number 3 pivot pin non steer end 5 Number 2 center pivot pin 2pins 15 Lift cylinder 6 Number 2 inner arm 16 Number 2 outer arm 7 Number 2 pivot pin s
114. form this test after fully charging the batteries For a more accurate determination of battery condition fully charge the batteries and allow the batteries to rest 24 hours before performing this procedure to allow the battery cells to equalize 1 Puton protective clothing and eye wear 2 Disconnect the battery pack from the machine 3 Be sure that the battery cable connections are free of corrosion 4 Be sure that the battery hold downs and cable connections are tight REV D Models without maintenance free or sealed batteries 5 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Result If any battery cell displays a specific gravity of less than 1 026 the battery must be replaced Check the battery acid level of each battery If needed replenish with distilled water to the bottom of the battery fill tube Do not overfill Install the battery vent caps Check each battery pack and verify that the batteries are wired correctly a batteries B5 b quick disconnect QD1 275A fuse F6 Genie GS 2032 and GS 2632 Part No 72963 September 2006 Section 3 Scheduled Maintenance Procedures REV D B 2 Inspect the Electrical Wiring Maintaining electrical wiring in good condition is essential to safe operation and good machine performance Failure to find and replace burnt chafed corroded or pinched wires could result in unsafe operating cond
115. ft enable PS2 Platform overload pressure switch option 23 Auxiliary down GS 3246 only QD Quick disconnect CB2 Circuit breaker 7A QD1 Battery quick disconnect CR Control relay QD3 Control cable to ground Horn with H2 option QD4 Control cable to platform CR48 Power to U5 R Resistor 6 D7 Voltage regulator R15 5000 ohm potentiometer F Fuse R21 75 ohm resistor POUTH1 F6 275A S7 Tilt level sensor F8 50A with U13 option SW Switch H1 aam FB Flashing beacons option SW5 Function enable G Gauge SW6 Steer left right G6 Hour meter SW25 DIP switch G7 Battery charge indicator TS66 Platform up down toggle switch GND Ground U Electronic component 7 H Horn or alarm U3 Encoder printed circuit board P LAT FO H M H Q L L E R H1 Horn U5 Electronic control module H2 Automotive style horn option U6 Motor controller H5 Multifunction alarm U9 Battery charger JC1 Joystick controller U13 Voltage inverter option KS1 Key switch U27 0 034 ohm inductor noise suppression L LED or light Y Valve coil L16 Lift Y1 Parallel L17 Drive Y1A High speed bypass option L19 Power Y2 Brake release WIRE COLOR LEGEND 8 L21 High Torque Steer right Color Description Color Description L25 Fault Y4 Steer left Di BL Blue RD Red Limit switch 2 Black WH White LS2 Platform up GS 3246 only Y6 Drive forward BN Brown YL Yellow LS6 Platform down Y7 Platfo
116. gative battery cable from the B terminal at motor controller U6 to QD1 Repair open in the 24V cable circuit from F6 to QD1 OR replace or repair QD1 OR repair open in 24V cable circuit from QD1 through terminal at U6 to terminal D1 at M6 Genie GS 2032 and GS 2632 Part No 72963 June 2004 REVA Continued from the previous page Check voltage at input side of Emergency Stop button P1 20V or more Check voltage at the input side of each contact at key switch KS1 20V or more Check the output side of the platform control contact at KS1 20V or more Turn KS1 to the ground control position and check output side of each contact 20V or more Refer to Chart 2 Pump Motor Will Not Operate OR repair open in wht wire C2 estop chassis OR consult the Genie Industries Service Department DN DN DN ov Section 5 Troubleshooting Flow Charts EIL Bd m M coo n1 Repair open in wire from the input side of P1 to CB2 OR reset or replace CB2 OR repair open in the wire from CB2 to QD1 Repair open in the wire from P1 to KS1 OR repair open in the wire jumper to each contact OR replace contact on P1 OR replace P1 Check the cam on KS1 bad good Replace contact OR refer to Platform Controls Inoperative Chart 6 OR consult the Genie Industries Service Department Check the cam on KS1 bad good Repl
117. ge into the hose from the function manifold to the brake Attempt to drive the machine in either direction and read the pressure on the gauge less than 200 psi 200 to 300 psi Pressure is good Replace the brakes OR consult the Genie Industries Service Department Chart 10A Turn the brake release wheels valve item A clockwise turn all the way and try to rotate the wheels wheels do not turn Attempt to drive the machine in either wheels direction and have an turn assistant try to rotate the non steer wheels This will require 2 people wheels do not turn Plumb a 0 to 500 psi 35 bar gauge into the hose from the function manifold to the brake Attempt to drive the machine in either direction and read the pressure on the gauge less than 200 psi 200 to 300 psi Pressure is good Replace the brakes OR consult the Genie Industries Service Department Replace the shuttle valve item B OR replace the brake release valve item A OR the function manifold or brake release manifold may have an internal defect OR consult the Genie Industries Service Department Rebuild or replace the brakes OR replace the brake release valve item A OR consult the Genie Industries Service Department If machine still does not drive at full speed with the platform in the stowed position replace the platform controls OR replace the platform controls circuit board U3 OR
118. han specified in this procedure Perform this procedure with the machine on firm level surface that is free of obstructions The degree of level sensor is listed under maximum inclination of the chassis on the serial plate 1 Remove the platform controls from the platform 2 Turn the key switch to platform control and pull out the red Emergency Stop buttons to the on position at both the ground and platform controls 3 Block the wheels at the non steer end of the machine 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 6 Place a 1 27 x 6x6 inch 32 3 mm x 15 cm x 15 cm thick steel block under both wheels at the steer end of the machine Part No 72963 Genie GS 2032 and GS 2632 4 41 Section Ae Repair Procedures June 2004 GROUND CONTROLS REV C 7 Lowerthe machine onto the blocks Steer end 8 Raise the platform 7 to 8 feet 2 1 to 2 4 m a 9 Lift the safety arm move it to the center of the s e scissor arm and rotate down to vertical position 10 Lower the scissor arms onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 11 Remove the tilt level sensor box cover retaining fasteners Remove the cover The tilt level sensor box is located on top of the chassis at the steer end of the machine If you are not installing a new level sensor proceed to
119. hazard Keep hands clear of the safety arm when lowering the platform 11 Remove the tilt level sensor box cover retaining fasteners Remove the cover The tilt level sensor box is located on top of the chassis at the steer end of the machine If you are not installing a new level sensor proceed to step 18 12 Tag and disconnect the wiring harness from the level sensor limit switch and alarm 13 Remove the tilt level sensor box retaining fasteners Remove the tilt level sensor box from the machine 14 Remove the tilt level sensor retaining fasteners Remove the tilt level sensor from the level sensor box Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section 4 e Repair Procedures REV C GROUND CONTROLS 15 Place the new tilt level sensor in the tilt level Steer end sensor box with the X on 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 Install the level sensor retaining fasteners A DANGER Tip over hazard The tilt level sensor must be installed with the X on 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 install the tilt level sensor as instructed could result in death or serious injury 16 Install the level sensor box onto the machine Instal
120. he level sensor is centered in the circles Be sure there are threads showing through the top of the adjusting fasteners Result The tilt sensor alarm should not sound 19 Raise the platform slightly 20 Return the safety arm to the stowed position 21 Lower the platform to the stowed position 22 Raise the machine approximately 2 inches 5 cm 23 Remove the blocks from under both wheels 24 Lower the machine and remove the jack 25 Remove the blocks from the wheels at the non steer end of the machine 26 Block the wheels at the steer end of the machine 27 Center a lifting jack under the drive chassis at the non steer end of the machine 28 Raise the machine approximately 5 inches 13 cm 29 Place a 4 07 x 6 x 6 inch 103 4 mm x 15 cm x 15 cm thick steel block under both wheels at the non steer end of the machine 30 Lower the machine onto the blocks 31 Raise the platform 6 to 7 feet 1 8 to 2 1 m Result The tilt sensor alarm should sound GROUND CONTROLS CE models When the platform is raised 7 to 8 feet 2 1 to 2 4 from the ground an alarm should sound and the lift and drive functions should not operate 32 Lower the platform to the stowed position 33 Raise the machine approximately 5 inches 13 cm 34 Remove the blocks from under both wheels 35 Lower the machine and remove the jack 36 Remove the blocks from the wheels at the steer end of the machine 37 Center a lifting jac
121. hole sw wire breaker and fuse are not tripped or blown oV Be sure the limit switches are clear of Check voltage at down ov Check voltage on the OV debris Be sure the pothole guards are deploying limit switch 156 Is there 20V or more on one side of LS6 other terminal at LS6 Adjust LS6 OR replace the LS6 contacts 20V or more Repair or replace the 44D wire from alarm 5 Be sure the batteries 20V or more 0156 are fully charged and properly connected With the platform raised ov Check 158 for correct good Repair or replace the to 6 feet 1 8 m check adjustment wire circuit between for 20V or more on one terminal B10 at ECM U5 side of LS8 bad and LS8 OR replace U5 Adjust LS8 20V or more Check for 20V or more ov Check LS7 for correct good Replace the LS8 on both sides of LS7 adjustment contacts OR repair or replace the wire circuit bad between LS8 and LS7 OR replace the LS7 contacts 20V or more Adjust LS7 Repair or replace the wire circuit between LS7 and the positive terminal at alarm H5 5 24 Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section 5 Troubleshooting Flow Charts esc M REVA This page intentionally left blank Part No 72963 Genie GS 2032 and GS 2632 5 25 Section 5 Troubleshooting Flow Charts June 2004 Chart 16 Fault Code 02 ECM Platform Communication Error Be sure the ci
122. ic No Description Item Function Torque 1 Diagnostic nipple GA EE El e DEEN 10 ft Ibs 14 Nm 2 Flow regulator valve 0 75 2 8 L min er GB ees Steer 35 ft Ibs 47 Nm 3 Relief valve 3000 to 3200 psi 207 to 221 CC uou Plattorm up em 20 ft lbs 27 Nm 4 Relief valve 3500 psi 241 3 bar CD System relief 20 ft lbs 27 Nm 5 Orifice washer 0 040 in 1 CE uiuis Steer circuit 6 Relief valve 1500 psi 103 4 bar Steering relief 20 ft Ibs 27 Nm 7 Check valve 30 psi 2 bar eic ES Brake 20 ft lbs 27 Nm 8 Solenoid valve 3 position 4 way CA Steer left right 20 ft lbs 27 Nm 9 Solenoid valve 2 position 2 way N O Clint Brake circuit 20 ft Ibs 27 Nm 10 Solenoid valve 2 position 4 way GH Drive speed select circuit 25 ft lbs 34 Nm 11 Solenoid valve 3 position 4 way Drive forward reverse 25 ft lbs 34 Nm 12 Solenoid valve 2 position 2 way CL iussis High speed bypass
123. ice Department Part No 72963 Genie GS 2032 and GS 2632 5 7 Section 5 Troubleshooting Flow Charts June 2004 Chart 3 All Functions Inoperative Power Unit Starts and Runs Be sure if the Error Indicator light is on at the platform controls you refer to the specific chart that relates to the error code that is displayed on the ECM Be sure the circuit breaker and fuse are not tripped or blown Be sure the batteries are fully charged and properly connected Be sure the hydraulic tank is filled to the correct level Check for a positive connection between electric motor and pump by removing pump from motor M5 leaving all hoses connected Visually check the coupling connection Replace pump coupling OR replace the pump OR replace the motor Test the hydraulic pump See Repair section Replace the pump Consult the Genie Industries Service Department REVA Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section 5 Troubleshooting Flow Charts m Chart 4 Ground With key switch turned ae ae in WH wire to ground controls and rom KS1 to Emergency Controls Emergency Stop Stop button P1 OR j uttons pulled out to the repair or replace P1 OR Inoperative position check bd open in WH wire voltage on the ground rom P1 to circuit Platform control contact at the breaker CB2 Controls input side of the key switch KS1 Operate Normally 20V or more Be sure
124. ice professional Attempting this procedure without the necessary skills will result in death or serious injury Software revision DO and higher 1 Push the red Emergency Stop button to the off position at the ground and platform controls Turn the key switch to the off position 2 Pull out the red Emergency Stop button to the on position at the ground and platform controls 3 Press and hold the lift function select and horn buttons and turn the key switch to platform controls Result The diagnostic display will show PS 4 Release the lift function select and horn buttons Result The diagnostic display will show the maximum lift speed percentage PLATFORM CONTROLS 5 Press the drive function select button Result The diagnostic display will show the stowed drive speed percentage Genie t function enable switch SW5 joystick controller JC1 with thumb rocker switch SW6 horn button BN5 machine on incline button BN6 lift function select button BN9 drive function select BN8 red Emergency Stop button P2 6 Press and hold the machine on incline button Result The diagnostic display will show the stowed high torque drive speed percentage 7 Usethe steering thumb rocker switch on the joystick to increase or decrease the stowed high torque drive speed percentage Refer to Section 2 Specifications 8 Turn the key switch to the off position Any change in software set
125. if the Error Indicator light is on at the platform controls you refer to the specific chart that relates to the error code that is displayed on the ECM Be sure the circuit breaker and fuse are not tripped or blown Be sure the batteries are properly connected Be sure the batteries are fully charged Check if internal cam at KS1 is activating the ground control contact Check voltage on output side of ground control contact at KS1 20V or more Replace KS1 Check voltage on the center terminal of the platform up down toggle switch TS66 at the ground controls Repair open in WH wire jumper from KS1 to the center terminal at TS66 20V or more Test or replace TS66 See Repair Section OR repair open in the WH B12 UP DWN SWITCH UP wire from TS66 to the ECM U5 OR repair open in the WH A12 UP DWN SWITCH DWN wire from 566 to U5 OR consult the Genie Industries Service Department Replace contact for ground controls at KS1 Part No 72963 Genie GS 2032 and GS 2632 Section 5 Troubleshooting Flow Charts June 2004 Chart 5 Platform Controls Inoperative Ground Controls Operate Normally Be sure if the Error Indicator light is on at the platform controls you refer to the specific chart that relates to the error code that is displayed on the ECM Be sure the circuit breaker and fuse are not tripped or blown Be sure the batteries are fully charged and
126. ire as a visual reference for use when crossing the start and finish lines Bring the machine to maximum drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line Continue at full speed and note the time when the machine reference point passes over the finish line Refer to Section 2 Specifications 3 16 Genie GS 2032 GS 2632 Part No 72963 September 2006 Section Scheduled Maintenance Procedures REV D B 10 Perform Hydraulic Oil Analysis Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil and a clogged suction strainer may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more often 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 D 1 Test or Replace the Hyaraulic Oil CHECKLIST B PROCEDURES B 11 Replace the Hydraulic Tank Return Filter 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
127. it board to the same configuration of the old board If replacing the circuit board use dielectric grease on all plug in connectors Motion Beacon The motion beacon option flashes only when operating a function Motion Alarm The motion alarm will sound when operating any function Lift Drive Cut Out This cuts out lift and drive functions when the machine exceeds the rating on the serial plate Required for Europe and Australia before serial number 47055 Configured on all machines after serial number 47054 Platform Overload This cuts out all functions when the pressure sensor is overloaded The additional weight must be removed from the platform and the Emergency Stop button must be cycled before any function can be resumed Required for France Descent Delay This option halts descent at approximately 7 feet 2 1 m controls must be released for 4 to 6 seconds before descent is re enabled Required for CE models Battery Drain Alarm When the machine is turned on and no function is activated for 10 minutes the alarm will sound once every 3 seconds This option can be activated by moving DIP switch 7 to position 1 When this option is configured the flashing dot in the diagnostic display window will remain illuminated when the lift mode is selected and activated Part No 72963 Genie GS 2032 and GS 2632 4 15 Section Ae Repair Procedures June 2004 Platform Components 2 1 Platform How to Rem
128. ithout disconnecting the wire and the negative lead of the volt meter to the ground point on the manifold Activate the controller in the uP direction and check the voltage 20V or more 0 or infinite Disconnect the wire ohms from the platform up directional valve coil on the function manifold item AG or BG and check the resistance See Repair Section 18 20 ohms Repair or replace the platform up directional valve cartridge item AG or BG OR consult the Genie Industries Service Department Are there mechanical restrictions keeping yes platform up function from moving no Repair or replace the platform lift cylinder OR consult the Genie Industries Service Department Chart 6 Repair open in the WH A6 up coil wire from the platform up directional valve coil item AG or BG to the ECM U5 see Repair Section OR replace U5 OR consult the Genie Industries Service Department Replace the platform up directional valve coil item AG or BG Remove the mechanical restrictions keeping platform up function from moving Part No 72963 Genie GS 2032 and GS 2632 Section 5 Troubleshooting Flow Charts June 2004 Chart 7 Platform Down Function Inoperative Be sure all other functions operate normally Be sure the circuit breaker and fuse are not tripped or blown Be sure the batteries are fully charged and properly connected With the key switch
129. itions and may cause component damage Electrocution hazard Contact with AWARNING hot or live 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 Inspect for a liberal coating of dielectric grease in all connections between the ECM and the platform controls 4 Turn the key switch to ground control and pull out the Emergency Stop button to the on position at both the ground and platform controls CHECKLIST B PROCEDURES 5 Raise the platform approximately 8 feet 2 4 m from the ground 6 Rotate the safety arm away from the machine and let it hang down 7 Lowerthe platform onto the safety arm Crushing hazard Keep hands AWARNING 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 EOM 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 th
130. k under the drive chassis at the ground controls side of the machine 38 Raise the machine approximately 2 inches 5 cm 39 Place a 1 06 x6x 6 inch 27 mm x 15 cm x 15 cm thick steel block under both wheels at the ground controls side of the machine 40 Lower the machine onto the blocks 41 Raise the platform 6 to 7 feet 1 8 to 2 1 m 42 Adjust the tilt level sensor retaining fasteners just until the tilt sensor alarm does not sound 43 Lower the platform to the stowed position 44 Raise the machine approximately 2 inches 5 cm 45 Remove the blocks from under both wheels 46 Lower the machine and remove the jack Part No 72963 Genie GS 2032 and GS 2632 Section Ae Repair Procedures June 2004 GROUND CONTROLS 47 Center a lifting jack under the drive chassis at the battery pack side of the machine 48 Raise the machine approximately 2 inches 5 cm 49 Place a 1 23 x 6x 6 inch 31 mm x 15 cm x 15 cm thick steel block under both wheels at the battery pack side of the machine 50 Lower the machine onto the blocks 51 Raise the platform 7 to 8 feet 2 1 to 2 4 m Result The tilt sensor alarm should sound Result If the tilt sensor alarm does not sound adjust the tilt level sensor until the alarm just begins to sound OR the down limit switch may need to be adjusted CE models When the platform is raised 7 to 8 feet 2 1 to 2 4 m from the ground an alarm should sound and the lift and d
131. l the level sensor box retaining fasteners 17 Connect the wiring harness to the level sensor limit switch and alarm 18 Tighten the level sensor adjusting fasteners until the bubble in the top of the level sensor is centered in the circles Be sure there are threads showing through the top of the adjusting fasteners O Result The tilt sensor alarm should not sound 19 Raise the platform slightly 20 Return the safety arm to the stowed position 21 Lower the platform to the stowed position MEM Non steer end scissor chassis tilt level sensor level sensor box alarm box retaining fastener level sensor retaining fastener rop Oo o 22 Raise the machine approximately 2 inches 5 cm 23 Remove the blocks from under both wheels 24 Lower the machine and remove the jack 25 Remove the blocks from the wheels at the non steer end of the machine Part No 72963 Genie GS 2032 and GS 2632 Section Ae Repair Procedures June 2004 GROUND CONTROLS 26 Block the wheels at the steer end of the machine 27 Center a lifting jack under the drive chassis at the non steer end of the machine 28 Raise the machine approximately 5 inches 13 cm 29 Place a 4 07 x6x 6 inch 103 4 mm x 15 cm x 15 cm thick steel block under both wheels at the non steer end of the machine 30 Lower the machine onto the blocks 31 Raise the platform 6 to 7 feet 1 8 to 2 1 m Result The tilt sen
132. lifting jack under the drive chassis at the steer end of the machine 3 Remove the cotter pin on the wheel lug nut of the motor to be removed Always replace the cotter pin with a new one when removing the castle nut 4 Loosen the wheel castle nut Do not remove it Raise the machine approximately 2 inches 5 cm Place blocks under the chassis for support AWARNING Crushing hazard The chassis will fall if it is not properly supported 6 Remove the wheel castle nut Remove the wheel REVA 7 Tag disconnect and plug the hydraulic hoses on the drive motor Cap the fittings AWARNING GE 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 Component damage hazard Hoses can be damaged if they are kinked or pinched CAUTION 8 Remove the drive motor mounting fasteners Remove the drive motor Torque specifications Drive motor mounting fasteners dry 75 ft lbs 101 7 Nm Drive motor mounting fasteners lubricated 56 ft lbs 76 3 Nm Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section Ae Repair Procedures p REVA STEER AXLE COMPONENTS 8 2 4 Remove the pin retaining fasteners from the Steer Cylinder rod end pivot pin Remove the pin UU Note the quantity and location
133. light is on Check voltage at the WH 39C pothole sw wire at pothole limit switch LS7 20V or more Raise the platform approximately 3 feet 0 9 m and check the voltage at the output side of LS7 20V or more Check voltage at the WH 21B pothole sw wire on the input side of limit Switch 158 20V or more Check voltage on the output side of LS8 20V or more Repair open in the WH B10 pothole sw wire from the output side of LS8 to the ECM U5 OR replace U5 OR see Chart 10A Brake Release Function Inoperative light is not on ov DV ov ov Raise the platform approximately 3 feet 0 9 m and drive the machine Does the machine drive at a reduced speed no Consult the Genie Industries Service Department Repair open in the WH 39C pothole sw wire from LS7 to the multi function alarm 5 Adjust LS7 so the pothole arm activates the switch OR replace the limit switch contact OR replace LS7 Repair open in the WH 21B pothole jumper wire from the output side of LS7 to the input side of 158 Adjust LS8 so the pothole arm activates the switch OR replace the limit switch contact OR replace the LS8 REVA Raise the platform to more than 6 feet 1 8 m and drive the machine If the machine does not drive and an alarm sounds the machine is operating normally Check the pothole guards for obstructions OR test the pothole guard limit switches See Repair
134. llowing 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 E E EE Pre delivery Preparation Report The pre delivery preparation report contains checklists for each type of scheduled inspection Make copies of the Pre delivery Preparation report to use for each inspection Store completed forms as required Maintenance Schedule There are five types of maintenance inspections that must be performed according to a schedule daily quarterly semi annually annually and two year The Scheduled Maintenance Procedures Section and the Maintenance Inspection Report have been divided into five subsections A B C D and E Use the following chart to determine which group s of procedures are required to perform a scheduled inspection Inspection Checklist Daily or every 8 hours A Quarterly or every 250 hours Semi annually or every 500 hours 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 ins
135. low 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 the oil pressure to dissipate ilv ini i AWARNING Bodily injury hazard Spraying gradually Do not allow oil to squirt or spray 2 Connect a 0 to 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 Emergency Stop button to the on position at both the ground and platform controls 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 4 50 Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section 4 Repair Procedures p REVA HYDRAULIC PUMP How to Remove the Hydraulic Pump When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Remove the mounting fasteners from the hydraulic filter bracket at the function manifold Move the filter
136. lt The diagnostic display will show the raised drive speed percentage 6 Use the steering thumb rocker switch on the joystick to increase or decrease the maximum raised drive speed percentage Refer to Section 2 Specifications 7 Turn the key switch to the off position Any change in software settings will not take effect until the key Switch is turned to the off position Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section Ae Repair Procedures REV B Software revision CO k Push in the red Emergency Stop button to the off position at the ground and platform controls Turn the key switch to the off position N Pull out the red Emergency Stop button to the on position at the ground and platform controls Press and hold the lift function select and horn buttons and turn the key switch to platform controls Result The diagnostic display will show PS Genie function enable switch SW5 joystick controller JC1 with thumb steering rocker SW6 horn button BN5 machine on incline button lift function select button BN9 drive function select BN8 red Emergency Stop button P2 4 Release the lift function select and horn buttons Result The diagnostic display will show the maximum lift speed percentage Press the drive function select button Result The diagnostic display will show PS PLATFORM CONTROLS 6 Press and hold the horn bu
137. ly Result models with software revision A2 and higher The alarm should not sound The system is functioning correctly 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 to be calibrated See Maintenance Procedure D 2 Calibrate the Platform Overload System if equipped 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 Genie GS 2032 and GS 2632 Part No 72963 June 2006 Section Scheduled Maintenance Procedures REV D D 1 Check the Scissor Arm Wear Pads Maintaining the scissor arm wear pads in good condition is essential to safe machine operation Continued use of worn out wear pads may result in component damage and unsafe operating conditions Perform this procedure with the platform in the stowed position 1 Measure the thickness of the wear pad at the ground controls side of the non steer end of the machine O Result The measurement is 0 21 inch 5 3 mm or more Proceed to step 2 Result The measurement is less than 0 21 inch 5 3 mm Replace both wear pads Refer to Repair Procedure 3 1 or 3 2 How to Replace the Scissor Arm Wear Pads m Sg EN 0 21 inches 5
138. ly QD Quick disconnect CB2 Circuit breaker 7A QD1 Battery quick disconnect CR Control relay QD3 Control cable to ground Horn with H2 option QD4 Control cable to platform CR48 Power to U5 R Resistor D7 Voltage regulator R15 5000 ohm potentiometer F Fuse R21 75 ohm resistor F6 275A S7 Tilt level sensor F8 50A with U13 option SW Switch FB Flashing beacons option SW5 Function enable G Gauge SW6 Steer left right G6 Hour meter SW25 DIP switch G7 Battery charge indicator TS66 Platform up down toggle switch GND Ground U Electronic component H Horn or alarm U3 Encoder printed circuit board H1 Horn 05 Electronic control module H2 Automotive style horn option U6 Motor controller H5 Multifunction alarm U9 Battery charger JC1 Joystick controller U13 Voltage inverter option KS1 Key switch U27 0 034 ohm inductor noise suppression L LED or light Y Valve coil L16 Lift Y1 Parallel L17 Drive Y1A High speed bypass option L19 Power Y2 Brake release L21 High Torque Steer right L25 Fault Y4 Steer left 15 Limit switch Y5 Drive reverse LS2 Platform up GS 3246 only Y6 Drive forward LS6 Platform down Y7 Platform down LS7 Pothole 8 Platform up LS8 Pothole Y9 Platform down GS 3246 only M5 Hydraulic power unit Y10 Auxiliary down GS 3246 only Y11 Auxiliary down GS 3246 only DIP SWITCHES 24V DC D7
139. m move it to the center of the Scissor arm and rotate down to a vertical position 34 Lower the scissor arms onto the safety arm Crushing hazard Keep hands AWARNING clear of the safety arm when lowering the platform 35 Raise the platform 7 to 8 feet 2 1 to 2 4 m 36 Return the safety arm to the stowed position 37 Lower the platform to the stowed position 38 Raise the machine approximately 2 inches 5 cm 39 Remove the blocks from under both wheels 40 Lower the machine and remove the jack Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section Ae Repair Procedures REV How to Install and Calibrate the 2 Level Sensor This procedure is for the following models GS 2032 Australia models GS 2032 CE models before serial number GS3204 51683 e 95 2632 ANSI CSA and Australia models GS 2632 CE models before serial number GS3204 51683 ADANGER Tip over hazard Failure to install or calibrate the tilt 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 Perform this procedure with the machine on a firm level surface that is free of obstructions 1 Remove the platform controls from the platform 2 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both th
140. m floor Secure the weight to the platform Refer to the chart below GS 2032 363 kg GS 2632 227 kg TROUBLESHOOTING THE PLATFORM OVERLOAD SYSTEM SCISSOR COMPONENTS 14 Raise the platform to 25 cm less than full height 15 Lift the safety arm move it to the center of the Scissor arm and rotate down to a vertical position 16 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 17 Install the cover onto the platform overload pressure switch box and install and tighten the cover retaining fasteners Do not over tighten 18 Apply Sentry Seal to one of the fasteners securing the cover onto the platform overload pressure switch box 19 Return the safety arm to the stowed position 20 Using the machine controls lower the platform to the stowed position and remove all test weight from the platform 21 Calibrate the lift relief valve See 6 3 How to Adjust the Platform Lift Relief Valve CONDITION POSSIBLE CAUSE SOLUTION CANNOT LIFT RATED LOAD AT MAX HEIGHT THE PRESSURE SWITCH ALARM CONTINUES TO SOUND AFTER ADJUSTMENT RELIEF VALVE SETTING TURN OFF RED EMERGENCY STOP SYSTEM NEEDS TO BE RESET BUTTON WAIT THREE SECONDS AND TURN BACK ON UP LIMIT SWITCH OUT OF ADJUSTMENT INCREASE RELIEF VALVE PRESSURE LOWER THE UP LIMIT SWITCH SLIGHTLY WRONG RATED LOAD FOR HEIGHT BEING TESTED TURN
141. m serial number 17408 to 43000 Remove the retaining fastener from the center pivot pin of the bellcrank After serial number 43000 Remove the retaining fastener from the center pivot pin of the bellcrank Remove the pin Note the quantity and the location of the spacers on the bellcrank 3 Remove the retaining fasteners from the steer links at each end of the bellcrank Note the quantity and the location of the spacers in between the bellcrank and the steer links 4 Raise the machine approximately 14 inches 36 cm Place blocks under the chassis for support Crushing hazard The chassis will AWARNING fall if it is not properly supported 4 Turn the yokes to the side so the bellcrank can be removed 4 76 Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section 4 Repair Procedures REVA 9 1 Drive Brake How to Remove a Drive Brake When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Support and secure the entry ladder to an appropriate lifting device 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 Center a
142. may cause component damage Extremely dirty conditions may require that the filter be replaced more often Beware of hot oil Contact with ACAUTION hot oil may cause severe burns The hydraulic filter is mounted on the function manifold next to the hydraulic power unit 1 Clean the area around the oil filter Remove the filter with an oil filter wrench 2 Apply a thin layer of oil to the new oil filter gasket 3 Install the new filter and tighten it securely by hand 4 Use a permanent ink marker to write the date and number of hours from the hour meter if equipped on the filter 5 Turn the key switch to ground control and pull out the Emergency Stop button to the on position at both the ground and platform controls 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 during the replacement procedure Properly dispose of the used filter Part No 72963 Genie GS 2032 and GS 2632 3 17 Section 3 Scheduled Maintenance Procedures September 2006 CHECKLIST B PROCEDURES B 12 Check the Module Tray Latch Components Maintaining the module tray latch components in good condition is essential to good performance and service life Failure to detect worn out latch components may result in module trays opening unexpectedly creating an unsafe operating condition Models before serial n
143. mbol used to alert personnelto potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Red used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury ADANGER AWARNING O 2n9e sed to indicate the presence of a potentially hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert symbol ACAUTION used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Green usedto indicate operation ormaintenance information other protective clothing if the situation e Be sure to wear protective eye wear and warrants it such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes aware of potential crushing hazards Workplace Safety Be sure to keep sparks flames and Ae lighted tobacco away from flammable and combustible materials like battery gases and engine fuels Always have an approved fire extinguisher within easy reach Be sure that all tools and working areas IW are properly maintained and ready f
144. ming a series of steps Part No 72963 Genie GS 2032 and GS 2632 4 1 Section Ae Repair Procedures June 2004 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 or toggle Switch 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 contains an electronic circuit board joystick membrane decal buttons switches and LEDs Potentiometer equipped joysticks can be adjusted to maintain performance For further information or assistance consult the Genie Industries Service Department REV B N EMERGENCY STOP BUTTON S d nm LY JC1 U3 b JOYSTICK PLATFORM CONTROLLER CONTROLS CIRCUIT BOARD 09 gt Platform controls with potentiometer equipped joystick EMERGENCY STOP BUTTON SS Ki e COU
145. move the lift cylinder index 8 from the machine AWARNING Crushing hazard The lift cylinder index 8 may become unbalanced and fall when it is removed from the machine if it is 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 CAUTION 51 Place a 4 x 4 x 48 inch 10 cm x 10 cm x 1 2 m long block across both sides of the chassis under the number 1 center pivot pin index 10 52 Attach a lifting strap from an overhead crane to the number 1 inner arm index 11 at the non steer end Raise the number 1 inner arm and remove the safety arm Lower the number 1 inner arm index 11 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 Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section 4 Repair Procedures REV B 53 Remove the cables and hydraulic hoses from the number 1 inner arm index 11 and lay them to the side Component damage hazard CAUTION Cables and hoses can be damaged if they are kinked or pinched 54 Support and secure the entry ladder to an appropriate lifting device 55 Remove the entry ladder mounting fasteners Remove the entry ladder from the machine Crushing hazard The entry ladder ACAUTION may become unbalanced and fall if not properly supported
146. nd GS 2632 ix June 2004 Section 6 Rev Schematics INTOGUCTION 6 1 Control Relay Layout 65 2032 ANSI CSA and Australia models 6 2 B Control Relay Layout GS 2032 CE models GS 2632 all models 6 3 B ECMPin outLegend 2 6 4 B Platform Controls Wiring Diagram models with potentiometer equipped joystick 6 6 A Platform Controls Wiring Diagram models with hall effect 6 7 B Ground Controls Wiring Diagram 6 8 B Level Sensor Box Wiring Diagram 2 6 9 B Electrical Symbols Legend ire 6 10 Electrical Schematic from serial number 17408 to 21064 6 11 B Electrical Schematic from serial number 21065 to 25141 6 13 B Electrical Schematic from serial number 25142 to 28936 6 15 B Electrical Schematic from serial number 28937 40925 6 17 B Electrical Schematic from serial number 40926 to 48103 6 19 A Electrical Schematic from serial number 48104 to 49299
147. nd from joystick White wire at platform Spare A4 Emergency Stop from platform Red wire at platform A5 Level sensor power A6 Platform up valve coil A7 Drive reverse valve coil A8 Motor controller terminal 1 A9 Motor controller terminal 3 A10 Overload sensor A11 Key switch to platform A12 Platform down from ground controls B1 Platform data link Blue wire at platform B2 Emergency Stop to platform Black wire at platform B3 Ground for electronic control module B4 Spare B5 Spare B6 Platform down valve coil B7 Steer left valve coil B8 Automotive style horn option B9 Multifunction alarm B10 Pothole limit switch B11 Spare B12 Platform up from ground controls C1 Platform data link Yellow wire at platform C2 Emergency Stop at ground controls main power C3 Spare C4 Spare C5 Spare C6 Drive forward valve coil C7 Steer right valve coil C8 Parallel coil c9 Brake release valve coil C10 Spare C11 Level sensor signal C12 Down limit switch Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section 6 Schematics REV B ECM PIN OUT LEGEND From serial number 25142 to 36100 Item Description A1 Flashing beacon A2 Platform ground from joystick Blue wire at platform 4 Emergency Stop from platform White wire at platform 5 Level sensor power A6 Pl
148. nd pull out the 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 item BC or CC 15 While activating the platform up function adjust the internal hex socket clockwise just until the platform begins to raise 16 Fully lower the platform 17 Add an additional 100 pounds 45 4 kg to the platform Secure the additional weight 18 Raise the platform slightly Result The power unit should not be able to lift the platform Result If the power unit lifts the platform adjust the internal hex socket counterclockwise until the adjustment is correct 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 height add hydraulic oil until the pump is functioning correctly Do not overfill the hydraulic reservoir CAUTION Component damage hazard Do not continue to operate the machine if the hydraulic pump is cavitating Part No 72963 Genie GS 2032 and GS 2632 Section Ae Repair Procedures June 2004 MANIFOLDS 6 7 Valve Coils How to Test a Coil A properly functioning coil provides an electromotive force which operates the solenoid valve Critical to normal operation is continuity within the coil that provides this force field AWARNING Electrocution hazard
149. ne until the number 1 inner arm will clear the level sensor box Component damage hazard Be CAUTION careful not to damage the level sensor box limit switch or level sensor while moving the scissor assembly 17 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 ADANGER Crushing hazard The scissor assembly will fall if both wear pads are allowed to slide out of the drive chassis SCISSOR COMPONENTS 18 Remove the old wear pad Note the position of the wear pad before it is removed so when the new one is installed it will be in the correct position 19 Install the new wear pad 20 Move the scissor assembly towards the other side of the machine until the other scissor arm wear pad is accessible ADANGER Crushing hazard The scissor assembly will fall if both wear pads are allowed to slide out of the drive chassis 21 Remove the old wear pad Note the position of the wear pad before it is removed so when the new one is installed it will be in the correct position 22 Install the new wear pad 23 Slide the scissor assembly back into the drive chassis 24 Lower the scissor assembly into position and install the pivot pins CAUTION Component damage hazard Be careful not to damage the level sensor box limit switch or level sensor
150. nents when the number 1 inner arm index 11 is removed from the machine CAUTION Part No 72963 Genie GS 2032 and GS 2632 Section Ae Repair Procedures June 2004 SCISSOR COMPONENTS How to Replace the Scissor Arm Wear Pads 1 Remove the platform See 2 1 How to Remove the Platform 2 Remove the mounting fasteners from the stationary wear pads on the platform Note the position of the wear pads before they are removed so when the new ones are installed they will be in the correct position 3 Support and secure the entry ladder to an appropriate lifting device 4 Remove the entry ladder mounting fasteners Remove the entry ladder from the machine Crushing hazard The entry ladder ACAUTION may become unbalanced and fall if not properly supported and secured to the lifting device Raise the platform 6 to 7 feet 1 8 to 2 1 m Lift the safety arm move it to the center of the Scissor arm and rotate down to a vertical position 7 Lowerthe scissor arms onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 8 Markthe mounting position of the level sensor box on the drive chassis 9 Remove the level sensor box cover REV B 10 Mark the mounting position of the level sensor on the level sensor box 11 Remove the level sensor box mounting fasteners and slide the box towards the non steer end of the machine as far as it can go Compone
151. nfinite ohms Replace the drive speed select valve coil item AJ or Bl or CJ Part No 72963 Genie GS 2032 and GS 2632 5 29 Section 5 Troubleshooting Flow Charts June 2004 ECC UE E SSS LLL SSS REVA This page intentionally left blank 5 30 Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section Ge 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 Be sure that all necessary tools and test equipment are available and ready for use Schematics About This Section There are two groups of schematics in this section An illustration legend precedes each group of drawings Electrical Schematics AWARNING Electrocution hazard Contact with electrically charged circuits 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 squir
152. ng 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 Perform this procedure with the platform in the stowed position Disconnect the battery pack from the machine AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Remove the return filter mounting bracket fasteners from the manifold Push the filter and accumulator out of the way Tag disconnect and plug the hydraulic pump inlet hose at the side of the hydraulic tank Remove the hydraulic tank retaining fasteners and remove the hydraulic tank from the machine Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section 4 Repair Procedures EVA Steer Axle Components 8 1 7 Tag disconnect and plug the hydraulic hoses Yoke and Drive Motor on the drive motor Cap the fittings Bodily injury hazard Spraying How to Remove the Yoke AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic and Drive Motor When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications Block the non steer wheels Center a lifting jack under the drive chassi
153. nnect plug R replace the harness pigtail Repair or replace the quick disconnect plug OR replace the control cable Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section 5 Troubleshooting Flow Charts REVA CHART 16 P2 EMERGENCY STOP BUTTON 9 MS u JC1 JOYSTICK CONTROLLER U3 PLATFORM a CONTROLS CIRCUIT BOARD Q Q Platform controls circuit board voltage regulator terminal 2 voltage regulator terminal 1 circuit board voltage regulator voltage regulator terminal 3 y Part No 72963 Genie GS 2032 and GS 2632 Section 5 Troubleshooting Flow Charts June 2004 CHART 16 Check for voltage at terminal 3 of the voltage regulator on U3 Replace U3 Continued from page 26 Check for continuity in Check for continuity in At X Consult the Genie the blue data line the green data line or Industries Service from pin D of the inuity the yellow data line Department platform controls quick from pin E of the disconnect to terminal platform controls quick B1 at U5 disconnect to terminal C1 at U5 no continuity Replace the coil cord no continuity assembly OR replace the control cable from the platform to U5
154. nt damage hazard Be CAUTION careful not to damage the level sensor box limit switch level sensor or wiring while moving the level sensor box 12 Secure the ends of the scissor arms together at both ends of the machine with a tie down strap or other appropriate device 13 Remove the pin retaining fasteners from the number 1 inner arm pivot pins item 11 at the steer end of the machine Use a slide hammer to remove the pins 14 Attach a lifting strap from an overhead crane to the steer end of the scissor arms 15 Slide the forks from a forklift under the scissor arms at the non steer end of the machine 16 Raise the scissor arms up with the overhead crane until the number 1 inner arm will clear the level sensor box CAUTION Component damage hazard Be careful not to damage the level sensor box limit switch or level sensor while moving the scissor assembly 17 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 Vay Crushing hazard scissor A DANGER assembly will fall if both wear pads are allowed to slide out of the drive chassis Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section 4 Repair Procedures REV B SCISSO
155. ntrols circuit board retaining fasteners 6 Carefully remove the platform controls circuit board from the platform control box lid PLATFORM CONTROLS 1 2 Joystick Controller Maintaining the joystick at the proper setting is essential to safe machine operation The joystick should operate smoothly over its entire range of motion Platform controls equipped with Hall effect joysticks do not require any calibration How to Calibrate the Potentiometer equipped Joystick 1 Turn the key switch to platform controls and pull out the Emergency Stop button to the on position at both the ground and platform controls 2 Remove the platform control box lid retaining fasteners Open the control box lid AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Part No 72963 Genie GS 2032 and GS 2632 4 3 Section Ae Repair Procedures June 2004 PLATFORM CONTROLS 3 Locate the potentiometer on the base of the joystick ol JC1 U U3 PLATFORM CONTROLS BOARD 9 joystick controller JC1 potentiometer shaft slot potentiometer shaft set screw platform controls circuit board U3 potentiometer brown wire purple wire ro Oo o 4 With a volt meter set to read DC volt
156. o 200 20V DC with diode schematic items AH AJ BL CJ and CN Solenoid valve 3 position 4 way 18 to 200 20V DC with diode schematic items AK BJ and CK Solenoid valve 3 position 4 way 25 to 27Q 20V DC with diode schematic items AG BH and CH Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Part No 72963 Genie GS 2032 and GS 2632 2 3 Section 2 Specifications June 2004 pma M SPECIFICATIONS REVA 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 11 4 8 40 ft lbs 54 2 Nm 8 3 4 16 1 10 69 ft lbs 93 6 Nm 10 7 8 14 1 12 93 ft lbs 126 1 Nm 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 8 12 1 24 208 ft lbs 282 Nm 24 1 7 8 12 1 SAE O ring Boss Port tube fitting installed into Steel SAE
157. o the ON light is position on From serial number 17408 to 21262 activate the function enable switch and activate the steer rocker switch in the LEFT direction and check to see if the error indicator light at the platform controls is on After serial number 21262 press the drive function select button and activate the function enable switch and activate the steer rocker switch in the LEFT direction and check to see if the error indicator light at the platform controls is on light is not on Activate the function enable switch and activate the steer left L function Does the motor turn on yes Continued on the next page Connect the positive lead from a volt meter to the WH C7 rt coil wire terminal at the steer right directional valve Coil item AF or BI OV without disconnecting the wire and the negative lead of the volt meter to the brown ground wire at the valve coil Activate the steer rocker switch in the RIGHT direction and check the voltage 20V or more Disconnect the wires from the coil on the 25 to 27 steer left directional ohms valve on the function manifold item AF or Bl and check the resistance of the valve coil See Repair Section 0 or infinite ohms Replace the steer left directional valve coil item AF or Check continuity of the steer left right microswitch SW6 inside the joystick controller handle JC1 good Repair or replace the wire
158. on at platform controls SW25 DIP switch U3 Platform controls circuit board REV B WIRE COLOR LEGEND Color Description BL Blue BK Black BN Brown GN Green GY Gray OR RD Red WH White YL Yellow Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section 6 Schematics Platform Controls Wiring Diagram REVA models with hall effect joystick d EMERGENCY STOP BUTTON KEN E SW25 DIP SWITCH RD gp PLATFORM CONTROLS GN 5 CIRCUIT BOARD 0000 eiea 000000 N d 00000000 IV N S GR B L 3 CEON JC1 GN Mila e elle g Ke amp m o YL BL WH BK RD 2 S SS _ H1 ALARM TO COIL CORD ASSEMBLY WIRE COLOR LEGEND Color Description BL Blue BK Black ABBREVIATION LEGEND Brown Description GN Green H1 Alarm GY Gray Joystick controller OR Orange PP Purple P2 Emergency Stop button at platform controls RD Red Sw25 DIP switch
159. ons operate normally Be sure the circuit breaker and fuse are not tripped or blown Be sure the batteries are fully charged and properly connected From serial number 17408 to 21262 With the key switch turned to platform controls and both Emergency Stop m buttons pulled out to the light is ON position press and hold the lift function enable button and activate the controller in the UP direction and check to see if the error indicator light at the platform controls is on After serial number 21262 With the key switch turned to platform controls and both Emergency Stop buttons pulled out to the ON position press the lift function select button and activate the controller in the UP direction and check to see if the error indicator light at the platform controls is on light is not on install a0 to 5000 PSI 3000 345 bar pressure more gauge at the quick disconnect coupling item AA or BA on the function manifold and activate the platform up function less than 3000 PSI Adjust the system relief valve item AC or BC OR repair or replace the platform lift cylinder OR the platform lowering valve item D may be stuck open OR the function manifold could have an internal defect Consult the Genie Industries Service Department Connect the positive lead from a volt meter to the coil on the platform up directional valve item AG or BG wire terminal w
160. option SW5 Function enable G Gauge SW6 Steer left right POUT11 G6 Hour meter SW25 DIP switch G7 Battery charge indicator TS66 Platform up down toggle switch LAT FO GND Ground U Electronic component 7 H Horn or alarm Encoder printed circuit board H Q L L E H H1 Horn 05 Electronic control module H2 Automotive style horn option U6 Motor controller H5 Multifunction alarm U9 Battery charger JC1 Joystick controller U13 Voltage inverter option KS1 Key switch U27 0 034 ohm inductor noise suppression L LED or light Y Valve coil L16 Lift Y1 Parallel L17 Drive Y1A High speed bypass option L19 Power Y2 Brake release WIRE COLOR LEG END 8 L21 High Torque Y3 Steer right Color Description Color Description Eos BL Blue RD Red LS Limit switch Drive reverra BK Black WH White LS2 Platform up GS 3246 only Y6 Drive forward BN Brown YL Yellow LS6 Platform down Y7 Platform down z _ Y8 Platform GN Green WH BL White Blue LS7 Pothole p LS8 Pothole Y9 Platform down GS 3246 only GY Gray WH BK White Black 5 Hydraulic power unit Y10 Auxiliary down GS 3246 only OR Orange WH RD White Red Y11 Auxiliary down GS 3246 only PP Purple WH YL White Yellow Part No 72963 Genie GS 2032 and GS 2632 June 2004 Section 6 Schematics E Electrical Schematic from serial number 49300 to 59999
161. or use Keep work surfaces clean and free of debris that could get into machine components and cause damage that your workshop or work area is A properly ventilated and well lit 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 i Be sure any forklift overhead crane or Be sure that fasteners intended for one ZA time use i e pins and self locking nuts are not reused These components may fail if they are used a second time Be sure to properly dispose of old oil or 2 other fluids Use an approved container Please be environmentally safe iv Genie GS 2032 and GS 2632 Part No 72963 June 2004 Table of Contents Introduction Important INFOMMALION eresi ii Section 1 Safety Rules General Safety Rules A iii Section 2 Rev Specifications A Machine Specifications esu dea ense a 2 1 A Performance Specifications 04 24 2 1 Hydraulic Specifications A 2 2 Manifold Component Specifications 2 3 A Hydraulic Hose and Fitting Torque Specifications eeeeeeneeeeeeeeeeere ee 2 4 Section 3 Rev Scheduled Maintenance Procedures ati foro B RT 3 1 Pre delivery Preparation
162. ove the Platform Perform this procedure with the platform extension fully retracted and locked in position 1 Machines with voltage inverter Disconnect the battery pack from the machine AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Disconnect the battery pack from the machine before removing the platform 2 Lowerthe platform to the stowed position 3 Remove the retaining fastener that holds the platform controls quick disconnect plug to the bottom of the platform 4 Disconnect the plug from the platform controls 5 Remove the cover from the AC outlet Label and disconnect the wiring from the outlet 6 Pullthe wiring through the platform tube If your machine is equipped with an air line to platform option the air line must be disconnected from the platform before removal 7 Supportthe platform with a forklift at the non steer end Do not lift it REV B 8 Attach a strap from the platform railings to the carriage on the forklift to help support the platform 9 Remove the platform pivot pin retaining fasteners from the platform pivot pins at the steer end of the machine 10 Use a slide hammer to remove the pins AWARNING Crushing hazard The platform will fall if it is not properly supported 11 Remove the plugs from the access holes in the side of the platform 12 Lift the steer end of the platform slightly to clear the scissor arms an
163. ow 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 The location of terminals mentioned in this section can be found on the appropriate electrical or hydraulic schematics provided in Section 6 Schematics Since various degrees of a particular function loss may occur selecting the appropriate flow chart may be troublesome When a function will not operate with the same speed or power as a machine in good working condition refer to the flow chart which most closely describes the problem General Repair Process Malfunction discovered Identify symptoms Troubleshoot Y problem Still exists Perform repair Retum to Service problem Solved LED Diagnostic Readout The diagnostic readout displays numerical codes that provide information about the machine operating status and about malfunctions The dot to the right of the numbers will blink during normal operation codes and remain on with fault codes The codes listed in the Fault Code Chart describe malfunctions and can aid in troubleshooting the machine by pinpointing the area or component affected 5 2 Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section 5 Troubleshooting Flow Charts m Fault Code Cha
164. pan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Korea Phone 82 25 587 267 Fax 8225 583 910 Genie U K Phone 44 0 1476 584333 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 431 183 581 102 Fax 31 183 581 566
165. pection report contains checklists for each type of scheduled inspection Make copies of the Maintenance Inspection Report to use for each inspection Store completed forms for three years 3 2 Genie GS 2032 and GS 2632 Part No 72963 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 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 Genie Industries USA 18340 NE 76th Street PO Box 97030 Genie UK The Maltings Wharf Road Grantham Lincolnshire Redmond WA 98073 9730 NG31 6BH England 425 881 1800 44 1476 584333 Copyright 2002 by Genie Industries Genie is a registered trademark of Genie Industries RevA Instructions Use the operator s manual on your machine The Pre delivery Preparation consists of
166. pment and special installation instructions for the approved optional fluids Consult the Genie Industries Service Department before use REVA Function pump Type Gear Displacement per revolution 0 244 cu in 4 cc Flow rate 2500 psi 172 bar 4 gpm 15 L min 10 micron with 25 psi 1 7 bar bypass Hydraulic tank return filter Function manifold System relief valve pressure maximum 3500 psi 241 bar Lift relief valve pressure 3000 to 3200 psi 207 to 221 bar Steer relief valve pressure 1500 psi 103 bar Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section 2 Specifications REVA Manifold Component Specifications Plugtorque SAE No 2 50 in lbs 6 Nm SAE No 4 13 ft Ibs 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 SPECIFICATIONS Valve Coil Resistance Description Specification Solenoid valve N C 23 25 2 position 2 way 20V DC schematic item D before serial number 28937 Solenoid valve N C 23 25 2 position 2 way 20V DC with diode schematic item D after serial number 28936 Solenoid valve 2 position 2 way N O 25 to 270 20V DC with diode schematic items CI and CL Solenoid valve 2 position 4 way 18 t
167. protect the electrical system resulting in a tripped circuit breaker or component damage AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Testthe coil for resistance See 6 8 How to Test a Coil 2 Connecta 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 The battery should read 9V DC or more when measured across the terminals Resistor 100 Genie part number 27287 o COIL 4 Een 100 9V RESISTOR BATTERY multimeter 9V DC battery 100 resistor coil Note Dotted lines in illustration indicate a reversed connection as specified in step 6 Oo MANIFOLDS Set a multimeter to read DC amperage The multimeter when set to read DC amperage should be capable of reading up to 800 mA Connect the negative lead to the other terminal on the coil If testing a single terminal coil connect the negative lead to the internal metallic ring at either end of the coil Momentarily connect the positive lead from the multimeter to the positive terminal on the 9V battery Note and record the current reading At the battery or coil terminals reverse the connections Note and record the current reading Result Both current readings are greater than 0 mA and are dif
168. ption Diagnostic DIP S sis Display Switch 5 2 Dik E Code Code ojo 83 8 Aaa 51555 2552 z 515 121915 82 10000000 33 1000100 34 100010001 35 10010000 e 36 1010000 37 110000001 38 100011001 Jele 39 j100000100 40 j101000100 ie 441 11000100111 fe 42 10011100 L 48 10101100 44 110011001 Jele p 45 j101100100 ele 4e 11010100 47 11100100 48 10111100 1 49 110111001 let Jejeje 50 pls ele 51 11110100 587 qme siepe 53 1001000 ele 54 10100000 fe 95 1100100011 56 10111000 Jejeje _57__ 11011000755 Leet TECH 58 mool Je 59 11111000 60 j1011000 feje 61 11010000 62 q11000 6 111000001 leste PLATFORM CONTROLS DIP Switch Function Definitions If replacing the circuit board note the toggle positions of the DIP switch before removal Set the DIP Switch toggle positions on the new circu
169. ption SW5 Function enable G Gauge SW6 Steer left right G6 Hour meter SW25 DIP switch G7 Battery charge indicator TS66 Platform up down toggle switch GND Ground U Electronic component H Horn or alarm U3 Encoder printed circuit board H1 Horn 05 Electronic control module H2 Automotive style horn option U6 Motor controller H5 Multifunction alarm U9 Battery charger JC1 Joystick controller U13 Voltage inverter option KS1 Key switch U27 0 034 ohm inductor noise suppression L LED or light Y Valve coil L16 Lift Y1 Parallel L17 Drive Y1A High speed bypass option 119 Power 2 Brake release m WIRE COLOR LEG END L21 High Torque Steer right Color Description Color Description L25 Fault Ster lon BL Blue RD Red LS Limit switch 2 BK Black WH White LS2 Platform up GS 3246 only Y6 Drive forward BN B YL Yell LS6 Platform down Y7 Platform down rown mE LS7 Pothole Y8 Platform up GN Green WH BL White Blue LS8 Pothole 9 Platform down GS 3246 only GY Gray WH BK White Black 5 Hydraulic power unit Y10 Auxiliary down GS 3246 only OR Orange WH RD White Red Y11 Auxiliary down GS 3246 only PP Purple WH YL White Yellow POUT11 PIN11 E D C B A 1 JCT Joystick CONTROLLER WH YL 5000 OHM SW 6sreer POTENTIOMETER e 2 SW5 FUNCTION ENABLE Ze 3 POWER LED 119 FAULT LED L25 E HIGH TO
170. pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Push in the 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 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 2032 and GS 2632 Part No 72963 September 2006 Section 3 Scheduled Maintenance Procedures REV D B 5 Test the Key Switch Proper key switch action and response is essential to safe machine operation The machine can be operated from the ground or platform controls and the activation of one or the other is accomplished with the key switch Failure of the key switch to activate the appropriate 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 Emergency Stop button to the on position at both the ground and platform controls 2 Turn the key switch to platform control 3 Checkthe platform up down function from the ground control
171. r serious injury Do not raise the platform above the maximum load position of the capacity indicator decal on the side of the platform To perform this step the lift relief valve will need to be adjusted Lift the safety arm move it to the center of the scissor arm and rotate down to a vertical position Remove the cover from the platform overload pressure switch box 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 To allow the platform overload system to reset the red Emergency Stop button must be cycled after each quarter turn of the nut Turning the nut into the hydraulic line will deactivate the alarm turning the nut out of the hydraulic line will activate the alarm 4 34 Genie GS 2032 and GS 2632 Part No 72963 June 2006 Section Ae Repair Procedures REV D 9 Slowly turn the nut of the platform overload pressure switch out of the hydraulic line just until the overload alarm sounds To allow for the platform overload System delay wait 3 seconds between each quarter turn of the nut 10 Turn the nut one quarter turn into the hydraulic line 11 Return the safety arm to the stowed position 12 Using the manual lowering knob lower the platform to the stowed position and remove all test weight from the platform 13 Using a suitable lifting device place a test weight in the center of the platfor
172. rcuit breaker and fuse are not tripped or blown Be sure the batteries are fully charged and properly connected Open the platform control box With the key switch turned to platform controls and both ov Emergency Stop buttons pulled out to the ON position check for voltage on the positive terminal 1 of the Emergency Stop button P2 at the platform controls 20V or more With the negative lead of ohmmeter connected to the negative terminal of the battery B5 check for voltage at terminal 1 of the voltage regulator on the platform controls circuit board U3 20V or more Continued on page 28 Before serial number 25142 Check for voltage on terminal B2 atthe 05 After serial number 25141 Check for voltage on terminal 30 at relay CR48 20V or more Disconnect the control cable quick disconnect DV plug at the ECM and check for voltage at terminal C of the quick disconnect plug 20V or more Connect the control cable quick disconnect plug at the ECM Disconnect the control cable quick disconnect plug at the platform and check for voltage at terminal C of the quick disconnect plug 20V or more Replace the coil cord assembly OR replace the platform controls Repair or replace the wire between P2 and U3 REVA Before serial number 25142 Replace U5 After serial number 25141 Troubleshoot CR48 Repair or replace the disco
173. replace the ECM U5 OR consult the Genie Industries Service Department Replace the shuttle valve item B OR replace the brake release valve item A OR the function manifold or brake release manifold may have an internal defect OR consult the Genie Industries Service Department Part No 72963 Genie GS 2032 and GS 2632 Section 5 Troubleshooting Flow Charts June 2004 Chart 11 Drive Forward Function Inoperative Be sure all other functions operate normally Be sure the circuit breaker and fuse are not tripped or blown Be sure the batteries are fully charged and properly connected With the key switch Connect the positive lead from a volt meter to the drive forward directional valve coil item Al or BJ wire terminal without disconnecting the wire and the negative lead of the volt meter to the brown ground wire on the coil Activate drive in the forward direction and check the voltage turned to platform controls and both Emergency Stop buttons pulled out to the ON position activate drive controller in the forward direction and check to see if the error indicator light at the platform controls is on light is on 20V or more Disconnect the wires from the drive forward directional valve coil item Al or BJ and check resistance of the coil See Repair Section light is not on 18 to 20 ohms Repair or replace the drive forward directional valve item Al or BJ
174. 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 Illustration 2 a drive forward reserve valve Genie GS 2032 and GS 2632 Part No 72963 September 2006 Section 3 Scheduled Maintenance Procedures REV D 10 Tag the forward and the reverse valve coils Remove the coils from the valve The forward valve coil has white and brown wires attached The reverse valve coil has white black and brown wires attached For reassembly it will be helpful to leave the wire harness attached to the valve coils For GS 2032 and GS 2632 before serial number GS3204 51608 proceed to step 11 For GS 2032 and GS 2632 after serial number GS3204 51607 proceed to step 20 11 Remove the drive forward reverse valve from the function manifold Cap the open port of the manifold 12 Carefully inspect the hex portion of the valve for an identification stamp O 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 Proceed to step 18 13 Install the drive forward reverse valve removed in step 11 into the function manifold and
175. ring handle at the ground controls platform does not lower Are there mechanical restrictions keeping the platform from lowering no yes Remove mechanical restrictions keeping the platform from lowering REVA Repair open in the WH B6 down coil wire from the platform lowering valve coil item D to the ECM U5 OR repair open in the brown ground wire circuit from the coil to the battery module tray OR replace U5 OR consult the Genie Industries Service Department Replace platform lowering valve coil item 0 Repair or replace the platform lowering valve cartridge item D Repair or replace the platform lowering valve cartridge item D OR repair or replace the lift cylinder OR replace the orifice or orifice washer item E OR consult the Genie Industries Service Department Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section 5 Troubleshooting Flow Charts esc E REVA This page intentionally left blank Part No 72963 Genie GS 2032 and GS 2632 5 13 Section 5 Troubleshooting Flow Charts June 2004 Chart 8 Steer Left Function Inoperative Be sure all other functions operate normally Be sure the circuit breaker and fuse are not tripped or blown Be sure the batteries are fully charged and properly connected With the key switch turned to platform controls and both Emergency Stop buttons pulled out t
176. rive functions should not operate 52 Lift the safety arm move it to the center of the Scissor arm and rotate down to a vertical position 5 Lower the scissor arms onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 54 Install the tilt level sensor box cover 55 Raise the platform slightly 56 Return the safety arm to the stowed position 57 Lower the platform to the stowed position 58 Raise the machine approximately 2 inches 5 cm 59 Remove the blocks from under both wheels 60 Lower the machine and remove the jack REV C 4 4 Level Sensor after serial number 47664 The tilt sensor sounds when the incline of the chassis exceeds the rating on the serial plate How to Install and Calibrate the 1 5 Level Sensor This procedure is for the following models GS 2032 ANSI and CSA models GS 2032 CE models after serial number GS3204 51682 GS 2632 CE models after serial number GS3204 51682 DANGER Tip over hazard Failure to install or calibrate the tilt 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 Perform this procedure with the machine on a firm level surface that is free of obstructions 1 Remove the platform controls from the platform 2 Turn the key s
177. rm 7 to 8 feet 2 1 to 2 4 m Result The tilt sensor alarm should sound W Result If the tilt sensor alarm does not sound adjust the tilt level sensor until the alarm just begins to sound OR the down limit switch may need to be adjusted CE models When the platform is raised 7 to 8 feet 2 1 to 2 4 from the ground an alarm should sound and the lift and drive functions should not operate Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section Ae Repair Procedures REV 52 Lift the safety arm move it to the center of the Scissor arm and rotate down to a vertical position 53 Lower the scissor arms onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 54 Install the tilt level sensor box cover 55 Raise the platform approximately 7 to 8 feet 2 1 to 2 4 m 56 Return the safety arm to the stowed position 57 Lower the platform to the stowed position 58 Raise the machine approximately 2 inches 5 cm 59 Remove the blocks from under both wheels 60 Lower the machine and remove the jack GROUND CONTROLS How to Install and Calibrate the 2 Level Sensor This procedure is for the following models GS 2032 CE and Australia models GS 2632 ADANGER Tip over hazard Failure to install or calibrate the tilt level sensor as instructed will cause death or serious injury Do not install or calibrate the level sensor other t
178. rm controls to CR48 OR repair or replace the CR48 socket OR replace CR48 Replace positive battery cable from the B terminal at U6 to D1 at 5 Replace the cable from the terminal at U6 to QD1 OR repair or replace QD1 OR replace the cable from QD1 to F6 OR replace F6 OR replace the cable from F6 to B5 Replace ground cable from A1 at M5 to M at U6 REVA Repair open in the ground cable circuit from terminal A1 at M5 to terminal M at U6 OR replace M5 OR consult the Genie Industries Service Department Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section 5 Troubleshooting Flow Charts EIL I n1 REVA CHART 2 Check for continuity in Replace ground cable the ground cable circuit from the B terminal at from the B terminal at U6 to QD1 OR repair or U6 through QD1 to the replace QD1 OR replace battery B5 the cable from QD1 to B5 Continued from the previous page continuity Activate the lift function Repair open in the WH and check voltage on A8 motor contr enable terminal 1 at U6 wire from terminal 1 at U6 to pin A8 of the AMP connector at ECM U5 20V or more Activate the lift function Repair open in the WH and check voltage on A9 motor cont enable terminal 3 at U6 wire from pin A9 at U5 to terminal 3 at U6 OR replace U5 OR consult the Genie Industries Service Department Replace M5 OR consult the Genie Industries Serv
179. rm down Y8 Platform GN Green WH BL White Blue LS7 Pothole p 158 Pothole Y9 Platform down 095 3246 only GY Gray WH BK White Black M5 Hydraulic power unit Y10 Auxiliary down GS 3246 only OR Orange WH RD White Red Y11 Auxiliary down GS 3246 only PP Purple WH YL White Yellow Part No 72963 Genie GS 2032 and GS 2632 6 20 June 2004 Section 6 Schematics E Electrical Schematic from serial number 40926 to 48103 Section 6 Schematics June 2004 Electrical Schematic REVA from serial number 48104 to 49299 A B C D E F G H L M ay 1 1 QD4 gt B ote TOF _ Ter WH RD 77F a WH A A RN x CR48 7 cz BL B B Y CB2 P1 PLATFORM POWER y e 5 BK D DH 7A EMERGENCY CONTROL KS1 RELAY 87A 87 85 CIRCUIT STOP KEY SWITCH TOUS OR E BREAKER B1 ie es 23D 2 RS 39C GROUND NC 4 0 1 NcHO CONTROL 156 H5 PS2 t 157 DOWN MULTI PLATFORM POTHOLE LI
180. rt after serial number 17407 Fault Code Problem Possible Causes Solution 01 Internal ECM error EPROM not programmed Replace ECM 02 See Chart 16 ECM Platform communication error Malfunctioning control cable OR malfunctioning platform controls Troubleshoot control cable OR troubleshoot platform controls 03 Undefined platform DIP switch settings DIP switch settings incorrect Correct DIP switch settings 12 See Chart 4 Chassis up down toggle closed at start up Malfunctioning up down switch Troubleshoot up down switch 18 See Charts 10 13 or 14 19 See Chart 15 42 See Chart 5 or Chart 8 Pothole guard failure Limit switch failure Platform left turn switch fault Malfunctioning pothole switch OR obstruction in pothole guard linkage Malfunctioning limit switch OR wire disconnected from limit switch Malfunctioning steer left microswitch Troubleshoot pothole switch OR remove obstruction Troubleshoot limit switch OR inspect wire connection Troubleshoot steer left microswitch 43 See Chart 5 or Chart 9 Platform right turn switch fault Malfunctioning steer right microswitch Troubleshoot steer right microswitch 46 See Chart 5 Platform drive enable switch fault Malfunctioning drive enable switch Troubleshoot drive enable switch 47 52 See Chart 11 53 See Chart 12 Platform jo
181. rward reverse valve This indicates the machine is equipped with a dynamic brake valve Proceed to step 22 Wi 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 27 23 Install the drive forward reverse valve removed in step 20 into the function manifold and securely tighten 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 For the machine to function correctly the reverse valve coil must be closest to the manifold 25 Install the coil nut onto the valve and tighten 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 REV D 28 Contact the Genie Industries 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 Industries Scissors Service Department 1 800 536 1800 Ext 8710 Genie GS 2032 and GS 2632 Part
182. s Result The machine functions should not operate 4 Turn the key switch to ground control 5 Checkthe machine functions from the platform controls Q Result The machine functions should not operate 6 Turn the key switch to the off position Result No machine functions should operate CHECKLIST B PROCEDURES B 6 Test the Automotive style Horn if equipped A functioning horn is essential to safe machine operation The horn is activated at the platform controls and sounds at the ground as a warning to ground personnel An improperly functioning horn will prevent the operator from alerting ground personnel of hazards or unsafe conditions 1 Turn the key switch to platform control and pull out the Emergency Stop button to the on position at both the ground and platform controls 2 Push down the horn button at the platform controls Result The horn should sound Part No 72963 Genie GS 2032 and GS 2632 3 11 Section 3 Scheduled Maintenance Procedures September 2006 CHECKLIST B PROCEDURES B 7 Test the Drive Brakes Proper brake action is essential to safe machine operation The drive brake function should operate smoothly free of hesitation jerking and unusual noise Hydraulically released individual wheel brakes can appear to operate normally when not fully operational Perform this procedure with the machine on a flat level surface that is free of obstructions Be sur
183. s 6 Press and hold the function enable switch 7 Move and hold the joystick controller 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 item BD or CD 9 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure ADANGER Tip over hazard Failure to adjust the relief valves to specification could cause the machine to tip over resulting in 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 4 64 Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section 4 Repair Procedures REV How to Adjust the Steering Relief Valve before serial number 36101 1 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the test port item AB on the function manifold AC 9 K9 Je Ap gt AA 17 10 C 2 1 6 Su ar a steer relief valve b function manifold test port 2 Turn the key switch to ground control and pull out the Emergency Stop button to the on position at both the ground and platform controls MANIFOLDS 3 Press and hold the steer thumb rocker switch to the right Allow the wheel
184. s at the steer end of the machine Remove the cotter pin from the wheel castle nut connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Component damage hazard CAUTION Hoses can be damaged if they are kinked or pinched Support and secure the yoke assembly to an appropriate lifting device Remove the retaining fastener from the steer link at the yoke assembly Note the quantity and location of the spacers when disconnecting the steer link from the yoke Always replace the cotter pin with assembly a new one when removing the castle nut 10 Remove the retaining fastener from the top of 2 the yoke pivot shaft 4 Loosen the wheel castle nut Do not remove it Raise the machine approximately 11 Lower the yoke assembly out of the chassis 14 inches 36 cm Place blocks under the Bodily injury hazard The yoke chassis for support ACAUTION motor assembly may fall if not properly supported when it is AWARNING Crushing hazard The chassis will removed from the chassis fall if it is not properly supported During re assembly be sure that the spacers are installed onto the steer link 6 Remove the wheel castle nut Remove the wheel Part No 72963 Genie GS 2032 and GS 2632 4 73 Section Ae Repair Procedures June 2004 STEER AXLE COMPONENTS How to Remove a Drive Motor 1 Block the non steer wheels 2 Center a
185. s to completely turn to the right then continue holding the switch while observing the pressure reading on the pressure gauge Note the pressure 4 Press and hold the steer thumb rocker switch to the left Allow the wheels to completely turn to the left then continue holding the switch while observing the pressure reading on the pressure gauge Note the pressure Refer to Section 2 Specifications 5 Turn the machine off Hold the steering relief valve with a wrench and remove the cap item AE 6 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap ADANGER Tip over hazard Failure to adjust the relief valves to specification could cause the machine to tip over resulting in death or serious injury Do not adjust the relief valve pressures higher than specifications 7 Repeat steps 3 and 4 to confirm the relief valve pressure Part No 72963 Genie GS 2032 and GS 2632 Section Ae Repair Procedures June 2004 MANIFOLDS REV C How to Adjust the Models without traction control Steering Relief Valve from serial number 36101 to 49425 after serial number 36100 vA D BB 1 Connect 0 to 5000 psi 0 to 350 bar pressure BA gauge to the test port item or CA on the 3 C BC function manifold Ka Models with traction control z BD gy CB WS m Q Bm t NN 2 36
186. securely tighten 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 For the machine to function correctly the reverse valve coil must be closest to the manifold CHECKLIST B PROCEDURES 15 Install the coil nut onto the valve and tighten 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 Hemove a Drive Brake 18 Contact the Genie Industries Service Parts Department and order kit part number 105457 19 Install the new valve received in the kit and mark the new valve with a white paint pen to identify new valve installation 20 Repeat this procedure beginning with step 1 If the machine fails to stop within the specified stopping distance after installing new brakes please contact the Genie Industries Scissors Service Department 1 800 536 1800 Ext 8710 Part No 72963 Genie GS 2032 and GS 2632 3 13 Section Scheduled Maintenance Procedures September 2006 CHECKLIST B PROCEDURES 21 Remove the drive forward reverse valve from the function manifold Cap 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 portion of the drive fo
187. select and horn buttons and turn the key switch to platform controls Result The diagnostic display will show PS 4 Release the lift function select and horn buttons Result The diagnostic display will show the maximum lift speed percentage 5 REV B Press the drive function select button Result The diagnostic display will show the stowed drive speed percentage Genie Am om J N a function enable switch SW5 b joystick controller JC1 with thumb steering rocker SW6 horn button BN5 d machine on incline button BN6 e lift function select button BN9 f drive function select BN8 g red Emergency Stop button P2 Use the steering thumb rocker switch on the joystick to increase or decrease the stowed drive speed percentage Refer to Section 2 Specifications Turn the key switch to the off position Any change in software settings will not take effect until the key Switch is turned to the off position 4 8 Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section Ae Repair Procedures REV B How to Adjust the High Torque Drive Speed ADANGER Tip over hazard Do not adjust the lift and or drive speed higher than specified in this procedure Setting the drive speed greater than specifications could cause the machine to tip over resulting in death or serious injury A DANGER Tip over hazard This procedure must only be performed by a trained serv
188. sition 34 Lower the scissor arms onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 35 Raise the platform 7 to 8 feet 2 1 to 2 4 m 36 Return the safety arm to the stowed position 37 Lower the platform to the stowed position 38 Raise the machine approximately 2 inches 5 cm 39 Remove the blocks from under both wheels 40 Lower the machine and remove the jack Part No 72963 Genie GS 2032 and GS 2632 Section Ae Repair Procedures June 2004 Hydraulic Pump REVA 5 1 4 Activate the platform up function from the Function Pump ground controls Result If the pressure gauge reads The hydraulic pump is attached to an electric 3200 psi 221 bar immediately stop The pump motor which makes up the Hydraulic Power Unit is good Result If pressure fails to reach How to Test the Hydraulic Pump 3200 psi 221 bar the pump is bad and will When removing a hose assembly need to be serviced or replaced or fitting the O ring on the fitting CAUTION Component damage hazard and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Disconnect and plug the high pressure hydraulic hose from the hydraulic pump Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to al
189. snap rings from the number 3 pivot pin index 14 7 Usea soft metal drift to remove the number pivot pin index 14 Remove the number 3 outer arm index 13 from the machine ACAUTION Bodily injury hazard The number 3 outer arm index 13 may become unbalanced and fall if not properly supported when it is removed from the machine 8 Remove the cable clamps from the number 3 inner arm index 12 9 Remove the mounting fasteners from the cable tray support at the steer end 10 Remove the external snap rings from the number 2 center pivot pin index 5 at the ground controls side Do not remove the pin 11 Slide the cable tray towards the battery pack side of the machine Remove it from the machine and lay it off to the side Component damage hazard CAUTION Cables can be damaged if they are kinked or pinched 12 Attach a lifting strap from an overhead crane to the lug on the rod end of the lift cylinder index 15 Part No 72963 Genie GS 2032 and GS 2632 Section Ae Repair Procedures June 2004 SCISSOR COMPONENTS 13 Remove the pin retaining fasteners from the cylinder rod end pivot pin index 3 Use a soft metal drift to remove the pin Bodily injury hazard The cylinder ACAUTION may fall if not properly supported when the pin is removed 14 Lower the lift cylinder index 15 onto the number 1 center pivot pin index 8 15 Attach a lifting strap from an overhead crane to the number 3
190. sor alarm should sound CE models When the platform is raised 7 to 8 feet 2 1 to 2 4 m from the ground an alarm should sound and the lift and drive functions should not operate 32 Lower the platform to the stowed position 33 Raise the machine approximately 5 inches 13 cm 34 Remove the blocks from under both wheels 35 Lower the machine and remove the jack 36 Remove the blocks from the wheels at the steer end of the machine 37 Center a lifting jack under the drive chassis at the ground controls side of the machine 38 Raise the machine approximately 2 inches 5 cm REV C 39 Place a 0 78 x 6 x 6 inch 20 mm x 15 cm x 15 cm thick steel block under both wheels at the ground controls side of the machine 40 Lower the machine onto the blocks 41 Raise the platform 6 to 7 feet 1 8 to 2 1 m 42 Adjust the tilt level sensor retaining fasteners just until the tilt sensor alarm does not sound 43 Lower the platform to the stowed position 44 Raise the machine approximately 2 inches 5 cm 45 Remove the blocks from under both wheels 46 Lower the machine and remove the jack 47 Center a lifting jack under the drive chassis at the battery pack side of the machine 48 Raise the machine approximately 2 inches 5 cm 49 Place a 0 95 x 6 x 6 inch 24 mm x 15 cm x 15 cm thick steel block under both wheels at the battery pack side of the machine 50 Lower the machine onto the blocks 51 Raise the platfo
191. step 18 12 Tag and disconnect the wiring harness from the level sensor limit switch and alarm 13 Remove the tilt level sensor box retaining fasteners Remove the tilt level sensor box from the machine 14 Remove the tilt level sensor retaining fasteners Remove the tilt level sensor from the level sensor box 15 Place the new tilt level sensor in the tilt level sensor box with the X on 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 ADANGER Tip over hazard The tilt level sensor must be installed with the X on 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 install the tilt level sensor as instructed could result in death or serious injury Non steer end scissor chassis tilt level sensor level sensor box alarm box retaining fastener level sensor retaining fastener rop Oo o 16 Install the level sensor box onto the machine Install the level sensor box retaining fasteners 17 Connect the wiring harness to the level sensor limit switch and alarm Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section Ae Repair Procedures REV 18 Tighten the level sensor adjusting fasteners until the bubble in the top of t
192. t Number Chart Title 1 A All Functions Will Not Operate A 5 4 2 Pump Motor Will Not Operate 5 6 3 A All Functions Inoperative Power Unit Starts and Huns 1 2 5 8 4 A Ground Controls Inoperative Platform Controls Operate Normally 5 9 5 A Platform Controls Inoperative Ground Controls Operate Normally essen 5 10 6 A Platform Up Function Inoperative 5 11 7 A Platform Down Function Inoperative 2244440 5 12 8 A Steer Left Function 5 14 9 Steer Right Function Inoperative 4 0000 5 16 10 A Drive Functions Inoperative All Other Functions Operate Normally eseeeemn 5 18 10A A Brake Release Function Inoperative 5 19 11 A Drive Forward Function Inoperative 5 20 12 A Drive Reverse Function Inoperative 5 21 13 A Machine Will Not Drive At Full Speed 5 22 14 A Machine Drives At Full Speed With Platform Raised 5 23 15 A Limit Switch Function Inoperative 5 24 16 A Fault Code 02 Platform Communication 5 26 17 B Fault Code 59 Parallel Series Coil 5 29 Part No 72963 Genie GS 2032 a
193. t or spray General Repair Process Malfunction Identify Troubleshoot discovered symptoms problem still exists Return to Y Perform service problem repair solved Part No 72963 Genie GS 2032 and GS 2632 6 1 Section 6 Schematics June 2004 Control Relay Layout GS 2032 ANSI CSA and Australia models REVB a b NC NO X NN S e N N NN MS S AO Ce KO 2 S electronic control module 05 CR48 power relay to U5 not used before serial number 25142 hydraulic tank motor controller U6 function manifold hydraulic pump 24V DC motor automotive style horn H2 option multifunction alarm H5 5 horn relay tilt level sensor S7 o Accu COD CL OH 6 2 Genie GS 2032 605 2632 72963 June 2004 Section Ge Schematics Control Relay Layout REV B GS 2032 CE models and GS 2632 all models batteries B5 electronic control module ECM U5 CR48 power relay to U5 ECM box lid module tray rotary latch battery quick disconnect QD1 275A fuse F6 automotive style horn H2 option multifunction alarm H5 5 horn relay tilt level sensor S7 Set Oo CO Er o 72963 Genie GS 2032 95 2632 6 3 Section 6 Schematics June 2004 ECM Pin out Legend REV B
194. t 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 Red used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Orange used to indicate the presence of a potentially hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert symbol ACAUTION used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Green used to indicate operation or maintenance information Indicates that a specific result is expected after performing a series of steps Indicates that an incorrect result has occurred after performing a series of steps Part No 72963 Genie GS 2032 and GS 2632 3 1 Section 3 Scheduled Maintenance Procedures June 2004 SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend The fo
195. t properly supported and secured to the lifting device Raise the platform 6 to 7 feet 1 8 to 2 1 m Lift the safety arm move it to the center of the Scissor arm and rotate down to a vertical position 7 Lowerthe scissor arms onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 8 Mark the mounting position of the level sensor box on the drive chassis 9 Remove the level sensor box cover 10 Mark the mounting position of the level sensor on the level sensor box 4 22 Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section Ae Repair Procedures REV B 11 Remove the level sensor box mounting fasteners and slide the box towards the non steer end of the machine as far as it can go Component damage hazard Be CAUTION careful not to damage the level sensor box limit switch level sensor or wiring while moving the level sensor box 12 Secure the ends of the scissor arms together at both ends of the machine with a tie down strap or other appropriate device 13 Remove the pin retaining fasteners from the number 1 inner arm pivot pins item 11 at the steer end of the machine Use a slide hammer to remove the pins 14 Attach a lifting strap from an overhead crane to the steer end of the scissor arms 15 Slide the forks from a forklift under the scissor arms at the non steer end of the machine 16 Raise the scissor arms up with the overhead cra
196. tability could be compromised resulting in the machine tipping over The platform overload system is designed to prevent machine operation in the event the machine 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 The maximum height limit switch located in the middle of the drive chassis under the scissor arms 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 over lift relief which would cause the pressure Switch to falsely indicate an overload condition a overload pressure switch b maximum height limit switch 1 Locate the lift valve coil on the function manifold a test port b lift valve coil 2 Tag and disconnect the black and white wires of the up limit switch wire harness from the bl
197. tch SW5 b joystick controller JC1 with thumb steering rocker SW6 horn button BN5 machine on incline button BN6 lift function enable button 9 red Emergency Stop button P2 0 Release the lift function enable and horn buttons Press and hold the lift function enable button Result The diagnostic display will show the maximum lift speed percentage Use the steering thumb rocker switch on the joystick to increase or decrease the maximum lift speed percentage Refer to Section 2 Specifications Turn the key switch to the off position Any change in software settings will not take effect until the key Switch is turned to the off position Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section Ae Repair Procedures REV B Software revision and higher ech N Push the red Emergency Stop button to the off position at the ground and platform controls Turn the key switch to the off position Pull out the red Emergency Stop button to the on position at the ground and platform controls At the platform controls press and hold the lift function select and horn buttons and turn the key switch to platform controls Result The diagnostic display will show PS Genie a function enable switch SW5 b joystick controller JC1 with thumb steering rocker SW6 horn button BN5 d machine on incline button e lift function select button BN9 f drive func
198. teer end 17 Number 2 pivot pin non steer end 8 Number 1 center pivot pin 18 Lift cylinder barrel end pivot pin 9 Number 1 inner arm 19 Number 1 outer arm 10 Number 1 pivot pin steer end 2pins 4 18 Genie 95 2032 95 2632 72963 June 2004 Section Ae Repair Procedures REV B 3 1 Scissor Assembly GS 2032 How to Disassemble the Scissor Assembly GS 2032 AWARNING 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 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 Two Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform See 2 1 How to Remove the Platform 2 Remove the cables from the side of the number 3 outer arm index 13 at the ground controls side Component damage hazard CAUTION Cables can be damaged if they are kinked or pinched SCISSOR COMPONENTS 3 Attach a lifting strap from an overhead crane to the number 3 outer arm index 13 4 Remove the external snap rings from the number 3 center pivot pin index 2 5 Use a soft metal drift to remove the number center pivot pin index 2 6 Remove the external
199. tform controls Turn the key switch to the off position 2 Remove the fasteners securing the top of the platform controls and open the platform control box 3 Rotate the platform control box to the position shown to correctly identify the configuration of the DIP switch settings 4 Locate the DIP switch on the circuit board Move the DIP switch settings to correspond with the configuration of the machine options indicated in the DIP Switch Code Chart pi P2 ON gue O EMERGENCY ES STOP BUTTON o E D BOARD REV B PLATFORM CONTROLS CIRCUIT before serial number 48055 ON 1 OFF 0 after serial number 48054 positio n platform controls circuit board U3 joystick controller JC1 a b enlarged view of DIP switch SW25 DIP switch SW25 Close the lid and install the fasteners Confirm the settings See 1 3 How to Determine the DIP Switch 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 Any change in DIP settings will not take effect until the key switch is turned to the off position Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section 4 e Repair Procedures REV B DIP Switch Code Chart A mark in the column indicates that the machine configuration includes this o
200. the number 1 outer arm index 19 to the non steer end and remove it from the machine Bodily injury hazard The number ACAUTION 1 outer arm index 19 may become unbalanced and fall if not properly supported when it is removed from the machine Note the position of the wear pads before the arm is removed so when the scissor assembly is installed they will be in the correct position 40 Attach a lifting strap from an overhead crane to the number 1 inner arm index 9 Do not lift it 41 Remove the pin retaining fasteners from both of the number 1 pivot pins index 10 at the steer end of the machine Use a slide hammer to remove the pins 42 Remove the number 1 inner arm index 9 from the machine Bodily injury hazard The number ACAUTION 1 inner arm index 49 may become unbalanced and fall if not properly supported when removed from the machine REV B How to Replace the Scissor Arm Wear Pads 1 Remove the platform See 2 1 How to Hemove the Platform 2 Remove the mounting fasteners from the stationary wear pads on the platform Note the position of the wear pads before they are removed so when the new ones are installed they will be in the correct position 3 Support and secure the entry ladder to an appropriate lifting device 4 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 no
201. the oil level indicator decal Do not overfill 12 Activate the pump to fill the hydraulic system with oil and bleed the system of air and check for leaks 13 Repeat steps 11 and 12 until the hydraulic tank and system are both full 14 Clean up any oil that may have spilled Properly discard the used oil Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section 4 Repair Procedures Observe and Obey 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 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 Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a 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 disconnecte
202. the on position Perform this procedure after confirming that the maximum height limit switch and the limit Switch bracket are not damaged and are functioning correctly Be sure the hydraulic oil level is between the FULL and app marks on the hydraulic tank 1 Apply a thin layer of dry film lubricant to the area of the chassis where the scissor arm wear pads make contact 2 Chock both sides of the wheels at the steer end of the machine 3 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 2032 677 kg GS 2632 508 kg REV D 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 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 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 ADANGER 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 o
203. tic A June 2004 REV B from serial number 21065 to 25141 WH A A WH C 1 D EX KEY SWITCH 4 4 4 BL B C B a i D C D E e e Pu 7 390 OR E E 2 1 blg 7 EMERGENCY D NC 4 NO N CHO CIRCUIT STOP H BREAKER PLATFORM C D M LS6 H5 PS2 LS7 DOWN MULTI PLATFORM POTHOLE p LIMIT SWITCH FUNCTION OVERLOAD GUARD Las ALARM PRESSURE SWITCH B SWITCH 1 g GROUND V CONTROL TS66 LS8 UP DOWN POTHOLE SWITCH GUARD SWITCH 8 D pel 1 D gt gt gt o e m D gt mmo gt T m S s T 5 7 E 2 gt gt 2 0 I shana 9 SG E ZS ZS S E SS 22954 ch 1 d 3 2 5 m 5 E 5 5 9 22426565 Sn 4 D gt 2 2 z d d re m zz o i 9 2 5 gt I 9 5 2 8 E hi o 5 8 DS amp m 2 2 Q 2 o S 9g 3 M SP 5 gt o 3 e m m d lt 9
204. tings will not take effect until the key Switch is turned to the off position Part No 72963 Genie GS 2032 and GS 2632 4 9 Section Ae Repair Procedures June 2004 PLATFORM CONTROLS How to Adjust the Raised Drive Speed 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 ADANGER 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 Software revision AO and BO 1 Push in the red Emergency Stop button to the off position at the ground and platform controls Turn the key switch to the off position 2 Pull out the red Emergency Stop button to the on position at the ground and platform controls REV 3 Press and hold the lift function enable and horn buttons and turn the key switch to platform controls Result The diagnostic display will show PS E a function enable switch SW5 b joystick controller JC1 with thumb steering rocker SW6 horn button BN5 machine on incline button lift function enable button BN9 red Emergency Stop button P2 TD 4 Release the lift function enable and horn buttons 5 Press and hold the horn button Resu
205. tion select BN8 g red Emergency Stop button P2 4 Release the lift function select and horn buttons Result The diagnostic display will show the 5 maximum lift speed percentage Press the lift function select button PLATFORM CONTROLS Use the steering thumb rocker switch on the joystick to increase or decrease the maximum lift speed percentage Refer to Section 2 Specifications Turn the key switch to the off position Any change in software settings will not take effect until the key Switch is turned to the off position Part No 72963 Genie GS 2032 and GS 2632 Section Ae Repair Procedures June 2004 PLATFORM CONTROLS How to Adjust the Stowed Drive Speed A DANGER 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 ADANGER 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 Software revision DO and higher 1 Push in the red Emergency Stop button to the off position at the ground and platform controls Turn the key switch to the off position 2 Pull out the red Emergency Stop button to the on position at the ground and platform controls 3 Press and hold the lift function
206. to Determine the DIP Switch Configuration Remove the platform controls from the platform Place the platform controls close to the diagnostic display on the hydraulic module side of the machine 3 Turn the key switch to platform control and pull out the red Emergency Stop buttons to the on position at both the ground and platform controls Press and hold the lift function enable button OR press the lift function select button Slowly move the joystick in the direction indicated by the blue arrow Result switch configuration will appear in the diagnostic display Genie o Q S yellow arrow joystick controller JC1 lift function select button BN9 red Emergency Stop button P2 lift function enable button BN9 oo Oo OC om Part No 72963 Genie GS 2032 and GS 2632 Section Ae Repair Procedures June 2004 PLATFORM CONTROLS How to Set the DIP Switch Codes Tip over hazard Do not adjust the DIP switch settings to other than what is specified in this procedure Exceeding specifications could cause the machine to tip over resulting in death or serious injury If replacing the circuit board note the toggle positions on the DIP Switch Set the DIP switch on the new circuit board to the same configuration as the old board 1 Pushin the red Emergency Stop button to the off position at the ground and pla
207. tting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Raise the platform 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 REVA GS 2032 models before serial number 23568 e Wo q m D lt SJ lift cylinder lowering cable solenoid valve schematic item D cable mounting bracket spring orifice schematic item E connector fitting hydraulic hose hard line assembly 855 2632 models amp GS 2032 models after serial number 23567 ea Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section 4 Repair Procedures REVA 3 Lower the scissor arms 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 at the barrel end of the lift cylinder 5 Loosen the adjustment nuts on the solenoid then disconnect the manual lowering cable from the solenoid During assembly the manual platform lowering cable needs to be properly adjusted Refer to 4 1 How to Adjust the Manual Platform Lowering Cable 6 Remove the mounting fasteners from the manual lowering cable mounting bracket
208. tton Result The diagnostic display will show the raised drive speed percentage 7 Usethe steering thumb rocker switch on the joystick to increase or decrease the maximum lift speed percentage Refer to Section 2 Specifications 8 Turn the key switch to the off position Any change in software settings will not take effect until the key Switch is turned to the off position Part No 72963 Genie GS 2032 and GS 2632 Section Ae Repair Procedures June 2004 PLATFORM CONTROLS Software revision DO and higher i Push in the red Emergency Stop button to the off position at the ground and platform controls Turn the key switch to the off position N Pull out the red Emergency Stop button to the on position at the ground and platform controls Co Press hold the lift function select and horn buttons and turn the key switch to platform controls Result The diagnostic display will show PS function enable switch SW5 joystick controller JC1 with thumb steering rocker SW6 horn button BN5 machine on incline button lift function select button BN9 drive function select BN8 red Emergency Stop button P2 b f 9 4 Release the lift function select and horn buttons Result The diagnostic display will show the maximum lift speed percentage REV B 5 Press and hold the horn button Result The diagnostic display will show the
209. ue black wires of the manifold wire harness at the lift valve coil on the manifold Part No 72963 Genie GS 2032 and GS 2632 3 19 Section 3 Scheduled Maintenance Procedures June 2004 CHECKLIST C PROCEDURES REV C 3 Securely connect together the terminals of the 9 Fully raise the platform Release the toggle two blue black wires of the manifold wire harness disconnected from the limit switch wire harness in step 2 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 Fully raise the platform Release the toggle switch Result The alarm should sound Result The alarm does not sound Calibrate the platform overload system See Maintenance Procedure D 2 Calibrate the Platform Overload System if equipped Using the manual lowering knob lower the platform to the stowed position Disconnect the two blue black wires of the manifold wire harness at the lift valve coil on the manifold 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 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 correct
210. ued from the previous page Repair or replace the steer cylinder OR consult the Genie less than Industries Service 1500 PSI Department Reset the steer relief Repair or replace the valve pressure steer cylinder OR item AE or BF replace the steer left See Repair Section right valve cartridge item AF or BI OR the less than function manifold could 1500 PSI have an internal defect Consult the Genie Replace the steer relief Industries Service valve item AE or BF Department Part No 72963 Genie GS 2032 and GS 2632 5 17 Section 5 Troubleshooting Flow Charts June 2004 Chart 10 All Drive Functions Inoperative Other Functions Operate Normally Be sure if the Error Indicator light is on at the platform controls you refer to the specific chart that relates to the error code that is displayed on the ECM Be sure the circuit breaker and fuse are not tripped or blown Be sure the batteries are fully charged and properly connected With the key switch turned to platform controls and both Emergency Stop buttons pulled out to the ON position activate drive forward and drive reverse functions Check to see if the error indicator light is on at the platform controls Replace the platform controls with known operating platform controls Activate the drive function Does the drive function operate Replace the ECM U5 OR consult the Genie Industries Service
211. umber 35800 1 Open both module trays and lubricate each module tray latch Using light oil apply a few drops to the side of the latch pin 2 Inspect each module tray latch pad if equipped Replace any worn pad before the latch fails to securely hold the module tray closed The module tray latch pad is attached to the drive chassis and located above the module tray latch when the module tray is closed Models after serial number 35799 1 Lubricate each module tray rotary latch Using light oil apply a few drops to each of the springs and to the sides of the rotary latch mechanism a rotary latch springs b module tray rotary latch 2 Inspect each module tray latch U bolt Tighten any loose U bolt retaining fastener before the latch fails to securely hold the module tray closed REV D 3 18 Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section 3 Scheduled Maintenance Procedures Checklist C Procedure C 1 yf Test the Platform Overload System if equipped 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 s
212. une 2004 Section 4 Repair Procedures REV 20 Raise the machine approximately 2 inches 5 cm 21 Place a 0 9 x 6x 6 inch 22 9 mm x 15 cm x 15 cm thick steel block under both wheels at the ground controls side of the machine 22 Lower the machine onto the blocks 23 Raise the platform 7 to 8 feet 2 1 to 2 4 m Result The level sensor alarm should not sound Result The level sensor alarm does sound Adjust the level sensor retaining fasteners just until the level sensor alarm does not sound 24 Lower the platform to the stowed position 25 Raise the machine approximately 2 inches 5 cm 26 Remove the blocks from under both wheels 27 Lower the machine and remove the jack 28 Center a lifting jack under the drive chassis at the battery pack side of the machine 29 Raise the machine approximately 2 inches 5 cm 30 Place a 1 04 x 6x 6 inch 26 4 mm x 15 cm x 15 cm thick steel block under both wheels at the battery pack side of the machine 31 Lower the machine onto the blocks GROUND CONTROLS 32 Raise the platform 7 to 8 feet 2 1 to 2 4 m O Result The platform should stop and an alarm should sound 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 33 Lift the safety arm move it to the center of the Scissor arm and rotate down to a vertical po
213. ury hazard The number ACAUTION 2 outer arm index 21 at the ground controls side may become unbalanced and fall if not properly supported when it is removed from the machine 37 Attach a lifting strap from an overhead crane to the number 2 outer arm index 21 at the battery pack side 38 Remove the external snap rings from the number 2 center pivot pin index 7 at the battery pack side 39 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 index 21 at the battery pack side may become unbalanced and fall if not properly supported when it is removed from the machine 40 Use a soft metal drift to tap the number 2 pivot pin index 22 in the other direction at the non steer end Remove the number 2 outer arm index 21 from the battery pack side of the machine Bodily injury hazard The number ACAUTION 2 outer arm index 21 at the battery pack side may become unbalanced and fall if not properly supported when it is removed from the machine Part No 72963 Genie GS 2032 and GS 2632 Section Ae Repair Procedures June 2004 SCISSOR COMPONENTS 41 Attach a lifting strap from an overhead crane to the number 2 inner arm index 20 42 Remove the external snap rings from the number 2 pivot pin index 9 at the steer end of the machine 43 Use a soft metal drift to remove the number 2 pivot pin
214. ve normally closed with manual over ride Ke Y8 LM im Solenoid operated 2 position 4 way directional valve Check valve pilot to open lt i gt Shuttle valve Brake Ad Single acting cylinder M A Solenoid operated 3 position 4 way directional valve Y2 Solenoid operated 2 position 2 way directional valve REV B June 2004 Section 6 Schematics Hydraulic Schematic from serial number 17408 to 36100 L K J F E D C B A M I LIFT LEFT RIGHT 1 PLATFORM E CYLINDER DRIVE MOTOR DRIVE MOTOR STEER STEER OVERLOAD LEFT RIGHT m _ e E E HAND 2 297 M o 5 J eme BRAKE LE E 995m MANUAL R e RELEASE RELEASE E emi ES MANIFOLD il H ll ode milicia d 3 e s e fe Su 00 cL olo dM gt x di N
215. while installing the scissor assembly Part No 72963 Genie GS 2032 and GS 2632 Section Ae Repair Procedures June 2004 SCISSOR COMPONENTS REV B 1 5 8 6 9 OJQ E 22 9 4 N ER 2 1 7 85 2632 N Steer End k Non steer End 1 Number 5 pivot pin steer end 13 Number 5 pivot pin non steer end 2 Number 4 center pivot pin 14 Number 4 inner arm 3 Number 4 pivot pin steer end 15 Number 4 outer arm 4 Number 3 outer arm 16 Number 4 pivot pin non steer end 5 Lift cylinder rod end pivot pin 17 Number 3 inner arm 6 Number 3 pivot pin steer end 18 Number 3 center pivot pin 7 Number 2 center pivot pin 2 pins 19 Number 3 pivot pin non steer end 8 Lift cylinder 20 Number 2 inner arm 9 Number 2 pivot pin steer end 21 Number 2 outer arm 10 Number 1 center pivot pin 22 Number 2 pivot pin non steer end 11 Number 1 inner arm 23 Lift cylinder barrel end pivot pin 12 Number 1 pivot pin steer end 2 pins 24 Number 1 outer arm 4 24 Genie 65 2032 and 95 2632 Part No 72963 June 2004 Section Ae Repair Procedures REV B 3 2 Scissor Assembly GS 2632 How to Disassemble the Scissor Assembly GS 2632 AWARNING Body injury hazard The procedures in this section require specific repair skills lifting equipment and a suitable workshop
216. witch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 3 Raise the platform 7 to 8 feet 2 1 to 2 4 m Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section 4 Repair Procedures REV 5 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 If you are not installing a new level sensor proceed to step 15 6 Turn the key switch to the off position and push in the red Emergency Stop button to the off position at the ground controls Tag and disconnect the level sensor wire harness from the chassis wire harness The wire harness connection is located next to the level sensor on top of the chassis at the steer end of the machine Remove the level sensor retaining fasteners Remove the level sensor from the machine Tag and disconnect the level sensor wires from the level sensor connector plug 10 Securely install the wires of the new level sensor into the level sensor connector plug 11 Place the new level sensor onto the level 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 ADANGER
217. x 6 may become unbalanced and fall if not properly supported when it is removed from the machine 26 Remove the safety arm from the number 2 inner arm index 6 that was just removed 27 Attach a lifting strap from an overhead crane to the number 1 inner arm index 9 28 Raise the number 1 inner arm index 9 approximately 2 feet 0 6 m and insert the safety arm between the number 1 inner arm index 9 and the number 1 outer arm index 19 Bodily injury hazard Keep hands ACAUTION clear of moving parts when lowering the scissor arms onto the safety arm Genie GS 2032 and GS 2632 Part No 72963 June 2004 Section 4 Repair Procedures REV B 29 Tag disconnect and plug the hydraulic hose on the lift cylinder index 15 Cap the fitting 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 30 Tag and disconnect the wires from the solenoid valve on the cylinder 31 Attach a lifting strap from an overhead crane to the lug on the rod end of the lift cylinder index 15 Raise the lift cylinder to a vertical position 32 Remove the pin retaining fasteners from the lift cylinder barrel end pin index 18 Use a soft metal drift to remove the pin Remove the lift cylinder index 15 from the machine AWARNING Crushing haz
218. yright 1997 by Genie Industries 72963 Rev C June 2004 Second Edition Third Printing Genie is a registered trademark of Genie Industries in the USA and many other countries GS is a trademark of Genie Industries ry 6 Printed on recycled paper Printed in U S A li Genie GS 2032 and GS 2632 Part No 72963 June 2004 Safety Rules Danger Failure to obey the instructions and safety rules this manual and the appropriate Operator s Manual on your machine will result in death or serious injury Many of the hazards identified in the operator s manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless You are trained and qualified to perform maintenance on this machine You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations You have the appropriate tools lifting equipment and a suitable workshop Part No 72963 Genie GS 2032 and GS 2632 lii June 2004 SAFETY RULES Personal Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority Read each procedure thoroughly This manual and the decals on the machine use signal words to identify the following Safety alert sy
219. ystick fault Forward coil fault Reverse coil fault Joystick potentiometer not centered Malfunctioning coil OR wire disconnected from coil Malfunctioning coil OR wire disconnected from coil Verify potentiometer setting Troubleshoot coil OR inspect wire connection Troubleshoot coil OR inspect wire connection 54 See Chart 6 55 7 Up fault Down coil fault Malfunctioning coil OR wire disconnected from coil Malfunctioning coil OR wire disconnected from coil Troubleshoot coil OR inspect wire connection Troubleshoot coil OR inspect wire connection 56 See Chart 9 57 See Chart 8 58 See Chart 10 or Right coil fault Left coil fault Brake coil fault Malfunctioning coil OR wire disconnected from coil Malfunctioning coil OR wire disconnected from coil Malfunctioning coil OR wire disconnected from coil Troubleshoot coil OR inspect wire connection Troubleshoot coil OR inspect wire connection Troubleshoot coil OR inspect wire connection 68 Low battery voltage Chart 10A 59 Series parallel coil fault DIP switch settings are Troubleshoot and correct incorrect DIP switch settings See Chart 17 Batteries discharged Charge batteries 88 ECM has been erased Static strap may be missing from the machine Replace static strap Part No 72963 Genie GS 2032 and GS 2632

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