Home

Service Manual

1. Section 6 Schematics September 2005 Hydraulic Schematic GS 2032 2632 and GS 2046 2646 3246 Models REV B euros LIFT CYLINDER LEFT E RIGHT uos 5 gt 1 MANUAL N RELEASE l AEN fi Y9 T HAND LO i wo Eri BRAKE O s 1 RELEASE D uvceneemi me mae t MANIFOLD T EA ON THE LIFT CYLINDER B1 1 STEER STEER LEFT RIGHT 1 03 CU IN DRIVE ro Mc MOTOR n Ono J 5 4 v 51 52 HP B AC M1 M4 Ne CS 1 L 9 11 1 2500 psi maximum 1 i I 172 bar maximum 7 7 THE ORIFICE IS LOCATED UNDERNEATH Y4 IN 1 mM Y1 lt NW 10 psi 0 7 bar n 000 ve X vs AG il Rests 8 Al Li 0 75 gpm 0 gt 2 8 L min p ie m __ 80 to 130 psi rcm Se 2 4 3 4 to 9 bar 7 gt boe Y8 FUNCTION MANIFOLD eomm 1 the 124 241 1 3500 psi maximum ABBREVIATION LEGEND 241 bar maximum 1 Item Description 000 AA Test port AB Relief valve system 1
2. Section 6 Schematics September 2005 Hydraulic Schematic GS 1530 1532 1930 1932 from serial number GS3005A 76000 to 76491 REVA GS 1530 1532 1930 1932 from serial number GS3005B 76000 to 76084 LIFT CYLINDER LEFT L ALL MODELS _BRAKE E _ M MANUAL PLATFORM Jor OVERLOAD ane t 1 MODELS W Y9 pume 1 O BRAKE 6 RELEASE Ol QO iam rs ee NS B1 THE ORIFICE IS LOCATED RIGHT AN ON THE LIFT CYLINDER 1 03 CU IN Reve DRIVE Pace saver PES MOTOR P 8 L v 51 52 HP B AC M1 M4 4 va lt si r orice M w ve vs i 4 on 11500 psi e 2108bar I H 9 TP 1 Heim G 0 7 e q HS Y8 1 FUNCTION MANIFOLD ee ee m am psi maximum L 241 bar maximum lt ABBREVIATION LEGEND p eye O 1 Item Description ur CE A Test port i B Check valve steer circuit 200 psi 3 0 Relief valve lift D Check valve brake circuit E Drive forward reverse f F Steer left right l JO MICRONWITIE G Flow regulator relief valve
3. ANSI CSA and Australia Models REV GS 1530 1532 1930 1932 and GS 2032 2632 and GS 2046 2646 3246 P1 adi x EMERGENCY LA 27 STOP NAT 8 lt N on 2 KS1 v1 key PLATFORM 1 SWITCH CONTROL 1 2 14 1 NOTE P 1 MACHINE SHOWN IN THE it 3 E STOWED POSITION WITH Ne THE POWER OFF Se x DP LS7 TS66 P GUARD PLATFORM SWITCH 1 UP DOWN CB2 N C H O 4 7A 8 5 7 BREAKER E LS8 POTHOLE GUARD SWITCH EP GE QE DE 5 gt pe S gg 7 5 9 X 2 23 B Q 9 d m gt 1 5 5 p WORK LIGHT 2 001 gt A OPTION 3 F6 275a FUSE 8 Se L GN A12 B12 B9 B10 QUT IN IN IN OUT IN BK ag OUT u 72222222 C BATTERY WH A1 OUT 5 CHARGER ELECTRONIC CONTROL MODULE OUT OUT B5 EG eee BATTERY U6 9 2 ss O 3O E CONTROLLER el SAY CR5 I Z HORN RELAY A 99 2 OPTION 485 c UE l U13 G6 EB 2 12 DC AC INVERTER HOUR FLASHING To 85 BEACONS OPTION H2 L AUTO STYLE HORN i OPTION 1 ES0141H Genie TEREX COMPANY GS 30 GS 32 GS 46 Part No 97385 September 2005 Section 6 Schematics
4. CE Models REV B GS 1530 1532 1930 1932 from serial number GS3005A 76389 to 79394 GS 1530 1532 1930 1932 from serial number GS3005B 76031 to 76920 P1 P 28 STOP WH 2 B Non 2 4 KS1 key PLATFORM 1 SWITCH CONTROL 1 2 14 1 P NOTE X Fi H5 ALARM MACHINE SHOWN IN THE STOWED POSITION WITH A THE POWER OFF Se x DP LS7 TS66 P GUARD PLATFORM SWITCH 1 UP DOWN CB2 N C H O 4 o LS8 POTHOLE U27 GUARD 47 mH INDUCTOR NOISE SUPPRESSION SWITCH ET c 5 v 3 8 2 9 X 323 B 2 2 9 5 5 ma work LIGHT 2 E QD1 4 IATA OPTION F6 275a FUSE 8 ee 12 B12 All B10 4 IN IN OUT u 1 ml A8 OUT C BATTERY WH A1 OUT 5 CHARGER ELECTRONIC CONTROL MODULE OUT OUT B5 EG PTUS d BATTERY U6 9 2 2 3O E CONTROLLER L T SAY CR5 24 HORN RELAY mr cud X P 30 H2OPTION 486 I U13 G6 FB cai DC AC INVERTER OUR FLASHING 85 BEACONS OPTION H2 AUTO STYLE HORN OPTION 1 ES0142F Genie 6 16 TEREX COMPANY GS 30 GS 32 GS 46 Part No 97385 September 2005 Section 6 Schematics Electrical Schematic REV B CE Models
5. REV A CE Models GS 2032 2632 after serial number GS3205 77290 GS 2046 2646 3246 after serial number GS4605 76734 NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF RD RD 4 6 4 WH WH 3 3 CR28 304 6 486 30 6 8 BL 1 1 E ZS beca 7x RELAY IO 05 0 t 24 7 4 PS2 PLATFORM OVERLOAD LS6 PRESSURE SWITCH N C H O 7 SWITCH N O H C of 2 CR27A CR27B CR27C OVERLOAD OVERLOAD OVERLOAD MOTOR CONT LOAD SENSE DOWN COIL t N C 86 2 86 86 7 ga za SENSOR p C52 LIMIT 4700 uF ae e t EEEE A 5 5 55 5 5 2 9i LEVEL 2 5 ts 85 6 g 5 2 a 3 CR27D 5 8 8 i OVERLOAD a DOWN DELAY 9 RR OB 3 IEEE I ol C2 Bi 9 A6 10 B6 C12 A4 2 Bi 5 l OUT OUT IN IN IN OUT Us ELECTRONIC CONTROL MODULE OUT OUT OUT OUT OUT C8 C7 B7 A7 C6 I 9 2 E Y1 YS Y4 Y5 Y6 Y9 Y7 Y8 PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM RIGHT LEFT REVERSE FORWARD DOWN DOWN GS 3246 4 4 X A X X Al X A X A X A X X e
6. REVA CE Models GS 1530 1532 1930 1932 after serial number GS3005A 79394 GS 1530 1532 1930 1932 after serial number GS3005B 76920 NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF RD RD 4 4 WH WH 3 3 CR28 304 6 486 30 6 CR48 BL 1 1 CUT OUT Le yes 2i POWER BK 2 2 MOTOR CONT RELAY TO US 87 85 87 85 E STOP OR 125 1 4 ME 4 PS2 PLATFORM OVERLOAD 156 PRESSURE SWITCH Ne DOWN Y ER SWITCH of CR27A CR27B CR27C MEE OVERLOAD OVERLOAD OVERLOAD motor conn LOAD SENSE DOWN COIL 30 86 30 86 30 86 1 Pot JL J E Oll LEVEL 87 85 87A 85 87 85 LS5 SENSOR UP 1 BOARD C57 Ma E 225565 amp Ps s 8 5 59 8 BK D CR27D 2 lt 2 5 A OVERLOAD a DOWN DELAY 2 9 5 2 o o gt x 2 5 A X gt 2 0 mI E dx C2 Bi 9 A6 10 B6 c12 CH IN OUT OUT IN OUT IN IN IN IN IN OUT Us ELECTRONIC CONTROL MODULE OUT OUT OUT OUT OUT C8 B7 AT C6 Sear ee ae ie I ee ee me ry 1 Y4 Y5 Y6 Y9 Y7 Y8 PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM RIGHT LEFT REVERSE FORWARD DOWN DOWN UP GS 3246 4 4 X A X X X A X A X A X X G
7. 2 5 ts 85 6 e 5 E i D NONE 5 5 59 8 BK D CR27D 2 5 2 5 A OVERLOAD 0 DOWN DELAY A 2 9 5 2 o o gt x 2 5 A X gt 2 0 mI E dx C2 B11 A6 A10 B6 C12 BI CH IN OUT OUT IN OUT IN IN IN OUT Us ELECTRONIC CONTROL MODULE C8 C7 B7 AT C6 Sear ee ae ie I ee ee me ry Y1 Y4 Y5 Y6 Y9 Y7 Y8 PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM RIGHT LEFT REVERSE FORWARD DOWN DOWN UP GS 3246 4 4 A X A X Al X X A X A X A X Al X GND ES0142F Part No 97385 TEREX COMPANY GS 30 GS 32 GS 46 Section 6 Schematics September 2005 Electrical Schematic CE Models REV B GS 2032 2632 from serial number GS3205 75407 to 77290 GS 2046 2646 3246 from serial number GS4605 75438 to 76734 E P2 QD3 EMERGENCY 4 4 BK POWER PLATFORM 3 D 3 RD POWER TO GROUND 3 1 WH 1 lorog 1 2 2 BL DATALINK HIGH I 5 5 OR DATA LINK LOW 1 U3
8. TEREX COMPANY Part No 97385 GS 30 GS 32 GS 46 4 63 Section 4 Repair Procedures September 2005 MANIFOLDS 6 2 Function Manifold Components GS 2032 GS 2632 GS 2046 GS 2646 and GS 3246 REV The function manifold is mounted behind an inspection door on the ground control side of the machine Index Schematic No Description Item Function EET Coil nut items AE AG and Al 1 Diagnostic nipple s ataq Testing 2 Relief valve 3500 psi 241 bar maximum AB uiuis System relief 3 Solenoid valve 3 position 4 way Steer left right 4 7 Steer circuit 5 Solenoid valve 2 position 4 way AE atid Drive speed select circuit 6 Relief valve 130 pst AP iene Brake release 7 Solenoid valve 3 position 5 way iunais Drive forward reverse 8 Flow regulator and relief valve 0 75 gpm 2 8 L min 1500 pst 103 Steer 9 Solenoid valve 2 position 4 way Platform up uuu 10 Relief valve 3000 to 3200 psi 207 to 221 bar Lum Liftireliet eere How to Install a Valve Cartridge 1 Dip the cartridge in clean oil to lube the O rings 2 Screw the cartridge in by
9. 4 42 GS 30 GS 32 GS 46 16 Number 5 inner arm 17 Number 5 outer arm 18 Number 5 pivot pin non steer end 19 Number 4 inner arm 20 Number 4 outer arm 21 Number 4 pivot pin non steer end 22 Upper lift cylinder barrel end pivot pin 23 Number 3 inner arm 24 Number 3 pivot pin non steer end 25 Number 2 inner arm 26 Number 2 outer arm 27 Number 2 pivot pin non steer end 28 Lower lift cylinder barrel end pivot pin 29 Number 1 outer arm Part No 97385 September 2005 Section 4 Repair Procedures REVA SCISSOR COMPONENTS 3 5 Scissor Assembly GS 3246 How to Disassemble the Scissor Assembly GS 3246 AWARNING 00 injury hazard The procedures in this section require specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is required When removing a hose assembly or fitting the O ring on the fitting GS 3246 and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications Cable bridge legend cable bridge 5 cable bridge 4A cable bridge 4B cable bridge 3A cable bridge 3B cable bridge 2A cable bridge 2B cable bridge 1 1 Remove the platform See 2 1 How to Remove the Platform sa ro O O 09 2 Support and secure
10. REVA Hydraulic cylinder Relief valve mo Dr Solenoid operated 2 position 2 way directional valve normally closed x 24 OS Orifice NIC PS2 Platform overload pressure switch Function manifold GS 1530 GS 1532 GS 1930 and GS 1932 Variable speed motor Fixed displacement pump 3 Bi directional motor 1224 Priority flow regulator Filter Part No 97385 Component Reference and Hydraulic Symbols Legend gt 6 Shuttle valve Solenoid operated 2 position 4 way directional valve s Accumulator _ Check valve Ly Pilot operated check valve with needle valve GLX i Solenoid operated 3 position 4 way directional valve All X vs Solenoid operated 3 position 4 way directional valve vell rl Solenoid operated 3 position 5 way directional valve Function manifold GS 2032 GS 2632 GS 2046 GS 2646 and GS 3246 Genie TEREX COMPANY GS 30 GS 32 GS 46
11. Electrical Schematic REV B ANSI CSA and Australia Models GS 1530 1532 1930 1932 and GS 2032 2632 and GS 2046 2646 3246 NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF 4 6 4 WH WH 3 3 4 8 CR48 BL 1 1 POWER BK 2 2 RELAY TO U5 5 m N O H C O LS6 DOWN LIMIT SWITCH p ECqTI 27 F LEVEL SENSOR CIRCUIT 1 BOARD I m o gt rmi 3 5 95 55 S7 SE 2 5 sS gt gt 99i LEVEL 6 Z 21 21 5 2822 8858 SENSOR 9 22 0 ss s i gt m a 9 69 BK 9 2454 9 zi D 5 9 z 2 5 z 9 2 8 IL zu 02 B11 C12 A10 A4 A2 B1 C11 AS IN IN IN IN IN OUT U5 ELECTRONIC CONTROL MODULE OUT OUT OUT OUT OUT OUT OUT C8 C7 B7 A7 C6 B6 AG DE x E 5 x Y1 Y3 Y4 Y5 Y6 Y9 Y7 Y8 PARALLEL STEER STEER
12. THE POWER OFF 22 7 TS66 POTHOLE PLATFORM SNITCH 4 UP DOWN N CHO 2 D 8 BREAKER E LS8 U27 47 mH INDUCTOR NOISE SUPPRESSION SWITCH LIT c 5 pe S 8 7 5 9 g 5 E 322 2 E 180 5 5 Jot QD1 Z j S did d F6 275a FUSE 8 ee ee A12 B12 B9 B10 IN IN OUT IN BK ag OUT u BATTERY t AVOUT U5 CHARGER ELECTRONIC CONTROL MODULE OUT OUT B5 _ ee AR BATTERY T U6 9 2 motor 2 30 E CONTROLLER gt 8 10 1 SAY CR5 P HORN RELAY Pw 39 H2OPTION 486 U13 G6 FB le DC AC INVERTER HOUR FLASHING To 85 METER BEACONS 1 OPTION H2 1 AUTO STYLE HORN 0 E OPTION 1 ES0142H Genie TEREX COMPANY 6 8 GS 30 GS 32 GS 46 Part No 97385 September 2005 Section 6 Schematics Electrical Schematic
13. Crushing hazard The lift cylinder ACAUTION Will fall if not properly supported when the pivot pin is removed 34 Placea 2x 4 x 10 inch 10 x 10 x 25 cm block onto the number 1 inner arm cylinder plate index 10 35 Lower the cylinder onto the block Bodily injury hazard Keep hands A CAUTION clear of moving parts when lowering the cylinder onto the block 36 Attach a lifting strap from an overhead crane to the number 3 inner arm index 15 Raise the arm to a vertical position 37 Remove the retaining fasteners from the number 3 pivot pin at the steer end of the machine index 6 Genie Part No 97385 TEREX COMPANY GS 30 GS 32 GS 46 4 37 Section 4 Repair Procedures September 2005 SCISSOR COMPONENTS 38 Use a soft metal drift to remove the number 3 pivot pin index 46 from the steer end of the machine Remove the number 3 inner arm index 15 from the machine Crushing hazard The number 3 ACAUTION inner arm index 15 may become unbalanced and fall if not properly supported when the pivot pin is removed 39 Remove the cables from the number 2A and 2B cable bridge and lay them off to the side Component damage hazard CAUTION Cables can be damaged if they are kinked or pinched 40 Disconnect the number 2A and 2B cable bridges from the scissor linkset and remove both cable bridges from the machine 41 Attach a lifting strap from an overhead crane to the number 2 ou
14. EM CE m BATTERY 06 9 2 2 3O CONTROLLER 10 F CRS I 7 E HORN RELAY T X P 30 H2OPTION 486 Sr 3 G6 FB 4 cai 12 DC AC INVERTER OUR FLASHING To 85 BEACONS OPTION H2 L AUTO STYLE HORN i OPTION 1 ES0142D Genie TEREX COMPANY 6 12 GS 30 GS 32 GS 46 Part No 97385 September 2005 Section 6 Schematics Electrical Schematic REV 8 CE Models GS 1530 1532 1930 1932 from serial number GS3005A 76000 to 76388 GS 1530 1532 1930 1932 before serial number GS3005B 76000 to 76030 NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF RD 4 6 4 WH WH 3 3 4 5 CR48 BL 1 1 Jo POWER BK 2 u RELAY US 8 Eso 268 N C PS2 PLATFORM OVERLOAD LS6 PRESSURE SWITCH N C H O Down LIMIT SWITCH N O H C 4 5 2 CR27A CR27B CR27C
15. 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 Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Tag and 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 3096 replace the Coil Valve Coil Resistance Specifications Description Specification Solenoid valve 3 position 4 way 18 to 212 20V DC with diode schematic items E and AC Solenoid valve 3 position 4 way 25 to 280 20V DC with diode schematic item F Solenoid valve 2 position 4 way 18 to 210 20V DC with diode schematic item H Solenoid valve 2 position 2 way N C 23 to 280 20V DC with diode schematic item N Solenoid valve 2 position 4 way 25 to 280 20V DC with diode schematic items AE and AI Solenoid valve 3 position 5 way 25 to 280 20V DC with diode schematic item AG Genie TEREX COMPANY GS 30 GS 32 GS 46 Part No 97385 September 2005 Section 4 Repair Procedures REV B How to Test a Coil Diode Genie incorporates spike suppressing diodes in all of its coils
16. AC Steer left right AD Check valve steer circuit V e 0 Drive speed POWER UNIT AF Relief valve brake release 4 gpm AG Drive forward reverse L sr tas ed AH Flow regulator relief valve Al Platform up AJ Relief valve lift HYDRAULIC TANK L Hand pump manual brake release M Needle valve manual brake release N Platform lowering valve 0 Orifice platform down circuit P Accumulator Q Relief valve platform down HS0036H R Pressure switch platform overload enie 6 34 TEREX COMPANY GS 30 GS 32 GS 46 Part No 97385 Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 4617 3375 1002 Genie Scandinavia Phone 46 31 0 Fax 446 31579020 Genie China Phone 86 21 53852570 Fax 86 21 53852569 Genie France Phone 433 0 2 37 26 09 99 Fax 433 0 2 37 26 09 98 Genie Malaysia Phone 65 98 480 775 Fax 65 67 533 4 Genie Iberica Phone 34 93 579 5042 Fax 34 93 579 5059 Genie Germany Phone 449 0 4202 88520 Fax 449 0 4202 8852 20 Genie J apan Phone 4813 3453 6082 Fax 81 3 3453 6083 Genie Korea Phone 482 25 587 267 Fax 82 25 583 910 Genie U K Phone 44 0 1476 584333 Fax 444 0 1476 584334 Genie Brasil Phone 455 11 41 665 755 Fax 55 11 41 665 754 Genie Mexico City Phone 52 55 5666 2 Fax 5255
17. Legend Y yes completed 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 May 2005 This page intentionally left blank Genie TEREX COMPANY 3 4 GS 30 GS 32 65 46 Part No 97385 May 2005 Section 3 Scheduled Maintenance Procedures Maintenance Inspection Report Model Checklist A Rev A YNR ChecklistB RevA YN A 1 Pre operation Serial number inspection 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 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 an N tag and remove t
18. Low battery voltage Batteries discharged Charge batteries 88 ECM has been erased Static strap may be missing from the machine Replace static strap Part No 97385 Genie TEREX COMPANY GS 30 GS 32 GS 46 Section 5 Fault Codes September 2005 T This page intentionally left blank Genie A TEREX COMPANY 5 4 GS 30 GS 32 GS 46 Part No 97385 September 2005 Section 6 Schematics Schematics About This Section There are two groups of schematics in this section An illustration legend precedes each group of drawings Electrical Schematics Observe and Obey Electrocution hazard Contact with AWARNING electrically charged circuits could M Troubleshooting and repair procedures shall be result in death or serious injury completed by a person trained and qualified on Remove all rings watches and the repair of this machine other jewelry M Immediately tag and remove from service a Hydraulic Schematics damaged or malfunctioning machine AWARNING Bodily injury hazard Spraying Repair any machine damage or malfunction hydraulic oil can penetrate and before operating the machine burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Before Troubleshooting Read understand and obey the safety rules and operating instructions in the appropriate
19. may become unbalanced and fall if not properly supported and secured to the lifting device Secure the ends of the scissor arms together at the steer end of the machine with a strap or other suitable device Secure the ends of the scissor arms together at the non steer end of the machine with a strap or other suitable device Remove the retaining fasteners securing the chassis mount bracket to the chassis at the steer end of the machine Attach a lifting strap from an overhead crane to the scissor arm assembly Raise the scissor arm assembly at the steer end with the overhead crane until the chassis mount bracket will clear the level sensor Genie Part No 97385 TEREX COMPANY GS 30 GS 32 GS 46 Section 4 Repair Procedures SCISSOR COMPONENTS 9 Remove the scissor assembly from the machine just enough to access both wear pads ADANGER Crushing hazard The scissor assembly will fall if not properly supported when removed from the drive chassis Component damage hazard Be careful not to damage the level sensor or limit switch while moving the scissor assembly CAUTION 10 Remove both old wear pads 11 Install two new wear pads 12 Slide the scissor assembly back into the drive chassis 13 Lower the scissor assembly into position and install the chassis mount bracket onto the chassis Securely install and tighten the fasteners Do not overtighten Component damage hazard Be
20. 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 GROUND CONTROLS Steer end 25 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 20 Raise the machine approximately 2 inches 5 cm Genie Part No 97385 TEREX COMPANY GS 30 GS 32 GS 46 4 57 Section 4 Repair Procedures September 2005 GROUND CONTROLS 21 GS 1530 and GS 1930 Place a 0 64 x 6x 6 inch 16 2 mm x 15 cm x 15 cm thick steel block under both wheels at the ground controls side of the machine GS 1532 and GS 1932 Place a 0 68 x 6x 6 inch 17 2 mm x 15 cm x 15 cm thick steel block under both wheels at the ground controls side of the machine GS 2032 and GS 2632 Place a 0 66 x 6x 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 GS 2046 GS 2646 and GS 3246 Place a 1 6 x 6 inch 25 4 mm x 15 cm x 15 cm thick steel block under both wh
21. 9 Pressure switch 8 normally open x t is x 2 N C 4 SENSOR Wire with description Circuits crossing no connection Diode 4 Circuits connection Connector Hour meter ZTN Light or flashing beacon Inductor noise suppression Limit switch Button or switch 1 Toggle switch CON 4 Emergency stop button ams CB2 Circuit breaker 30 86 87A ter 85 Control relay A Fuse Horn or alarm lt LED 09 Battery charger Level sensor Solenoid valve Solenoid valve with diode 6V DC Battery Capacitor am 2 di 5 S 7 N N WH B FPE 2 KS1 li KEY PLATFORM 1 SWITCH CONTROL I 4 3 GROUND 7 CONTROL p di Key switch DON Ace EIE Jct Joystick JOYSTICK CONTROLLER SW6 STEER LEFT RIGHT Part No 97385 GS 30 GS 32 GS 46 Section 6 Schematics September 2005 Electrical Schematic
22. GS 1530 1532 1930 1932 from serial number GS3005A 76389 to 79394 GS 1530 1532 1930 1932 from serial number GS3005B 76031 to 76920 NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF RD 4 6 4 WH WH 3 3 4 CR48 BL 1 1 POWER BK 2 2 RELAY TO US 5 Eso eS R24 25 OHM PS2 PLATFORM OVERLOAD LS6 PRESSURE SWITCH N C H O DOWN LIMIT SWITCH N O H C 4 amp 2 CR27A CR27B CR27C 9 OVERLOAD OVERLOAD fF 7 1 MOTOR CONT LOAD SENSE DOWN COIL 1 NC 4 27 30 86 30 86 30 86 LC pe 1 LEVEL 87 85 874 85 87 85 l 1 SENSOR LS5 CIRCUIT ian BOARD s 5 gt SWITCH gogog g 30 86 5 5 2 5 5 S7 5 8 gt LEVEL 5 DJ 5 2 21 ms 5 2 3 zz 5 SENSOR s 85 3 2 i 8 5 59 5
23. Manuals for these models Title Part No Genie GS 1530 and GS 1930 Service Manual First Edition before serial number 17408 39528 Genie GS 1530 and GS 1930 Service Manual Second Edition from serial number 17408 to 59999 72876 Genie GS 1530 and GS 1930 Service Manual Third Edition from serial number 60000 to 75999 96316 Genie GS 2032 Service Manual First Edition before serial number 17408 46326 Genie GS 2032 and GS 2632 Service Manual Second Edition from serial number 17408 to 59999 72963 Genie GS 2032 and GS 2632 Service Manual Third Edition from serial number 60000 to 75406 96316 Genie GS 2046 GS 2646 and GS 3246 Service Manual First Edition before serial number 17408 48339 Genie GS 2046 GS 2646 and GS 3246 Service Manual Second Edition from serial number 17408 to 59999 72972 Genie GS 2046 GS 2646 and GS 3246 Service Manual Third Edition from serial number 60000 to 75437 96316 Copyright 1997 by Genie Industries 97385 Rev September 2005 Fourth Edition Second Printing Genie is a registered trademark of Genie Industries in the USA and many other countries GS is a trademark of Genie Industries 4 Printed on recycled paper Printed in U S A Genie A TEREX COMPANY li GS
24. POWER UNIT 15 Umi 172 bar BYPASS H Platform up L J Relief valve system HYDRAULIC TANK L Hand pump manual brake release M Needle valve manual brake release N Platform lowering valve 0 Orifice platform down circuit P Accumulator R Pressure switch platform overload HS0035F 5 Check valve drive circuit Genie 6 32 GS 30 GS 32 GS 46 Part No 97385 September 200 5 Section 6 Schematics REVA Hydraulic Schematic GS 1530 1532 1930 1932 after serial number GS3005A 76491 GS 1530 1532 1930 1932 after serial number GS3005B 76084 LIFT CYLINDER ALL MODELS BRAKE EA N ts PLATFORM la OVERLOAD La 5 W gt Y9 n 5 PUMP H H BRAKE HR RELEASE 0 059 inch 191095 M Vey B1 THE ORIFICE IS LOCATED RIGHT UNDERNEATH THE FITTING STEER STEER LEFT DRIVE ie LEFT RIGHT Pug DM MOTOR 8 L 51 52 HP B AC M1 M4 4 va lt lt 10 psi 0 7 bar a Y x Y6 vs
25. 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 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 Test the coil for resistance See 6 4 How to Test a Coil 2 Connect a 100 resistor to the negative terminal of a known good 9V DC battery Connect the other end of the resistor to a terminal on the Coil The battery should read 9V DC or more when measured across the terminals Resistor 100 Genie part number 27287 3 Setamultimeter to read DC amperage The multimeter when set to read DC amperage should be capable of reading up to 800 mA 4 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 MANIFOLDS COIL A MULTI 1 100 9V RESISTOR a multimeter b 9VDO battery 0 100 resistor d coil Note Dotted lines in illustration indicate a reversed connection as specified in step 6 5 Momentarily connect the positive lead from the multim
26. The brake release hand pump manifold is mounted behind the entry ladder Index Schematic No Description Item Function Torque 1 Hand pump recorte Manual brake release 30 ft lbs 41 Nm 2 Needle valve Manual brake release enable 45 50 in lbs 5 Nm Note alpha callouts refer to corresponding notes on the hydraulic schematic Genie A TEREX COMPANY 4 78 GS 30 GS 32 GS 46 Part No 97385 September 2005 Section 5 Fault Codes Fault Codes Before Troubleshooting Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necessary tools and test equipment are available and ready for use Observe and Obey Be aware of the following hazards and follow Troubleshooting and repair procedures shall be generally accepted safe workshop practices completed by a person trained and qualified on i 17117111 Crushing hazard When testing the repair of this machine ADANGER am hydraulic Immediately tag and remove from service component always support damaged or malfunctioning machine the structure and secure it from movement Repair any machine damage or malfunction before operating the machine AWARNING Electrocution hazard Contact T with electrically charged circuits
27. Unless M You are trained and qualified to perform maintenance on this machine You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations You have the appropriate tools lifting equipment and a suitable workshop Genie TEREX COMPANY Part No 97385 GS 30 GS 32 65 46 V Section 1 Safety Rules September 2005 SAFETY RULES Personal Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority Read each procedure thoroughly This manual and the decals on the machine use signal words to identify the following Safety alert symbol used to alert personnelto potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death J 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 safet
28. Unless otherwise specified perform each death or serous repair procedure with the machine in the injury Remove all rings watches following configuration and other jewelry Machine parked on a firm level surface juny Spraying Platform in the stowed position AWARNING hydraulic oil can penetrate and Key switch in the off position with the key burn skin Loosen hydraulic removed connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 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 Genie TEREX COMPANY Part No 97385 GS 30 GS 32 GS 46 5 Section 5 Fault Codes September 2005 _ s a j sss OO FAULT CODES About This Section LED Diagnostic Readout When a malfunction is discovered the fault code charts in this section will help a service professional pinpoint the cause of the problem To use this section basic hand tools and certain pieces of test equipment are required voltmeter ohmmeter pressure gauges General Repair Process The diagnostic readout displays numerical codes that provide information about the machine Identify a Troubleshoot symptoms operating status and about malfunctions The dot to the right of the numbers remain on when a 4 fa
29. a cai le DC AC INVERTER OUR FLASHING To 85 BEACONS cm OPTION L AUTO STYLE HORN i OPTION 1 ES0142F Genie TEREX COMPANY 6 24 GS 30 GS 32 GS 46 Part No 97385 September 2005 Section 6 Schematics Electrical Schematic REV B CE Models GS 2032 2632 from serial number GS3205 75407 to 77290 GS 2046 2646 3246 from serial number GS4605 75438 to 76734 NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF RD RD 4 4 4 WH WH 30 86 CR48 BL 1 1 yas 2 2 RELAY TO U5 gr 85 E STOP 98 5 R24 ME NC LS6 D PS2 Down SWITCH N O H C 4 2 CR27A CR27B CR27C MEE OVERLOAD OVERLOAD OVERLOAD pass motor conn LOAD SENSE DOWN COIL ux 30 86 30 86 30 86 0 Pot J J OF LEVEL 87 85 87A 85 87 85 LS5 SENSOR UP 1 BOARD C57
30. index 5 at the ground control side 30 Place a rod through the number 4 center pivot pin at the ground control side index 5 and twist to remove the pin 31 Remove the retaining fasteners from the number 4 pivot pin index 421 at the non steer end 32 Use a soft metal drift to remove the number 4 pivot pin index 21 from the non steer end of the machine Remove the number 4 outer arm at the ground control side index 20 from the machine Crushing hazard The number 4 ACAUTION outer arm at the ground control side index 420 may become unbalanced and fall if not properly supported when removed from the machine 33 Attach a lifting strap from an overhead crane to the number 4 outer arm at the battery side index 20 34 Remove the retaining fasteners from the number 4 center pivot pin index 5 at the battery side 35 Place a rod through the number 4 center pivot pin at the battery side index 5 and twist to remove the pin SCISSOR COMPONENTS 36 Remove the number 4 outer arm index 20 from the machine Crushing hazard The number 4 A CAUTION outer arm index 420 may become unbalanced and fall if not properly supported when removed from the machine 37 Attach a lifting strap from an overhead crane to the number 4 inner arm index 19 Raise the arm to a vertical position 38 Remove the retaining fasteners from the number 4 pivot pin at the steer end of the machine index 6 39 Use a soft
31. kao 6 deem PLATFORM CONTROLS CIRCUIT BOARD 9 8 joystick controller JC1 b alarm 1 c platform controls circuit board U3 d red Emergency Stop button P2 REV 1 1 Circuit Boards How to Remove the Platform Controls Circuit Board 1 Pushin the red Emergency Stop button to the off position at both the ground and platform controls 2 Remove the fasteners securing the platform control box together Open the control box 3 Locate the circuit board mounted to the top half of the platform control box AWARNING Electrocution 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 wire harness connectors from the circuit board 5 Carefully remove the circuit board retaining fasteners and remove the circuit board from the control box Genie A TEREX COMPANY 4 2 GS 30 GS 32 GS 46 Part No 97385 October 2005 Section 4 Repair Procedures REV 1 2 Controller
32. stowed drive speed percentage Press and hold the speed select button Result The diagnostic display will show the stowed high torque drive speed percentage Use the steering thumb rocker switch on the joystick to increase or decrease the stowed high torque drive speed percentage 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 97385 GS 30 GS 32 GS 46 4 7 Section 4 Repair Procedures October 2005 PLATFORM CONTROLS REV C 1 3 Software Configuration The Electronic Control Module ECM contains programming for all configurations of the Genie GS 30 GS 32 and GS 46 The machine can be adjusted to a different configuration using the buttons at the platform controls How to Determine the 8 joystick controller 1 Software Configu ration b lift function select button c red Emergency Stop button P2 1 Remove the platform controls from the platform d blue arrow 2 Turn key switch to platform control and pull 4 Slowly move the joystick in the direction out the red Emergency Stop button to the on indicated by the blue arrow D arare ground ane platform Result The machine configuration code will appear in the diagnostic display Result The diagnostic display at the platform controls will show the battery condition See 1 4 How to Determine the Battery Voltage 5 Pushin t
33. 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 Genie Part No 97385 TEREX COMPANY GS 30 GS 32 GS 46 Section 3 Scheduled Maintenance Procedures May 2005 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 Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Bodily injury hazard Batteries contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water Perform this procedure 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
34. 30 GS 32 65 46 Part No 97385 September 2005 INTRODUCTION Serial Number Legend Genie Model GS 1930 Serial number GS3005A 12345 Model year 2005 Manufacture date 04 12 05 Electrical schematic number 50141 Machine unladen weight 2 714 Ib 1 231 kg Rated work load including occupants 500 Ib 227 kg Maximum allowable inclination of the chassis N A GS30 05 12345 Gradeability N A Model Maximum allowable side force 100 Ib 445 kg Sequence Maximum number of platform occupants 2 number Model year Country of manufacture USA This machine complies with Facility code used only for models manufactured ANSI A92 6 1999 in multiple facilities B354 2 01 Genie Industries 18340 NE 76th Street Redmond WA 98052 USA PN 77055 TEREX COMPANY No 97385 GS 30 GS 32 GS 46 ili September 2005 This page intentionally left blank Genie A TEREX COMPANY iv GS 30 GS 32 65 46 PartNo 97385 September 2005 Section 1 Safety Rules Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the appropriate Operator s Manual on your machine will result in death or serious injury Many of the hazards identified in the operator s manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance
35. 9 OVERLOAD OVERLOAD OVERLOAD sss a MOTOR CONT LOAD SENSE DOWN COIL f 27 30 86 30 86 30 86 N C r l LEVEL i 87 85 87A 85 87 85 l SENSOR LS5 CIRCUIT UP BOARD C5 4 LIMIT 4700 uF SWITCH t 304 86 5 5 5 5 5 si S7 Y m gt gt Y 9i LEVEL Miss TIJ 2 5 5 4 2 2822 SENSOR Ter 85 3 2 eheu i 8 5 59 5 3 BK 2 5 1 CR27D Be 5 5 5 OVERLOAD a0 DOWN DELAY 9 A m o a 2 154 2 9 2 3 LL Q I LL cl C2 Bi 9 A6 10 B6 C12 A4 A2 Bi 5 l IN OUT OUT IN IN IN OUT Us ELECTRONIC CONTROL MODULE OUT OUT OUT OUT OUT C8 C7 B7 A7 C6 ee ee T x d Kcd cc CA x LES gt Y1 YS Y4 Y5 Y6 Y9 Y7 Y8 PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM RIGHT LEFT REVERSE FORWARD DOWN DOWN GS 3246 4 __ L_ Le L GND 4 ES0142D Genie TEREX COMPANY Part No 97385 GS 30 GS 32 GS 46 6 13 Section 6
36. C9 Work light L30 option C10 Not used C11 Level sensor signal S7 input C12 Down limit switch LS66 input No 97385 TEREX COMPANY GS 30 GS 32 GS 46 Section 6 Schematics September 2005 Ground Controls and Level Sensor Harness REVA GROUNDCONTROLS GROUND CONTROLS e MOTOR CONTROLLER B TERMINAL B Bec CB2 KS1 7A CIRCUIT KEY SWITCH 3 1 BREAKER MOTOR CONTROLLER TERMINAL 1 WH G6 SPIN OMNES NS BN amp HOUR METER ECM PIN 812 0 TS66 PLATFORM UP DOWN ECM PIN 12 DOWN TOGGLE SWITCH CR48 TERMINAL 30 WH ECM PIN A11 1 1 gt EMERGENCY STOP LEVEL SENSOR HARNESS ANSI AND CSA MODELS 0 H5 LS6 MULTI FUNCTION ALARM S7 DOWN LIMIT SWITCH SHOWN IN STOWED POSITION e ECM PIN B9 LEVEL SENSOR 2 e __ crag TERMINAL 87 13 14 e e WH CR48 TERMINAL 87 Fi ppm BK 4g 902 ECM PIN C12 RD Y Pe SN ECM PIN C11 BN GROUND le RD ECM PIN A5 NOT USED L 4 LEVEL SENSOR HARNESS CE MODELS AND ANSI CSA MODELS WITH PLATFORM OVERLOAD H5 LS6 MULTI FUNCTION ALARM S7 DOWN LIMIT SWITCH 1 Bi
37. Check the Scissor Arm Wear 3 20 D 2 Calibrate the Platform Overload System if equipped 3 22 D 3 Replace the Hydraulic Tank Return Filter 3 25 Checklist E Procedure E 1 Test or Replace the Hydraulic Oil 3 26 Genie GS 30 GS 32 GS 46 PartNo 97385 September 2005 Section 4 Rev PartNo 97385 TABLE OF CONTENTS Repair Procedures MEE 4 1 Platform Controls 1 1 CIRCUIT 5 4 2 1 2 Controller Adjustments 4 3 13 Software Configuration 2 ioc erai a obo a ee 4 8 Platform Components 2 1 4 12 22 Extension ox u u u uuu n tte eres 4 13 ScissorComponents 3 1 Scissor Assembly GS 1530 95 1532 4 14 32 Scissor Assembly GS 1930 and GS 1932 4 20 3 3 Scissor Assembly GS 2032 and 95 2046 4 28 34 Scissor Assembly GS 2632 and 95 2646 4 34 3 5 Scissor Assembly 65 3246 4 42 36 4 50 Ground Controls 41 Manual Platform Lowering Cable 4 55 4 2 4 56
38. GS 3246 Tire size solid rubber 15 5in 38 1 12 7 cm Tire contact area 10 sq in 64 5 cm Castle nut torque dry 300 ft lbs 406 7 Nm Castle nut torque lubricated 225 ft lbs 305 Nm Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie Part No 97385 TEREX COMPANY GS 30 GS 32 GS 46 2 1 Section 2 Specifications September 2005 SPECIFICATIONS Performance Specifications Drive speed maximum GS 1530 GS 1532 GS 1930 GS 1932 Platform stowed fast 2 5 mph 40 ft 10 7 sec 4 km h 12 2 m 10 7 sec Platform stowed slow 1 1 mph 40 ft 24 8 sec 1 8 km h 12 2 m 24 8 sec Platform raised 0 5 mph 40 ft 55 sec 0 8 km h 12 2 m 55 sec GS 2032 GS 2632 GS 2046 GS 2646 GS 3246 Platform stowed fast 2 2 mph 40 ft 12 4 sec 3 5 km h 12 2 m 12 4 sec Platform stowed slow 1 1 mph 40 ft 24 8 sec 1 8 km h 12 2 m 24 8 sec Platform raised 0 5 mph 40 ft 55 sec 0 8 km h 12 2 m 55 sec Braking distance maximum 24 in 12 in 61 cm 30 cm High range on paved surface Gradeability GS 3246 25 All other models 30 Airborne noise emissions 70 dB Maximum sound level at normal operation workstations A weighted REV B Function speed maximum from platform controls with 1 person in platform GS 1530 GS 1532 P
39. Le Le 4 GND ES0142H enie Part No 97385 A TEREX COMPANY GS 30 GS 32 GS 46 Section 6 Schematics September 2005 Electrical Schematic CE Models REVA GS 2032 2632 after serial number GS3205 77290 GS 2046 2646 3246 after serial number GS4605 76734 2 QD3 4 4 BK POWER PLATFORM EK T 3 2 3 RD POWER TO GROUND BD 1 1 WH 1 opos 2 2 BL DATALINK HIGH t 5 5 OR DATA LINK LOW 1 U3 D7 PLATFORM CONTROLS VOLTAGE PRINTED CIRCUIT BOARD REGULATOR HALL EFFECT JC1 ae worsTick 2 GN 1 aw SW5 swe FUNCTION ENABLE STEER LEFT RIGHT OR i r J 29 BK PLATFORM CONTROLS MEMBRANE DECAL LIFT LED L16 DRIVE LED L17 POUT4 HIGH TORQUE LED L21 PIN1 DIAGNOSTIC DISPLAY PIN2 HIGH TORQUE BN6 PIN3 HORN BN5 PIN4 DRIVE ENABLE BN8 POUT11 LIFT ENABLE PIN11 PLATFORM CONTROLLER 2 50142 gt lt TEREX COMPANY GS 30 GS 32 GS 46 Part No 97385 September 2005 Section 6 Schematics
40. Optional Hydraulic Oil The hydraulic tank is a vented type tank The breather cap has an internal air filter that can become clogged or over time can deteriorate If the breather cap is faulty or improperly installed impurities can enter the hydraulic system which may cause component damage Extremely dirty conditions may require that the cap be inspected more often 1 Remove and discard the hydraulic tank breather cap 2 Install and new cap onto the tank Genie TEREX COMPANY 3 22 GS 30 GS 32 GS 46 REVA Part No 97385 May 2005 Section 3 Scheduled Maintenance Procedures RES Checklist D Procedures E Se 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 GS 1530 32 and GS 1930 32 1 Measure the distance between the number one outer arm cross tube and the chassis deck at the ground controls side of the non steer end of the machine Result The measurement is 0 94 inch 24 mm or more Proceed to step 2 Result The measurement is less than 0 94 inch 24 mm Replace both wear pads Refer to Repair Procedure 3 1 or 3 2 How to Replace the Scissor Arm Repair Pads 2 Measure the distance between the numb
41. Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Raise the platform 7 to 8 feet 2 1 to 2 4 m 2 Lift the safety arm move it to the center of the scissor arm and rotate down to a vertical position 3 Lower the platform onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 4 Tag and disconnect the wiring from the solenoid valve coil at the barrel end of the lift cylinder 5 Models with platform overload option Tag and disconnect the wiring from the platform overload switch Solenoid valve 2 position 2 way N C 20 ft lbs schematic item N 27 Nm Coil nut 5 ft lbs 7Nm Genie Part No 97385 TEREX COMPANY GS 30 GS 32 GS 46 4 51 Section 4 Repair Procedures September 2005 SCISSOR COMPONENTS 6 Loosen the adjustment nuts on the solenoid valve and disconnect the manual lowering cable from the valve During assembly the manual platform lowering cable needs to be properly adjusted See 4 1 How to Adjust the Manual Platform Lowering Cable 7 Remove the fasteners securing the manual lowering cable mount bracket to the cylinder Remove the bracket from the cylinder 8 Tag disconnect and plug the hydraulic hoses on the lift cylinder Cap the fittings on the cylinder AWARNING s injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pres
42. This procedure must only be performed by a trained service professional Attempting this procedure without the necessary skills will result in death or serious injury On machines with software revision A4 and higher setting the raised drive speed percentage to zero will result in the steer function being disabled when the platform is above the down limit switch Refer to 1 2 How to Determine the Software Revision Level 1 Pull out the red Emergency Stop button to the on position at the ground controls 2 Push in the red Emergency Stop button to the off position at the platform controls 3 Turn the key switch to platform control 4 Atthe platform controls press and hold the lift function select and horn buttons and pull out the red Emergency Stop button to the on position Result The diagnostic display will show PS 5 Release the lift function select and horn buttons Result The diagnostic display will show the maximum lift 50660 percentage PLATFORM CONTROLS gees 9 C a joystick controller JC1 with thumb steering rocker SW6 horn button BN5 lift function select button BN9 diagnostic display G8 red Emergency Stop button P2 drive function select BN8 speed select button BN6 p 20 6 Press the drive function select button Result The diagnostic display will show the stowed drive speed percentage 7 Use the steering thumb rocke
43. and or hose end must be replaced and then torqued to specification during installation Refer to Disconnect the number 3 cable bridge from the number 3 outer arm index 11 and remove the cable bridge from the machine Section 2 Hydraulic Hose and Fitting Torque Specifications Remove the platform See 2 1 How to Hemove Remove the retaining fasteners from the number 4 pivot pin index 1 Use a soft metal drift to remove the number 4 the Platform pivot pin index 1 Remove the platform ket f h hine 2 Support and secure the entry ladder to an Hom The machine appropriate lifting device 8 Attach a lifting strap from an overhead crane to the number 3 outer arm at the ground control 3 Remove the fasteners from the entry ladder and side index 11 remove the entry ladder from the machine 9 Remove the retaining fasteners from the number 3 center pivot pin index 2 at the ground control side Crushing hazard The entry ladder ACAUTION may become unbalanced and fall if not properly supported and secured to the lifting device 10 Place a rod through the number 3 center pivot pin at the ground control side index 2 and 4 Remove the cables from the number 3 cable twist to remove the pin bridge and lay them off to the side 11 Remove the retaining fasteners from the number 3 pivot pin index 12 at the non steer end Component damage hazard CAUTION Cables can be damaged if they are kinked or pinc
44. both sides of the wheels at the steer end of the machine 4 Remove the platform controls from the platform 10 Install the relief valve cap Perform this test from the ground with the platform controls Do not stand in the platform 11 Repeat steps 5 through 7 to confirm the relief valve pressure 5 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls GS 32 and GS 46 a b 0 0 test port system relief valve steer relief valve lift relief valve GS 1530 32 and GS 1930 32 a test port b system relief valve Genie TEREX COMPANY GS 30 GS 32 GS 46 4 67 Part No 97385 Section 4 Repair Procedures September 2005 MANIFOLDS REV B How to Adjust the 7 Move and hold the joystick fully in either Platform Lift Relief Valve direction while observing the pressure reading on the pressure gauge Note the pressure Be sure that the hydraulic oil level Refer to Section 2 Specifications is at the FULL mark on the hydraulic 8 Turn the machine off Hold the system relief tank valve with a wrench and remove the cap 1 Locate the system relief valve on the function hydraulic schematic item or AB manifold item 1 9 Adjustthe internal hex socket Turn it clockwise 2 Connect a 0 to 5000 psi 0 to 350 bar to increase the pressure or counterclockwise to pressure gauge to the test port on the function
45. component damage Dealer service is required When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform See 2 1 How to Remove the Platform 2 Remove the cables from the number 3 outer arm index 11 at the ground controls side Component damage hazard CAUTION Cables can be damaged if they are kinked or pinched 3 Remove the cables from the number 3 cable bridge and lay them off to the side Component damage hazard CAUTION Cables can be damaged if they are kinked or pinched Models with dual number 3 outer arms 4 Attach a lifting strap from an overhead crane to the number 3 outer arm at the ground controls side of the machine index 11 GS 1530 GS 1532 Cable bridge legend a cable bridge 3 b cable bridge 2 C cable bridge 1 5 Remove the external snap rings and retaining fasteners from the number 3 center pivot pin at the ground control side of the machine index 2 6 Use a soft metal drift to remove the number center pivot pin at the ground control side of the machine index 2 7 Remove the retaining fasteners from the number 3 pivot pin index 12 at the non steer end of the machine 8 Use a soft metal drift to remove the number 3 pivot pin index 12 from the non steer end of the machin
46. from the machine 9 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 Genie A TEREX COMPANY GS 30 GS 32 GS 46 Part No 97385 September 2005 Section 4 Repair Procedures REVA 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 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
47. hand until the top O ring is met then torque to specification 3 If required install the valve coil s onto the valve stem Install the coil nut onto the valve stem and torque to specification Genie Torque 4 5 ft los 5 7 Nm 5 7 ft los 7 9 Nm 20 ft lbs 27 Nm 25 ft lbs 34 Nm 18 ft lbs 24 Nm 25 ft lbs 34 Nm 20 ft lbs 27 Nm 25 ft lbs 34 Nm 26 ft lbs 35 Nm 25 ft lbs 34 Nm 20 ft lbs 27 Nm TEREX COMPANY 4 64 GS 30 GS 32 GS 46 Part No 97385 September 2005 Section 4 Repair Procedures REV B MANIFOLDS Note alpha numeric callouts refer to corresponding notes on the electrical schematic Note alpha callouts refer to corresponding notes on the hydraulic schematic Genie Part No 97385 GS 30 GS 32 GS 46 4 65 Section 4 Repair Procedures September 2005 ESE MANIFOLDS REV B 6 3 Check Valve Manifold Components GS 1530 GS 1532 GS 1930 and GS 1932 The check valve manifold is mounted on the function manifold Index Schematic No Description Item Function Torque 1 Check valve 200 psi 13 8 bar une n IE Drive circuit 20 ft lbs 27 Nm D Note alpha callouts refer to corresponding notes on the hydraulic schematic How to Install a Valve Cartridge 1 Dip the cartridge in clean oil to lube
48. 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 On machines with software revision A4 and higher setting the raised drive speed percentage to zero will result in the steer function being disabled when the platform is above the down limit switch Refer to 1 2 How to Determine the Software Revision Level 1 Pull out the red Emergency Stop button to the on position at the ground controls 2 Push in the red Emergency Stop button to the off position at the platform controls 3 Turn the key switch to platform control 4 Atthe platform controls press and hold the lift function select and horn buttons and pull out the red Emergency Stop button to the on position Result The diagnostic display will show PS 5 Release the lift function select and horn buttons Result The diagnostic display will show the maximum lift 50660 percentage Genie TEREX COMPANY ey e PLATFORM CONTROLS a joystick controller JC1 with thumb steering rocker SW6 horn button BN5 lift function select button BN9 diagnostic display G8 red Emergency Stop button P2 drive function select BN8 speed select button BN6 5 20 Press the drive function select button Result The diagnostic display will show the
49. key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls GS 1530 32 and GS 1930 32 a test port b steer relief valve Genie Part No 97385 TEREX COMPANY GS 30 GS 32 GS 46 Section 4 Repair Procedures September 2005 MANIFOLDS 5 Activate the function enable switch and press and hold the steer thumb rocker switch to the right Allow the wheels to completely turn to the right Continue holding the switch while observing the pressure reading on the pressure gauge Note the pressure Refer to Section 2 Specifications 6 Press and hold the steer thumb rocker switch to the left Allow the wheels to completely turn to the left Continue holding the switch while observing the pressure reading on the pressure gauge 7 Turnthe machine off Hold the steer relief valve with a wrench and remove the cap schematic item G or AH 8 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Component damage hazard Do CAUTION not adjust the relief valve pressures higher than specifications 9 Install the relief valve cap 10 Repeat steps 5 through 6 to confirm the relief valve pressure GS 32 and GS 46 test port System relief valve steer relief valve lift relief valve REV B 6 5 Valve Coils How to Test a Coil
50. metal drift to remove the number 4 pivot pin index 6 from the steer end of the machine Remove the number 4 inner arm index 19 from the machine Crushing hazard The number 4 ACAUTION inner arm index 19 may become unbalanced and fall if not properly supported when removed from the machine 40 Remove the cables from the number 3A and 3B cable bridges and lay them off to the side Component damage hazard CAUTION Cables can be damaged if they are kinked or pinched 41 Disconnect the number 3A and 3B cable bridges from the scissor linkset and remove both cable bridges from the machine 42 Attach a lifting strap from an overhead crane to the number 3 outer arm at the ground control side index 7 43 Remove the retaining fasteners from the number 3 center pivot pin index 8 at the ground control side 44 Place a rod through the number 3 center pivot pin at the ground control side index 8 and twist to remove the pin 45 Remove the retaining fasteners from the number 3 pivot pin index 24 at the non steer end Genie Part No 97385 TEREX COMPANY GS 30 GS 32 GS 46 Section 4 Repair Procedures September 2005 SCISSOR COMPONENTS 46 Use a soft metal drift to remove the number 3 pivot pin index 24 from the non steer end of the machine Remove the number 3 outer arm at the ground control side index 7 from the machine Crushing hazard The number 3 ACAUTION outer arm at t
51. module tray 3 Tag and disconnect the hydraulic tank return hard line from the hydraulic filter head and remove the hard line from the tank Cap the fitting on the filter head 4 Tag and disconnect the hydraulic pump inlet hard line and remove the hard line from the tank Cap the fitting on the pump 5 Remove the hydraulic tank retaining fasteners and remove the hydraulic tank from the machine 6 Drain all of the oil into a suitable container Refer to Section 2 Specifications for capacity information AWARNING injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 7 Clean up any oil that may have spilled Properly discard the used oil 8 Clean the inside of the hydraulic tank using a mild solvent Allow the tank to dry completely 9 Install the hydraulic tank and install and tighten the hydraulic tank retaining fasteners Torque to specification Torque specifications 35 in Ibs 4 Nm Hydraulic tank retaining fasteners dry Hydraulic tank retaining fasteners lubricated 26 in lbs 2 9Nm Genie Part No 97385 TEREX COMPANY GS 30 GS 32 GS 46 Section 3 Scheduled Maintenance Procedures May 2005 CHECKLIST E PROCEDURE 10 Install the hydraulic pump inlet hard line into the tank Install the fitting onto the pump and torque to specif
52. pin index 14 at the non steer end of the machine GS 46 4 21 Section 4 Repair Procedures September 2005 SCISSOR COMPONENTS 8 Use a soft metal drift to remove the number 4 pivot pin index 14 from the non steer end of the machine Remove the number 4 outer arm at the ground control side index 13 from the machine AWARNING Crushing hazard The number 3 outer arm may become unbalanced and fall if not properly supported when removed from the machine 9 Attach a lifting strap from an overhead crane to the number 4 outer arm at the battery pack side of the machine index 13 10 Remove the external snap rings and retaining fasteners from the number 4 center pivot pin at the battery pack side of the machine index 2 11 Use a soft metal drift to remove the number 4 center pivot pin at the battery pack side of the machine index 2 12 Remove the number 4 outer arm at the battery pack side index 13 from the machine AWARNING Crushing hazard The number 4 outer arm may become unbalanced and fall if not properly supported when removed from the machine Models with a single number 4 outer arm assembly 13 Attach a lifting strap from an overhead crane to the number 4 outer arm index 13 14 Remove the external snap rings and retaining fasteners from the number 4 center pivot pins index 2 15 Use a soft metal drift to remove the number 4 center pivot pins index 2 REVA 16 Remove the
53. retaining fasteners from the number 4 pivot pin index 14 at the non steer end of the machine 17 Use a soft metal drift to remove the number 4 pivot pin index 14 from the non steer end of the machine Remove the number 4 outer arm index 13 from the machine AWARNING Crushing hazard The number 4 outer arm may become unbalanced and fall if not properly supported when removed from the machine All models 18 Remove the number 4 cable bridge mounting fasteners and remove the cable bridge from the machine 19 Attach a lifting strap from an overhead crane to the number 4 inner arm index 12 20 Remove the retaining fasteners from the number 4 pivot pin index 3 21 Use a soft metal drift to remove the number 4 pivot pin index 3 at the steer end Remove the number 4 inner arm index 12 from the machine Crushing hazard The number 4 ACAUTION inner arm may become unbalanced and fall if not properly supported when removed from the machine 22 Remove the cables from the number 3 cable bridge and lay them off to the side Component damage hazard CAUTION Cables can be damaged if they are kinked or pinched 23 Remove the number 3 cable bridge mounting fasteners and remove the cable bridge from the machine Genie A TEREX COMPANY GS 30 GS 32 GS 46 Part No 97385 September 2005 Section 4 Repair Procedures REVA 24 Attach a lifting strap from an overhead crane to the number 3 o
54. side index 5 and twist to remove the pin Genie A TEREX COMPANY GS 30 GS 32 GS 46 Part No 97385 September 2005 Section 4 Repair Procedures REVA 30 Remove the retaining fasteners from the number 2 pivot pin index 15 at the non steer end 31 Use a soft metal drift to remove the number 2 pivot pin index 15 from the non steer end of the machine Remove the number 2 outer arm at the ground control side index 14 from the machine Crushing hazard The number 2 ACAUTION outer arm at the ground control side index 14 may become unbalanced and fall if not properly supported when the pivot pin is removed 32 Attach a lifting strap from an overhead crane to the number 2 outer arm at the battery side index 14 33 Remove the retaining fasteners from the number 2 center pivot pin index 5 at the battery side 34 Place a rod through the number 2 center pivot pin at the battery side index 5 and twist to remove the pin Crushing hazard The number 2 ACAUTION outer arm index 14 may become unbalanced and fall if not properly supported when the pivot pin is removed 35 Remove the number 2 outer arm index 14 from the machine Crushing hazard The number 2 ACAUTION outer arm index 14 may become unbalanced and fall if not properly supported when removed from the machine 36 Attach a lifting strap from an overhead crane to the number 2 inner arm index 13 Raise the arm
55. soft metal drift to remove the number 3 pivot pin index 12 from the non steer end of the machine Remove the number 3 outer arm index 11 from the machine AWARNING Crushing hazard The number 3 outer arm may become unbalanced and fall if not properly supported when removed from the machine All models 18 Remove the number 3 cable bridge mounting fasteners and remove the cable bridge from the machine 19 Attach a lifting strap from an overhead crane to the lug on the rod end of the lift cylinder for support Do not apply any lifting pressure REVA 20 Remove the pin retaining fasteners from the lift cylinder rod end pivot pin index 3 Use a soft metal drift to remove the pin Bodily injury hazard The cylinder ACAUTION may fall when the rod end pivot pin is removed if not properly supported 21 Lower the cylinder onto the number 1 inner arm index 8 Component damage hazard CAUTION Cables can be damaged if they are kinked or pinched 22 Attach a lifting strap from an overhead crane to the number 3 inner arm index 10 23 Remove the retaining fasteners from the number 3 pivot pin index 4 at the steer end 24 Use a soft metal drift to remove the number 3 pivot pin index 4 Remove the number 3 inner arm index 10 from the machine AWARNING Bodily injury hazard The number 3 inner arm may become unbalanced and fall if not properly supported when removed from the machine 25 Remove the c
56. strap from an overhead crane to the number 2 outer arm at the ground control side index 26 65 Remove the retaining fasteners from the number 2 center pivot pin index 11 at the ground control side 66 Place a rod through the number 2 center pivot pin at the ground control side index 11 and twist to remove the pin 67 Remove the retaining fasteners from the number 2 pivot pin index 27 at the non steer end 68 Use a soft metal drift to remove the number 2 pivot pin index 27 from the non steer end of the machine Remove the number 2 outer arm at the ground control side index 26 from the machine Crushing hazard The number 2 ACAUTION outer arm at the ground control side index 426 may become unbalanced and fall if not properly supported when the pivot pin is removed 69 Attach a lifting strap from an overhead crane to the number 2 outer arm at the battery side index 26 70 Remove the retaining fasteners from the number 2 center pivot pin index 11 at the battery side 71 Place a rod through the number 2 center pivot pin at the battery side index 11 and twist to remove the pin Crushing hazard The number 2 ACAUTION outer arm index 26 may become unbalanced and fall if not properly supported when the pivot pin is removed SCISSOR COMPONENTS 72 Remove the number 2 outer arm index 26 from the machine Crushing hazard The number 2 A CAUTION outer arm index 426 may become unbalan
57. the O rings 2 Screw the cartridge in by hand until the top O ring is met then torque to specification 3 If required install the valve coil s onto the valve stem Install the coil nut onto the valve stem and torque to specification Genie TEREX COMPANY 4 66 GS 30 GS 32 GS 46 Part No 97385 September 2005 Section 4 Repair Procedures _ REV 8 MANIFOLDS 6 4 6 Press and hold the function enable switch Valve Adjustments 7 Move and hold the joystick fully in either direction while observing the pressure reading on the pressure gauge Note the pressure Refer to Section 2 Specifications Function Manifold How to Adjust the 8 Turn the machine off Hold the system relief System Relief Valve valve with wrench and remove the Be sure that the hydraulic oil level schematic item or AB is at the FuLL mark on the hydraulic tank Locate the system relief valve on the function manifold item Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure 74711111 hazard Failure to adjust the relief valves to specification could result in the machine tipping over causing death or serious injury Do not adjust the relief valve pressures higher than specifications 2 Connect a 0 5000 psi 0 to 350 bar pressure gauge to the test port on the function manifold schematic item A or AA 3 Chock
58. the entry ladder to an appropriate lifting device 5 Disconnect the number 5 cable bridge from the number 5 outer arm index 17 and remove the cable bridge from the machine 3 Remove the fasteners from the entry ladder and remove the entry ladder from the machine Crushing hazard The entry ladder ACAUTION may become unbalanced and fall 8 if not properly supported and secured to the lifting device 7 Use a soft metal drift to remove the number 6 pivot pin index 1 Remove the platform mount bracket from the machine Remove the retaining fasteners from the number 6 pivot pin index 1 4 Remove the cables from the number 5 cable bridge and lay them off to the side 8 Attach a lifting strap from an overhead crane to the number 5 outer arm at the ground control side index 17 Component damage hazard CAUTION Cables can be damaged if they are kinked or pinched Genie TEREX COMPANY Part No 97385 GS 30 GS 32 GS 46 4 43 Section 4 Repair Procedures September 2005 SCISSOR COMPONENTS 9 Remove the retaining fasteners from the number 5 center pivot pin index 2 at the ground control side 10 Place a rod through the number 5 center pivot pin at the ground control side index 2 and twist to remove the pin 11 Remove the retaining fasteners from the number 5 pivot pin index 18 at the non steer end 12 Use a soft metal drift to remove the number 5 pivot pin index 18 from the non s
59. this procedure to allow the battery cells to equalize 1 Puton protective clothing and eye wear 2 Be sure that the battery cable connections are free of corrosion 3 Be sure that the battery retaining fasteners and cable connections are tight REVA Models without maintenance free or sealed batteries 4 Remove the battery vent caps from all batteries 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 5 Checkthe battery acid level of each battery If needed replenish with distilled water to the bottom of the battery fill tube Do not overfill 6 Install the battery vent caps U9 Battery Charger batteries B5 275A fuse F6 quick disconnect QD1 battery charger U9 Qo om All models 7 Check each battery pack and verify that the batteries are wired correctly Genie TEREX COMPANY GS 30 GS 32 GS 46 Part No 97385 May 2005 Section 3 Scheduled Maintenance Procedures eserd REVA CHECKLIST B PROCEDURES 8 Inspect the battery charger plug and pigtail for damage or excessive insulation wear Replace as required 9 Connectthe battery charger to a properly grounded 115V 60Hz or 230V 60Hz single phase AC power supply Result The charger should operate and begin charging the batteries W If simultan
60. to a vertical position SCISSOR COMPONENTS 37 Remove the retaining fasteners from the number 2 pivot pin at the steer end of the machine index 6 38 Use a soft metal drift to remove the number 2 pivot pin index 6 from the steer end of the machine Remove the number 2 inner arm index 13 from the machine Crushing hazard The number 2 ACAUTION inner arm index 13 may become unbalanced and fall if not properly supported when the pivot pin is removed 39 Attach a lifting strap from an overhead crane to the number 1 inner arm index 8 40 Raise the number 1 inner arm index 8 approximately 2 feet 60 cm 41 Place a4 x 4 48 inch 10 cm x 10 cm 1 2 long block across both sides of the chassis under the number 1 center pivot pin index 7 42 Lower the scissor arms onto the block that was placed across the chassis Bodily injury hazard Keep hands ACAUTION clear of moving parts when lowering the scissor arms 43 Attach a lifting strap from an overhead crane to the lug of the rod end of the lower lift cylinder 44 Tag disconnect and plug the hydraulic hose on the lower lift cylinder Cap the fittings on the 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 45 Tag and disconnect the wire harness from the solenoid val
61. to verify that changing the oil is necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test See E 1 Test or Replace the Hydraulic Oil Inspect the Hydraulic Tank Cap Venting System Genie requires that this procedure be performed quarterly or every 250 hours whichever comes first Perform this procedure more often if dusty conditions exist A free breathing hydraulic tank cap is essential for good machine performance and service life A dirty or clogged cap may cause the machine to perform poorly Extremely dirty conditions may require that the cap be inspected more often 1 Remove the breather cap from the hydraulic tank Check for proper venting Result Air passes through the breather cap Result If air does not pass through the cap clean or replace the cap Proceed to step 3 When checking for positive tank cap venting air should pass freely through the cap 3 Using a mild solvent carefully wash the cap venting system Dry using low pressure compressed air Repeat step 2 4 Install the breather cap onto the hydraulic tank Genie Part No 97385 TEREX COMPANY GS 30 GS 32 GS 46 Section 3 Scheduled Maintenance Procedures May 2005 CHECKLIST B PROCEDURES B 13 Check the Module Tray Latch Components Maintaining the module tray latch components in good condition is essential to goo
62. upper lift cylinder Cap the fittings on the cylinder AWARNING aera injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 21 Tag and disconnect the wire harness from the solenoid valve on the cylinder 22 Remove the cables from the number 4A and 4B cable bridges and lay them off to the side Component damage hazard CAUTION Cables can be damaged if they are kinked or pinched 23 Disconnect the number 4A and 4B cable bridges from the scissor linkset and remove both cable bridges from the machine 24 Attach a lifting strap from an overhead crane to the lug of the rod end of the upper lift cylinder 25 Remove the retaining fasteners from the upper lift cylinder rod end pivot pin index 3 Genie A TEREX COMPANY GS 30 GS 32 GS 46 Part No 97385 September 2005 Section 4 Repair Procedures REVA 26 Use a soft metal drift to remove the upper lift cylinder rod end pivot pin index 3 from the machine Crushing hazard The lift cylinder ACAUTION may become unbalanced and fall if not properly supported when the pivot pin is removed 27 Lower the cylinder onto the linkset 28 Attach a lifting strap from an overhead crane to the number 4 outer arm at the ground control side index 20 29 Remove the retaining fasteners from the number 4 center pivot pin
63. voltage at all times when the machine is in normal operation Limp Mode If the battery level falls to less than 17 8V DC the single bar in the diagnostic display will be flashing and machine drive speed is limited to that of the raised drive speed Refer to Section 2 Specifications the battery level is 22 6V DC or higher the battery level is 21 6 to 22 5V DC the battery level is 20 7 to 21 5V DC the battery level is 19 7 to 20 6V DC the battery level is 17 8 to 19 6V DC the battery level is less than 17 8V DC WOW Genie Part No 97385 TEREX COMPANY GS 30 GS 32 GS 46 Section 4 Repair Procedures September 2005 Platform Components 2 1 Platform How to Remove the Platform Perform this procedure with the platform extension fully retracted and locked in position 1 Raise the platform to approximately 3 ft 1 m 2 Remove the retaining fasteners securing the platform to the platform mount at the steer end of the machine Lower the platform to the stowed position 4 Disconnect the battery packs from the machine AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 5 Disconnect the platform controls from the control cable at the platform 6 Remove the cover from the AC outlet Tag and disconnect the wiring from the outlet AWARNING Electrocution hazard C
64. 07 5 PLATFORM CONTROLS VOLTAGE PRINTED CIRCUIT BOARD REGULATOR HALL EFFECT JC1 GENERATOR c GN 1 WH BL SW5 SW6 FUNCTION ENABLE STEER LEFT RIGHT OR il E BK 1 8 BK PLATFORM CONTROLS 2 MEMBRANE DECAL POUT1 4 LIFT LED 116 POUT2 Ge DRIVE LEDL17 POUT3 Need La 4 HIGH TORQUE LED L21 G8 POUT4 DIAGNOSTIC 1 DISPLAY PIN1 HIGH TORQUE BN6 PIN2 HORN BN5 PIN3 DRIVE ENABLE BN8 PIN4 LIFT ENABLE BN9 POUT11 Bia PLATFORM Nr MES CONTROLLER ES0142F G TEREX COMPANY GS 30 GS 32 GS 46 enie 6 26 Part No 97385 September 2005 Section 6 Schematics 2 2 This page intentionally left blank Genie TEREX COMPANY Part No 97385 GS 30 GS 32 GS 46 6 27 Section 6 Schematics September 2005 Electrical Schematic CE Models REVA GS 2032 2632 after serial number GS3205 77290 GS 2046 2646 3246 after serial number GS4605 76734 P1 EMERGENCY E d STOP sli N on L 2 KS1 v1 key PLATFORM 1 SWITCH CONTROL B1 4 1 NOTE x J RM MACHINE SHOWN IN THE 2143 STOWED POSITION WITH Sg E
65. 084 68 921 80 85 90 Se SS Sp SP 90 122 120 130 11 7 7 160 217 176 180 270 366 280 379 298 300 310 430 583 450 610 510 691 474 470 500 560 759 640 867 680 922 770 1044 78 710 750 1016 90 1342 840 1139 7 790 1071 970 1315 1090 1477 908 0 1080 1220 1654 7 1120 1518 1360 1844 1530 2074 1260 1240 1510 1700 1979 2670 2223 2190 2670 3000 3 5 8 KS Ka Es LUBED in Ibs Nm in Ibs Nm in ibs Nm 6 63 68 775 91 103 116 155 1 95 260 DRY LUBED Nm ft lbs Nm ft ibs Nm_ ft lbs Nm 5 6 32 31 4 42 6 2 46 7 62 3 81 108 129 172 202 269 30 278 371 394 535 536 1055 2 o olor N MIN A e m N G oe Q3 N A A J A TEREX COMPANY Part No 97385 GS 30 GS 32 GS 46 2 7 Section 2 Specifications September 2005 REV This page intentionally left blank Genie A TEREX COMPANY 2 8 GS 30 GS 32 GS 46 Part No 97385 May 2005 Section 3 Scheduled Maintenance Procedures Scheduled Maintenance Procedures Observe and Obey Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine Scheduled maintenance inspecti
66. 1 Block the non steer wheels 2 Remove the cotter pin from the wheel castle nut Always replace the cotter pin with a new one when removing the castle nut 3 Loosen the wheel castle nut Do not remove it 4 Center a lifting jack under the drive chassis at the steer end of the machine 5 Raise the machine approximately 6 inches 15 cm Place blocks under the chassis for support Crushing hazard The chassis AWARNING could fall if not properly supported 6 Remove the wheel castle nut Remove the wheel Steer Axle Components 7 Tag disconnect and plug the hydraulic hoses on the drive motor Cap the fittings on the drive motor AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Component damage hazard Hoses can be damaged if they are kinked or pinched CAUTION 8 Support and secure the yoke assembly to an appropriate lifting device 9 Remove the retaining fastener from the steer link at the yoke assembly Note the quantity and location of the spacers when disconnecting the steer link from the yoke assembly 10 Remove the retaining fastener from the top of the yoke pivot shaft The pivot shaft retaining fastener is located above the main deck 11 Lower the yoke assembly out of the chassis Bodily injury hazard The yoke ACAUTION motor assem
67. 2 pivot pin at the non steer end index 20 in the other direction Remove the number 2 outer arm index 19 from the battery pack side of the machine Bodily injury hazard The number ACAUTION 2 outer arm at the battery pack side may become unbalanced and fall if not properly supported when removed from the machine 50 Remove the number 3 pivot pin index 17 from the non steer end of the machine 51 Attach a lifting strap from an overhead crane to the number 2 inner arm index 18 52 Remove the retaining fasteners from the number 2 pivot pin index 8 at the steer end of the machine 53 Use a soft metal drift to remove the number 2 pivot pin index 8 Remove the number 2 inner arm index 18 from the machine Bodily injury hazard The number ACAUTION 2 inner arm may become unbalanced and fall if not properly supported when removed from the machine 54 Remove the safety arm from the number 2 inner arm index 18 that was just removed 55 Attach a lifting strap from an overhead crane to the number 1 inner arm index 10 56 Raise the number 1 inner arm index 10 approximately 2 feet 60 cm and install the safety arm between the number 1 inner arm index 10 and the number 1 outer arm index 22 at the non steer end of the machine Lower the scissor arms onto the safety arm Bodily injury hazard Keep hands ACAUTION clear of moving parts when lowering the scissor arms onto the safety arm Par
68. 3 3 4 or 3 5 How to Replace the Scissor Arm Repair Pads 2 Measure the distance between the number one outer arm cross tube and the fork lift tube at the battery pack side of the non steer end of the machine Result The measurement is 0 94 inch 24 mm or more Proceed to step 3 Result The measurement is less than 0 94 inch 24 mm Replace both wear pads Refer to Repair Procedure 3 3 3 4 or 3 5 How to Replace the Scissor Arm Repair Pads outer arm cross tube Cross tube to chassis specification REVA 3 Apply a thin layer of dry film lubricant to the area of the chassis where the scissor arm wear pads make contact Measurement minimum 0 94 inch 24 mm 3 24 GS 30 GS 32 GS 46 Part No 97385 May 2005 Section 3 Scheduled Maintenance Procedures REVA D 2 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 the on positio
69. 3 BK 2 5 CR27D 58 OVERLOAD a DOWN DELAY Q a 2 154 2 9 ge 2 2 g 8 8 9 8 AL ee LiT a C2 Bi 9 A6 10 B6 C12 A4 2 Bi 5 l OUT OUT IN IN IN OUT Us ELECTRONIC CONTROL MODULE OUT OUT OUT OUT OUT C8 C7 B7 A7 C6 a oe aaa x Y1 YS Y4 Y5 Y6 Y9 Y7 Y8 PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM RIGHT LEFT REVERSE FORWARD DOWN DOWN GS 3246 4 4 e Le Le GND 4 4 ES0142F Genie TEREX COMPANY Part No 97385 GS 30 GS 32 GS 46 6 17 Section 6 Schematics September 2005 Electrical Schematic CE Models REV B GS 1530 1532 1930 1932 from serial number GS3005A 76389 to 79394 GS 1530 1532 1930 1932 from serial number GS3005B 76031 to 76920 RS P2 QD3 EMERGENCY 4 4 BK POWER PLATFORM 3 D 3 RD POWER TO GROUND 3 1 WH 1 lorog 1 2 2 BL DATALINK HIGH 5 5 OR DATA LINK LOW p U3 D7 g D
70. 32 GS 46 Part No 97385 May 2005 Section 3 Scheduled Maintenance Procedures REVA 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 Checkthe tire surface and sidewalls for cuts cracks punctures and unusual wear 2 Check each wheel for damage bends and cracks 3 Remove the cotter pin and check each castle nut for proper torque Refer to Section 2 Specifications 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 CHECKLIST B PROCEDURES 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 pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Pus
71. 385 TEREX COMPANY GS 30 GS 32 GS 46 Section 2 Specifications September 2005 aaa SSS SaaS SPECIFICATIONS REV B Manifold Component Specifications Plug torque SAE No 2 50 in lbs 6 Nm SAE No 4 13 ft lbs 18 Nm SAE No 6 18 ft lbs 24 Nm SAE No 8 50 ft lbs 68 Nm SAE No 10 55 ft lbs 75 Nm SAE No 12 75 ft lbs 102 Nm Valve Coil Resistance Description Specification Solenoid valve 3 position 4 way 18 to 210 20V DC with diode schematic item E and AC Solenoid valve 3 position 4 way 25 to 280 20V DC with diode schematic item F Solenoid valve 2 position 4 way 18 to 210 20V DC with diode schematic item H Solenoid valve 2 position 2 way N C 23 to 280 20V DC with diode schematic item N Solenoid valve 2 position 4 way 25 to 280 20V DC with diode schematic item AE and AI Solenoid valve 3 position 5 way 25 to 280 20V DC with diode schematic item AG Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie A TEREX COMPANY 2 4 GS 30 GS 32 GS 46 Part No 97385 September 2005 Section 2 Specifications a REV B SPECIFICATIONS Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with JIC 37 flared fittings and hose ends Genie specifications require that fittings and hose ends be torqued to specification w
72. 4 Turn the key switch to ground control 5 Check the machine functions from the platform controls Result The machine functions should not operate 6 Turn the key switch to the off position Result No function should operate REVA B 6 Test the Automotive style Horn if equipped 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 red Emergency Stop button to the on position at both the ground and platform controls 2 Push down the horn button at the platform controls Result The horn should sound Genie TEREX COMPANY GS 30 GS 32 GS 46 Part No 97385 May 2005 Section 3 Scheduled Maintenance Procedures REVA 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 firm level surface that is free of obstructions Be sure the platform extension deck is fully retracted and the platform is in the stowed position 1 Mark a test line on the ground for
73. 50 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 Use Chevron Aviation A hydraulic oil when in ambient temperatures consistently below 0 F 17 Use Shell Tellus T46 hydraulic oil when oil temperatures consistently exceed 205 F 96 C Genie specifications require additional equipment and special installation instructions for the approved optional fluids Consult the Genie Industries Service Department before use SPECIFICATIONS Function pump Type Gear Displacement per revolution 0 244 cu in 4cc 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 1800 to 3500 psi 124 to 241 bar Steer relief valve pressure 1500 psi 103 bar Check valve manifold GS 1530 GS 1532 GS 1930 GS 1932 Check valve pressure maximum 200 psi 13 8 bar Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie Part No 97
74. 5666 3241 Genie Holland Phone 431 183 581 2 Fax 31 183 581 566 Service Manual GS 30 GS 32 GS 46 from serial number GS3005A 7 6000 from serial number GS3205B 76000 from serial number 653205 75407 from serial number G 4605 75438 97385 Rev B1 G Part No
75. Adjustments Platform lift 50660 stowed drive speed raised drive speed and high torque drive speed are adjustable to compensate for wear in the hydraulic pump and drive motors The function speeds are determined by the percentage of total controller output For further information or assistance consult the Genie Industries Service Department ADANGER 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 Select a test area that is firm level and free of obstructions How to Determine the Software Revision Level 1 Remove the platform controls from the platform 2 Place the platform controls close to the diagnostic display on the power unit side of the machine PLATFORM CONTROLS 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 3 joystick controller JC1 lift function select button BN9 red Emergency Stop button P2 yellow arrow Qo om 4 Press the lift function select button 5 Slowly move the joystick in the
76. C PLATFORM CONTROLS VOLTAGE PRINTED CIRCUIT BOARD REGULATOR HALL EFFECT JC1 I M ye GN WH BL SW5 SW6 FUNCTION ENABLE STEER LEFT RIGHT PINS On 1 m PINS 0 3 BK PLATFORM CONTROLS MEMBRANE DECAL LIFT LED 116 DRIVE LED 7 4 HIGH TORQUE LED L21 POUT4 DIAGNOSTIC 1 DISPLAY PIN1 HIGH TORQUE BN6 PIN2 HORN BN5 PIN3 DRIVE ENABLE BN8 PIN4 LIFT ENABLE BN9 POUT11 PLATFORM BK NE CONTROLLER ES0142F Genie TEREX COMPANY GS 30 GS 32 GS 46 Part No 97385 September 2005 Section 6 Schematics 2 2 This page intentionally left blank Genie TEREX COMPANY Part No 97385 GS 30 GS 32 GS 46 6 19 Section 6 Schematics September 2005 EF Electrical Schematic CE Models REVA GS 1530 1532 1930 1932 after serial number GS3005A 79394 GS 1530 1532 1930 1932 after serial number GS3005B 76920 P1 2 21 STOP sli N or 2 1 KS1 Y key PLATFORM 1 l SWITCH CONTROL B1 4 1 NOTE x J RM MACHINE SHOWN IN THE X AE STOWED POSITION WITH S E N CHO 4 THE PO
77. CAUTION careful not to damage the level sensor or limit switch while moving the scissor assembly Section 4 Repair Procedures September 2005 SC ISSOR COMPONENTS 9 9 C REVA N GGG 9 GS 1930 GS 1932 Non steer End 1 Number 5 pivot pin 12 Number 4 inner arm 2 Number 4 center pivot pin 2 pins 13 Number 4 outer arm 3 Number 4 pivot pin steer end 14 Number 4 pivot pin non steer end 4 Number 3 center pivot pin 2 pins 15 Number 3 inner arm 5 Lift cylinder rod end pivot pin 16 Number 3 outer arm 6 Number 3 pivot pin steer end 17 Number 3 pivot pin non steer end 7 Number 2 center pivot pin 2 pins 18 Number 2 inner arm 8 Number 2 pivot pin steer end 19 Number 2 outer arm 9 Number 1 center pivot pin 2 pins 20 Number 2 pivot pin non steer end 10 Number 1 inner arm 21 Lift cylinder barrel end pivot pin 11 Number 1 pivot pin 22 Number 1 outer arm Genie 4 20 GS 30 GS 32 GS 46 Part No 97385 September 2005 Section 4 Repair Procedures REVA SCISSOR COMPONENTS 3 2 Scissor Assembly GS 1930 and GS 1932 How to Disassemble the Scissor Assembly GS 1930 and GS 1932 AWARNING 00 injury hazard The procedures in this section require specific repair skills lifting equipment and a
78. CK ON DOWN LIMIT SWITCH OUT OF ADJUSTMENT RAISE THE DOWN LIMIT SWITCH TESTED WRONG RATED LOAD FOR HEIGHT BEING 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 97385 A TEREX COMPANY GS 30 GS 32 GS 46 Section 3 Scheduled Maintenance Procedures May 2005 CHECKLIST D PROCEDURES D 3 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 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 tank return filter is mounted on the function manifold next to the hydraulic power unit 1 Clean the area around the oil filter Remove the filter with an oil filter wrench 2 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 onto the filter REVA 5 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the grou
79. DC Section 3 Scheduled Maintenance Procedures May 2005 Checklist C Procedures C 1 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 stability 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 REVA 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 whe
80. DRIVE DRIVE PLATFORM PLATFORM PLATFORM RIGHT LEFT REVERSE FORWARD DOWN DOWN UP GS 3246 4 e o L L GND 4 ES0141H Genie TEREX COMPANY Part No 97385 GS 30 GS 32 GS 46 6 9 Section 6 Schematics September 2005 Electrical Schematic ANSI CSA and Australia Models REV GS 1530 1532 1930 1932 and GS 2032 2632 and GS 2046 2646 3246 a P2 QD3 4 4 BK POWER PLATFORM T r 3 D 3 RD POWER TO GROUND BD 3 1 WH 1 lorog 1 2 2 BL DATALINK HIGH 5 5 OR DATALINK LOW U3 PLATFORM CONTROLS VOLTAGE PRINTED CIRCUIT BOARD REGULATOR HALL EFFECT JC1 GENERATOR c GN 1 WH BL SW5 SW6 FUNCTION ENABLE STEER LEFT RIGHT OR il E BK 1 8 1 BK PLATFORM CONTROLS MEMBRANE DECAL POUT1 4 LIFT LED 116 POUT2 Ge DRIVE LEDL17 POUT3 Need La 4 HIGH TORQUE LED L21 G8 POUT4 DIAGNOSTIC 1 DISPLAY PIN1 HIGH TORQUE BN6 PIN2 HORN BN5 PIN3 DRIVE ENABLE BN8 PIN4 LIFT ENABLE BN9 POUT11 PLATFORM Nr MES CONTR
81. ENTS 3 4 Scissor Assembly GS 2632 and GS 2646 How to Disassemble the Scissor Assembly GS 2632 and GS 2646 AWARNING P dily injury hazard The procedures in this section require specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant GS 2632 component damage Dealer GS 2646 service is required Cable bridge legend When removing a hose assembly or fitting the O ring on the fitting a cable bridge 4 and or hose end must be replaced gt 5 and then torqued to specification d cable bridge 2A during installation Refer to e cable bridge 2B f cable bridge 1 Section 2 Hydraulic Hose and Fitting Torque Specifications 4 Remove the cables from the number 4 cable 1 Remove the platform See 2 1 How to Remove bridge and lay them off to the side CAUTION Component damage hazard 2 Support and secure the entry ladder to an Cables can be damaged if they appropriate lifting device are kinked or pinched 3 Remove the fasteners from the entry ladder and 5 Disconnect the number 4 cable bridge from the remove the entry ladder from the machine number 4 outer arm index 13 and remove the cable bridge from the machine Crushing hazard The entry ladder ACAUTION may become unbalanced and fall 6 Remove the retaining fasteners from the if not properly supported and number 5 p
82. Genie Service Manual Refer to inside cover for additional serial number information Part No 97385 Rev B1 October 2005 GS 30 from serial number GS3005A 76000 from serial number GS3005B 76000 GS 32 from serial number GS3205 75407 GS 46 from serial number GS4605 75438 September 2005 Introduction Important Read understand and obey the safety rules and operating instructions in the appropriate Operator s Manual on your machine before attempting any maintenance procedure Basic mechanical hydraulic and electrical skills are required to perform most procedures However several procedures require specialized skills tools lifting equipment and a suitable workshop In these instances we strongly recommend that maintenance and repair be performed at an authorized Genie dealer service center 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
83. Hydraulic Pump 51 Funcion PUMP uu tr un 4 60 Genie GS 30 GS 32 GS 46 ix September 2005 TABLE OF CONTENTS Section 4 Section 5 Rev Rev Repair Procedures continued Manifolds 6 1 Function Manifold Components GS 1530 GS 1532 GS 1930andGS 1932 4 62 6 2 Function Manifold Components GS 2032 GS 2632 GS 2046 GS 2646 and GS 3246 4 64 6 3 Check Valve Manifold Components GS 1530 GS 1532 GS 1930 and 035 1992 4 66 6 4 Valve Adjustments Function Manifold 4 67 65 Valve 4 70 Hydraulic Tank PAL tee eene mers 4 72 Steer Axle Components 81 Yoke and Drive Motor 44 4 73 82 SteerCylide an ERR ee eed 4 74 8 3 Steet BellGrank uuu awu ua 4 75 Non steer Axle Components 9d Dr vebBrake u erbe etie bees 4 76 Brake Release Hand Pump Components 10 1 Brake Release Hand Pump Components 4 78 Fault Codes A 5 1 Fault Code Chait u uuu a aa 5 3 Genie GS 30 GS 32 GS 46 PartNo 97385 September 2005 TABLE OF CONTENTS Section 6 Rev Schematics A RN 61 A Electrical Component and Wire Color Legends 6 2 A ECMPin
84. L st T 1500 psi 8 i LH 403 bar H LC 0 75 gpm ON 10 psi 2 8 L min 0 7 bar TP ee ee TT 1 p 6 tL T Y8 FUNCTION MANIFOLD i 1800 to 3500 psi 1 4 124 to 241 bar 4 SS eNO pe 3500 psi maximum 241 maximum Ime ABBREVIATION LEGEND a SS SS SS Item Description Test port 5 Check valve steer circuit gt 13 8 bar a C Relief valve lift D Check valve brake circuit E Drive forward reverse f F Steer left right 10 MICRON WITH G Flow regulator relief valve 4 gpm 2500 psi 25 1 7 bar H Platf L POWER UNIT 15 L min 172 bar BYPASS J atform up Relief valve system HYDRAULIC TANK L Hand pump manual brake release M Needle valve manual brake release N Platform lowering valve 0 Orifice platform down circuit P Accumulator R Pressure switch platform overload HS0035F1 5 Check valve drive circuit No 97385 TEREX COMPANY GS 30 GS 32 GS 46
85. ND ES0142H enie Part No 97385 A TEREX COMPANY GS 30 GS 32 GS 46 Section 6 Schematics September 2005 Electrical Schematic CE Models REVA GS 1530 1532 1930 1932 after serial number GS3005A 79394 GS 1530 1532 1930 1932 after serial number GS3005B 76920 C P2 QD3 EMERGENCY 3 5 3 RDN POWER TO GROUND 2 2 BL DATALINK HIGH 5 5 OR DATALINK LOW U3 PLATFORM CONTROLS PRINTED CIRCUIT BOARD LJ D7 5V DC VOLTAGE REGULATOR GY GN HALL EFFECT WH BL JC1 JOYSTICK CONTROLLER PP SW5 FUNCTION ENABLE OR SW6 STEER LEFT RIGHT BK BK PLATFORM CONTROLS MEMBRANE DECAL LIFT LED 116 DRIVE LED L17 POUT4 HIGH TORQUE LED L21 PIN1 DIAGNOSTIC DISPLAY PIN2 HIGH TORQUE BN6 HORN BN5 PIN3 PIN4 DRIVE ENABLE BN8 POUT11 LIFT ENABLE PIN11 PLATFORM CONTROLLER 2 50142 G A TEREX COMPANY GS 30 GS 32 GS 46 enie 6 22 Part No 97385 September 2005 Section 6 Schematics 2 2 This page intentionally left blank Ge
86. NTS 41 Remove the number 2 cable bridge mounting fasteners and remove the cable bridge from the machine 42 Attach a lifting strap from an overhead crane to the number 2 outer arm index 19 at the ground controls side 43 Use a soft metal drift to remove the number 2 center pivot pin index 7 at the ground controls side 44 Remove the retaining fasteners from the number 2 pivot pin index 420 at the non steer end of the machine 45 Use a soft metal drift to tap the number 2 pivot pin index 20 halfway out at the non steer end of the machine Remove the number 2 outer arm index 19 from the ground controls side of the machine Bodily injury hazard The number ACAUTION 2 outer arm at the ground controls side may become unbalanced and fall if not properly supported when removed from the machine 46 Attach a lifting strap from an overhead crane to the number 2 outer arm index 19 at the battery pack side 47 Remove the external snap rings and retaining fasteners from the number 2 center pivot pin index 7 at the battery pack side 48 Use a soft metal drift to remove the number 2 center pivot pin index 7 at the battery pack side Bodily injury hazard The number ACAUTION 2 outer arm at the battery pack side may become unbalanced and fall if not properly supported when removed from the machine Genie A TEREX COMPANY GS 30 GS 32 GS 46 REV A 49 Use a soft metal drift to tap the number
87. OLLER 50141 gt lt TEREX COMPANY GS 30 GS 32 GS 46 Part No 97385 September 2005 Section 6 Schematics 2 2 This page intentionally left blank Genie TEREX COMPANY Part No 97385 GS 30 GS 32 GS 46 6 11 Section 6 Schematics September 2005 Electrical Schematic CE Models REV B GS 1530 1532 1930 1932 from serial number GS3005A 76000 to 76388 GS 1530 1532 1930 1932 before serial number GS3005B 76000 to 76030 P1 P 28 EMERGENCY CA d s STOP WH 2 B Non 447 2 KS1 v1 key PLATFORM 1 SWITCH CONTROL 2 14 1 NOTE P ALARM MACHINE SHOWN IN THE 213 STOWED POSITION WITH THE POWER OFF Se x 1 157 TS66 POTHOLE PLATFORM 1 UP DOWN N C H O 2 D 8 gu 1584 027 GUARD 47 mH INDUCTOR NOISE SUPPRESSION SWITCH LIT c 5 v 95 5 i X 322 D l 2 2 S Leo 5 5 Jot QD1 oe d F6 275a FUSE 8 ee A12 B12 B9 B10 A IN IN OUT IN u IM A8 OUT BATTERY t AVOUT U5 CHARGER ELECTRONIC CONTROL MODULE OUT OUT B5
88. S 64 Attach a lifting strap from an overhead crane to the number 1 inner arm index 10 at the non steer end Raise the number 1 inner arm and remove the safety arm Lower the number 1 inner arm index 10 onto the block that was placed across the chassis Bodily injury hazard Keep hands ACAUTION clear of moving parts when lowering the arms onto the block 65 Remove the cables from the number 1 cable bridge and lay them off to the side Component damage hazard CAUTION Cables can be damaged if they are kinked or pinched 66 Support and secure the entry ladder to an appropriate lifting device 67 Remove the fasteners from the entry ladder and remove the entry ladder from the machine Crushing hazard The entry ladder ACAUTION may become unbalanced and fall if not properly supported and secured to the lifting device 68 Attach a lifting strap from an overhead crane to the number 1 outer arm index 22 Do not apply any lifting pressure 69 Remove the external snap rings and retaining fasteners from the number 1 center pivot pins index 11 70 Remove the number 1 cable bridge from the machine 71 Use a soft metal drift to remove the number 1 center pivot pins index 9 Bodily injury hazard The number ACAUTION 1 outer arm may become unbalanced and fall if not properly supported when the pin is removed Genie Part No 97385 TEREX COMPANY GS 30 GS 32 GS 46 Section 4 Repai
89. SHOWN IN STOWED POSITION e ECM PIN B9 LEVEL SENSOR 2 _ TERMINAL 87 112 213 14 re e MH LBK CR48 TERMINAL 87 NOHC HD Z 1 22 NCHO BK 4e PBK 2 GN ECM PIN C11 BN GROUND le RD ECM PIN A5 r i NOT USED WB CR27D TERMINALS 85 87 AND 87A BK ECM PIN B6 A TEREX COMPANY GS 30 GS 32 GS 46 Part No 97385 September 2005 PLATFORM CONTROLS GEN 5 BK RD WH BL H1 A ALARM Part No 97385 P2 MERGENCY STOP RD GS 30 GS 32 GS 46 Section 6 Schematics Wiring Diagram Platform Control Box Section 6 Schematics September 2005 Limit Switch Legend GS 2032 GS 2632 GS 2046 GS 2646 GS 1530 GS 3246 GS 1532 GS 1930 GS 1932 Limit Switch Legend a maximum height limit switch LS5 CE models b down limit switch LS6 c pothole switches LS7 LS8 REVA ALL MODELS 6 6 GS 30 GS 32 GS 46 Part No 97385 September 2005 Section 6 Schematics Electrical Symbols Legend REVA NO Fases a mt
90. SOR COMPONENTS REVA 6 2 GS 2032 GS 2046 Steer end Non steer end 1 Number 4 pivot pin 10 Number 3 inner arm 2 Number 3 outer arm 11 Number 3 outer arm 3 Number 3 center pivot pin 2 pins 12 Number 3 pivot pin non steer end 4 Lift cylinder rod end pivot pin 13 Number 2 inner arm 5 Number 3 pivot pin steer end 14 Number 2 outer arm 6 Number 2 center pivot pin 2 pins 15 Number 2 pivot pin non steer end 7 Number 2 pivot pin steer end 16 Lift cylinder barrel end pivot pin 8 Number 1 center pivot pin 2 pins 17 Number 1 outer arm 9 Number 1 pivot pin Genie A TEREX COMPANY GS 30 GS 32 GS 46 Part No 97385 September 2005 Section 4 Repair Procedures REVA SCISSOR COMPONENTS 3 3 Scissor Assembly GS 2032 and GS 2046 How to Disassemble the Scissor Assembly GS 2032 and GS 2046 AWARNING P dily injury hazard The procedures in this section require specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant 95 2032 68 2046 Cable bridge legend component damage Dealer a bridge 3 service is required b cable bridge 2A c cable bridge 2B d cable bridge 1 When removing a hose assembly or fitting the O ring on the fitting 5
91. Schematics September 2005 Electrical Schematic CE Models REV B GS 1530 1532 1930 1932 from serial number GS3005A 76000 to 76388 GS 1530 1532 1930 1932 before serial number GS3005B 76000 to 76030 RS P2 QD3 EMERGENCY 4 4 BK POWER PLATFORM 3 D 3 RD POWER TO GROUND 3 1 WH 1 lorog 1 2 2 BL DATALINK HIGH I 5 5 OR DATA LINK LOW p U3 D7 g DC PLATFORM CONTROLS VOLTAGE PRINTED CIRCUIT BOARD REGULATOR HALL EFFECT JC1 I 0 v 0 ye 6 GN WH BL SW5 SW6 FUNCTION ENABLE STEER LEFT RIGHT PIN9 en il m PINS 0 3 BK PLATFORM CONTROLS MEMBRANE DECAL LIFT LED 116 DRIVE LED 7 4 HIGH TORQUE LED L21 POUT4 DIAGNOSTIC 1 DISPLAY PIN1 HIGH TORQUE BN6 PIN2 HORN BN5 PIN3 DRIVE ENABLE BN8 PIN4 LIFT ENABLE BN9 POUT11 PLATFORM BK NE CONTROLLER ES0142D Genie TEREX COMPANY GS 30 GS 32 GS 46 Part No 97385 September 2005 Section 6 Schematics 2 2 This page intentionally left blank Genie TEREX COMPANY Part No 97385 GS 30 GS 32 GS 46 6 15 Section 6 Schematics September 2005 Electrical Schematic
92. Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 3 Press the lift function select button lt 8 8 lift function select button BN9 b drive function select button BN8 Part No 97385 Genie CHECKLIST B PROCEDURES Press and hold the function enable switch on the joystick Raise the platform approximately 4 feet 1 2 m from the ground Press the drive function select button Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line Continue at full speed and note the time when your reference point on the machine passes over the finish line Refer to Section 2 Specifications GS 30 GS 32 GS 46 3 15 Section 3 Scheduled Maintenance Procedures May 2005 CHECKLIST B PROCEDURES B 10 Test the Slow Drive Speed 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 firm level surface th
93. WER OFF lt 22 7 6 P GUARD PLATFORM SWITCH 1 UP DOWN CB2 N C H O 7A J 9 gt BREAKER E LS8 U27 47 mH INDUCTOR NOISE SUPPRESSION SWITCH E c 5 pe S 9 25228 B T 2 8 8 E 180 2 5 5 54 WORK LIGHT 2 2 QD1 ro OPTION F6 275a FUSE 8 ee ee A12 B12 B9 B10 IN IN OUT IN u A8 OUT BATTERY WH A1 OUT 5 CHARGER ELECTRONIC CONTROL MODULE OUT OUT B8 B3 E Mm U6 X INS cud 06 om x CONTROLLER gt 8 10 ao el SAY CR5 P HORN RELAY Pw 39 H2OPTION 486 ccr 3 G6 FB petes 2 DC AC INVERTER OUR 85 METER BEACONS T 1 OPTION L AUTO STYLE HORN OPTION ES0142H Genie TEREX COMPANY 6 20 GS 30 GS 32 GS 46 Part No 97385 September 2005 Section 6 Schematics Electrical Schematic
94. ables from the number 2 cable bridge and lay them off to the side Component damage hazard CAUTION Cables can be damaged if they are kinked or pinched 26 Remove the external snap rings and retaining fasteners from the number 2 center pivot pin index 5 at the ground controls side 27 Remove the number 2 cable bridge mounting fasteners and remove the cable bridge from the machine 28 Attach a lifting strap from an overhead crane to the number 2 outer arm index 14 at the ground controls side 29 Use a soft metal drift to remove the number 2 center pivot pin index 5 at the ground controls side Genie 4 16 A TEREX COMPANY GS 30 GS 32 GS 46 Part No 97385 September 2005 Section 4 Repair Procedures REVA 30 Remove the retaining fasteners from the number 2 pivot pin index 15 at the non steer end of the machine 31 Use a soft metal drift to tap the number 2 pivot pin index 15 halfway out at the non steer end of the machine Remove the number 2 outer arm index 14 from the ground controls side of the machine Bodily injury hazard The number ACAUTION 2 outer arm at the ground controls side may become unbalanced and fall if not properly supported when removed from the machine 32 Attach a lifting strap from an overhead crane to the number 2 outer arm index 14 at the battery pack side 33 Remove the external snap rings and retaining fasteners from the number 2 center pivot p
95. adjusted See 4 1 How to Adjust the Manual Platform Lowering Cable 7 Remove the fasteners securing the manual lowering cable mount bracket to the cylinder Remove the bracket from the cylinder 8 Tag disconnect and plug the hydraulic hoses on the lift cylinder Cap the fittings on the cylinder AWARNING 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 9 Attach a lifting strap from an overhead crane to the rod end of the lift cylinder for support 10 Remove the retaining fasteners from the lift cylinder rod end pivot pin Use a soft metal drift to remove the pin AWARNING Crushing hazard The lift cylinder will fall if not properly supported 11 Lower the cylinder to a horizontal position Bodily injury hazard Keep hands ACAUTION clear of moving parts when lowering the cylinder Genie Part No 97385 TEREX COMPANY GS 30 GS 32 GS 46 Section 4 Repair Procedures September 2005 SCISSOR COMPONENTS REV 12 Attach a lifting strap from an overhead crane or similar lifting device to the barrel end of the lift cylinder for support 13 Remove the retaining fasteners from the lift cylinder barrel end pivot pin Use a soft metal drift to remove the pin AWARNING Crushing hazard The lift cylinder will fall if not properly supported when the pi
96. at 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 key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls Lower the platform to the stowed position Press the slow speed select button 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 3 16 GS 30 GS 32 GS 46 Genie REVA a slow speed select button BN6 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line Continue at full speed and note the time when your reference point on the machine passes over the finish line Refer to Section 2 Specifications Part No 97385 May 2005 Section 3 Scheduled Maintenance Procedures REVA CHECKLIST B PROCEDURES B 11 B 12 Perform Hydraulic Oil Analysis Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more often Refer to Section 2 Specifications Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination
97. attery positive and the black wire to battery negative The inverter will then operate correctly and begin supplying AC power If the right fault LED 123 blinks one time the power draw is too high The tool being used requires too much power to operate or is being used at or near the limit of the inverter for an extended period of time Reduce the power draw The inverter will then operate correctly and begin supplying AC power If the right fault LED 123 blinks two times the Ground Fault Interrupt GFI has been activated A short circuit or partial short exists between the AC hot and ground in the tool or outlet Check the tool for burnt chafed corroded and loose wires and inspect the tool for internal moisture Correct the short circuit or moisture issue OR inspect the wiring in the power to platform box The inverter will then operate correctly and begin supplying AC power If right fault LED 123 blinks three times the inverter is overheated Allow the inverter to cool The inverter will then operate correctly and begin supplying AC power If the battery 25 volt fault LED 25V blinks one time the battery voltage is over 30V Operate the machine to lower the voltage level The inverter will then operate correctly and begin supplying AC power If the battery 21 volt fault LED 21V blinks one time the battery voltage is less than 20V DC The inverter will continue to operate until the battery voltage falls to 17 8V
98. bly may fall if not properly supported when it is removed from the chassis Genie Part No 97385 TEREX COMPANY GS 30 GS 32 GS 46 Section 4 Repair Procedures September 2005 STEER AXLE COMPONENTS How to Remove a Drive Motor 1 Block the non steer wheels 2 Remove the cotter pin from the wheel castle nut of the motor to be removed Always replace the cotter pin with a new one when removing the castle nut 3 Loosen the wheel castle nut Do not remove it 4 Center a lifting jack under the drive chassis at the steer end of the machine 5 Raise the machine approximately 2 inches 5 cm Place blocks under the chassis for support Crushing hazard The chassis AWARNING could fall if not properly supported 6 Remove the wheel castle nut Remove the wheel 7 Tag disconnect and plug the hydraulic hoses on the drive motor Cap the fittings on the drive motor AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn 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 motor Torque specifications REVA 8 2 Steer Cylinder How to Remove the Steer Cylinder When removing a hose assembly or fitting the O ring on the fitting and
99. ced and fall if not properly supported when removed from the machine 73 Attach a lifting strap from an overhead crane to the number 2 inner arm index 25 Raise the arm to a vertical position 74 Remove the retaining fasteners from the number 2 pivot pin at the steer end of the machine index 12 75 Use a soft metal drift to remove the number 2 pivot pin index 12 from the steer end of the machine Remove the number 2 inner arm index 25 from the machine Crushing hazard The number 2 A CAUTION inner arm index 25 may become unbalanced and fall if not properly supported when the pivot pin is removed 76 Attach a lifting strap from an overhead crane to the number 1 inner arm index 14 77 Raise the number 1 inner arm index 14 approximately 2 feet 60 cm 78 Place a 4 x 4 x48 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 13 79 Lower the scissor arms onto the block that was placed across the chassis Bodily injury hazard Keep hands ACAUTION clear of moving parts when lowering the scissor arms 80 Attach a lifting strap from an overhead crane to the lug of the rod end of the lower lift cylinder Genie Part No 97385 TEREX COMPANY GS 30 GS 32 GS 46 Section 4 Repair Procedures September 2005 SCISSOR COMPONENTS 81 Tag disconnect and plug the hydraulic hose on the lower lift cylinder Cap the fitt
100. chine Genie A TEREX COMPANY GS 30 GS 32 GS 46 Part No 97385 September 2005 Section 4 Repair Procedures REVA 50 Attach a lifting strap from an overhead crane to the number 2 inner arm index 18 Raise the arm to a vertical position 51 Remove the retaining fasteners from the number 2 pivot pin at the steer end of the machine index 8 52 Use a soft metal drift to remove the number 2 pivot pin index 8 from the steer end of the machine Remove the number 2 inner arm index 18 from the machine Crushing hazard The number 2 ACAUTION inner arm index 18 may become unbalanced and fall if not properly supported when the pivot pin is removed 53 Attach a lifting strap from an overhead crane to the number 1 inner arm index 10 54 Raise the number 1 inner arm index 10 approximately 2 feet 60 cm 55 Place a 4 x 4 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 9 56 Lower the scissor arms onto the block that was placed across the chassis Bodily injury hazard Keep hands ACAUTION clear of moving parts when lowering the scissor arms 57 Attach a lifting strap from an overhead crane to the lug of the rod end of the lower lift cylinder Part No 97385 Genie GS 30 GS 32 GS 46 SCISSOR COMPONENTS 58 Tag disconnect and plug the hydraulic hose on the lower lift cylinder Cap the fitt
101. chine with a strap or other suitable device 6 Remove the retaining fasteners securing the chassis mount bracket to the chassis at the steer end of the machine 7 Attach a lifting strap from an overhead crane to the scissor arm assembly 8 Raise the scissor arm assembly at the steer end with the overhead crane until the chassis mount bracket will clear the level sensor SCISSOR COMPONENTS 9 Move the scissor assembly towards the non steer end of the machine slightly and to one side of the machine until one of the scissor arm wear pads is accessible Do not allow both wear pads to slide out of the drive chassis Component damage hazard Be CAUTION careful not to damage the level sensor or limit switch while moving the scissor assembly 10 Remove the old wear pad 11 Install the new wear pad 12 Rotate the scissor assembly towards the other side of the machine until the other scissor arm wear pad is accessible Do not allow both wear pads to slide out of the drive chassis R Crushing hazard The scissor A DANGE assembly will fall if both wear pads are allowed to slide out of the drive chassis Component damage hazard Be careful not to damage the level sensor or limit switch while moving the scissor assembly CAUTION 13 Remove the old wear pad 14 Install the new wear pad 15 Slide the scissor assembly back into the drive chassis 16 Lower the scissor assembly into position and install the chassis mou
102. d 3 to the front or rear How to Install and Calibrate the 1 5 Level Sensor 7717111 hazard Failure to install DANGER or calibrate the level sensor as instructed will compromise machine stability and cause the machine to tip over resulting in death or serious injury Do not install or calibrate the level sensor other than specified in this procedure 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 key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 3 Raise the platform 7 to 8 feet 2 1 to 2 4 m REVA 4 Liftthe safety arm move it to the center of the scissor arm and rotate down to a vertical position 5 Lower the platform onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 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 7 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 8 Remove the level sensor retaining fasteners Remove the level sensor
103. d performance and service life Failure to detect worn out latch components may result in module trays opening unexpectedly creating an unsafe operating condition 1 Inspect each module tray rotary latch and related components for wear Tighten any loose fasteners 2 Lubricate each module tray rotary latch Using light oil apply a few drops to each of the springs and to the sides of the rotary latch mechanism 3 18 GS 30 GS 32 GS 46 Genie TEREX COMPANY REVA Part No 97385 Section 3 Scheduled Maintenance Procedures May 2005 REVA B 14 3 Inspect the Voltage Inverter if equipped g 1 Inspect the inverter plug and pigtail for damage or excessive insulation wear Replace as required 2 Turn the key switch to the on position and pull out the red Emergency Stop button to the on position at both the ground and platform controls x x a right fault LED b left fault LED c 25VLED x d 21VLED x x Genie Part No 97385 TEREX COMPANY GS 30 GS 32 GS 46 CHECKLIST B PROCEDURES Connect an appropriate power tool to the inverter Activate the tool Result The power tool should operate There may be a brief 0 5 second delay if the power tool has not been used in the previous 10 minutes If the left fault LED REV_POL is illuminated the inverter is connected to batteries with the incorrect polarity Correct the polarity issue with the red wire to b
104. decrease the pressure manifold schematic item A or AA ip i i E 4 d 3 Chock both sides of the wheels at the steer end could result the machine tipping over causing death or serious 4 Remove the platform controls from the platform injury Do not adjust the relief valve pressures higher than of the machine Perform this test from the ground with the platform controls Do not specifications stand in the platform 10 Install the relief valve cap 5 Turn the key switch to platform control and pull 11 Repeat steps 4 through 7 to confirm the relief out the red Emergency Stop button to the on valve pressure position at both the ground and platform controls 12 Place maximum rated load into the platform Secure the load to the platform Refer to 6 Press and hold the function enable switch Section 2 Specifications a C D Q e GS 32 and GS 46 a b 0 0 GS 1530 32 and GS 1930 32 test port system relief valve steer relief valve lift relief valve a test port b system relief valve lift relief valve Genie A TEREX COMPANY 4 68 GS 30 GS 32 GS 46 Part No 97385 September 2005 Section 4 Repair Procedures REV B 13 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 14 Hold the lift relief valve with a wrench and
105. direction indicated by the yellow arrow Result The software revision level will appear in the diagnostic display at the ground controls Result If the software revision level does not appear in the diagnostic display turn the key Switch to ground control and move the platform lift switch in the down direction The software revision level will appear in the diagnostic display at the ground controls 6 Push in the red Emergency Stop button to the off position at both the ground and platform controls and turn the key switch to the off position Genie Part No 97385 TEREX COMPANY GS 30 GS 32 GS 46 4 3 Section 4 Repair Procedures October 2005 PLATFORM CONTROLS How to Adjust the Lift Speed 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 Tip over hazard This procedure must only be performed by a trained service professional Attempting this procedure without the necessary skills will result in death or serious injury 1 Pull out the red Emergency Stop button to the on position at the ground controls 2 Push in red Emergency Stop button to the off position at the platform controls 3 Turn the key switch to platform control 4 Atthe platform controls pres
106. e 24 Place a rod through the number 3 center pivot pin at the ground control side index 4 and twist to remove the pin 25 Remove the retaining fasteners from the number 3 pivot pin index 17 at the non steer end 26 Use a soft metal drift to remove the number 3 pivot pin index 17 from the non steer end of the machine Remove the number 3 outer arm at the ground control side index 16 from the machine Crushing hazard The number 3 ACAUTION outer arm at the ground control side index 16 may become unbalanced and fall if not properly supported when removed from the machine 27 Attach a lifting strap from an overhead crane to the number 3 outer arm at the battery side index 16 28 Remove the retaining fasteners from the number 3 center pivot pin index 4 at the battery side 29 Place a rod through the number 3 center pivot pin at the battery side index 4 and twist to remove the pin SCISSOR COMPONENTS 30 Remove the number 3 outer arm index 16 from the machine Crushing hazard The number 3 ACAUTION outer arm index 16 may become unbalanced and fall if not properly supported when removed from the machine 31 Attach a lifting strap from an overhead crane to the lug of the rod end of the lift cylinder 32 Remove the retaining fasteners from the lift cylinder rod end pivot pin index 5 33 Use a soft metal drift to remove the lift cylinder rod end pivot pin index 5 from the machine
107. e Remove the number 3 outer arm at the ground control side index 11 from the machine AWARNING Crushing hazard The number 3 outer arm may become unbalanced and fall if not properly supported when removed from the machine 9 Attach a lifting strap from an overhead crane to the number 3 outer arm at the battery pack side of the machine index 11 Genie Part No 97385 TEREX COMPANY GS 30 GS 32 GS 46 Section 4 Repair Procedures September 2005 SCISSOR COMPONENTS 10 Remove the external snap rings and retaining fasteners from the number 3 center pivot pin at the battery pack side of the machine index 2 11 Use a soft metal drift to remove the number 3 center pivot pin at the battery pack side of the machine index 2 12 Remove the number 3 outer arm at the battery pack side index 11 from the machine AWARNING Crushing hazard The number 3 outer arm may become unbalanced and fall if not properly supported when removed from the machine Models with a single number 3 outer arm assembly 13 Attach a lifting strap from an overhead crane to the number 3 outer arm index 11 14 Remove the external snap rings and retaining fasteners from the number 3 center pivot pins index 2 15 Use a soft metal drift to remove the number 3 center pivot pins index 2 16 Remove the retaining fasteners from the number 3 pivot pin index 12 at the non steer end of the machine 17 Use a
108. e 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 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
109. e lower lift cylinder rod end pivot pin index 9 from the machine Crushing hazard The lower lift ACAUTION cylinder will fall if not properly supported when the pivot pin is removed 57 Place a 2 4x 10 inch 10 x 10 x 25 cm block onto the number 1 inner arm cylinder plate index 14 58 Lower the cylinder onto the block Bodily injury hazard Keep hands ACAUTION clear of moving parts when lowering the cylinder 59 Attach a lifting strap from an overhead crane to the number 3 inner arm index 23 Raise the arm to a vertical position 60 Remove the retaining fasteners from the number 3 pivot pin at the steer end of the machine index 10 61 Use a soft metal drift to remove the number 3 pivot pin index 10 from the steer end of the machine Remove the number 3 inner arm index 23 from the machine Crushing hazard The number 3 ACAUTION inner arm index 23 may become unbalanced and fall if not properly supported when the pivot pin is removed 62 Remove the cables from the number 2A and 2B cable bridges and lay them off to the side Component damage hazard CAUTION Cables can be damaged if they are kinked or pinched Genie TEREX COMPANY GS 30 GS 32 GS 46 Part No 97385 September 2005 Section 4 Repair Procedures REVA 63 Disconnect the number 2A and 2B cable bridges from the scissor linkset and remove both cable bridges from the machine 64 Attach a lifting
110. e 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 W Indicates that an incorrect result has occurred after performing a series of steps Genie Part No 97385 TEREX COMPANY GS 30 GS 32 GS 46 3 1 Section 3 Scheduled Maintenance Procedures May 2005 SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend The following symbols have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appears at the beginning of a maintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Indicates that a cold motor or pump will be requi
111. e previous page to determine approximately 30 in Ibs 3 4 Nm the correct number of flats for the tighteni ition 2 Make areference mark on one of the flats of the Proper aded getan 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 e y Voy i Figure 1 a hydraulic hose b hexnut c reference mark Figure 2 d body hex fittin 9 a body hex fitting b reference mark 0 second mark 4 Tighten the hex nut until the mark on the hex nut is aligned with the second mark on the body hex fitting 5 Operate all machine functions and inspect the hoses and fittings and related components to confirm that there are no leaks Genie A TEREX COMPANY 2 6 GS 30 GS 32 GS 46 Part No 97385 September 2005 Section 2 Specifications REV B SPECIFICATIONS SAE FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual Black Oxide Bolts LUBED DRY LUBED in Ibs in lbs Nm 100 11 3 80 9 140 15 8 130 14 7 10 1 120 LUBED DRY LUBED DRY LUBED Nm Nm Nm 176 17 18 19 19 20 512 53 85 m gt 5 35 2 37 50 55 60 813 80 1
112. eels 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 O 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 REVA 29 Raise the machine approximately 2 inches 5 cm 30 GS 1530 and GS 1930 Place a 0 77 x6x 6 inch 19 6 mm x 15 cm x 15 cm thick steel block under both wheels at the battery pack side of the machine GS 1532 and GS 1932 Place a 0 83 x6 x6 inch 21 1 mm x 15 cm x 15 cm thick steel block under both wheels at the battery pack side of the machine GS 2032 and GS 2632 Place a 0 8 x 6 x 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 GS 2046 GS 2646 and GS 3246 Place a 1 22 6 6 inch 31mm 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 Res
113. ematics REV B ECM Pin out Legend ECM PIN OUT LEGEND UN Item Description 1 Flashing beacon 1 output WA A2 Ground from E 22 ia White wire at platform controls 12 Plug 9560020 4 Power from platform controls to ECM input DAR Red wire at platform controls XX 5 Level sensor power 57 output AA 12 A6 Platform up coil Y8 output L A7 Drive reverse coil Y5 output A8 Motor controller U6 terminal 1 s A9 Motor controller U6 terminal 3 A10 Overload sensor PS2 input 11 Key switch to platform control input 12 Platform down TS66 input B1 Platform data link high input Blue wire at platform controls B2 Plug B3 ECM ground output B4 Plug B5 Plug B6 Platform down coil Y7 output B7 Steer left coil Y4 output B8 Automotive style horn H2 option output B9 Multi function alarm H5 output B10 Pothole limit switch input B11 Drive enable power up limit switch input B12 Platform up TS66 input C1 Platform data link low input Orange wire at platform controls C2 Power to ECM input C3 Plug C4 Plug C5 Not used C6 Drive forward coil Y6 output C7 Steer right coil Y3 output C8 Parallel coil Y 1 not available on GS 1530 32 and GS 1930 32
114. eously the charger alarm sounds and the LEDs blink one time correct the charger connections at the fuse and battery The charger will then operate correctly and begin charging the batteries If simultaneously the charger alarm sounds and the LEDs blink two times the input voltage is too low or too high Correct the voltage issue The charger will then operate correctly and begin charging the batteries If simultaneously the charger alarm sounds and the LEDs blink three times the charger is overheated Allow the charger to cool The charger will then operate correctly and begin charging the batteries For best results use an extension of adequate size with a length no longer than 50 feet 15 m If you have any further questions regarding the battery charger operation please contact the Genie Industries Scissor Service Department Genie TEREX COMPANY Part No 97385 GS 30 GS 32 GS 46 3 9 Section 3 Scheduled Maintenance Procedures May 2005 CHECKLIST B PROCEDURES B 2 Inspect the Electrical Wiring Maintaining electrical wiring in good condition is essential to safe operation and good machine performance Failure to find and replace burnt chafed corroded or pinched wires could result in unsafe operating conditions and may cause component damage Electrocution hazard Contact with AWARNING hot or live circuits could result in death or serious injury Remove all rings watches and ot
115. er at the non steer end of the machine with a strap or other suitable device 94 Remove the retaining fasteners securing the chassis mount bracket to the chassis 95 Remove the linkset from the machine Bodily injury hazard The number ACAUTION 1 inner and outer arms index 14 and 29 may become unbalanced and fall if not properly supported when removed from the machine CAUTION Component damage hazard Be CAUTION Component damage hazard Be sure not to damage the limit switch careful not to damage the valve or or level sensor box components fittings on the cylinder while when the number 1 inner and removing it from the machine outer arms index 14 and 29 is 87 Remove the cables from the number 1 cable ev eC oi e machine bridge and lay them off to the side Component damage hazard CAUTION Cables can be damaged if they are kinked or pinched Genie TEREX COMPANY GS 30 GS 32 GS 46 Part No 97385 September 2005 Section 4 Repair Procedures REVA How to Replace the Scissor Arm Wear Pads 1 Remove the platform See 2 1 How to Hemove the Platform 2 Support and secure the entry ladder to an appropriate lifting device 3 Remove the fasteners from the entry ladder and remove the entry ladder from the machine Crushing hazard The entry ladder ACAUTION may become unbalanced and fall if not properly supported and secured to the lifting device 4 Secure the ends of the scissor arms t
116. er one outer arm cross tube and the chassis deck at the battery pack side of the non steer end of the machine Result The measurement is 0 94 inch 24 mm or more Proceed to step 3 Result The measurement is less than 0 94 inch 24 mm Replace both wear pads Refer to Repair Procedure 3 1 or 3 2 How to Replace the Scissor Arm Repair Pads 1 Ao Jj i J EET SAL E 1 a wear pad b outer arm cross tube C chassis deck 3 Apply a thin layer of dry film lubricant to the area of the chassis where the scissor arm wear pads make contact Cross tube to chassis specification 0 94 inch 24 mm Measurement minimum Genie Part No 97385 TEREX COMPANY GS 30 GS 32 GS 46 Section 3 Scheduled Maintenance Procedures May 2005 CHECKLIST D PROCEDURES GS 2032 GS 2632 GS 2046 GS 2646 and GS 3246 1 Measure the distance between the number one outer arm cross tube and the fork lift tube at the ground controls side of the non steer end of the machine Result The measurement is 0 94 inch 24 mm or more Proceed to step 2 Result The measurement is less than 0 94 inch 24 mm Replace both wear pads Refer to Repair Procedure 3
117. eter to the positive terminal on the 9V battery Note and record the current reading 6 Atthe battery or coil terminals reverse the connections Note and record the current reading Result Both current readings are greater than 0 mA and are different by a minimum of 20 The coil is good Result If one or both of the current readings are 0 mA or if the two current readings do not differ by a minimum of 20 the coil and or its internal diode are faulty and the coil should be replaced Genie Part No 97385 TEREX COMPANY GS 30 GS 32 GS 46 Section 4 Repair Procedures September 2005 Hydraulic Tank 7 1 Hydraulic Tank The primary functions of the hydraulic tank are to cool and deaerate the hydraulic fluid during operation It utilizes internal suction strainers for the pump supply lines and has an external return line filter How to Remove the Hydraulic Tank CAUTION Component damage hazard The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system When removing a hose assembly or fitting the fitting and or hose end must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications Perform this procedure with the platform in the stowed position 1 Disconnect the battery pack from the machine AWARNING Electrocution hazard Contact wit
118. g thumb rocker switch on the joystick to increase or decrease the value See 1 4 Machine Configuration Code Chartfor configuration settings 9 Press and hold the speed select button for a minimum of 3 seconds to set the ones value 10 Turn the key switch to the off position Any change in software settings 7 Press and hold the lift function select button for will not take effect until the key a minimum of 3 seconds to set the tens value switch is turned to the off position Genio Part No 97385 GS 30 GS 32 GS 46 4 9 Section 4 Repair Procedures October 2005 aaa SSE ESF PLATFORM CONTROLS REV Machine Configuration Code Chart A mark in the four right columns indicates that the machine configuration code in the left column includes this option MACHINE CONFIGURATION CODES MACHINE CONFIGURATION CODES GS 1530 GS 1532 GS 1930 GS 1932 GS 2032 GS 2632 GS 2046 GS 2646 6 Machine Machine 5 Motion Lift Drive Platform Descent Puas Motion Lift Drive Platform Cut Out Overload Delay Alarm Cut Out Overload Diagnostic Diagnostic Display Display 32 33 4 55 36 38 39 20 42 43 45 48 53 54 56 60 Genie A TEREX COMPANY 4 10 GS 30 GS 32 GS 46 Part No 97385 October 2005 Section 4 Repair Procedures REV How to Activate the Battery Drain Alarm Option 1 Pull out the red Emergency Stop button to the on po
119. h electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry REVA 2 Remove the drain plug from the hydraulic tank and allow all of the oil from the tank to drain into a suitable container Refer to Section 2 Specifications AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Tag and disconnect the hydraulic tank return hard line from the filter Remove the hard line from the machine Cap the fitting on the filter head 4 Tag and disconnect the hydraulic tank hard line from the pump Remove the hard line from the machine Cap the fitting on the pump 5 Remove the hydraulic tank retaining fasteners and remove the hydraulic tank from the machine Torque specifications 35 in lbs 4Nm Hydraulic tank retaining fasteners dry Hydraulic tank retaining fasteners lubricated 26 in lbs 2 9 Nm Genie A TEREX COMPANY GS 30 GS 32 GS 46 Part No 97385 September 2005 Section 4 Repair Procedures REVA 8 1 Yoke and Drive Motor How to Remove the Yoke and Drive Motor Assembly When removing a hose assembly or fitting the fitting and or hose end must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications
120. h a lifting strap from an overhead crane to the lug on the rod end of the lift cylinder for support Do not apply any lifting pressure 34 Remove the pin retaining fasteners from the lift cylinder rod end pivot pin index 5 Use a soft metal drift to remove the pin Bodily injury hazard The cylinder ACAUTION may fall when the rod end pivot pin is removed if not properly supported 35 Lower the cylinder onto the number 1 inner arm index 9 Component damage hazard CAUTION Cables can be damaged if they are kinked or pinched 36 Attach a lifting strap from an overhead crane to the number 3 inner arm index 15 37 Remove the retaining fasteners from the number 3 pivot pin index 6 at the steer end 38 Use a soft metal drift to remove the number 3 pivot pin index 6 Remove the number 3 inner arm index 15 from the machine Bodily injury hazard The number ACAUTION 3 inner arm may become unbalanced and fall if not properly supported when removed from the machine 39 Remove the cables from the number 2 cable bridge and lay them off to the side Component damage hazard CAUTION Cables can be damaged if they are kinked or pinched 40 Remove the external snap rings and retaining fasteners from the number 2 center pivot pin index 7 at the ground controls side Genie Part No 97385 TEREX COMPANY GS 30 GS 32 GS 46 Section 4 Repair Procedures September 2005 SCISSOR COMPONE
121. he cover retaining fastener s Do not over tighten TROUBLESHOOTING THE PLATFORM OVERLOAD SYSTEM CHECKLIST D PROCEDURES 18 Apply Sentry Seal to the fastener s securing the cover onto the platform overload pressure switch 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 Refer to Repair Procedure 6 3 How to Adjust the Platform Lift Relief Valve CONDITION POSSIBLE CAUSE SOLUTION CANNOT LIFT RATED LOAD AT MAXHEIGHT THE PRESSURE SWITCH ALARM CONTINUES TO SOUND AFTER ADJUSTMENT RELIEF VALVE SETTING SYSTEM NEEDS TO BE RESET INCREASE RELIEF VALVE PRESSURE TURN OFF RED EMERGENCY STOP BUTTON WAIT THREE SECONDS AND TURN BACK ON UP LIMIT SWITCH OUT OF ADJUSTMENT LOWER THE UP LIMIT SWITCH SLIGHTLY TESTED WRONG RATED LOAD FOR HEIGHT BEING PRESSURE SWITCH OUT OF ADJUSTMENT TURN THEPRESSURE SWITCH NUT INTO PUT CORRECT RATED LOAD IN PLATFORM THE HYDRAULIC LINE 1 4 TURN BATTERIES ARE NOT FULLY CHARGED CHARGE BATTERIES PROPERLY OVERLOAD SYSTEM NOT ADJUSTED REPEAT CALIBRATION PROCEDURE SLIDER CHANNEL NOT LUBRICATED LUBRICATE SLIDER CHANNELS AT DOWN LIMIT THE PRESSURE SWITCH ALARM CONTINUES TO SOUND AFTER ADJUSTMENT SYSTEM NEEDS TO BE RESET TURN OFF RED EMERGENCY STOP BUTTON WAIT THREE SECONDS AND TURN BA
122. he 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 Fully raise the platform Release the toggle switch Result models with software revision AO and A1 The alarm should not sound and fault code 54 should be present in the diagnostic display The system is functioning correctly 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 Hevision Level 10 Lower the platform to the stowed position Genie TEREX COMPANY GS 30 GS 32 GS 46 3 21 Part No 97385 Section 3 Scheduled Maintenance Procedures May 2005 CHECKLIST C PROCEDURES C 2 Replace the Hydraulic Tank Breather Cap Models with
123. he ground control side index 47 may become unbalanced and fall if not properly supported when removed from the machine 47 Attach a lifting strap from an overhead crane to the number 3 outer arm at the battery side index 7 48 Remove the retaining fasteners from the number 3 center pivot pin index 8 at the battery side 49 Place a rod through the number 3 center pivot pin at the battery side index 8 and twist to remove the pin 50 Remove the number 3 outer arm index 7 from the machine Crushing hazard The number 3 ACAUTION outer arm index 7 may become unbalanced and fall if not properly supported when removed from the machine 51 Attach a lifting strap from an overhead crane to the lug of the rod end of the upper lift cylinder 52 Raise the lift cylinder to a vertical position 53 Remove the pin retaining fasteners from the lift cylinder barrel end pivot pin index 22 Remove the lift cylinder from the machine Crushing hazard The lift cylinder ACAUTION will fall if not properly supported when the pivot pin is removed Component damage hazard Be careful not to damage the valve or fittings on the cylinder while removing it from the machine CAUTION REVA 54 Attach a lifting strap from an overhead crane to the lug of the rod end of the lower lift cylinder 55 Remove the retaining fasteners from the lower lift cylinder rod end pivot pin index 9 56 Use a soft metal drift to remove th
124. he machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable N no remove from service R repaired A 2 Function tests Perform after 40 hours A 3 30 day service Perform every 100 hours A 4 Grease steer yokes Comments No 97385 TEREX COMPANY 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 Drive speed slow B 11 Hydraulic oil analysis B 12 Tank venting system B 13 Latch components B 14 Voltage inverter B 1 Batteries B 2 Electrical wiring if equipped ChecklistC RevA C 1 Platform overload if equipped C 2 Breather cap models with optional oil ChecklistD RevA YN D 1 Scissor arm wear pads D 2 Platform overload if equipped D 3 Hydraulic filter Checklist E Rev Y NR E 1 Hydraulic oil GS 30 GS 32 GS 46 Section 3 Scheduled Maintenance Procedures May 2005 Checklist A Procedures A 1 Perform Pre operation Inspection Completing a Pre operation Inspection is essential to safe machine operation The Pre operation Inspection is a visual inspection performed by the operator prior to each work shift The inspection is designed to discover if anything
125. he red Emergency Stop button to the off position at both the ground and platform controls and turn the key switch to the off 3 Pressthe lift function select button position Machine Option Definitions Motion Alarm The motion alarm will sound when operating any function Lift Drive Cut Out In addition to an alarm sounding lift and drive functions are disabled when the platform is raised above the down limit switch and the incline of the chassis exceeds the rating on the serial plate Configured on all machines Platform Overload When the platform overload limit switch is tripped signaling an overload condition in the platform all machine functions are disabled The additional weight must be removed from the platform and the power cycled from off to on before any function can be resumed Required for CE models Descent Delay This option halts descent for 4 to 6 seconds All controls must be released and re engaged before descent is re enabled Required for CE models Battery Drain Alarm When the machine is turned on and in the stowed position and no function is activated for 2 minutes an alarm will sound once every 3 seconds When this option is configured a dot in the diagnostic display window will remain continuously illuminated when the ECM is in the SC mode OR when the platform up function is activated Genie A TEREX COMPANY 4 8 GS 30 GS 32 GS 46 Part No 97385 October 2005 Section 4 Repair Proced
126. hed Genie TEREX COMPANY GS 30 GS 32 GS 46 4 29 Part No 97385 Section 4 Repair Procedures September 2005 SCISSOR COMPONENTS 12 Use a soft metal drift to remove the number 3 pivot pin index 12 from the non steer end of the machine Remove the number 3 outer arm at the ground control side index 11 from the machine Crushing hazard The number 3 ACAUTION outer arm at the ground control side index 11 may become unbalanced and fall if not properly supported when removed from the machine 13 Attach a lifting strap from an overhead crane to the number 3 outer arm at the battery side index 11 14 Remove the retaining fasteners from the number 3 center pivot pin index 2 at the battery side 15 Place a rod through the number 3 center pivot pin at the battery side index 2 and twist to remove the pin 16 Remove the number 3 outer arm index 11 from the machine Crushing hazard The number 3 ACAUTION outer arm index 11 may become unbalanced and fall if not properly supported when removed from the machine 17 Attach a lifting strap from an overhead crane to the lug of the rod end of the lift cylinder 18 Remove the retaining fasteners from the lift cylinder rod end pivot pin index 3 19 Use a soft metal drift to remove the lift cylinder rod end pivot pin index from the machine Crushing hazard The lift cylinder ACAUTION will fall if not properly supported
127. hen they are removed and installed or when new hoses or fittings are installed SAE O ring Boss Port gt JIC 37 Fittings tube fitting installed into Aluminum swivel nut or hose connection SAE Dash size Torque SAE Dash size Thread Size Flats 4 11 ft lbs 14 9 Nm 4 7 16 20 2 6 23 ft lbs 31 2 Nm 6 9 16 18 1 1 4 8 40 ft lbs 54 2 Nm 8 3 4 16 1 10 69 ft lbs 93 6 Nm 10 4 1 12 93 ft lbs 126 1 Nm 12 1 1 16 12 1 16 139 ft lbs 188 5 Nm 16 1 5 16 12 1 20 172 ft lbs 233 2 Nm 20 1 5 e 12 1 24 208 ft lbs 282 Nm 24 1 2 1 SAE O ring Boss Port tube fitting installed into Steel SAE Dash size Torque 4 16 ft lbs 21 7 Nm 6 35 ft lbs 47 5 Nm 8 60 ft lbs 81 3 Nm 10 105 ft lbs 142 4 Nm 12 140 ft lbs 190 Nm 16 210 ft lbs 284 7 Nm 20 260 ft lbs 352 5 Nm 24 315 ft lbs 427 1 Nm Genie TEREX COMPANY Part No 97385 GS 30 GS 32 GS 46 2 5 Section 2 Specifications September 2005 SPECIFICATIONS REV B Torque Procedure 3 Working clockwise on the body hex fitting make 2222222 second mark with a 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 uem 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 th
128. her jewelry 1 Inspect the underside of the chassis for damaged or missing ground strap s 2 Inspect the following areas for burnt chafed corroded and loose wires Ground control panel Hydraulic power unit module tray Battery pack module tray Scissor arms Platform controls 3 Inspect for a liberal coating of dielectric grease in the following locations Between the ECM and platform controls All wire harness connectors Level sensor REVA 4 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 5 Raise the platform approximately 8 feet 2 4 m from the ground 6 Rotate the safety arm away from the machine and let it hang down 7 Lower the platform onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 8 Inspect the center chassis area and scissor arms for burnt chafed and pinched cables 9 Inspect the following areas for burnt chafed corroded pinched and loose wires Scissor arms ECM to platform controls Power to platform wiring 10 Inspect for a liberal coating of dielectric grease in all connections between the ECM and the platform controls 11 Raise the platform and return the safety arm to the stowed position 12 Lower the platform to the stowed position and turn the machine off Genie TEREX COMPANY GS 30 GS
129. hin the red Emergency Stop button at the ground controls to the off position Result No machine functions should operate 3 Turn key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 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 Part No 97385 TEREX COMPANY GS 30 GS 32 GS 46 Section 3 Scheduled Maintenance Procedures May 2005 CHECKLIST B PROCEDURES 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 red Emergency Stop button to the on position at both the ground and platform controls 2 Turn the key switch to platform control 3 Check the platform up down function from the ground controls Result The machine functions should not operate
130. ication Refer to Section 2 Specifications 11 Install the hydraulic pump return hard line into the tank Install the fitting onto the hydraulic filter head and torque to specification Refer to Section 2 Specifications 12 Fill the tank with hydraulic oil until the fluid is at the FULL indicator on the hydraulic tank Do not overfill 13 Activate the pump to fill the hydraulic system with oil and bleed the system of air Component damage hazard The CAUTION pump can be damaged if operated without oil Be careful not to empty the hydraulic tank while in the process of filling the hydraulic system Do not allow the pump to cavitate 14 Repeat steps 12 through 13 until the hydraulic system and tank are both full Genie TEREX COMPANY 3 30 GS 30 GS 32 GS 46 REVA Part No 97385 September 2005 Section 4 Repair Procedures Observe and Obey Repair procedures shall be completed by a person trained and qualified on the repair of this machine M Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Repairs Start Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necessary tools and parts are available and ready for use Read each procedure completely and adhere to the i
131. in index 5 at the battery pack side 34 Use a soft metal drift to remove the number 2 center pivot pin index 5 at the battery pack side Bodily injury hazard The number ACAUTION 2 outer arm at the battery pack side may become unbalanced and fall if not properly supported when removed from the machine 35 Use a soft metal drift to tap the number 2 pivot pin index 15 in the other direction at the non steer end Remove the number 2 outer arm index 14 from the battery pack side of the machine Bodily injury hazard The number ACAUTION 2 outer arm at the battery pack side may become unbalanced and fall if not properly supported when removed from the machine 36 Attach a lifting strap from an overhead crane to the number 2 inner arm index 13 37 Remove the retaining fasteners from the number 2 pivot pin index 6 at the steer end of the machine SCISSOR COMPONENTS 38 Use a soft metal drift to remove the number 2 pivot pin index 6 Remove the number 2 inner arm index 13 from the machine Bodily injury hazard The number ACAUTION 2 inner arm may become unbalanced and fall if not properly supported when removed from the machine 39 Remove the safety arm from the number 2 inner arm index 13 that was just removed 40 Attach a lifting strap from an overhead crane to the number 1 inner arm index 8 41 Raise the number 1 inner arm index 8 approximately 2 feet 60 cm and install the safe
132. inder will fall if not properly supported 11 Lower the cylinder onto the number 2 inner arm 12 Attach a lifting strap from an overhead crane or similar lifting device to the barrel end of the lift cylinder for support 13 Remove the retaining fasteners from the lift cylinder barrel end pivot pin Use a soft metal drift to remove the pin AWARNING Crushing hazard The lift cylinder will fall if not properly supported when the pin is removed 14 Support and secure the lift cylinder to an appropriate lifting device 15 Remove the lift cylinder through the scissor arms at the steer end of the machine Crushing hazard The lift cylinder ACAUTION may become unbalanced and fall if not properly supported and secured to the lifting device Component damage hazard Be careful not to damage the valve or fittings on the cylinder while removing it from the machine CAUTION Torque specification SCISSOR COMPONENTS How to Remove the Lift Cylinder GS 2032 GS 2632 GS 2046 and GS 2646 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 fitting and or hose end must be torqued to specification during installation Refer to
133. ing the scissor assembly 13 Remove the old wear pad 14 Install the new wear pad 15 Slide the scissor assembly back into the drive chassis 16 Lower the scissor assembly into position and install the chassis mount bracket onto the chassis Securely install and tighten the fasteners Do not overtighten Component damage hazard Be CAUTION careful not to damage the level sensor or limit switch while moving the scissor assembly Genie SCISSOR COMPONENTS TEREX COMPANY Part No 97385 GS 30 GS 32 GS 46 Section 4 Repair Procedures September 2005 SCISSOR COMPONENTS 968 9 N 5 Na N 9 90 099 9 OOO Steer end Non steer end 9 Number 6 pivot pin Number 5 center pivot pin 2 pins Upper lift cylinder rod end pivot pin Number 5 pivot pin steer end Number 4 center pivot pin 2 pins Number 4 pivot pin steer end Number 3 outer arm Number 3 center pivot pin 2 pins Lower lift cylinder rod end pivot pin 10 Number 3 pivot pin steer end 11 Number 2 center pivot pin 2 pins 12 Number 2 pivot pin steer end 13 Number 1 center pivot pin 2 pins 14 Number 1 inner arm 15 Number 1 pivot pin steer end 2 pins Genie
134. ings on the cylinder AWARNING injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 59 Tag and disconnect the wire harness from the solenoid valve on the cylinder 60 Tag and disconnect the wires and manual lowering cable from the solenoid valve on the cylinder 61 Models with platform overload option Tag and disconnect the wire harness from the platform overload switch 62 Raise the lift cylinder to a vertical position 63 Remove the pin retaining fasteners from the lift cylinder barrel end pivot pin index 21 Use a soft metal drift to remove the pin Remove the lift cylinder from the machine Crushing hazard The lift cylinder ACAUTION will fall if not properly supported when the pivot pin is removed Component damage hazard Be careful not to damage the valve or fittings on the cylinder while removing it from the machine CAUTION Section 4 Repair Procedures September 2005 SCISSOR COMPONENTS 64 Remove the cables from the number 1 cable bridge and lay them off to the side Component damage hazard CAUTION Cables can be damaged if they are kinked or pinched 65 Disconnect the number 1 cable bridge from the number 1 outer arm index 22 and remove the cable bridge from the machine 66 Attach a lifting strap from an overhead crane to the number 1 inne
135. ings on the cylinder AWARNING Wien 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 82 Tag and disconnect the wire harness from the solenoid valve on the cylinder 83 Tag and disconnect the wires and manual lowering cable from the solenoid valve on the cylinder 84 Models with platform overload option Tag and disconnect the wire harness from the platform overload switch 85 Raise the lift cylinder to a vertical position 86 Remove the pin retaining fasteners from the lift cylinder barrel end pivot pin index 28 Use a soft metal drift to remove the pin Remove the lift cylinder from the machine Crushing hazard The lift cylinder ACAUTION will fall if not properly supported when the pivot pin is removed REVA 88 Disconnect the number 1 cable bridge from the number 1 outer arm index 29 and remove the cable bridge from the machine 89 Attach a lifting strap from an overhead crane to the number 1 inner arm index 14 90 Raise the arm slightly and remove the block 91 Lower the arm to the stowed position Bodily injury hazard Keep hands ACAUTION clear of moving parts when lowering the scissor arms 92 Secure the ends of the scissor arms together at the steer end of the machine with a strap or other suitable device 93 Secure the ends of the scissor arms togeth
136. 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 REVA 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 TEREX COMPANY GS 30 GS 32 65 46 Part No 97385 May 2005 Section 3 Scheduled Maintenance Procedures REVA A 3 Perform 30 Day Service The 30 day maintenance procedure is a one time 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 maintenance procedures 3 Inspect the Tires and Wheels including castle nut torque 3 Replace the Hydraulic Tank Return Filter CHECKLIST A PROCEDURES A 4 Grease the Steer Yokes Genie specifications require that
137. ivot pin index 1 secured to the lifting device Genie TEREX COMPANY Part No 97385 GS 30 GS 32 GS 46 4 35 Section 4 Repair Procedures September 2005 SCISSOR COMPONENTS 7 Usea soft metal drift to remove the number 5 pivot pin index 1 Remove the platform mount bracket from the machine 8 Attach a lifting strap from an overhead crane to the number 4 outer arm at the ground control side index 13 9 Remove the retaining fasteners from the number 4 center pivot pin index 2 at the ground control side 10 Place a rod through the number 4 center pivot pin at the ground control side index 2 and twist to remove the pin 11 Remove the retaining fasteners from the number 4 pivot pin index 15 at the non steer end 12 Use a soft metal drift to remove the number 4 pivot pin index 14 from the non steer end of the machine Remove the number 4 outer arm at the ground control side index 13 from the machine Crushing hazard The number 4 ACAUTION outer arm at the ground control side index 13 may become unbalanced and fall if not properly supported when removed from the machine 13 Attach a lifting strap from an overhead crane to the number 4 outer arm at the battery side index 13 14 Remove the retaining fasteners from the number 4 center pivot pin index 2 at the battery side REVA 15 Place a rod through the number 4 center pivot pin at the battery side index 2 and t
138. l on the side of the platform could result in the machine tipping over resulting in death or serious injury Do not raise the platform above the maximum load position of the capacity indicator decal on the side of the platform To perform this step the lift relief valve will need to be adjusted Genie Part No 97385 TEREX COMPANY GS 30 GS 32 GS 46 3 25 Section 3 Scheduled Maintenance Procedures May 2005 CHECKLIST D PROCEDURES 7 Lift the safety arm move it to the center of the scissor arm and rotate down to a vertical position 8 Models with round pressure switch Remove the retaining ring securing the cover to the pressure switch and remove the cover Using a flat blade turn the slotted switch adjustment screw of the platform overload pressure switch into the hydraulic line in 90 increments until the overload alarm does not sound Models with box shaped pressure switch Remove the fasteners securing the cover to the pressure switch and remove the cover Using a wrench turn the nut of the platform overload pressure switch into the hydraulic line in 90 increments until the overload alarm does not sound To allow the platform overload system to reset the red Emergency Stop button must be cycled after each quarter turn of REVA 9 Slowly turn the nut or adjustment screw of the platform overload pressure switch out of the hydraulic line just until the overload alarm sounds To all
139. latform down LS7 Pothole LS8 Pothole M5 Hydraulic power unit Normally closed NCHO Normally closed held open NOHC Normally open held closed Power switch P1 Emergency Stop button at ground controls P2 Emergency Stop button at platform controls PS2 Platform overload pressure switch option QD Quick disconnect QD1 Battery quick disconnect 003 Control cable to ground QD4 Control cable to platform R24 Resistor 25 ohm SW Switch SW5 Function enable SW6 Steer left right S7 Tilt level sensor TS66 Platform up down toggle switch Electronic component U3 Platform controls printed circuit board U5 Electronic control module U6 Motor controller U9 Battery charger U13 Voltage inverter option U27 47 mH inductor noise suppression Valve coil Y1 Parallel GS 2032 GS 2632 and all GS 46 Y3 Steer right Y4 Steer left Y5 Drive reverse Y6 Drive forward Y7 Platform down Y8 Platform up Y9 Platform down GS 3246 WIRE COLOR LEGEND Color Description BK Black BL Blue BN Brown GN Green GY Gray OR Orange OR BK Orange Black PP Purple RD Red RD BK Red Black WH White enie September 2005 REV A A TEREX COMPANY GS 30 GS 32 GS 46 Part No 97385 September 2005 Section 6 Sch
140. latform up Platform down GS 1930 GS 1932 15 to 17 seconds 16 to 18 seconds Platform up Platform down GS 2032 GS 2046 15 to 17 seconds 22 to 24 seconds Platform up Platform down GS 2632 GS 2646 28 to 32 seconds 26 to 30 seconds Platform up Platform down GS 3246 28 to 32 seconds 22 to 26 seconds Platform up Platform down 55 to 59 seconds 38 to 42 seconds Rated work load at full height maximum GS 1530 and GS 1532 600 Ibs 272 kg GS 1930 GS 1932 and GS 2632 500 Ibs 227 kg GS 2032 800 Ibs 363 kg GS 2046 1200 Ibs 544 kg GS 2646 1000 Ibs 454 kg GS 3246 700 Ibs 317 kg Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie A TEREX COMPANY 2 2 GS 30 GS 32 GS 46 Part No 97385 September 2005 Section 2 Specifications REV B Hydraulic Specifications Hydraulic Oil Specifications Hydraulic oil type ISO viscosity grade Chevron Rykon MV equivalent Multi viscosity Viscosity index 200 Cleanliness level minimum 15 13 Water content maximum 200 ppm Chevron Rykon MV oil is fully compatible and mixable with Shell Donax TG Dexron Ill oils Genie specifications require hydraulic oils which are designed to give maximum protection to hydraulic systems have the ability to perform over a wide temperature range and have a minimum viscosity index of 1
141. ling new rivets make sure the rivet heads are not above the surface of the wear pad Genie Part No 97385 TEREX COMPANY GS 30 GS 32 GS 46 Section 4 Repair Procedures September 2005 Scissor Components REVA O KD 2 9 5 6 GS 1530 m GS 1532 Steer End Non steer End 1 Number 4 pivot pin 9 Number 1 pivot pin 2 Number 3 outer arm 10 Number 3 inner arm 3 Number 3 center pivot pin 2 pins 11 Number 3 outer arm 4 Lift cylinder rod end pivot pin 12 Number 3 pivot pin non steer end 5 Number 3 pivot pin steer end 13 Number 2 inner arm 6 Number 2 center pivot pin 2 pins 14 Number 2 outer arm 7 Number 2 pivot pin steer end 15 Number 2 pivot pin non steer end 8 Number 1 center pivot pin 2 pins 16 Lift cylinder barrel end pivot pin 17 Number 1 outer arm Genie A TEREX COMPANY 4 14 GS 30 GS 32 GS 46 Part No 97385 September 2005 Section 4 Repair Procedures REVA SCISSOR COMPONENTS 3 1 Scissor Assembly GS 1530 and GS 1532 How to Disassemble the Scissor Assembly GS 1530 and GS 1532 AWARNING P dily injury hazard The procedures in this section require specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant
142. ly 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 Genie Part No 97385 TEREX COMPANY GS 30 GS 32 GS 46 4 1 Section 4 Repair Procedures October 2005 Platform Controls The platform controls used to operate the machine from the platform or while standing on the ground can also be used to tune the performance of the machine Moving the joystick or activating a button sends a signal to the Electronic Control Module ECM When the ECM is in the function mode the platform controls are used to operate the various machine functions When the ECM is in the programming mode PS is shown in the diagnostic display window the platform controls are used to adjust the function speed parameters The platform controls consist of an electronic circuit board joystick membrane decal buttons LEDs and a diagnostic display For further information or assistance consult the Genie Industries Service Department ERN JC1 JOYSTICK CONTROLLER 6
143. n 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 CHECKLIST D PROCEDURES 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 1532 484 kg GS 1932 435 kg GS 2032 693 kg GS 2632 479 kg GS 2046 985 kg GS 2646 798 kg GS 3246 699 kg 4 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 5 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 6 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 deca
144. n is removed 14 Support and secure the lift cylinder to an appropriate lifting device 15 Remove the lift cylinder through the scissor arms at the steer end of the machine Crushing hazard The lift cylinder ACAUTION may become unbalanced and fall if not properly supported and secured to the lifting device Component damage hazard Be CAUTION careful not to damage the valve or fittings on the cylinder while removing it from the machine Torque specification Solenoid valve 2 position 2 way N C 20 ft lbs schematic item N 27 Nm Coil nut 5 ft lbs 7Nm Genie A TEREX COMPANY 4 54 GS 30 GS 32 GS 46 Part No 97385 September 2005 Section 4 Repair Procedures REVA 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 down to a vertical position 3 Lower the platform onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 4 Pullthe handle of the manual platform lowering cable out until considerable resistance is felt Release the handle 5 Mea
145. n 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 3 overload pressure switch b maximum height limit switch Genie TEREX COMPANY GS 30 GS 32 GS 46 Part No 97385 May 2005 Section 3 Scheduled Maintenance Procedures REVA 1 Locate the lift valve coil on the function manifold GS 1532 GS 1932 A PRR 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 blue black wires of the manifold wire harness at the lift valve coil on the manifold 3 Securely connect together the terminals of the two blue black wires of the manifold wire harness disconnected from the limit switch wire harness in step 2 4 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls CHECKLIST C PROCEDURES 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 t
146. nd and platform controls 6 Activate and hold the platform up toggle switch 7 Inspect the filter and related components to be sure that there are no leaks 8 Clean up any oil that may have spilled Torque specifications Hydraulic tank drain plug dry 40 in lbs 4 5 Nm Hydraulic tank drain plug lubricated 30 in lbs 3 4 Nm Genie TEREX COMPANY GS 30 GS 32 GS 46 Part No 97385 May 2005 Section 3 Scheduled Maintenance Procedures Checklist E Procedure REVA 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 may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more often Refer to Section 2 Specifications Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test Perform this procedure with the platform in the stowed position 1 Disconnect the battery pack from the machine AWARNING Electrocution hazard Contact with hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry 2 Open the power unit
147. nd of the bellcrank Note the quantity and location of the spacers between the bellcrank and the steer links 3 Center a lifting jack under the drive chassis at the steer end 4 Raise the machine approximately 14 inches 36 cm Place blocks under the chassis for support AWARNING Crushing hazard The chassis could fall if not properly supported 5 Turn the yokes to the side so the bellcrank can be removed 6 Remove the bellcrank from the machine Note the quantity and the location of the spacers in between the bellcrank and the steer links Genie TEREX COMPANY Part No 97385 GS 30 GS 32 GS 46 4 75 Section 4 Repair Procedures September 2005 Non steer Axle Components 9 1 Drive Brake How to Remove a Drive Brake When removing a hose assembly or fitting the fitting and or hose end must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Support and secure the entry ladder to an appropriate lifting device 2 Remove the entry ladder mounting fasteners Remove the entry ladder from the machine Crushing hazard The entry ladder ACAUTION may become unbalanced and fall if itis not properly supported and secured to the lifting device 3 Block the steer wheels 4 Remove the cotter pin from the wheel castle nut Always replace the cotter pin with new one when removing the castle nut 5 Loosen the wheel ca
148. nds of the scissor arms together at the steer end of the machine with a strap or other suitable device Secure the ends of the scissor arms together at the non steer end of the machine with a strap or other suitable device Remove the retaining fasteners securing the chassis mount bracket to the chassis at the steer end of the machine Attach a lifting strap from an overhead crane to the scissor arm assembly Raise the scissor arm assembly at the steer end with the overhead crane until the chassis mount bracket will clear the level sensor Move the scissor assembly towards the non steer end of the machine slightly and to one side of the machine until one of the scissor arm wear pads is accessible Do not allow both wear pads to slide out of the drive chassis Component damage hazard Be CAUTION careful not to damage the level sensor or limit switch while moving the scissor assembly Part No 97385 September 2005 Section 4 Repair Procedures REVA 10 Remove the old wear pad 11 Install the new wear pad 12 Rotate the scissor assembly towards the other side of the machine until the other scissor arm wear pad is accessible Do not allow both wear pads to slide out of the drive chassis ADANGER Crushing hazard The scissor assembly will fall if both wear pads are allowed to slide out of the drive chassis Component damage hazard Be CAUTION careful not to damage the level sensor or limit switch while mov
149. nie TEREX COMPANY Part No 97385 GS 30 GS 32 GS 46 6 3 Section 6 Schematics September 2005 Electrical Schematic CE Models REV B GS 2032 2632 from serial number GS3205 75407 to 77290 GS 2046 2646 3246 from serial number GS4605 75438 to 76734 P1 x EMERGENCY X Pd STOP WH 2 B Non i 2 4 KS1 key PLATFORM 1 SWITCH CONTROL B 4 1 NOTE ALARM MACHINE SHOWN IN THE 213 STOWED POSITION WITH THE POWER OFF Se x 1 157 TS66 POTHOLE PLATFORM UP DOWN 4 CB2 N C H O 4 LS8 BREAKER 4 U27 GUARD 47 mH INDUCTOR NOISE SUPPRESSION SWITCH c 5 v S gg 7 5 9 2322 B EE 2 d Leo 5 5 7 g QD1 oe d F6 275a FUSE 8 ee A12 B12 B9 B10 IN IN IN OUT IN z u pep A8 OUT BATTERY A1 OUT 5 CHARGER ELECTRONIC CONTROL MODULE OUT OUT B5 ee BATTERY U6 9 2 motor O 3O CONTROLLER S Tuc SAY CR5 E HORN RELAY X P 30 H2OPTION 486 U13 G6 FB
150. nstructions 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 disconnected 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 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 potential
151. nt bracket onto the chassis Securely install and tighten the fasteners Do not overtighten Component damage hazard Be CAUTION careful not to damage the level sensor or limit switch while moving the scissor assembly Genie Part No 97385 TEREX COMPANY GS 30 GS 32 GS 46 Section 4 Repair Procedures September 2005 SCISSOR COMPONENTS Steer end e amp GG GG N amp 9 9 dub GS 2632 GS 2646 E Non steer end 9 Number 5 pivot Number 4 center pivot 2 pins Number 4 pivot pin steer end Number 3 center pivot pin 2 pins Lift cylinder rod end pivot pin Number 3 pivot pin steer end Number 2 center pivot pin 2 pins Number 2 pivot pin steer end Number 1 center pivot pin 2 pins 10 Number 1 inner arm 11 Number 1 pivot pin 12 Number 4 inner arm 13 Number 4 outer arm 14 Number 4 pivot pin non steer end 15 Number 3 inner arm 16 Number 3 outer arm 17 Number 3 pivot pin non steer end 18 Number 2 inner arm 19 Number 2 outer arm 20 Number 2 pivot pin non steer end 21 Lift cylinder barrel end pivot pin 22 Number 1 outer arm Genie 4 34 A TEREX COMPANY GS 30 GS 32 GS 46 Part No 97385 September 2005 Section 4 Repair Procedures REVA SCISSOR COMPON
152. ogether at the steer end of the machine with a strap or other suitable device 5 Secure the ends of the scissor arms together at the non steer end of the machine with a strap or other suitable device 6 Remove the retaining fasteners securing the chassis mount bracket to the chassis at the steer end of the machine 7 Attach a lifting strap from an overhead crane to the scissor arm assembly 8 Raise the scissor arm assembly at the steer end with the overhead crane until the chassis mount bracket will clear the level sensor 9 Move the scissor assembly towards the non steer end of the machine slightly and to one side of the machine until one of the scissor arm wear pads is accessible Do not allow both wear pads to slide out of the drive chassis Component damage hazard Be CAUTION careful not to damage the level sensor or limit switch while moving the scissor assembly SCISSOR COMPONENTS 10 Remove the old wear pad 11 Install the new wear pad 12 Rotate the scissor assembly towards the other side of the machine until the other scissor arm wear pad is accessible Do not allow both wear pads to slide out of the drive chassis Crushing hazard The scissor ADANGE assembly will fall if both wear pads are allowed to slide out of the drive chassis Component damage hazard Be careful not to damage the level sensor or limit switch while moving the scissor assembly CAUTION 13 Remove the old wear pad 14 Ins
153. ons shall be completed daily quarterly semi annually annually and every two years as specified on the Maintenance Inspection Report AWARNING Failure to perform each procedure as presented and scheduled could result in death serious injury or substantial damage M Immediately tag and remove from service a damaged or malfunctioning machine M Repair any machine damage or malfunction before operating the machine Keep records on all inspections for three years Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection Unless otherwise specified perform each maintenance procedure with the machine in the following configuration Machine parked on a firm level surface Platform in the stowed position Key switch in the off position with the key removed The red Emergency Stop button in the off position at both ground and platform controls Wheels chocked All external AC power supply disconnected from the machine About This Section This section contains detailed procedures for each scheduled maintenance inspection Each procedure includes a description safety warnings and step by step instructions Symbols Legend Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Red used to indicate the presenc
154. ontact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 7 Disconnect the wiring from the platform and pull the wiring free of the platform 8 9 REVA Models with air line to platform option Disconnect the air line from the platform Pull the air line free of the platform Support the platform with a forklift at the non steer end Do not apply any lifting pressure 10 Attach a strap from the lanyard anchorage point on the platform railings to the carriage on the forklift to help support the platform GS 1530 32 and GS 1930 32 Lift the steer end of the platform slightly to clear the platform mount and slide the platform towards the non steer end of the machine until the platform slide blocks at the non steer end of the machine are visible through the access holes in the bottom of the platform All other models Lift the steer end of the platform slightly to clear the platform mount and slide the platform towards the steer end of the machine until the platform slide blocks at the non steer end of the machine are visible through the access holes in the bottom of the platform AWARNING Crushing hazard The platform will fall if not properly supported 12 Carefully lift the platform off of the machine and Genie A TEREX COMPANY place it on a structure capable of supporting it Note the position of the wear pads before the pla
155. operator s manual on your machine General Repair Process Be sure that all necessary tools and test equipment are available and ready for use Malfunction Identify Troubleshoot discovered symptoms problem Still exists Perform repair Retum to Service solved Genie TEREX COMPANY Part No 97385 GS 30 GS 32 GS 46 6 1 Section 6 Schematics c v SS Electrical Component and Wire Color Legends ELECTRICAL COMPONENT LEGEND Item Description BS Battery BN Button 5 Horn BN6 High torque Drive select BN9 Lift select C5 Capacitor 4700 uF CB2 Circuit breaker 7A CR Control relay CR5 Horn relay with H2 option CR27A Overload motor controller option CR27B Overload load sense option CR27C Overload down coil option CR27D Overload down delay option CR48 Power relay to U5 e stop D7 Voltage regulator Platform controls circuit board F6 Fuse 275A FB Flashing beacons G6 Hour meter GND Ground Horn or alarm H1 Horn H2 Automotive style horn option H5 Multifunction alarm JC1 Joystick controller KS1 Key switch LED or light L16 Lift L17 Drive L21 High torque L30 Work light option LS Limit switch LS5 Platform up option LS6 P
156. or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Block the non steer wheels 2 Remove the pin retaining fasteners from the rod end pivot pin Remove the pivot pin Note the quantity and location of the spacers when removing the pivot pin 3 Remove the pin retaining fasteners from the barrel end pivot pin Remove the pin Note the quantity and location of the spacers when removing the pivot pin 4 Remove the steer cylinder from the machine 5 Tag disconnect and plug the hydraulic hoses from the steer cylinder Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Drive motor mounting fasteners dry 75 ft lbs CAUTION Component damage hazard 101 7 Nm Hoses can be damaged if they are kinked or pinched Drive motor mounting fasteners lubricated 56 ft lbs 76 3 Nm Genie TEREX COMPANY GS 30 GS 32 GS 46 Part No 97385 September 2005 Section 4 Repair Procedures e e LL LL LLL REVA STEER AXLE COMPONENTS 8 3 Steer Bellcrank How to Remove the Steer Bellcrank 1 Remove the steer cylinder See 8 2 How to Remove the Steer Cylinder 2 Remove the retaining fasteners from the steer links at each e
157. ot steer left microswitch 43 Platform right turn switch fault Malfunctioning steer right microswitch Troubleshoot steer right microswitch 46 Platform drive enable switch fault Malfunctioning drive enable switch Troubleshoot drive enable switch 47 Platform joystick fault Joystick potentiometer not centered Verify potentiometer setting 52 Forward coil fault Malfunctioning coil OR wire disconnected from coil Troubleshoot coil OR inspect wire connection 53 Reverse coil fault Malfunctioning coil OR wire disconnected from coil Troubleshoot coil OR inspect wire connection 54 Up coil fault Malfunctioning coil OR wire disconnected from coil Troubleshoot coil OR inspect wire connection 55 Down coil fault Malfunctioning coil OR wire disconnected from coil Troubleshoot coil OR inspect wire connection 56 Steer right coil fault Malfunctioning coil OR wire disconnected from coil Troubleshoot coil OR inspect wire connection 57 Steer left coil fault Malfunctioning coil OR wire disconnected from coil Troubleshoot coil OR inspect wire connection 58 Brake coil fault Malfunctioning coil OR wire disconnected from coil Troubleshoot coil OR inspect wire connection 59 Series parallel coil fault DIP switch settings are incorrect Troubleshoot and correct DIP switch settings 68
158. out Legend 22 2 enne 6 3 Wiring Diagram Ground Controls and Level Sensor Harness 6 4 B Wiring Diagram Platform Control Box 2 6 5 A Eiimit 00 6 6 A Electrical Symbols Legend 6 7 Electrical Schematics ANSI CSA and Australia Models B GS 1530 1532 1930 1932 GS 2032 2632 5 2046 2646 3246 iiiter it 6 8 Electrical Schematics CE Models B GS 1530 1532 1930 1 932 from serial number GS3005A 76000 to 76388 GS 1530 1532 1930 1 932 from serial number GS3005B 76000 to 76030 6 12 B GS 1530 1532 1930 1932 from serial number GS3005A 76389 to 79394 GS 1530 1532 1930 1 932 from serial number GS3005B 76031 to 76920 6 16 GS 1530 1532 1930 1932 after serial number GS3005A 79394 GS 1530 1532 1 930 1 932 after serial number 3530050 76920 6 20 B GS 2032 2632 from serial number GS3205 75407 to 77290 GS 2046 2646 3246 from serial number GS4605 75438 to 76734 6 24 GS 2032 2632 after serial number GS3205 77290 GS 2046 2646 3246 after serial number 254605 76734 6 28 Hydraulic Schematics A Component Reference and Hydraulic Symbols Legend 6 31 A GS 1530 1532 1930 1932 from serial number GS3005A 76000 to 76491 GS 1530 1532 1930 1 932 from serial number GS3005B 76000 to 76084 6 32 A GS 1530 1532 1930 1 932 afte
159. ow for the platform overload system delay wait 3 seconds between each quarter turn of the nut or adjustment screw 10 Turn the nut or adjustment screw 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 platform floor Secure the weight to the platform Refer to the chart below the nut or slotted switch GS 1532 272 kg adjustment screw GS 1932 227 kg Turning the nut or slotted switch adjustment screw into the GS 2032 363 kg hydraulic line will deactivate the alarm turning the nut or slotted GS 2632 227 kg switch adjustment screw out of the hydraulic line will activate the GS 2046 544 kg alarm GS 2646 454 kg GS 3246 317 kg Genie TEREX COMPANY GS 30 GS 32 GS 46 Part No 97385 May 2005 Section 3 Scheduled Maintenance Procedures REVA 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 and install and tighten t
160. ow to Install a Valve Cartridge 1 Dip the cartridge in clean oil to lube the O rings 2 Screw the cartridge in by hand until the top O ring is met then torque to specification 3 If required install the valve coil s onto the valve stem Install the coil nut onto the valve stem and torque to specification Genie REV B Torque 4 5 ft lbs 5 7 Nm 5 7 ft los 7 9 Nm 18 ft lbs 24 Nm 20 ft lbs 27 Nm 20 ft lbs 27 Nm 25 ft lbs 34 Nm 25 ft lbs 34 Nm 26 ft lbs 35 Nm 25 ft lbs 34 Nm 20 ft lbs 27 Nm TEREX COMPANY 4 62 GS 30 GS 32 GS 46 Part No 97385 September 2005 Section 4 Repair Procedures REV B MANIFOLDS e Before serial number GS3005A 76492 drive reverse coil Y5 Before serial number GS3005B 76085 drive reverse coil Y5 After serial number GS3005A 76491 drive forward coil Y6 After serial number GS3005B 76084 drive forward coil Y6 Note alpha callouts refer to corresponding notes on the hydraulic schematic Before serial number GS3005A 76492 drive forward coil Y6 Before serial number GS3005B 76085 drive forward coil Y6 After serial number GS3005A 76491 drive reverse coil Y5 After serial number GS3005B 76084 drive reverse coil Y5 Note alpha numeric callouts refer to corresponding notes on the electrical schematic
161. pair Procedures REVA How to Remove the 6 Hydraulic Pump When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Disconnect the battery pack from the machine Electrocution hazard Contact with 8 AWARNING electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 2 Tag and disconnect the hydraulic power unit cables at the motor controller 3 Disconnect the filter head from the filter head mounting bracket Rotate the filter out and away from the hydraulic power unit 4 Remove the hydraulic power unit retaining fasteners 5 Tag disconnect and plug the hydraulic hard line from the pump Cap the fitting on the pump Genie TEREX COMPANY HYDRAULIC PUMP Tag disconnect and plug the high pressure hose at the pump Cap the fitting on the pump 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 Remove the hydraulic power unit from the machine Remove the pump mounting bolts Carefully remove the pump NCI R Tip over hazard After replacing 2 the hydraulic pump it is critical to return the function speed setting
162. r Procedures September 2005 72 Slide the number 1 outer arm index 22 to the non steer end and remove it from the machine Bodily injury hazard The number ACAUTION 1 outer arm may become unbalanced and fall if not properly supported when removed from the machine 73 Attach the strap from an overhead crane to the number 1 inner arm index 10 Do not lift it 74 Remove the upper fasteners securing the number 1 inner arm pivot bracket to the end of the chassis Loosen the lower fasteners 75 Remove the number 1 inner arm index 10 from the machine Bodily injury hazard The number ACAUTION 1 inner arm may become unbalanced and fall if not properly supported when removed from the machine Component damage hazard Be sure not to damage the limit switch or level sensor box components when the number 1 inner arm is removed from the machine CAUTION REVA How to Replace the Scissor Arm Wear Pads 1 Remove the platform See 2 1 How to Remove the Platform 2 Support and secure the entry ladder to an appropriate lifting device 3 Remove the fasteners from the entry ladder and remove the entry ladder from the machine Crushing hazard The entry ladder ACAUTION may become unbalanced and fall if not properly supported and secured to the lifting device 4 Secure the ends of the scissor arms together at the steer end of the machine with a strap or other suitable device 5 Secure the ends of the scissor a
163. r arm index 10 67 Raise the arm slightly and remove the block 68 Lower the arm to the stowed position ACAUTION Bodily injury hazard Keep hands clear of moving parts when lowering the scissor arms 69 Secure the ends of the scissor arms together at the steer end of the machine with a strap or other suitable device 70 Secure the ends of the scissor arms together at the non steer end of the machine with a strap or other suitable device 71 Remove the retaining fasteners securing the chassis mount bracket to the chassis 72 Remove the linkset from the machine ACAUTION Bodily injury hazard The number 1 inner and outer arms index 10 and 22 may become unbalanced and fall if not properly supported when removed from the machine Component damage hazard Be CAUTION sure not to damage the limit switch or level sensor box components when the number 1 inner and outer arms index 10 and 22 is removed from the machine Genie A TEREX COMPANY GS 30 GS 32 GS 46 REV A How to Replace the Scissor Arm Wear Pads 1 ACAUTION Remove the platform See 2 1 How to Remove the Platform Support and secure the entry ladder to an appropriate lifting device Remove the fasteners from the entry ladder and remove the entry ladder from the machine Crushing hazard The entry ladder may become unbalanced and fall if not properly supported and secured to the lifting device Secure the e
164. r replaced or fitting the fitting and or hose CAUTION Component damage hazard end must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Tag disconnect and plug the high pressure hydraulic hose from the hydraulic pump AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic 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 connections very slowly to allow 5 Remove the pressure gauge and reconnect the the oil pressure to dissipate hydraulic hose Torque to specification gradually Do not allow oil to squirt ilv ini i AWARNING Bodily injury hazard Spraying 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 red Emergency Stop button to the on position at both the ground and platform controls Genie 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 A TEREX COMPANY 4 60 GS 30 GS 32 GS 46 Part No 97385 September 2005 Section 4 Re
165. r serial number GS3005A 76491 GS 1530 1532 1930 1 932 after serial number 353005 76084 6 33 B Hydraulic Schematic GS 2032 2632 and GS 2046 2646 3246 Models 6 34 Genie TEREX COMPANY Part No 97385 GS 30 GS 32 65 46 xi September 2005 SESE TABLE OF CONTENTS This page intentionally left blank Genie A TEREX COMPANY xii GS 30 GS 32 GS 46 PartNo 97385 September 2005 Section 2 Specifications REV B Machine Specifications Batteries Standard Voltage 6V DC Group GC2 Type T 105 Quantity 4 Battery capacity maximum 225AH Reserve capacity 25A rate 447 minutes Batteries Maintenance free option Voltage 6V DC Group GC2 Type 6V AGM Quantity 4 Battery capacity maximum 200AH Reserve capacity 25A rate 380 minutes Fluid capacities Hydraulic tank 3 75 gallons All models 14 2 liters Hydraulic system including tank 5 gallons GS 3246 19 liters Hydraulic system including tank 4 5 gallons All other models 18 liters For operational specifications refer to the Operator s Manual Specifications Tires and wheels GS 1530 GS 1532 GS 1930 GS 1932 Tire size solid rubber 12x 4 5 30 5 x 11 4 cm Tire contact area 9 sqin 58 cm Castle nut torque dry 300 ft lbs 406 7 Nm Castle nut torque lubricated 225 ft lbs 305 Nm GS 2032 GS 2632 GS 2046 GS 2646
166. r switch on the joystick to increase or decrease the stowed drive speed percentage Refer to Section 2 Specifications for function speeds 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 Genie Part No 97385 TEREX COMPANY GS 30 GS 32 GS 46 4 5 Section 4 Repair Procedures October 2005 PLATFORM CONTROLS How to Adjust the Raised Drive Speed ADANGER ADANGER 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 Tip over hazard This procedure must only be performed by a trained service professional Attempting this procedure without the necessary skills will result in death or serious injury On machines with software revision A4 and higher setting the raised drive speed percentage to zero will result in the steer function being disabled when the platform is above the down limit switch Refer to 1 2 How to Determine the Software Revision Level REV P SS joystick controller JC1 with thumb steering rocker SW6 horn button BN5 lift function select button BN9 diagnostic display G8 red Emergency Stop button P2 drive function select BN8 g speed select b
167. red to perform this procedure Indicates that dealer service will be required to perform this procedure Bee Pre delivery Preparation Report The pre delivery preparation report contains checklists for each type of scheduled inspection Make copies of the Pre delivery Preparation report to use for each inspection Store completed forms as required Maintenance Schedule There are five types of maintenance inspections that must be performed according to a schedule daily quarterly semi annually annually and two year The Scheduled Maintenance Procedures Section and the Maintenance Inspection Report have been divided into five subsections A B C D and E Use the following chart to determine which group s of procedures are required to perform a scheduled inspection Inspection Checklist Daily or every 8 hours A Quarterly or every 250 hours A B Semi annually or every 500 hours A B C Annually or every 1000 hours A B C D Two year or every 2000 hours A B C D E Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection Make copies of the Maintenance Inspection Report to use for each inspection Store completed forms for three years Genie TEREX COMPANY 3 2 GS 30 GS 32 GS 46 Part No 97385 Pre Delivery Preparation Fundamentals It is the responsibility of the dealer to perform the Pre delivery Preparation The Pr
168. reference 2 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls Lower the platform to the stowed position Press the drive function select button N a drive function select button BN8 Part No 97385 GS 30 65 32 GS 46 CHECKLIST PROCEDURES 5 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the test line Bring the machine to top drive speed before reaching the test line Release the function enable switch or the joystick when your reference point on the machine crosses the test line Measure the distance between the test line and your machine reference point Refer to Section 2 Specifications The brakes must be able to hold the machine on any slope it is able to climb Section 3 Scheduled Maintenance Procedures May 2005 CHECKLIST B PROCEDURES B 8 Test the Drive Speed Stowed Position Proper drive functions are essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range Perform this procedure with the machine on firm level surface that is free of obstructions 1 Create start and finish lines by marking t
169. remove the cap schematic item C or AJ 15 While activating the platform up function adjust the internal hex socket clockwise just until the platform fully raises 16 Fully lower the platform 17 Add an additional 50 pounds 22 7 kg to the platform Secure the additional weight 18 Attempt to raise the platform Result The power unit should not be able to lift the platform Result If the power unit lifts the platform adjust the internal hex socket counterclockwise until the platform will not raise 19 Install the relief valve cap 20 Remove the weight from the platform 21 Bleed the hydraulic system by raising the platform to full height If the pump cavitates or the platform fails to reach full height add hydraulic oil until the pump is functioning correctly Do not overfill the hydraulic tank Component damage hazard Do CAUTION not continue to operate the machine if the hydraulic pump is cavitating MANIFOLDS How to Adjust the Steer Relief Valve Be sure that the hydraulic oil level is at the FULL mark on the hydraulic tank 1 Locate the steer relief valve on the function manifold schematic item G or AH 2 0 to 5000 psi 0 to 350 bar pressure gauge to the test port schematic item A or AA on the function manifold 3 Remove the platform controls from the platform Perform this test from the ground with the platform controls Do not stand in the platform 4 Turn the
170. rms together at the non steer end of the machine with a strap or other suitable device 6 Remove the retaining fasteners securing the chassis mount bracket to the chassis at the steer end of the machine 7 Attach a lifting strap from an overhead crane to the scissor arm assembly 8 Raise the scissor arm assembly at the steer end with the overhead crane until the chassis mount bracket will clear the level sensor Genie A TEREX COMPANY GS 30 GS 32 GS 46 Part No 97385 September 2005 Section 4 Repair Procedures er REVA 9 Remove the scissor assembly from the machine just enough to access both wear pads ADANGER Crushing hazard The scissor assembly will fall if not properly supported when removed from the drive chassis Component damage hazard Be CAUTION careful not to damage the level sensor or limit switch while moving the scissor assembly 10 Remove both old wear pads 11 Install two new wear pads 12 Slide the scissor assembly back into the drive chassis 13 Lower the scissor assembly into position and install the chassis mount bracket onto the chassis Securely install and tighten the fasteners Do not over tighten Component damage hazard Be CAUTION careful not to damage the level sensor or limit switch while moving the scissor assembly Genie TEREX COMPANY Part No 97385 GS 30 GS 32 GS 46 4 27 Section 4 Repair Procedures September 2005 SCIS
171. s to original factory specifications Failure to restore the machine to original factory specifications could cause the machine to tip over resulting in death or serious injury Part No 97385 GS 30 GS 32 GS 46 4 61 Section 4 Repair Procedures September 2005 Manifolds 6 1 Function Manifold Components GS 1530 GS 1532 GS 1930 and GS 1932 The function manifold is mounted under the machine between the module trays Index Schematic No Description Item Function ENE u a cases eee DII IEEE Coil nut items E and 1 Diagnostic nipple Testing 2 CME CK teris Steer circuit 3 Relief valve 3000 to 3200 psi 207 to 221 bar Lift 616 4 Check valve 10 psi 0 7 bar Drive circuit 5 Solenoid valve 3 position 4 way Drive forward reverse 6 Solenoid valve 3 position 4 way Steer left right 7 Flow regulator and relief valve 0 75 gpm 2 8 L min 1500 psi 103 a Steer circuit 8 Solenoid valve 2 position 4 way El saisis Platform up ese 9 Relief valve 3500 psi 241 bar maximum System relief H
172. s and hold the lift function select and horn buttons and pull out the red Emergency Stop button to the on position Result The diagnostic display will show PS 5 Release the lift function select and horn buttons Result The diagnostic display will show the maximum lift soeed percentage 6 Press the lift function select button REV 0 joystick controller JC1 with thumb steering rocker SW6 horn button BN5 lift function select button BN9 diagnostic display G8 red Emergency Stop button P2 drive function select BN8 speed select button BN6 w 0 20 7 Use the steering thumb rocker switch on the joystick to increase or decrease the maximum lift 50660 percentage Refer to Section 2 Specifications for function speeds 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 Genie A TEREX COMPANY 4 4 GS 30 GS 32 GS 46 Part No 97385 October 2005 Section 4 Repair Procedures REV How to Adjust the Stowed Drive Speed 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
173. sition at the ground controls 2 Pushin the red Emergency Stop button to the off position at the platform controls 3 Turn the key switch to platform control 4 Atthe platform controls press and hold the lift function select and speed select buttons and pull out the red Emergency Stop button to the on position Result The diagnostic display at the platform controls and the ECM will show SC 5 Release the lift function select and speed select buttons Result The diagnostic display will show the current configuration 6 Press the speed select button Result The ones digit setting will be activated and the current ones setting will flash in the diagnostic display 7 Press the horn button Result A dot located at the lower right of the diagnostic display window will become illuminated This indicates that the battery drain alarm option has been activated 8 Press and hold the speed select button for a minimum of 3 seconds or until the ones setting stops flashing 9 Turn the key switch to the off position To deactivate the battery drain alarm option on a machine which has the option activated repeat this procedure When the ECM is in the SC mode and the option is deactivated there will not be an illuminated dot in the diagnostic display window PLATFORM CONTROLS How to Determine the Battery Voltage The diagnostic display on the platform controls is used to indicate the battery
174. solenoid valve coil at the barrel end of the lift cylinder 5 Models with platform overload option Tag and disconnect the wiring from the platform overload switch REVA lift cylinder orifice schematic item O connector fitting hydraulic hose manual lowering cable solenoid valve schematic item N g cable mount bracket Loosen the adjustment nuts the solenoid valve and disconnect the manual lowering cable from the valve During assembly the manual platform lowering cable needs to be properly adjusted See 4 1 How to Adjust the Manual Platform Lowering Cable Remove the fasteners securing the manual lowering cable mount bracket to the cylinder Remove the bracket from the cylinder Tag disconnect and plug the hydraulic hoses on the lift cylinder Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying Genie A TEREX COMPANY 4 50 GS 30 GS 32 hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray GS 46 Part No 97385 September 2005 Section 4 Repair Procedures REVA 9 Attach a lifting strap from an overhead crane to the rod end of the lift cylinder for support 10 Remove the retaining fasteners from the lift cylinder rod end pivot pin Use a soft metal drift to remove the pin AWARNING Crushing hazard The lift cyl
175. stle nut Do not remove it 6 Center a lifting jack under the drive chassis at the non steer end REVA 7 Raise the machine approximately 2 inches 5 cm Place blocks under the chassis for support Crushing hazard The chassis AWARNING could fall if not properly supported 8 Remove the wheel castle nut Remove the wheel 9 Tag disconnect and plug the hydraulic hose from the brake Cap the fitting 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 not properly supported when the mounting fasteners are removed Torque specifications Brake mounting fasteners dry 75 ft lbs 102 Nm Brake mounting fasteners lubricated 56 ft lbs 76 Nm Genie A TEREX COMPANY GS 30 GS 32 GS 46 Part No 97385 September 2005 Section 4 Repair Procedures a e yojy REV A This page intentionally left blank Genie TEREX COMPANY Part No 97385 GS 30 GS 32 GS 46 4 77 Section 4 Repair Procedures September 2005 Brake Release Hand Pump Components REVA 10 1 Brake Release Hand Pump Components
176. suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant GS 1930 component damage Dealer 65 1932 service is required When removing a hose assembly a ll or fitting the O ring on the fitting a bridge 4 and or hose end must be replaced dien oe and then torqued to specification d cable ee 1 during installation Refer to Section 2 Hydraulic Hose and Models with dual Fitting Torque Specifications number 4 outer arms 1 Remove the platform See 2 1 How to Remove 4 the Platform 2 Remove the cables from the number 4 outer arm index 13 at the ground controls side 5 Component damage hazard CAUTION Cables can be damaged if they are kinked or pinched 3 Remove the cables from the number 4 cable B bridge and lay them off to the side Component damage hazard CAUTION Cables can be damaged if they 7 are kinked pinched Genie TEREX COMPANY Part No 97385 GS 30 GS 32 Attach a lifting strap from an overhead crane to the number 4 outer arm at the ground controls side of the machine index 13 Remove the external snap rings and retaining fasteners from the number 4 center pivot pin at the ground control side of the machine index 2 Use a soft metal drift to remove the number 4 center pivot pin at the ground control side of the machine index 2 Remove the retaining fasteners from the number 4 pivot
177. supported when the pin is removed 57 Slide the number 1 outer arm index 17 to the non steer end and remove it from the machine Bodily injury hazard The number ACAUTION 1 outer arm may become unbalanced and fall if not properly supported when removed from the machine 58 Attach the strap from an overhead crane to the number 1 inner arm index 8 Do not lift it 59 Remove the upper fasteners securing the number 1 inner arm pivot bracket to the end of the chassis Loosen the lower fasteners 60 Remove the number 1 inner arm index 8 from the machine Bodily injury hazard The number ACAUTION 1 inner arm may become unbalanced and fall if not properly supported when removed from the machine Component damage hazard Be remove the entry ladder from the machine CAUTION ACAUTION Crushing hazard The entry ladder or level sensor box components may become unbalanced and fall when the number 1 inner arm is if not properly supported and removed from the machine secured to the lifting device Genie TEREX COMPANY GS 30 GS 32 GS 46 Part No 97385 September 2005 0000 REVA How to Replace the Scissor Arm Wear Pads 1 Remove the platform See 2 1 How to Remove the Platform Support and secure the entry ladder to an appropriate lifting device Remove the fasteners from the entry ladder and remove the entry ladder from the machine ACAUTION Crushing hazard The entry ladder
178. sure the distance between the base of the handle and cable mounting nut Result The measurement should be no greater than 1 8 inch 3 mm Platform manual lowering cable specification Ground Controls Skip to step 8 if the measurement is correct 6 To adjust loosen the upper lock nut on the cable mounting bracket at the cylinder Turn the lower lock nut clockwise to decrease the distance or counterclockwise to increase the distance Tighten the upper lock nut i manual lowering cable sheath upper lock nut cable mounting bracket lower lock nut cable mounting nut end of the lowering cable manual lowering valve hydraulic schematic item N 4 oS X0 9 m 20 9 7 Repeat this procedure beginning with step 4 Raise the platform and rotate the safety arm to the stowed position 9 Pull the manual lowering handle at the ground controls 2 to 3 times to ensure it is functioning correctly Gap lowering handle to mounting nut 0 to 1 8 inch 0to 3 mm Genie Part No 97385 TEREX COMPANY GS 30 GS 32 GS 46 Section 4 Repair Procedures September 2005 GROUND CONTROLS 4 2 Level Sensor The Electronic Control Module ECM is programmed to deactivate the lift and drive functions and activate an alarm when a signal is received from the level sensor The tilt alarm sounds when the incline of the chassis exceeds 1 5 to the side an
179. sure to dissipate gradually Do not allow oil to squirt or spray 9 Attach a lifting strap from an overhead crane to the rod end of the lift cylinder for support 10 Remove the retaining fasteners from the lift REVA 12 Attach a lifting strap from an overhead crane or similar lifting device to the barrel end of the lift cylinder for support 13 Remove the retaining fasteners from the lift cylinder barrel end pivot pin Use a soft metal drift to remove the pin AWARNING Crushing hazard The lift cylinder will fall if not properly supported when the pin is removed 14 Support and secure the lift cylinder to an appropriate lifting device 15 Remove the lift cylinder through the scissor arms at the steer end of the machine Crushing hazard The lift cylinder ACAUTION may become unbalanced and fall if not properly supported and secured to the lifting device Component damage hazard Be careful not to damage the valve or fittings on the cylinder while removing it from the machine CAUTION Torque specification Solenoid valve 2 position 2 way N C 20 ft Ibs cylinder rod end pivot pin Use a soft metal drift schematic item N 27 Nm to remove the pin Coil nut 5 ft lbs AWARNING Crushing hazard The lift cylinder 7Nm will fall if not properly supported 11 Lower the cylinder onto the number 1 inner arm cylinder plate Bodily injury hazard Keep hands ACAUTION clear of moving parts when lo
180. t No 97385 September 2005 Section 4 Repair Procedures REVA 57 Attach a lifting strap from an overhead crane to the lug on the rod end of the lift cylinder index 5 Raise the lift cylinder approximately 3 ft 1m 58 Tag disconnect and plug the hydraulic hoses on the lift cylinder Cap the fittings on the cylinder AWARNING injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 59 Tag and disconnect the wires and manual lowering cable from the solenoid valve on the cylinder 60 Models with platform overload option Tag and disconnect the wire harness from the platform overload switch 61 Raise the lift cylinder to a vertical position 62 Remove the pin retaining fasteners from the lift cylinder barrel end pin index 21 Use a soft metal drift to remove the pin Remove the lift cylinder from the machine AWARNING Crushing hazard The lift cylinder may become unbalanced and fall when it is removed from the machine if not properly attached to the overhead crane Component damage hazard Be careful not to damage the valve or fittings on the cylinder while removing it from the machine 63 Place a 4 x 4 48 inch 10 cm 10 cm 1 2 long block across both sides of the chassis under the number 1 center pivot pin index 11 CAUTION SCISSOR COMPONENT
181. tached to the overhead crane Component damage hazard Be careful not to damage the valve or fittings on the cylinder while removing it from the machine 48 Place a 4 x 4 x48 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 7 CAUTION 49 Attach a lifting strap from an overhead crane to the number 1 inner arm index 8 at the non steer end Raise the number 1 inner arm and remove the safety arm Lower the number 1 inner arm index 8 onto the block that was placed across the chassis Bodily injury hazard Keep hands ACAUTION clear of moving parts when lowering the arms onto the block 50 Remove the cables from the number 1 cable bridge and lay them off to the side Component damage hazard CAUTION Cables can be damaged if they are kinked or pinched 51 Support and secure the entry ladder to an appropriate lifting device 52 Remove the fasteners from the entry ladder and REVA 53 Attach a lifting strap from an overhead crane to the number 1 outer arm index 17 Do not apply any lifting pressure 54 Remove the external snap rings and retaining fasteners from the number 1 center pivot pins index 7 55 Remove the number 1 cable bridge from the machine 56 Use a soft metal drift to remove the number 1 center pivot pins index 7 Bodily injury hazard The number ACAUTION 1 outer arm may become unbalanced and fall if not properly
182. tall the new wear pad 15 Slide the scissor assembly back into the drive chassis 16 Lower the scissor assembly into position and install the chassis mount bracket onto the chassis Securely install and tighten the fasteners Do not over tighten Component damage hazard Be CAUTION careful not to damage the level sensor or limit switch while moving the scissor assembly Genie Part No 97385 TEREX COMPANY GS 30 GS 32 GS 46 Section 4 Repair Procedures September 2005 SCISSOR COMPONENTS 3 6 Lift Cylinder How to Remove the Lift Cylinder GS 1530 GS 1532 GS 1930 and GS 1932 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 fitting and or hose end must be torqued to specification during installation Refer to Section 2 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 3 Lower the platform onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 4 Tag and disconnect the wiring from the
183. teer end of the machine Remove the number 5 outer arm at the ground control side index 17 from the machine Crushing hazard The number 5 ACAUTION outer arm at the ground control side index 17 may become unbalanced and fall if not properly supported when removed from the machine 13 Attach a lifting strap from an overhead crane to the number 5 outer arm at the battery side index 17 14 Remove the retaining fasteners from the number 5 center pivot pin index 42 at the battery side 15 Place a rod through the number 5 center pivot pin at the battery side index 2 and twist to remove the pin 16 Remove the number 5 outer arm index 17 from the machine Crushing hazard The number 5 ACAUTION outer arm index 17 may become unbalanced and fall if not properly supported when removed from the machine 17 Attach a lifting strap from an overhead crane to the number 5 inner arm index 16 Raise the arm to a vertical position REVA 18 Remove the retaining fasteners from the number 5 pivot pin at the steer end of the machine index 4 19 Use a soft metal drift to remove the number 5 pivot pin index 18 from the steer end of the machine Remove the number 5 inner arm index 16 from the machine Crushing hazard The number 5 ACAUTION inner arm index 16 may become unbalanced and fall if not properly supported when removed from the machine 20 Tag disconnect and plug the hydraulic hose on the
184. ter arm at the ground control side index 19 42 Remove the retaining fasteners from the number 2 center pivot pin index 7 at the ground control side 43 Place a rod through the number 2 center pivot pin at the ground control side index 7 and twist to remove the pin 44 Remove the retaining fasteners from the number 2 pivot pin index 420 at the non steer end REVA 45 Use a soft metal drift to remove the number 2 pivot pin index 20 from the non steer end of the machine Remove the number 2 outer arm at the ground control side index 19 from the machine Crushing hazard The number 2 ACAUTION outer arm at the ground control side index 19 may become unbalanced and fall if not properly supported when the pivot pin is removed 46 Attach a lifting strap from an overhead crane to the number 2 outer arm at the battery side index 19 47 Remove the retaining fasteners from the number 2 center pivot pin index 7 at the battery side 48 Place a rod through the number 2 center pivot pin at the battery side index 7 and twist to remove the pin Crushing hazard The number 2 ACAUTION outer arm index 19 may become unbalanced and fall if not properly supported when the pivot pin is removed 49 Remove the number 2 outer arm index 19 from the machine Crushing hazard The number 2 ACAUTION outer arm index 19 may become unbalanced and fall if not properly supported when removed from the ma
185. tform is removed so when the platform is installed they will be in the correct position 4 12 GS 30 GS 32 GS 46 Part No 97385 September 2005 Section 4 Repair Procedures REVA 2 2 Platform Extension How to Remove the Platform Extension 1 Lower the platform to the stowed position 2 Extend the platform approximately 3 feet 1 m 3 Remove the platform controls from the platform and lay them off to the side of the machine 4 Support the platform extension with a forklift at the steer end of the machine Do not apply any lifting pressure 5 Attach a strap from the platform extension railings to the carriage on the forklift to help support the platform extension 6 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 22 Z N roller bracket assembly b assembly retaining fastener c platform roller bolt wI 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 How to Replace the Platform Extension Wear Pads 1 Remove the Platform Extension See 2 2 How to Remove the Platform Extension 2 Drill out the rivets which hold the wear pads in place 3 Install the new wear pads using new rivets When instal
186. the Steer Yokes 44004 3 7 Genie GS 30 GS 32 GS 46 vii September 2005 TABLE OF CONTENTS Section 3 Rev Scheduled Maintenance Procedures continued Checklist B Procedures vill 3 Inspect the Batteries sena eene t venu ut 3 8 B 2 Inspect the Electrical Wiring 3 10 B 3 Inspect the Tires and Wheels including castle nut torque 3 11 B 4 Test the Emergency 3 11 5 the Key SWItGlry u uuu t A ne e 3 12 B 6 Test the Automotive style Horn if equipped 3 12 Brive 0 3 13 B 8 Test the Drive Speed Stowed Position 3 14 9 Test the Drive Speed Raised 3 15 B 10 Perform Hydraulic Analysis 3 16 B 11 Inspect the Hydraulic Cap Venting System 3 16 B 12 Check the Module Tray Latch Components 3 17 B 13 Inspect the Voltage Inverter 3 18 Checklist C Procedures C4 Testthe Platform Overload System if equipped 3 19 C 2 Replace the Hydraulic Tank Breather Cap Models with Optional Hydraulic 3 21 Checklist D Procedures D 1
187. ty arm between the number 1 inner arm index 8 and the number 1 outer arm index 17 Lower the scissor arms onto the safety arm Bodily injury hazard Keep hands ACAUTION clear of moving parts when lowering the scissor arms onto the safety arm 42 Attach a lifting strap from an overhead crane to the lug on the rod end of the lift cylinder index 3 Raise the lift cylinder approximately 3 ft 1 43 Tag disconnect and plug the hydraulic hoses on the lift cylinder Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 44 Tag and disconnect the wires and manual lowering cable from the solenoid valve on the cylinder 45 Models with platform overload option Tag and disconnect the wire harness from the platform overload switch Genie Part No 97385 TEREX COMPANY GS 30 GS 32 GS 46 Section 4 Repair Procedures September 2005 SCISSOR COMPONENTS 46 Raise the lift cylinder to a vertical position 47 Remove the pin retaining fasteners from the lift cylinder barrel end pin index 16 Use a soft metal drift to remove the pin Remove the lift cylinder from the machine AWARNING Crushing hazard The lift cylinder could become unbalanced and fall when it is removed from the machine if not properly at
188. uids Use an approved container Please be environmentally safe Genie A TEREX COMPANY vi GS 30 GS 32 65 46 Part No 97385 September 2005 Introduction Section 1 Section 2 Section 3 Rev wo U Ww Rev Table of Contents Important InformallOh il Serial Number Information il Serial iii Safety Rules General Safety Rv led E De V Specifications Machine 2 1 Performance Specifications 2 0 24420 2 2 Hydraulic lt teas 2 3 Manifold Component 2 4 Hydraulic Hose and Fitting Torque Specifications 2 5 SAE and Metric Fasteners Torque Charts 2 7 Scheduled Maintenance Procedures 3 1 Pre delivery Preparation Report 1 3 3 Maintenance Inspection 3 5 Checklist A Procedures Part No 97385 A 1 Perform Pre operation 3 6 A2 Perforin Function Tests u l 3 6 7 3 7 4 Grease
189. ult 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 position Genie A TEREX COMPANY GS 30 GS 32 GS 46 Part No 97385 September 2005 Section 4 Repair Procedures REV GROUND CONTROLS 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 Genie TEREX COMPANY Part No 97385 GS 30 GS 32 GS 46 4 59 Section 4 Repair Procedures September 2005 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 the motor which 3200 psi 221 bar immediately stop The pump 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 o
190. ult code is displayed Malfunction discovered v problem still exists The codes listed in the Fault Code Chart describe malfunctions and can aid in Perform troubleshooting the machine by pinpointing the repair area or component affected Return to service problem solved Genie A TEREX COMPANY 5 2 GS 30 GS 32 GS 46 Part No 97385 September 2005 Section 5 Fault Codes neva Fault Code Chart Fault Code Problem Possible Causes Solution 01 Internal ECM error EPROM not programmed Replace ECM 02 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 Chassis up down toggle closed at start up Malfunctioning up down switch Troubleshoot up down switch 18 Pothole guard failure Malfunctioning pothole switch OR obstruction in pothole guard linkage Troubleshoot pothole switch OR remove obstruction 19 Limit switch failure Malfunctioning limit switch OR wire disconnected from limit switch Troubleshoot limit switch OR inspect wire connection 42 Platform left turn switch fault Malfunctioning steer left microswitch Troublesho
191. ures REV How to Change the Software Configuration 1 Pull out the red Emergency Stop button to the on position at the ground controls Push in the red Emergency Stop button to the off position at the platform controls 3 Turn the key switch to platform control At the platform controls press and hold the lift function select and speed select buttons and pull out the red Emergency Stop button to the on position Result The diagnostic display at the platform controls and the ECM will show SC PLATFORM CONTROLS 8 eu 6994 9 C joystick controller JC1 with thumb steering rocker SW6 lift function select button BN9 diagnostic display red Emergency Stop button P2 drive function select button BN8 Speed select button BN6 w O a O0 cg Release the lift function select and speed select 8 Press the speed select button buttons Result The diagnostic display will show the current configuration Press the lift function select button Result The tens digit setting will be activated and the current tens setting will flash in the diagnostic display Use the steering thumb rocker switch on the joystick to increase or decrease the value See 1 4 Machine Configuration Code Chart for configuration settings Result The ones digit setting will be activated and the current ones setting will flash in the diagnostic display Use the steerin
192. uter arm index 4 at the ground controls side 25 Remove the external snap rings and retaining fasteners from the number 3 center pivot pins index 4 26 Use a soft metal drift to remove the number 3 center pivot pin index 4 at the ground control side 27 Remove the retaining fasteners from the number 3 pivot pin index 17 at the non steer end of the machine 28 Use a soft metal drift to tap the number 3 pivot pin index 17 halfway out at the non steer end of the machine Remove the number 3 outer arm index 16 at the ground controls side from the machine Bodily injury hazard The number ACAUTION 3 outer arm at the ground controls side may become unbalanced and fall if not properly supported when removed from the machine 29 Attach a lifting strap from an overhead crane to the number 3 outer arm index 16 at the battery pack side 30 Use a soft metal drift to remove the number 3 center pivot pin index 4 at the battery pack side of the machine 31 Use a soft metal drift to tap the number 3 pivot pin index 17 in the other direction Remove the number 3 outer arm index 16 from the battery pack side of the machine Bodily injury hazard The number ACAUTION 3 outer arm at the battery pack side may become unbalanced and fall if not properly supported when removed from the machine SCISSOR COMPONENTS 32 Remove the number 3 pivot pin index 17 from the non steer end of the machine 33 Attac
193. utton 6 w 6 Press hold the horn button Result The diagnostic display will show the raised drive speed percentage 7 Use the steering thumb rocker switch on the joystick to increase or decrease the maximum lift 50660 percentage Refer to Section 2 Specifications for function speeds 8 Turn the key switch to the off position 1 Pull out the red Emergency Stop button to the on position at the ground controls Push in the red Emergency Stop button to the off position at the platform controls 3 Turn the key switch to platform control At the platform controls press and hold the lift function select and horn buttons and pull out the red Emergency Stop button to the on position Result The diagnostic display will show PS Release the lift function select and horn buttons Result The diagnostic display will show the maximum lift speed percentage Genie A TEREX COMPANY Any change in software settings will not take effect until the key switch is turned to the off position GS 30 GS 32 GS 46 Part No 97385 October 2005 Section 4 Repair Procedures REV How to Adjust the Slow or High Torque Drive Speed 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
194. ve on the cylinder Genie Part No 97385 TEREX COMPANY GS 30 GS 32 GS 46 4 31 Section 4 Repair Procedures September 2005 SCISSOR COMPONENTS 46 Tag and disconnect the wires and manual lowering cable from the solenoid valve on the cylinder 47 Models with platform overload option Tag and disconnect the wire harness from the platform overload switch 48 Raise the lift cylinder to a vertical position 49 Remove the pin retaining fasteners from the lift cylinder barrel end pivot pin index 16 Use a soft metal drift to remove the pin Remove the lift cylinder from the machine Crushing hazard The lift cylinder ACAUTION will fall if not properly supported when the pivot pin is removed Component damage hazard Be careful not to damage the valve or fittings on the cylinder while removing it from the machine CAUTION 50 Remove the cables from the number 1 cable REVA 54 Lower the arm to the stowed position Bodily injury hazard Keep hands ACAUTION clear of moving parts when lowering the scissor arms 55 Secure the ends of the scissor arms together at the steer end of the machine with a strap or other suitable device 56 Secure the ends of the scissor arms together at the non steer end of the machine with a strap or other suitable device 57 Remove the retaining fasteners securing the chassis mount bracket to the chassis 58 Remove the linkset from the machine Bodily injur
195. wering the cylinder Genie 4 52 TEREX COMPANY GS 30 GS 32 GS 46 Part No 97385 September 2005 Section 4 Repair Procedures REVA How to Remove the Lift Cylinder GS 3246 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 fitting and or hose end must be torqued to specification during installation Refer to Section 2 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 3 Lower the platform onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 4 Tag and disconnect the wiring from the solenoid valve coil at the barrel end of the lift cylinder Skip to step 9 if removing the upper cylinder 5 Models with platform overload option Tag and disconnect the wiring from the platform overload switch SCISSOR COMPONENTS 6 Loosen the adjustment nuts on the solenoid valve and disconnect the manual lowering cable from the valve During assembly the manual platform lowering cable needs to be properly
196. when the pivot pin is removed 20 Place a 2 x 4 x 10 inch 10 x 10 x 25 cm block onto the number 1 inner arm cylinder plate index 8 REVA 21 Lower the cylinder onto the block Bodily injury hazard Keep hands ACAUTION clear of moving parts when lowering the cylinder onto the block 22 Attach a lifting strap from an overhead crane to the number 3 inner arm index 10 Raise the arm to a vertical position 23 Remove the retaining fasteners from the number 3 pivot pin at the steer end of the machine index 4 24 Use a soft metal drift to remove the number 3 pivot pin index 4 from the steer end of the machine Remove the number 3 inner arm index 10 from the machine Crushing hazard The number 3 ACAUTION inner arm index 10 may become unbalanced and fall if not properly supported when the pivot pin is removed 25 Remove the cables from the number 2A and 2B cable bridge and lay them off to the side Component damage hazard CAUTION Cables can be damaged if they are kinked or pinched 26 Disconnect the number 2A and 2B cable bridges from the scissor linkset and remove both cable bridges from the machine 27 Attach a lifting strap from an overhead crane to the number 2 outer arm at the ground control side index 14 28 Remove the retaining fasteners from the number 2 center pivot pin index 5 at the ground control side 29 Place a rod through the number 2 center pivot pin at the ground control
197. wist to remove the pin 16 Remove the number 4 outer arm index 13 from the machine Crushing hazard The number 4 ACAUTION outer arm index 13 may become unbalanced and fall if not properly supported when removed from the machine 17 Attach a lifting strap from an overhead crane to the number 4 inner arm index 12 Raise the arm to a vertical position 18 Remove the retaining fasteners from the number 4 pivot pin at the steer end of the machine index 3 19 Use a soft metal drift to remove the number 4 pivot pin index 3 from the steer end of the machine Remove the number 4 inner arm index 12 from the machine Crushing hazard The number 4 ACAUTION inner arm index 12 may become unbalanced and fall if not properly supported when removed from the machine 20 Remove the cables from the number 3A and 3B cable bridge and lay them off to the side Component damage hazard CAUTION Cables can be damaged if they are kinked or pinched 21 Disconnect the number 3A and 3B cable bridges from the scissor linkset and remove both cable bridges from the machine Genie A TEREX COMPANY GS 30 GS 32 GS 46 Part No 97385 September 2005 Section 4 Repair Procedures REVA 22 Attach a lifting strap from an overhead crane to the number 3 outer arm at the ground control side index 16 23 Remove the retaining fasteners from the number 3 center pivot pin index 4 at the ground control sid
198. wo lines on the ground 40 feet 12 2 m apart out the red Emergency Stop button to the on position at both the ground and platform controls Lower the platform to the stowed position Press the drive function select button lt e999 ET a drive function select button BN8 Turn the key switch to platform control and pull Genie TEREX COMPANY GS 30 GS 32 GS 46 REVA Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line Continue at full speed and note the time when your reference point on the machine passes over the finish line Refer to Section 2 Specifications Part No 97385 May 2005 Section 3 Scheduled Maintenance Procedures REVA 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
199. y 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 ormaintenance information Be sure to wear protective eye wear and other protective clothing if the situation warrants it such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes al Be aware of potential crushing hazards Workplace Safety Be sure to keep sparks flames and W lighted tobacco away from flammable and combustible materials like battery gases and engine fuels Always have an approved fire extinguisher within easy reach Be sure that all tools and working areas are properly maintained and ready for use Keep work surfaces clean and free of debris that could get into machine components and cause damage Be sure that your workshop or work area is 209 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 Be sure any forklift overhead crane or Be sure that fasteners intended for one time use i e cotter pins and self locking nuts are not reused These components may fail if they are used a second time Be sure to properly dispose of old oil or 2 other fl
200. y hazard The number ACAUTION 1 inner and outer arms index 8 and 17 may become unbalanced and fall if not properly supported when removed from the machine Component damage hazard Be i CAUTION sure not to damage the limit switch CAUTION Component damage hazard or level sensor box components Cables can be damaged if they when the number 1 inner and are kinked or pinched outer arms index 8 and 17 is 51 Disconnect the number 1 cable bridge from the removed machina number 1 outer arm index 17 and remove the cable bridge from the machine 52 Attach a lifting strap from an overhead crane to the number 1 inner arm index 8 53 Raise the arm slightly and remove the block Genie 4 32 A TEREX COMPANY GS 30 GS 32 GS 46 Part No 97385 September 2005 Section 4 Repair Procedures REVA How to Replace the Scissor Arm Wear Pads 1 Remove the platform See 2 1 How to Remove the Platform 2 Support and secure the entry ladder to an appropriate lifting device 3 Remove the fasteners from the entry ladder and remove the entry ladder from the machine Crushing hazard The entry ladder ACAUTION may become unbalanced and fall if not properly supported and secured to the lifting device 4 Secure the ends of the scissor arms together at the steer end of the machine with a strap or other suitable device 5 Secure the ends of the scissor arms together at the non steer end of the ma

Service Manual

Contents

Download Pdf Manuals

Related Search

Related Contents