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1. A B D E F G H J K L M N 90n CUN 1 ie 1 1 p X oc 1 MACHINE SHOWN 5 2 22 y Y IN THE STOWED PAPER Smit J LANE ME ONE POSITION WITH EA c G LOW TEMPERATURE THE POWER OFF 5 6 gt manns Q a CUT OUT MODULE pee e x m ak Ben BN WH BK 5 2 2 P1 T y IX LAS 8 Ew EMERGENCY KEY SWITCH 200 OHM NOT CONNECTED SI 10W why H WITH LOW TEMPERATURE BK 55 55 ORIRD aoe sae a CUTQUTOPTION Nu 33 88 Y 23344 B BL ce e Er 888 amp l C49 C46 2 A Y gt wn Ace T Gal m 5 e 7T1777 RD 8 C52 C53 E i 18 LIMIT ee oem f Tti 5 i a tc 1 BREAKER it P 8 422 2 4 ET SENSOR RD La 9 i 1 OPTION Vs go go T7 E BN RD A A RD V C50 C48 gt 35 5 o
2. 1 5 nez 152 oo zur o 9 2 629 595 i22 2 15 m 2 1029 1 44 51 1 r 1 Fos X 6 9 1 195 lt 1 oo L l i 1 cya auosNas L1 1 vo 8 gt rx lt l 4 aunouo 988 He amp 1 Lv I m avos ple LAA 2 pis eS cc 8 H 42 14 9 F4 i g iB 2 an z 9 9 9 BX ac 5 25 0 9 pe aNd un 4 lt lt 4 gt 2 7o SO g lt one 5 2 lt lt 2 0 lt a 2 c 9 o gt OX u yosnas ero 0
3. 5 nez 152 oo zur o 629 595 nu i22 2 15 m ez ean 1029 1 44 51 1 r 1 5 lee 1 is 6 9 i 1 195 lt Br 1 gt L l i Ls 1 AWOSNIS NER 1 m EM v 8 8 rx lt l Lee 4 aunouo 988 He amp 1 LO N Il m 2 Ke avos LAA PAS cc 8 H 42 14 9 F4 i g u 2 an x z 9 2 lt p ac ocr 5 25 o DP INUA un 4 lt lt 4 gt 8 7o lt one o 2 lt lt 2 0 lt a 2 9 o gt aX u cosas b gt qu ets 0 109 JAHA lt lt De ya lt 4 MS 310HLOd 5 5 pes Ee 291
4. A C D F G H J K L apis N BK 2 2 1 BK eee 20 gt 3 WH WH 3 5 8 L LT BL ACINPUT 7 oa TO AC OUTLET OPTION 1 POWER TO PLATFORM RDT 1 gt 1 RD 110V 240V AC WH 22 gt 2 1 WH 3 3 1 4 4 BR 5 gt 5 L BR 8 PLATFORM CONTROL CABLE C41 2 H5 1 x ALARM FBV Ly Ly 2 BL ALARM OUT FLASHING C BEACONS 3 RD SENSOR V OUT H2 OPTION N TN 4 WH AUTO HORN OUT PS AUTO STYLE 5 POTHOLE LIMIT SW ADT lt lt BK HORN 6 BR GROUND N C H O OPTION NOTE 7 OR DOWN LIMIT sw 157 E MACHINE SHOWN 8 RD BK LEVEL SENSOR PoTHOLE RD p gt 15600 BLANH CYL PRESSURE WH LIMIT BOSTON AITH ORANH PLAT HEIGHT 3 log SWITCH SWITCH THE POWER OFF BK LOAD SENSE GND T N C H O OR 29 gt 24 WH LS8 POTHOLE S7 GUARD ORRDES BE SWITCH C11 SENSOR EMERGENCY KEY SWITCH D
5. 2000 psi _ 138 T Mt MI a JOK A M PRESSURE Gas a SELECTOR j o9 MANIFOLD 11500 psi 4 1103 bar tee E SE PEN Mm cn OST FUNCTION MANIFOLD DI 28 Umi DH gt lt 22 2 J Y8 0 25 3000 psi 0 25 3500 psi 0 95 L min 207 bar L 0 95 L min 8 241 bar Te o gt DL ag IM FY 1 POWER UNIT MIL HYDRAULIC TANK HS0254B Genie BRAND Part No 228901 GS 30 GS 32 GS 46 GS 47 297 Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Scandinavia Phone 0046 3157 5154 Fax 0046 3157 5104 Genie France Phone 0033 237 260 986 Fax 0033 237 260 998 Genie Iberica Phone 0034 935 725 090 Fax 0034 935 725 080 Genie Germany Phone 0800 180 9017 Phone 0049 4221 491 821 Fax 0049 4221 491 820 Genie Australia Pty Ltd Phone 461 7 3456 4444 Fax 61 7 3375 1002 Genie China Phone 86 21 53853768 Fax 86 21 53852
6. pex oui m i 258 288 io 22 Oo 08 E g 202 ex i e 3 LER 191 2 1 Ne 5 12 OFS a EI S30 NI Odo 202 Y 9 41 if al LPS 1 rr 8 5 5 e sd eo Y ify ar j SS 0 UID Cn 18 ary TTT Iso 5 roti 2 21 1585 1 IEL H 9 lt 1 158 zl 5 1 lt 9 RI AAR sl Tom m T apap 5 L CUT uis SIE j Pye E 1 a uosnas clau A HOSN3S 1 1 s gt gt s ay A HOSN3S o o 77 SS Pw Be L 57 V v K HA lt 1 e RE 48 1 2 2 1 tc 92 9 au HE XX 18 QNO 1 L 5 ES 5 d 5 1 ya s gt 5 HMWHO we l 5 HMI o lt 2 3943 38 SAIC 8 9 a rz gt an 2 2 2 m
7. November 2014 Electrical Schematic GS 4047 CE and AUS Models from serial number GS4712C 101 Service Manual 5 as 554 8 ug arg 3 wed z 1 3 our 202 oo 9 HHA gt gt 220 in zur T Ix GED ug z al 4 BOULE 595 2 2 5 amp I omn x 1 Iu gy loal amp 5 1 om 5928 i 1 arity 2 poc 1 197 cag FOS X 1 8 i Ol YI onm TETI 190 i lt AAA atom d L 1 9I T oml o YYY E ge L 1 on A H tc 55 Qu A HORNS 1 s gt gt HOSN3S Lv 4 L rc 20 6 XH i 81 lt Nodoa at 1 1 S Ha QNO 81 au Le lt 19 l DO J a iz 8 1 212 a lt ul 5
8. A B D E F G H J K L M N ENE a a AT n C2 Pd D _ _ 08 1 lt 1 1 PCON V OUT RD 1 RD PCON V OUT L1 1 PCON V OUT RD 2 lt RD lt JE NOTE E gt _ESTOP WH 2 2 WH ESTOP 2 lt lt 2 WH 3 BK lt p ALARM FROM i opa iE FROM C415 1 DATA LINK BL amp 3 BL DATA LINK ts lt DATA LINKt BL 4 lt gt E STOP WH 4 ia POSITION WITH X 2 DATA LINK OR 4 4 OR DATA LINK 4 LINK 5 lt 6 E STOP WH THE POWER OFF x Ex PCON V OUT BR 5 5 BR PCON V OUT 9 4 5 PCON V OUT BR 6 1 po 6 lt lt 6 16 lt 6 x I D EMERGENCY 44 2 U3 PLATFORM CONTROLS PRINTED CIRCUIT BOARD 2 l gt JOYSTICK AXIS 1 YL 31 ELECTRONIC CONTROL MODULE ale JCS PLATFORM cr CONTROLLER CONTROLLER gt DRIVE ENABLE WHj5 gt STEER LEFT BL 46 gt STEER 7 Y Y Y JOYSTICK 5VDC RD48 2 7 Y Y Y YY Y Y 3 1 2 3 4 6 5 7 8 9 10 11 12 JOYSTICK GND BK 10 m m m cr x I x 2 X 411 9 o gt
9. A B D E F G H J K L M N 90n CUN 1 ie 1 1 p X oc 1 MACHINE SHOWN 5 2 22 y Y IN THE STOWED PAPER Smit J LANE ME ONE POSITION WITH EA c G LOW TEMPERATURE THE POWER OFF 5 6 gt manns Q a CUT OUT MODULE pee e x m ak Ben BN WH BK 5 2 2 P1 T y IX LAS 8 Ew EMERGENCY KEY SWITCH 200 OHM NOT CONNECTED SI 10W why H WITH LOW TEMPERATURE BK 55 55 ORIRD aoe sae a CUTQUTOPTION Nu 33 88 Y 23344 B BL ce e Er 888 amp l C49 C46 2 A Y gt wn Ace T Gal m 5 e 7T1777 RD 8 C52 C53 E i 18 LIMIT ee oem f Tti 5 i a tc 1 BREAKER it P 8 422 2 4 ET SENSOR RD La 9 i 1 OPTION Vs go go T7 E BN RD A A RD V C50 C48 gt 35 5 o C47 C45 TI TI 858 WH se 6244545322520 E 5 1982 1988 BN B lt B BK v z 20 eo DC AC INVERTER 5 88 gs 5 2 m CYLINDER PRESSURE OPTIONAL Gontector 8 8 5 5 PLATFORM HEIGHT 5 3 c9
10. DTC Message on Problem Possible Failure Number GCON LCD Description Causes Mode U001 kd U001 SWITCHFAULT Short circuit of the GCON main function conc circuit of the GCON main function enable Ali GCON functions GS46 amp GCON MAIN FTN EN enable switch at system startup GCON inhibited GS47 U002 9830 UOOZ SWITCHFAULT Short circuit of the GCON up directional Short circuit of the GCON up directional switch ions GCON PLAT UP switch at system startup GCON ECM GS46 amp platform down GS47 U003 2 U003 SWITCHFAULT Short circuit of the down directional Short circuit of the GCON down directional switch 4 1908 GCON PLAT DOWN switch at system startup GCON ECM GS46 amp platform up GS47 U004 e U004 SWITCHFAULT Short circuit of the GCON LCD scroll up Short circuit of the GCON LCD scroll up switch LOD menu GS46 amp GCON LCD UP switch at system startup GCON ECM inhibited GS47 0005 U005 SWITCHFAULT Short circuit of the GCON LCD scroll down Short circuit of the GCON LCD scroll down switch GCON LCD menu GS46 8 GCON LCD DOWN switch at system startup GCON ECM inhibited GS47 0006 2 U006 SWITCHFAULT Short circuit of the GCON LCD enter switch Short circuit of the GCON LCD enter switch x 6546 amp GCON LCD ENTER at system startup GCON ECM inhibited GS47 U007 2
11. A C E F G H J K L M N E gt d __ 03 _ 1 lt 1 E PCON V OUT RD 1 1 RD PCON V OUT 1 1 PCON V OUT RD 2 2 RD lt H1 1 gt WH 2 4 21 ESTOP 2 lt 2 ESTOP WH 8 lt 8 BK lt 5 1 ALARM FROM C41E 1 DATA LINK BL 3 lt lt 3 BL DATA LINK 3 lt lt DATA LINK BL 4 lt 4 E STOP WH k DATA LINK OR 4 lt lt OR DATA LINK 4 lt lt 4 DATA LINK OR 5 5 E STOP WH x V OUT BR 5 lt lt 54 BR PCON V OUT lt lt 5 PCON V OUT BR 6 lt lt 6 1 P2 6 lt 6 076 6 F DEMERGENOY DE B 2 U3 PLATFORM CONTROLS PRINTED CIRCUIT BOARD 2 JOYSTICK AXIS 1 YL 41 gt 2 EN1 gt STEER SWITCH 3 TK PLATFORM gt DRIVE ENABLEGCOM YL74 CONTROLLER CONTROLLER X DRIVE ENABLE WH45 X STEER LEFT BL 6 STEER RIGHT GR47 JOYSTICK 5VDC RD 8 3 x9 gt JOYSTICK GND 10 411 gt CHASSIS GND 12 5 4 MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF 110V 240V AC POWER TO PLATFORM AC INPUT _ 9980 _ _ 9016 5 NES 1 1 GR 14 OUTLET 2 gt 2 2 2 BK 3 3 w 3 3 pr a d _
12. 9 amp 225 H gt H g 9 lt lt BX Pa 98z LRL 5 lt lt 2 102 aw d N 88 s lt g _ l yaad o lt lt 5 l 2 lt lt 2 0 lt 52 amp 5 18 PE 885 o o gt a lt lt us A 5 SE u LLL ESI gt 102 JAHA lt lt De ya MS FIOHLOd 5 L4 5 Lc o pter lt E L HM Le 2 gt gt Yn HOLOSTS 3unsssud 1411 o 8 8 ee T OHON gi E Q MS du NDFIOHLOd 5 8 Q Oa 881 o MS LIWITTIOHLOd 1109 T IVa ug 12 2z4 9 LeSL yg v5 v Qu do io i 8 A dH rece 12 17 edge Heo ug 5658 She t gt v ua 8 3 gt 78 1109 LHD 315 XC gt x 9 lt lt 9 s gt s ua NHOH HM 4 5 annowa ua 0 lt lt 8i PE 1no Wey WW 718 u lt a gt gt 1109 131 43315 TTS 5 T9 1 9 9 gt 9 ua 3 lt gt 3 5 a ne
13. 11 Torque Procedure eet rt i ntn PATI ea ge EA Ie Een 12 SAE and Metric Fasteners Torque 5 14 Genie viii GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Section 3 Part No 228901 Table of Contents Scheduled Maintenance Procedures 15 EA 15 Pre Delivery Preparation Report sss 19 Maintenance Inspection nnns 20 Checklist A Procedures 21 1 Inspect the Manuals 21 2 Perform Pre operation 2 20 244 0000 22 Function Tests eii ied tete 22 4 Perform 30 Day 23 5 Grease the Steer Yokes eee nennen 23 1 1 1 1 1 1 1 GS 30 GS 32 GS 46 GS 47 ix November 2014 Table of Contents Checklist B Procedures eeeeeeeeeeeeeeeeeeeeeenee nennen nennen nennen nnn nnn 24 B 1 Inspect the eene 24 B 2 Inspect the Electrical 27 B 3 Inspect the Electrical nn 28 B 4 Inspect the Tires Wheels and
14. Coil Nut item AC 4 5 ft lbs 5 7 Nm Coil Nut items AE AG and AI 5 7 ft lbs 7 9 Nm 1 Diagnostic nipple AA Testing 2 Relief Valve 3700 psi 255 bar maximum AB System relief 20 ft lbs 27 Nm 3 Solenoid valve 3 position 4 way AC Steer left right 25 ft lbs 34 Nm 4 Check valve GS 3232 and GS 3246 AK Lift 23 ft lbs 31 Nm with load sense installed 5 Check disc AD Steer circuit 18 ft lbs 24 Nm 6 Solenoid valve 2 position 4 way AE Drive speed select 25 ft lbs 34 Nm circuit 7 Relief valve AF Brake release 20 ft lbs 27 Nm 8 Solenoid valve 3 position 5 way AG Drive 25 ft lbs 34 Nm forward reverse 9 Flow regulator and relief valve AH Steer circuit 26 ft lbs 35 Nm 0 75 2 8 L min 1500 psi 103 bar 10 Solenoid valve 2 position 4 way Al Platform up 25 ft lbs 34 Nm 11 Relief valve AJ Lift relief 20 ft lbs 27 Nm How to Install a Valve Cartridge 1 Dip the cartridge in clean oil to lube the O rings 2 5 the cartridge in by hand until the top O ring is met then torque to specifications 3 If required install the valve coil s onto the valve stem Install the coil nut onto the valve stem and torque to specifications Lo Qai 1 1 90 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual Manifolds 0 9 Note alpha callouts refer to corresponding notes on the
15. lt 2 2 oV 1 sO SES T WM AT LT BL TO OUTLET OPTION POWER TO PLATFORM RD 15 gt 1 AD 110V 240V AC WH 2 2 I WH GR 3 8 I BL OR 42 4 LOR BR 8 5 I Bh TFORM IOL Gi Xr63 TOPLAI CONTROL GABLE 2 J1 C5 5 7 H5 Ao cu p RD ECM LOGIC V RD 1 x TN ALARM FB ro PCON V OUT FD 2 BL ALARM QUT E pail WH E STOP WH 8 RD SENSOR V OUT H2 BEACONS GA DATA LINK GR 4 WH AUTO HORN OUT AUTO STYLE OPTION DATALINK 5 OR RD POTHOLE LIMIT SW RD 86 ZN HORN BR PCON V OUT BR 6 BR GROUND OPTION NOTE ECMV BR 7 OR DOWN LIMIT W 157 MACHINE SHOWN PLATFORM MODE 8 RD BK LEVEL SENSOR Bp L 4 11 Bk STOWED GROUND MODE WH 9 BK GROUND co WH GUARD UMIT POSITION WITH dE M c10 M THE POWER OFF Lal RD DRIVER V BK LS GROUND N C H O OR p2 2 WH 158 21 pomore P4 KS1 BK SWITCH EMERGENCY KEY SWITCH 1 1 BK 57 5 PCON 1 ELECTRONIC 11 CONTROL 4 MODULE 1 OFF C8 cl WH e e RD eK c c we isia r B BR 8 t BR GCON B 54 BR c gt BR SEN
16. 67 2 3 Loading or Updating Machine 68 2 4 Using Wi Fi Router to Connect to the SmartLink Web Service Tool 73 2 5 Service Override 75 2 6 Sensors EE 77 2 7 Manual Platform Lowering Cable seen 81 2 8 Outrigger 83 Genie BRAND Part No 228901 GS 30 GS 32 GS 46 GS 47 xi November 2014 5 Table of Contents Hydraulic Tank e 85 3 1 Hydraulic 85 Hydraulic 86 4 1 Hydraulic 86 Manifolds RIEGO BEAR ORI EIE I P DES 88 5 1 Function Manifold Components 65 1530 GS 1532 65 1930 and 565 1932 4 2 2 88 5 2 Function Manifold Components GS 2032 GS 2632 65 3232 GS 2046 65 2646 and 65 3246 90 5 3 Function Manifold Components 65 4047 92 5 4 Check Valve Manifold Components 65 1530 GS 1532 65 1930 and 565 1932 4 2 94 5 5 Lift Pressure Selector Manifold Components 65 4047 95 5 6 Outrigger Function Manifold Components 65 3232 96 5 7 Outrigger Cylinder Manifold Components 5
17. z 9 9 9 BX ac 5 25 0 9 pe aNd un 4 lt lt 4 Pr En aqu e 5 2 lt lt 2 0 lt a 2 c 9 o gt OX u yosnas ero 1109 SAG ua r2 c14 9 Lv vau MS 5 LX 1 HM y8 22 8 YX 2 8 8 la teat 4 a 9 9 851 19 ETa 9440 9 lt 1a lt 8 A Qu 1 5 2 ce ps 88 ug PEER 258 E 7 gt 7 8 i 3 gt 18 1109 1HOl udis lt gt x Ha 9 lt lt 9 5 s ua NHOH HM 5 4 5 1 4 lt 8 1 2 Pa 2 1no Nuvi 328 e C gt 8 18 1109 1437 9215 EDS 5 9 gt 9 4 X ggi 5 7 Qq B E 1 SAA A ALY zi X A Wo3 o 11 8l 3 yatHm 2 lt E4 2 l aoto HM o o e 2 ua i r 44 12 3d0W WHOL Id ya oC o 109 NMO
18. Rear of Ground Controls ECM models without outriggers J4 J2 Ji J3 ea Ek yh o4 IR 5112 51195 s B JE BIB 5 1816 816 6 Bu 1 7 e Rear of Ground Controls ECM models with outriggers Genie BRAND GS 30 GS 32 GS 46 GS 47 209 Part No 228901 Service Manual November 2014 Coo a TEESE Fee ef Diagnostics I O Map without Load Sense all models except GS 3232 GCON Pin Number Circuit Function Type Wire Gauge and Color J1 Connector Gray J1 01 ECM Power Power Input 14 RD J1 02 PCON E Stop Power Power Output 18 RD J1 03 PCON E Stop Return Power Input 18 WH J1 04 Link to PCON CANH Data Bus 18GR J1 05 Link to PCON CANL Data Bus 18 OR J1 06 PCON Ground Ground Output 18 BR J1 07 GCON Ground Ground Input 14 BR J1 08 Key Switch PCON Mode Digital Input 18 BK J1 09 Key Switch GCON Mode Digital Input 18 WH J1 10 GCON Emergency Mode Digital Input 18 WH BK J1 11 No Circuit N A N A J1 12 Driver Power Power Input 14 RD J 2 Connector Black J2 01 Platform Up Coil Digital Output 18 OR J2 02 Platform Down Coil Digital Output 18 OR BK J2 03 Steer Left Coil Digital
19. Steer End 1 Number 6 pivot pin 2 Number 5 center pivot pin 2 pins 3 Upper lift cylinder rod end pivot pin 4 Number 5 pivot pin steer end 5 Number 4 center pivot pin 2 pins 6 Number 4 pivot pin steer end 7 Number 3 outer arm 8 Number 3 center pivot pin 2 pins 9 Lower lift cylinder rod end pivot pin 10 Number 3 pivot pin steer end 11 Number 2 center pivot pin 2 pins 12 Number 2 pivot pin steer end 13 Number 1 center pivot pin 2 pins 14 Number 1 inner arm 15 Number 1 pivot pin steer end 2 pins Part No 228901 Genie BRAND GS 30 GS 32 GS 46 GS 47 Non steer End 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 155 Service Manual November 2014 Scissor Components 9 5 Scissor Assembly GS 3232 and GS 3246 How to Disassemble the Scissor Assembly GS 3232 and GS 3246 AWARNING Bodi y injury hazard The procedures in this section require specific repair skills lifting equipment and a suitable workshop Attempting
20. 1 OUTLET Tus 752005 ALARM o3_ AD 1 1 1 AD WH 2 2 E STOP WH BK BL axs DATA 4 BL WH OR 4 4 DATA WH E STOP BR 5 lt 5 BR x x pe e 1x EMERGENCY U3 STOP PLATFORM CONTROLS PRINTED CIRCUIT BOARD YL JOYSTICK AXIS 1 BK STEER SWITCH YL DRIVE ENABLE NOTE WH or BLOR DRIVE ENABLE MACHINE SHOWN 5 2 IN THE STOWED D POSITION WITH THE POWER OFF JOYSTICK GND BK CHASSIS GND Jce 1 PLATFORM CONTROLLER Part No 228901 BRAND GS 30 GS 32 GS 46 GS 47 Genie L M N 239 Service Manual November 2014 Electrical Schematic GS 1530 32 GS 1930 32 ANSI and CSA Models from serial number GS3010A 110000 and GS3011A 110827 240 241 November 2014 Service Manual Electrical Schematic GS 1530 32 and GS 1930 32 ANSI and CSA Models from serial number GS3011A 110828 November 2014 Service Manual Electrical Schematic GS 1530 32 and GS 1930 32 ANSI and CSA Models from serial number GS3011A 110828
21. g u 2 lt TON 26 5 2 lt lt 288 ies 925 5 lt lt D INU 7 5 ree ED lt lt 5 5 ete NS 2 lt lt 2 0 lt 2 5 5 gt aX u 5 ero 109 JAHA lt lt De ya 2 lt 4 MS FIOHLOd 5 5 t o 5 291 LX L HM NAS 8 225 2 lt 2 8 8 fa FEST TIOHLOd 3 8 9 9 881 MS LIAM NOHLOd 10 HAVE lt e lt e HM e Le yg y 5 v au uo d 1 8 HOSN3S d e 12 m E AP t a i euge PEREN 258 7 gt 7 8 gt 78 1109 1HOl udis gt x Ha 9 lt lt 9 s gt s ua annoy NHOH OLNY HM 5 Hq 5 1 4 lt lt 4a 8 E g g 10 18 lt lt gt gt 8 18 1109 1 31 5331 vans 5 T9 1 9 9 gt 9 3 X gt 4 E 5 5 dwv N gt eal 1 2 pu A A A d 5 pe EE wl X A Wo3
22. Y893 0 098 in 0 036 in 0 9 mm RETRACT RETRACT 4 0 9 mm PRESSURE PRESSURE SENSE PORT SENSE PORT x eat 296 GS 30 GS 32 GS 46 GS 47 HS0040C Part No 228901 November 2014 Service Manual Hydraulic Schematics GS 4047 from serial number GS4712C 101 and GS4715D 101 THE ORIFICE IS LOCATED UNDERNEATH THE PLUG LEFT y C_ RIGHT OPPOSITE THE HOSE INLET OF THE LIFT CYLINDER BRAKE 3500 pei maximum UPPER LIFT CYLINDER 241 bar maximum cues 1 dm ie HAND x d H7 PRESSURE 0 059 inch gam 1 49 TRANSDUCER 4 maur RELEASE cm PRESSURE R px 370 to 450 psi MANIFOLD Dk 26 to 31 bar Le 21 H E STEER STEER MANUAL RIGHT LEFT M THE ORIFICE IS LOCATED UNDERNEATH THE PLUG 15 7 OPPOSITE THE HOSE INLET THE LIFT CYLINDER ee Bi LOWER LIFT CYLINDER 4 75 GU IN LEFT RIGHT 78 DRIVE DRIVE 3500 ps maximum 0 076 1 93 mm 1 82
23. 2 S ul g 2 gt wi g u xxx Y7 E amp E P STEER STEER 5 pa LEFTAC16 15 RIGHT 1 15 ha ry res BK GR WH AN ZN cnl A RRI 7 PLATFORM i X tay ACY IX 4 Yl to IEF Y6 Y5 z z cry DRIVE C13 DRIVE m m FORWARD REVERSE amp amp SSS SSS E 4 4 AN T e N 1 MANIFOLD V e i ES0535 F 266 GS 30 GS 32 55 46 GS 47 Part No 228901 November 2014 Service Manual Electrical Schematic GS 1530 32 and GS 1930 32 CE and AUS Models from serial numbers GS3011A 110828 and GS3011C 10000 A C D E F G H J K L M N P data C3 1 l T ES X PCON V OUT RD 1 1 RD PCON V OUT 1 1 PCON V OUT RD 2 lt RD lt H1 1 gt 5 2 lt lt 2 WH ESTOP 2 lt lt 2 ESTOP 3 lt BK iL ALARM FROM C41 E gt _DATALINK BL 1 3 BL DATA LINK 3 lt lt 3 DATA LINK BL 4 gt E STOP WH X E gt DATA LINK OR 4 lt lt 4 OR DATA LINK 4 lt lt 4 DATA LINK OR 5 lt lt E STOP WH 7 PCON V OUT BR 5 lt lt 8 BR PON V OUT 5 5 PCON V QUT BR 6 1 P2 2
24. 1 8 Select the Software tab at the header bar Result The following screen will be displayed Genie smart Link Genie BRAND GS 30 GS 32 GS 46 GS 47 71 Part No 228901 Service Manual November 2014 Ground Controls 9 Select the Update Machine Software button Result The following screen will be displayed Genie smart Link Home Help Software Current slab 2012 prod Loaded Genie Flash File selected Build Time 01 08 55 Feb 29 2012 Summar Large Slab and 3232 Production Run application CN file chosen sewed 10 Select the Choose File button and navigate to the downloaded Genie Flash file gff Note Verify it is the correct flash file 11 Select the Load Flash File button to verify the file is a gff file Result The following screen will be displayed Genie smart Link Home Help Loaded slab 2012N prod Choose File No file chosen 12 Select the Reprogram Device s button to start the ECM software update Result The following screen will be displayed after the software update is complete Note Do not turn off power while the ECM is being reprogrammed Genie smart Link Home Help Loaded Genie Flash File selected 21 37 46 Nov 01 2012 Slab 2012N prod Bootloader 17 10 28 Jun 0
25. A C E F G H E gt amp _ _ 2 _ E C8 _ 1 ES X PCON V OUT RD 1 1 RD PCON V OUT 1 1 PCON V OUT RD 2 lt RD gi H1 gt 5 2 lt lt 2 WH ESTOP 2 lt lt 2 ESTOP 3 lt BK iL ALARM FROM C41 E gt _DATALINK BL 1 3 BL DATA LINK 3 lt lt 3 DATA LINK BL 4 gt E STOP WH X E gt DATA LINK OR 4 lt lt 4 OR DATA LINK 4 lt lt 4 DATA LINK OR 5 lt lt E STOP WH 7 PCON V OUT BR 5 lt lt 8 BR PON V OUT 5 5 PCON V QUT BR 6 1 P2 2 4 Sx EMERGENCY 166 6266261 2 U3 PLATFORM CONTROLS PRINTED CIRCUIT BOARD em JOYSTICK AXIS 1 d 1 gt STEER SWITCH 3 Um PLATFORM 5 DRIVE ENABLE COM YL 4 SONTROLLER CONTROLLER DRIVE ENABLE WH15 gt STEER LEFT BL 6 5 STEER RIGHT GR47 5 JOYSTICK 5VDC RD4 amp gt JOYSTICK GND BK410 x11 gt CHASSIS GND 12 MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF 110V 240V AC POWER TO PLATFORM AC INPUT _ 258 _ ODIS AG 13 gt 1 1_ 6a 11 1 Laat OUTLET 2 2 2 gt gt 2 3 3 WH 4 3 8 BL L _ L e Ground QUTLET BOX STUD ES0535 F from serial number GS4712C 101 K L M N Genie Part No 228901 BRAND GS 30 GS 32 GS 46 GS 47 287
26. DP e gt q 1 zurpo 8 g L fi 23 o ols E Plage oru g k 255 ata HM gt lt au qu gt 5 Sor 99 ako ok ag N e N Part No 228901 GS 30 GS 32 GS 46 GS 47 250 NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF 8 LF PRESS TRANSDUCER WH lt RR PRESS TRANSDUCER GR RF PRESS TRANSDUCER OR s K LR PRESS TRANSDUCER BL November 2014 RD RD RD RD 6 Eun NAME 80541 IS LOM 3 ul 5 2 111 i 5 gt gt LF OUTRIGGER 4 AN 4 B C36 c gt c B gt LS GND LS GND WH PRESS TRANSDUCER LS GND BK WH LR PRESS TRANSDUCER BK LS GND WH RR PRESS TRANSDUCER RD SENSOR V OUT 15 GND RD SENSOR V RD SENSOR V OUT BK LS GND BK LS GND BK Service Ma
27. ces cm zou 2 1 FES E VITE A 4 109 2 N V 5 1 5 eet lz rz x T A gi a E 1 L E 1 i 40153 2 lt HM o lt lt 2 59 XI IQON WHO Y 1d lt areca AWA ug 4 28 LNO ANOOd lt 0 lt a INT VIVO u9 5 80 100 WHOS 9 59 a H 40189 0 4 LNO A HWHO 3 BVN3 lt lt 21007 WO lt r u6 5 8 8 lt z 8 a E le 85 N am lt 3LLOHHL OW 55 Iz Q9 1 lt 22 ZZ D E 1 1 HWHO a lt 4 1 5 Af ua pod Eee OR e E 1 xa I OS id 220 1 1 5 i i I o 1 E n oz z ic 95 E hi 15 x x ie 5 ES 7 gt 1 1 2 a i 1 tr suoi B x 1 RE Af 2201 Q MEE BO re 5 5855 x 4 au Cya Zack 8 S 58 8 OBES 06 a 84 59 506 rasa 0 OF uto coz 5 Er
28. o JA I2 5 NS DRINKIN AOR o d gt ojojo To N ed gt a 214 210 20 570 762 583 791 778 1055 682 09 1233 Genie BRAND 14 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual Scheduled Maintenance Procedures Observe and Obey AWARNING 44 WN 5 Part No 228901 Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine Scheduled maintenance inspections shall be completed daily quarterly semi annually annually and every 2 years as specified of the Maintenance inspection Report The frequency and extent of periodic examinations and tests may also depend on national regulations Failure to perform each procedure as presented and scheduled may cause death serious injury or substantial damage Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Use only Genie approved replacement parts Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection Machine Configuration Unless otherwise specified perform each Genie BRAND GS 30 GS 32 GS 46 GS 47 15
29. o lt JNT YLA yo o lt a f Nn lt lt 3 YO 1109 WHOS XE a gt 9 40189 HM o 4 A NOOd Qu a lt lt 5 gt 3 18VN3 OW 225 A 21007 N94 Qu lt r u5 i E 8 amp amp 8 loz 05 E tr S N tr Bs 24 5 5 5 lt tr d ce 550 m n 1 89 Y 355 5 Sa 8 52 x t e m x x HM 1 1 n T v Ex ina oar 1 5 5 T g ZAIL gt a EU m n aoe gu qu uoOozu th Eo 5 55 zi 1 u ER 5 qy HE 8t s Gl zl G t d HM qu o9 ake ot ag N e Ww N Part No 228901 GS 30 GS 32 GS 46 GS 47 274 November 2014 Service Manual Electrical Schematic GS 3232 CE and AUS Models from serial numbers GS3211A 110000 and GS3212C 10000
30. DRIVE ENABLE COM YL 4 SONTROLLER CONTROLLER DRIVE ENABLE WH15 gt STEER LEFT BL 6 5 STEER RIGHT GR47 5 JOYSTICK 5VDC RD4 amp 3 9 gt JOYSTICK GND BK410 11 7 CHASSIS GND 12 NOTE 4 MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF 110V 240V AC POWER TO PLATFORM AC INPUT _ 258 _ ODIS 5 1 gt gt 1 GR 1 gt gt 1 GR YL OUTLET 2 2 22 3 3 WH 4 3 8 BL L _ L e Ground 6 QUTLET BOX STUD 7 8 ES0535 F Genie BRAND Part No 228901 GS 30 GS 32 GS 46 GS 47 271 Service Manual November 2014 es Electrical Schematic GS 2032 and GS 2632 CE and AUS Models from serial numbers GS3211A 110000 and GS3212C 10000 272 November 2014 Service Manual Electrical Schematic GS 3232 CE and AUS Models from serial numbers GS3211A 110000 and GS3212C 10000 273 November 2014 Electrical Schematic GS 3232 CE and AUS Models from serial numbers GS3211A 110000 and GS3212C 10000 Service Manual
31. _ _ _ Brake Release Hand Pump Components 8 1 Brake Release Hand Pump Components The brake release hand pump manifold is mounted behind the entry ladder Index No Description Schematic Item Function Torque 1 Hand pump L Manual brake release 30 ft lbs 41 Nm 2 Needle valve M Manual brake release enable 45 50 in Ibs 5 Nm Note alpha callouts refer to corresponding notes on the hydraulic schematic 1 1 1 1 1 1 112 GS 30 65 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual Scissor Components 1 9 9 2 9 1106 1532 6 P Steer End Non steer End 1 Number 4 pivot pin 10 Number 3 inner arm 2 Number 3 center pivot pin 2 pins 11 Number 3 outer arm 3 Lift cylinder rod end pivot pin 12 Number 3 pivot pin non steer end 4 Number 3 pivot pin steer end 13 Number 2 inner arm 5 Number 2 center pivot pin 2 pins 14 Number 2 outer arm 6 Number 2 pivot pin steer end 15 Number 2 pivot pin non steer end 7 Number 1 center pivot pin 2 pins 16 Lift cylinder barrel end pivot pin 8 Number 1 inner arm 17 Number 1 outer arm 9 Number 1 pivot pin LLL Genie BRAND Part No 228901 GS 30 GS 32 GS 46 GS 47 113 Service Manual November 2014 Scissor Components 9 1 Scissor Assembl
32. 245 m L c 1 8 40193 2 9 pa l aoto of HM o o ei Jg uo 2 2 ug 1 1 N JOWN WHOLLY Td o lt TOS WHOdILV 1d pz 6 lt lt 4 99 INO A 94 ug EN INIT VIVO 0 lt a INIT VINO gt 1109 dN WHOS 2 ua t lt Er o 30153 lt P 4 110 A NOOd gt HWHO 3 1HVN3 OW 225 A 01901 WO Qqu 1 gt 9 9 5 8 amp a 852 Ne 3 3 A rd as N 9 suiosHLOW 2 55 e 224 2 o0 8 5 5 gt 55 9 1 21 19 5 lt ul 5 oe 1 we SalQrzZ 58 8 26148 or 50 I 651200 5 g PGIBES 85 8 871 LETS 25209 m a 5 HM t 120 E 1 1 1 09 1 ost i Iq lt 1 1 1 1 Imr o a Im 9 1 T 1 1 1 1 1 1 1 1 1 1 lt 1 9 lt tes age gu dac 8558 92295 a i E 0 au m SES p 8 f5 zk n gt a au 25 EE 8 a N e N Part No 228901
33. 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 11 12 Connect the battery pack to the machine Turn the key switch to ground controls Press and hold the ground control scroll up and scroll down buttons Scissor Components 13 Pull out the red Emergency Stop button to the on position at the ground controls 14 Using the ground control menu buttons navigate to Service Override Mode Select Service Override Mode Note The machine must be in Service Override Mode to raise the platform While in Service Override Mode only the GCON will operate with limited functionality The platform will raise a predetermined amount of time and stop 15 Raise the platform and rotate the safety arm to the stowed position 16 Fully lower the platform to the stowed position Note After replacing the pressure transducer calibrating the platform overload system is not required If the machine begins to nuisance trip frequently a no load calibration is recommended Refer to Repair Procedure 9 10 How to Calibrate the Platform Overload System if equipped Torque specifications Genie BRAND Part No 228901 GS 30 GS 32 Pressure transducer if equipped 27 ft lbs schematic item R 37 Nm GS 46 GS 47 197 Service Manual
34. H107 COILFAULT een bun eee ee eR All functions GS 2646AV DECK EXTEND OPEN pen circuit in the platform extend circuit extend valve coil open circui inhibited GCON ECM H108 H108 COILFAULT Short circuit of the platform extend circuit to 520 All functions GS 2646AV DECK EXTEND BAT battery positive GCON ECM inhibited H109 H109 COILFAULT Short circuit of the platform retract circuit to E All functions GS 2646AV DECK RETRACT BAT battery negative GCON ECM inhibited 110 HTTGICOILEAUET Open circuit in the platform retract circuit 2 70 44 All functions GS 2646AV DECK RETRACT OPEN P inhibited GCON ECM H111 H111 COILFAULT Short circuit of the platform retract circuit to 2 1024 All functions GS 2646AV DECK RETRACT BAT battery positive ECM inhibited H114 H114 COILFAULT Short circuit of the platform enable circuit to Snot orot All functions GS 2646AV DECK ENABLE BAT battery positive GCON ECM inhibited H115 H115 COILFAULT Short circuit of ble circuit Short circuit in PED harness All functions GS 2646AV DECK ENABLE is ECM inhibited Genie BRAND Part No 228901 GS 30 GS 32 GS 46 GS 47 223 Service Manual Diagnostics Type Faults November 2014 eoo ESSE ts
35. HYDRAULIC TANK To Outrigger Manifold In Port GS 3232 Models To Outrigger Manifold Out Port GS 3232 Models HS0036R Part No 228901 Genie BRAND GS 30 GS 32 GS 46 GS 47 295 Service Manual November 2014 Hydraulic Schematics GS 3232 from serial number GS3211A 110000 and GS3212C 10000 LF OUTRIGGER CYLINDER RF OUTRIGGER CYLINDER EXTEND 2 q ZA ipee 0 037 in 0 037 in 0 94 mm 0 94 mm 35 f 9 088 in 0 085 in 0 9mm 0 9 mm PRESSURE Bj Ral R1 R2 PRESSURE SENSE PORT SENSE PORT a 1 OUTRIGGER 1 MANIFOLD 69 M From Pump 0 25 gpm 3700 psi 0 95 Limim 255 bar IN gt TA To Function Manifold PORT oul 3500 psi maximum L 241 bar maximum a ee a Pra r LR OUTRIGGER l RR OUTRIGGER CYLINDER CYLINDER 22 EXTEND EXTEND 7 dL OH Kol 0 087 in 0 037 in 0 94 0 94
36. Part No 228901 Genie BRAND GS 30 GS 32 GS 46 GS 47 211 Service Manual November 2014 Diagnostics I O Map without Load Sense 65 3232 only GCON Pin Number Circuit Function Type Wire Gauge and Color J1 Connector Gray J1 01 ECM Power Power Input 14 RD J1 02 PCON E Stop Power Power Output 18 RD J1 03 PCON E Stop Return Power Input 18 WH J1 04 Link to PCON CANH Data Bus 18GR J1 05 Link to PCON CANL Data Bus 18 OR J1 06 PCON Ground Ground Output 18 BR J1 07 GCON Ground Ground Input 14 BR J1 08 Key Switch PCON Mode Digital Input 18 BK J1 09 Key Switch GCON Mode Digital Input 18 WH J1 10 GCON Emergency Mode Digital Input 18 WH BK J1 11 No Circuit N A N A J1 12 Driver Power Power Input 14 RD J 2 Connector Black J2 01 Platform Up Coil Digital Output 18 OR J2 02 Platform Down Coil Digital Output 18 OR BK J2 03 Steer Left Coil Digital Output 18 BL BK J2 04 Steer Right Coil Digital Output 18 BL J2 05 Parallel Coil GS 32 amp GS 46 Digital Output 18 RD WH J2 06 Drive Forward Coil Digital Output 18 WH J2 07 No Circuit N A N A J2 08 Motor Controller Enable Digital Output 18 GR WH J2 09 No Circuit N A N A J2 10 Drive Reverse Coil Digital Output 18 WH BK J2 11 Motor Controller Throttle Analog Output 18 GR J2 12 No Circuit N A N A 212 Genie BRAND GS 30
37. 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 Genie 38 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual B 15 Inspect the Voltage Inverter if equipped Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Perform this procedure more often if dusty conditions exist 1 Inspectthe 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 a right fault LED b left fault LED 25V LED d 21V LED 3 Connect an appropriate power tool to the inverter Activate the tool Part No 228901 Checklist B Procedures 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 POL is illuminated the inverter is connected to batteries with the incorrect polarity Correct the polarity issue with the red wire to battery positive and the black wire to battery negative The inverter will then operate correctly and begin supplying
38. 85 8 GND BK412 m d T o m 6 e 1 8 S S 3 EX 5 a a a 44 5 5 5 G 8 D 8 o 2 E E co m m 2 5 2 99 i 5 110V 240V 4 5 g 2 8 E POWER TO PLATFORM e 8 9 u AC INPUT 2 _ 92016 E t m on oc a BE 8 3 3 5 4 u F 2 2 l 2 gt gt 2 BK 3 RO WH F 3 5 9 8 Ya5 Y40 pa acne OUTRIGGER OUTRIGGER BEND 29 2 5 ACK X n X GND on om ona ER 7 Nl Ground ju T X T ca C29 C27 AC iLer sox STUD 229282892 C36 CEN 538 C397 ee Wo UU 7 S re Om om Y36 Y34 OUTRIGGER 1 OUTRIGGER OUTRIGGER RETRACT c26 0 g cas 5 9 5 x 85 ee Lg 5 5 25 X AL OX 6 2 56 28 amp SS V S RA F E B C28 Cae T 2 54 215 2 2 1122 5225 S 58254100 g g EROM s 226 5 228 5 226 5 258 208 pg p p p 0214 855 9 4 4 844 4 BES 99 68344 22 2 2 2 2 2 g 5 5 GER mE in m t T in 039 27 5 SN 2 6 44 a amp a T 7 a Tv BENE EE gt
39. All PCON drive and GS32 U033 JSTICKFAULT acceptable calibration range at system startup steer functions OUT OF CAL RANGE PCON joystick hin GS46 amp startup GCON ECM inhibited GS47 U034 GS30 U034 JSTICKFAULT Short circuit of the PCON drive joystick Short circuit of PCON drive joystick signal circuit All PCON drive and 6532 OUT OF RANGE HI signal to battery positive at system startup PCON joystick steer functions GS46 amp inhibited GS47 U035 GS30 U035 JSTICKFAULT Short circuit of the PCON drive joystick Short circuit of PCON drive joystick signal circuit All PCON drive and 6532 OUT OF RANGE LO signal to battery negative at system startup PCON joystick steer functions GS46 amp GCON ECM inhibited GS47 U036 22 U036 SWITCHFAULT Mis wiring or short circuit of GCON key Short circuit of the PCON drive enable switch All functions switch ECM inhibited GS46 amp GS47 U037 GS30 Short circuit in the foot switch harness 6532 EE E Foot switch pressed at machine startup Foot switch GS46 amp GCON ECM GS47 0038 2 U038 SWITCHFAULT Mis wiring or short circuit of foot switch to 3 in thie foot switch hamess All functions GS46 amp FOOTSWITCH BAT battery positive GCON ECM inhibited GS47 U039 U039 SWITCHFAULT Mis wiring open or short circuit of foot in the foot switch harness All functions GS46 am
40. All functions inhibited except for down function C025 GS30 GS32 GS46 amp GS47 C025 SYSTEMFAULT PLAT OVLD NOCAL Platform overload system not calibrated Platform overload system not calibrated GCON or PCON ECM All functions inhibited 230 Genie BRAND GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual Observe and Obey Schematics About This Section There are two groups of schematics in this section Electrical Schematics AWARNING V Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine before operating the machine Before Troubleshooting V Immediately tag and remove from service a damaged or malfunctioning machine A WARNING V Repair any machine damage or malfunction Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine V Be sure that all necessary tools and test equipment are available and ready for use Part No 228901 Genie BRAND GS 30 GS 32 GS 46 GS 47 Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Hydraulic Schematics Bodily injury hazard Spraying hydraulic oil
41. November 2014 Service Manual 1 Diagnostics Faults continued DTC Message on Problem Possible Failure Number GCON LCD Description Causes Mode H049 H049 COILFAULT Short circuit of the outrigger extend Short circuit in outrigger extend coil harness Only outrigger 65 3232 O R il to batt ti Outrigger extend coil short circuit extend function GCON ECM disabled H050 H050 COILFAULT Open circuit in the outrigger extend hamess 65 3232 O R EXTEND OPEN coil circuit GCON ECM disabled H051 H051 COILFAULT Short circuit of the outrigger extend extend E hames t GS 3232 O R EXTEND BAT coil to battery positive Utrigger Extena Sher Hae GCON ECM platform down H052 H052 COILFAULT Short circuit of the outrigger retract 4 hamess ore a GS 3232 O R RETRACT BAT coil to battery negative GCON ECM disabled H053 H053 COILFAULT Open circuit in the outrigger retract hamess 65 3232 O R RETRACT OPEN coil circuit GCON ECM disabled H054 H054 COILFAULT Short circuit of the outrigger retract DUREE retrac eol hamess nee GS 3232 O R RETRACT BAT coil to battery positive GCON ECM platform down H057 H057 COILFAULT Short circuit of the left
42. Platform raised Braking distance maximum High range on paved surface 0 5 mph 40 ft 55 sec 0 8 km h 12 2 55 sec 24 in 12 in 61 cm 30 cm Gradeability GS 1930 GS 1932 GS 2632 GS 3232 GS 3246 and GS 4047 GS 1530 GS 1532 GS 2032 GS 2046 and GS 2646 Airborne noise emissions Sound pressure level at ground workstation Sound pressure level at platform workstation 25 30 lt 70 dBA lt 70 dBA Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation Genie BRAND GS 30 GS 32 GS 46 GS 47 Part No 228901 Service Manual November 2014 Specifications Function speed maximum from platform controls with 1 person in platform GS 1530 and GS 1532 Platform up fast mode Platform up slow mode Platform down 15 to 17 seconds 31 to 33 seconds 28 to 30 seconds GS 1930 and GS 1932 Platform up fast mode Platform up slow mode Platform down 15 to 17 seconds 31 to 33 seconds 28 to 30 seconds GS 2032 and GS 2046 Platform up fast mode Platform up slow mode Platform down 28 to 32 seconds 58 to 62 seconds 26 to 30 seconds GS 2632 and GS 2646 Platform up fast mode Platform up slow mode Platform down 28 to 32 seconds 58 to 62 seconds 22 to 26 seconds GS 3232 and GS 3246 Platform up fast mode Platform up s
43. Raise the machine approximately 2 inches 5 cm Place blocks under the chassis for support Remove the blocks from under both wheels Lower the machine and remove the blocks 29 30 31 32 33 Genie BRAND GS 30 GS 32 GS 46 GS 47 Service Manual Ground Controls Center a lifting jack under the drive chassis at the battery pack side of the machine Raise the machine approximately 2 inches 5 cm Place blocks under the chassis for support GS 1530 and GS 1930 Place a 0 77 x 6 x 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 x 6 x 6 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 GS 2632 and GS 3232 Place a 0 8x 6x6 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 GS 3246 and GS 4047 Place 1 22 x 6 x 6 inch 31mm x 15 cm x 15 cm thick steel block under both wheels at the battery pack side of the machine Lower the machine onto the blocks Raise the platform 7 to 8 feet 2 1 to 2 4 m Result The platform should stop an alarm should sound and fault code LL appears in the diagnostic display Result The platform does not stop or the level sensor alarm does not sound Adjust the level sensor until the alarm just begins to sound OR t
44. maximum load in the center of the platform deck Secure the weight to the platform Refer to the chart below 11 Press the Enter button to select Platform Overload 12 Use the Menu Up or Menu Down buttons to GS 1530 GS 15322 272 9 scroll to Platform Overload Calibrate GS 1930 and GS 1932 227 kg he E b Platf 13 Press the Enter button to select Platform GS 2032 363 kg Overload Calibrate GS 2632 227 kg 5 227 kg 14 Confirm the Platform Overload Calibrate selection by pressing the Enter button again Note In the event of frequent nuisance trips occurring after calibrating GS 3232 machine itis 15 Use the Menu Up or Menu Down buttons to recommended to recalibrate the machine full load select Full Load calibration and no load with 250 kg of weight in the platform 16 Press the Enter button to select Full Load GS 2046 544 kg calibration GS 2646 454 kg GS 3246 317 kg GS 4047 350 kg Genie BRAND Part No 228901 GS 30 GS 32 GS 46 GS 47 199 Service Manual ss si Scissor Components 17 18 19 20 200 Press the Enter button to confirm rated load is in the platform At the ground controls press and hold the Function Enable and Platform Up buttons until the platform reaches maximum height All Models except GS 4047 When the platform reaches maximum height press the ground controls Enter button Allow the ground controls to gather data GS 4
45. 126 Remove the platform See 10 1 How to 32 Remove the Platform Remove the cables from the number 4 outer arm index 13 at the ground controls side 33 Component damage hazard Cables can be damaged if they are kinked or pinched 35 Remove the cables from the number 4 cable bridge and lay them off to the side Component damage hazard November 2014 Remove the number 4 cable bridge mounting fasteners and remove the cable bridge from the machine Attach a lifting strap from an overhead crane to the number 4 inner arm index 12 Remove the retaining fasteners from the number 4 pivot pin index 3 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 Cables can be damaged if they Crushing hazard The number are kinked or pinched A CAUTION 4 inner arm may become unbalanced and fall if not Attach a lifting strap from an overhead crane properly supported when to the number 4 outer arm index 13 removed from the machine Remove ean 36 Remove the cables from the number 3 cable fasteners from the number 4 center pivot pins index 2 Use a soft metal drift to remove the number 4 center pivot pins index 2 Remove the retaining fasteners from the number 4 pivot pin index 14 at the non steer end of the machine 37 Use a soft metal drift to remove the number 4 pivot pin index 14 from t
46. 2 1 2 1 1 1 212411 04 0 180 928 Litt Cylinder rre eee e e hee adds 183 9 9 Pressure cete e rr tree bo e de 196 9 10 Platform Overload 198 9 11 Platform Overload Recovery 203 Platform 205 10 71 205 10 2 Platform eret 206 Genie BRAND Part No 228901 GS 30 GS 32 GS 46 GS 47 xiii November 2014 nO Table of Contents Section 5 DiAQNOSUCS A E 207 nii fore 207 GCON Map without Load Sense all machines except GS 3232 210 GCON Map with Load Sense all machines except 3232 211 GCON Map without Load Sense GS 3232 212 GCON I O Map with Load Sense GS 3232 214 Operation Indicator Codes 216 Diagnostic Trouble Codes 216 Troubleshooting HXXX and PXXX Faults seen 217 Fault Inspection Procedure enne 218 Type
47. 4 Toa A 5 4 E PLATFORM HEIGHT c lo d z ES RD 5 020 _ 623 SENSOR Mc 144 bd 144 15 51 3 sS Ad RE 08 Rcs 5 WH 3 3 WH SIG 799799999999 AR A oe Q s BS ______ CONTRO 4 7 2 8 BATTERY _ E 15 PLATFORM rt ELECTRONIC C19 C24 OVERLOAD 5 a A amp A RD lt L A HAD V E C C BL C C WH ss8l TC Y Y Y Y Y Y Y Y Y Y B B L BK B amp B BK 8 2 3 4 5 7 6 9 10 12 g 3 d I x X T E 5 9 e 1 aaa 5 2 a 8 5 8 2 5 5 55 Li o 5 E M 493 6 g 2 T i 5 4 5 p a tr t E ul 5 ui xxx a Y7 n 2 gt PLATFORM odi STEER STEER 5 pa DOWN LEFT ACI6 C15 RIGHT C22 v 554 ao d 4 1 BK GR WH ALOX l A 7 Ya 5 RA SZ PARALLEL T E TT PLATFORM A X PARALLEL ACY eve eae Y6 Y5 DRIVE C13 DRIVE 015 m FORWARD REVERSE amp amp oS SSS SS gt H 12 I T e N 15 MANIFOLD V e i ES0535 F Genie A TEREX BRAND 278 GS 30 55 32 GS 46 GS 47 Part No 228901 N
48. ACAUTION Crushing hazard The lift AWARNING Bodily injury hazard Spraying cylinder will fall if not properly hydraulic oil can penetrate and supported when the pivot pin is burn skin Loosen hydraulic removed connections very slowly to allow the oil pressure to dissipate 50 Lower the cylinder onto the linkset 5 si nob allow ata 51 Attach a lifting strap from an overhead crane q to the number 4 outer arm at the ground 44 Tag and disconnect the wire harness from the solenoid valve on the cylinder 52 Remove the retaining fasteners from the number 4 center pivot pin index 5 at the ground control side Genie Part No 228901 BRAND GS 30 GS 32 GS 46 GS 47 159 Service Manual ss ss Scissor Components 53 55 Place a rod through the number 4 center pivot pin at the ground control side index 5 and twist to remove the pin Remove the retaining fasteners from the number 4 pivot pin index 21 at the non steer end 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 59 A CAUTION 60 November 2014 Remove the number 4 outer arm index 20 from the machine Crushing hazard The number 4 outer arm index 20 may become unbalanced and fall if not properly supported when removed from the machine Attach a lifting strap
49. C 2 Platform overload if equipped C 3 Breather cap models with optional oil A 5 Grease steer yokes Inspector signature Inspector title Checklist B YNR Checklist D YNR D 1 Scissor arm wear pads D 2 Hydraulic filter Inspector company Instructions e Make copies of this report to use for each inspection e Select the appropriate checklist s for the type of inspection s to perform Daily or every 8 hours A Quarterly or every A B 250 hours Semi annually or every 500 hours Annually or A B C D every 1000 hours 0 2000 hours e Place a check in the appropriate box after each inspection procedure is completed e Use the step by step procedures in this section to learn how to perform these inspections e If any inspection receives tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable no remove from service R repaired 20 B 1 Batteries B 2 Electrical wiring Checklist E YNR B 3 Electrical contactor E 1 Hydraulic oil B 4 Tires and wheels B 5 Emergency stop B 6 Key switch B 7 Horn if equipped B 8 Drive brakes B 9 Drive speed stowed B 10 Drive speed raised B 11 Drive speed slow B 12 Hydraulic
50. GS 2632 ANSI and CSA Models from serial number GS3211A 110000 245 November 2014 Service Manual Electrical Schematic GS 2032 and GS 2632 ANSI and CSA Models from serial number GS3211A 110000 1 5 10 gt 152 oo zur o 9 2 629 595 589 322 luu p HD m Zd 15 m 2 1029 1 44 5 4 r 1 LP diit 1 NY ie 9 1 195 lt 1 oo L l i 1 cya auosNas L1 1 vo 8 gt rx lt l 4 aunouo 988 He amp 1 pov ri X8 Ls z 8 5 E C aes EL IAA po eS cc 8 3 i g iB 2 an
51. GS47 Genie BRAND Part No 228901 GS 30 GS 32 GS 46 GS 47 225 Service Manual Type UXXX Faults continued November 2014 eoo ESSE ts Diagnostics DTC Message on Problem Possible Failure Number GCON LCD Description Causes Mode 0020 5 U020 SWITCHFAULT Short circuit of the PCON high lift speed Short circuit of the PCON hi lift speed switch L CON Pratform GS46 amp PCON HI LIFT SPD switch at system startup ECM inhibited GS47 0021 U021 SWITCHFAULT Short circuit of the PCON up directional Short circuit of the PCON up directional switch PCON platform up UP switch at system startup GCON ECM function inhibited GS46 amp GS47 0022 6530 U022 SWITCHFAULT Short circuit of the PCON down directional Short circuit of the PCON down directional PCON platform 6532 DOWN switch at system startu switch down functions 6546 8 inhibited GS47 0023 U023 SWITCHFAULT Short circuit of the PCON outrigger enable Short circuit of the PCON outrigger enable All outrigger GS 3232 PCON O R ENABLE switch at system startup GCON ECM functions inhibited U033 PCON drive joystick is not in neutral position at GS30 PCON drive joystick signal is outside Joy
52. Lift the safety arm move it to the center of the scissor arm and rotate down to a vertical position lift cylinder orifice schematic item O connector fitting hydraulic hose pressure transducer schematic item R if equipped manual lowering cable g solenoid valve schematic item N h cable mount bracket Part No 228901 GS 30 GS 32 GS 46 GS 47 183 Service Manual November 2014 Scissor Components 4 Lower the platform onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 5 Using a suitable lifting device support the link stack at the steer end of the machine 6 Atthe ground controls turn the key switch to the off position and push in the red Emergency Stop button to the off position 7 Disconnect the battery pack from the machine A WARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 8 Tagand disconnect the wiring from the solenoid valve coil at the barrel end of the lift cylinder 9 If equipped tag and disconnect the three pin connector from the pressure transducer harness To remove the pressure transducer refer to Repair Procedure 9 9 How to Remove the Pressure Transducer if equipped 10 Loosen the adjustment nuts on the solenoid valve and disconnect the manual lowering ca
53. Result The measurement is 0 90 inch o 22 9 mm or more Proceed to step 3 Genie requires that this procedure be performed Result The measurement is less than every 1000 hours or annually whichever comes 0 90 inch 22 9 mm Replace both wear pads first Refer to Repair Procedure 9 1 or 9 2 How to Replace the Scissor Arm Wear Pads Maintaining the condition of the scissor arm wear pads is essential to safe machine operation Continued use of worn out wear pads may result in component damage and unsafe operating conditions Note Perform this procedure with the machine on a firm level surface that is free of obstructions GS 1530 GS 1532 GS 1930 and GS 1932 1 Measure the distance between the number one inner arm cross tube and the chassis deck at the ground controls side of the non steer end of the machine Refer to illustration 1 Result The measurement is 0 90 inch 22 9 mm or more Proceed to step 2 Result The measurement is less than 0 90 inch 22 9 mm Replace both wear pads Refer to Repair Procedure 9 1 or 9 2 How to Replace the Scissor Arm Wear Pads Illustration 1 a wear pad b inner arm cross tube c chassis deck Genie BRAND Part No 228901 GS 30 GS 32 GS 46 GS 47 51 Service Manual November 2014 Checklist D Procedures 3 Apply a thin lay
54. Service Manual November 2014 ees Electrical Schematic GS 4047 CE and AUS Models from serial number GS4712C 101 288 November 2014 Service Manual Electrical Schematic Foot Switch option All Models from serial number GS3010A 110000 GS3011C 10000 GS3211A 110000 GS3212C 10000 GS4612A 110000 GS4612C 10000 and GS4712C 101 289 Service Manual November 2014 42 Electrical Schematic Foot Switch option Models from serial number GS3010A 110000 GS3011C 10000 GS 3211A 110000 GS3212C 10000 GS4612A 110000 GS4612C 10000 and GS4712C 101 A B C D E F G H J K C2 4 oa fea 3 m3 l 1 lt 1 E gt V OUT RD 1 1 RD PCON V OUT 1 4 _PCON V OUT RD 2 gt RD lt H1 E2 1 ESTOP WH 2 2 WH ESTOP 2 2 L EsroP WH 3 gt BK 2 1 ALARM FROM C41E 1 DATA BL 8 4 81 BL DATA LIN L8 81 DATA LINK BL 4 lt gt E STOP WH DATA LINK 4 amp 4 DATA LINK 4 lt lt l DATA LINK OR 5 gt E STOP WH Ex PCON V OUT BR 5 5 BR PCON V OUT 15 5 PCON V OUT BR 6 1 P2 6 6 FS NO GR EMERGENCY gt FS NG YL 2 NOTE 1 U3 PLATFORM CONTROLS MAGHINE SHOWN PRINTED CIRCUIT B
55. lever arm retaining screw squeeze connector lever arm platform height sensor harness connection platform height sensor fastener large platform height sensor bracket j fastener platform height sensor k platform height sensor assembly F7 O 7D anog Gi 1 1 1 m 182 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual 9 8 Lift Cylinder How to Remove the Lift Cylinder AWARNING Bodily 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 Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications GS 1530 GS 1532 GS 1930 and GS 1932 Note Models without a pressure transducer follow steps 1 through 23 27 and 28 Models equipped with a pressure transducer follow steps 1 through 28 1 Turn the key switch to ground controls and pull out the red Emergency Stop button to the on position at both ground and platform controls 2 Raise the platform 7 to 8 feet 2 1 to 2 4 m Genie BRAND 3 Scissor Components
56. to the lug on the rod end of the lift cylinder index 3 Raise the lift cylinder Crushing hazard The lift approximately 3 ft 1 m CAUTION cylinder will 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 Genie 118 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 a se 62 Placea4x4 x 48 inch 10 cm x 10 cm x 63 1 2 m long block across both sides of the chassis under the number 1 center pivot pin index 7 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 CAUTION Bodily injury hazard Keep hands clear of moving parts when lowering the scissor arms 64 Remove the cables from the number 1 cable 65 66 A CAUTION Part No 228901 bridge and lay them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched 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 will fall if not properly supported and secured to the li
57. 105 Tag and disconnect the wire harness from the solenoid valve on the cylinder 106 Tag and disconnect the wires and manual lowering cable from the solenoid valve on the cylinder Scissor Components 107 Models with platform overload option Tag and disconnect the wire harness from the platform overload pressure transducer Note After replacing the scissor assembly the platform overload system must be calibrated Refer to Repair Procedure 9 10 How to Calibrate the Platform Overload System if equipped 108 Raise the lift cylinder to a vertical position 109 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 A CAUTION Crushing hazard The lift cylinder 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 110 Remove the cables from the number 1 cable bridge and lay them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched 111 Remove the cables from the number 1 cable bridge and lay them off to the side 112 Disconnect the number 1 cable bridge from the number 1 outer arm index 34 and remove the cable bridge from the machine Genie Part 228901 GS 30 GS 32 GS 46 GS 47 177 Se
58. 109 JAHA lt lt De ya lt 4 I qu s LX 1 HM y8 22 8 YX 2 8 8 hea Wi MSdY NDFIOHLOd a 8 Og 581 O MS LIAM NOHLOd HAVO 1100 ETV lt ug zeze HM Pe Te yg r gt t d lt 8 z 09 06 1 6 t a E euge 5 2 7 PEER 258 E 7 gt 7 8 i 3 gt 18 1109 1HOl udis lt gt x Ha 9 lt lt 9 5 s ua NHOH HM 5 4 5 1 4 lt 2 u8 8 E g E 1no Nuvi 328 e C gt 8 18 1109 1437 9215 EDS 5 9 gt 9 4 X ggi 5 7 Qq B E 1 SAA A ALY zi X A Wo3 o 11 8l 3 yatHm 2 lt E4 2 l T9 oto HM o lt lt o ov HO e 2 ua iR xi 3gow WHOLLY 1d o lt TOS r2 xr 99 INO A 94 04 o EN INIT VIVO a INIT gt 100 WHOS 1 14 5 30153 0 4 110 A 9 HWHO 3 THVN3 OW A 225 A 01901 W93 Qqu 1 gt
59. 16 6 6 6 EMERGENCY LAN STOP U3 PLATFORM CONTROLS PRINTED CIRCUIT BOARD 2 gt JOYSTICK AXIS 1 YL 41 He EN1 gt STEER SWITCH COM BK 3 Um PLATFORM 5 DRIVE ENABLE COM YL 4 SONTROLLER CONTROLLER DRIVE ENABLE WH15 gt STEER LEFT BL 6 5 STEER RIGHT GR47 5 JOYSTICK 5VDC RD4 amp l 3 l gt JOYSTICK GND BK410 x11 gt CHASSIS GND 12 4 MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF 110V 240V AC POWER TO PLATFORM AC INPUT _ 258 _ ODIS 5 11 GR 1 gt gt 1 GR YL OUTLET 2 2 2 gt 2 _ BK 3 3 WH 4 3 8 BL a a L e Ground 6 QUTLET BOX STUD 7 8 ES0535 F Genie Part No 228901 GS 30 GS 32 GS 46 GS 47 267 Service Manual November 2014 Electrical Schematic GS 1530 32 and GS 1930 32 CE and AUS Models from serial numbers GS3011A 110828 and GS3011C 10000 268 November 2014 Service Manual Electrical Schematic GS 2032 and GS 2632 CE and AUS Models from serial numbers GS3211A 110000 and GS3212C 10000 269 Service Manual November 2014 42 Electrical Schematic GS 2032 and GS 2632 CE and AUS Models from serial numbers GS3211A 110000 and GS3212C 10000
60. 18 Support and secure the lift cylinder to an appropriate lifting device 19 Remove the lift cylinder through the scissor arms at the steer end of the machine ACAUTION Crushing hazard The lift cylinder will 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 20 Install new cylinder fittings hoses and pressure transducer if equipped Torque specifications Solenoid valve 2 position 2 way 20 ft Ibs N C 27 Nm schematic item N Coil Nut 5 ft lbs 7Nm Pressure transducer if equipped 27 ft lbs schematic item R 37 Nm Gon BRAND GS 30 GS 32 GS 46 GS 47 185 Part No 228901 Scissor Components 21 Remove the lifting device supporting the link stack at the steer end of the machine 22 Connect the battery pack to the machine 23 Turn the key switch to ground control Models without a pressure transducer continue at step 27 Models with a pressure transducer continue at step 24 24 Press and hold the ground control scroll up and scroll down buttons 25 Pull out the red Emergency Stop button to the on position at the ground controls 26 Using the ground control menu buttons navigate to Service Override Mode Select Service Override Mode Note The machine must be in Service Override Mode to raise the platform W
61. 2 pins 8 Number 4 pivot pin steer end 9 Number 3 outer arm 10 Number 3 center pivot pin 2 pins 11 Lower lift cylinder rod end pivot pin 12 Number 3 pivot pin steer end 168 GS 4047 13 Number 2 center pivot pin 2 pins 14 Number 2 pivot pin steer end 15 Number 1 center pivot pin 2 pins 16 Number 1 inner arm 17 Number 1 pivot pin steer end 2 pins 18 Number 6 inner arm 19 Number 6 outer arm 20 Number 6 pivot pin non steer end 21 Number 5 inner arm 22 Number 5 outer arm 23 Number 5 pivot pin non steer end 24 Number 4 inner arm Genie BRAND GS 30 GS 32 GS 46 GS 47 amp 6 9 amp amp 8 6 amp 9 9 9 Non steer End 25 Number 4 outer arm 26 Number 4 pivot pin non steer end 27 Upper lift cylinder barrel end pivot pin 28 Number 3 inner arm 29 Number 3 pivot pin non steer end 30 Number 2 inner arm 31 Number 2 outer arm 32 Number 2 pivot pin non steer end 33 Lower lift cylinder barrel end pivot pin 34 Number 1 outer arm Part No 228901 November 2014 Service Manual 9 6 Scissor Assembly GS 4047 How to Disassemble the Scissor Assembly GS 4047 AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could resul
62. 224 Genie BRAND GS 30 GS 32 GS 46 GS 47 DTC Message on Problem Possible Failure Number GCON LCD Description Causes Mode Short circuit in switched power 1 down limit 6532 P001 PWR FAULT Short circuit of the switched power 1 switch pothole limit switch digital tilt switch All functions SW PWR1 BAT circuit to battery negative harness inhibited GCON ECM GS47 Short circuit in switched power 1 down limit GS32 P003 PWR FAULT Short circuit of the switched power 1 Switch pothole limit switch digital tilt switch All functions SW PWR1 BAT circuit to battery positive harness inhibited pois GCON ECM GS47 P004 GS30 P004 DEVICEFAULT Short circuit of the automotive horn circuit to Short circuit omotive horn Automotive horn GS32 HORN BAT battery negative Automotive hiom hortelreut inhibited GS46 amp ECM 6547 005 6530 Open circuit in automotive horn harness GS32 EODEM UM LT Open circuit of the automotive horn circuit Automotive horn open ee nom GS46 amp GCON ECM 5 6547 006 6530 P006 DEVICEFAULT Short circuit of the automotive horn circuit to Short circuit au omotive horn harness Automotive horn GS32 HORN BAT batt iti Automotive horn short circui inhibited GS46 amp attery positive GCON ECM inhibited GS47 P007 G930 Pooz DEVICEFAUL
63. 39 3 Nm 8 ORFS Adj Non adj 60 ft lbs 81 3 Nm 37 Adj Non adj 52 ft lbs 70 5 Nm 10 ORFS Adj Non adj 100 ft lbs 135 6 Nm 37 Adj Non adj 85 ft lbs 115 3 Nm 12 All types 135 ft lbs 183 Nm 16 All types 200 ft lbs 271 2 Nm 20 All types 250 ft lbs 339 Nm 24 All types 305 ft lbs 413 5 Nm io 11 Service Manual November 2014 Specifications Torque Procedure SIC 37 fittings 1 Seal Lok fittings 1 Replace the O ring The O ring must be replaced anytime the seal has been broken The O ring cannot be re used if the fitting or 2 hose end has been tightened beyond finger tight Note The O ring in Parker Seal Lok fittings and hose end are custom size O rings They are not standard size O rings They are available in the O ring field service kit Genie part number 49612 2 Lubricate the O ring before installation 3 Be sure the O ring face seal is seated and retained properly 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight 5 Tighten the nut or fitting to the appropriate torque Refer to the appropriate torque chart in this section 6 Operate all machine functions and inspect the hose fittings and related components to confirm there are no leaks Genie Align the tube flare hex nut against the nose of the fitting body body hex fitting and tighten the hex nut to the body hex fitting to hand
64. 5 205 5 0 lt 5 Lie 5 21 94 Sele lt 015 014 Qu 2 lt lt 2 D ub e 8 09 075 OK us y ra E HM lt lt 1 Et i cuss oco Ge SEES i gt w N N t i as L Nee Hg gt HM INYO lt 4 Hetu d LL p dis MSqdwnosiOdOd 4 Bye PRX gt gor 41 9 mi Hm z 5z Q 19 T3TIVdvd _ E g 8 La aj L Oy 8 L X HM yg gt gt 7 9 6 z a MS FIOHLOd gio 8 91 gegr 851 she gt 7 5 st 18 100 4331 lt pr 8 9 s L ua S LNO NHOH OLfIV HM o o A HOSNAS dH o lt z gt gt zq 8 2 WHY YN 18 o 1100 1431 mu E gt lt 6 9 gt gt 9 lt 7 t o 5 77 gt R E 8 5 a EU 1 EU 5 ES x X eig 2 l Ns 1 5 Y YA dOLS 3 8 HM 9 lt E 2 g IEEE 2 HM a lt lt gt gt 0 lt lt 14 d EN __ 3gOH WHOs LV 1d 38 o NMOd zg 22555 AWO3 lt 99 LNO A NOOd
65. ACAUTION Crushing hazard The lift cylinder will fall if not properly supported when the pivot pin is removed 18 Support and secure the lift cylinder to an appropriate lifting device 19 Remove the lift cylinder through the scissor arms at the steer end of the machine ACAUTION Crushing hazard The lift 13 Attach a lifting strap from an overhead crane cylinder will become unbalanced or similar lifting device to the barrel end of the and fall if not properly supported lift cylinder for support and secured to the lifting device 14 Remove the fasteners from the lift cylinder Component damage hazard Be rod end pivot pin Use a soft metal drift to careful not to damage the valve remove the pin or fittings on the cylinder while removing it from the machine ACAUTION Crushing hazard The lift cylinder will fall if not properly supported when the pivot pin is removed 15 Lower the cylinder onto the number 1 inner arm oylinder plate 16 Attach a lifting strap from an overhead crane or similar lifting device to the barrel end of the lift cylinder for support Genie 194 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual Scissor Components 20 Install new cylinder fittings hoses and Torque specifications pressure transducer if equipped Solenoid valve 2 position 2 way 20 ft lbs N C 27 Nm schematic item N Relief valve 20 ft lbs schematic item Q 27 Nm Coil Nut 5
66. C47 C45 TI TI 858 WH se 6244545322520 E 5 1982 1988 BN B lt B BK v z 20 eo DC AC INVERTER 5 88 gs 5 2 m CYLINDER PRESSURE OPTIONAL Gontector 8 8 5 5 PLATFORM HEIGHT 5 3 c9 4 Toa A 5 4 E PLATFORM HEIGHT c lo d z ES RD 5 020 _ 623 SENSOR Mc 144 bd 144 15 51 3 sS Ad RE 08 Rcs 5 WH 3 3 WH SIG 799799999999 AR A oe Q s BS ______ CONTRO 4 7 2 8 BATTERY _ E 15 PLATFORM rt ELECTRONIC C19 C24 OVERLOAD 5 a A amp A RD lt L A HAD V E C C BL C C WH ss8l TC Y Y Y Y Y Y Y Y Y Y B B L BK B amp B BK 8 2 3 4 5 7 6 9 10 12 g 3 d I x X T E 5 9 e 1 aaa 5 2 a 8 5 8 2 5 5 55 Li o 5 E M 493 6 g 2 T i 5 4 5 p a tr t E ul 5 ui xxx a Y7 n 2 gt PLATFORM odi STEER STEER 5 pa DOWN LEFT ACI6 C15 RIGHT C22 v 554 ao d 4 1 BK GR WH ALOX l A 7 Ya 5 RA SZ PARALLEL T E TT PLATFORM A X PARA
67. EMERGENCY STOP 9 NC 9 GROUND MODE BK J1 ECM 8 PLATFORM MODE 41 ECM PIN 9 WH EMERGENCY STOP J1 ECM 10 ee ee Genie 234 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual Limit Switch Legend 08 2032 65 2632 05 3232 65 2046 65 2646 65 3246 GS 1530 GS 1532 GS 1930 GS 1932 GS 1530 GS 1532 GS 1930 GS 1932 GS 2032 GS 2632 GS 3232 GS 2046 GS 2646 GS 3246 GS 4047 Limit Switch Legend down limit switch LS6 b pothole limit switches LS7 LS8 c 22ft 6 7 maximum drive height when outriggers are not deployed LS1 LS10 GS 3232 Genie BRAND Part No 228901 GS 30 GS 32 GS 46 GS 47 235 Service Manual November 2014 Electrical Symbol Legend PCON 1 N C 4 4 OFF 2 OM 80 gt 8 x a OB 10 e3 ____ GCON fn 8 Wire with description or color Limit Switch Motor Controller Key switch D1 22 Ms Circuits crossing no connection Emergency Stop button Motor Solenoid valve with diode V y E O EM TIT Diode Circuit breaker Battery charger Level sensor 2 415 1 Av 5 Circuit connection Fuse 6V o
68. GS 30 GS 32 GS 46 GS 47 258 November 2014 Service Manual Electrical Schematic GS 3246 GS 4047 ANSI and CSA Models from serial number GS4612A 110000 and GS4715D 101 A C E F G H J K L M N es EEEE S 2 1 lt e 1 1 E PCON V OUT RD 1 1 RD PCON V OUT 1 1 PCON V OUT RD 2 RD lt H1 gt WH 2 4 21 ESTOP 2 lt 2 ESTOP WH 8 lt BK lt 5 1 ALARM FROM C41E 1 DATA LINK BL 3 lt lt 3 BL DATA LINK 3 lt lt DATA LINK BL 4 lt E STOP WH k DATA LINK OR 4 OR DATA LINK 4 amp A4 DATA LINK OR 5 E STOP WH x V OUT BR 5 lt lt 54 BR PCON V OUT 5 lt lt 5 PCON V OUT BR 6 lt 6 1 p2 lt x76 lt C6 DEMERGENOY NC Lona U3 PLATFORM CONTROLS PRINTED CIRCUIT BOARD 2 gt JOYSTICK AXIS 1 1 gt 2 EN1 gt STEER SWITCH 3 TK PLATFORM gt DRIVE ENABLEGCOM YL74 CONTROLLER CONTROLLER X DRIVE ENABLE WH45 X STEER LEFT BL 6 STEER RIGHT GR47 JOYSTICK 5VDC RD 8 3 x9 gt JOYSTICK GND 10 411 gt CHASSIS GND 12 5 4 MACHINE SHOW
69. LX L HM gt 2 4 8 8 lt amp l NMsduvnosoHlod 2 5 881 O 6 gt lt 2 _8 8 au oE mei 8 e s aa s3E95 258 7 gt 7 8 i 3 gt 78 1109 LHD uas lt lt De Ha 9 lt lt 9 5 s ua NHOH HM lt 5 1 1 ug lt 8 E g 1no Nuvi 18 9 lt gt gt 48 18 1109 1487 4331 TT 5 8 lt lt gt 9 gt 9 4 X ggi NT 3 o 5 e 1 SAA A AY X A Wo3 l TI 34 5 lt e l SOW HA o o 9 2 wa lt E xi 3gow WHOLLY 1d o lt TOS WHOdILV 1d r2 lt lt 4 99 INO A 094 Wg EN INIT VIVO a viva u56 gt 100 dn WHOS 5 ua t lt r 30153 lt 4 1f10 A NOOd 9 HWHO 3 THVN3 OW A 225 A 21901 W93 qu 1 gt 9 2 9 5 8 3 a 852 Ne 3 3 a ot 3 lk
70. November 2014 Scissor Components 9 10 Platform Overload System How to Calibrate the Platform Overload System if equipped Perform this procedure with the machine in the stowed position and on a firm level surface that is free of obstructions Personnel are not allowed in the platform while calibrating the platform overload system Perform this procedure in an environment that allows the platform to be fully raised Models rated for indoor use only should be calibrated inside a facility with enough ceiling height to fully raise the platform If the facility height is not suitable to fully raise the platform then an indoor only rated model may be calibrated outdoors if wind speeds are less then 28 mph 12 5 m s Only use flat weights while calibrating indoor only rated machines outdoors Perform this procedure after confirming that the platform height sensor is not damaged and functions correctly There are two options to the platform overload calibration procedure in this section Full Load Calibration and No Load Calibration Full Load Calibration has two steps requiring calibration with and without rated load in the platform No Load Calibration does not require rated load in the platform Note No Load Calibration can be completed stand alone to fulfill the C 2 overload calibration requirements if the machine has completed the Full Load Calibration procedure Note If a new Ground Controller is installed on a m
71. Page 204 Schematics Page 206 Page 209 Page 211 through Page 264 Page 268 D 09 2013 Maintenance Page 23 Page 45 Repair Page 69 Page 74 Page 78 Page 80 Page 164 Page 166 Page 169 Page 172 Diagnostics Page 187 Page 189 D1 06 2014 Specifications Page 3 Page 6 Page 7 Maintenance B 8 B 9 B 10 B11 Diagnostics FXXX Faults CXXX Faults Reference Examples Section Maintenance B 3 Section Repair Procedure 4 2 Electronic Version Click on any procedure page number highlighted in blue to view Section Fault Codes All charts the update Section Schematics Legends and schematics Part No 228901 Genie BRAND GS 30 GS 32 GS 46 GS 47 iii Service Manual November 2014 24 Introduction Revision History Revision Date Section Procedure Page Description E 11 2014 2 Spec Perform without Perform with 4 Repair 5 8 9 11 6 Schem 258 Reference Examples Section Maintenance B 3 Section Repair Procedure 4 2 Electronic Version Click on any procedure page number highlighted in blue to view Section Fault Codes All charts the update Section Schematics Legends and schematics Genie iv GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual Introduction Serial Number Legend Genie A TEREX COMPANY Model GS 1930 Serial number GS301
72. _ GND VH Ground 6 OUTLET BOX STUD i 7 8 ES0534 Genie BRAND Part No 228901 GS 30 GS 32 GS 46 GS 47 247 Service Manual November 2014 Electrical Schematic GS 2032 and GS 2632 ANSI and CSA Models from serial number GS3211A 110000 248 November 2014 Service Manual Electrical Schematic GS 3232 ANSI and CSA Models from serial number GS3211A 110000 249 November 2014 Service Manual Electrical Schematic GS 3232 ANSI and CSA Models from serial number GS3211A 110000 4 6 2 5 uso an e our Li E 12 SPB 205 BP moo 5 1 595 Qo gt gt V 270 E Meh Sl ies ote 155 dT 1 152 158551 x 7 E 1 SEE 1 1 lt oa 1225 y i NAA a Y 12
73. at or below the height of the Down Limit Switch Refer to Repair Procedure 9 10 How to Calibrate the Platform Overload System if equipped a overload pressure transducer b platform height sensor Genie BRAND GS 30 GS 32 GS 46 GS 47 49 Part No 228901 Service Manual November 2014 Checklist C Procedures C 3 Replace the Hydraulic Tank Breather Cap Models with Optional Hydraulic Oil Genie requires that this procedure be performed every 500 hours or six months whichever comes first The hydraulic tank is a vented type tank The breather cap has an internal air filter that can become clogged or over time can deteriorate If the breather cap is faulty or improperly installed impurities can enter the hydraulic system which may cause component damage Extremely dirty conditions may require that the cap be inspected more often 1 Remove and discard the hydraulic tank breather cap 2 Install the new cap onto the tank 50 GS 30 GS 32 GS 46 GS 47 Genie Part No 228901 November 2014 Service Manual Checklist D Procedures D 1 2 Measure the distance between the number one inner arm cross tube and the chassis Check the Scissor Arm Wear deck at the battery pack side of the non steer Pads end of the machine Refer to illustration 1
74. end with the overhead crane until the chassis mount bracket will clear the level sensor 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 Part No 228901 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 35 36 Genie BRAND GS 30 GS 32 GS 46 GS 47 Service Manual Scissor Components Remove both old wear pads Install two new wear pads Slide the scissor assembly back into the drive chassis 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 careful not to damage the level sensor or limit switch while moving the scissor assembly Service Manual Scissor Components November 2014 000 9 2 N 4 eG Steer End 1 Number 7 pivot pin 2 Number 6 center pivot pin 2 pins 3 Number 6 pivot pin steer end 4 Number 5 center pivot pin 5 Upper lift cylinder rod end pivot pin 6 Number 5 pivot pin steer end 7 Number 4 center pivot pin
75. limited functionality The platform will raise a predetermined amount of time and stop 22 Raise the platform and return the safety arm to the stowed position 23 Fully lower the platform to the stowed position 24 Remove the platform See 10 1 How to Remove the Platform 25 Support and secure the entry ladder to an appropriate lifting device 26 Remove the fasteners from the entry ladder and remove the entry ladder from the machine CAUTION Crushing hazard The entry ladder will fall if not properly supported and secured to the lifting device Genie BRAND GS 30 GS 32 GS 46 GS 47 121 Service Manual es 7 Scissor Components 27 28 29 30 31 32 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 Remove the scissor assembly from the machine just enough to access both wear pads A DANGER Crushing hazard The scissor 122 assembly will fall if not properl
76. ok Short circuit of the chassis digital tilt switch pater doen an org 6532 F007 SWITCHFAULT Short circuit of the chassis digital tilt switch at circuit elevated position If CHASSISTILT BAT system startup Chassis digital tilt switch short circuit PPO GS46 amp machine is in stowed GCON ECM BR GS47 position all functionality is resumed F008 2 F008 SENSORFAULT Short circuit of the Platform Overload 4 circuit FF CET GS46 amp OVLD XDUCER BAT Transducer circuit to battery positive GCON ECM GS47 F009 6330 009 Short circuit of the Platform Overload Short circuitin the transducer circuii GS32 OVLD XDUCER BAT Transducer circuit to battery negative Faulty pressure transducer All functions inhibited GS46 amp 5 GCON ECM GS47 All functions inhibited except F010 platform down as long GS30 F010 SENSORFAULT Short circuit of the Platform Height Sensor Short circuit in the platform height circuit as machine is in the GS32 PLAT HEIGHT BAT circuit to battery positive Faulty platform height sensor elevated position If GS46 amp GCON ECM machine is in stowed GS47 position all functionality is resumed All functions inhibited except 2011 platform down as long GS30 F011 SENSORFAULT Short circuit of the Platform Height Sensor Short circuit in the platform height circuit as machine is in the GS32 PLAT HEIGHT BAT circuitto battery negative Faulty platfor
77. position 19 Press and hold the ground control scroll up and scroll down buttons 20 Pull out the red Emergency Stop button to the on position at the ground controls 21 Using the ground control menu buttons navigate to Service Override Mode Select Service Override Mode Note The machine must be in Service Override Mode to raise the platform While in Service Override Mode only the GCON will operate with limited functionality The platform will raise a predetermined amount of time and stop 22 Raise the platform and return the safety arm to the stowed position 23 Fully lower the platform to the stowed position 24 Remove the platform See 10 1 How to Remove the Platform 25 Support and secure the entry ladder to an appropriate lifting device 26 Remove the fasteners from the entry ladder and remove the entry ladder from the machine ACAUTION Crushing hazard The entry ladder will fall if not properly supported and secured to the lifting device Genie GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 a se 27 28 29 30 31 32 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
78. procedure with the machine in the following configuration e Machine parked on a firm level surface e Key switch in the off position with the key removed e The red Emergency Stop button in the off position at both ground and platform controls e Wheels chocked e All external AC power supply disconnected from the machine e Platform in the stowed position Service Manual November 2014 Scheduled Maintenance Procedures 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 A DANGER Indicates a imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury ACAUTION Indicates a potentially hazardous situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Indicates that a specific result is expected after performing a series of steps Indicates that an incorrect result has occurred after performing a series of steps Maint
79. 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 GS 30 GS 32 GS 46 GS 47 123 Service Manual November 2014 Scissor Components 9 2 Scissor Assembly GS 1930 and GS 1932 How to Disassemble the Scissor Assembly GS 1930 and GS 1932 AWARNING Bodi y 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 Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications Note Machines equipped with a Platform Height Sensor begin the Scissor Disassembly procedure at step 1 Machines without a Platform Height Sensor begin the Scissor Disassembly procedure at step 24 1 Turn the key switch to ground controls and pull out the red Emergency Stop button to the on position at both ground and platform controls 2 Raise the platform 7 to 8 feet 2 1 to 2 4 m Li
80. 2 gt gt 2 BK 5 RO 33 3 gt gt 3 BL 5 Y35 Y33 40 9 OUTRIGGER OUTRIGGER BEND c31 629 C27 x Ro ME NO t 7 N Ground c31 C29 C27 gox STUD C397 ee Pe 1997 Y34 BF RA OUTRIGGER n OUTRIGGER o3 OUTRIGGER c28 RETRACT coc 2 xx a Eom 31 X ALOX 188 84 C30 C26 v2 gt gt gt gt gt 929721 aa z l l l l 26 amp o mu u i lt 2 2 2 2 111 1 E fh fh 5 5 c 5 5 9 7484 E E E gt le gt gt 97 9 9 ce m m a ta a em tn a SUTRIGGER 1 6 1 4 3 T LEVEL SENSOR 1 1 11 5 ees Ss Se 11 Genie GS 30 GS 32 GS 46 GS 47 Service Manual November 2014 Electrical Schematic GS 3232 ANSI and CSA Models from serial number GS3211A 110000 252 November 2014 Service Manual Electrical Schematic GS 2046 and GS 2646 ANSI and CSA Models from serial number GS4612A 1 10000 253 November 2014 Service Manual Electrical Schematic GS 2046 and GS 2646 ANSI and CSA Models from serial number GS4612A 110000
81. 2 A AAA A AZ i EL X A Wo3 lt To xt 40193 l GOW DAJTO 2 wa lt 300A WHOLLY Td 8 ec 109 rz AWO lt 9 NO A 94 ug o lt Pu INIT VIVO an lt a HNN viva wo lt lt gt 1109 df WHOS 30153 4 1f10 A NOOd du a lt gt HWHO 3 THVN3 OW 225 A 01901 WO qu 1 E H5 9 E a gt oz 8 25 Ne 3 9 lt l a cs LoS 5 S 18 89 2212 2 282 8 af o L x i en 3 HM a E m tr zu obs S40 gt o 9 SUEG 2 age q gu HERES M BSEC Gg 04205 TEG a 5 qu o e 2 2502 8 815 S207 HM zz du 25 lt 89 N e to N Part No 228901 GS 30 GS 32 GS 46 GS 47 286 November 2014 Service Manual Electrical Schematic GS 4047 and AUS Models
82. 2 way 2 position 4 way blocking valve directional valve normally open a d Q Y7 Priority flow regulator Brake Solenoid operated 2 position 2 way valve normally closed Proportional solenoid operated 2 position 2 way directional valve normally closed o UB Accumulator Check valve I Solenoid operated 2 position 2 way directional valve normally closed lt D gt vui Solenoid operated 3 position 5 way directional valve OX C Rum Fixed displacement Shuttle valve Solenoid operated 3 position Solenoid operated 3 position pump 4 way directional valve 4 way directional valve 0 037 incn e en Filter Orifice with size Genie BRAND Part No 228901 GS 30 GS 32 GS 46 GS 47 291 Service Manual November 2014 Hydraulic Component Reference Legend Function Manifold Function Manifold GS 2032 GS 2632 GS 3232 GS 2046 GS 2646 and GS 4047 GS 3246 Function Manifold Lift Pressure Selector Brake Release Manifold GS 1530 GS 1532 GS 1930 and GS 1932 Manifold All Models GS 4047 Outrigger Manifold Front Outrigger Cylinder Rear Outrigger Cylinder GS 3232 GS 3232 GS 3232 Genie 292 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Ser
83. 2014 Service Manual The ground controls used to operate the machine from the ground can also be used to tune the performance of the machine The ground controls consist of an Electronic Control Module ECM emergency stop button key switch and circuit breaker Activating the function enable button and the up or down at the same time sends a signal to the ECM This allows the platform to be raised or lowered at the ground controls Note Steer and drive functions are not available at the ground controls When the ECM is in the set up mode the ground controls are used to adjust the function speed parameters machine models or machine options For further information or assistance consult the Genie Product Support Genie BRAND GS 30 GS 32 GS 46 GS 47 65 Part No 228901 Ground Controls Tt 5 machine setup escape button machine setup scroll up button LCD readout machine setup scroll down button machine setup enter button Key switch KS1 red Emergency Stop 1 circuit breaker CB2 ECM U5 platform down button lift function enable button platform up button Service Manual November 2014 Ground Controls 2 1 Software Revision Level How to Determine the Software Revision Level The machine software revision level is displayed at the ground controls LCD display 1 Turn the key switch to the ground control
84. 228901 GS 30 GS 32 GS 46 GS 47 37 Service Manual November 2014 Checklist B Procedures B 13 Inspect the Hydraulic Tank Cap Venting System Genie requires that this procedure be performed every 250 hours or quarterly 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 2 Check for proper venting Result Air passes through the breather Result If air does not pass through the clean or replace the cap Proceed to step 3 Note When checking for positive tank cap venting air should pass freely through the cap 3 Using a mild solvent carefully wash the cap venting system Dry using low pressure compressed air Repeat step 2 4 Install the breather cap onto the hydraulic tank B 14 Check the Module Tray Latch Components Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the module tray latch components in good condition is essential to good performance and service life Failure to detect worn out latch components may result in module trays opening unexpectedly creating an unsafe operating condition
85. 37 Nm 191 Part No 228901 GS 30 GS 32 GS 46 GS 47 Service Manual November 2014 Scissor Components 21 Remove the lifting device supporting the link stack at the steer end of the machine 22 Connect the battery pack to the machine 23 Turn the key switch to ground control Models without a pressure transducer continue at step 27 Models with a pressure transducer continue at step 24 24 Press and hold the ground control scroll up and scroll down buttons 25 Pull out the red Emergency Stop button to the on position at the ground controls 26 Using the ground control menu buttons navigate to Service Override Mode Select Service Override Mode Note The machine must be in Service Override Mode to raise the platform While in Service Override Mode only the GCON will operate with limited functionality The platform will raise a predetermined amount of time and stop 27 Raise the platform and rotate the safety arm to the stowed position 28 Fully lower the platform to the stowed position Note Models with a pressure transducer calibrate the Platform Overload System Refer to Repair Procedure 9 10 How to Calibrate the Platform Overload System if equipped GS 4047 AWARNING Bodily 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 a
86. 93 Secure the ends of the scissor arms together at the non steer end of the machine with a strap or other suitable device 94 Remove the retaining fasteners securing the chassis mount bracket to the chassis 95 Remove the linkset from the machine 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 sure not to damage the limit switch or level sensor components when the number 1 inner and outer arms index 10 and 22 are removed from the machine How to Replace the Scissor Arm Wear Pads Note Machines equipped with a Platform Height Sensor begin at step 1 Machines without a Platform Height Sensor begin at step 24 1 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 Raise the platform 7 to 8 feet 2 1 to 2 4 m 3 Liftthe safety arm move it to the center of the scissor arm and rotate down to a vertical position 4 Lower the platform onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 5 At the ground control turn the key switch to the off position and push in the red Emergency Stop button to the off position 6 Disconnect the battery pack from the machine A WARNING Electrocution burn hazard Cont
87. All functions H102 H102 COILFAULT Short circuit of the relief valve circuit to Relief valve coil short circuit inhibited except GS 4047 RELIEF VALVE BAT battery positive platform down while GCON ECM above limit switch Short circuit in relief valve harness All f nctions H103 H103 COILFAULT Short circuit of the relief valve circuit to Relief valve coil short circuit inhibited except GS 4047 RELIEF VALVE BAT battery negative platform down while GCON ECM above limit switch Open circuit in relief valve harness H104 HIDE COME Relief valve circuit open valve coil open circuit inhibited except GS 4047 RELIEF VALVE OPEN P platform down while GCON ECM SIE above limit switch 222 Genie BRAND GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual uc n oua Js 1 7 Diagnostics Type HXXX Faults continued DTC Message on Problem Possible Failure Number GCON LCD Description Causes Mode H106 H106 COILFAULT Short circuit of the platform extend circuit to ea aan All functions GS 2646AV DECK EXTEND BAT battery negative GCON ECM inhibited H107
88. BL 3 lt 91 BL DATA LINK 3 lt lt DATA LINK BL 4 lt 4 gt E STOP WH k DATA LINK OR 4 6 OR DATA LINK 4 lt lt 4 DATA LINK OR 5 5 E STOP WH x V OUT BR 5 lt lt 54 BR PCON V OUT lt lt 5 PCON V OUT BR 6 lt lt 61 gt 1 P2 6X 6K 16 6 7 D EMERGENCY cV STOP 8 2 U3 PLATFORM GONTROLS PRINTED CIRCUIT BOARD 2 gt JOYSTICK AXIS 1 YL 41 2 EN1 gt STEER SWITCH 3 TK PLATFORM gt DRIVE ENABLEGCOM YL74 CONTROLLER CONTROLLER X DRIVE ENABLE WH45 X STEER LEFT BL 6 STEER RIGHT GR47 gt JOYSTICK 5VDG RD 8 3 xa gt JOYSTICK GND BK410 411 gt CHASSIS GND 12 Errem 4 MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF 110V 240V POWER TO PLATFORM AG INPUT e gt 5 1 1 1 1 1 L env OUTLET 2 2 2 2 BK A A 3 3 WH _ _ GND VH Ground 6 OUTLET BOX STUD i 7 8 ES0534 F Genie BRAND Part No 228901 GS 30 GS 32 GS 46 GS 47 243 Service Manual November 2014 Electrical Schematic GS 1530 32 GS 1930 32 ANSI and CSA Models from serial number GS3011A 110828 244 November 2014 Service Manual Electrical Schematic GS 2032
89. Cables can be damaged if they are kinked or pinched 36 Disconnect the number 4 cable bridge from the number 4 outer arm index 13 and remove the cable bridge from the machine Remove the retaining fasteners from the number 5 pivot pin index 1 Use a soft metal drift to remove the number 38 5 pivot pin index 1 Remove the platform mount bracket from the machine Attach a lifting strap from an overhead crane to the number 4 outer arm at the ground control side index 13 Remove the retaining fasteners from the number 4 center pivot pin index 2 at the ground control side Genie BRAND 4 outer arm at the ground control side index 13 may become unbalanced and fall if not properly supported when removed from the machine Attach a lifting strap from an overhead crane to the number 4 outer arm at the battery side index 13 Remove the retaining fasteners from the number 4 center pivot pin index 2 at the battery side Place a rod through the number 4 center pivot pin at the battery side index 2 and twist to remove the pin GS 30 GS 32 GS 46 GS 47 147 Service Manual es es Scissor Components 39 A CAUTION 40 41 42 A CAUTION 43 148 Remove the number 4 outer arm index 13 from the machine Crushing hazard The number 4 outer arm index 13 may become unbalanced and fall if not properly supported when removed from the machine Attach a lif
90. Diagnostic Trouble Codes that may occur are explained below Indicate a malfunction associated with devices that control hydraulic functions in the electrical system The HXXX faults are divided into short circuit battery negative short circuit to battery positive open circuit and generic shorts Examples of these devices are solenoid controlled hydraulic valves and motor controller Type PXXX Indicate a malfunction associated with power type devices in the electrical system The PXXX faults are divided into short circuit to battery negative short circuit to battery positive open circuit and generic shorts Examples of these devices are horns sensor power and alarms Type Indicate a malfunction associated with user interface devices in the electrical system The UXXX faults are divided into short circuit to battery negative short circuit to battery positive open circuit and generic shorts Examples of these devices are GCON up and down switches and PCON drive joystick Type FXXX Indicate a malfunction associated with machine feedback devices in the electrical system The faults are divided into short circuit to battery negative short circuit to battery positive open circuit and generic shorts Examples of these devices are limit switches height sensors and pressure transducers Indicate a malfunction associated with controls devices in
91. Disconnect the battery pack from the machine Electrocution burn hazard A WARNING Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 0 0 Part No 228901 GS 30 GS 32 GS 46 GS 47 85 Service Manual November 2014 Hydraulic Pump 4 1 4 Function Pump The hydraulic pump is attached to the motor which makes up the hydraulic power unit How to Test the Hydraulic Pump Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 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 5 1 Tag disconnect and plug the high pressure hydraulic hose from the hydraulic pump 2 Connect a0 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 ground and platform controls Genie Activate the platform up function from the ground controls Result If the pressure gauge reads 3200 psi 221 bar immediately stop The pump is good Result If the pressure gauge fails to r
92. E o 55 js g 8 5 5 5 es HWHD i 12595 Q x I r HM 279 amp co m Larz 3 i 1 oO 8 x EST o 50 21220 5 2 b 85128 958 8 871 LETS t 5 25 200 a ore a a 5 HM t 120 E 1 1 1 1 ost Iq lt 1 1 1 or 1 1 Imr o d imr o T 1 1 1 1 1 1 1 1 1 1 2 lt E gt 9 a SHES 2 T8520 age Qe ELSE e gt 92uE9 5 0 au m SF Su 8 2 55 HS gt 25 EE 8 a N e N Part No 228901 GS 30 GS 32 GS 46 GS 47 242 November 2014 Service Manual Electrical Schematic GS 1530 32 and GS 1930 32 ANSI and CSA Models from serial number GS3011A 110828 A B D E F G H J K L M N gt d __ 03 _ 1 lt 1 T m E PCON V OUT RD 1 1 RD PCON V OUT 1 1 PCON V OUT RD 2 2 RD lt H1 1 ESTOP WH 2 2 WHET 2 lt 2 ESTOP WH 8 lt 8 BK lt 5 1 ALARM FROM C41E 1 DATA LINK
93. F 10 20 30 40 50 Ambient air temperature 1 Chevron hydraulic oil 5606A 2 Petro Canada Environ MV 46 3 UCON Hydrolube HP 5046D 4 Chevron Rando HD premium oil MV Genie BRAND GS 30 GS 32 GS 46 GS 47 7 Part No 228901 Service Manual November 2014 Specifications Chevron Rando HD Premium Oil MV Fluid Properties ISO Grade 32 Viscosity index 200 Kinematic Viscosity cSt 200 F 100 C 7 5 cSt 104 F 40 C 33 5 Brookfield Viscosity cP 4 F 20 C 1040 cP 22 F 30 C 3310 Flash point 375 F 190 C Pour point 58 F 50 C Maximum continuous operating 171 F 77 C temperature Note An hydraulic oil heating system is recommended when the ambient temperature is consistently below 0 F 18 C Note Do not operate the machine when the ambient temperature is below 20 F 29 C with Rando HD Premium MV Chevron 5606A Hydraulic Oil Fluid Properties ISO Grade 15 Viscosity index 300 Kinematic Viscosity cSt 200 F 100 C 5 5 cSt 104 F 40 C 15 0 cSt 40 F 40 C 510 Flash point 180 F 82 C Pour point 81 F 63 C Maximum continuous operating 124 F 51 C temperature Continued use of Chevron 5606A hydraulic fluid or equivalent when ambient temperatures are consistently above 32 F 0 C may result in component damage Petro Canada Environ MV 46 Fluid Properties ISO Grade 46
94. GS 32 GS 46 GS 47 165 Service Manual ss si Scissor Components 10 11 12 13 14 15 16 Remove the fasteners securing the platform height sensor cover to the large platform height sensor bracket Remove the platform height sensor cover Tag and disconnect the platform height sensor from the platform height sensor harness Remove the fastener securing the platform height sensor assembly to the number 1 inner arm Remove the platform height sensor assembly from the number 1 pivot pin Remove the plastic nut securing the squeeze connector to the large platform height sensor bracket Remove the squeeze connector from the large platform height sensor bracket Remove the fasteners securing the large platform height sensor bracket to the number 1 inner arm pivot bracket Remove the large platform height sensor bracket from the number 1 inner arm pivot bracket Install the fasteners removed in 14 to the number 1 inner arm pivot bracket and chassis Tip over hazard Failure DANGER to install the fasteners securing 166 the number 1 inner arm pivot bracket to the chassis could result in the machine tipping over causing death or serious injury November 2014 17 Connect the battery pack to the machine 18 Turn the key switch to the ground control position 19 Press and hold the ground control scroll up and scroll down buttons 20 Pull out the red Emergency Stop button to the on
95. Manual before serial number 17408 Genie GS 2046 GS 2646 and GS 3246 72972 Service Manual from serial number 17409 to 59999 Genie GS 2046 GS 2646 and GS 3246 96316 Service Manual from serial number 60000 to 75437 Genie GS 2046 GS 2646 and GS 3246 97385 Service Manual from serial number 75438 to A 109999 and C 101 to C 9999 Copyright 2011 by Terex Corporation 228901 Rev E November 2014 Fifth Edition Fifth Printing Genie is a registered trademark of Terex South Dakota Inc in the U S A and many other countries GS is a trademark of Terex South Dakota Inc Genie ii GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual Introduction Revision History Revision Date Section Procedure Page Description A 04 2011 New Release B 01 2012 Specifications Machine Performance Hydraulic Maintenance Inspection Report B 1 B 3 B 17 C 1 D 1 Repair 4 2 4 12 4 14 4 20 4 22 4 25 4 26 4 27 4 28 4 29 4 30 4 32 4 33 4 60 4 68 4 78 4 90 4 103 4 105 4 108 4 111 4 115 4 119 4 120 Diagnostics 5 2 5 4 5 5 5 6 5 7 5 8 5 10 5 12 5 15 5 16 Schematics All legends diagrams and schematics B1 06 2012 Maintenance C 1 07 2013 Specifications Page 7 Page 8 Page 9 Repair Page 48 Page 56 Page 61 Page 63 Page 161 Page 174 Page 175 Diagnostics Page 190 Page 194 Page 199 Page 201
96. Menu Down buttons to scroll to Outriggers Press the Enter button to select Outriggers Use the Menu Up or Menu Down buttons to scroll to Calibrate Outriggers Press the Enter button to select Calibrate Outriggers Press and hold the Enter button while the system gathers data to calibrate the outrigger level sensor AWARNING Crushing hazard Keep body 13 84 parts away from outriggers during outrigger movement Continue holding the Enter button after the outrigger level sensor is calibrated The outriggers will retract while the outrigger system gathers and saves data 14 15 November 2014 Continue holding the Enter button after the outriggers retract The outriggers will now extend and the system will gather and save data to calibrate the outriggers Continue holding the Enter button after the outriggers extend The outriggers will now retract while the outrigger system gathers and saves data Result The alarms at the ground and platform controls should sound for 1 second The outrigger system is calibrated Note After installing a new outrigger level sensor the new outrigger level sensor must be calibrated following this procedure Genie GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual 3 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 fo
97. SD 57201 6150 605 882 4000 Genie UK The Maltings Wharf Road Grantham Lincolnshire NG31 6BH England 44 1476 584333 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 Legend Y yes acceptable no remove from service 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 Service Manual November 2014 es Maintenance Inspection Report Model Checklist A YNR Serial number Date Hour meter Machine owner Inspected by print Checklist C YNR 1 Inspect the manuals and decals 2 Pre operation inspection C 1 Pressure transducer and platform height sensor if equipped A 3 Function tests Perform after 40 hours A 4 30 day service Perform after 100 hours
98. SEEN 8 x eu a MSCHVND TOHLOd Al 6 Oa 881 i0 HWY 13 TIVdvd N 6 6 5 10 lt d LI A HOSN3S Qu lt lt 1 2 855 84 uz te e e gt S3595 Soa R r gt 8 3 gt 19 1100 4351 gt r9 xc94 9 5 gt 5 LNO NHOH OLNY HM 4 lt d o aNnow ua 0 lt 8 5 Pa 2 ANNOYS 5 179 189 lt lt gt m 1109 1497 93316 NT ua T9 eT1 9 9 5 9 I ug Ex S 4 gt Hi l Jas 5 5 a lt 7 4 4 E E 4 e E m 1 928 2 9 NI SEE if ETAT KL TSH Ix x x A WO E 2 ol L Tan 1 5 22222 4015 3 9 pd HM o lt LA JL LX 300A WHOALW1d ya e 7109 NMOd Yd pzz e A WO3 rn 90 110 A 94 o lt ANN viva lt 5 5 VIVO 3 W0 1109 WHOS 1v 1d Na lt 90153 o E LNO A NOOd lt gt w HAV OW e 35 A 9ISO1WO3 lt r u9 5 9 5 8 5
99. Stop button to the on position at both ground and platform controls Locate the diagnostic port on the side of the GCON Remove one of the fasteners securing the cover and set aside Loosen the other fastener Do not remove it a diagnostic port 70 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual 4 Connect one end of a CAT5 Ethernet cable into the diagnostic port Connect the other end into a PC or laptop Result The ground controls LCD display will show the following OPEN WEB BROWSER lt IP ADDRESS gt 5 Read and record the IP address Note The display wil only show the IP address for 3 seconds Press the scroll up button to display the IP address for another 3 seconds iti 6 Launch a web browser such as Internet Explorer amp Chrome or Firefox on your PC or laptop Type the IP address from step 5 into the web browser address bar and press enter Result The following screen will be displayed smart Link Username Ground Controls 7 Enter the following username and password then select OK Username smart link Password SL1000 Note The username and password are case sensitive Result The following screen will be displayed rtLink machine parameters perform software updates and handle machine diagnostics 2 Ca E OH 7 es em
100. U007 SWITCHFAULT Short circuit of the GCON LCD escape Short circuit of the LCD escape switch ieee GCON LCD ESCAPE switch at system startup GCON ECM 6546 amp inhibited GS47 U014 U014 SWITCHFAULT Short circuit of the PCON drive enable switch Short circuit of the PCON drive enable switch A Bari aue PCON DRIVE EN at system startup GCON ECM and Steer IUNCHONS GS46 amp inhibited GS47 0015 2 U015 SWITCHFAULT Short circuit of the PCON steer left switch at Short circuit of the PCON steer left switch n uns GS46 amp PCON STEER LEFT system startup GCON ECM inhibited GS47 0016 U016 SWITCHFAULT Short circuit of the PCON steer right switch at Short circuit of the PCON steer right switch A dnd GS46 amp PCON STEER RIGHT system startup GCON ECM inhibited GS47 U017 2 U017 SWITCHFAULT Short circuit of the PCON horn switch at Short circuit of the PCON horn switch PCON horn switch 6546 amp PCON HORN system startup GCON ECM function inhibited GS47 U018 U018 SWITCHFAULT Short circuit of the PCON low drive speed Short circuit of the PCON low drive speed switch dive PCON LO DRIV SPD switch at system startup GCON ECM GS46 amp speed GS47 U019 2 U019 SWITCHFAULT Short circuit of the PCON low lift speed Short circuit of the PCON low lift speed switch Platform up amp GS46 amp PCON LO LIFT SPD switch at system startup GCON ECM inhibited
101. Viscosity index 154 Kinematic Viscosity cSt 200 F 100 C 8 0 cSt 104 F 40 C 44 4 Flash point 482 F 250 C Pour point 49 F 45 C Maximum continuous operating 180 F 82 C temperature UCON Hydrolube HP 5046 Fluid Properties ISO Grade 46 Viscosity index 192 Kinematic Viscosity cSt 149 F 65 C 22 cSt 104 F 40 C 46 cSt 0 F 18 C 1300 Flash point None Pour point 81 F 63 C Maximum continuous operating 189 F 87 C temperature Note Use of Chevron 5606A hydraulic fluid or equivalent is required when ambient temperatures are consistently below 0 F 17 C unless an oil heating system is used Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation Genie 8 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual Hydraulic Component Specifications Function manifold GS 4047 Specifications System relief valve pressure 3500 psi maximum 241 bar Function pump GS 1530 GS1532 GS 1930 and Platform relief valve pressure 3000 psi GS 1932 206 bar Type Gear Steer relief valve pressure 1500 psi Displacement per revolution 0 244 cu in 103 bar 4cc Outrigger manifold Flow rate 2500 psi 172 bar Relief valve pressure maximum 3500 psi 11 3 L min 241 bar Hydraulic tank return filter 10 m
102. acid Neutralize battery acid spills with baking soda and water AWARNING 1 Put on protective clothing and eye wear 2 Release the battery pack latch and rotate the battery pack out and away from the chassis 3 Be sure that the battery cable connections are free of corrosion Note Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables 4 Be sure that the battery retainers and cable connections are tight 5 Fully charge the batteries Allow the batteries to rest 24 hours before performing this procedure to allow the battery cells to equalize Models without maintenance free or sealed batteries 6 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results 7 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows e Add 0 004 to the reading of each cell for every 10 5 5 C above 80 F 26 7 C e Subtract 0 004 from the reading of each cell for every 10 5 5 C below 80 F 26 7 Result All battery cells display an adjusted specific gravity of 1 277 or higher The battery is fully charged Proceed to step 11 Result One or more battery cells display specific gravity of 1 217 or below Proceed to step 8 8 Perform an equalizing charge OR fully charge the batteries and allow the batteries to rest at least 6 hou
103. barrel end pivot pin 17 Number 1 outer arm Genie GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual 9 3 Scissor Assembly GS 2032 and GS 2046 How to Disassemble the Scissor Assembly GS 2032 and GS 2046 AWARNING Bodily 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 Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications Note Machines equipped with a Platform Height Sensor begin the Scissor Disassembly procedure at step 1 Machines without a Platform Height Sensor begin the Scissor Disassembly procedure at step 24 1 the key switch to ground controls and pull out the red Emergency Stop button to the on position at both ground and platform controls Scissor Components 2 Raise the platform 7 to 8 feet 2 1 to 2 4 Lift the safety arm move it to the center of the scissor arm and rotate down to a vertical position 4 Lower the platform onto the safety arm A WARNING Crushing hazard Keep hands clear of the safety arm when l
104. be sure that they are legible and in good condition Result The operator s manual is appropriate for the machine and all manuals are legible and in good condition 4 Result The operator s manual is not appropriate for the machine or all manuals are not in good condition or is illegible Remove the machine from service until the manual is replaced Checklist A Procedures 3 Open the operator s manual to the decals inspection section Carefully and thoroughly inspect all decals on the machine for legibility and damage Result The machine is equipped with all required decals and all decals are legible and in good condition Result The machine is not equipped with all required decals or one or more decals are illegible or in poor condition Remove the machine from service until the decals are replaced 4 Always return the manuals to the storage container after use Note Contact your authorized Genie distributor or Genie if replacement manuals or decals are needed Genie BRAND GS 30 GS 32 GS 46 GS 47 21 Part No 228901 Service Manual November 2014 Checklist A Procedures A 2 Perform Pre operation Inspection Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Completing a Pre operation Inspection is essential to safe machine operation The Pre operation Inspection is a visual inspection performed by the operator p
105. callouts refer to corresponding notes the hydraulic schematic Note alpha numeric callouts refer to corresponding notes on the electrical schematic How to Install a Valve Cartridge 1 Dip the cartridge in clean oil to lube the O rings 2 Screw the cartridge in by hand until the top O ring is met then torque to specifications If required install the valve coil s onto the valve stem Install the coil nut onto the valve stem and torque to specifications Gri 1 1 96 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual _ Manifolds 5 7 Outrigger Cylinder Manifold Components GS 3232 The outrigger function manifold is mounted behind an inspection door at the battery side of the machine Index No Description Schematic Item Function Torque Coil nut item CA CB CC CD 4 5 ft lbs 5 7 Nm 1 Solenoid valve 2 position 2 way CA CB CC CD Outrigger 25 ft lbs 34 Nm extend retract 2 Orifice plug 0 037 inch 0 94 mm CE Outrigger retract 3 Check valve pilot operated CF Retract flow control 20 ft lbs 27 1 Nm 4 Pressure transducer CG Outrigger auto level 16 ft lbs 21 7 Nm CF 3 MM 2 CE RES i O CC and CD T vas Y34 CA and CB Front Outriggers Rear Outriggers Note alpha callouts refer to cor
106. 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 231 Service Manual November 2014 Electrical Component and Wire Color Legends ELECTRICAL COMPONENT LEGEND ELECTRICAL COMPONENT LEGEND cont Item Description Item Description 5 Batteries Connector 5 Battery Pack 24V DC 4 each 6 DC all C37 Left Rear Outrigger Pressure Transducer machines except GS 4047 GS 3232 B10 Battery Pack 24 V DC Wired in Parallel C38 Right Rear Outrigger Pressure Transducer 4 each 12 V DC GS 4047 GS 3232 Connector C39 Outrigger Sensor Power GS 3232 C40 Up Limit Switch GS 3232 C1 Anderson Connector C41 Platform Control Bus C2 PCON Cable Connector C43 Key Switch Platform Mode C3 PCON Coil Cord Connector C44 Key Switch Emergency Stop C4 Power Control J1 C45 Automotive Style Horn C5 Sensors amp Switches J3 C46 Emergency Stop C6 Function Manifold J2 C47 GCON Alarm C7 Sensor Power Bus C48 Circuit Breaker MTR V C8 Sensor Ground Bus C49 Emergency Stop ECM Driver V C9 Pot Hole Limit Switch C50 Circuit Breaker ECM Driver V C10 Down Limit Switch C51 Key Switch Ground Mode C11 7 Level Sensor C52 GCON Alarm C12 Function Manifold Ground Bus C53 Automotive Style Horn C13 Drive Reverse Co
107. cylinder rod end pivot pin index 11 Use a soft metal drift to remove the lower lift cylinder rod end pivot pin index 11 from the machine Crushing hazard The lift cylinder will fall if not properly supported when the pivot pin is removed Place a 4 x 4 x 10 inch 10 x 10 x 25 block onto the number 1 inner arm cylinder plate index 16 Lower the cylinder onto the block Bodily injury hazard Keep hands clear of moving parts when lowering the cylinder 85 86 A CAUTION 87 88 89 90 Genie BRAND GS 30 GS 32 GS 46 GS 47 Service Manual Scissor Components Attach a lifting strap from an overhead crane to the number 3 inner arm index 28 Raise the arm to a vertical position Remove the retaining fasteners from the number 3 pivot pin at the steer end of the machine index 12 Use a soft metal drift to remove the number 3 pivot pin index 12 from the steer end of the machine Remove the number 3 inner arm index 28 from the machine Crushing hazard The number 3 inner arm index 28 may become unbalanced and fall if not properly supported when the pivot pin is removed Attach a lifting strap from an overhead crane to the number 2 outer arm at the ground control side index 31 Remove the retaining fasteners from the number 2 center pivot pin index 13 at the ground control side Place a rod through the number 2 center pivot pin at the ground c
108. 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 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 Part No 228901 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 35 36 Genie BRAND GS 30 GS 32 GS 46 GS 47 Service Manual Scissor Components Remove both old wear pads Install two new wear pads Slide the scissor assembly back into the drive chassis 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 careful not to damage the level sensor or limit switch while moving the scissor assembly 143 Service Manual November 2014 eh P Scissor Components 2 amp ee 6 96 O G amp Ge 90 105 2632 E 7765 2646 C Steer End Non steer End 1 Number 5 pivot pin 12 N
109. from an overhead crane to the number 4 inner arm index 19 Raise the arm to a vertical position 61 Remove the retaining fasteners from the A CAUTION Crushing hazard The number number 4 pivot pin at the steer end of the 4 outer arm at the ground control machine index 6 side index 20 may become unbalanced and fall if not 62 Use a soft metal drift to remove the number properly supported when 4 pivot pin index 6 from the steer end of the removed from the machine machine Remove the number 4 inner arm index 19 from the machine 56 Attach a lifting strap from an overhead crane to the number 4 outer arm at the battery side ACAUTION Crushing hazard The number index 20 4 inner arm index 19 may become unbalanced and fall if 57 Remove the retaining fasteners from the not properly supported when number 4 center pivot pin index 5 at the removed from the machine battery side 63 Remove the cables from the number 3A and 58 Place a rod through the number 4 center pivot pin at the battery side index 5 and twist to 3B cable bridges and lay them off to the side remove the pin Component damage hazard Cables can be damaged if they are kinked or pinched Genie 160 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 64 65 66 67 68 69 CAUTION 70 Part No 228901 Disconnect the number 3A and 3B cable bridges from the scissor linkset and remove both cable bridges
110. from the machine Attach a lifting strap from an overhead crane to the number 3 outer arm at the ground control side index 7 Remove the retaining fasteners from the number 3 center pivot pin index 8 at the ground control side Place a rod through the number 3 center pivot pin at the ground control side index 8 and twist to remove the pin Remove the retaining fasteners from the number 3 pivot pin index 24 at the non steer end 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 outer arm at the ground control side index 7 may become unbalanced and fall if not properly supported when removed from the machine Attach a lifting strap from an overhead crane to the number 3 outer arm at the battery side index 7 Gen BRAND GS 30 GS 32 GS 46 GS 47 Service Manual Scissor Components 71 Remove the retaining fasteners from the number 3 center pivot pin index 8 at the battery side 72 Place a rod through the number center pivot pin at the battery side index 8 and twist to remove the pin 73 Remove the number 3 outer arm index 7 from the machine CAUTION Crushing hazard The number 3 outer arm index 7 may become unbalanced and fall if not properly supported when removed from the machine 7
111. front outrigger harness 4 GS 3232 LF RIGGER BAT coil to battery positive GCON ECM platform down H060 H060 COILFAULT Short circuit he left rear outrigger 2 ua hamess ieee GS 3232 LR RIGGER BAT coil to battery positive GCON ECM platform down H063 H063 COILFAULT Short circuit of the right front outrigger Short creat right front outrigger coil harness A TURCHOTIS 65 3232 RF RIGGER BAT coil to battery positive Right front outrigger coil short circuit inhibited excep GCON ECM platform down H066 H066 COILFAULT Short circuit of he right rear outrigger Bi harness ae excep GS 3232 RR RIGGER BAT coil to battery positive GCON ECM platform down H067 GS30 H067 FAULT Short circuit of the motor controller Short circuit in motor controller enable wire A func ions GS32 MC ENABLE BAT circuitto battery neaative Motor Controller inhibited excep GS46 amp ty egets GCON ECM platform down GS47 pk Short circuit in motor controller enable wire GS32 H069 FAULT Short circuit of the motor controller Motor Controller exc circuit to battery positive GCON ECM GS46 amp platform down Contactor Coi GS47 H070 GS30 H070 FAULT Short circuit of the motor controller Short circuit in motor controller throttle wire func ions 6532 MC THROTTLE BAT throttle circuit to battery negative S Motor Controller inhibited excep GS46 amp 5 Ynegauve
112. ft lbs 406 7 Nm 7 5 gallons 28 4 liters Castle nut torque lubricated 225 ft lbs 305 Nm 4 5 gallons 18 liters GS 2032 GS 2632 GS 3232 GS 2046 GS 2646 GS 3246 GS 4047 Tire size solid rubber 15x 5in 38 1 x 12 7 cm Tire contact area 15 sq in 96 7 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 or obligation Genie GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual Specifications Performance Specifications models without proportional lift 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 2 5 mph 40 ft 24 8 sec 1 8 km h 12 2 m 24 8 sec 0 5 mph 40 ft 55 sec 0 8 km h 12 2 m 55 sec GS 2032 GS 2632 GS 3232 GS 2046 GS 2646 GS 3246 Platform stowed fast Platform stowed slow Platform raised 2 2 mph 40 ft 12 4 sec 3 5 km h 12 2 12 4 sec 1 1 mph 40 ft 24 8 sec 1 8 km h 12 2 m 24 8 sec 0 5 mph 40 ft 55 sec 0 8 km h 12 2 m 55 sec Platform stowed slow Platform raised GS 4047 Platform stowed fast 2 0 mph 40 ft 13 7 sec 3 2 km h 12 2 13 7 sec Platform stowed slow 1 0 mph 40 ft 27 4 sec 1 6 km h 12 2 27 4 sec
113. gt le gt gt 929 3 o o 9 ce m m a ta a em tn a 88 ri l 4 x PTI PT2 PT3 PT4 OUTRIGGER 876 5 4 3 2 LFOUTRIGGER RFOUTRIGGER LR OUTRIGGER RR OUTRIGGER LEVEL SENSOR 1 1 j 44 T 1 301 1 T 6 4 3 2 15 I4 t M d de M LI 8 C84 AN A 6 4 3 2 15 80538 B Genie BRAND Part No 228901 GS 30 GS 32 GS 46 GS 47 275 Service Manual November 2014 es Electrical Schematic GS 3232 CE and AUS Models from serial numbers GS3211A 110000 and GS3212C 10000 276 November 2014 Service Manual Electrical Schematic GS 2046 and GS 2646 CE and AUS Models from serial numbers GS4612A 110000 and GS4612C 10000 277 Service Manual November 2014 42 Electrical Schematic GS 2046 and GS 2646 CE and AUS Models from serial numbers GS4612A 110000 and GS4612C 10000
114. height sensor assembly 13 Working with the platform height sensor 7 Remove the platform height sensor cover assembly remove the Deustch connector from the plastic clip 14 Remove the fasteners securing the platform height sensor to the small platform height sensor bracket 15 Remove the platform height sensor from the small angle sensor bracket 16 Remove the plastic nut securing the squeeze connector to the large platform height sensor bracket Steer End a fasteners platform height sensor cover b platform height sensor cover 8 Tagand disconnect the platform height sensor from the platform height sensor harness Genie BRAND Part No 228901 GS 30 GS 32 GS 46 GS 47 181 Service Manual November 2014 Scissor Components 17 Remove the squeeze connector from the 18 Remove the fasteners securing the large large platform height sensor bracket platform height bracket to the number 1 inner arm pivot bracket 19 Remove the large platform height sensor bracket from the number 1 inner arm pivot N bracket SA oe ADANGER Tip over hazard Failure to install the fasteners securing the large platform height sensor bracket and number 1 inner arm pivot bracket to the chassis could result in the machine tipping over causing death or serious injury Steer End number 1 inner arm fastener platform height sensor assembly number 1 pivot pin
115. machine ACAUTION Crushing hazard The entry ladder will fall if not properly supported and secured to the lifting device 27 Remove the cables from the number 3 cable 28 29 30 bridge and lay them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched Disconnect the number 3 cable bridge from the number 3 outer arm index 11 and remove the cable bridge from the machine Remove the retaining fasteners from the number 4 pivot pin index 1 Use a soft metal drift to remove the number 4 pivot pin index 1 Remove the platform mount bracket from the machine 33 35 A CAUTION 36 37 38 Service Manual Scissor Components Place a rod through the number 3 center pivot pin at the ground control side index 2 and twist to remove the pin Remove the retaining fasteners from the number 3 pivot pin index 12 at the non steer end 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 outer arm at the ground control side index 11 may become unbalanced and fall if not properly supported when removed from the machine Attach a lifting strap from an overhead crane to the number 3 outer arm at the battery side index 11 Remove the retaining fasteners from the number 3 center piv
116. machine Remove the number 3 outer arm at the ground control side index 16 from the machine Crushing hazard The number 3 outer arm at the ground control side index 16 may become unbalanced and fall if not properly supported when removed from the machine Attach a lifting strap from an overhead crane to the number 3 outer arm at the battery side index 16 Part No 228901 November 2014 Service Manual Scissor Components 51 Remove the retaining fasteners from the 58 Lower the cylinder onto the block number 3 center pivot pin index 4 at the A battery side CAUTION Bodily injury hazard Keep 52 Place a rod through the number 3 center pivot pin at the battery side index 4 and twist to remove the pin 59 53 Remove the number 3 outer arm index 16 from the machine 60 A CAUTION Crushing hazard The number 3 outer arm index 16 may become unbalanced and fall if not properly supported when 61 removed from the machine 54 Attach a lifting strap from an overhead crane to the lug of the rod end of the lift cylinder hands clear of moving parts when lowering the cylinder Attach a lifting strap from an overhead crane to the number 3 inner arm index 15 Raise the arm to a vertical position Remove the retaining fasteners from the number 3 pivot pin at the steer end of the machine index 6 61 Use a soft metal drift to remove the number 3 pivot pin index 6 from the steer end of
117. outer arm at the battery pack side may become unbalanced and fall if not properly supported when removed from the machine Genie Part No 228901 BRAND GS 30 GS 32 GS 46 GS 47 127 Service Manual es Scissor Components 53 55 Remove the cables from the number 2 cable bridge and lay them off to the side Component damage hazard 60 November 2014 Attach a lifting strap from an overhead crane to the number 2 outer arm index 19 at the battery pack side Cables can damaded ifthe 61 Remove the external snap rings and retaining are kinked or fasteners from the number 2 center pivot pin index 7 at the battery pack side 54 Remove the external snap rings and retaining 62 Use a soft metal drift to remove the number fasteners from the number 2 center pivot pin 2 center pivot pin index 7 at the battery index 7 at the ground controls side pack side Remove the number 2 cable bridge mounting Bodily injury hazard The fasteners and remove the cable bridge from A CAUTION number 2 outer arm at the the machine battery pack side may become 56 Attach a lifting strap from an overhead crane unbalanced and fall if not to the number 2 outer arm index 19 at the properly supported when ground controls side removed from the machine 57 Use a soft metal drift to remove the number 63 Use a soft metal drift to tap the number 2 pivot 2 center pivot pin index 7 at the ground
118. pin index 20 in the other direction at the controls side non steer end Remove the number 2 outer 58 Remove the retaining fasteners from the y backside of number 2 pivot pin index 20 at the non steer end of the machine A CAUTION Bodily injury hazard The 59 Use a soft metal drift to tap the number 2 pivot E 2 id arm i uii pin index 20 halfway out at the non steer ici pac us ale SE end of the machine Remove the number unbalanced and fall if not 2 outer arm index 19 from the ground properly supported when controls side of the machine removed from the machine CAUTION Bodily injury hazard The 64 Remove the number 3 pivot pin index 17 number 2 outer arm at the from the non steer end of the machine 2 2 fall if 65 Attach a lifting strap from an overhead crane not properly supported when to the number 2 inner arm index 18 removed from the machine Genie 128 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 A 66 67 Remove the retaining fasteners from the number 2 pivot pin index 8 at the steer end of the machine 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 ACAUTION Bodily injury hazard The 68 69 70 number 2 inner arm may become unbalanced and fall if not properly supported when removed from the machine Remove the safety arm from the number 2 inner
119. pin index 3 Use a soft metal drift to remove the pin 27 Attach a lifting strap from an overhead crane to the number 3 outer arm index 11 ACAUTION Bodily injury hazard The x cylinder may fall when the 28 Remove the external snap rings and retaining rod end pivot pin is removed if fasteners from the number 3 center pivot pins not properly supported index 2 29 Use a soft metal drift to remove the number 35 Lower the cylinder onto the number 1 inner 3 center pivot pins index 2 arm index 8 30 Remove the retaining fasteners from the Component damage hazard number 3 pivot pin index 12 at the Cables can be damaged if they non steer end of the machine are kinked or pinched 31 Use a soft metal drift to remove the number 36 Attach a lifting strap from an overhead crane 3 pivot pin index 12 from the non steer end to the number 3 inner arm index 10 of the machine Remove the number 3 outer arm index 11 from the machine 37 Remove the retaining fasteners from the number 3 pivot pin index 4 at the steer end AWARNING Crushing hazard The number am ui 3 outer arm may become se a sott metal to remove the number unbalanced and fall if not 3 pivot pin index 4 Remove the number properly supported when 3 inner arm index 10 from the machine removed from the machine Porter Spre an 32 Remove the number 3 cable bridge mounting becomei nbalahced d fall if remove
120. pivot CAUTION B fall when the pin index 17 halfway out at the non steer rod end pivot pin is removed if end of the machine Remove the number not properly supported 3 outer arm index 16 at the ground controls side from the machine 49 Lower the cylinder onto the number 1 inner A CAUTION Bodily injury hazard The number 3 outer arm at the Component damage hazard ground controls side may Cables can be damaged if they become unbalanced and fall if are kinked or pinched not properly supported when removed from the machine 50 Attach a lifting strap from an overhead crane to the number 3 inner arm index 15 43 Attach a lifting strap from an overhead crane M to the number 3 outer arm index 16 at the 91 Remove the retaining fasteners from the battery pack side number 3 pivot pin index 6 at the steer end 44 Use a soft metal drift to remove the number 52 Use a soft metal drift to remove the number 3 center pivot pin index 4 at the battery 3 pivot pin index 6 Remove the number pack side of the machine 3 inner arm index 15 from the machine 45 Use a soft metal drift to tap the number 3 pivot CAUTION Bodily injury hazard The pin index 17 in the other direction Remove number 3 inner arm may the number 3 outer arm index 16 from the become unbalanced and fall if battery pack side of the machine not properly supported when removed from the machine CAUTION Bodily injury hazard The number 3
121. smart Link lt IP ADDRESS gt b 2012E prod 01 08 55 Feb 29 2012 Large Slab and 3232 Production 21 37 46 Nov 01 2012 ype GR SLAB 7 Read and record the IP address Run application Bootloader 17 10 28 Jun 01 2011 Load Fia Genie BRAND Part No 228901 GS 30 GS 32 GS 46 GS 47 69 Service Manual November 2014 Ground Controls 11 Select the Reprogram Device s button to Machine Application Mode start the ECM software update Result The following screen will be displayed after the software update is complete 1 Open the GCON compartment Note Some models will require opening the ground control box to access the GCON Note Do not turn off power while the ECM is being reprogrammed 2 Genie smart Link Home Help Build Time 21 37 46 Nov 01 2012 Summary Slab 2012N prod Bootloader 17 10 28 Jun 01 2011 12 Select the Run Application button to exit the software update mode 13 Push in the red Emergency Stop button and disconnect the CAT5 cable from the 14 Secure the diagnostic port cover using the retaining fasteners removed in step 5 Do not over tighten 15 Perform a function test Refer to the Operator s Manual on your machine 16 Return the machine to service Genie Turn the key switch to ground controls or platform controls and pull out the red Emergency
122. strap 6 Carefully remove the alarm from the platform control box Genie BRAND GS 30 GS 32 GS 46 GS 47 63 Service Manual November 2014 es si Platform Controls Disconnect the white wires from the 1 4 5 Platform Emergency Stop Button How to Remove the Platform Controls Emergency Stop Button 1 64 Push in the red Emergency Stop button to the off position at both the ground and platform controls Disconnect the platform controls from the control cable at the platform Remove the fasteners securing the platform control box to the platform control bracket Remove the fasteners securing the bottom cover to the platform control box Open the control box Genie GS 30 GS 32 GS 46 GS 47 AWARNING Emergency Stop base Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Component damage hazard Electrostatic discharge ESD can damage printed circuit board components Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap Carefully remove the Emergency Stop base from the Emergency Stop button Carefully remove the retaining ring from the Emergency Stop button Carefully remove the Emergency Stop button from the platform control box Part No 228901 November
123. the 65 Remove the cables from cable bridges f h i j k number 4 center pivot pin index 7 at the Spa battery side Component damage hazard Cables can be damaged if they are kinked or pinched Genie Part No 228901 BRAND GS 30 GS 32 GS 46 GS 47 173 Service Manual ss ss Scissor Components 66 67 68 69 70 A CAUTION 71 174 Attach a lifting strap from an overhead crane to the number 3 outer arm at the ground control side index 9 Remove the retaining fasteners from the number 3 center pivot pin index 10 at the ground control side Place a rod through the number 3 center pivot pin at the ground control side index 10 and twist to remove the pin Remove the retaining fasteners from the number 3 pivot pin index 29 at the non steer end Use a soft metal drift to remove the number 3 pivot pin index 29 from the non steer end of the machine Remove the number 3 outer arm at the ground control side index 9 from the machine Crushing hazard The number 3 outer arm at the ground control side index 9 may become unbalanced and fall if not properly supported when removed from the machine Attach a lifting strap from an overhead crane to the number 3 outer arm at the battery side index 9 72 CAUTION 73 74 75 CAUTION 76 Genie GS 30 GS 32 GS 46 GS 47 November 2014 Remove the number 3 outer arm index 9 from the ma
124. the electrical system Examples of these devices are platform controls and ground controls ECM Genie 216 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual Diagnostics Troubleshooting HXXX and PXXX Faults The procedure below illustrates typical steps for diagnosing and fixing faults of type HXXX and Diagnostic Chart No 1 Check the faulted device for a short or open circuit Good Replace faulted device gt Good V Check short or open circuit of the harness or Ne Repair or replace harness an or 2 Good connector between Ground Controls and faulted device 3 connector Good V No 3 Check GCON Electronic Control Module ECM Good Replace ECM gt Wiring Diagram The wiring diagram shown below illustrates how fault type HXXX and devices are typically wired The signal of these types of devices originates at the Ground Controls and terminates at system ground GCON Electronic Control Module ECM Signal Wire Signal Side Device Return Side Return Wire Vl In order to successfully troubleshoot HXXX PXXX type faults the entire faulted out circuit must be investigated Genie BRAND Part No 228901 GS 30 GS 32 GS 46 GS 47 217 Service Manual November 2014 Diagnostics Fault Inspection Procedure Check the device associated wit
125. the filter head Tag and disconnect the hydraulic pump inlet hard line and remove the hard line from the tank Cap the fitting on the pump Remove the hydraulic tank retaining fasteners and remove the hydraulic tank from the machine Drain all of the oil into a suitable container Refer to Section 2 Specifications for capacity information AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Clean up any oil that may have spilled Properly discard the used oil Clean the inside of the hydraulic tank using a mild solvent Allow the tank to dry completely Part No 228901 November 2014 Service Manual 9 Install the hydraulic tank and install and 13 tighten the hydraulic tank retaining fasteners Torque to specification Torque specifications Hydraulic tank retaining fasteners dry 35 in Ibs 4 Nm Hydraulic tank retaining fasteners 26 in Ibs lubricated 2 9 Nm 10 Install the hydraulic pump inlet hard line into the tank Install the fitting onto the pump and 14 torque to specification Refer to Section 2 Specifications 11 Install the hydraulic pump return hard line into the tank Install the fitting onto the hydraulic filter head and torque to specification Refer to Section 2 Specifications 12 Fill the tank with hydraulic oil until the fluid
126. the ground with the platform controls Do not stand in the platform Be sure the hydraulic oil level is at the FULL mark on the hydraulic tank 1 Locate the pressure selector relief valve on the pressure selector manifold schematic item DM 2 Connect a0 to 5000 psi 0 to 350 bar pressure gauge to the test port on the function manifold schematic item DA GS 32 GS 46 and GS 47 a test port b system relief valve C Steer relief valve d lift relief valve Genie BRAND GS 30 GS 32 GS 46 GS 47 101 Service Manual November 2014 Manifolds 3 Using a suitable lifting device place and secure the maximum rated load in the center of the platform deck Maximum load GS 4047 GS 4047 770 16 CE and AS models 350 kg GS 4047 550 16 ANSI and CSA models 250 kg 4 Remove the platform controls from the platform 5 the key switch to platform controls and pull out the red Emergency Stop button to the on position at both ground and platform controls 6 Press and hold the lift function enable button and the press the platform up button to raise the platform 4 ft 1 2 m above the stowed position Result The platform does not rise Perform steps 7 through 10 to increase the pressure in small increments until the platform rises Then proceed to step 12 Result The platform rises Perform steps 7 through 10 to decrease the pressure in small increments until the p
127. the malfunction affecting the operation of the machine should be fully understood to ensure Service Override mode is required surface and if equipped with the outriggers auto leveled or fully retracted A DANGER Tip over hazard Operating the machine on a surface that is not level while in Service Override mode will result in death or serious injury Follow proper operating procedures and safety precautions Do not use Service Override mode if you are not trained and familiar with the operation of the machine Turn the key switch to the ground controls position and pull out the red Emergency Stop button to the on position at the platform controls 2 Press and hold the ground control scroll up and scroll down buttons Ground Control Menu Buttons scroll down button enter button scroll up button escape button LCD display Genie BRAND GS 30 GS 32 GS 46 GS 47 75 226901 Service Manual November 2014 ee a a 7 Ground Controls 3 Pull out the red Emergency Stop button to the 6 Press the Enter button posto Result The ground controls LCD display will Result The ground controls LCD display will show an alternating message every show the following 1 5 seconds LIFT SETUP TEST t MAKE SURE THE SVC OVERRIDE MACHINE IS 4 Release the Scroll Up and Scroll Down buttons after t
128. the other fastener Do not remove it 1E a diagnostic port Connect one end of a CAT5 Ethernet cable into the diagnostic port Connect the other end into the ethernet port of the portable wireless router Result The ground controls LCD display will show the following OPEN WEB BROWSER IP ADDRESS GS 30 GS 32 GS 46 GS 47 73 Service Manual November 2014 Ground Controls 5 Read and record the IP address Note The display wil only show the IP address for 3 seconds Press the scroll up button to display the IP address for another 3 seconds ii 6 OnaPC laptop or mobile device set up a wireless network for the portable router Note Refer to the Operating System s procedure for connecting to a wireless network 7 After establishing a new wireless network select the appropriate network your portable wireless router Note Refer to the Operating System s procedure for connecting to a wireless network 8 Launch a web browser such as Internet Explorer amp Chrome or Firefox on your PC laptop or mobile device Type the IP address from step 5 into the web browser address bar and press enter Result The following screen will be displayed 9 Enter the following username and password then select OK Username smart link Password SL1000 Note The username and password are case sensitive Result The following screen
129. thin layer of oil to the new oil filter gasket 3 Install the new filter and tighten it securely by hand Genie 0 ___ Part No 228901 GS 30 GS 32 65 46 GS 47 53 Service Manual November 2014 Checklist E Procedures E 1 Test or Replace the Hydraulic Oil Genie requires that this procedure be performed every 2000 hours or every two years whichever comes first Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more often Refer to Section 2 Specifications Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test 1 Disconnect the battery pack from the machine AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 2 Open the power unit module tray 54 GS 30 65 32 GS 46 GS 47 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
130. tight approximately 30 in Ibs 3 4 Nm Using a permanent ink marker make a reference mark on one the flats of the hex nut and continue the mark onto the body of the hex fitting Refer to Illustration 1 put gt 5 Illustration 1 hex nut b reference mark body hex fitting 12 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual E a Specifications 3 Working clockwise on the body hex fitting make a second mark with a permanent ink marker to indicate the proper tightening position Refer to Illustration 2 Note Use the JIC 37 Fitting table in this section to determine the correct number of flats for the proper tightening position Note The marks indicate the correct tightening positions have been determined Use the second mark on the body hex fitting to properly tighten the joint after it has been loosened Illustration 2 a body hex fitting b reference mark C Second mark 4 Tighten the hex nut until the mark on the hex nut is aligned with the second mark on the body hex fitting 5 Operate all machine functions and inspect the hose fittings and related components to confirm there are no leaks Genie BRAND Part No 228901 GS 30 GS 32 GS 46 GS 47 13 Service Manual November 2014 Specifications SAE FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this ma
131. wear protective eye wear and is properly ventilated and well lit other protective clothing if the situation UNS warrants it Be aware of potential crushing hazards such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Genie BRAND GS 30 GS 32 GS 46 GS 47 vii November 2014 Table of Contents Introduction Introduction ii Important ii seriall Number Monna OM ort ii Revision FISTONY iii Serial Number Legend ihm egerit rg diga rad das V Section 1 Safety vi General Safety vi Section 2 Specifications EX A XAR EB e VERE Na SR 1 Machine Specifications 1 Performance Specifications models without proportional lift function 3 Performance Specifications models with proportional lift 5 Hydraulic eee nennen nemen 7 Hydraulic Component Specifications 9 Manifold Component 01 0 10 Hydraulic Hose and Fitting Torque
132. 0 5 mph 40 ft 55 sec 0 8 km h 12 2 m 55 sec Platform stowed slow Platform raised GS 4047 Platform stowed fast 2 0 mph 40 ft 13 7 sec 3 2 km h 12 2 13 7 sec Platform stowed slow 1 0 mph 40 ft 27 4 sec 1 6 km h 12 2 27 4 sec Platform raised Braking distance maximum High range on paved surface 0 5 mph 40 ft 55 sec 0 8 km h 12 2 55 sec 24 in 12 in 61 cm 30 cm Gradeability GS 1930 GS 1932 GS 2632 GS 3232 GS 3246 and GS 4047 GS 1530 GS 1532 GS 2032 GS 2046 and GS 2646 Airborne noise emissions Sound pressure level at ground workstation Sound pressure level at platform workstation 25 30 lt 70 dBA lt 70 dBA Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation Genie BRAND GS 30 GS 32 GS 46 GS 47 Part No 228901 Service Manual November 2014 Specifications Function speed maximum from platform controls with 1 person in platform GS 1530 and GS 1532 Platform Up full speed Platform down GS 1930 1930PAR and GS 1932 Platform Up full speed Platform down 15 to 17 seconds 18 to 25 seconds 15 to 17 seconds 18 to 25 seconds GS 2032 and GS 2632 Platform Up full speed Platform down GS 2046 and GS 2646 28 to 32 seconds 24 to 28 seconds Platform Up full sp
133. 014 Service Manual Electrical Schematic GS 3246 GS 4047 ANSI and CSA Models from serial number GS4612A 110000 and GS4715D 101 257 November 2014 Service Manual Electrical Schematic GS 3246 GS 4047 ANSI and CSA Models from serial number GS4612A 110000 and GS4715D 101 E i Bae oo Des tr Q me l 5 OFS 8201 Ud 8 595 ou iol 270 I Id Iv 2 1 t 1139 51 1 i r 1 FE mM 1 NVA 6 ME 195 lt 1 L 1 AHOSN3S 1 SS Lirica 8 8 rx lt l 4 m 2 9 9 Ket 1 a l D3 OAA d pis eS cc 8 H 42 14 9 i
134. 047 from serial number GS4612A 110000 and GS4715D 101 258 Gonio Part No 228901 GS 30 GS 32 GS 46 GS 47 XV November 2014 5 Table of Contents Electrical Schematics CE and Australia Models 261 GS 1530 1532 1930 1932 from serial number GS3010A 110000 to GS3011A 110827 262 GS 1530 1532 1930 1932 from serial number 3011 110828 from serial number 553011 10000 24222 266 GS 2032 and GS 2632 from serial number GS3211A 110000 from serial number 653212 10000 270 GS 3232 from serial number GS3211A 110000 from serial number 653212 10000 274 GS 2046 and GS 2646 from serial number GS4612A 110000 from serial number 654612 10000 278 GS 3246 from serial number GS4612A 110000 from serial number 654612 10000 282 GS 4047 from serial number 654712 101 286 Electrical Schematic Foot Switch option Models 289 Foot Switch option All Models from serial number GS3010A 110000 GS3011C 10000 GS3211A 110000 GS3212C 10000 GS4612A 110000 GS4612C 10000 and GS4712C 101
135. 047 only Press and hold the Menu Enter button to determine the maximum height The machine will lower for 1 2 seconds and then raise in 1 2 second durations until maximum height is reached When the platform reaches the maximum height a message will appear on the LCD screen to release the Menu Enter button If at any point the Menu Enter button is released before the message appears on the LCD screen the calibration procedure will restart at step 18 When prompted press and hold the Function Enable and Platform Down buttons The platform will lower then automatically stop at a predetermined point to gather data Allow the ground controls to gather data 21 November 2014 Continue pressing the Function Enable and Platform Down buttons throughout the lowering and data gathering sequence The machine will stop to gather data and lower several times before the machine reaches the stowed position When the platform reaches the stowed position press the enter button Note If the machine is switched to PCON mode to drive the machine to an area for weight removal step 3 and steps 5 through 14 will have to be repeated before Full Load Calibration Part 2 is performed Additionally the CO25 fault will appear This is expected and the data collected in Full Load Calibration Part 1 has not been lost 22 23 Using a suitable lifting device remove the test weight from the platform deck After the weight is removed from the pla
136. 1 2011 13 Select the Run Application button to exit the software update mode 14 Push in the red Emergency Stop button and disconnect the CAT5 cable from the GCON 15 Secure the diagnostic port cover using the retaining fasteners removed in step 5 Do not over tighten 16 Perform a function test Refer to the Operator s Manual on your machine 17 Return the machine to service Bootloader 17 10 28 Jun 01 2011 Load Flash File Genie 72 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual 2 4 Using a Wi Fi Router to Connect to the SmartLink Web Service Tool Note Before using a portable wireless router to connect to the Smart Link Service Tool web site the router must be configured to the type of connection desired Refer to the portable wireless router users manual for set up and configuration instructions 1 Open the GCON compartment Note Some models will require opening the ground control box to access the GCON 2 Turn the key switch to ground controls or platform controls and pull out the red Emergency Stop button to the on position at both ground and platform controls Result The display at the platform controls will show CH See example below EN 12 LH Part No 228901 Ground Controls Locate the diagnostic port on the side of the GCON Remove one of the fasteners securing the cover and set aside Loosen
137. 1 to 2 4 m 3 Liftthe safety arm move it to the center of the Scissor arm and rotate down to a vertical position Gri o 186 GS 30 65 32 GS 46 GS 47 Part No 228901 lift cylinder orifice schematic item O connector fitting hydraulic hose pressure transducer schematic item R if equipped manual lowering cable solenoid valve schematic item N cable mount bracket November 2014 Service Manual 4 Lower the platform onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 5 Using a suitable lifting device support the link stack at the steer end of the machine 6 Atthe ground controls turn the key switch to the off position and push in the red Emergency Stop button to the off position 7 Disconnect the battery pack from the machine A WARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 8 Tagand disconnect the wiring from the solenoid valve coil at the barrel end of the lift cylinder 9 If equipped tag and disconnect the three pin connector from the pressure transducer harness To remove the pressure transducer refer to Repair Procedure 9 9 How to Remove the Pressure Transducer if equipped 10 Loosen the adjustment nuts on the solenoid valve and disconnect the manual loweri
138. 10828 and GS3011C 10000 265 Service Manual November 2014 Electrical Schematic GS 1530 32 and GS 1930 32 CE and AUS Models from serial numbers GS3011A 110828 and GS3011C 10000 A G H J K L M N ___ 581 __ 1 1 1 gt X Hid dd rf FF Fi NOTE wil2 2 Ye lca PME 7 D woe abl 4 MACHINE SHOWN 3 2 3 TO cal ee ee eq IY Y YY 9 Yi IN THE STOWED onis Le 4 lv cT EM NL pa ae POSITION WITH rcu cu Tub nem tor LOW TEMPERATURE THE POWER OFF PBN 5 lt 5 mom moa T 29 eee NL IWH BK BKRD BN RD gt gt WH BK 5 pi 2 2 P1 _ EMERGENCY Nil NOT CONNECTED _ STOP KEY SWITCH 200 OHM d WITH LOW TEMPERATURE C43 10W 99 aay YN CUT QUTOPTION BK 22 223 OR RD 22 D E Ss gg gg i l i
139. 18 GR BK Genie BRAND Part No 228901 GS 30 GS 32 GS 46 GS 47 213 Service Manual November 2014 Diagnostics GCON I O Map with Load Sense GS 3232 only GCON Pin Number Circuit Function Type Wire Gauge and Color J1 Connector Gray J1 01 ECM Power Power Input 14 RD J1 02 PCON E Stop Power Power Output 18 RD J1 03 PCON E Stop Return Power Input 18 WH J1 04 Link to PCON CANH Data Bus 18GR J1 05 Link to PCON CANL Data Bus 18 OR J1 06 PCON Ground Ground Output 18 BR J1 07 GCON Ground Ground Input 14 BR J1 08 Key Switch PCON Mode Digital Input 18 BK J1 09 Key Switch GCON Mode Digital Input 18 WH J1 10 GCON Emergency Mode Digital Input 18 WH BK J1 11 No Circuit N A N A J1 12 Driver Power Power Input 14 RD J 2 Connector Black J2 01 Platform Up Coil Digital Output 18 OR J2 02 Platform Down Coil Digital Output 18 OR BK J2 03 Steer Left Coil Digital Output 18 BL BK J2 04 Steer Right Coil Digital Output 18 BL J2 05 Parallel Coil GS 32 GS 46 amp GS 47 Digital Output 18 RD WH J2 06 Drive Forward Coil Digital Output 18 WH J2 07 Ground GS 4047 Ground Input 18 BR J2 08 Motor Controller Enable Digital Output 18 GR WH J2 09 Lift Pressure Selector GS 4047 N A N A J2 10 Drive Reverse Coil Digital Output 18 WH BK J2 11 Motor Controller Throttle Analog Output 18 GR J2 12 No Circuit N A N A
140. 1C 12345 Model year 2011 Manufacture date 03 01 2011 Electrical schematic number ES0535 Machine unladen weight 3255 Ibs 1476 kg G S30 1 1 1 2345 Rated work load including occupants 500 Ibs 227 kg Maximum allowable inclination of the chassis a waa 1 5 Side 3 Front 3 Rear Model Sequence Outriggers retracted number N A Model year Outriggers deployed N A Gradeability 30 16 7 Outdoor rating Facility code Maximum allowable side force N A used only for model manufactured Maximum wind speed N A in multiple facilities Maximum number of platform occupants N A Indoor rating Maximum allowable side force 90 Ibs 400 Maximum wind speed 0 mph 0 m s Maximum number of platform occupants 2 Nominal Power Country of manufacture Manufacturer European Representative Genie Industries Genie UK LTD 18340 NE 76th Street The Maltings Redmond WA 98052 USA Wharf Road Grantham Lin NG31 6BH United Kingdom This machine complies with EN 280 S 77055 mmy Model Model year Facility code for models manufactured in multiple facilities Sequence number Serial label Serial number stamped on chassis 00 009 Genie BRAND Part No 228901 GS 30 GS 32 GS 46 GS 47 Service Manual November 2014 Safety Rules Danger Failure to obey the instructions and s
141. 2 13 14 15 16 17 18 19 20 Part No 228901 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both ground and platform controls Hold the lift relief valve with a wrench and remove the cap schematic item C AJ or DJ While activating the platform up function adjust the internal hex socket clockwise just until the platform fully rises Fully lower the platform to the stowed position Add an additional 50 pounds 22 7 kg to the platform Secure the additional weight Attempt to raise the platform Result The power unit should not be able to lift platform Result If the power unit lifts the platform adjust the internal hex nut socket counterclockwise until the platform will not rise Install the relief valve cap Remove the weight from the platform 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 Service Manual Manifolds How to Adjust the Lift Pressure Selector Valve GS 4047 only Note The System Relief Valve and Platform Lift Relief Valve must be adjusted before making an adjustment to the Lift Pressure Selector Valve Refer to How to Adjust the System Relief Valve and How to Adjust the Platform Lift Relief Valve in this section Perform this test from
142. 2 Specifications gt 2 7 models with proportional lift a drive steer function enable switch b drive speed select button c blue arrow d drive function button Genie BRAND Part No 228901 GS 30 GS 32 GS 46 GS 47 33 Service Manual November 2014 Checklist B Procedures B 10 Models with proportional lift Test the Drive Speed Platform 5 Press the lift function button Raised 6 Press and hold the function enable switch on the control handle 7 Move the control handle in the direction Genie requires that this procedure be performed indicated by the blue arrow on the control every 250 hours or quarterly whichever comes panel first All models Proper drive functions are essential to safe Raise the platform approximately 4 feet machine operation The drive function should 1 2 m from the ground respond quickly and smoothly to operator control Drive performance should also be free of hesitation 9 Choose point on the machine i e contact jerking and unusual noise over the entire patch of a tire as a visual reference for use proportionally controlled speed range when crossing the start and finish lines Note Perform this procedure with the machine on 10 Press the drive function button if equipped a firm level surface that is free of obstructions 1 Create start and finish lines by
143. 214 Genie BRAND GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual T E 2 Diagnostics GCON I O Map with Load Sense GS 3232 only continued GCON Pin Number Circuit Function Type Wire Gauge and Color J 3 Connector Green J3 01 No Circuit N A N A J3 02 GCON Alarm Digital Output 18 BL J3 03 Switch Sensor Power Digital Output 14 RD J3 04 Automotive Horn Digital Output 18 WH J3 05 Pothole Limit Switch Digital Input 18 OR RD J3 06 Ground Ground Input 18 GR J3 07 Down Limit Switch Digital Input 18 OR J3 08 Level Sensor Digital Input 18 RD BK J3 09 Platform Overload Pressure Transducer Ground Input 18 BL WH J3 10 Platform Height Sensor Ground Input 18 OR WH J3 11 No Circuit N A N A J3 12 Load Sense Ground Ground Input 18 BK J 4 Connector Brown J4 01 Left Front Pressure Transducer Analog Input 18 WH J4 02 Right Front Pressure Transducer Analog Input 18 OR J4 03 Left Rear Pressure Transducer Analog Input 18 BL J4 04 Right Rear Pressure Transducer Analog Input 18 GR J4 05 Lever Sensor X Axis Analog Input 18 OR J4 06 Lever Sensor Y Axis Analog Input 18 BR J4 07 Left Front Outrigger Coil Digital Output 18 RD WH J4 08 Right Front Outrigger Coil Digital Output 18 OR WH J4 09 Left Rear Outrigger Coil Digital Output 18 BL WH J4 10 Right Rear Outrigger Coil Digital Output 18 GR WH J4 11 Outr
144. 2632 GS 2046 GS 2646 and GS 3246 Result The voltage reading of the pressure transducer is between 1V and 5V The pressure transducer is functioning properly Result The voltage reading of the pressure transducer is between OV and 1V The pressure transducer is not functioning Checklist C Procedures 12 Remove the probes from the rubber boot of the pressure transducer cable Platform Height Sensor 13 Working at platform height sensor assembly follow the platform height sensor cable to its end point at the chassis deck 14 Using the positive post of a multimeter probe securely fit the post into pin C of the platform height sensor cable rubber boot Refer to the illustration below 15 Using the negative post of a multimeter probe securely fit the post into pin B of the platform height sensor cable rubber boot Refer to the illustration below properly Replace the pressure transducer Refer to Repair Procedure 9 9 How to Remove the Pressure Transducer if equipped GS 3232 and 65 4047 Result The voltage reading of the pressure transducer is between 0 2V and 6 25V The pressure transducer is functioning properly Result The voltage reading of the pressure transducer is between OV and 0 2V or greater than 6 25V The pressure transducer is not functioning properly Replace the pressure transducer Refer to Repair Procedure 9 9 How to Remove the Pressure Transducer if equipped 11 Atthe gro
145. 290 Hydraulic nennen nennen 291 Hydraulic Symbols Legend sse 291 Hydraulic Component Reference 292 Hydraulic Component Abbreviation Legend 293 1530 1532 1930 and 1932 from serial number GS3010A 110000 from serial number 6 3011 10000 seme 294 GS 2032 2632 3232 from serial number GS3211A 110000 from serial number GS3212C 10000 GS 2046 GS 2646 GS 3246 from serial number GS46124A 110000 from serial number 654612 10000 295 GS 3232 from serial number GS3211A 110000 from serial number 653212 10000 296 GS 4047 from serial number GS4712C 101 and 6 47150 101 297 Genie xvi GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual Machine Specifications Specifications Platform Overload Pressure Transducer if equipped All models except GS 3232 and GS 4047 Batteries Standard Input voltage 8 to 30 VDC All models except GS 4047 2 Signal voltage 1to5V Voltage 6V DC Platform Overload Pressure Transducer Group GC2 if equipped GS 3232 and GS
146. 4 Attach a lifting strap from an overhead crane to the lug of the rod end of the upper lift cylinder 75 Raise the lift cylinder to a vertical position 76 Remove the pin retaining fasteners from the lift cylinder barrel end pivot pin index 22 Remove the lift cylinder from the machine CAUTION Crushing hazard The lift cylinder 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 161 Service Manual es 7 Scissor Components 77 78 79 Attach a lifting strap from an overhead crane to the lug of the rod end of the lower lift cylinder Remove the retaining fasteners from the lower lift cylinder rod end pivot pin index 9 Use a soft metal drift to remove the lower lift cylinder rod end pivot pin index 9 from the machine A CAUTION Crushing hazard The lift cylinder will fall if not properly supported when the pivot pin is removed 80 Placea4x 4x 10 inch 10 x 10 x 25 cm block onto the number 1 inner arm cylinder plate index 14 84 A CAUTION 85 November 2014 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 inner arm index 23 may become unbalanced and fall if not properly supported when the piv
147. 4047 Type 1 15 Input voltage 8 to 30 VDC Quantity Signal voltage 0 25 to 6 25 V Battery capacity maximum C20 225AH Angle Sensor if equipped Reserve capacity 25A rate 447 minutes Input voltage 8 to 30 VDC Weight each 1 Signal voltage 3 to 4 V PMW output Batteries Standard GS 4047 Outrigger Pressure Transducer GS 3232 only Input volt 8 to 30 VDC Voltage Put volage BE Signal voltage 1to5V Group GC2 T T 1275 er ype For operational specifications refer to the Quantity Operator s Manual Battery capacity maximum C20 150AH Reserve capacity 25A rate 280 minutes Weight each 82 Ibs 37 kg Batteries Maintenance free option All models except GS 4047 Voltage 6V DC Group GC2 Type 6V AGM Quantity 4 Battery capacity maximum 200AH Reserve capacity 25A rate 380 minutes Weight each 62 Ibs 28 kg Genie Part No 228901 GS 30 GS 32 GS 46 GS 47 1 Service Manual November 2014 Specifications Fluid capacities Hydraulic tank All models except GS 4047 Hydraulic tank GS 4047 Hydraulic system including tank GS 3232 and GS 3246 Hydraulic system including tank GS 4047 Hydraulic system including tank All other models Tires and wheels 3 75 gallons GS 1530 GS 1532 GS 1930 GS 1932 14 2 liters size solid rubber 12 x 4 5 in 6 5 gallons 30 5 x 11 4 cm 24 6 liters Tire contact area 9 sq 2 5 gallons 58 cm 19 liters Castle nut torque dry 300
148. 47 H020 6530 H020 COILFAULT Open circuit in the drive reverse 1 t Short Siren drive reverse 1 Drive reverse GS32 DRIVE REV1 OPEN Drive reverse 1 coil open circuit function inhibited GS46 amp circuit GCON ECM unction inhibited GS47 H021 GS30 H021 COILFAULT Short circuit of the drive reverse 1 Short circuit in drive reverse 1 hamess A functions GS32 DRIVE REV1 BAT circuit to battery positive Drive reverse 1 coil short circuit inhibited except GS46 amp ECM platform down GS47 H027 0530 Hoez COILFAULT Short circuit of the steer right circuit Short circuit in steer right hamess All functions GS32 DRIVE STEER RIGHT BAT to battery positive Steer right coil short circuit inhibited except GS46 amp GCON ECM platform down GS47 H030 GS30 2 Short circuit in steer left harness All functions GS32 TBAT 2 steer left circuit Steer left coil short circuit inhibited except GS46 amp GCON platform down GS47 H033 3 Hi Lo speed coil GS30 H033 COILFAULT Short circuit of the hi lo speed coil Short circuit in Hi Lo speed coil hamess disabled Machine 6532 HI LO SPEED BAT to battery positive speed coll short circuit will operate in low GS46 amp d GCON ECM p GS47 speed mode Genie BRAND 220 GS 30 GS 32 GS 46 GS 47 Part No 228901
149. 5 lt 198 hi y _ 2 orn 2 5 1 Mitta Sst x 1 L olay QNO 81 v Ui ONS 51 eei 1 2 lt lt 2 esola qe m por a 8 EN 4 g eae 9 lt 4 Ss Ls 7 5 o lt S ues i 2 lt lt lt lt a Horoa HO o lt 5 00 u 3255 HM lt K bs l 2E cus lt gt 99 8 5 7100 T 2 27 5 38 2 5 M 5 98 A HOSN3S LL MS 3 10H10d Bun pron rv tae 8 21 8 n TTT 1 H 8 DIA 2 P Al Q 0 HWY 1102 T3 TTvuvd z cez4 5 8 a 8 8 Pel auto 2 OWON MS 3 10HLOd 1 6 855 82 6 MSquynOzlOHIOd ques BERE 897 ots t 4 ud 92535 gt 8 8 gt t 19 1100 us x gt 9 8 4 S s ua lt NO NYOH OLNY HM 4 lt 5 H 5 I A HOSN3S Qu c 1 14 470 WHY TW 18 e gt 1100 145743315 Fae ug tT 92 9 ua X lt gt 4 NT 3 Z Im ae i
150. 5 3232 97 5 8 Valve Adjustments Function 98 9 9 Valve 104 Genie xii GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Nh a a Table of Contents Steer Axle 2 2 4444 4 00000 107 6 1 Yoke and Drive 107 6 2 Steer Cylinder ids 109 6 3 Steer Bellcrank ideo e o t be iR 110 Non Steer Axle 4 44 4 111 7 1 Drive Brake cite ve iva c ce dev e ud ces 111 Brake Release Hand Pump Components sese 112 8 1 Brake Release Hand Pump Components 112 Scissor Components 04 1 52 tnnt tenen nn nnn 113 9 1 Scissor Assembly GS 1530 and 5 1532 114 9 2 Scissor Assembly 65 1930 and 5 1932 124 9 3 Scissor Assembly 65 2032 and 65 2046 20 135 9 4 Scissor Assembly GS 2632 and 65 2646 145 9 5 Scissor Assembly 65 3232 and 5 3246 sss 156 9 6 Scissor Assembly 55 4047 169 9 7 Platform Height
151. 51 Service Manual Scissor Components Attach a lifting strap from an overhead crane to the number 2 outer arm index 14 at the battery pack side Remove the external snap rings and retaining fasteners from the number 2 center pivot pin index 5 at the battery pack side 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 2 outer arm at the battery pack side may become unbalanced and fall if not properly supported when removed from the machine 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 2 outer arm at the battery pack side may become unbalanced and fall if not properly supported when removed from the machine Attach a lifting strap from an overhead crane to the number 2 inner arm index 13 Remove the retaining fasteners from the number 2 pivot pin index 6 at the steer end of the machine Service Manual es 7 Scissor Components 52 CAUTION 53 55 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 2 inner arm may become unbalanced and fall if not properly supported when removed from the machine Remove th
152. 569 Genie Sinapore Phone 65 67533544 Fax 65 67533544 Genie Japan Phone 81 3 6436 2020 Fax 81 3 5445 1231 Genie Korea Phone 82 2 558 7267 Fax 82 2 558 3910 Genie U K Phone 0044 1476 584 333 Fax 0044 1476 584 330 Genie Brasil Phone 55 11 4082 5600 Fax 55 22 4082 5630 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566
153. 8901 GS 30 GS 32 GS 46 GS 47 35 Service Manual November 2014 Checklist B Procedures B 11 Test the Drive Speed Platform Stowed Slow Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Proper drive functions are essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range Note 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 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 4 Press the drive speed select button until the low drive speed light is on 5 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the test line 6 Press the drive function button if equipped 7 Pressand hold the drive steer function enable switch on the control handle models with proportional lift a drive steer function enable switch b drive speed s
154. 9 2 9 5 8 a 852 e Ne 3 3 N x beg suiosHLOW 2 55 5 224 2 o0 8 5 5 gt es HWHD 1 PUES E 12595 x I r HM ul 7 5 oe m 25102 3 i 1 8 x EET 5 m 50 71 06 5 2 5 85128 958 8 871 LETS 5 25 200 x m 5 HM t 120 I lxog os Iq lt 1 1 or 1 1 Imr o a mF oj 1 T 1 1 1 1 1 1 1 1 1 1 2 lt E gt 9 a SHES 5 T8520 age Qe ELSE gt 92uE9 5 0 au m 8 f5 zk n HM gt 25 EE 8 a N e N Part No 228901 GS 30 GS 32 GS 46 GS 47 254 November 2014 Service Manual Electrical Schematic GS 2046 and GS 2646 ANSI and CSA Models from serial number GS4612A 110000 A C E F G H J K L M N E gt d __ 03 _ 1 lt 1 E PCON V OUT RD 1 1 RD PCON V OUT 1 1 PCON V OUT RD 2 2 RD lt H1 1 gt WH 2 4 21 EST
155. A WARNING will fall if not properly supported circuits could result in death or serious injury Remove all rings 12 Carefully lift the platform off of the machine watches and other jewelry and place it on a structure capable of supporting it Note Take notice of the wear pad position before the platform is removed Correct wear pad position is essential for proper platform functionality Genie BRAND Part No 228901 GS 30 GS 32 GS 46 GS 47 205 Service Manual ee se Platform Components 10 2 Platform Extension How to Remove the Platform Extension 1 Lower the platform to the stowed position 2 Extend the platform approximately 3 ft 1 m Remove the platform controls from the 1 platform 4 Support the platform extension with a forklift 2 at the steer end of the machine Do not apply any lifting pressure 3 5 Attach a strap from the platform extension railings to the carriage on the forklift to help support the platform extension 6 Remove the fasteners from each platform extension roller bracket assembly Remove each assembly from the machine Note Do not remove the platform roller bolt 206 a roller bracket assembly b assembly retaining fastener platform roller bolt Genie GS 30 GS 32 GS 46 GS 47 November 2014 Remove the platform roller wheels from the machine Carefully slide the platform extension out from the platform and place it on a stru
156. AAAA ous 220 Type PAAK entia Sar dere 224 Type UXXX Fault rete tte tiec deett rds 225 Type FAAK Faults i eR egi is 227 Type CXXX 230 Genie xiv GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 wee ee ee S Table of Contents Section 6 s Ca EN a eaa CE ao FR CEU 231 231 Electrical Component Wire Color LegendS 232 Wiring Diagram Ground and Platform 234 Limit Switch 235 Electrical Symbol 11 111 236 Electrical Schematics ANSI and CSA Models 237 GS 1530 32 and GS 1930 32 from serial number GS3010A 110000 to 3011 110827 238 GS 1530 1532 1930 1932 from serial number 653011 110828 242 65 2032 and GS 2632 from serial number 53211 110000 246 GS 3232 from serial number 653211 110000 250 GS 2046 GS 2646 from serial number 54612 110000 254 GS 3246 and GS 4
157. 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 DC GS 30 GS 32 GS 46 GS 47 39 Service Manual November 2014 Checklist B Procedures B 16 Test
158. An improperly functioning horn will prevent the operator from alerting ground personal of hazards or unsafe conditions 1 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 30 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual B 8 Test the Drive Brakes Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Proper brake action is essential to safe machine operation The drive brake function should operate smoothly free of hesitation jerking and unusual noise Hydraulically released individual wheel brakes can appear to operate normally when not fully operational Note Perform this procedure with the machine on a firm level surface that is free of obstructions Note Be sure the platform deck extension deck is fully retracted and the platform is in the stowed position 1 Mark a test line on the ground for reference 2 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls Lower the platform to the stowed position 4 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the test line 5 Press the dr
159. B Procedures Install the vent caps and neutralize any electrolyte that may have spilled All models except GS 4047 a batteries B5 b 275A fuse F6 quick disconnect QD1 Service Manual November 2014 Checklist B Procedures All models 13 Check each battery pack and verify that the batteries are wired correctly 14 Inspect the battery charger plug and pigtail for damage or excessive insulation wear Replace as required 15 Connect the battery charger to a properly grounded single phase AC power supply Result The charger should operate and begin charging the batteries If simultaneously the charger alarm sounds and the LEDs blink one time correct the charger connections at the fuse and battery The charger will then operate correctly and begin charging the batteries If simultaneously the charger alarm sounds and the LEDs blink two times the input voltage is too low or too high Correct the voltage issue The charger will then operate correctly and begin charging the batteries GS 4047 only If simultaneously the charger alarm sounds d batteries BS and the LEDs blink three times the charger is e 275A fuse F6 overheated Allow the charger to cool The f quick disconnect QD1 charger will then operate correctly and begin charging the batteries Note For best results use an extension cord of adequate size with a length no longer than 50 feet 15 m Note If you have any further ques
160. Castle Nut Torque 28 B 5 Test the Emergency 22 2 1 anran ANEA NNNNA 29 B 6 Test the Key Switch ii enne eed 30 7 Test the Automotive Style Horn if equipped 30 B 8 Test the Drive 1 31 B 9 Test the Drive Speed Platform Stowed 32 B 10 Test the Drive Speed Platform 34 B 11 Test the Drive Speed Platform Stowed SIOW 36 B 12 Perform Hydraulic Oil 37 B 13 Inspect the Hydraulic Tank Cap Venting 38 B 14 Check the Module Tray Latch 38 B 15 Inspect the Voltage Inverter if equipped 39 B 16 Test the Down Limit Switch Level Sensor and Pothole Limit Switches 40 B 17 Test the Up Limit Switch if equipped and Maximum Drive Height Limit Switches if 45 Genie X GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Table of Contents Checkli
161. D display Genie 60 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual 1 1 Circuit Board 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 Disconnect the platform controls from the control cable at the platform 3 Remove the fasteners securing the platform control box to the platform control bracket 4 Remove the fasteners securing the bottom cover to the platform control box Open the control box 5 Remove the ties securing the wire harness 6 Disconnect the red and black wires from the alarm 7 Carefully remove the alarm from the platform control box Platform Controls 8 Carefully disconnect all wire harness connectors from the platform controls circuit board A WARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Component damage hazard Electrostatic discharge ESD can damage printed circuit board components Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap 9 Carefully remove the platform controls circuit board fasteners 10 Carefully remove the platform controls circuit board from the platform control box 11 Remove the transparent caps fr
162. DER 95 3232 and GS 3246 MODELS LET 1 y 9 087 inch 0 94 0 gt 2500 psi maximum 172 bar maximum THE ORIFICE IS LOCATED UNDERNEATH THE PLUG OPPOSITE THE HOSE INLET OF THE LIFT CYLINDER LEFT j RIGHT BRAKE RELEASE BRAKE PRESSURE M 370 to 450 psi AUN 26 to 31 bar MANUAL VC RELEASE HF ine a by BRAKE RELEASE MANIFOLD gt me em el B1 STEER STEER LEFT RIGHT LEFT RIGHT 475CU IN DRIVE DRIVE P 78cc MOTOR MOTOR 4 0 25 gpm 0 95 Limin 11500 ps 0 75 1103 2 8 Limin AH 1 i 0 25 1800 to 3700 psi 0 95 L min 124 to 255 bar 1 1025 gpm 3700 psi 70 85 255 bar his INSTALLED ON VIA 4 4 98 3232 and 95 3246 MODELS WITH PLATFORM OVERLOAD INSTALLED POWER UNIT 18 Lmin 172 bar NOT CONNECTED 4 1 on 65 3232 95 3232 E NE 1 7 A L
163. G WHOA 1d bag xr 99 INO A 94 04 o EN INIT VIVO a INIT u56 s lt e gt 100 dN WHOS 1 14 5 30153 0 4 110 A 9 HWHO 3 THVN3 OW A 225 A 01901 W93 Qqu 1 gt 9 2 9 5 8 5 lt a 852 5 Ag gt 208 4 N x beg suiosHLOW 2 55 5 224 2 o0 8 5 5 gt es HWHD i E 12595 I r HM 1 e s d N T m T iac 250 2 3 i 1 8 i x 5 50 x a 21200 EIZ 5 sgt 19388 9 9 stsl a oz 25 200 x m 5 8 HM lou PET Iq lt 1 1 or 1 1 Imr o a mF oj 1 T 1 1 1 1 1 1 1 1 1 1 2 lt E gt 9 a SHES 5 T8520 age Qe ELSE gt 92uE9 5 0 au m 8 f5 zk n HM gt zz 25 EE 8 a N e N Part No 228901 GS 30 GS 32 GS 46 GS 47 246 November 2014 Service Manual Electrical Schematic GS 2032 and GS 2632 ANSI and CSA Models from serial number GS3211A 110000
164. GCON ECM platform down GS47 Genie BRAND Part No 228901 GS 30 GS 32 GS 46 GS 47 221 Service Manual eoo ESSE Diagnostics Type HXXX Faults continued November 2014 Message Problem Possible Failure Number GCON LCD Description Causes Mode H072 GS30 H072 FAULT Short circuit of the motor controller throttle Short circuit in motor controller throttle wire All functions GS32 MC THROTTLE BAT ircuit to batt iti Motor Controller inhibited except 6546 amp n d GCON ECM platform down GS47 Short or open circuit in left front outrigger H074 HO74 COILFAULT hie left outrigger circuit pers D ues e Left front outrigger 65 3232 LF RIGGER battery positive negative or Left front outrigger coil short circuit or open functions inhibited open circuit circuit GCON ECM Short or open circuit in left rear outrigger MES FIOTS COIERABET batie pien ahi outrigger coil short circuit or open Left rear outrigger GS 3232 LR RIGGER pos 9 iuh 99 functions inhibited open circuit circuit ECM Short or open circuit in right front outrigger H076 HO76 COILFAUET outrigger coil short circuit or open Right front outrigger GS 3232 RF RIGGER mede ee functions inhibited open circuit circuit GCON ECM Short or open circuit in right rear
165. GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual T E 2 Diagnostics I O Map without Load Sense 65 3232 only continued GCON Pin Number Circuit Function Type Wire Gauge and Color J 3 Connector Green J3 01 No Circuit N A N A J3 02 GCON Alarm Digital Output 18 BL J3 03 Switch Sensor Power Digital Output 14 RD J3 04 Automotive Horn Digital Output 18 WH J3 05 Pothole Limit Switch Digital Input 18 OR RD J3 06 Ground Ground Input 18 GR J3 07 Down Limit Switch Digital Input 18 OR J3 08 Level Sensor Digital Input 18 RD BK J3 09 Ground Ground Input 18 BK J3 10 Ground Ground Input 18 BK J3 11 No Circuit N A N A J3 12 Load Sense Ground Ground Input 18 BK J 4 Connector Brown J4 01 Left Front Pressure Transducer Analog Input 18 WH J4 02 Right Front Pressure Transducer Analog Input 18 OR J4 03 Left Rear Pressure Transducer Analog Input 18 BL J4 04 Right Rear Pressure Transducer Analog Input 18 GR J4 05 Lever Sensor X Axis Analog Input 18 OR J4 06 Lever Sensor Y Axis Analog Input 18 BR J4 07 Left Front Outrigger Coil Digital Output 18 RD WH J4 08 Right Front Outrigger Coil Digital Output 18 OR WH J4 09 Left Rear Outrigger Coil Digital Output 18 BL WH J4 10 Right Rear Outrigger Coil Digital Output 18 GR WH J4 11 Outrigger Extend Coil Digital Output 18 GR J4 12 Outrigger Retract Coil Digital Output
166. GS 32 GS 46 GS 47 145 Part No 228901 Service Manual ss si Scissor Components 12 13 14 15 16 Remove the plastic nut securing the squeeze connector to the large platform height sensor bracket Remove the squeeze connector from the large platform height sensor bracket Remove the fasteners securing the large platform height sensor bracket to the number 1 inner arm pivot bracket Remove the large platform height sensor bracket from the number 1 inner arm pivot bracket Install the fasteners removed in 14 to the number 1 inner arm pivot bracket and chassis Tip over hazard Failure to install the fasteners securing 17 18 19 20 146 the number 1 inner arm pivot bracket to the chassis could result in the machine tipping over causing death or serious injury Connect the battery pack to the machine Turn the key switch to ground controls Press and hold the ground control scroll up and scroll down buttons Pull out the red Emergency Stop button to the on position at the ground controls November 2014 21 Using the ground control menu buttons navigate to Service Override Mode Select Service Override Mode Note The machine must be in Service Override Mode to raise the platform While in Service Override Mode only the GCON will operate with limited functionality The platform will raise a predetermined amount of time and stop 22 Raise the platform and rotate the safet
167. Genie A TEREX BRAND Service Manual GS 1530 32 GS 1930 32 GS 2032 GS 2632 GS 3232 GS 2046 GS 2646 GS 3246 GS 4047 Serial Number Range from GS3010A 110000 from GS3011C 10000 from GS3010A 110000 from GS3011C 10000 from GS3211A 110000 from GS3212C 10000 from GS3211A 110000 from GS3212C 10000 from GS3211A 110000 from GS3212C 10000 from GS4612A 110000 from GS4612C 10000 from GS4612A 110000 from GS4612C 10000 from GS4612A 110000 from GS4612C 10000 from GS4712C 101 from GS4715D 101 Part No 228901 RevE November 2014 Service Manual November 2014 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 This manual provides detailed scheduled maintenance information for the machine owner and user It also provides troubleshooting and repair procedures for qualified service professionals Basic mechanical hydraulic and electrical skills are required to perform most procedures However several procedures require specialized skills tools lifting equipment and a suitable workshop In these instances we strongly recommend that maintenance and repair be performed at an authorized Genie dealer service center Compliance Machine Classification Group A Type 3 as defined by ISO 16368 Machine Design Life Unrestricted with proper operation insp
168. H White S7 Level Sensor WH BK White Black 8 Outrigger Level Sensor GS 3232 14 Platform Height Sensor YL Yellow U Electronic Component U3 PCON Printed Circuit Board 05 Electronic Control Module U6 Motor Controller U9 Battery Charger U13 Voltage Inverter option Y Valve Coil Y1 Parallel GS 32 GS 46 amp GS47 models Y2 Lift Pressure Selector GS 4047 Y3 Steer Right Y4 Steer Left Y5 Drive Reverse Y6 Drive Forward Y7 Platform Down Y8 Platform Up Y9 Platform Down GS 3232 amp GS 3246 Y33 Left Rear Outrigger GS 3232 Y34 Right Rear Outrigger GS 3232 Y35 Left Front Outrigger GS 3232 Y36 Right Front Outrigger GS 3232 Y39 Outrigger Retract GS 3232 Y40 Outrigger Extend GS 3232 Genie 233 Service Manual November 2014 Wiring Diagram Ground and Platform Controls BR AD TO COIL CORD BL 2 a JC9 JOYSTICK CONTROLLER R ee ee CB2 GROUND CONTROLS is rhe aT KEY SWITCH MOTOR CONTROLLER TERMINAL AD q B ECMLOGICV pp Jt ECM PIN 1 ECM DRIVER V AD Ji ECM PIN 12 P1
169. How to Calibrate the Platform Overload System if equipped 75 Raise the lift cylinder to a vertical position 76 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 ACAUTION Crushing hazard The lift cylinder will 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 Service Manual November 2014 Scissor Components 77 Place a4 x 4x 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 11 78 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 83 and remove the safety arm Lower the number 1 inner arm index 10 onto the block that was placed across the chassis CAUTION Bodily injury hazard Keep hands clear of moving parts CAUTION when lowering the scissor arms 79 Remove the cables from the number 1 cable bridge and lay them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched 80 Support and secure the entry ladder to an appropriate lifting device 81 Remove the fasteners from the entry ladder and remove
170. Hydraulic Pump 6 Tag disconnect and plug the high pressure hose from the pump Cap the fitting on the pump A WARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 7 Remove the hydraulic power unit from the machine 8 Remove the pump mounting bolts Carefully remove the pump ADANGER Tip over hazard After replacing Genie BRAND GS 30 GS 32 GS 46 GS 47 87 Part No 228901 the hydraulic pump it is critical to return the function speed settings to original factory specifications Failure to restore the machine to original factory specifications could cause the machine to tip over resulting in death or serious injury Service Manual sl Manifolds 5 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 November 2014 Index No Description Schematic Function Torque Coil Nut item F 4 5 ft lbs 5 7 Nm Coil Nut items E and H 5 7 ft lbs 7 9 Nm 1 Diagnostic nipple A Testing 2 Check disc B Steer circuit 18 ft Ibs 24 Nm 3 Relief valve 1800 to 3700 psi 124 to C Lift relief 20 ft lbs 27 Nm 255 bar 4 Check valve 10 psi 0 7 bar D Drive circuit 20 ft lbs 27 Nm 5 S
171. LLEL ACY eve eae Y6 Y5 DRIVE C13 DRIVE 015 m FORWARD REVERSE amp amp oS SSS SS gt H 12 I T e N 15 MANIFOLD V e i ES0535 F Genie A TEREX BRAND 270 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual Electrical Schematic GS 2032 GS 2632 and AUS Models from serial numbers GS3211A 110000 and GS3212C 10000 A B C D E F G H J K L M N G2 C3 1 gt l T ES X PCON V OUT RD 1 1 RD PCON V OUT 1 1 PCON V OUT RD 2 lt RD lt H1 1 gt 8 1 12 4 27 2 2 ESTOP 3 lt BK iL ALARM FROM C41 E gt _DATALINK BL 1 3 BL DATA LINK 3 lt lt 3 DATA LINK BL 4 gt E STOP WH X E gt DATA LINK OR 4 lt lt 4 OR DATA LINK 4 lt lt 4 DATA LINK OR 5 lt lt E STOP WH a PCON V OUT BR 5 lt lt 8 BR PON V OUT 5 5 PCON V QUT BR 6 1 P2 4 Sx EMERGENCY a 166 16 661 2 U3 PLATFORM CONTROLS PRINTED CIRCUIT BOARD 2 em JOYSTICK AXIS 1 d 1 gt STEER SWITCH 3 Um PLATFORM 5
172. N IN THE STOWED POSITION WITH THE POWER OFF 110V 240V AC POWER TO PLATFORM AC INPUT _ 993 _ _ 9016 _ ERN 5 1 1 GR 1 1 L env OUTLET 2 gt 2 2 2 BK 3 3 w 3 3 pr a d _ _ GND VH Ground 6 OUTLET BOX STUD i 7 8 ES0534 Genie BRAND Part No 228901 GS 30 GS 32 GS 46 GS 47 259 Service Manual November 2014 Electrical Schematic GS 3246 GS 4047 ANSI and CSA Models from serial number GS4612A 110000 and GS4715D 101 260 November 2014 Service Manual Electrical Schematic GS 1530 32 and GS 1930 32 CE and AUS Models from serial number GS3010A 110000 to GS3011A 110827 261 Service Manual November 2014 Electrical Schematic GS 1530 32 and GS 1930 32 CE and AUS Models from serial number GS3010A 110000 to GS3011A 110827
173. NPUT _ 258 _ ODIS 5 1 gt gt 1 GR 1 gt gt 1 GR YL OUTLET 2 2 22 3 3 WH 4 3 8 BL L _ L e Ground 6 QUTLET BOX STUD 7 8 ES0535 F Genie BRAND Part No 228901 GS 30 GS 32 GS 46 GS 47 279 Service Manual November 2014 es Electrical Schematic 65 2046 65 2646 AUS Models from serial numbers GS4612A 110000 GS4612C 10000 280 November 2014 Service Manual Electrical Schematic GS 3246 CE and AUS Models from serial numbers GS4612A 110000 and GS4612C 10000 281 November 2014 Service Manual Electrical Schematic GS 3246 CE and AUS Models from serial numbers GS4612A 110000 and GS4612C 10000 PS L Tec wea 5 al o 15 lt u n 4 gt G
174. OARD IN THE STOWED PLATFORM POSITION WITH THE POWER OFF CONTROLLER gt JOYSTICK AXIS 1 YL 41 with FOOT SWITCH x2 JCS gt __ SWITCH BK43 JOYSTICK 5 DRIVE ENABLE COM YL 44 CONTROLLER gt DRIVE ENABLE WH15 2077 _ gt STEER LEFT BL 6 FS _ SIEEH RIGHT anat 5 JOYSTICK 5VDC RD48 FS NC WH B lt B YL FS NG FS NO RD G c GR Fs NO TS TONER T wm 5 JOYSTICK GND BK 10 xn gt CHASSIS GND BK412 L C102 RD FS POWER BK 1 1 L 8k FS POWER La BK FS NC WH 2 2 WH FS NC oF FS NO RD 735 8 RD FS NO FOOT 5 4 SWITCH a ye eee 80534 F ES0535F ES0538B and 50541 Genie A TEREX BRAND 290 GS 30 55 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual Hydraulic Symbols Legend Y8 Hydraulic cylinder Variable speed motor Pressure transducer Solenoid operated 2 position 4 way directional valve S l v ee Yi Relief valve Bi directional motor Solenoid operated Solenoid operated 2 position
175. OP 2 lt 2 ESTOP WH 8 lt 8 BK lt 5 1 ALARM FROM C41E 1 DATA LINK BL 3 lt lt 3 BL DATA LINK 3 lt lt DATA LINK BL 4 lt 4 E STOP WH k DATA LINK OR 4 lt lt OR DATA LINK 4 lt lt 4 DATA LINK OR 5 5 E STOP WH x V OUT BR 5 lt lt 54 BR PCON V OUT lt lt 5 PCON V OUT BR 6 lt lt 6 1 P2 6 lt 6 076 6 F DEMERGENOY DE B 2 U3 PLATFORM CONTROLS PRINTED CIRCUIT BOARD 2 JOYSTICK AXIS 1 YL 41 gt 2 EN1 gt STEER SWITCH 3 TK PLATFORM gt DRIVE ENABLEGCOM YL74 CONTROLLER CONTROLLER X DRIVE ENABLE WH45 X STEER LEFT BL 6 STEER RIGHT GR47 JOYSTICK 5VDC RD 8 3 x9 gt JOYSTICK GND 10 411 gt CHASSIS GND 12 5 4 MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF 110V 240V AC POWER TO PLATFORM AC INPUT _ 9980 _ _ 9016 5 NES 1 1 GR 14 OUTLET 2 gt 2 2 2 BK 3 3 w 3 3 pr a d _ _ GND VH Ground 6 OUTLET BOX STUD i 7 8 ES0534 Genie BRAND Part No 228901 GS 30 GS 32 GS 46 GS 47 255 Service Manual November 2014 Electrical Schematic GS 2046 and GS 2646 ANSI and CSA Models from serial number GS4612A 1 10000 256 November 2
176. Output 18 BL BK J2 04 Steer Right Coil Digital Output 18 BL J2 05 Parallel Coil GS 32 amp GS 46 Digital Output 18 RD WH J2 06 Drive Forward Coil Digital Output 18 WH J2 07 No Circuit N A N A J2 08 Motor Controller Enable Digital Output 18 GR WH J2 09 No Circuit N A N A J2 10 Drive Reverse Coil Digital Output 18 WH BK J2 11 Motor Controller Throttle Analog Output 18 GR J2 12 No Circuit N A N A J 3 Connector Green J3 01 No Circuit N A N A J3 02 GCON Alarm Digital Output 18 BL J3 03 Switch Sensor Power Digital Output 14 RD J3 04 Automotive Horn Digital Output 18 WH J3 05 Pothole Limit Switch Digital Input 18 OR RD J3 06 Ground Ground Input 18 BR J3 07 Down Limit Switch Digital Input 18 OR J3 08 Level Sensor Digital Input 18 RD BK J3 09 Ground Ground Input 18 BK J3 10 Ground Ground Input 18 BK J3 11 No Circuit N A N A J3 12 Load Sense Ground Ground Input 18 BK 210 Genie BRAND GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual Diagnostics GCON I O Map with Load Sense all model except GS 3232 GCON Pin Number Circuit Function Type Wire Gauge and Color J1 Connector Gray J1 01 ECM Power Power Input 14RD J1 02 PCON E Stop Power Power Output 18 RD J1 03 PCON E Stop Return Power Input 18 WH J1 04 Link to PCON CANH Data Bus 18GR J1 05 Lin
177. Procedure 9 10 How to Calibrate the Platform Overload System if equipped 71 Raise the lift cylinder to a vertical position 72 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 ACAUTION Crushing hazard The lift 73 74 75 76 77 cylinder 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 Remove the cables from the number 1 cable bridge and lay them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched Disconnect the number 1 cable bridge from the number 1 outer arm index 17 and remove the cable bridge from the machine Attach a lifting strap from an overhead crane to the number 1 inner arm index 8 Raise the arm slightly and remove the block Lower the arm to the stowed position ACAUTION Bodily injury hazard Keep lt 140 GS 30 GS 32 GS 46 GS 47 Part No 228901 hands clear of moving parts when lowering the scissor arms November 2014 78 79 80 81 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
178. S POTHOLE 9 Disable the down limit switch Loosen the fastener securing the roller arm to the limit GUARDS STUCK switch and rotate the roller arm 90 degrees in a downwards direction Do not activate the LCD displ switch contacts epiey 10 Turn the key switch to platform control FA F7 11 Raise the platform and return the safety arm to the stowed position 12 Working at the platform controls press the lift function select button Lower the platform to the stowed position LED display Result The ground controls LCD displays PHS POTHOLE GUARDS STUCK and the 13 Press and hold the drive steer function enable platform controls LED displays PHS The switch on the control handle Attempt to drive alarm sounds and the lift function operates and steer the machine The machine is functioning properly Result The ground controls LCD displays Refer to the Operation Indicator Codes below PHS POTHOLE GUARDS STUCK and the Result The ground controls LCD does not platform controls LED displays PHS The display PHS POTHOLE GUARDS STUCK alarm sounds and the drive and steer and the platform controls LED does not functions do not operate The machine is display PHS The alarm does not sound and functioning properly the lift function does not operate Replace the Bi Result The ground controls LCD does not down limit switch display PHS POTHOLE GUARDS STUCK and the platform contr
179. S 30 GS 32 GS 46 GS 47 105 Service Manual November 2014 SS es Manifolds Note Dotted lines in illustration indicate a reversed connection as specified in step 6 5 Momentarily connect the positive lead from the multimeter to the positive terminal on the 9V battery Note and record the 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 current readings are greater than 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 Gri 1 1 11 106 GS 30 65 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual 6 1 Yoke and Drive Motor How to Remove the Yoke and Drive Motor Assembly Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Block the non steer tires 2 Remove the cotter from the wheel castle nut Note Always replace the cotter pin with a new one when removing the castle nut 3 Loosen the wheel castle nut Do not remove it 4 Center a lifting jack under the drive cha
180. S32 GS46 amp GS47 C004 GCON ECM FAULT TYPE 4 GCON ECM master switch error Short circuit in the master switch circuit GCON ECM All functions inhibited C005 GS30 GS32 GS46 amp GS47 C005 GCOM ECM FAULT TYPE 5 GCON ECM safety switch error Short circuit in the safety switch circuit GCON ECM All functions inhibited C006 GS30 GS32 GS46 amp GS47 C006 GCON ECM FAULT TYPE 6 GCON input redundancy error Input conditioning circuit failure GCON ECM All functions C007 GS30 GS32 GS46 amp GS47 C007 GCON ECM FAULT TYPE 7 GCON EOM inter processor communication error Incorrectly programmed device Error in loading software device GCON ECM All functions C009 GS30 GS32 GS46 amp GS47 C009 GCON ECM FAULT FAULT TYPE 9 GCON fault type 9 Contact Genie support C021 GS30 GS32 GS46 amp GS47 C021 PCON DETECTED PCON not detected error PCON is missing Communication bus failure GCON or PCON ECM C023 GS30 GS32 GS46 amp GS47 C023 MACHINE MODEL FAULT Discrepancy between model detected and model programmed Incorrect machine model programmed GCON or PCON ECM C024 GS30 6532 6546 amp GS47 C024 PARAMETER PROGRAM FAULT Discrepancy between model detected and model programmed Incorrect machine model programmed GCON or PCON
181. SD 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 7 Carefully remove the joystick fasteners Carefully remove the joystick from the platform control box Torque specifications 9 in Ibs 1 Nm Joystick fasteners Genie 62 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual 1 3 Platform Controls Alarm Platform Controls 5 Disconnect the red and black wires from the alarm AWARNING How to Remove the Platform Controls Alarm 1 Pushin the red Emergency Stop button to the off position at both the ground and platform controls 2 Disconnect the platform controls from the control cable at the platform 3 Remove the fasteners securing the platform control box to the platform control bracket 4 Remove the fasteners securing the bottom cover to the platform control box Open the control box Part No 228901 Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Component damage hazard Electrostatic discharge ESD can damage printed circuit board components Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist
182. SOR v 1 PLATFORM UP COIL 2 OR BK PLATFORM DOWN COIL WH 5 3 BL BK STEER LEFT COIL CB2 4 BL STEER RIGHT COIL 7A 5 CIRCUIT CIRCUIT 6 WH DRIVE FORWARD COIL __ _ gt Nor RD QR WH MOTOR CONTROLLER ENABLE coNNEeTED 10 WH BK DRIVE REVERSE COIL a 11 5 11 GR MOTOR CONTROLER THROTTLE v6 14 yal C16 G18 12 x U13 SE MOTOR DRIVE STEER PLATFORM 6 FORWARD LEFT DOWN pe OK eS SSS Sa 2 BK GRMH x A X azy U6 RD Lf L4 Ld MOTOR GR FUSE CONTROLLER rome _ M te GRH C13 C15 5 Y8 U9 DRIVE STEER PLATFORM REVERSE RIGHT uP 7 CHARGER ct ct m v 25 Lt Lt Ly NOT CONNECTED WITH MOTOR CONTROLLER CUT OFF POWER OPTION SI ba t BR rs BR BR BLACK AND WHITE WIRES CUT POWER I BR p MOTOR CONTROLLER WHEN THE BR BK 8 CHARGERS PLUGGED IN OPTION MANIFOLD V BR Eu BR SENSOR V BR RD 200 RD 1 ES0534 B Genie A TEREX BRAND 238 GS 30 GS 32 GS 46 GS 47 Part No 228901 ES0534 B A B C D November 2014 Service Manual Electrical Schematic GS 1530 32 and GS 1930 32 ANSI and CSA Models from serial number GS3010 110000 to GS3011A 110827 E F G H J K
183. T Short circuit of the GCON alarm circuito Short circuit in GCON alarm harness GCON alarm GS32 GCON ALARM BAT batt ti GCON alarm short circuit inhibited GS46 amp sj attery negative GCON ECM inhibited GS47 P009 13520 P009 DEVICEFAULT Short circuit of the GCON alarm circuit to in alarm namess GCON alarm 6532 GCON ALARM BAT battery positive OCON alarm short circuit inhibited 6546 8 2 GCON ECM gt 6547 P013 CE P013 PWR FAULT Short circuit of the PCON power return circuit Short circuit in PCON power return harness All functions GS46 PWRET BAT to battery negative ECM inhibited GS47 015 5 P015 PWR FAULT Short circuit of the PCON power return circuit Short circuit in PCON power return harness All functions GS46 8 PCON PWRET BAT to battery positive GCON inhibited GS47 P018 Ee 018 PWR FAULT Short circuit of the PCON power circuit to Short circuit in PCON power harness All functions PCON POWER BAT battery negative GCON ECM inhibited GS46 amp GS47 P019 2 018 PWR FAULT Short circuit of the PCON power circuit to Short circuit in PCON power harness All functions 6546 8 PCON POWER BAT battery positive ECM inhibited GS47 Part No 228901 November 2014 Service Manual 1 Diagnostics Faults
184. TING ON THE LEFT RIGHT ZN 4 75 CU DRIVE DRIVE LIFT CYLINDER P P 78 MOTOR MOTOR 4 lt oN S id 5 i L 51 2 as 4 Ya X P gt 0 25 _ 0 95 Limin n T 11500 psi 108 bar 0 75 gpm b 2 8 TP TN MV MEE 0 25 gpm 1800 to 3700 psi 0 95 Limin 124 to 255 bar Te 0 25 3700 psi 0 85 L min 255 bar 200 pst 13 8 bar _ 4 7 A 10 MICRON WITH 25 psi 1 7 bar 4 gpm 2500 psi POWER UNIT 15 Limin 172 bar BYPASS J HYDRAULIC TANK HS0035K Genie BRAND 294 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual Hydraulic Schematics GS 2032 2632 3232 from serial number GS3211A 110000 and GS3212C 10000 GS 2046 2646 3246 from serial number GS4612A 110000 and GS4612C 10000 1 LIFT CYLINDER PM ALL MODELS 2 AUS MODELS s oN e 0 037 inch qm i 0 94 mm Y7 TRANSDUCER 2 0 059 inch THE ORIFICE IS LOCATED y 1 5mm UNDERNEATH THE HOSE 0 FITTING ON THE LIFT CYLINDER Nue 1 UPPER LIFT CYLIN
185. a xea RH CN o CONTROL O roek o lt clwitsie I 4 DE MODULE BH _ 2 BR WH gt BR 2 zea eam GCON Tex SENSOR V EI B3 BLWH gt BL ORMWH WH BK BK PLATFORM UP COIL OR BK PLATFORM DOWN COIL OR 5 BL BK STEER LEFT COIL CB2 BL STEER RIGHT COIL 7A CIRCUIT oix WH DRIVE FORWARD COIL __ Oss mh MOTOR CONTROLLER ENABLE PET uo CONNECTED Y Y Y ee WH BK DRIVE REVERSE COIL C14 C16 L ul GR MOTOR CONTROLER THROTTLE 013 RO ae PLATFORM Ves S14 sic 6 DG AC INVERTER FORWARD DOWN PLATFORM r3 r3 HEIGHT Ex Em Lie Lie ous c aoa mn GR WH A4 C13 C15 C17 C24 IY Y5 Y3 Y8 ULE DRIVE STEER PLATFORM gai REVERSE RIGHT 7 1 1 Ct PT5 Msie A X A X X PLATFORM HO Lt Lf Lt OVERLOAD CONNECTED WITH MOTOR CONTROLLER CUT OFF POWER OPTION C12 ul DLE gt A BR 1 E BR BLACK AND WHITE WIRES CUT BR MOTOR CONTROLLER MOTOR CONTROLLER WHEN THE BR 8 POWER CUT OFF OPTION CHARGER IS PLUGGED IN OPTION 1 SSS 4 MANIFOLD V BR BR SENSOR V BR RD 200 RD D1 R30 200 Q 10 50535 262 Genie A TEREX BRAND GS 30 GS 32 GS 46 GS 47 Part No 228901 FROM C49 0535 B A B C D E November 2014 Service Manua
186. achine the Full Load Calibration procedure is required to maintain rated load platform capacity If a No Load Calibration is performed machine lifting performance will be significantly reduced Note Ambient temperature must be above 32 F 0 C before calibrating the Platform Overload System Note To calibrate the platform overload system follow the menu structure indicated on the ground control LCD display Genie 198 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual 4 4 74 Scissor Components Full Load Calibration Part 1 5 Turnthe key switch to ground control 1 Fully charge the batteries and check the 6 Atthe ground controls press and hold the hydraulic fluid level Menu Up and Menu Down buttons Note The hydraulic fluid level must be between 7 While pressing both buttons down pull out the the FULL and ADD marks on the hydraulic tank red Emergency Stop Button 2 Apply a thin layer of dry film lubricant to the 8 Release the Menu Up and Menu Down area of the chassis and platform where the buttons after the ground controller powers up ke contact Sassa afm Wear padsma 9 Use the Menu Up or Menu Down buttons to 3 Chock both sides of the wheels at the steer scroll to Select Option Press the Enter end of the machine button 4 Using a suitable lifting device place a test 10 Use the Menu Up or Menu Down buttons to weight corresponding to the machine scroll to Platform Overload
187. acing the scissor assembly the platform overload system must be calibrated Refer to Repair Procedure 9 10 How to Calibrate the Platform Overload System if equipped 85 Raise the lift cylinder to a vertical position 86 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 CAUTION Crushing hazard The lift cylinder 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 8 Remove the cables from the number 1 cable bridge and lay them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched 88 Disconnect the number 1 cable bridge from the number 1 outer arm index 22 and remove the cable bridge from the machine 89 Attach a lifting strap from an overhead crane to the number 1 inner arm index 10 90 Raise the arm slightly and remove the block Genie BRAND GS 30 GS 32 GS 46 GS 47 151 Service Manual November 2014 Scissor Components 91 Lower the arm to the stowed position ACAUTION Bodily injury hazard Keep hands 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
188. act with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Genie 152 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 a se 10 11 12 13 14 15 16 Remove the fasteners securing the platform height sensor cover to the large platform height sensor bracket Remove the platform height sensor cover Tag and disconnect the platform height sensor from the platform height sensor harness Remove the fastener securing the platform height sensor assembly to the number 1 inner arm Remove the platform height sensor assembly from the number 1 pivot pin Remove the plastic nut securing the squeeze connector to the large platform height sensor bracket Remove the squeeze connector from the large platform height sensor bracket Remove the fasteners securing the large platform height sensor bracket to the number 1 inner arm pivot bracket Remove the large platform height sensor bracket from the number 1 inner arm pivot bracket Install the fasteners removed in 14 to the number 1 inner arm pivot bracket and chassis NNa hazard Failure to install the fasteners securing Part No 228901 the number 1 inner arm pivot bracket to the chassis could result in the machine tipping over causing death or serious injury Service Manual Scissor Components 17 Connect the battery pack to the mac
189. afety rules in this manual and the appropriate Operator s Manual on your machine will result in death or serious injury Many of the hazards identified in the operator s manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless You are trained and qualified to perform maintenance on this machine You read understand and obey e manufacturer s instructions and safety rules e employer s safety rules and worksite regulations e applicable governmental regulations MI You have the appropriate tools lifting equipment and a suitable workshop Gri 1 1 1 vi GS 30 65 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual 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 A Read each procedure thoroughly This manual and the decals on the machine use signal words to identify the following Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death A DANGER Indicates a imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Indicates a potentially hazardous situation which if not avoided could result in
190. and scroll down buttons 20 Pull out the red Emergency Stop button to the on position at the ground controls 21 Using the ground control menu buttons navigate to Service Override Mode Select Service Override Mode Cable bridge and platform height sensor cable bridge 5 cable bridge 4A cable bridge 4B cable bridge 3A cable bridge 3B cable bridge 2A cable bridge 2B cable bridge 1 platform height sensor Note The machine must be in Service Override Mode to raise the platform While in Service Override Mode only the GCON will operate with limited functionality The platform will raise a predetermined amount of time and stop 2507000099 Genie BRAND Part No 228901 GS 30 GS 32 GS 46 GS 47 157 Service Manual es 7 Scissor Components 24 25 26 Remove the platform See 10 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 will fall if not properly supported and secured to the lifting device 27 Remove the cables from the number 5 cable 28 29 30 31 32 158 bridge and lay them off to the side Disconnect the number 4 cable bridge from the number 5 outer arm index 17 and remove the cable bridge from the machine Remove the retaining fasteners from the number 6 pivot pin inde
191. are SAE O ring Boss Port tube fitting installed into Aluminum all types SAE Dash Size Torque installed Seal Lok Fittings hose end ORFS 4 14 ft lbs 19 Nm 6 23 ft lbs 31 2 Nm 8 36 ft lbs 54 2 Nm 10 62 ft lbs 84 Nm 12 84 ft lbs 114 Nm 16 125 ft Ibs 169 5 Nm 20 151 ft Ibs 204 7 Nm 24 184 ft lbs 249 5 Nm SAE Dash Size Torque 4 10 ft lbs 13 6 Nm 6 30 ft lbs 40 7 Nm 8 40 ft lbs 54 2 Nm 10 60 ft lbs 81 3 Nm 12 85 ft lbs 115 Nm 16 110 ft Ibs 150 Nm 20 140 ft Ibs 190 Nm 24 180 ft lbs 245 Nm JIC 37 Fittings swivel nut or hose connection Adjustable Fitting a jam nut Non adjustable fitting SAE O ring Boss Port tube fitting installed into Steel SAE Dash Size Torque SAE Dash Size Thread Size Flats 4 7 16 20 2 6 9 16 18 1 8 3 4 16 1 10 7 8 14 1 12 1 1 16 12 1 16 1 5 16 12 1 20 1 5 8 12 1 24 1 7 8 12 1 Gen BRAND GS 30 GS 32 GS 46 GS 47 Part No 228901 4 ORFS 37 Adj 15 ft lbs 20 3 Nm ORFS Non adj 26 ft lbs 35 3 Nm 37 Non adj 22 ft lbs 30 Nm 6 ORFS Adj Non adj 35 ftlbs 47 5 Nm 37 Adj Non adj 29 ft lbs
192. arm index 18 that was just removed Attach a lifting strap from an overhead crane to the number 1 inner arm index 10 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 ACAUTION Bodily injury hazard Keep 71 Part No 228901 hands clear of moving parts when lowering the scissor arms onto the safety arm 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 1 m Genie 0 GS 30 GS 32 GS 46 GS 47 129 Service Manual Scissor Components 72 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 73 Tag and disconnect the wires and manual lowering cable from the solenoid valve on the cylinder 74 Models with platform overload option Tag and disconnect the wire harness from the platform overload pressure transducer Note After replacing the scissor assembly the platform overload system must be calibrated Refer to Repair Procedure 9 10
193. arm at the A CAUTION ground control side index 14 may become unbalanced and fall if not properly supported when the pivot pin is removed 55 Attach a lifting strap from an overhead crane to the number 2 outer arm at the battery side index 14 56 Remove the retaining fasteners from the number 2 center pivot pin index 5 at the battery side 57 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 CAUTION 2 outer arm index 14 may become unbalanced and fall if not properly supported when the pivot pin is removed 58 Remove the number 2 outer arm index 14 from the machine Crushing hazard The number CAUTION 2 outer arm index 14 may become unbalanced and fall if not properly supported when removed from the machine 59 60 61 Scissor Components Attach a lifting strap from an overhead crane to the number 2 inner arm index 13 Raise the arm to a vertical position Remove the retaining fasteners from the number 2 pivot pin at the steer end of the machine index 6 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 CAUTION Crushing hazard The number 62 63 65 2 inner arm index 13 may become unbalanced and fall if not properly supported when the pivot pin is removed At
194. arm cross tube b fork lift tube c wear pad Genie 52 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual D 2 Replace the Hydraulic Tank Return Filter Element Genie requires that this procedure be performed every 1000 hours or annually whichever comes first Replacement of the hydraulic tank return filter is essential for good machine performance and service life A dirty or clogged filter may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter be replaced Checklist D Procedures 4 Use a permanent ink marker to write the date and number of hours from the hour meter onto the filter 5 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 6 Activate and hold the platform up toggle Switch 7 nspectthe filter and related components to be sure that there are no leaks 8 Clean up any oil that may have spilled Torque specifications Hydraulic drain plug dry 40 in Ibs more often 4 5 Nm A CAUTION Beware of hot oil Contact with Hydraulic drain plug lubricated 30 in Ibs hot oil may cause severe burns 3 4 Nm Note The hydraulic tank return filter is mounted on the function manifold next to the hydraulic power unit 1 Clean the area around the oil filter Remove the filter with an oil filter wrench 2 Applya
195. arm to the limit switch and rotate the roller arm 90 degrees in a upwards direction Do not activate the switch contacts Turn the key switch to platform control Raise the platform and return the safety arm to the stowed position Lower the platform to the stowed position Level Sensor 27 28 Gri 1 1 1 1 42 GS 30 65 32 GS 46 GS 47 Part No 228901 Move the machine onto a grade which exceeds the rating of the level sensor Refer to the serial label on the machine Standing on the up hill side of the machine press and hold the high or low speed lift enable button November 2014 Service Manual TTT 8 a a ea _ Checklist B Procedures 29 Press the platform up button and attempt to 30 Standing on the up hill side of the machine Part No 228901 raise the platform to approximately 8 feet 2 4 m Result The ground controls LCD displays press and hold the drive steer function enable Switch on the control handle Attempt to drive and steer the machine LL MACHINE TILTED and the platform Result The ground controls LCD displays controls LED displays LL The alarm sounds LL MACHINE TILTED and the platform and the platform stops lifting after the pothole controls LED displays LL The alarm sounds guards are deployed The machine is and the machine will not steer or drive The functioning properly Refer to the Operation machine is functioning properly Result The groun
196. assis 117 Remove the linkset from the machine ACAUTION Bodily injury hazard The number 1 inner and outer arms index 14 and 29 may become unbalanced and fall if not properly supported when removed from the machine Component damage hazard Be sure not to damage the limit switch or level sensor components when the number 1 inner and outer arms index 14 and 29 are removed from the machine Gen BRAND Scissor Components How to Replace the Scissor Arm Wear Pads Note Machines equipped with a Platform Height Sensor begin at step 1 Machines without a Platform Height Sensor begin at step 24 1 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 Raise the platform 7 to 8 feet 2 1 to 2 4 Lift the safety arm move it to the center of the scissor arm and rotate down to a vertical position Lower the platform onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform At the ground control turn the key switch to the off position and push in the red Emergency Stop button to the off position Disconnect the battery pack from the machine AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Part No 228901 GS 30
197. atform 3 Turn the key switch to platform controls and pull out the red Emergency Stop button to the on position at both ground and platform controls Ground Controls 4 Raise the platform 7 to 8 feet 2 1 to 2 4 m Lift the safety arm move it to the center of the scissor arm and rotate down to a vertical position 6 Lower the platform onto the safety arm A WARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform If you are not installing a new level sensor proceed to step 15 7 the key switch to the off position and push in the red Emergency Stop button to the off position at the ground controls 8 Tagand disconnect the level sensor wire harness from the chassis wire harness Note The wire harness connection is located next to the level sensor on top of the chassis at the steer end of the machine 9 Remove the level sensor retaining fasteners and remove the level sensor from the machine 10 Tagand disconnect the level sensor wires from the level sensor connector plug 11 Securely install the wires of the new level sensor into the level sensor connector plug Genie BRAND GS 30 GS 32 GS 46 GS 47 77 Part No 228901 Service Manual November 2014 Ground Controls 12 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 o
198. ble from the valve Note During assembly the manual platform lowering cable needs to be properly adjusted See 2 7 How to Adjust the Manual Platform Lowering Cable 11 Remove the fasteners securing the manual lowering cable mount bracket to the cylinder Remove the bracket from the cylinder 12 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 13 Attach a lifting strap from an overhead crane to the rod end of the lift cylinder for support 14 Remove the fasteners from the lift cylinder rod end pivot pin Use a soft metal drift to remove the pin ACAUTION Crushing hazard The lift cylinder will fall if not properly supported when the pivot pin is removed 15 Lower the cylinder onto the number 2 inner arm 16 Attach a lifting strap from an overhead crane or similar lifting device to the barrel end of the lift cylinder for support Genie 184 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual 17 Remove the fasteners from the lift cylinder barrel end pivot pin Use a soft metal drift to remove the pin ACAUTION C ushing hazard The lift cylinder will fall if not properly supported when the pivot pin is removed
199. cal position Remove the retaining fasteners from the number 2 pivot pin at the steer end of the machine index 14 Use a soft metal drift to remove the number 2 pivot pin index 14 from the steer end of the machine Remove the number 2 inner arm index 30 from the machine Crushing hazard The number 2 inner arm index 30 may become unbalanced and fall if not properly supported when the pivot pin is removed Attach a lifting strap from an overhead crane to the number 1 inner arm index 16 100 Raise the number 1 inner arm index 16 approximately 2 feet 60 cm 101 Placea4 x4 x48 inch 10 cm x 10 cm x LLL 176 GS 30 GS 32 GS 46 GS 47 1 2 m long block across both sides of the chassis under the number 1 center pivot pin index 15 Part No 228901 November 2014 Service Manual 102 Lower the scissor arms onto the block that was placed across the chassis ACAUTION Bodily injury hazard Keep hands clear of moving parts when lowering the scissor arms 103 Attach a lifting strap from an overhead crane to the lug of the rod end of the lower lift cylinder 104 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
200. ced and fall if not properly supported when removed from the machine Genie GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 4 4 74 40 Attach lifting strap from an overhead crane Service Manual Scissor Components h 45 Remove the cables from the number 4A and to the number 5 index 16 Raise 4B cable bridges and lay them off to the side the arm to a vertical position m Component damage hazard 41 Remove the retaining fasteners from the Cables can be damaged if they number 5 pivot pin at the steer end of the are kinked or pinched machine index 4 42 Use a soft metal drift to remove the number 46 Disconnect the number 4A and 4B cable 5 pivot pin index 18 from the steer end of bridges from the scissor linkset and remove the machine Remove the number 5 inner arm both cable bridges from the machine gee meening 47 Attach a lifting strap from an overhead crane Crushing hazard The number to the lug of the rod end of the upper lift CAUTION 5 inner arm index 16 may cylinder become unbalanced and fall if 48 Remove the retaining fasteners from the not properly supported when upper lift cylinder rod end pivot pin index 3 removed from the machine 49 Use a soft metal drift to remove the upper lift 43 disconnect and plug the hydraulic hose cylinder rod end pivot pin index 3 from the on the upper lift cylinder Cap the fittings on machine the cylinder
201. chine Crushing hazard The number 3 outer arm index 9 may become unbalanced and fall if not properly supported when removed from the machine Attach a lifting strap from an overhead crane to the number 3 inner arm index 28 Raise the number 3 inner arm and place a 4 x 4 x 48 inch 10 cm x 10 cm x 1 2 m block across the link stack to gain access to the barrel end pivot pin index 27 Attach a lifting strap from an overhead crane to the lug of the rod end of the upper lift cylinder Raise the lift cylinder to a vertical position Crushing hazard The lift cylinder 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 Use a soft metal drift to remove the upper lift cylinder barrel end pivot pin index 27 from the machine Part No 228901 November 2014 77 78 79 80 81 CAUTION 82 83 CAUTION Part No 228901 Attach a lifting strap from an overhead crane to the number 3 inner arm index 28 Raise the number 3 inner arm and remove the 4 x 4 x 48 inch 10 cm x 10 cm x 1 2 m block from the link stack Lower the number 3 inner arm index 28 and remove the lifting strap Attach a lifting strap from an overhead crane to the lug of the rod end of the lower lift cylinder Remove the retaining fasteners from the lower lift
202. chine push the arm of the maximum drive height limit switch towards the steer end of the machine to activate the limit switch Result The platform stops rising The machine is functioning properly Result The platform continues to rise Adjust or replace the maximum drive height limit switch Note Repeat this procedure for the maximum drive height limit switch at ground controls side of the machine 7 Return the safety arm to the stowed position 8 Lower the platform to the stowed position and turn off the machine Genie BRAND GS 30 GS 32 GS 46 GS 47 45 Part No 228901 Service Manual November 2014 Checklist Procedures C 1 4 Lower the platform onto the safety arm Test the Platform Overload AWARNING Crushing hazard Keep hands Pressure Transducer and ae Me owering the platform Platform Height Sensor if j equipped 5 At the ground control turn the key switch to the off position and push in the red Emergency Stop button to the off position Genie requires that this procedure be performed Pressure Transducer every 500 hours or six months whichever comes 6 Working at the barrel end of the lift cylinder ii Min the machine fails to lift the maximum follow the pressure transducer cable down the rated load scissor stack to its end point at the chassis Testing the platform overload pressure transducer deck and platform height sensor regularly is essential to 7 Using the
203. cles 9 Connect the outrigger level sensor wire harness to the new outrigger level sensor 10 Close the access door at the battery side of the machine 11 Calibrate the new outrigger level sensor Refer to Section 2 8 How to Calibrate the Outrigger System Genie BRAND Part No 228901 GS 30 GS 32 GS 46 GS 47 81 Service Manual November 2014 Ground Controls 5 Measure the distance between the base of the Skip to step 8 if the measurement is handle and cable mounting nut correct Result The measurement should be no 6 To adjust loosen the upper lock nut on the greater than 0 125 inch 3 mm 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 Note Proceed to step 8 if measurement is correct Platform manual lowering cable specification Gap lowering handle to mounting 0 to 0 125 inch nut 0to3mm a manual lowering cable sheath upper lock nut cable mounting bracket lower lock nut cable mounting nut end of lowering cable manual lowering valve hydraulic schematic item N aro 1 1 1 82 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual 7 Repeat this procedure beginning with step 4 Raise the platform and rotate the safety arm to
204. connect the manual lowering cable from the valve Note During assembly the manual platform lowering cable needs to be properly adjusted See 2 7 How to Adjust the Manual Platform Lowering Cable 11 Remove the fasteners securing the manual lowering cable mount bracket to the cylinder Remove the bracket from the cylinder 12 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 13 Attach a lifting strap from an overhead crane or similar lifting device to the barrel end of the lift cylinder for support 14 Remove the fasteners from the lift cylinder rod end pivot pin Use a soft metal drift to remove the pin 9 If equipped tag and disconnect the three pin ACAUTION Crushing hazard The lift connector from the pressure transducer cylinder will fall if not properly harness To remove the pressure transducer supported when the pivot pin is refer to Repair Procedure 9 9 How to removed Remove the Pressure Transducer if equipped Genie 190 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual 15 Lower the cylinder onto the number 1 inner arm cylinder plate 16 Attach a lifting strap from an overhead crane or similar lifting device t
205. ctor 4 Locate the electrical contactor mounted on the fuse bracket 5 Visually inspect the contact points of the contactor for the following items e Excessive burns e Excessive arcs e Excessive pitting A WARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Note Replace the contactor if any damage is found B 4 Inspect the Tires and Wheels including castle nut torque Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the tires and wheels in good condition is essential to safe operation and good performance Tire and or wheel failure could result in a machine tip over Component damage may also result if problems are not discovered and repaired in a timely fashion 1 Check the tire surface and sidewalls for cuts cracks punctures and unusual wear 2 Check each wheel for damage bends cracks 3 Remove the cotter pin and check the castle nut for proper torque Refer to Section 2 Specifications Note Always replace the cotter pin with a new one when removing the castle nut or when checking the torque of the castle nut 4 Install a new cotter pin Bend the cotter pin to lock in place Genie 28 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual B 5 Test the Emergency Stop Genie
206. cture capable of supporting it How to Replace the Platform Extension Wear Pads Remove the Platform Extension See 10 2 How to Remove the Platform Extension Drill out the rivets which hold the wear pads in place Install the new wear pads using new rivets When installing the new rivets make sure the rivet heads are not above the surface of the wear pad Part No 228901 November 2014 Service Manual Observe and Obey V Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine V Immediately tag and remove from service a damaged or malfunctioning machine V Repair any machine damage or malfunction before operating the machine Unless otherwise specified perform each repair procedure with the machine in the following configuration e Machine parked on a firm level surface e Platform in the stowed position e Key switch in the off position with the key removed e The red Emergency Stop button in the off position at both ground and platform controls e Wheels chocked All external AC power supply disconnected from the machine Diagnostics 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 Vl Read each appropriate fault code tho
207. cylinder AF Relief valve brake circuit DM Relief valve Iii AG Drive forward reverse DN Flow regulator relive valve DE Flatformlowering valve Al Platform up AJ Relief valve lift AK Check valve lift GS 3232 and GS 3246 equipped with load sense only Part No 228901 Genie BRAND GS 30 GS 32 GS 46 GS 47 293 Service Manual November 2014 Hydraulic Schematics Hydraulic Schematic GS 1530 1532 1930 1932 from serial number GS3010A 110000 and GS3011C 10000 LEFT RIGHT LIFT CYLINDER ALL MODELS BRAKE RELEASE BRAKE PRESSURE 370 to 450 psi 2 26 to 31 bar gt MANUAL t PLATFORM N RELEASE OVERLOAD 0 037 inch A CE amp AUS MODELS 0 94 mm Cv HAND ni WO T PUMP T Wy 7 d 1 0 TOR 1 RELEASE NES R C 0 037 inch PRESSURE L4 TRANSDUCER THE ORIFICE 1 LOCATED L UNDERNEATH THE STEER STEER LEFT RIGHT HOSE FIT
208. cylinder will fall if not properly supported when the pivot pin is removed 18 Support and secure the lift cylinder to an appropriate lifting device 19 Remove the lift cylinder through the scissor arms at the steer end of the machine ACAUTION Crushing hazard The lift cylinder will 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 20 Install new cylinder fittings hoses and pressure transducer if equipped Torque specifications 21 Remove the lifting device supporting the link stack at the steer end of the machine 22 Connect the battery pack to the machine 23 Turn the key switch to ground control Models without a pressure transducer continue at step 27 Models with a pressure transducer continue at step 24 24 Press and hold the ground control scroll up and scroll down buttons 25 Pull out the red Emergency Stop button to the on position at the ground controls 26 Using the ground control menu buttons navigate to Service Override Mode Select Service Override Mode Note The machine must be in Service Override Mode to raise the platform While in Service Override Mode only the GCON will operate with limited functionality The platform will raise a predetermined amount of time and stop 27 Raise the platform and rotate the safety arm
209. d 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 A WARNING 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 c Inspect the following areas for burnt chafed corroded pinched and loose wires e Scissor arms ECM to platform controls e 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 Service Manual November 2014 Checklist B Procedures B 3 Inspect the Electrical Contactor Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the electrical contactor in good condition is essential to safe machine performance Failure to locate a worn or damaged contactor could result in unsafe operating conditions and may cause component damage 1 Atthe ground controls turn the key switch to the off position 2 Pushin the ground controls red Emergency Stop button to the off position 3 Open the battery tray and disconnect the Anderson conne
210. d chassis 71744 hazard Failure to install the fasteners securing the number 1 inner arm pivot bracket to the chassis could result in the machine tipping over causing death or serious injury Connect the battery pack to the machine Turn the key switch to ground controls Press and hold the ground control scroll up and scroll down buttons Pull out the red Emergency Stop button to the on position at the ground controls 21 November 2014 Using the ground control menu buttons navigate to Service Override Mode Select Service Override Mode Note The machine must be in Service Override Mode to raise the platform While in Service Override Mode only the GCON will operate with limited functionality The platform will raise a predetermined amount of time and stop 22 23 Genie GS 30 GS 32 GS 46 GS 47 Raise the platform and rotate the safety arm to the stowed position Fully lower the platform to the stowed position 665 2032 05 2046 Cable bridge and platform height sensor cable bridge 3 cable bridge 2A cable bridge 2B cable bridge 1 platform height sensor Part No 228901 November 2014 a se 24 25 26 Remove the platform See 10 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
211. d controls LCD does Result The ground controls LCD does not display LL MACHINE TILTED and the display LL MACHINE TILTED and the platform controls LED does not display LL platform controls LED does not display LL The alarm does not sound and the steer and The alarm does not sound and the platform drive functions operate Adjust or replace the continues to lift after the pothole guards are level sensor mC Shon epee 31 Lower the platform to the stowed position LL MACHINE TILTED LCD display w G LED display Move the machine onto a firm level surface Pothole Limit Switches 32 33 Genie BRAND GS 30 GS 32 GS 46 GS 47 43 Place a wooden block approximately 2 inches 5 cm tall under the right pothole guard Press and hold the high or low speed lift enable button Service Manual Checklist Procedures 34 44 Press the platform up button and attempt to raise the platform to approximately 8 feet 2 4m Result The pothole guard contacts the block and does not fully deploy The ground controls LCD displays PHS POTHOLE GUARDS STUCK and the platform controls LED displays PHS The alarm sounds and the platform will lift to 8 feet 2 4 m or beyond The machine is functioning properly Refer to the Operation Indicator Codes below Result The pothole guard contacts
212. d from the machine Component damage hazard Be sure not to damage the limit switch or level sensor components when the number 1 inner arm is removed from the machine Service Manual Scissor Components How to Replace the Scissor Arm Wear Pads Note Machines equipped with a Platform Height Sensor begin at step 1 Machines without a Platform Height Sensor begin at step 24 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 Raise the platform 7 to 8 feet 2 1 to 2 4 m Lift the safety arm move it to the center of the scissor arm and rotate down to a vertical position 4 Lower the platform onto the safety arm A WARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 5 At the ground control turn the key switch to the off position and push in the red Emergency Stop button to the off position 6 Disconnect the battery pack from the machine A WARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Genie BRAND GS 30 GS 32 GS 46 GS 47 131 Service Manual ss si Scissor Components 10 11 12 13 14 15 16 Remove the fasteners securing the platform height sensor cover to the large platform height sensor bracket Remove the plat
213. d of the bellcrank Note While removing the retaining fasteners take note of the quantity and location of the spacers between the bellcrank and the steer links 3 Center a lifting jack under the drive chassis at the steer end of the machine 4 Raisethe machine approximately 14 inches 36 cm Place blocks under the chassis for support a apply Loctite to fastener threads Note While removing the bellcrank from the machine take note of the quantity and location of the spacers between the bellcrank and the steer links A WARNING Crushing hazard The chassis will fall if not properly supported Note Before re installing the steer bellcrank onto the machine apply a small amount of Loctite onto the threads of the fasteners Torque the fasteners to 31 ft lbs 42 Nm Qai 1 1 1 1 1 110 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual 7 1 Drive Brake How to Remove the Drive Brake Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications 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 A CAUTION Crushing hazard The entry ladder will fall if not properly supp
214. de Mode only the GCON will operate with limited functionality The platform will raise a predetermined amount of time and stop 22 Raise the platform and return the safety arm to the stowed position 23 Fully lower the platform to the stowed position 24 Remove the platform See 10 1 How to Remove the Platform 25 Support and secure the entry ladder to an appropriate lifting device 26 Remove the fasteners from the entry ladder and remove the entry ladder from the machine ACAUTION Crushing hazard The entry ladder will fall if not properly supported and secured to the lifting device Genie GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 27 28 29 30 31 32 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 Remove the scissor assembly from the machine just enough to access both wear pads ADANGER Crushing hazard The scissor assembly will fall if not
215. death or serious injury ACAUTION Indicates a potentially hazardous Part No 228901 situation which if not avoided may cause minor or moderate injury Safety Rules Workplace 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 Be sure to keep sparks flames and lighted tobacco away from flammable and combustible materials like battery gases and engine fuels Always have an approved fire extinguisher within easy reach Be sure that all tools and working areas N are properly maintained and ready for use Keep work surfaces clean and free of debris that could get into machine components and cause damage 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 sure to properly dispose of old oil or Indicates a potentially hazardous 2 other fluids Use an approved container situation which if not avoided Please be environmentally safe may result in property damage Be sure that your workshop or work area Be sure to
216. ded Hydraulic Fluid Hydraulic oil type Chevron Rando HD Premium Viscosity grade 32 Viscosity index 200 Optional Hydraulic Fluids Shell Tellus S2 V 32 Shell Tellus S2 V 46 Chevron 5606A Petro Canada Environ MV 46 UCON Hydrolube HP 5046 Mineral based Biodegradable Fire resistant Note Genie specifications require additional equipment and special installation instructions for the approved optional fluids Consult Genie Product Support before use Optional fluids may not have the same hydraulic lifespan and may result in component damage Note Extended machine operation can cause the hydraulic fluid temperature to increase beyond it s maximum allowable range If the hydraulic fluid temperature consistently exceeds 200 F 90 C an optional oil cooler may be required Specifications Do not top off with incompatible hydraulic fluids Hydraulic fluids may be incompatible due to the differences in base additive chemistry When incompatible fluids are mixed insoluble materials may form and deposit in the hydraulic system plugging hydraulic lines filters control valves and may result in component damage Note Do not operate the machine when the ambient air temperature is consistently above 120 F 49 C Hydraulic Fluid Temperature Range 40 22 4 40 30 20 10 0 14 32 50 68 86 104 122
217. draulic oil can penetrate and Note When removing a hose assembly or fitting burn skin Loosen hydraulic the O ring if equipped on the fitting and or hose connections very slowly to allow end must be replaced All connections must be the oil pressure to dissipate torqued to specification during installation Refer to gradually Do not allow oil to Specifications Hydraulic Hose and Fitting Torque squirt or spray Specifications Component damage hazard 1 Block the non steer tires Hoses can be damaged if they kinked inched 2 Remove the pin retaining fasteners from the eet rod end pivot pin Remove the pivot pin Note While removing the pin retaining fasteners take note of the quantity and location of the spacers when removing the pivot pin 3 Remove the pin retaining fasteners from the barrel end pivot pin Remove the pin Note While removing the pin retaining fasteners take note of the quantity and location of the spacers when removing the pivot pin Genie _ _ 0 0 0 0 Part No 228901 GS 30 GS 32 65 46 GS 47 109 Service Manual November 2014 Steer Axle Components 6 3 5 Turn the yokes to the side so the bellcrank Steer Bellcrank can be removed 6 Remove the bellcrank from the machine How to Remove the 47 Steer Bellcrank Remove the Steer Cylinder dA AV 7 ovs 1 Remove the steer cylinder See 6 2 How to 75 2 Remove the retaining fasteners from the steer links at each en
218. e Result If the resistance is not within the adjusted specification plus or minus 10 replace the coil Genie 104 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual Valve Coil Resistance Specifications Note The following coil resistance specifications are at an ambient temperature of 68 F 20 C As valve coil resistance is sensitive to changes in air temperature the coil resistance will typically increase or decrease by 4 for each 18 F 7 7 C that your air temperature increases or decreases from 68 F 20 C Description Specification Solenoid valve 3 position 4 way 27 20 20V DC with diode schematic item F AC or DC Solenoid valve 3 position 4 way 190 20V DC with diode schematic item E Solenoid valve 2 position 4 way 190 20 DC with diode schematic H Al or Dl Solenoid valve 2 position 2 way N C 250 20V DC with diode schematic item N Solenoid valve 2 position 4 way 190 20V DC with diode schematic item AE or DE Solenoid valve 3 position 5 way 190 20V DC with diode schematic item AG or DG Solenoid vale 2 position 2 way 27 20 20V DC with diode schematic item CA CB CC and CD Solenoid valve 3 position 4 way 190 20V DC with diode schematic item BA Manifolds Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches a
219. e 61 Remove the number 4 outer arm index 25 number 4 center pivot pin index 7 at the from the machine ground control side ACAUTION Crushing hazard The number 55 Place a rod through the number 4 center pivot 4 outer arm index 25 may pin at the ground control side index 7 and become unbalanced and fall if twist to remove the pin not properly supported when 56 Remove the retaining fasteners from the mom tie machine p PICO ep aue 62 Attach a lifting strap from an overhead crane to the number 4 inner arm index 24 Raise 57 Use a soft metal drift to remove the number the arm to a vertical position in rd 428 Feuer 6 Remove the retaining fasteners from the arm at the ground control side index 25 pivot BITE from the machine machine index 8 64 Use a soft metal drift to remove the number A CAUTION Crushing hazard The number 4 pivot pin index 8 from the steer end of the 4 outer arm at the ground control machine Remove the number 4 inner arm SIC Index es become index 24 from the machine unbalanced and fall if not properly supported when Crushing hazard The number removed from the machine A CAUTION 4 inner arm index 24 may become unbalanced and fall if 58 Attach a lifting strap from an overhead crane not properly supported when to the number 4 outer arm at the battery side removed from the machine index 25 59 Remove the retaining fasteners from
220. e GCON I O Map in this section to identify the faulted out circuit pin Short to ground resistance should be greater than 5k For short to B type faults measure resistance between pins J1 12 driver power and the GCON pin associated with the fault code Refer to the in this section to identify the faulted out circuit pin Short to power resistance should be greater than 50k Replace GCON ECM Genie BRAND Part No 228901 GS 30 GS 32 GS 46 GS 47 219 Service Manual November 2014 eoo ESSE ts Diagnostics Type HXXX Faults DTC Message on Problem Possible Failure Number GCON LCD Description Causes Mode H001 GS30 H001 COILFAULT Short circuit of the platform up 1 Short circuit in p at om up 1 harness Platform up function GS32 PLAT UP4 BAT ircuit to batt ti Platform up 1 coil short circuit inhibited GS46 amp 8 circuit to battery negative ECM inhibited GS47 H002 GS30 H002 COILFAULT Open circuit in the platform up 1 Short circuit in p al orm up 1 harness Platform up function GS32 PLAT UP1 OPEN circui Platform up 1 coil open circuit inhibited GS46 amp ECM 6547 H003 GS30 Short circu
221. e approximately 2 inches 5 cm Place blocks under the chassis for support Steer End Non steer end limit switch level sensor mount bracket level sensor S7 alarm H5 level sensor retaining fasteners scissor chassis Part 228901 November 2014 4 74 22 23 24 25 26 27 28 228901 GS 1530 65 1930 Place a 0 64 x 6 x 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 GS 2632 and GS 3232 Place a 0 66 x 6 x 6 inch 16 8 mm x 15 cm x 15 cm thick steel block under both wheels at the ground controls side of the machine GS 2046 GS 2646 GS 3246 and GS 4047 Place 1 x 6 6 inch 25 4 mm x 15 cm x 15 cm thick steel block under both wheels at the ground controls side of the machine Lower the machine onto the blocks Raise the platform 7 to 8 feet 2 1 to 2 4 m Result The level sensor alarm should not sound Result The level sensor alarm does sound and fault code LL appears in the diagnostic display Adjust the level sensor retaining fasteners just until the level sensor alarm does not sound Lower the platform to the stowed position
222. e hazardous conditions Repair Procedures Machine Configuration Unless otherwise specified perform each repair procedure with the machine in the following configuration Genie BRAND GS 30 GS 32 GS 46 GS 47 Machine parked on a firm level surface 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 Platform in the stowed position 57 Service Manual November 2014 Repair Procedures About This Section Symbols Legend Most of the procedures in this section should only Safety alert symbol used to alert be performed by trained service professional in a personnel to potential personal suitably equipped workshop Select the injury hazards Obey all safety appropriate repair procedure after troubleshooting the problem messages that follow this symbol to avoid possible injury or death Perform disassembly procedures to the point ADANGER Indicates a imminently hazardous where repairs can be completed Then to re assemble perform the disassembly steps in reverse order situation which if not avoided will result in death or serious injury A WARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a potentially hazardous m Gen
223. e safety arm from the number 2 inner arm index 13 that was just removed Attach a lifting strap from an overhead crane to the number 1 inner arm index 8 Raise the number 1 inner arm index 8 approximately 2 feet 60 cm and install the safety arm between the number 1 inner arm index 8 and the number 1 outer arm index 17 Lower the scissor arms onto the safety arm 57 AWARNING 59 November 2014 Tag disconnect and plug the hydraulic hoses on the lift cylinder Cap the fittings on the cylinder 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 wires and manual lowering cable from the solenoid valve on the cylinder Models with platform overload option Tag and disconnect the wire harness from the platform overload pressure transducer Note After replacing the scissor assembly the platform overload system must be calibrated Refer to Repair Procedure 9 10 How to Calibrate the Platform Overload System if equipped Bodily injury hazard Keep A CAUTION hands clear of moving parts 60 Raise the lift cylinder to a vertical position dtu T 61 Remove the pin retaining fasteners from the lift cylinder barrel end pin index 16 Use 56 Attach a lifting strap from an overhead crane E dir Remove
224. each 3200 psi 221 bar the pump is bad and will need to be serviced or replaced Component damage hazard There is no relief valve in the hydraulic pump and the pump can be damaged if the pressure is allowed to exceed 3200 psi 221 bar When testing the pump activate the pump in one second intervals until 3200 psi 221 bar is confirmed Do not over pressurize the pump Remove the pressure gauge and reconnect the hydraulic hose Torque to specifications 86 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual How to Remove the Hydraulic Pump Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Disconnect the battery pack from the machine A WARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 2 Tag and disconnect the hydraulic power unit cables at the motor controller 3 Disconnect the filter head from the filter head mounting bracket Rotate the filter out and away from the hydraulic power unit 4 Remove the hydraulic power unit retaining fasteners 5 Tag disconnect and plug the hydraulic tank hard line from the pump Cap the fitting on the pump
225. ection and scheduled maintenance Technical Publications Genie has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in suggestions for improvement All communications will be carefully considered for future printings of this and all other manuals Contact Us Internet www genielift com E mail awp techpub terex com Serial Number Information Genie offers the following Service Manuals for these models Title Part No Genie GS 1530 and GS 1930 Service 39528 Manual before serial number 17408 Genie GS 1530 and GS 1930 Service 72876 Manual from serial number 17408 to 59999 Genie GS 1530 and GS 1930 Service 96316 Manual from serial number 60000 to 75999 Genie GS 1530 and GS 1930 Service 97385 Manual from serial number A 760000 to A 109999 B 760000 to B 98941 and C 101 to C 9999 Genie GS 2032 Service Manual before 46326 serial number 17408 Genie GS 2032 and GS 2632 from serial 72963 number 17408 to 59999 Genie GS 2032 and GS 2632 Service 96316 Manual from serial number 60000 to 75406 Genie GS 2032 GS 2632 and GS 3232 97385 Service Manual from serial number 75407 to A 109999 and C 101 to C 9999 Genie GS 2046 GS 2646 and GS 3246 48339 Service
226. ed The machine alarm will sound at 1 beep per second 29 Service Manual November 2014 Checklist B Procedures B 6 Test the Key Switch Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Proper key switch action and response is essential to safe machine operation The machine can be operated from the ground or platform controls and the activation of one or the other is accomplished with the key switch Failure of the key switch to activate the appropriate control panel could cause a hazardous operating situation Perform this procedure from the ground using the platform controls Do not stand in the platform 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Turnthe key switch to platform controls 3 Check the platform up down function from the ground controls Result The machine functions should not operate 4 Turnthe key switch to ground control Check the machine functions from the platform controls Result The machine functions should not operate 6 the key switch to the off position Result No function should operate B 7 Test the Automotive style Horn if equipped Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first The horn is activated at the platform controls and sounds at the ground as a warning to ground personal
227. eed Platform down 28 to 32 seconds 28 to 32 seconds GS 3232 and GS 3246 Platform Up full speed Platform down 55 to 59 seconds 28 to 32 seconds GS 4047 Platform Up full speed Platform down 71 to 76 seconds 41 to 46 seconds Rated work load at full height maximum GS 1530 and GS 1532 600 Ibs 272 kg GS 1930 GS 1932 500 Ibs GS 2632 and GS 3232 227 kg GS 1930PAR 400 Ibs 181 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 GS 4047 770 16 CE and AS models 350 kg GS 4047 5505 ANSI and CSA models 250 kg GS 3232 Outrigger leveling capacity maximum Side to side 5 Front to rear 3 Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation Genie GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual Hydraulic Specifications Hydraulic Fluid Specifications Genie specifications require hydraulic oils which are designed to give maximum protection to hydraulic systems have the ability to perform over a wide temperature range and the viscosity index should exceed 140 They should provide excellent antiwear oxidation prevention corrosion inhibition seal conditioning and foam and aeration suppression properties Cleanliness level ISO 15 13 minimum Water content 250 ppm maximum Recommen
228. elect button blue arrow d drive function button Genie 36 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual Move the control handle in the direction indicated by the blue arrow on the control panel until the machine begins to move forward 9 Bring the machine to top drive speed before reaching the start line Begin timing when the selected reference point on the machine crosses the start line 10 Continue at full speed and note the time when your reference point on the machine passes the finish line Refer to Section 2 Specifications Checklist B Procedures B 12 Perform Hydraulic Oil Analysis Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more often Refer to Section 2 Specifications Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test See E 1 Test or Replace the Hydraulic Oil Genie BRAND Part No
229. enance Symbols Legend Note The following symbols have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appear 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 dealer service will be required to perform this procedure Indicates that a cold motor or pump will be required to perform this procedure Genie 16 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual a Scheduled Maintenance Procedures Pre delivery Preparation Report The pre delivery preparation report contains checklists for each type of scheduled inspection Make copies for each inspection Store completed forms as required Maintenance Schedule The Scheduled Maintenance Procedures section and the Maintenance Inspection Report have been divided into subsections 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 Annually or every 1000 hours A B C D Two year or every 2000 hours A B C Dt E Maintenance Inspection Report The maintenance inspection report contains checklists for each t
230. er Axle Components How to Remove a Drive Motor 7 Tag disconnect and plug the hydraulic hoses on the drive motor the fittings on the 1 Block the non steer tires drive motor 2 Remove the cotter pin from the wheel castle Bodily injury hazard Spraying A WARNING hydraulic oil can penetrate and 3 Note Always replace the cotter pin with a new burn skin Loosen hydraulic one when removing the castle nut connections very slowly to allow the oil pressure to dissipate 4 Loosen the wheel castle nut Do not remove gradually Do not allow oil to E squirt or spray 5 Raise the machine approximately 2 inches 5 cm Place blocks under the chassis for support Component damage hazard Hoses can be damaged if they are kinked or pinched Crushing hazard The chassis A WARNING will fall if not properly supported 8 Remove the drive motor mounting fasteners Remove the motor 6 Remove the wheel castle nut Remove the Torque specifications wheel Drive motor mounting fasteners 75 ft lbs dry 101 7 Nm Drive motor mounting fasteners 56 ft lbs lubricated 76 3 Nm Genie 108 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual Steer Axle Components 6 2 4 Remove the steer cylinder from the machine Steer Cylinder 5 Tag disconnect and plug the hydraulic hoses from the steer cylinder Cap the fittings on the cylinder How to Remove the Bodily injury hazard Spraying Steer Cylinder AWARNING hy
231. er of dry film lubricant to the area of the chassis where the scissor arm wear pads make contact Cross tube to chassis specification 6 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 90 inch 22 9 mm Measurement minimum GS 2032 GS 2632 GS 3232 GS 2046 GS 2646 GS 3246 and GS 4047 4 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 Refer to Illustration 2 Result The measurement is 0 88 inch 22 4 mm or more Proceed to step 2 Result The measurement is less than 0 88 inch 22 4 mm Replace both wear pads Refer to Repair Procedure 9 3 9 4 9 5 or 9 6 How to Replace the Scissor Arm Wear Pads 5 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 Refer to Illustration 2 Result The measurement is 0 88 inch 22 4 mm or more Proceed to step 3 Result The measurement is less than 0 88 inch 22 4 mm Replace both wear pads Refer to Repair Procedure 9 3 9 4 9 5 or 9 6 How to Replace the Scissor Arm Wear Pads 0 88 inch 22 4 Measurement minimum Illustration 2 a Outer
232. est the Up Limit Switch if equipped and Maximum Drive Height Limit Switches if equipped Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the limit switches is essential to safe operation and good machine performance Operating the machine with a faulty limit switch could result in reduced machine performance and a potentially unsafe operating condition Note Perform this procedure with the machine on a firm level surface that is free of obstructions Up Limit Switch if equipped 1 Turn the key switch to ground control and raise the platform approximately 8 feet 2 4 from the ground 2 Rotate the safety arm away from the machine and let it hang down 3 Lower the platform onto the safety arm A WARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform Checklist B Procedures 4 While raising the platform from the ground controls push the arm of the up limit switch towards the steer end of the machine to activate the limit switch Result The platform stops rising The machine is functioning properly Result The platform continues to rise Adjust or replace the up limit switch Maximum Drive Height Limit Switches if equipped 5 Lower the platform onto the safety arm 6 While raising the platform from the ground controls and working with the maximum drive height limit switch at the battery side of the ma
233. etaining fasteners and remove the outrigger level sensor from the machine 1 1 1L GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual 4 2 Ground Controls 6 Place the new outrigger level sensor onto the 2 7 outrigger level sensor base with the flat side Manual Platform Lowering Cable of the outrigger level sensor closest to the battery side access door Refer to the The manual platform lowering cable lowers the illustration below 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 257 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 a A WARNING Crushing hazard Keep hands clear of the safety arm when a outrigger level sensor GS 3232 lowering the platform 7 Secure the outrigger level sensor onto the base with the retaining fasteners removed in step 5 4 Pull the handle of the manual platform lowering cable out until considerable resistance is felt Release the handle 8 Adjust the outrigger level sensor retaining fasteners until the bubble at the top of the level sensor is centered in the cir
234. 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 Remove the scissor assembly from the machine just enough to access both wear pads A DANGER Crushing hazard The scissor 154 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 33 35 36 Genie GS 30 GS 32 GS 46 GS 47 November 2014 Remove both old wear pads Install two new wear pads Slide the scissor assembly back into the drive chassis 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 careful not to damage the level sensor or limit switch while moving the scissor assembly Part No 228901 November 2014 Service Manual Oe Scissor Components N e 2 amp 9 2 2 9 9 e amp amp 9 8 2 9 GS 3232 GS 3246
235. form height sensor cover Tag and disconnect the platform height sensor from the platform height sensor harness Remove the fastener securing the platform height sensor assembly to the number 1 inner arm Remove the platform height sensor assembly from the number 1 pivot pin Remove the plastic nut securing the squeeze connector to the large platform height sensor bracket Remove the squeeze connector from the large platform height sensor bracket Remove the fasteners securing the large platform height sensor bracket to the number 1 inner arm pivot bracket Remove the large platform height sensor bracket from the number 1 inner arm pivot bracket Install the fasteners removed in 14 to the number 1 inner arm pivot bracket and chassis Tip over hazard Failure DANGER to install the fasteners securing 132 the number 1 inner arm pivot bracket to the chassis could result in the machine tipping over causing death or serious injury November 2014 17 Connect the battery pack to the machine 18 Turn the key switch to the ground control position 19 Press and hold the ground control scroll up and scroll down buttons 20 Pull out the red Emergency Stop button to the on position at the ground controls 21 Using the ground control menu buttons navigate to Service Override Mode Select Service Override Mode Note The machine must be in Service Override Mode to raise the platform While in Service Overri
236. ft lbs 7Nm Pressure transducer if equipped 27 ft lbs e schematic item R 37 Nm Check valve 20 ft lbs schematic item DK 27 Nm 21 Remove the lifting device supporting the link stack at the steer end of the machine 22 Connect the battery pack to the machine 23 Turn the key switch to ground controls 24 Press and hold the ground control scroll up and scroll down buttons 25 Pull out the red Emergency Stop button to the on position at the ground controls Upper Lift Cylinder relief valve schematic item Q lift cylinder connector fitting hydraulic hose check valve schematic item DK Genie BRAND Part No 228901 GS 30 GS 32 GS 46 GS 47 195 Service Manual November 2014 Scissor Components 26 Using the ground control menu buttons navigate to Service Override Mode Select Service Override Mode Note The machine must be in Service Override Mode to raise the platform While in Service Override Mode only the GCON will operate with limited functionality The platform will raise a predetermined amount of time and stop 27 Raise the platform and rotate the safety arm to the stowed position 28 Fully lower the platform to the stowed position Note Models with a pressure transducer calibrate the Platform Overload System Refer to Repair Procedure 9 10 How to Calibrate the Platform Overload System if equipped 9 9 Pressure Transducer How to Rem
237. ft the safety arm move it to the center of the scissor arm and rotate down to a vertical position 4 Lower the platform onto the safety arm A WARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 5 At the ground controls turn the key switch to the off position and push in the red Emergency Stop button to the off position 6 Disconnect the battery pack from the machine A WARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 7 Remove the fasteners securing the large platform height sensor cover to the large platform height sensor bracket 8 Remove the platform height sensor cover 9 Tagand disconnect the platform height sensor from the platform height sensor harness 10 Remove the fastener securing the platform height sensor assembly to the number 1 inner arm 11 Remove the platform height sensor assembly from the number 1 pivot pin Genie 124 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual 12 Remove the plastic nut securing the squeeze connector to the large platform height sensor bracket 13 Remove the squeeze connector from the large platform height sensor bracket 14 Remove the fasteners securing the large platform height sensor bracket to the number 1 inner arm pivot bracket 15 Remove the large platform he
238. fting device 67 68 69 70 CAUTION 71 CAUTION 72 Genie BRAND GS 30 GS 32 GS 46 GS 47 Service Manual Scissor Components Attach a lifting strap from an overhead crane to the number 1 outer arm index 17 Do not apply any lifting pressure Remove the external snap rings and retaining fasteners from the number 1 center pivot pins index 7 Remove the number 1 cable bridge from the machine Use a soft metal drift to remove the number 1 center pivot pins index 7 Bodily injury hazard The number 1 outer arm may become unbalanced and fall if not properly supported when the pin is removed Slide the number 1 outer arm index 17 to the non steer end and remove it from the machine Bodily injury hazard The number 1 outer arm may become unbalanced and fall if not properly supported when removed from the machine Attach the strap from an overhead crane to the number 1 inner arm index 8 Do not lift it 119 Service Manual es 7 Scissor Components 73 74 Remove the upper fasteners securing the number 1 inner arm pivot bracket to the end of the chassis Loosen the lower fasteners Remove the number 1 inner arm index 8 from the machine ACAUTION Bodily injury hazard The 120 number 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 t
239. ftware Note Before updating the machine software open a web browser and navigate to the following location for the Genie Machine Software Download portal http firmware genielift com Perform a search by applying the appropriate filters and download the machine software Note There are two procedures available to update the machine software These are Bootloader Mode and Machine Application Mode Bootloader Mode The Bootloader mode is only available with the key switch in the GCON position It allows the user to update or reinstall the machine software by directing the system into the Bootloader Choose this mode if the GCON ECM is not opertaing correctly Machine Application Mode The machine Application mode is available with the key switch in the GCON or PCON position This mode of machine software update requires the user to enter the Machine Service Tool Choose this mode if the machine is operating correctly and you are updating the machine software Bootloader Mode 1 Open the GCON compartment Note Some models will require opening the ground control box to access the GCON 2 Turn the key switch to the ground controls position and pull out the red Emergency Stop button to the on position at the platform controls At the ground controls press and hold the Enter and Escape buttons a LCD display b enter button c escape button 4 Pull out the red Emergency Stop button to the on positi
240. functions inhibited GS46 amp DUE y GCON ECM GS47 F035 GS30 Foss SENSORFAULT Height Sensor setting is lower than calibrated Short circuit in the level roll sensor circuit 6532 OVLD RANGE LOW t d height Faulty level sensor All functions inhibited 6546 8 E i GCON ECM GS47 Hie Short circuit in the left front outrigger sensor 6532 F036 SENSORFAULT Height Sensor setting is higher than circuit All functions inhibited OVLD RANGE HI calibrated maximum height Faulty pressure transducer d GS46 amp GCON ECM GS47 Short circuit in the left front outrigger sensor F072 F072 SENSORFAULT 5 circuit GS 2646AV FUNCTION CUT Function Cutout sensor B fault Faulty pressure transducer All functions inhibited GCON ECM Short circuit in the right front outrigger sensor F073 F073 SENSORFAULT circuit GS 2646AV DECK SENSOR B Power Deck sensor B fault Faulty pressure transducer All functions inhibited GCON ECM Genie BRAND Part No 228901 GS 30 GS 32 GS 46 GS 47 229 Service Manual November 2014 Diagnostics Type CXXX Faults DTC Message on Number GCON LCD Problem Description Possible Causes Failure Mode C001 GS30 GS32 GS46 amp GS47 C001 GCON ECM FAULT TYPE 1 GCON ECM CRC check error Incorrect software file GCON ECM internal failure All functions inhibited C004 GS30 G
241. g the ground control menu buttons navigate to Service Override Mode Select Service Override Mode Note The machine must be in Service Override Mode to raise the platform While in Service Override Mode only the GCON will operate with limited functionality The platform will raise a predetermined amount of time and stop Genie 170 GS 30 GS 32 GS 46 GS 47 Raise the platform and rotate the safety arm to the stowed position Fully lower the platform to the stowed position Cable bridge and platform height sensor cable bridge 6 cable bridge 5B cable bridge 5A cable bridge 4B cable bridge 4A cable bridge 1A platform height sensor cable bridge 1B cable bridge 2A cable bridge 2B cable bridge 2C cable bridge 2D Part No 228901 November 2014 a se 24 25 26 27 28 29 30 31 Remove the platform See 10 1 How to Remove the Platform Remove the cables from cable bridges a b c dande Remove the retaining fasteners from the number 7 pivot pin index 1 Use a soft metal drift to remove the number 7 pivot pin index 1 Remove the platform mount bracket from the machine Attach a lifting strap from an overhead crane to the number 6 outer arm at the ground control side index 19 Remove the retaining fasteners from the number 6 center pivot pin index 2 at the ground control side Place a rod through the number 6 center pivot pi
242. ged circuits could result in death or serious injury Remove all rings watches and other jewelry Genie BRAND GS 30 GS 32 GS 46 GS 47 141 Service Manual ss si Scissor Components 10 11 12 13 14 15 16 Remove the fasteners securing the platform height sensor cover to the large platform height sensor bracket Remove the platform height sensor cover Tag and disconnect the platform height sensor from the platform height sensor harness Remove the fastener securing the platform height sensor assembly to the number 1 inner arm Remove the platform height sensor assembly from the number 1 pivot pin Remove the plastic nut securing the squeeze connector to the large platform height sensor bracket Remove the squeeze connector from the large platform height sensor bracket Remove the fasteners securing the large platform height sensor bracket to the number 1 inner arm pivot bracket Remove the large platform height sensor bracket from the number 1 inner arm pivot bracket Install the fasteners removed in 14 to the number 1 inner arm pivot bracket and chassis Tip over hazard Failure DANGER to install the fasteners securing 142 the number 1 inner arm pivot bracket to the chassis could result in the machine tipping over causing death or serious injury November 2014 17 Connect the battery pack to the machine 18 Turn the key switch to the ground control
243. h the faulted circuit 1 Disconnect the faulted device connector 2 Using a multi meter measure resistance between the two terminals of the faulted device 3 Resistance should be as follows Device Typical Resistance Solenoid Valve Drive 27 20 Solenoid Valve Steer 190 Solenoid Valve Platform Up 250 Solenoid Valve Platform Down 6 25 0 GCON and PCON Alarm 21M O Automotive Horn 1 0 0 Motor Controller Enable 5 7Tk Q Motor Controller Throttle 5 7k Q Contactor Coil 470 Disconnect the GCON ECM connectors J1 J2 and J3 Disconnect the faulted device connector Check the continuity between the GCON ECM connector and the signal side of the faulted device Result Resistance should be close to 0 Q Check the continuity between the return side of faulted device and system ground Result Resistance should be close to 0 Q Check resistance between return side and signal side of the harness plug of faulted device Result Resistance should be 1M Q or higher OK Go to step 3 No Good Replace or repair harness Gri 1 11 1 1 218 GS 30 65 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual Diagnostics 03 Check the GCON ECM 1 Disconnect the GCON ECM connectors J1 J2 and J3 For short to B type faults measure resistance between pins J1 7 ground and the GCON pin associated with the fault code Refer to th
244. he on position at the ground controls Using the ground control menu buttons navigate to Service Override Mode Select Service Override Mode Note The machine must be in Service Override Mode to raise the platform While in Service Override Mode only the GCON will operate with limited functionality The platform will raise a predetermined amount of time and stop 22 Part No 228901 Raise the platform and rotate the safety arm to the stowed position 23 24 25 Genie BRAND GS 30 GS 32 GS 46 GS 47 Scissor Components Fully lower the platform to the stowed position 1530 _ _ Cable bridge and platform height sensor cable bridge 3 b cable bridge 2 c cable bridge 1 d platform height sensor Remove the platform See 10 1 How to Remove the Platform Remove the cables from the number 3 outer arm index 11 at the ground controls side Component damage hazard Cables can be damaged if they are kinked or pinched 115 Service Manual ss si Scissor Components 26 Remove the cables from the number 3 cable bridge and lay them off to the side Component damage hazard 33 November 2014 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 Cables can be damaged if they 34 Remove the pin retaining fasteners from the are kinked or pinched lift cylinder rod end pivot
245. he down limit switch may need to be adjusted 79 Service Manual November 2014 Ground Controls 35 Lift the safety arm move it to the center of the scissor arm and rotate down to a vertical position Lower the platform onto the safety arm AWARNING Crushing hazard Keep hands 36 37 38 39 40 41 80 clear of the safety arm when lowering the platform Raise the platform 7 to 8 feet 2 1 to 2 4 m Return the safety arm to the stowed position Lower the platform to the stowed position Raise the machine approximately 2 inches 5 cm Place blocks under the chassis for support Remove the blocks from under both wheels Lower the machine and remove the jack How to Install the Outrigger Level Sensor ADANGER Tip over hazard Failure to install the outrigger level sensor as instructed will compromise machine stability and cause the machine to tip over resulting in death or serious injury Do not install the outrigger level sensor other than specified in this procedure 1 Move the machine to an area that has a firm level surface and is free of obstructions 2 Turn the key switch to the off position and push in the red Emergency Stop button to the off position at both the ground and platform controls 3 Open the access door at the battery side of the machine 4 Tag and disconnect the outrigger level sensor wire harness from the outrigger level sensor 5 Remove the outrigger level sensor r
246. he ground controller powers up alternating message 5 Atthe ground controls use the Scroll Down button to scroll to SVC Override Result The ground controls LCD display will STOWED AND ON show the following LEVEL SURFACE LIFT SETUP TEST 1 7 Pressthe Enter button SVC OVERRIDE Result The ground controls LCD display will show the following CONFIRM SERVICE OVERRIDE MODE 8 Pressthe Enter button Result The ground controls LCD display will show the following C028 SERVICE OVERRIDE MODE ON Gri 1 76 GS 30 65 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual 2 6 Level Sensors The Electronic Control Module ECM is programmed to deactivate the lift and drive functions and activate an alarm when a signal is received from the level sensor The tilt alarm sounds when the incline of the chassis exceeds 1 5 to the side and 3 to the front or rear How to Install and Calibrate the 1 5 Level Sensor A DANGER Tip over hazard Failure to install 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 1 Move the machine to an area that has a firm level surface and is free of obstructions 2 Remove the platform controls from the pl
247. he limit switch or level sensor components when the number 1 inner arm is removed from the machine November 2014 How to Replace the Scissor Arm Wear Pads Note Machines equipped with a Platform Height Sensor begin at step 1 Machines without a Platform Height Sensor begin at step 24 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 Raise the platform 7 to 8 feet 2 1 to 2 4 m 3 Liftthe safety arm move it to the center of the scissor arm and rotate down to a vertical position 4 Lower the platform onto the safety arm A WARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 5 At the ground control turn the key switch to the off position and push in the red Emergency Stop button to the off position 6 Disconnect the battery pack from the machine A WARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 h 1 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 a se 10 11 12 13 14 15 16 Remove the fasteners securing the platform height sensor cover to the large platform height sensor bracket Remove the platform height sensor cover Tag and disconnect the platform height sensor f
248. he non steer end of the machine Remove the number 4 outer arm index 13 from the machine 38 Crushing hazard The number 4 outer arm may become unbalanced and fall if not properly supported when removed from the machine Genie GS 30 GS 32 GS 46 GS 47 bridge and lay them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched Remove the number 3 cable bridge mounting fasteners and remove the cable bridge from the machine Attach a lifting strap from an overhead crane to the number 3 outer arm index 4 at the ground controls side Part No 228901 November 2014 a se 39 Remove the external snap rings and retaining fasteners from the number 3 center pivot pins index 4 46 47 Service Manual Scissor Components Remove the number 3 pivot pin index 17 from the non steer end of the machine Attach a lifting strap from an overhead crane 40 Use a soft metal drift to remove the number to the lug on the rod end of the lift cylinder for 3 center pivot pin index 4 at the ground support Do not apply any lifting pressure 48 Remove the pin retaining fasteners from the 41 Remove the retaining fasteners from the lift cylinder rod end pivot pin index 5 Use a number 3 pivot pin index 17 at the soft metal drift to remove the pin non steer end of the machine Bodily iniurv hazard The 42 Use a soft metal drift to tap the number 3
249. hile moving the scissor assembly 9 7 Platform Height Sensor How to Disassemble the Platform Height Sensor Assembly if equipped Note When a Platform Height Sensor Assembly is removed or replaced the platform overload system must be calibrated Refer to Repair Procedure 9 10 How to Calibrate the Platform Overload System if equipped and follow the no load calibration procedure 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 Turnthe key switch to the off position Genie 180 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual Scissor Components 5 Disconnect the battery pack from the 9 Remove the fastener securing the platform machine height sensor assembly to the number 1 inner arm Electrocution burn hazard A WARNING Contact with electrically charged 10 Remove the platform height sensor assembly circuits could result in death or from the number 1 pivot pin serious injury Remove all rings 11 Remove the set screw securing the lever arm watches and other jewelry to the platform height sensor 6 Remove the fasteners securing the large 12 Remove the lever arm from the platform platform height sensor cover to the large
250. hile in Service Override Mode only the GCON will operate with limited functionality The platform will raise a predetermined amount of time and stop 27 Raise the platform and rotate the safety arm to the stowed position 28 Fully lower the platform to the stowed position Note Models with a pressure transducer calibrate the Platform Overload System Refer to Repair Procedure 9 10 How to Calibrate the Platform Overload System if equipped Service Manual November 2014 Scissor Components GS 2032 GS 2632 GS 2046 and GS 2646 AWARNING Bodily injury hazard 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 Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications Note Models without a pressure transducer follow steps 1 through 23 27 and 28 Models equipped with a pressure transducer follow steps 1 through 28 1 Turn the key switch to ground controls and pull out the red Emergency Stop button to the on position at both ground and platform controls 2 Raise the platform 7 to 8 feet 2
251. hine 18 Turn the key switch to the ground control position 19 Press and hold the ground control scroll up and scroll down buttons 20 Pull out the red Emergency Stop button to the on position at the ground controls 21 Using the ground control menu buttons navigate to Service Override Mode Select Service Override Mode Note The machine must be in Service Override Mode to raise the platform While in Service Override Mode only the GCON will operate with limited functionality The platform will raise a predetermined amount of time and stop 22 Raise the platform and return the safety arm to the stowed position 23 Fully lower the platform to the stowed position 24 Remove the platform See 10 1 How to Remove the Platform 25 Support and secure the entry ladder to an appropriate lifting device 26 Remove the fasteners from the entry ladder and remove the entry ladder from the machine CAUTION Crushing hazard The entry ladder will fall if not properly supported and secured to the lifting device Genie BRAND GS 30 GS 32 GS 46 GS 47 153 Service Manual es 7 Scissor Components 27 28 29 30 31 32 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
252. hine Tag and disconnect the wire harness from the solenoid valve on the cylinder Component damage hazard Cables can be damaged if they are kinked or pinched Attach a lifting strap from an overhead crane to the lug of the rod end of the upper lift cylinder number 5 pivot pin index 23 at the 50 Remove the retaining fasteners from the non steer end upper lift cylinder rod end pivot pin index 5 45 Use a soft metal drift to remove the number 51 Use a soft metal drift to remove the upper lift 5 pivot pin index 23 from the non steer end cylinder rod end pivot pin index 5 from the of the machine Remove the number 5 outer machine arm at the ground control side index 22 from the machine ACAUTION Crushing hazard The lift cylinder will fall if not properly ACAUTION Crushing hazard The number supported when the pivot pin is 5 outer arm at the ground control removed side index 22 may become unbalanced and fall if not 52 Lower the cylinder onto the linkset properly supported when removed from the machine Genie 172 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 a se 53 Attach lifting strap from an overhead crane to the number 4 outer arm at the ground control side index 25 60 Service Manual Scissor Components Place a rod through the number 4 center pivot pin at the battery side index 7 and twist to remove the pin 54 Remove the retaining fasteners from th
253. hydraulic schematic Note alpha numeric callouts refer to corresponding notes on the electrical schematic Genie BRAND Part No 228901 GS 30 GS 32 GS 46 GS 47 91 Service Manual November 2014 sl Manifolds 5 3 Function Manifold Components GS 4047 The function manifold is mounted behind an inspection door at the ground control side of the machine Index No Description Schematic Item Function Torque Coil Nut item DC 4 5 ft lbs 5 7 Nm Coil Nut items DE DG and DI 5 7 ft lbs 7 9 Nm 1 Diagnostic nipple DA Testing 2 Relief Valve 3500 psi 241 bar DB System relief 20 ft lbs 27 Nm maximum 3 Solenoid valve 3 position 4 way DC Steer left right 25 ft lbs 34 Nm 4 Check disc DD Steer circuit 18 ft lbs 24 Nm 5 Solenoid valve 2 position 4 way DE Drive speed select 25 ft lbs 34 Nm circuit 6 Relief valve DF Brake release 20 ft lbs 27 Nm 7 Solenoid valve 3 position 5 way DG Die 25 ft lbs 34 Nm forward reverse 8 Flow regulator and relief valve DH Steer circuit 26 ft lbs 35 Nm 0 75 gpm 2 8 L min 1500 psi 103 bar 9 Solenoid valve 2 position 4 way DI Platform up 25 ft lbs 34 Nm 10 Relief valve DJ Lift relief 20 ft lbs 27 Nm How to Install a Valve Cartridge 1 Dip the cartridge in clean oil to lube the O rings 2 Screw the cartridge in by hand until the top O ring is met then torque to specifications If requi
254. icron with Check valve manifold 25 psi 1 7 bar 65 1530 65 1532 65 1930 65 1932 b pee Check valve pressure maximum 200 psi Function pump GS 2032 GS 2632 GS 3232 13 8 bar 2046 GS 2646 05 3246 GS 4047 Lift pressure selector manifold GS 4047 Type Gear Platform relief valve pressure 2000 psi Displacement per revolution 0 355 cu in maximum 138 bar 5 5 cc Flow rate 2500 psi 172 bar o Continuous improvement of our products is a 10 micron with 25 psi 1 7 bar Hydraulic tank return filter bypass Function manifold All models except GS 4047 System relief valve pressure 3700 psi maximum 255 bar Lift relief valve pressure 1800 to 3700 psi 142 to 241 bar Genie policy Product specifications are subject to change without notice or obligation Steer relief valve pressure 1500 psi 103 bar Genie Part No 228901 GS 30 GS 32 GS 46 GS 47 9 Service Manual November 2014 Specifications Manifold Component Specifications Plug torque SAE No 2 50 in lbs 6 Nm SAE No 4 13 ft lbs 18 Nm SAE No 6 18 ft lbs 24 Nm SAE No 8 50 ft lbs 68 Nm SAE No 10 55 ft lbs 75 Nm SAE No 12 75 ft lbs 102 Nm 10 Valve coil resistance Note The following coil resistance specifications are at an ambient temperature of 68 F 20 C As valve coil resistance is sensitive to change in air temperature the coil resistance will typically increase or decrease b
255. ie situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Indicates that a specific result is expected after performing a series of steps Indicates that an incorrect result has occurred after performing a series of steps 58 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual TE Te T tt Platform Controls The platform controls are used to operate the machine from the platform Activating a function 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 The platform controls consist of an Emergency Stop button electronic circuit board proportional control handle drive steer enable switch alarm function buttons and LED display For further information or assistance consult the Genie Product Support a red Emergency Stop button P2 platform controls circuit board U3 proportional control handle and drive steer enable switch JC9 d alarm H1 o Genie BRAND Part No 228901 GS 30 GS 32 GS 46 GS 47 59 Service Manual November 2014 Pla
256. ift cylinder to a vertical position 108 Remove the pin retaining fasteners from the lift cylinder barrel end pin index 28 Use a Soft metal drift to remove the pin Remove the lift cylinder from the machine CAUTION Crushing hazard The lift cylinder 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 109 Remove the cables from the number 1 cable bridge and lay them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched 110 Disconnect the number 1 cable bridge from the number 1 outer arm index 29 and remove the cable bridge from the machine 111 Attach a lifting strap from an overhead crane to the number 1 inner arm index 14 112 Raise the arm slightly and remove the block 113 Lower the arm to the stowed position CAUTION Bodily injury hazard Keep hands clear of moving parts when lowering the scissor arms Genie 164 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual 114 Secure the ends of the scissor arms together at the steer end of the machine with a strap or other suitable device 115 Secure the ends of the scissor arms together at the non steer end of the machine with a strap or other suitable device 116 Remove the retaining fasteners securing the chassis mount bracket to the ch
257. igger Extend Coil Digital Output 18 GR J4 12 Outrigger Retract Coil Digital Output 18 GR BK Genie BRAND Part No 228901 GS 30 GS 32 GS 46 GS 47 215 Service Manual November 2014 Diagnostics Operation Indicator Codes OIC These codes are generated by the electrical system to indicate machine operating status such as Off level Overload Cutout Chassis Mode Operation and Pothole Guard Stuck during normal operation These codes are not indicators of a device malfunction in the electrical system Code Condition LL Off Level OL Platform Overloaded CE and Australia CH Chassis Mode Operation PHS Pothole Guard Stuck nd No Drive option Ld Lifting Disabled GS 3232 only Note The Ld Operation Indicator Code will appear when the outriggers are not fully retracted the machine is not auto leveled an outrigger has lost contact with the ground or either level sensor detects the machine is no longer level When any of the above scenarios occur the lift function is disabled The lift function will also be disabled while extending or retracting the outriggers and during the outrigger auto level procedure While performing the above operations the Ld Operation Indicator Code will appear Diagnostic Trouble Codes DTC These codes are generated by the system to indicate that a device or circuit malfunction has been detected in the electrical system The types of
258. ight sensor bracket from the number 1 inner arm pivot bracket 16 Install the fasteners removed in 14 to the number 1 inner arm pivot bracket and chassis ADANGER Tip over hazard Failure to install the fasteners securing the number 1 inner arm pivot bracket to the chassis could result in the machine tipping over causing death or serious injury 17 Connect the battery pack to the machine 18 Turn the key switch to ground controls 19 Press and hold the ground control scroll up and scroll down buttons 20 Pull out the red Emergency Stop button to the on position at the ground controls Scissor Components 21 Using the ground control menu buttons navigate to Service Override Mode Select Service Override Mode Note The machine must be in Service Override Mode to raise the platform While in Service Override Mode only the GCON will operate with limited functionality The platform will raise a predetermined amount of time and stop 22 Raise the platform and rotate the safety arm to the stowed position 23 Fully lower the platform to the stowed position DE GS 1930 05 1932 Cable bridge and platform height sensor cable bridge 4 b cable bridge 3 c cable bridge 2 d cable bridge 1 e platform height sensor Genie BRAND Part No 228901 GS 30 GS 32 GS 46 GS 47 125 Service Manual es si Scissor Components 24 25 26 27 28 29 30 31 AWARNING
259. il C70 Platform Down Coil GS 3232 amp C14 Drive Forward Coil GS 3246 C15 Steer Right Coil C71 Platform Down Coil GS 3232 amp C16 Steer Left Coil GS 3246 C17 Platform Up Coil C84 Lift Pressure Selector Coil GS 4047 C18 Platform Down Coil C19 Load Sense Cable CB2 Circuit Breaker 7A C20 Platform Height Cable E Enclosure C21 Load Sense Ground Cable C22 Parallel Coil 1 Platform Control Box C23 Platform Height Sensor EN4 AC Outlet Box C24 Platform Overload Transducer C25 Outrigger J4 08 3232 FB Flashing Beacon option C26 Outrigger Retract Coil GS 3232 FS1 Foot Switch option C27 Outrigger Extend Coil GS 3232 C28 Right Rear Outrigger Coil GS 3232 GND Ground Stud C29 Left Rear Outrigger Coil GS 3232 H Horn or Alarm C30 Right Front Outrigger Coil GS 3232 C31 Left Front Outrigger Coil GS 3232 ET Horm OF Alarm C32 Outrigger Manifold Ground Bus GS 332 H2 Automotive Style Hori option C33 Outrigger Sensor Power Bus GS 3232 H5 Multifunction Alarm C34 Outrigger Level Sensor Ground Bus J Connector Plug GS 3232 C35 Left Front Outrigger Pressure Transducer E Eun on Mn US GS 3232 2 C36 Right Front Outrigger Pressure Transducer J3 Sensors amp Switches 05 GS 3232 J4 Outriggers U5 GS 3232 45 PCON Coil Cord to Platform Controls Board J6 PCON Emergency Stop amp Alarm to Platform Controls PC Board J7 Joystick to Platform Con
260. ire proportionally controlled speed range Note 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 Turnthe key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 3 Lower the platform to the stowed position 4 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the test line 5 Check to make sure the low drive speed light is off If the low dive speed light is on press the drive speed select button to turn off the low drive speed function 6 Press the drive function button if equipped Genie 32 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual Checklist B Procedures 7 Press and hold the drive steer function enable 8 Move the control handle in the direction Switch on the control handle indicated by the blue arrow on the control panel until the machine begins to move forward EN a 9 Bring the machine to top drive speed before reaching the start line Begin timing when the selected reference point on the machine crosses the start line id WY 10 Continue at full speed and note the time when your reference point on the machine passes the finish line Refer to Section
261. is at the full indicator on the hydraulic tank Do not overfill Genie BRAND Part No 228901 Checklist E Procedures Activate the pump to fill the hydraulic system with oil and bleed the system of air Component damage hazard The pump can be damaged if operated without oil Be careful not to empty the hydraulic tank while in the process of filling the hydraulic system Do not allow the pump to cavitate Repeat steps 12 through 13 until the hydraulic system and tank are both full GS 30 GS 32 GS 46 GS 47 55 Service Manual November 2014 This page intentionally left blank lt 56 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual Observe and Obey Repair procedures shall be completed by person trained and qualified on the repair of this machine Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Repairs Start Part No 228901 Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necessary tools and parts are available and ready for use Use only Genie approved replacement parts Read each procedure completely and adhere to the instructions Attempting shortcuts may produc
262. it in platform up 1 harness All functions GS32 Serena pon DE 54 up 1 Platform up 1 coil short circuit inhibited except GS46 amp GCON ECM platform down GS47 H009 H009 COILFAULT Short circuit of the plattorm down 1 pa 40 All functions GS46 amp PLAT DOWN1 BAT 1 circuit to battery positive GCON ECM inhibited GS47 H013 6530 H013 COILFAULT Short circuit of the drive forward d Short circuit in drive m Drive forward GS32 DRIVE FWD1 BAT 1 circuit to batt ti Drive forward 1 coil short circuit function inhibited GS46 amp 1 circuit to battery negative GCON ECM unction inhibited GS47 H014 GS30 HO14 COILFAULT Open circuit in the drive forward 1 Open circuitin drive torward 1 harness Drive forward GS32 DRIVE FWD1 OPEN eds Drive forward 1 coil open circuit function inhibited GS46 amp E circuit GCON ECM unction inhibited GS47 H015 GS30 H015 COILFAULT Short circuit of the drive forward 1 Short circuit in drive orward 1 harness All functions GS32 DRIVE FWD1 BAT circuit to battery positive Drive forward 1 coil short circuit inhibited except GS46 amp i GCON ECM platform down GS47 H019 6530 H019 COILFAULT Short circuit of the drive forward 1 t Short ren drive aca Drive reverse 6332 DRIVE REV1 BAT circuit to battery negative reverse fF1 short circuit function inhibited GS46 amp y ECM GS
263. itch to the off position Gri 1 1 1 1 1 48 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual C 2 Calibrate the Platform Overload System if equipped Genie requires 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 Calibrating 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 platform is overloaded Models equipped with the platform overload option are provided with two additional machine control components the overload pressure transducer and the platform height sensor The overload pressure transducer located at the barrel end of the lift cylinder is used to determine the pressure inside the lift cylinder Checklist C Procedures The platform height sensor located at the steer end of the chassis battery side is used to determine the height of the platform The overload pressure transducer and the platform height sensor provide the ECM with necessary information to determine the load in the platform Note The overload system will not measure loads
264. ith a Platform Height Sensor begin the Scissor Disassembly procedure at step 1 Machines without a Platform Height Sensor begin the Scissor Disassembly procedure at step 24 1 the key switch to ground controls and pull out the red Emergency Stop button to the on position at both ground and platform controls 2 Raise the platform 7 to 8 feet 2 1 to 2 4 m Scissor Components 3 Liftthe safety arm move it to the center of the Scissor arm and rotate down to a vertical position 4 Lower the platform onto the safety arm A WARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 5 At the ground controls turn the key switch to the off position and push in the red Emergency Stop button to the off position 6 Disconnect the battery pack from the machine A WARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 7 Remove the fasteners securing the large platform height sensor cover to the large platform height sensor bracket Remove the platform height sensor cover 9 Tagand disconnect the platform height sensor from the platform height sensor harness 10 Remove the fastener securing the platform height sensor assembly to the number 1 inner arm 11 Remove the platform height sensor assembly from the number 1 pivot pin Genie BRAND GS 30
265. ive function button if equipped Gon BRAND Checklist B Procedures 6 Press and hold the drive steer function enable switch on the control handle J models with proportional lift a drive steer function enable switch b blue arrow c drive function button Part No 228901 GS 30 GS 32 GS 46 GS 47 31 Service Manual November 2014 Checklist B Procedures 7 Move the control handle in the direction indicated by the blue arrow on the control panel until the machine begins to move forward 8 Bring the machine to top drive speed before reaching the test line Release the drive steer function enable switch or the joystick when your reference point on the machine crosses the test line 9 Measure the distance between the test line and your machine reference point Refer to Section 2 Specifications Note The brakes must be able to hold the machine on any slope it is able to climb B 9 Test the Drive Speed Platform Stowed Fast Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Proper drive functions are essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the ent
266. k from the machine A WARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 7 Remove the fasteners securing the large platform height sensor cover to the large platform height sensor bracket 8 Remove the platform height sensor cover 9 Tagand disconnect the platform height sensor from the platform height sensor harness 10 Remove the fastener securing the platform height sensor assembly to the number 1 inner arm Genie 114 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual 11 12 13 14 15 16 17 18 19 20 21 Remove the platform height sensor assembly from the number 1 pivot pin Remove the plastic nut securing the squeeze connector to the large platform height sensor bracket Remove the squeeze connector from the large platform height sensor bracket Remove the fasteners securing the large platform height sensor bracket to the number 1 inner arm pivot bracket Remove the large platform height sensor bracket from the number 1 inner arm pivot bracket Install the fasteners removed in 14 to the number 1 inner arm pivot bracket and chassis Connect the battery pack to the machine Turn the key switch to ground controls Press and hold the ground control scroll up and scroll down buttons Pull out the red Emergency Stop button to t
267. k to PCON CANL Data Bus 18 OR J1 06 PCON Ground Ground Output 18 BR J1 07 GCON Ground Ground Input 14BR J1 08 Key Switch PCON Mode Digital Input 18 BK J1 09 Key Switch GCON Mode Digital Input 18 WH J1 10 GCON Emergency Mode Digital Input 18 WH BK 41 11 No Circuit N A N A J1 12 Driver Power Power Input 14 RD J 2 Connector Black J2 01 Platform Up Coil Digital Output 18 OR J2 02 Platform Down Coil Digital Output 18 OR BK J2 03 Steer Left Coil Digital Output 18 BL BK J2 04 Steer Right Coil Digital Output 18 BL J2 05 Parallel Coil GS 32 GS 46 amp GS 47 Digital Output 18 RD WH J2 06 Drive Forward Coil Digital Output 18 WH J2 07 Ground GS 4047 Ground Input 18 BR J2 08 Motor Controller Enable Digital Output 18 GR WH J2 09 Lift Pressure Selector GS 4047 N A N A J2 10 Drive Reverse Coil Digital Output 18 WH BK J2 11 Motor Controller Throttle Analog Output 18 GR J2 12 No Circuit N A N A J 3 Connector Green J3 01 No Circuit N A N A J3 02 GCON Alarm Digital Output 18 BL J3 03 Switch Sensor Power Digital Output 14 RD J3 04 Automotive Horn Digital Output 18 WH J3 05 Pothole Limit Switch Digital Input 18 OR RD J3 06 Ground Ground Input 18 BR J3 07 Down Limit Switch Digital Input 18 OR J3 08 Level Sensor Digital Input 18 RD BK J3 09 Platform Overload Pressure Transducer Ground Input 18 BL WH J3 10 Platform Height Sensor Ground Input 18 OR WH J3 11 No Circuit N A N A J3 12 Load Sense Ground Ground Input 18 BK
268. l Electrical Schematic GS 1530 32 GS 1930 32 and AUS Models from serial number GS3010 110000 to GS3011A 110827 F G H L M N BK 1 EN4 GND GROUND he pd en 2 A ALARM c3 1 aeh 2 RD 2 lt lt 2 WH 2 8 BL 3 8 BL 4 E STOP OR 4 4 DATA LINK OR 5 WH E STOP BR 5 5 PCON V BR 6 P2 D ATESA T EMERGENCY 3 8 STOP U3 PLATFORM CONTROLS PRINTED CIRCUIT BOARD 1 YL JOYSTICK AXIS 1 3 BK STEER SWITCH COM 4 YL DRIVE ENABLE COM 5 or BL OR DRIVE ENABLE MACHINE SHOWN 4 INTHE STOWED RD JOYSTICK DC POSITION WITH THE POWER OFF 10 BK JOYSTICK BK CHASSIS GND JC9 NCC EN1 PLATFORM 5 CONTROLLER LI ol ll LII LL 6 7 8 Genie BRAND Part No 228901 GS 30 GS 32 GS 46 GS 47 263 Service Manual November 2014 Electrical Schematic GS 1530 32 and GS 1930 32 CE and AUS Models from serial number GS3010A 110000 and GS3011A 110827 264 November 2014 Service Manual Electrical Schematic GS 1530 32 and GS 1930 32 CE and AUS Models from serial numbers GS3011A 1
269. l out the red Emergency Stop button to the on position at both ground and platform controls 2 Raise the platform 7 to 8 feet 2 1 to 2 4 m lift cylinder orifice schematic item O connector fitting hydraulic hose pressure transducer schematic item R if equipped manual lowering cable 9 solenoid valve schematic item h cable mount bracket Genie BRAND Part No 228901 GS 30 GS 32 GS 46 GS 47 189 Service Manual November 2014 Scissor Components 4 Lower the platform onto the safety arm A WARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 5 Using a suitable lifting device support the link stack at the steer end of the machine 6 Atthe ground controls turn the key switch to the off position and push in the red Emergency Stop button to the off position 7 Disconnect the battery pack from the machine A WARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Note At the lower lift cylinder install the orifice fitting with the small opening of the orifice fitting closest to the supply hose 8 Tagand disconnect the wiring from the solenoid valve coil at the barrel end of the lift cylinder Skip to step 13 if removing the upper cylinder 10 Loosen the adjustment nuts on the solenoid valve and dis
270. lace the Hydraulic Tank Return Filter Element Checklist A Procedures A 5 Grease the Steer Yokes Genie specifications require that this procedure be performed every 100 hours of operation Regular application of lubrication to the steer yokes is essential to good machine performance and service life Continued use of an insufficiently greased steer yoke will result in component damage 1 Locate the grease fitting on the top of the steer yoke 2 Pump multipurpose grease into the steer yoke until the steer yoke is full and grease is being forced past the bearings Repeat this step for the other steer yoke Grease Specification Chevron Ultra duty grease EP NLGI 1 lithium based or equivalent Genie BRAND GS 30 GS 32 GS 46 GS 47 23 Part No 228901 Service Manual November 2014 Checklist B Procedures B 1 Inspect the Batteries Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Proper battery condition is essential to good machine performance and operational safety Improper fluid levels or damaged cables and connections can result in component damage and hazardous conditions AWARNING Electrocution burn 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
271. latform does not rise Then follow steps 7 through 10 again to Turn the machine off Hold the lift pressure selector valve with a wrench and remove the cap schematic item DM GS 4047 a lift pressure selector valve b solenoid valve Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure A DANGER Tip over hazard Failure to adjust the relief valves to increase the pressure in small increments 9 until the platform is able to rise 10 11 Genie 102 GS 30 GS 32 GS 46 GS 47 specification could result in the machine tipping over causing death or serious injury Do not adjust the relief valve pressures higher than specifications Install the relief valve cap Fully lower the platform to the stowed position Using a suitable lifting device add and secure an additional 150 Ibs 68 kg to the platform deck Part No 228901 November 2014 Service Manual Manifolds 12 Raise the platform 4 the key switch to platform controls and pull out the red Emergency Stop button to the 2 platform does not rise Proceed to on position at both ground and platform SIEP tae controls Result The platform rises Perform steps 7 through 10 to decrease the pressure in small increments until the platform does not rise 13 Fully lower the platform to the stowed position 14 Using a suitable lifting device remove the weight fr
272. latform height sensor cover to the large platform height sensor bracket 8 Remove the platform height sensor cover 9 Tagand disconnect the platform height sensor from the platform height sensor harness 10 Remove the fastener securing the platform height sensor assembly to the number 1 inner arm 11 Remove the platform height sensor assembly from the number 1 pivot pin 12 Remove the plastic nut securing the squeeze connector to the large platform height sensor bracket Genie 156 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual Scissor Components 13 Remove the squeeze connector from the 22 Raise the platform and rotate the safety arm large platform height sensor bracket to the stowed position 14 Remove the fasteners securing the large 23 Fully lower the platform to the stowed platform height sensor bracket to the number position 1 inner arm pivot bracket 15 Remove the large platform height sensor bracket from the number 1 inner arm pivot bracket 16 Install the fasteners removed in 14 to the number 1 inner arm pivot bracket and chassis ADANGER Tip over hazard Failure to install the fasteners securing the number 1 inner arm pivot bracket to the chassis could result in the machine tipping over causing death or serious injury 17 Connect the battery pack to the machine 18 Turn the key switch to ground controls 19 Press and hold the ground control scroll up
273. lect No Load calibration Press the Enter button to select No Load calibration 49 Press the Enter button to confirm no load is in the platform At the ground controls press and hold the Function Enable and Platform Up buttons until the platform reaches maximum height All Models except GS 4047 When the platform reaches maximum height press the ground controls Enter button Allow the ground controls to gather data GS 4047 only Press and hold the Menu Enter button to determine the maximum height The machine will lower for 1 2 seconds and then raise in 1 2 second durations until maximum height is reached When the platform reaches the maximum height a message will appear on the LCD screen to release the Menu Enter button If at any point the Menu Enter button is released before the message appears on the LCD screen the calibration procedure will restart at step 16 20 Genie GS 30 GS 32 GS 46 GS 47 November 2014 When prompted press and hold the Function Enable and Platform Down buttons to lower the platform The platform will move down then automatically stop at a predetermined point to gather data Allow the ground controls to gather data Continue pressing the Function Enable and Platform Down buttons throughout the lowering and data gathering sequence The machine will stop to gather data and lower several times before the machine reaches the stowed position When the platform reaches the stowed p
274. low mode Platform down 55 to 59 seconds 108 to 112 seconds 38 to 42 seconds GS 4047 Platform up fast mode Platform up slow mode 69 to 73 seconds 118 to 122 seconds Platform down 39 to 43 seconds Rated work load at full height maximum GS 1530 and GS 1532 600 Ibs 272 kg GS 1930 GS 1932 500 Ibs GS 2632 and GS 3232 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 GS 4047 770 Ibs CE and AS models 350 kg GS 4047 550 Ibs ANSI and CSA models 250 kg GS 3232 Outrigger leveling capacity maximum Side to side 5 Front to rear 3 Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation Genie GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual Specifications Performance Specifications models with proportional lift 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 2 5 mph 40 ft 24 8 sec 1 8 km h 12 2 m 24 8 sec 0 5 mph 40 ft 55 sec 0 8 km h 12 2 m 55 sec GS 2032 GS 2632 GS 3232 GS 2046 GS 2646 GS 3246 Platform stowed fast Platform stowed slow Platform raised 2 2 mph 40 ft 12 4 sec 3 5 km h 12 2 12 4 sec 1 1 mph 40 ft 24 8 sec 1 8 km h 12 2 m 24 8 sec
275. lt 4 DATA LINK OR 5 lt lt E STOP WH a PCON V OUT BR 5 lt lt 8 BR PON V OUT 5 5 PCON V QUT BR 6 1 P2 4 Sx EMERGENCY a 166 16 661 2 U3 PLATFORM CONTROLS PRINTED CIRCUIT BOARD 2 em JOYSTICK AXIS 1 d 1 gt STEER SWITCH 3 Um PLATFORM 5 DRIVE ENABLE COM YL 4 SONTROLLER CONTROLLER DRIVE ENABLE WH15 gt STEER LEFT BL 6 5 STEER RIGHT GR47 5 JOYSTICK 5VDC RD4 amp 3 9 gt JOYSTICK GND BK410 11 7 CHASSIS GND 12 NOTE 4 MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF 110V 240V AC POWER TO PLATFORM AC INPUT _ 258 _ ODIS 5 1 gt gt 1 GR 1 gt gt 1 GR YL OUTLET 2 2 22 3 3 WH 4 3 8 BL L _ L e Ground 6 QUTLET BOX STUD 7 8 ES0535 F Genie BRAND Part No 228901 GS 30 GS 32 GS 46 GS 47 283 Service Manual November 2014 a ee Electrical Schematic GS 3246 CE and AUS Models from serial numbers GS4612A 110000 and GS4612C 10000 284 November 2014 Service Manual Electrical Schematic GS 4047 CE and AUS Models from serial number GS4712C 101 285
276. m gt 8 6 gt 8 5 TILLOHHL el 2 55 ah l lt v zz gt B 8 lt lt i o c a S 5 r9 x e g9 2 vis m 8 82 x HM E d t a z 8 8 ug r Nx x tn 1 S 5 E3 ya gt a o 9 5 49 Ws PEETA 77 iz 1 winds le E T i cle or Bw 8 B 5 ju dii ic HM 53 lt 22 95 a Ww 228901 GS 30 GS 32 GS 46 GS 47 282 November 2014 Service Manual Electrical Schematic GS 3246 CE and AUS Models from serial numbers GS4612A 110000 and GS4612C 10000 A B C D E F G H J K L M N G2 C3 1 gt l T ES X PCON V OUT RD 1 1 RD PCON V OUT 1 1 PCON V OUT RD 2 lt RD lt H1 1 gt 8 1 12 4 27 2 2 ESTOP 3 lt BK iL ALARM FROM C41 E gt _DATALINK BL 1 3 BL DATA LINK 3 lt lt 3 DATA LINK BL 4 gt E STOP WH X E gt DATA LINK OR 4 lt lt 4 OR DATA LINK 4 lt
277. m height sensor elevated position If GS46 amp GCON ECM machine is in stowed GS47 position all functionality is resumed Part No 228901 Genie BRAND GS 30 GS 32 GS 46 GS 47 227 Service Manual eoo TEESE ts Diagnostics Type FXXX Faults continued November 2014 228 Genie BRAND GS 30 GS 32 GS 46 GS 47 DTC Message on Problem Possible Failure Number GCON LCD Description Causes Mode o3 m Short circuit in the level pitch sensor circuit F012 F012 SENSORFAULT Short circuit of the Level Pitch Sensor circuit Faulty level sensor All functions inhibited GS 3232 LEVEL PITCH BAT battery positive GCON ECM F013 FO13 SENSORFAULT Short circuit of the Level Pitch Sensor circuit ERU IU 69 3232 LEVEL battery negative GCON ECM oru Short circuit in the level roll sensor circuit F014 F014 SENSORFAULT Short circuit of the Level Roll Sensor circuit Faulty level sensor All functions inhibited GS 3232 LEVEL ROLL BAT battery positive GCON ECM F015 FO15 SENSORFAULT Short circuit of the Level Roll Sensor circuit ied GS 3232 LEVEL ROLL BAT battery negative GCON ECM Short circuit in the left front outrigger sen
278. m reaches the stowed position press the Enter button When prompted push the red Emergency Stop button in to complete the Platform Overload Calibration procedure Service Manual Scissor Components No Load Calibration 1 Fully charge the batteries and check the hydraulic fluid level Note The hydraulic fluid level must be between the FULL and ADD marks on the hydraulic tank 2 10 11 Genie BRAND GS 30 GS 32 GS 46 GS 47 Apply a thin layer of dry film lubricant to the area of the chassis where the scissor arm wear pads make contact Chock both sides of the wheels at the steer end of the machine Turn the key switch to ground control At the ground controls press and hold the Menu Up and Menu Down buttons While pressing both buttons down pull out the red Emergency Stop Button Release the Menu Up and Menu Down buttons after the ground controller powers up At the ground controls use the Menu Up or Menu Down buttons to scroll to Platform Overload Press the Enter button to select the Platform Overload Use the Menu Up or Menu Down buttons to scroll to Platform Overload Calibrate Press the Enter button to select Platform Overload Calibrate 201 Service Manual es 7 Scissor Components 12 13 14 15 16 17 202 Confirm the Platform Overload Calibrate selection by pressing the Enter button again Use the Menu Up or Menu Down buttons to se
279. machine with a strap or other suitable device Remove the retaining fasteners securing the chassis mount bracket to the chassis Remove the linkset from the machine ACAUTION Bodily injury hazard The Part No 228901 number 1 inner and outer arms index 8 and 17 may become unbalanced and fall if not properly supported when removed from the machine Component damage hazard Be sure not to damage the limit switch or level sensor components when the number 1 inner and outer arms index 8 and 17 are removed from the machine Service Manual Scissor Components How to Replace the Scissor Arm Wear Pads Note Machines equipped with a Platform Height Sensor begin at step 1 Machines without a Platform Height Sensor begin at step 24 1 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 Raise the platform 7 to 8 feet 2 1 to 2 4 3 Liftthe safety arm move it to the center of the scissor arm and rotate down to a vertical position 4 Lower the platform onto the safety arm A WARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 5 At the ground control turn the key switch to the off position and push in the red Emergency Stop button to the off position 6 Disconnect the battery pack from the machine A WARNING Electrocution burn hazard Contact with electrically char
280. marking two lines on the ground 40 feet 12 2 m apart 2 Turnthe key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls Models without proportional lift 3 Press hold the high or low speed lift enable button Or press the lift function button if equipped 4 Pressthe platform up button Genie 34 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual Checklist B Procedures 11 Press and hold the drive steer function enable 12 Move the control handle in the direction switch on the control handle indicated by the blue arrow on the control panel until the machine begins to move forward a 13 Bring the machine to top drive speed before reaching the start line Begin timing when the selected reference point on the machine crosses the start line 14 Continue at full speed and note the time when your reference point on the machine passes the finish line Refer to Section 2 Specifications ay 9 4 M H A models with proportional lift drive steer function enable switch platform up button slow speed lift enable button high speed lift enable button blue arrow drive function button lift function button aro Qaaon e Genie BRAND Part No 22
281. n at the ground control side index 2 and twist to remove the pin Remove the retaining fasteners from the 33 35 36 A CAUTION 37 Service Manual Scissor Components Attach a lifting strap from an overhead crane to the number 6 outer arm at the battery side index 19 Remove the retaining fasteners from the number 6 center pivot pin index 2 at the battery side Place a rod through the number 6 center pivot pin at the battery side index 2 and twist to remove the pin Remove the number 6 outer arm index 19 from the machine Crushing hazard The number 6 outer arm index 19 may become unbalanced and fall if not properly supported when removed from the machine Attach a lifting strap from an overhead crane to the number 6 inner arm index 18 Raise the arm to a vertical position number 6 pivot pin index 20 at the 38 Remove the retaining fasteners from the non steer end number 6 pivot pin at the steer end of the machine index 3 32 Use a soft metal drift to remove the number 6 pivot pin index 20 from the non steer end 39 Use a soft metal drift to remove the number of the machine Remove the number 6 outer 6 pivot pin index 3 from the steer end of the arm at the ground control side index 19 machine Remove the number 6 inner arm from the machine index 18 from the machine Crushing hazard The number CAUTION Crushing hazard The number CAUTION 6 outer arm at the ground cont
282. n the level sensor base closest to the short side of the level sensor mount FNIT hazard The level sensor must be installed with the 13 14 15 16 78 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 level sensor as instructed could result in the machine tipping over causing death or serious injury 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 0 375 inch 10 mm Connect the chassis wire harness to the level sensor wire harness Turn the key switch to the ground control and pull out the red Emergency Stop button to the on position at the ground controls Adjust the level sensor retaining fasteners until the bubble at the top of the level sensor is centered in the circles Result The tilt sensor alarm should not sound 18 19 20 21 Y Genie GS 30 GS 32 GS 46 GS 47 Raise the platform slightly Return the safety arm to the stowed position Lower the platform to the stowed position Center a lifting jack under the drive chassis at the ground controls side of the machine Raise the machin
283. nd control side index 26 may become unbalanced and fall if not properly supported when the pivot pin is removed 92 Attach a lifting strap from an overhead crane 93 A CAUTION Part No 228901 to the number 2 outer arm at the battery side index 26 Remove the retaining fasteners from the number 2 center pivot pin index 11 at the battery side 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 outer arm index 26 may become unbalanced and fall if not properly supported when the pivot pin is removed Service Manual Scissor Components 95 Remove the number 2 outer arm index 26 A CAUTION 97 98 A CAUTION 99 from the machine Crushing hazard The number 2 outer arm index 26 may become unbalanced and fall if not properly supported when removed from the machine Attach a lifting strap from an overhead crane to the number 2 inner arm index 25 Raise the arm to a vertical position Remove the retaining fasteners from the number 2 pivot pin at the steer end of the machine index 12 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 inner arm index 25 may become unbalanced and fall if not properly supported when the pivot pin is removed At
284. nd lay them off to the side 43 Placea4x4x 10 inch 10 x 10 x 25 Component damage hazard block onto the number 1 inner arm cylinder Cables can be damaged if they plate index 8 are kinked or pinched 44 Lower the cylinder onto the block 49 Disconnect the number 2A and 2B cable ilv Ini bridges from the scissor linkset and remove Bodily injury hazard Keep CAUTION hands clear of moving parts both cable bridges from the machine when lowering the cylinder 50 Attach a lifting strap from an overhead crane to the number 2 outer arm at the ground 45 Attach a lifting strap from an overhead crane control side index 14 to the number 3 inner arm index 10 Raise M the arm to a vertical position 51 Remove the retaining fasteners from the number 2 center pivot pin index 5 at the 46 Remove the retaining fasteners from the ground control side number 3 pivot pin at the steer end of the machine index 4 52 Place a rod through the number 2 center pivot pin at the ground control side index 5 and twist to remove the pin 53 Remove the retaining fasteners from the number 2 pivot pin index 15 at the non steer end Genie 138 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual 54 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 The number 2 outer
285. nd other jewelry AWARNING 1 Test the coil resistance See 5 9 How to Test a Coil in this section 2 Connect a 100 resistor to the negative terminal of a known good 9V DC battery Connect the other end of the resistor to a terminal on the coil Note The battery should read 9V DC or more when measured across the terminals Resistor 100 Genie part number 27287 3 Seta multimeter to read DC amperage Note 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 Note If testing a single terminal coil connect the negative lead to the internal metallic ring at either end of the coil Proportional solenoid valve 2 position 23 90 2 way 20V DC with diode schematic item DN How to Test a Coil Diode Genie incorporates spike suppressing diodes in all of its coils Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil Faulty diodes can fail to protect the electrical system resulting in a tripped circuit breaker or component damage 1 9 1 1 t aa V 1 1 multimeter 2 9V DC battery 3 100 resistor 4 coil Genie BRAND Part No 228901 G
286. nd significant component damage Dealer service is required Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Turn the key switch to ground controls and pull out the red Emergency Stop button to the on position at both ground and platform controls 2 Raise the platform 7 to 8 feet 2 1 to 2 4 m Genie 192 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual Scissor Components 3 Liftthe safety arm move it to the center of the 4 scissor arm and rotate down to a vertical position AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform Lower the platform onto the safety arm 5 Using a suitable lifting device support the link stack at the steer end of the machine 6 Atthe ground controls turn the key switch to the off position and push in the red Emergency Stop button to the off position 7 Disconnect the battery pack from the machine A WARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 8 Tagand disconnect the wiring from the solenoid valve coil at the barrel end of the lift cylinder Ski
287. ng cable from the valve Note During assembly the manual platform lowering cable needs to be properly adjusted See 2 7 How to Adjust the Manual Platform Lowering Cable Scissor Components 11 Remove the fasteners securing the manual lowering cable mount bracket to the cylinder Remove the bracket from the cylinder 12 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 13 Attach a lifting strap from an overhead crane to the rod end of the lift cylinder for support 14 Remove the fasteners from the lift cylinder rod end pivot pin Use a soft metal drift to remove the pin ACAUTION Crushing hazard The lift cylinder will fall if not properly supported when the pivot pin is removed 15 Lower the cylinder onto the number 1 inner arm cylinder plate 16 Attach a lifting strap from an overhead crane or similar lifting device to the barrel end of the lift cylinder for support Part No 228901 Genie BRAND GS 30 GS 32 GS 46 GS 47 Service Manual November 2014 Scissor Components 17 Remove the fasteners from the lift cylinder barrel end pivot pin Use a soft metal drift to remove the pin ACAUTION Crushing hazard The lift
288. nual A574 High Strength THREAD Grade 5 Ny Grade 8 Black Oxide Bolts LUBED LUBED DRY LUBED in lbs Nm in Ibs Nm in Ibs Nm in Ibs Nm ___ 44 ___20 80 9 100 113 10 124 140 158 130 147 ___28 90 101 120 135 120 13 5 160 18 740 158 OO DRY LUBED DRY LUBED ft lbs Nm Nm ft lbs Nm ft lbs Nm Nm _ 13 19 19 257 20 271 27 366 24 325 312 31 42 33 447 44 596 538 515 35 2 35 474 37 501 49 664 43 583 49 664 50 67 8 70 947 61 827 555 55 745 60 813 80 1084 68 921 57 773 75 1016 80 1084 110 149 93 126 64 867 85 115 90 122 120 162 105 142 122 120 162 130 176 170 230 140 i199 149 150 203 160 217 210 284 180 244 176 170 230 180 244 240 325 200 271 366 280 379 380 515 320 433 298 406 310 420 420 569 350 474 320 433 430 583 450 60 610 827 510 691 350 474 470 637 500 678 670 908 560 759 480 650 640 867 680 922 910 1233 770 1044 530 718 710 962 750 1016 990 1342 840 1139 670 908 890 1206 1080 1464 1440 1952 1220 1654 840 2670 1640 2190 3000 METRIC FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in
289. nual Electrical Schematic GS 3232 ANSI and CSA Models from serial number GS3211A 110000 Part No 228901 BRAND E F G H J K L N fry _ C2 __ 1 lt gt V OUT RD 1 1 RD PCON V QUT 1 1 1 PCON V QUT RD 2 lt lt RD gi H1 E gt ESTOP WH 2 2 WH ESTOP l2 2 ESTOP WH 3 BK _ ALARM FROM C415 1 DATA LINK BL 3 63 BL DATA LINK ts 3 DATA BL 4 lt gt E STOP WH 2 DATA LINK OR 4 4 OR DATA LINK 4 DATA LINK OR 5 lt 6 E STOP WH x Ex PCON V OUT BR 5 5 BR PCON V OUT 15 5 PCON V OUT BR 6 P2 6 6 76 66 Stop NOY U3 PLATFORM CONTROLS PRINTED CIRCUIT BOARD gt JOYSTICK AXIS 1 1 2 05 JCS ELECTRONIC CONTROL MODULE STEER SWITCH COM BK 3 S OVETICKC PLATFORM gt DRIVE ENABLE COM YL 44 CONTROLLER CONTROLLER gt DRIVE ENABLE 5 STEER LEFT BL 46 STEER RIGHT GR 7 Y Y Y Y Y JOYSTICK 5VDC 8 YY Y Y Y 65 7 8 9 10 11 12 JOYSTICK GND m a a I tr X 9 9 CHASSIS GND a Ls o m 5 0 3 5 5 5 2 8 8 9 5 ca x tr z o B 3 a 8 8 8 5 110V 240V AC Zz a E POWER TO PLATFORM E E 1 es 2 M P BE 8 8 3 5 u 2 2 l
290. number pin at the ground control side index 7 and 2 outer arm index 19 may twist to remove the pin become unbalanced and fall if 67 Remove the retaining fasteners from the id properly number 2 pivot pin index 20 at the 72 Remove the number 2 outer arm index 19 68 Use a soft metal drift to remove the number from the machine 2 pivot pin index 20 from the non steer end of the machine Remove the number 2 outer ACAUTION Crushing hazard The number arm at the ground control side index 19 2 outer arm index 19 may from the machine become unbalanced and fall if not properly supported when CAUTION The number 2 outer arm at the removed from the machine ground control side index 19 may become unbalanced and 73 Attach a lifting strap from an overhead crane fall if not properly supported to the number 2 inner arm index 18 Raise when the pivot pin is removed the arm to a vertical position 69 Attach a lifting strap from an overhead crane ame die FE fasteners to the number 2 outer arm at the battery side nuns 2 pivot pirt al E SESLENE OPINE index 19 machine index 8 T 75 Use a soft metal drift to remove the number i 2 VM 2 pivot pin index 8 from the steer end of the battery side machine Remove the number 2 inner arm index 18 from the machine CAUTION Crushing hazard The number 2 inner arm index 18 may become unbalanced and fall if not properly supported
291. o the barrel end of the lift cylinder for support 17 Remove the fasteners from the lift cylinder barrel end pivot pin Use a soft metal drift to remove the pin ACAUTION Crushing hazard The lift cylinder will fall if not properly supported when the pivot pin is removed 18 Support and secure the lift cylinder to an appropriate lifting device 19 Remove the lift cylinder through the scissor arms at the steer end of the machine CAUTION Crushing hazard The lift cylinder will 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 Scissor Components 20 Install new cylinder fittings hoses and pressure transducer if equipped 2 2 2 Upper Lift Cylinder lift cylinder orifice fitting schematic item O connector fitting hydraulic hose solenoid valve schematic item N relief valve schematic item Q Note At the upper lift cylinder install the orifice fitting with the small opening of the orifice fitting closest to the supply hose Torque specifications Genie BRAND Solenoid valve 2 position 2 way 20 ft lbs N C 27 Nm schematic item N Relief valve 20 ft lbs schematic item Q 27 Nm Coil Nut 5 ft Ibs 7 Nm Pressure transducer if equipped 27 ft lbs schematic item R
292. oil analysis B 13 Tank venting system B 14 Latch components B 15 Voltage inverter if equipped B 16 Down limit switch and pothole limit switches B 17 Up limit switch and max drive height limit switches if equipped Genie BRAND GS 30 GS 32 GS 46 GS 47 Comments Part No 228901 November 2014 Service Manual A 1 Inspect the Manuals and Decals Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Maintaining the operator s and safety manuals in good condition is essential to safe machine operation Manuals are included with each machine and should be stored in the container provided in the platform An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition In addition maintaining all of the safety and instructional decals in good condition is mandatory for safe machine operation Decals alert operators and personnel to the many possible hazards associated with using this machine They also provide users with operation and maintenance information An illegible decal will fail to alert personnel of a procedure or hazard and could result in unsafe operating conditions 1 Check to make sure that the operator s and safety manuals are present and complete in the storage container on the platform 2 Examine the pages of each manual to
293. olenoid valve 3 position 4 way E oe 25 ft lbs 34 Nm forward reverse 6 Solenoid valve 3 position 4 way F Steer left right 25 ft lbs 34 Nm 7 Flow regulator and relief valve G Steer circuit 26 ft lbs 35 Nm 0 75 gpm 2 8 L min 1500 psi 130 bar 8 Solenoid valve 2 position 4 way H Platform up 25 ft lbs 34 Nm 9 Relief valve 3700 psi 255 bar maximum System relief 20 ft lbs 27 Nm How to Install a Valve Cartridge 1 Dip the cartridge in clean oil to lube the O rings 2 Screw the cartridge in by hand until the top O ring is met then torque to specifications If required install the valve coil s onto the valve stem Install the coil nut onto the valve stem and torque to specifications 88 GS 30 GS 32 GS 46 GS 47 Genie Part No 228901 Service Manual Manifolds November 2014 S Sb lt ES lt Note alpha callouts refer to corresponding notes on the hydraulic schematic Note alpha numeric callouts refer to corresponding notes on the electrical schematic Genie BRAND Part No 228901 GS 30 GS 32 GS 46 GS 47 89 Service Manual November 2014 OS EE gt Manifolds 5 2 Function Manifold Components GS 2032 GS 2632 GS 3232 GS 2046 GS 2646 and GS 3246 The function manifold is mounted behind an inspection door at the ground control side of the machine Index No Description Schematic Item Function Torque
294. ols LED does not display PHS The alarm does not sound and the steer and drive functions operate Replace the down limit switch 14 Press and hold the high or low speed lift enable button Gonio Part No 228901 GS 30 GS 32 65 46 GS 47 41 Service Manual November 2014 Checklist B Procedures 15 Press the platform up button Raise the platform approximately 12 inches 0 3 m Result The ground controls LCD displays PHS POTHOLE GUARDS STUCK and the platform controls LED displays PHS The alarm sounds The machine is functioning properly Result The ground controls LCD does not display PHS POTHOLE GUARDS STUCK and the platform controls LED does not display PHS The alarm does not sound Replace the down limit switch 16 Raise the platform 7 to 8 feet 2 1 to 2 4 17 Lift the safety arm move it to the center of the scissor arm and rotate down to a vertical position 18 Lower the platform onto the safety arm A WARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 19 Turn the key switch to the off position 20 Disconnect the platform controls from the ECM cable 21 Securely install the connector of the ECM cable into the platform control cable 23 24 25 26 Working at the platform securely install the connector of the platform controls into the platform control cable Enable the down limit switch Loosen the fastener securing the roller
295. om the platform controls circuit board and save Circuit board fastener torque specifications 5 in Ibs 0 6 Nm Note Before installing a circuit board place the transparent caps removed in step 11 over the circuit board buttons Hand tighten until screws seat Note After installing the circuit board check for proper button operation Excessive torque of the circuit board fasteners will cause the buttons to bind Moderate torque of the circuit board fasteners will not allow the buttons to engage Genie BRAND GS 30 GS 32 GS 46 GS 47 61 Part No 228901 Service Manual November 2014 Platform Controls 1 2 Joystick How to Remove the Joystick 1 Push in the red Emergency Stop button to the off position at both the ground and platform controls 2 Disconnect the platform controls from the control cable at the platform 3 Remove the fasteners securing the platform control box to the platform control bracket 4 Remove the fasteners securing the bottom cover to the platform control box Open the control box 5 Remove the ties securing the joystick wire harness 6 Carefully disconnect the joystick wire harness from the platform controls circuit board A WARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Component damage hazard Electrostatic discharge E
296. om the platform How to Adjust the Steer Relief Valve Perform this test from the ground with the platform controls Do not stand in the platform Be sure the hydraulic oil level is at the FULL mark GS 1530 32 and GS 1930 32 on the hydraulic tank a test port 1 Locate the steer relief valve on the function b steer relief valve manifold schematic item G AH or DH 5 Activate the function enable switch and press 2 Connect a 0 to 5000 psi 0 to 350 bar and hold the steer thumb rocker switch to the pressure gauge to the test port on the function right Allow the wheels to completely turn to manifold schematic item A AA or DA the right Continue holding the switch while 3 Remove the platform controls from the observing the pressure reading on the platform 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 Genie BRAND Part No 228901 GS 30 GS 32 GS 46 GS 47 103 Service Manual November 2014 Manifolds 7 machine off Hold the steer relief valve with a wrench and remove the cap schematic item G AH or DH 8 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Component damage hazard Do not adj
297. on at the ground controls Result The ground controls LCD display will show the following SOFTWARE UPDATE CONNECT ETHERNET Genie 68 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual Ground Controls 5 Locate the diagnostic port on the side of the 8 Launch a web browser such as Internet GCON Remove one of the fasteners securing Explorer amp Chrome or Firefox amp on your the cover and set aside Loosen the other PC or laptop Type the IP address from step fastener Do not remove it 7 into the web browser address bar and press enter Result The following screen will be displayed Genie smart Link m Help Software Current slab 2012 prod Loaded No Genie Flash File selected Build Time 01 08 55 Feb 29 2012 Summar y Large Slab and 3232 Production d Run application lt a file chosen 0 Bootloader 17 10 28 Jun 01 2011 o kf a diagnostic port 9 Select the Choose File button and navigate to the downloaded Genie Flash file gff 6 Connect one end of a CAT5 Ethernet cable into the diagnostic port Connect the other end Note Verify it is the correct flash file into a PC or laptop 10 Select the Load Flash File button to verify the Result The ground controls LCD display will file is a gff file show the following Result The following screen will be displayed OPEN WEB BROWSER Genie
298. ontrol side index 13 and twist to remove the pin Remove the retaining fasteners from the number 2 pivot pin index 32 at the non steer end 175 Service Manual es Scissor Components 91 A CAUTION 92 93 A CAUTION Use a soft metal drift to remove the number 2 pivot pin index 32 from the non steer end of the machine Remove the number 2 outer arm at the ground control side index 31 from the machine Crushing hazard The number 2 outer arm at the ground control side index 31 may become unbalanced and fall if not properly supported when the pivot pin is removed Attach a lifting strap from an overhead crane to the number 2 outer arm at the battery side index 31 Remove the retaining fasteners from the number 2 center pivot pin index 13 at the battery side Place a rod through the number 2 center pivot pin at the battery side index 13 and twist to remove the pin Crushing hazard The number 2 outer arm index 31 may become unbalanced and fall if not properly supported when the pivot pin is removed November 2014 95 Remove the number 2 outer arm index 31 A CAUTION 97 98 A CAUTION 99 from the machine Crushing hazard The number 2 outer arm index 31 may become unbalanced and fall if not properly supported when removed from the machine Attach a lifting strap from an overhead crane to the number 2 inner arm index 30 Raise the arm to a verti
299. orted and secured to the lifting device Block the steer wheels 4 Remove the cotter from the wheel castle nut Note Always replace the cotter pin with a new one when removing the castle nut 5 Loosen the wheel castle nut Do not remove it Non Steer Axle Components 7 Raise the machine approximately 2 inches 5 cm Place blocks under the chassis for support A WARNING Crushing hazard The chassis will 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 A CAUTION Crushing hazard The brake will fall if not properly supported when the mounting fasteners are removed Torque specifications Brake mounting fasteners dry 75 ft lbs 6 Center a lifting jack under the drive chassis at 102 Nm the non steer end of the machine Brake mounting fasteners lubricated 56 ft lbs 76 Nm Genie _ 0 Part No 228901 GS 30 GS 32 GS 46 GS 47 111 Service Manual November 2014
300. osition press the Enter button When prompted push the red Emergency Stop button in to complete the No Load Calibration procedure Part No 228901 November 2014 Service Manual 9 11 Platform Overload Recovery Message If the ground controls LCD screen displays OL PLATFORM OVERLOADED the emergency lowering system has been used while the platform was overloaded How to Clear the Platform Overload Recovery Message Note This message shall be cleared by a person trained and qualified on the troubleshooting and repair of this machine Note Use the following chart to identify the description of each LCD screen control button used in this procedure 2 4 Escape Scrollup Scroll down Enter 1 Turn the key switch to the ground controls position and pull out the red Emergency Stop button to the on position at the platform controls 2 Press and hold the ground control scroll up and scroll down buttons Repair Procedures Pull out the red Emergency Stop button at the ground controls Result The ground control LCD display will show the following LIFT SETUP TEST SELECT MODEL Press the scroll down button Result The ground control LCD display will show the following LIFTSETUP TEST SELECT OPTION Press the enter button Result The ground control LCD display will show the following SELECT OPTION PLAT OVERLOAD Pres
301. ot pin index 2 at the battery side Place a rod through the number 3 center pivot pin at the battery side index 2 and twist to remove the pin 31 Attach a lifting strap from an overhead crane 39 Remove the number 3 outer arm index 11 to the number 3 outer arm at the ground from the machine control side index 11 32 Remove the retaining fasteners from the A CAUTION 7 4 number center pivot pin index 2 the become unbalanced and tall if ground control side not properly supported when removed from the machine Genie Part No 228901 BRAND GS 30 GS 32 GS 46 GS 47 Service Manual es 7 Scissor Components November 2014 40 Attach a lifting strap from an overhead 47 Use a soft metal drift to remove the number to the lug of the rod end of the lift cylinder 3 pivot pin index 4 from the steer end of the 41 Remove the retaining fasteners from the lift machine Remove the number 3 inner arm cylinder rod end pivot pin index 3 index 10 from the machine 42 Use a soft metal drift to remove the lift ACAUTION Crushing hazard The number cylinder rod end pivot pin index 3 from the 3 inner arm index 10 may machine become unbalanced and fall if not properly supported when the ACAUTION Crushing hazard The lift pivot pin is removed cylinder will fall if not properly supported when the pivot pin is 48 Remove the cables from the number 2A and removed 2B cable bridges a
302. ot pin is removed Remove the cables from the number 2A and 2B cable bridges and lay them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched Disconnect the number 2A and 2B cable bridges from the scissor linkset and remove both cable bridges from the machine Attach a lifting strap from an overhead crane to the number 2 outer arm at the ground control side index 26 Remove the retaining fasteners from the number 2 center pivot pin index 11 at the ground control side Place a rod through the number 2 center pivot pin at the ground control side index 11 and twist to remove the pin Remove the retaining fasteners from the number 2 pivot pin index 27 at the 86 81 Lower the cylinder onto the block CAUTION Bodily injury hazard Keep hands clear of moving parts 87 when lowering the cylinder 82 Attach a lifting strap from an overhead crane 88 to the number 3 inner arm index 23 Raise the arm to a vertical position 83 Remove the retaining fasteners from the 89 number 3 pivot pin at the steer end of the machine index 10 90 non steer end Genie 162 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 91 A CAUTION 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 The number 2 outer arm at the grou
303. outrigger 1077 HO7T COILFAULT outrigger coil short circuit or open Right rear outrigger GS 3232 RR RIGGER dc functions inhibited open circuit circuit GCON ECM 078 Short or open circuit platform down 9530 HO7 amp COILFAULT themes Platform down PLAT DOWN1 Pos 9 Platform down 1 coil short or open circuit function inhibited GS46 amp open circuit GCON ECM GS47 Hi Lo speed coil disabled Machine will H079 operate in high speed GS32 H079 COILFAULT Short circuit of the HI LO speed circuit to lt Short circuit inj FIULO speed harmess mode open circuit or atas HI LO speed coil short or open circuit short with battery GS46 amp HI LO SPEED battery positive negative or open circuit 5 GS47 GCON negative Machine will operate in low speed mode if short with battery positive H080 GS30 H080 COILFAULT Short circuit of the steer left circuit to battery Short or open circuit in steer left harness Steer left function 6532 STEER LEFT negative or open circuit Steer left coil short of open circuit inhibited 6946 8 9 ECM GS47 H081 6530 H081 COILFAULT Short circuit of the steer right circuit to battery Short open circuit mE right harness Steer right function GS32 STEER RIGHT ti ircuit Steer right coil short or open circuit inhibited GS46 amp negative or open circuit GCON ECM 6547 Short circuit in relief valve harness
304. ove the Pressure Transducer if equipped Note Calibrating the platform overload system is not required if the pressure transducer is the only component replaced on the machine lift structure In the event of frequent nuisance trips occurring after a pressure transducer is replaced a no load calibration is recommended Refer to Repair Procedure 9 10 How to Calibrate the Platform Overload System if equipped 1 the key switch to ground controls and pull out the red Emergency Stop button to the on position at both ground and platform controls 2 Raise the platform 7 to 8 feet 2 1 to 2 4 m 3 Liftthe safety arm move it to the center of the Scissor arm and rotate down to a vertical position 4 Lower the platform onto the safety arm 5 Atthe ground controls turn the key switch to the off position and push in the red Emergency Stop button to the off position Genie 196 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual 6 Disconnect the battery pack from the machine A WARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Pull the manual lowering cable and hold for 3 seconds Tag and disconnect the three pin connector from the pressure transducer harness Slowly loosen the pressure transducer from the lift cylinder and remove Discard the pressure transducer
305. ovember 2014 Service Manual Electrical Schematic GS 2046 and GS 2646 CE and AUS Models from serial numbers GS4612A 110000 and GS4612C 10000 A B C D E F G H J K L M N G2 C3 1 gt l T ES X PCON V OUT RD 1 1 RD PCON V OUT 1 1 PCON V OUT RD 2 lt RD lt H1 1 gt 8 1 12 4 27 2 2 ESTOP 3 lt BK iL ALARM FROM C41 E gt _DATALINK BL 1 3 BL DATA LINK 3 lt lt 3 DATA LINK BL 4 gt E STOP WH X E gt DATA LINK OR 4 lt lt 4 OR DATA LINK 4 lt lt 4 DATA LINK OR 5 lt lt E STOP WH a PCON V OUT BR 5 lt lt 8 BR PON V OUT 5 5 PCON V QUT BR 6 1 P2 4 Sx EMERGENCY a 166 16 661 2 U3 PLATFORM CONTROLS PRINTED CIRCUIT BOARD 2 em JOYSTICK AXIS 1 d 1 gt STEER SWITCH 3 Um PLATFORM 5 DRIVE ENABLE COM YL 4 SONTROLLER CONTROLLER DRIVE ENABLE WH15 gt STEER LEFT BL 6 5 STEER RIGHT GR47 5 JOYSTICK 5VDC RD4 amp 3 9 gt JOYSTICK GND BK410 11 7 CHASSIS GND 12 NOTE 4 MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF 110V 240V AC POWER TO PLATFORM AC I
306. owering the platform 5 At the ground controls turn the key switch to the off position and push in the red Emergency Stop button to the off position 6 Disconnect the battery pack from the machine A WARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 7 Remove the fasteners securing the large platform height sensor cover to the large platform height sensor bracket 8 Remove the platform height sensor cover 9 Tagand disconnect the platform height sensor from the platform height sensor harness 10 Remove the fastener securing the platform height sensor assembly to the number 1 inner arm 11 Remove the platform height sensor assembly from the number 1 pivot pin Genie BRAND GS 30 GS 32 GS 46 GS 47 135 Part No 228901 Service Manual ss ss Scissor Components 12 13 14 15 16 17 18 19 20 136 Remove the plastic nut securing the squeeze connector to the large platform height sensor bracket Remove the squeeze connector from the large platform height sensor bracket Remove the fasteners securing the large platform height sensor bracket to the number 1 inner arm pivot bracket Remove the large platform height sensor bracket from the number 1 inner arm pivot bracket Install the fasteners removed in 14 to the number 1 inner arm pivot bracket an
307. p FOOTSW OPEN BAT Switch to battery negative GCON ECM inhibited GS47 0040 6530 Short circuit the foot switch harness GS32 U040 SWITCHFAULT PCON deck switch pressed at machine Foot switch All functions 6546 amp FOOTSW TIMEOUT startup inhibited ECM GS47 GS 3232 excluded 226 Genie BRAND GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 _ _ _ Diagnostics Type FXXX Faults Service Manual DTC Message on Problem Possible Failure Number GCON LCD Description Causes Mode F001 F001 SWITCHFAULT Short circuit of the up limit 1 switch at quoc S ei pM Platform up function GS 3232 UP LIMIT1 BAT system startup GCON ECM inhibited F003 GS30 cane Short circuit of the down limit switch circuit All functions 6332 4 1 the down limit 1 switchat Down limit 1 switch short circuit inhibited except GS46 amp p GCON ECM platform down GS47 All functions inhibited except F005 platform down as long GS30 ad 219 Short circuit of the pothole switch circuit as machine is in the GS32 EU MET MUS the pothole limit 1 switch at Pothole limit 1 switch short circuit elevated position If GS46 amp i y GCON ECM machine is in stowed GS47 position all functionality is resumed All functions inhibited except
308. p to step 13 if removing the upper cylinder a relieve valve schematic item Q 9 If equipped tag and disconnect the three pin b lift cylinder connector from the pressure transducer c connector fitting harness To remove the pressure transducer d hydraulic hose refer to Repair Procedure 9 9 How to e pressure transducer schematic item R if Remove the Pressure Transducer if equipped equipped manual lowering cable g solenoid valve schematic item DO h cable mount bracket 10 Loosen the adjustment nuts on the solenoid valve and disconnect the manual lowering cable from the valve Note During assembly the manual platform lowering cable needs to be properly adjusted See 2 7 How to Adjust the Manual Platform Lowering Cable Genie BRAND Part No 228901 GS 30 GS 32 GS 46 GS 47 193 Service Manual November 2014 Scissor Components 11 Remove the fasteners securing the manual lowering cable mount bracket to the cylinder Remove the bracket from the cylinder 12 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 17 Remove the fasteners from the lift cylinder barrel end pivot pin Use a soft metal drift to remove the pin
309. position at the ground controls 21 Using the ground control menu buttons navigate to Service Override Mode Select Service Override Mode Note The machine must be in Service Override Mode to raise the platform While in Service Override Mode only the GCON will operate with limited functionality The platform will raise a predetermined amount of time and stop 22 Raise the platform and return the safety arm to the stowed position 23 Fully lower the platform to the stowed position 24 Remove the platform See 10 1 How to Remove the Platform 25 Support and secure the entry ladder to an appropriate lifting device 26 Remove the fasteners from the entry ladder and remove the entry ladder from the machine ACAUTION Crushing hazard The entry ladder will fall if not properly supported and secured to the lifting device Genie GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 27 28 29 30 31 32 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
310. positive post of a multimeter probe safe machine operation Continued use of an securely fit the post into pin C of the pressure improperly operating platform overload pressure transducer cable rubber boot Refer to the transducer or platform height sensor could result illustration below in the system not sensing an overloaded platform condition Machine stability could be compromised 8 Using the negative post of a multimeter probe resulting in the machine tipping over securely fit the post into pin B of the pressure transducer cable rubber boot Refer to the Note Perform this procedure with the machine on illustration below a firm level surface that is free of obstructions 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 Raise the platform 7 to 8 feet 2 1 to 2 4 m Lift the safety arm move it to the center of the scissor arm and rotate down to a vertical position negative post b positive post pressure transducer cable d ECM pressure transducer wire harness Gri 46 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual 9 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position 10 Using the multimeter measure the voltage reading of the pressure transducer at pin C and B GS 1532 GS 1932 GS 2032 GS
311. properly Part No 228901 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 35 36 Genie BRAND GS 30 GS 32 GS 46 GS 47 Service Manual Scissor Components Remove both old wear pads Install two new wear pads Slide the scissor assembly back into the drive chassis 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 careful not to damage the level sensor or limit switch while moving the scissor assembly 133 Service Manual November 2014 Scissor Components 9 49 3 5 8 5 Steer End s f GS 2046 K Non steer End 1 Number 4 pivot pin 2 Number 3 center pivot pin 2 pins 3 Lift cylinder rod end pivot pin 4 Number 3 pivot pin steer end 5 Number 2 center pivot pin 2 pins 6 Number 2 pivot pin steer end 7 Number 1 center pivot pin 2 pins 8 Number 1 inner arm 9 Number 1 pivot pin 134 10 Number 3 inner arm 11 Number 3 outer arm 12 Number 3 pivot pin non steer end 13 Number 2 inner arm 14 Number 2 outer arm 15 Number 2 pivot pin non steer end 16 Lift cylinder
312. r the pump supply lines and has an external return line filter How to Remove the Hydraulic Tank Component damage hazard The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Hydraulic Tank 2 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 3 Tag and disconnect the hydraulic tank hard line from the pump Remove the hard line from the machine Cap the fitting on the pump 4 Remove the hydraulic tank retaining fasteners and remove the hydraulic tank from the machine 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 5 Remove the hydraulic tank cap and drain the tank into a suitable container Torque specifications Specifications Hydraulic Hose and Fitting Torque Hydraulic retaining fasteners dry 35 in Ibs Specifications 4 Nm Perform this procedure with the platform in the Hydraulic tank retaining fasteners 26 4 stowed position lubricated 2 9 Nm 1
313. r 12V DC battery Deutsch connector tee 200 Q 122 Resistor Contactor Horn or alarm Flashing beacon V gia V sie Platform height sensor Pressure transducer Genie 236 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual Electrical Schematic GS 1530 32 and GS 1930 32 ANSI and CSA Models from serial number GS3010A 110000 to GS3011A 110827 237 Service Manual November 2014 42 Electrical Schematic GS 1530 32 and GS 1930 32ANSI and CSA Models from serial number GS3010A 110000 to GS3011A 110827 A B D E F G H J K L M N QD30_ QD16_ eR 159 1 6n GR 1 1 T2 DD
314. red install the valve coil s onto the valve stem Install the coil nut onto the valve stem and torque to specifications 1 1 1 92 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual Manifolds O Note alpha callouts refer to corresponding notes on the hydraulic schematic Note alpha numeric callouts refer to corresponding notes on the electrical schematic Genie BRAND Part No 228901 GS 30 GS 32 GS 46 GS 47 93 Service Manual November 2014 OS ET es Manifolds 5 4 Check Valve Manifold Components GS 1530 GS 1532 GS 1930 and GS 1932 The check valve manifold is mounted on the function manifold Index No Description Schematic Item Function Torque 1 Check valve 200 psi 13 8 bar S Drive circuit 20 ft lbs 27 Nm J Note alpha callouts refer to corresponding notes on the hydraulic schematic How to Install a Valve Cartridge 1 Dip the cartridge in clean oil to lube the O rings 2 Screw the cartridge in by hand until the top O ring is met then torque to specifications 3 If required install the valve coil s onto the valve stem Install the coil nut onto the valve stem and torque to specifications 1 1 1 11 94 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual Manifolds 5 5 Lift Press
315. relief valve Genie 4 Part 228901 GS 30 GS 32 GS 46 GS 47 99 Service Manual November 2014 Manifolds 5 the key switch to platform controls and 8 Adjust the internal hex socket Turn it pull out the red Emergency Stop button to the clockwise to increase the pressure or on position at both ground and platform counterclockwise to decrease the pressure controls ADANGER Tip over hazard Failure to adjust the relief valves to specification could result in the machine tipping over causing death or serious injury Do not adjust the relief valve pressures higher than specifications e 9 Install the relief valve cap 10 Repeat steps 5 and 6 to confirm the relief valve pressure 11 Place maximum rated load into the platform Secure the load to the platform Refer to Section 2 Specifications GS 1530 32 and GS 1930 32 a test port b system relief valve c lift relief valve 6 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 7 Turnthe machine off Hold the system relief valve with a wrench and remove the cap schematic item I AB or DB GS 32 GS 46 and GS 47 a test port b system relief valve C Steer relief valve d lift relief valve 1 1 100 GS 30 65 32 GS 46 GS 47 Part No 228901 November 2014 1
316. requires that this procedure be performed every 250 hours or quarterly whichever comes first A properly functioning Emergency Stop button 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 Push the red Emergency Stop button at the ground controls to the off position Result No machine functions should operate Geni BRAND GS 30 GS 32 GS 46 GS 47 Part No 228901 Checklist B Procedures 3 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 4 Push down the red Emergency Stop button at the platform controls to the off position Result No machine functions should operate Note The red Emergency Stop button at the ground controls will stop all machine operation even if the key is switched to platform control Note If in ground controls mode and the red Emergency Stop button at the platform controls is pushed in the ground controls LCD will display Platform EStop Depress
317. responding notes on the hydraulic schematic Note alpha numeric callouts refer to corresponding notes on the electrical schematic How to Install a Valve Cartridge 1 Dip the cartridge in clean oil to lube the O rings 2 Screw the cartridge by hand until the top O ring is met then torque to specifications 3 If required install the valve coil s onto the valve stem Install the coil nut onto the valve stem and torque to specifications Genie BRAND Part No 228901 GS 30 GS 32 GS 46 GS 47 97 Service Manual November 2014 Manifolds 5 8 Valve Adjustments Function Manifold Perform this test from the ground with the platform controls Do not stand in the platform Be sure the hydraulic oil level is at the FULL mark on the hydraulic tank How to Adjust the System Relief Valve 1 98 Locate the system relief valve on the function manifold schematic item AB or DB Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the test port on the function manifold schematic item A AA or DA Chock both sides of the wheels at the steer end of the machine Remove the platform controls from the platform Genie GS 30 GS 32 GS 46 GS 47 Turn the key switch to platform controls and pull out the red Emergency Stop button to the on position at both ground and platform controls GS 1530 32 and GS 1930 32 a test port b system relief valve Move and hold
318. rior to each work shift The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The Pre operation Inspection also serves to determine if routine maintenance procedures are required Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine A 3 Perform Function Tests Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first 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 22 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual A 4 Perform 30 Day Service The 30 day maintenance procedure is a onetime procedure to be performed after the first 30 days or 40 hours of usage After this interval refer to the maintenance tables for continued scheduled maintenance 1 Berform the following maintenance procedures e B 4 Inspect the Tires Wheels and Castle Nut Torque e D 2 Rep
319. rm height sensor bracket from the number 1 inner arm pivot bracket Install the fasteners removed in 14 to the number 1 inner arm pivot bracket and chassis NNa hazard Failure to install the fasteners securing Part No 228901 the number 1 inner arm pivot bracket to the chassis could result in the machine tipping over causing death or serious injury Service Manual Scissor Components 17 Connect the battery pack to the machine 18 Turn the key switch to the ground control position 19 Press and hold the ground control scroll up and scroll down buttons 20 Pull out the red Emergency Stop button to the on position at the ground controls 21 Using the ground control menu buttons navigate to Service Override Mode Select Service Override Mode Note The machine must be in Service Override Mode to raise the platform While in Service Override Mode only the GCON will operate with limited functionality The platform will raise a predetermined amount of time and stop 22 Raise the platform and return the safety arm to the stowed position 23 Fully lower the platform to the stowed position 24 Remove the platform See 10 1 How to Remove the Platform 25 Support and secure the entry ladder to an appropriate lifting device 26 Remove the fasteners from the entry ladder and remove the entry ladder from the machine CAUTION Crushing hazard The entry ladder will fall if not properly
320. rm height sensor cover to the large platform height sensor bracket Remove the platform height sensor cover 9 Tagand disconnect the platform height sensor from the platform height sensor harness 10 Remove the fastener securing the platform height sensor assembly to the number 1 inner arm 11 Remove the platform height sensor assembly from the number 1 pivot pin 12 Remove the plastic nut securing the squeeze connector to the large platform height sensor bracket Gon BRAND GS 30 GS 32 GS 46 GS 47 169 Service Manual November 2014 Scissor Components 13 Remove the squeeze connector from the 22 large platform height sensor bracket 14 Remove the fasteners securing the large 23 platform height sensor bracket to the number 1 inner arm pivot bracket 15 Remove the large platform height sensor bracket from the number 1 inner arm pivot bracket 16 Install the fasteners removed in 14 to the number 1 inner arm pivot bracket and chassis ADANGER Tip over hazard Failure to install the fasteners securing the number 1 inner arm pivot bracket to the chassis could result in the machine tipping over causing death or serious injury 17 Connect the battery pack to the machine 18 Turn the key switch to ground controls 19 Press and hold the ground control scroll up and scroll down buttons 20 Pull out the red Emergency Stop button to the on position at the ground controls 21 Usin
321. rol 5 inner arm index 16 side index 19 may become become unbalanced and fall if unbalanced and fall if not not properly supported when properly supported when removed from the machine removed from the machine Genie Part No 228901 BRAND GS 30 GS 32 GS 46 GS 47 Service Manual es Scissor Components 40 Tag disconnect and plug the hydraulic hose AWARNING 41 42 43 the upper lift cylinder Cap the fittings on the cylinder 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 Attach a lifting strap from an overhead crane to the number 5 outer arm at the ground control side index 22 Remove the retaining fasteners from the number 5 center pivot pin index 4 at the ground control side Place a rod through the number 5 center pivot pin at the ground control side index 4 and twist to remove the pin Remove the retaining fasteners from the November 2014 46 Attach a lifting strap from an overhead crane 47 A CAUTION 48 49 to the number 5 outer arm at the battery side index 22 Remove the number 5 outer arm index 22 from the machine Crushing hazard The number 5 outer arm at the battery side index 22 may become unbalanced and fall if not properly supported when removed from the mac
322. rom the platform height sensor harness Remove the fastener securing the platform height sensor assembly to the number 1 inner arm Remove the platform height sensor assembly from the number 1 pivot pin Remove the plastic nut securing the squeeze connector to the large platform height sensor bracket Remove the squeeze connector from the large platform height sensor bracket Remove the fasteners securing the large platform height sensor bracket to the number 1 inner arm pivot bracket Remove the large platform height sensor bracket from the number 1 inner arm pivot bracket Install the fasteners removed in 14 to the number 1 inner arm pivot bracket and chassis NNa hazard Failure to install the fasteners securing Part No 228901 the number 1 inner arm pivot bracket to the chassis could result in the machine tipping over causing death or serious injury Service Manual Scissor Components 17 Connect the battery pack to the machine 18 Turn the key switch to the ground control position 19 Press and hold the ground control scroll up and scroll down buttons 20 Pull out the red Emergency Stop button to the on position at the ground controls 21 Using the ground control menu buttons navigate to Service Override Mode Select Service Override Mode Note The machine must be in Service Override Mode to raise the platform While in Service Override Mode only the GCON will operate with
323. roughly Attempting short cuts may produce hazardous conditions V Be aware of the following hazards and follow generally accepted safe workshop practices ADANGER Crushing hazard When testing or replacing any hydraulic component always support the structure and secure it from movement Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray AWARNING About This Section When a malfunction is discovered the fault code charts in this section will help a service professional pinpoint the cause of the problem To use this section basic hand tools and certain pieces of test equipment are required voltmeter ohmmeter pressure gauges Genie BRAND GS 30 GS 32 GS 46 GS 47 Part No 228901 207 Service Manual November 2014 mec n a _ __ Diagnostics General Repair Process Definitions GSDS Genie SmartLink Diagnostic System Malfunction discovered Identify Troubleshoot ECM Electronic Control Module symptoms GCON Ground Controls PCON Pla
324. rs 9 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results Genie 24 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 a 2 7 10 Check the ambient air temperature and adjust 11 Part No 228901 the specific gravity reading for each cell as follows e Add 0 004 to the reading of each cell for every 10 5 5 C above 80 F 26 7 e Subtract 0 004 from the reading of each cell for every 10 5 5 C below 80 F 26 7 C Result All battery cells display a specific gravity of 1 277 or greater The battery is fully charged Proceed to step 11 Result One or more battery cells display a specific gravity from 1 218 to 1 269 The battery is still usable but at a lower performance The battery will need to be recharged more often Proceed to step 11 Result One or more battery cells display a specific gravity from 1 217 to 1 173 The battery is approaching the end of it s life Proceed to step 11 Result The difference in specific gravity readings between cells is greater than 0 1 OR the specific gravity of one or more cells is 1 172 or less Replace the battery Check the battery acid level If needed replenish with distilled water to 1 8 inch 3 mm below the bottom of the battery fill tube Do not overfill Genie BRAND GS 30 GS 32 GS 46 GS 47 25 Service Manual Checklist
325. rvice Manual November 2014 Scissor Components 113 Attach a lifting strap from an overhead crane to the number 1 inner arm index 16 114 Raise the arm slightly and remove the block 115 Lower the arm to the stowed position ACAUTION Bodily injury hazard Keep hands clear of moving parts when lowering the scissor arms 116 Secure the ends of the scissor arms together at the steer end of the machine with a strap or other suitable device 117 Secure the ends of the scissor arms together at the non steer end of the machine with a strap or other suitable device 118 Remove the retaining fasteners securing the chassis mount bracket to the chassis 119 Remove the linkset from the machine ACAUTION Bodily injury hazard The number 1 inner and outer arms index 16 and 34 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 components when the number 1 inner and outer arms index 16 and 34 are removed from the machine How to Replace the Scissor Arm Wear Pads Note Machines equipped with a Platform Height Sensor begin at step 1 Machines without a Platform Height Sensor begin at step 24 1 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 Raise the platform 7 to 8 feet 2 1 to 2 4 m 3 Lif
326. s or platform controls position Pull out the red Emergency Stop button to the on position at both ground and platform controls Result The display at the platform controls will show CH See example below LH wie Result The display at the ground controls will show the machine model and hour meter information After 3 seconds the machine model will not show on the display See example below Press the ground control scroll down button Result The ground control LCD display will indicate the software revision and hour meter information After 5 seconds the ground controls LCD display will display machine model and hour meter information again See example below 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 4 6 a ground control LCD display b ground control scroll down button READY GS1930 00000 0 Hours 66 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual 2 2 2 Machine Setup How to Setup the Machine from Ground Controls The ground controls can be used to setup the machine parameters from the ground Features that can be adjusted from the ground controls include machine Model Options and Speed setup This menu can only be entered from ground controls with the key switch in
327. s the enter button Result The ground control LCD display will show the following PLAT OVERLOAD CALIBRATE Part No 228901 GS 30 GS 32 GS 46 GS 47 203 Service Manual November 2014 Repair Procedures 7 Press and hold the scroll down button for 5 seconds Result The ground control LCD display will show the following RESET OVLD RECOVERY 8 Press the enter button Result The ground control LCD display will show the following INPUT PASSWORD k k k k 9 Press the buttons in the following sequence down down up enter Note After each key press an asterisk will appear on the second line of the LCD display Result The ground control LCD display will show the following OVLD RECOVERY RESET Note After 3 seconds the LCD display will return to SELECT OPTION PLAT OVERLOAD 10 Push in the red Emergency stop button 1 1 1 204 GS 30 65 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual a Platform Components 10 1 7 Disconnect the wiring from the platform and pull the wiring free of the platform Platform M 8 Models with air line to platform option Disconnect the air line from the platform Pull How to Remove the Platform the air line free of the platform 9 Support the platform with a forklift at the non steer end Do not apply any lifting pressure Perform this proced
328. sor 2016 F016 SENSORFAULT Short circuit of the Left Front Outrigger circuit extend is ciate GS 3232 LF RIGGER BAT Sensor circuit to battery positive Faulty pressure transducer S GCON ECM Outrigger can still be retracted Short circuit in the left front outrigger sensor kaa 2017 F017 SENSORFAULT Short circuit of the Left Front Outrigger circuit extend is Poches GS 3232 LF RIGGER BAT Sensor circuit to battery negative Faulty pressure transducer j GCON ECM Outrigger can still be retracted Short circuit in the right front outrigger sensor b pod il F018 F018 SENSORFAULT Short circuit of the Right Front Outrigger circuit extend is GS 3232 RF RIGGER BAT Sensor circuit to battery positive Faulty pressure transducer Outri il b GCON ECM utrigger can still be retracted Short circuit in the right front outrigger sensor 2 2 F019 F019 SENSORFAULT Short circuit of the Right Front Outrigger circuit extend is GS 3232 RF RIGGER BAT Sensor circuit to battery negative Faulty pressure transducer Outri il b GCON ECM utrigger can still be retracted Short circuit in the left rear outrigger sensor ad m F020 F020 SENSORFAULT Short circuit of the Left Rear Outrigger circuit extend is ciated GS 3232 LR RIGGER BAT Sensor circuit to battery positive Faulty pressure transducer Outri ill b GCON ECM utrigger can still be retracted Short circuit in the left rear outrigger sen
329. sor d F021 F021 SENSORFAULT Short circuit of the Left Rear Outrigger circuit extend is alive GS 3232 LR RIGGER BAT Sensor circuit to battery negative Faulty pressure transducer SEES GCON ECM Outrigger can still be retracted Short circuit in the right rear outrigger sensor pigh rear oufgger F022 F022 SENSORFAULT Short circuit of the Right Rear Outrigger circuit extend is NA GS 3232 RR RIGGER BAT Sensor circuit to battery positive Faulty pressure transducer Outri ill b GCON utrigger can still be retracted Part No 228901 November 2014 Service Manual uc n oua Js 1 7 Diagnostics Type FXXX Faults continued DTC Message on Problem Possible Failure Number GCON LCD Description Causes Mode Short circuit in the right rear outrigger sensor 2 F023 F023 SENSORFAULT Short circuit of the Right Rear Outrigger circuit extendiis GS 3232 RR RIGGER BAT Sensor circuit to battery negative Faulty pressure transducer S Outrigger can still be GCON ECM retracted F034 0530 Fog4 SENSORFAULT Height Sensor settings are not calibrated circuli the level rol senso TRE GS32 OVLD PLAT HEIGHT correct Faulty level sensor All
330. ssis at the steer end of the machine 5 Raise the machine approximately 6 inches 15 cm Place blocks under the chassis for support A WARNING Crushing hazard The chassis will 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 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 While removing the retaining fasteners take note of the quantity and location of the spacers when disconnecting the steer link from the yoke assembly 10 Remove the retaining fastener from the top of the yoke pivot shaft Note The pivot shaft retaining fastener is located above the main deck 11 Lower the yoke assembly out of the chassis CAUTION Bodily injury hazard The yoke motor assembly may fall if not properly supported when it is removed from the chassis Genie BRAND GS 30 GS 32 GS 46 GS 47 107 Part No 228901 Service Manual November 2014 Ste
331. st nnne enne enne nnne nennen nennen 46 C 1 Test the Platform Overload Pressure Transducer and Platform Height Sensor if equipped sse 46 C 2 Calibrate the Platform Overload System if 49 C 3 Repalce the Hydraulic Tank Breather Cap Models with Optional Hydraulic 50 Checklist D Procedures nnn nnne nnn nnn nnn 51 D 1 Check the Scissor Arm Wear 51 D 2 Replace the Hydraulic Tank Return Filter 53 Checklist E Procedures ierit tette tene te en eren 54 E 1 Test or Replace the Hydraulic 54 Section 4 Repair Procedures rion te RR sd RARE Ca UA 57 MM 57 Platform Controls eee eterne nn thoi netta snnm nne saa annm 59 1 1 Circuit Board ceisiai iaaa 61 62 1 3 Plattrom Controls Alarm rr trn ei 63 1 4 Platfrom Emergency Stop Button seen en 64 Ground 65 2 1 Software Revision Level sseseeseseeeeeee entren nennen trn nnns 66 2 2 Machine Setup ecce etate
332. supported and secured to the lifting device Genie BRAND GS 30 GS 32 GS 46 GS 47 179 Service Manual November 2014 Scissor Components 27 Secure the ends of the scissor arms together at the steer end of the machine with a strap or other suitable device 28 Secure the ends of the scissor arms together at the non steer end of the machine with a strap or other suitable device 29 Remove the retaining fasteners securing the chassis mount bracket to the chassis at the steer end of the machine 30 Attach lifting strap from an overhead crane to the scissor arm assembly 31 Raise the scissor arm assembly at the steer end with the overhead crane until the chassis mount bracket will clear the level sensor 32 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 33 Remove both old wear pads 34 Install two new wear pads 35 Slide the scissor assembly back into the drive chassis 36 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 careful not to damage the level sensor or limit switch w
333. t in death or serious injury and significant component damage Dealer service is strongly recommended Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications Note Machines equipped with a Platform Height Sensor begin the Scissor Disassembly procedure at step 1 Machines without a Platform Height Sensor begin the Scissor Disassembly procedure at step 24 1 the key switch to ground controls and pull out the red Emergency Stop button to the on position at both ground and platform controls 2 Raise the platform 7 to 8 feet 2 1 to 2 4 m Part No 228901 Scissor Components 3 Liftthe safety arm move it to the center of the Scissor arm and rotate down to a vertical position 4 Lower the platform onto the safety arm A WARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 5 At the ground controls turn the key switch to the off position and push in the red Emergency Stop button to the off position 6 Disconnect the battery pack from the machine A WARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 7 Remove the fasteners securing the large platfo
334. tach a lifting strap from an overhead crane to the number 1 inner arm index 14 100 Raise the number 1 inner arm index 14 approximately 2 feet 60 cm 101 Placea4 x4 x48 inch 10 cm x 10 cm x Genie GS 30 GS 32 GS 46 GS 47 BRAND 1 2 m long block across both sides of the chassis under the number 1 center pivot pin index 13 163 Service Manual November 2014 Scissor Components 102 Lower the scissor arms onto the block that was placed across the chassis ACAUTION Bodily injury hazard Keep hands clear of moving parts when lowering the scissor arms 103 Attach a lifting strap from an overhead crane to the lug of the rod end of the lower lift cylinder 104 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 105 Tag and disconnect the wire harness from the solenoid valve on the cylinder 106 Models with platform overload option Tag and disconnect the wire harness from the platform overload pressure transducer Note After replacing the scissor assembly the platform overload system must be calibrated Refer to Repair Procedure 9 10 How to Calibrate the Platform Overload System if equipped 107 Raise the l
335. tach a lifting strap from an overhead crane to the number 1 inner arm index 8 Raise the number 1 inner arm index 8 approximately 2 feet 60 cm Place a4 x 4x 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 7 Lower the scissor arms onto the block that was placed across the chassis CAUTION Bodily injury hazard Keep Genie BRAND hands clear of moving parts when lowering the scissor arms Part No 228901 GS 30 GS 32 GS 46 GS 47 139 Service Manual November 2014 Scissor Components 66 Attach a lifting strap from an overhead crane to the lug of the rod end of the lower lift cylinder 67 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 68 Tag and disconnect the wire harness from the solenoid valve on the cylinder 69 Tag and disconnect the wires and manual lowering cable from the solenoid valve on the cylinder 70 Models with platform overload option Tag and disconnect the wire harness from the platform overload pressure transducer Note After replacing the scissor assembly the platform overload system must be calibrated Refer to Repair
336. tform deck press the Enter button to confirm the weight has been removed Full Load Calibration Part 2 24 Genie GS 30 GS 32 GS 46 GS 47 At the ground controls press and hold the Function Enable and Platform Up buttons until the platform reaches maximum height Part No 228901 November 2014 a se 25 26 27 28 Part No 228901 All Models except GS 4047 When the platform reaches maximum height press the Enter button Allow the ground controls to gather data GS 4047 only Press and hold the Menu Enter button to determine the maximum height The machine will lower for 1 2 seconds and then raise in 1 2 second durations until maximum height is reached When the platform reaches the maximum height a message will appear on the LCD screen to release the Menu Enter button If at any point the Menu Enter button is released before the message appears on the LCD screen the calibration procedure will restart at step 24 When prompted press and hold the Function Enable and Platform Down buttons to lower the platform The platform will move down then automatically stop at a predetermined point to gather data Allow the ground controls to gather data Continue pressing the Function Enable and Platform Down buttons throughout the lowering and data gathering sequence The machine will stop to gather data and lower several times before the machine reaches the stowed position When the platfor
337. tform Controls problem still exists OIC Operational Indicator Codes Return to Service DTC Diagnostic Trouble Codes repair problem solved Gri 1 1 1 1 1 208 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual GCON LCD Diagnostic Readout H001 COILFAULT PLAT UP1 Bat The diagnostic readout displays alpha numeric codes that provide information about the machine operating status and about malfunctions The codes listed in the Diagnostic Trouble Code Charts describe malfunctions and can aid in troubleshooting the machine by pinpointing the area or component affected Models are listed below each code to assist in the troubleshooting codes for a specific model Genie SmartLink Diagnostic System This machine is equipped with the Genie SmartLink Diagnostic System GSDS The GSDS indicates a machine malfunction has happened by displaying Operational Indicator Codes OIC and Diagnostic Trouble Codes DTC These codes are displayed at the Platform Controls and the Ground Controls The Ground Controls will display a brief description of the code at the LCD display as well Refer to the GCON I O Maps Operational Indicator Codes OIC and Diagnostic Trouble Codes DTC in this section to assist in troubleshooting faults Diagnostics GCON ECM Connector Layout
338. tform Controls Operational Indicator Codes These codes are generated by the electrical system to indicate machine operating status During normal operation a code will appear in the platform controls LED readout if a condition such as off level overload cutout chassis mode operation or pothole guard stuck occurs If the platform controls LED readout displays an operational indicator code such as LL the fault condition must be repaired or removed before resuming machine operation Push in and pull out the red Emergency Stop button to reset the system Lud EAJ ES TE Platform Controls LED Readout Code Condition LL Off level OL Platform Overload CE and Australia CH Chassis Mode Operation PHS Pothole Guard Stuck nd No Drive option Ld Lifting Disabled GS 3232 only Note The Ld Operation Indicator Code will appear when the outriggers are not fully retracted the machine is not auto leveled an outrigger has lost contact with the ground or either level sensor detects the machine is no longer level When any of the above scenarios occur the lift function is disabled The lift function will also be disabled while extending or retracting the outriggers and during the outrigger auto level procedure While performing the above operations the Ld Operation Indicator Code will appear Note A code and a description of a code can also be viewed at the ground controls LC
339. the Down Limit Switch Level Sensor and Pothole Limit Switches Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the limit switches is essential to safe operation and good machine performance Operating the machine with a faulty limit switch could result in reduced machine performance and a potentially unsafe operating condition Note 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 Raise the platform 7 to 8 feet 2 1 to 2 4 m Lift the safety arm move it to the center of the scissor arm and rotate down to a vertical position 4 Lower the platform onto the safety arm A WARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 5 the key switch to the off position 6 Tagand disconnect the platform control box at the platform 7 Follow the platform control cable down the scissor stack to the alarm bracket on the chassis deck Tag and disconnect the platform control cable from the ECM cable at the 6 pin Deutsch connector 8 Securely install the platform control box harness plug into the 6 pin Deutsch connector of the ECM cable Genie 40 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 TTT ee a a a __ Down Limit Switch Service Manual Checklist B Procedures PH
340. the block and does not fully deploy The ground controls LCD does not display PHS POTHOLE GUARDS STUCK and the platform controls LED does not display PHS The alarm does not sound and the machine will continue to lift the platform after the pothole guards are deployed Adjust or replace the pothole limit switch PHS POTHOLE GUARDS STUCK LCD display Ls EN FES PHS LED display 35 36 37 38 39 Genie GS 30 GS 32 GS 46 GS 47 November 2014 Press and hold the drive steer function enable switch on the control handle Attempt to drive and steer the machine Result The ground controls LCD displays PHS POTHOLE GUARDS STUCK and the platform controls LED displays PHS The alarm sounds and the machine will not steer or drive The machine is functioning properly Result The ground controls LCD does not display PHS POTHOLE GUARDS STUCK and the platform controls LED does not display PHS The alarm does not sound and the steer and drive functions operate Adjust or replace the down limit switch Lower the platform to the stowed position and remove the block under the right pothole guard Repeat this procedure beginning with step 33 for the left pothole guard Lower the platform to the stowed position remove the block under the left pothole guard Turn off the machine Part No 228901 November 2014 Service Manual B 17 T
341. the cable bridge from not properly supported when T machine removed from the machine Genie 116 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 a se 39 40 41 42 43 45 CAUTION Part No 228901 Remove the cables from the number 2 cable bridge and lay them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched Remove the external snap rings and retaining fasteners from the number 2 center pivot pin index 5 at the ground controls side Remove the number 2 cable bridge mounting fasteners and remove the cable bridge from the machine Attach a lifting strap from an overhead crane to the number 2 outer arm index 14 at the ground controls side Use a soft metal drift to remove the number 2 center pivot pin index 5 at the ground controls side Remove the retaining fasteners from the number 2 pivot pin index 15 at the non steer end of the machine 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 2 outer arm at the ground controls side may become unbalanced and fall if not properly supported when removed from the machine Gen BRAND GS 30 GS 32 GS 46 GS 47 46 47 48 A CAUTION 49 A CAUTION 50
342. the entry ladder from the machine CAUTION Crushing hazard The entry ladder will fall if not properly supported and secured to the lifting device 86 CAUTION 87 82 Attach a lifting strap from an overhead crane to the number 1 outer arm index 22 Do not apply any lifting pressure 130 Genie GS 30 GS 32 GS 46 GS 47 Remove the external snap rings and retaining fasteners from the number 1 center pivot pins index 11 Remove the number 1 cable bridge from the machine Use a soft metal drift to remove the number 1 center pivot pins index 9 Bodily injury hazard The number 1 outer arm may become unbalanced and fall if not properly supported when the pin is removed Slide the number 1 outer arm index 22 to the non steer end and remove it from the machine Bodily injury hazard The number 1 outer arm may become unbalanced and fall if not properly supported when removed from the machine Attach the strap from an overhead crane to the number 1 inner arm index 10 Do not lift it Part No 228901 November 2014 A 88 89 Remove the upper fasteners securing the number 1 inner arm pivot bracket to the end of the chassis Loosen the lower fasteners Remove the number 1 inner arm index 10 from the machine ACAUTION Bodily injury hazard The Part No 228901 number 1 inner arm may become unbalanced and fall if not properly supported when remove
343. the ground controls position A DANGER A DANGER Tip over hazard Do not adjust function speeds 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 3 Tip over hazard This procedure must only be performed by a trained service professional Attempting this procedure without the necessary skills could result in death or serious injury Note Select a test area that is firm level and free Ground Controls Press and hold the ground control scroll up and scroll down buttons Ground Control Menu Buttons scroll down button b enter button scroll up button d escape button e LCD display Pull out the red Emergency Stop button to the on position at the ground controls Result The ground controls LCD display will show the following LIFT SETUP TEST SELECT MODEL of obstructions 4 Use the ground control menu buttons to select machine Model Options and Speed Setup 1 Turn the key switch to the ground controls parameters Follow the menu structure position and pull out the red Emergency Stop indicated on the ground control LCD display button to the on position at the platform controls Genie _______________ 228901 GS 30 65 32 65 46 GS 47 67 Service Manual November 2014 Ground Controls 2 3 Loading or Updating Machine So
344. the joystick fully in either direction while observing the pressure reading on the pressure gauge Note the pressure Refer to Section 2 Specifications Turn the machine off Hold the system relief valve with a wrench and remove the cap schematic item I AB or DB Part No 228901 November 2014 Service Manual 8 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure A DANGER Tip over hazard Failure to adjust the relief valves to specification could result in the machine tipping over causing death or serious injury Do not Manifolds How to Adjust the Platform Lift Relief Valve Perform this test from the ground with the platform controls Do not stand in the platform Be sure the hydraulic oil level is at the FULL mark on the hydraulic tank adjust the relief valve pressures 1 higher than specifications Locate the system relief valve on the function manifold schematic item AB or DB 9 Install th lief val 2 Connect a 0 to 5000 psi 0 to 350 bar De ESSE vale cap pressure gauge to the test port on the function 10 Repeat steps 5 and 6 to confirm the relief manifold schematic item A AA or DA valve pressure 3 Chock both sides of the wheels at the steer end of the machine 4 Remove the platform controls from the platform GS 32 GS 46 and GS 47 a test port b system relief valve C Steer relief valve d lift
345. the machine Remove the number 3 inner arm index 15 from the machine Crushing hazard The number 55 Remove the retaining fasteners from the lift CAUTION 3 inner arm index 15 may cylinder rod end pivot pin index 5 become unbalanced and fall if 56 Use a soft metal drift to remove the lift is cylinder rod end pivot pin index 5 from the pivot p 62 Remove the cables from the number 2 and ACAUTION Crushing hazard The lift 2B cable bridge and lay them off to the side cylinder will fall if not properly supported when the pivot pin is removed 57 Placea4x4x10inch 10x 10 x 25 block onto the number 1 inner arm cylinder plate index 10 Genie BRAND Part No 228901 GS 30 GS 32 GS 46 GS 47 Component damage hazard Cables can be damaged if they are kinked or pinched Disconnect the number 2A and 2B cable bridges from the scissor linkset and remove both cable bridges from the machine Attach a lifting strap from an overhead crane to the number 2 outer arm at the ground control side index 19 149 Service Manual Scissor Components November 2014 65 Remove the retaining fasteners from the 71 Place a rod through the number 2 center pivot number 2 center pivot pin index 7 at the pin at the battery side index 7 and twist to ground control side remove the pin 66 Place a rod through the number 2 center pivot CAUTION Crushing hazard The
346. the stowed position 9 Pullthe manual lowering handle at the ground controls 2 to 3 times to ensure it is functioning correctly Ground Controls 2 8 Outrigger Calibration The Electronic Control Module ECM is programmed to deactivate the drive and steer functions while the outriggers are deployed and activate an alarm when a signal is received from the outrigger level sensor indicating the outriggers are not deployed or the machine is out of level The ECM is also used to calibrate the outrigger level sensor to achieve a levelness of 0 0 5 front to back and side to side while the outriggers are deployed For further information or assistance consult the Genie Product Support How to Calibrate the Outrigger System 1 Move the machine to an area that has a firm level surface and is free of obstructions Use digital level to confirm Turn the key switch to ground controls At the ground controls press and hold the Menu Up and Menu Down buttons 4 While pressing both buttons down pull out the red Emergency Stop Button 5 Release the Menu Up and Menu Down buttons after the ground controller powers up Genie BRAND GS 30 GS 32 GS 46 GS 47 83 Part No 228901 Service Manual m n j7 tl Ground Controls 10 11 12 Use the Menu Up or Menu Down buttons to scroll to Machine Options Press the Enter button to select Machine Options Use the Menu Up or
347. this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is required Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications Note Machines equipped with a Platform Height Sensor begin the Scissor Disassembly procedure at step 1 Machines without a Platform Height Sensor begin the Scissor Disassembly procedure at step 24 1 Turn the key switch to ground controls and pull out the red Emergency Stop button to the on position at both ground and platform controls 2 Raise the platform 7 to 8 feet 2 1 to 2 4 m 3 Liftthe safety arm move it to the center of the Scissor arm and rotate down to a vertical position 4 Lower the platform onto the safety arm A WARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 5 At the ground controls turn the key switch to the off position and push in the red Emergency Stop button to the off position 6 Disconnect the battery pack from the machine A WARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 7 Remove the fasteners securing the large p
348. this manual Class 10 9 D E 130 ko A Co gt IN I Q r ze 2 lt w m ze c Uu m lt la lo CIN c m ClO _ Blo 3 wizi lt o o Pr PA c a NITE Ij r o m ho o rus 7 lt o Ind KO md Ed BEC nel EINE od colo IND IND TM x _ e 4 w Ed e A ma gt N N m A N co em zl o e I gt ho gt S NOUN NIA DIN Bt eal ended ee 4 71 Ko N QS NON Ip gt NA 02 ojojo ojo o o 42 lt gt SIRENS o QUO fey oo Co lt 5 5 ood 05 212 Gil Oo 1 0 O 1 c w m 2 2
349. ting strap from an overhead crane to the number 4 inner arm index 12 Raise the arm to a vertical position Remove the retaining fasteners from the number 4 pivot pin at the steer end of the machine index 3 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 inner arm index 12 may become unbalanced and fall if not properly supported when removed from the machine Remove the cables from the number 3A and 3B cable bridge and lay them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched 45 46 47 48 49 A CAUTION 50 Genie GS 30 GS 32 GS 46 GS 47 November 2014 Disconnect the number 3A and 3B cable bridges from the scissor linkset and remove both cable bridges from the machine Attach a lifting strap from an overhead crane to the number 3 outer arm at the ground control side index 16 Remove the retaining fasteners from the number 3 center pivot pin index 4 at the ground control side Place a rod through the number 3 center pivot pin at the ground control side index 4 and twist to remove the pin Remove the retaining fasteners from the number 3 pivot pin index 17 at the non steer end Use a soft metal drift to remove the number 3 pivot pin index 17 from the non steer end of the
350. tions regarding the battery charger operation please contact the Genie Scissor Service Department 1 1 1 1 1 26 GS 30 65 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual B 2 Inspect the Electrical Wiring Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining electrical wiring in good condition is essential to safe operation and good machine performance Failure to find and replace burnt chafed corroded or pinched wires could result in unsafe operating conditions and may cause component damage AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Inspect the underside of the chassis for damaged or missing ground strap s 2 Inspect the following areas for burnt chafed corroded and loose wires e Ground control panel e Hydraulic power unit module tray e Battery tray s e Scissor arms e Platform controls 3 Inspect for a liberal coating of dielectric grease in the following locations e Between the ECM and platform controls e All wire harness connectors e Level sensor Gen BRAND GS 30 GS 32 GS 46 GS 47 27 Part No 228901 Checklist B Procedures 4 the key switch to ground control and pull out the red Emergency Stop button to the on position at both groun
351. tn C49 C46 ye A Y E 1 xax 1 156 DOWN C52 2 13 LIMIT pne H2 g 2 SW EL S7 3 hour H5 AUTO 5 5 LEVEL BREAKER ALARM aD 21 8 422 2 4 SENSOR A o gt OPTION o o RD A A RD V 050 5 8 647 C45 o 99 92 52 amp L g 5bo RD BK C lt CG WH SIG B51 5821526 E 5 Liez 1322 BN B lt B BK E NT DC AC INVERTER 5 88 gs 5 2 a m CYLINDER PRESSURE OPTIONAL EE e p ee Contactor ReBRQAagkieou 8 5 4 a e PLATFORM HEIGHT U13 N O H C T 2 Sco cow E x 5 28 x 814 4 2T g lt lt a a PLATFORM HEIGHT e22656884z amp B 1 2 2 ap 52895 EL 20m SENSOR A Fd beled i 3 HE i s cur 5 gt 3 WH 4 SIG AA AA AA AAA AA AR AM A 5 Bs 2 ene 1 1 1 id 1 15 BATTERY PLATFORM aera lias C19 2 C24 OVERLOAD 5 a MODULE A lt lt A RD A lt A RD 99 V n C C BL I YY Y Y Y Y yY YY B Bt BK B lt B1 BK 8 l 2 3 4 5 7 9 10 12 E ay x 1 DX 0x x x X o a m re 2 a CONNECTED CONNECTED a 9 1 8 8 1008 888 gt o 8 an 6 2 2
352. to the stowed position 28 Fully lower the platform to the stowed Solenoid valve 2 position 2 way 20 ft lbs position N C 27 Nm schematic item Note Models with a pressure transducer calibrate the Platform Overload System Refer to Repair Coil Nut 7 Procedure 9 10 How to Calibrate the Platform i Overload System if equipped Pressure transducer if equipped 27 ft lbs schematic item R 37 Nm 188 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual Scissor Components GS 3232 and GS 3246 3 Liftthe safety arm move it to the center of the scissor arm and rotate down to a vertical A WARNING Bodily injury hazard The position procedures in this section require specific repair skills lifting equipment and a suitable m workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is required Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications Note Models without a pressure transducer follow steps 1 through 21 25 and 26 Models equipped with a pressure transducer follow steps 1 through 26 1 Turn the key switch to ground controls and pul
353. trols PC Board Genie 232 BRAND GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual Electrical Component and Wire Color Legends Part No 228901 BRAND GS 30 GS 32 GS 46 GS 47 ELECTRICAL COMPONENT LEGEND cont WIRE COLOR LEGEND Item Description Color Description JC9 Joystick Controller BK Black K1 Contactor Motor Controller Power N O H C BK RD Black Red KS1 Key Switch BL Blue LS Limit Switch BL BK Blue Black LS1 Maximum Drive Height GS 3232 LS6 Platform Down BL OR Blue Orange Forol BL WH Blue White LS8 Pothole LS10 Maximum Drive Height GS 3232 BR Brown M5 Hydraulic Power Unit GR Green N C Normally Closed GR BK Green Black N C H O Normally Closed Held Open GR WH Green White N O H C Normally Open Held Closed GR YL Green Yellow P Power Switch LB Light Blue P1 Emergency Stop Button at Ground Controls P2 Emergency Stop Button at Platform OR Orange Controls OR BK Orange Black PT Pressure Transducer OR RD Orange Red PT1 Left Front Outrigger GS 3232 PT2 Right Front Outrigger GS 3232 OR WH Orange White PT3 Left Rear Outrigger GS 3232 RD Red PT4 Right Rear Outrigger GS 3232 PT15 Platform Overload option RD BK Red Black R30 Resistor 20 Ohm 10W RD WH Red White 5 Sensor W
354. tthe safety arm move it to the center of the scissor arm and rotate down to a vertical position 4 Lower the platform onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 5 At the ground control turn the key switch to the off position and push in the red Emergency Stop button to the off position 6 Disconnect the battery pack from the machine A WARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Genie 178 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 a se 10 11 12 13 14 15 16 Remove the fasteners securing the platform height sensor cover to the large platform height sensor bracket Remove the platform height sensor cover Tag and disconnect the platform height sensor from the platform height sensor harness Remove the fastener securing the platform height sensor assembly to the number 1 inner arm Remove the platform height sensor assembly from the number 1 pivot pin Remove the plastic nut securing the squeeze connector to the large platform height sensor bracket Remove the squeeze connector from the large platform height sensor bracket Remove the fasteners securing the large platform height sensor bracket to the number 1 inner arm pivot bracket Remove the large platfo
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356. umber 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 144 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual 9 4 Scissor Assembly GS 2632 and GS 2646 How to Disassemble the Scissor Assembly GS 2632 and GS 2646 AWARNING Bodily 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 Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications Note Machines equipped w
357. und control turn the key switch to a negative post b positive post c platform height sensor cable d ECM platform height sensor wire harness 16 Turn the key switch to ground control and pull out the red Emergency Stop button to the on the off position and push in the red position Emergency Stop button to the off position Genie 0 0 0 0 Part No 228901 GS 30 GS 32 65 46 GS 47 47 Service Manual November 2014 as Checklist Procedures 17 Using the multimeter measure the voltage reading of the pressure transducer at pin C and B Result The voltage reading of the platform height sensor is between 1V and 4V The platform height sensor is functioning properly Result The voltage reading of the platform height sensor is OV or above 5V The platform height sensor is not functioning properly Replace the platform height sensor Refer to Repair Procedure 9 7 How to Disassemble the Platform Height Sensor Assembly if equipped 18 At the ground control turn the key switch to the off position and push in the red Emergency Stop button to the off position 19 Remove the probes from the rubber boot of the platform height sensor cable 20 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position 21 Raise the platform 12 inches 30 5 cm 22 Return the safety arm to the stowed position 23 Lower the platform to the stowed position 24 Turn the key sw
358. ure Selector Manifold Components GS 4047 The lift pressure selector manifold is mounted behind an inspection door at the ground control side of the machine Index No Description Schematic Item Function Torque Coil nut item DN 4 5 ft lbs 5 7 Nm Plug 13 ft lbs 18 Nm 1 ni ae selector valve 200 1 DM Lift relief 20 ft lbs 27 Nm 2 Solenoid valve 2 position 2 way DN Lift circuit 20 ft lbs 27 Nm DM 1 Note alpha callouts refer to corresponding notes on the hydraulic schematic How to Install a Valve Cartridge 1 Dip the cartridge in clean oil to lube the O rings 2 Screw the cartridge in by hand until the top O ring is met then torque to specifications 3 If required install the valve coil s onto the valve stem Install the coil nut onto the valve stem and torque to specifications Genie BRAND Part No 228901 GS 30 GS 32 GS 46 GS 47 95 Service Manual November 2014 sl Manifolds 5 6 Outrigger Function Manifold Components GS 3232 The outrigger function manifold is mounted behind an inspection door at the battery side of the machine Index No Description Schematic Item Function Torque Coil nut item BA 4 5 ft lbs 5 7 Nm Outrigger 1 Solenoid valve 3 position 4 way BA extendiratrad 25 ft lbs 34 Nm BB Outrigger circuit 20 ft lbs 27 Nm maximum Note alpha
359. ure with the platform extension fully retracted and locked in position Raise e plauormtiodpprepdntetely SAC 10 Attach a strap from the lanyard anchorage 2 Remove the retaining fasteners securing the point on the platform railings to the carriage platform to the platform mount at the steer on the forklift to help support the platform 11 GS 1530 32 and GS 1930 32 Lift the steer Lower the platform to the stowed position 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 4 Disconnect the battery pack from the machine AWARNING Electrocution burn hazard Contact with electrically charged holes in the bottom of the platform circuits could result in death or All other models Lift the steer end of the serious injury Remove all rings platform slightly to clear the platform mount watches and other jewelry and slide the platform towards the steer end of the machine until the platform slide blocks 5 Disconnect the platform controls from the at the non steer end of the machine are control cable at the platform visible through the access holes in the bottom 6 Remove the cover from the AC outlet Tag of the platform and disconnect the wiring from the outlet A WARNING Electrocution burn hazard Crushing hazard The platform Contact with electrically charged
360. ust the relief valve pressures higher than specifications 9 Install the relief valve cap 10 Repeat steps 5 and 6 to confirm the relief valve pressure GS 32 GS 46 and GS 47 a test port b system relief valve C Steer relief valve d lift relief valve 5 9 Valve Coils How to Test a Coil A properly functioning coil provides an electromagnetic force which operates the solenoid valve Critical to normal operation is continuity within the coil Zero resistance or infinite resistance indicates the coil has failed Since coil resistance is sensitive to temperature resistance values outside specification can produce erratic operation When coil resistance decreases below specification amperage increases As resistance rises above specification voltage increases While valves may operate when coil resistance is outside specification maintaining coils within specification will help ensure proper valve function over a wide range of operating temperatures A WARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Note If the machine has been in operation allow the coil to cool at least 3 hours before performing this test 1 Tagand disconnect the wiring from the coil to be tested 2 Testthe coil resistance using a multimeter set to resistance W Refer to the Valve Coil Resistance Specification tabl
361. vice Manual Hydraulic Component Abbreviation Legend Item Description Item Description A Test port BA 3 position 4 way directional valve outrigger cylinder B Check valve steer circuit Relief valve lift BB Relief valve outrigger circuit D Check valve drive circuit CA Right front outrigger extend retract Drive Left front outrigger extend retract F Steer left right CC Right rear outrigger extend retract G Flow regulator relief valve CD Left rear outrigger extend retract H Platform up CE Orifice plug outrigger retract Relief valve system CF Check valve pilot operated L Hand pump manual brake release Needle valve manual brake release DA Test port N Platform lowering valve Relief valve system Orifice platform down circuit DE steer Erion Accumulator DD Check valve steer circuit Q Relief valve platform down DE Driyerspeed R Pressure transducer platform overload CE only Relief valve brake release S Check valve drive circuit DG Drive forward reverse AA Test Port DH Flow regulator relief valve AB Relief valve system pi Platform up AC Steer left right DJ Relief valve lift AD Check dics steer circuit DK _ Check valve upper cylinder AE Drive speed DL Check valve lower
362. when the pivot pin is removed Genie 150 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 4 4 74 76 77 78 79 Attach a lifting strap from overhead crane to the number 1 inner arm index 10 Raise the number 1 inner arm index 10 approximately 2 feet 60 cm Place a 4 x 4 x 48 inch 10 cm x 10 cm x 1 2 m long block across both sides of the chassis under the number 1 center pivot pin index 9 Lower the scissor arms onto the block that was placed across the chassis A CAUTION Bodily injury hazard Keep 80 81 hands clear of moving parts when lowering the scissor arms Attach a lifting strap from an overhead crane to the lug of the rod end of the lower lift cylinder Tag disconnect and plug the hydraulic hose on the lower lift cylinder Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying 82 83 Part No 228901 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 wire harness from the solenoid valve on the cylinder Tag and disconnect the wires and manual lowering cable from the solenoid valve on the cylinder Service Manual Scissor Components 84 Models with platform overload option Tag and disconnect the wire harness from the platform overload pressure transducer Note After repl
363. will be displayed Genie smart Link Machi jates and handle machine diagnostics to ac machine parameters perform software upd ps STET a 2 2 Bu DM 2 of Fue m 10 After using the Smart Link Service Tool web site push in the red Emergency Stop button and disconnect the CAT5 cable from the GCON 11 Secure the diagnostic port cover using the retaining fasteners removed in step 3 Do not over tighten 12 Perform a function test Refer to the Operator s Manual on your machine Genie 74 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual Ground Controls 2 5 Note Perform this operation on a firm level Service Override Mode The Electronic Control Module ECM is programmed with a Service Override mode Service Override mode is only indented for certain circumstances and is not part of the normal machine operation Service Override mode should only be accessed by trained personal to repair faults and or a malfunctioning machine Note Service Override mode can only be entered at the ground controls and is intended to allow the platform to be raised or lowered Once the platform has reached the maximum allowable height the system will exit Service Override mode Repeat this procedure to lower the platform Note When in Service Override mode an audible alarm will sound Note Before entering Service Override mode fault codes or
364. x 1 Use a soft metal drift to remove the number 6 pivot pin index 1 Remove the platform mount bracket from the machine Attach a lifting strap from an overhead crane to the number 5 outer arm at the ground control side index 17 Remove the retaining fasteners from the number 5 center pivot pin index 2 at the ground control side 33 35 A CAUTION 36 37 38 39 November 2014 Place a rod through the number 5 center pivot pin at the ground control side index 2 and twist to remove the pin Remove the retaining fasteners from the number 5 pivot pin index 18 at the non steer end Use a soft metal drift to remove the number 5 pivot pin index 18 from the non steer end of the machine Remove the number 5 outer arm at the ground control side index 17 from the machine Crushing hazard The number 5 outer arm at the ground control side index 17 may become unbalanced and fall if not properly supported when removed from the machine Attach a lifting strap from an overhead crane to the number 5 outer arm at the battery side index 17 Remove the retaining fasteners from the number 5 center pivot pin index 2 at the battery side Place a rod through the number 5 center pivot pin at the battery side index 2 and twist to remove the pin Remove the number 5 outer arm index 17 from the machine Crushing hazard The number A CAUTION 5 outer arm index 17 may become unbalan
365. y GS 1530 and GS 1532 How to Disassemble the Scissor Assembly GS 1530 and GS 1532 AWARNING Bodi y 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 Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications Note Machines equipped with a Platform Height Sensor begin the Scissor Disassembly procedure at step 1 Machines without a Platform Height Sensor begin the Scissor Disassembly procedure at step 24 1 Turn the key switch to ground controls and pull out the red Emergency Stop button to the on position at both ground and platform controls 2 Raise the platform 7 to 8 feet 2 1 to 2 4 m 3 Liftthe safety arm move it to the center of the scissor arm and rotate down to a vertical position 4 Lower the platform onto the safety arm A WARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 5 At the ground controls turn the key switch to the off position and push in the red Emergency Stop button to the off position 6 Disconnect the battery pac
366. y 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 33 35 36 Genie GS 30 GS 32 GS 46 GS 47 November 2014 Remove both old wear pads Install two new wear pads Slide the scissor assembly back into the drive chassis 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 careful not to damage the level sensor or limit switch while moving the scissor assembly Part No 228901 November 2014 Service Manual Scissor Components 2 amp e GGG 2 2 2 9 9 9 9 Steer End GS 1930 GS 1932 Non steer End 1 Number 5 pivot pin 2 Number 4 center pivot pin 2 pins 3 Number 4 pivot pin steer end 4 Number 3 center pivot pin 2 pins 5 Lift cylinder rod end pivot pin 6 Number 3 pivot pin steer end 7 Number 2 center pivot pin 2 pins 8 Number 2 pivot pin steer end 9 Number 1 center pivot pin 2 pins 10 Number 1 inner arm 11 Number 1 pivot pin Part No 228901 Genie BRAND 12 Number 4 inner arm 13 Number 4 outer arm
367. y 4 of each 18 F 7 7 C that your air temperature increases or decreases from 68 F 20 C Specification 27 20 Description Solenoid valve 3 position 4 way 20V DC with diode schematic items F AC or DC Solenoid valve 3 position 4 way 20V 190 DC with diode schematic item E Solenoid valve 2 position 4 way 20V 190 DC with diode schematic items Al or DI Solenoid valve 2 position 2 way 250 N C 20V DC with diode schematic item N Solenoid valve 2 position 4 way 20V 190 DC with diode schematic item AE or DE Solenoid valve 3 position 5 way 20V 190 DC with diode schematic item AG or DG Solenoid valve 2 position 2 way 20V DC with diode schematic items CA CB CC and CD Solenoid valve 3 position 4 way 20V 190 DC with diode schematic item BA 27 20 Solenoid valve 2 position 2 way 20V 23 90 DC with diode schematic item DN Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation Genie GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual Specifications Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with Parker Seal Lok ORFS or 37 JIC fittings and hose ends Genie specifications require that fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings
368. y arm to the stowed position 23 Fully lower the platform to the stowed position OR uA iil 99 2632 5 2646 Cable bridge and platform height sensor cable bridge 4 cable bridge 3A cable bridge 3B cable bridge 2A cable bridge 2B cable bridge 1 platform height sensor __ 1 h 1 GS 30 GS 32 GS 46 GS 47 Part No 228901 November 2014 a se 24 25 26 Remove the platform See 10 1 How to 33 Remove the Platform Support and secure the entry ladder to an appropriate lifting device 34 Remove the fasteners from the entry ladder and remove the entry ladder from the machine 35 A CAUTION Crushing hazard The entry 28 29 30 31 32 Part No 228901 ladder will fall if not properly supported and secured to the lifting device Service Manual Scissor Components Place a rod through the number 4 center pivot pin at the ground control side index 2 and twist to remove the pin Remove the retaining fasteners from the number 4 pivot pin index 15 at the non steer end 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 A CAUTION Crushing hazard The number Remove the cables from the number 4 cable bridge and lay them off to the side Component damage hazard
369. ype of scheduled inspection Make copies of the Maintenance Inspection Report to use for each inspection Maintain completed forms for a minimum of 4 years or in compliance with your employer jobsite and governmental regulations and requirements Genie BRAND Part No 228901 GS 30 GS 32 GS 46 GS 47 17 Service Manual November 2014 This page intentionally left blank Gri 1 1 1 1 e o 18 GS 30 65 32 GS 46 GS 47 Part No 228901 November 2014 Service Manual Pre Delivery Preparation Report Fundamentals It is the responsibility of the dealer to perform the Pre delivery Preparation The Pre delivery Preparation is performed prior to each delivery The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service A damaged or modified machine must never be used If damage or any variation from factory delivered condition is discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual Genie TEREX BRAND Terex South Dakota Inc USA 500 Oak Wood Road PO Box 1150 Watertown

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