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Service Manual - Genie Industries

1. P1 7 EMERGENCY S Z S STOP NAT B ENS OR 2 KS1 i v KEY PLATFORM SWITCH CONTROL 4 1 T N ALARM MACHINE SHOWN IN THE x STOWED POSITION WITH LN THE POWER OFF 2 157 POTHOLE TS66 GUARD PLATFORM SWITCH 1 UP DOWN CB2 lt e P M CIRCUIT BREAKER 4 5 158 U27 P GUARD 47 mH INDUCTOR NOISE SUPPRESSION SWITH Ed c gt 280 9 RA 22 3 3 m b 2 E y L30 2 S 5 WORK LIGHT 2 2 QD1 9 LAAN OPTION ERU E F6 9 275A FUSE 12 12 B9 B10 IN IN IN OUT IN U9 A8 OUT 2 HARGER G A1 OUT U5 ELECTRONIC CONTROL MODULE OUT OUT fm EM NER AC INPUT Vly U6 9 g O 30 E CONTROLLER 10 HORN RELAY A 59 H2OPTION 85 j 913 G6 FB ci DC AC INVERTER HOUR FLASHING 87 55 METER BEACONS OPTION H2 AUTO STYLE HORN u i OPTION ES0142B Genie 6 32 GS 30 GS 32 GS 46 Part No 96316 June 2009 Section 6 Schematics Electrical Schema
2. REVC ANSI CSA and Australia Models GS 1530 1532 1930 1932 from serial number GS3003 60000 to GS3005 74999 NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF RD RD 4 4 4 WH WH 3 3 juo Y g s CR48 BL 1 1 pas BK 2 2 M RELAY U5 87 m E STOP p e N O H C 4 OF LS6 DOWN LIMIT SWITCH z Epe senson lt g 9 52 4 57 z fo 33 g LEVEL 9 23822 8 SENSOR 9 g 7 5 n 5 po oc 5 g s iB 3 988 L LG C2 B11 C12 A10 A4 A2 B1 C1 C11 A5 IN IN IN IN IN IN IN IN IN OUT U5 ELECTRONIC CONTROL MODULE OUT OUT OUT OUT OUT OUT OUT C8 C7 B7 A7 C6 B6 A6 en Me gh I ge ee a TOOT 2 8 2 2 Y1 Y3 Y4 Y5 Y6 Y9 Y7 Y8 PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM RIGHT LEFT REVERSE FORWARD DOWN DOWN UP GS 3246 koX EPX GND ES0141B Genie Part No 96316 GS 30 GS 32 GS 46 6 9 Section 6 Schematics October 2008 Electrical Schematic
3. EMERGENCY STOP B ENS OR ELSE N 2 KS1 vq Key PLATFORM SWTCH CONTROL 1 H5 N ALARM MACHINE SHOWN IN THE x 5 STOWED POSITION WITH S lt THE POWER OFF SEES Z 157 TS66 POTHOLE PLATFORM 1 UP DOWN CB2 N C H O 4 E 2 Ph Of CIRCUIT BREAKER 4 158 POTHOLE GUARD SWITCH eue c C gt 2 28070 9 E 2222 E 2g 230 2 5 5 wonkuenr 2 OPTION 3 QD1 a I b m d F6 9 275A FUSE l GN A12 B12 B9 B10 A9 OUT IN IN OUT IN U9 BK ag OUT rz G A1 OUT U5 ELECTRONIC CONTROL MODULE OUT OUT B3 AC INPUT UG a sre O 30 7 T CONTROLLER 10 2 CR5 HORN RELAY A 59 H2OPTION 85 U13 A at DC AC INVERTER 429 i 85 OPTION METER BEACONS OPTION H2 AUTO STYLE HORN i OPTION ES0141B Genie 6 8 GS 30 GS 32 GS 46 Part No 96316 October 2008 Section 6 Schematics Electrical Schematic
4. October 2008 Section 6 Schematics Electrical Schematic REV C CE Models GS 1530 1532 1930 1932 from serial number GS3003 60000 to GS3005 74999 NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF zm RD RD 4 4 4 WH WH 3 3 Y 30 s CR48 BL 1 1 yas 2 2 RELAY U5 gr 85 E STOP p 98R T55 54 PS2 gt AM nono 196 PRESSURE DM SWITCH SWITCH A e 5 CR27A CR27B CR27C 9 OVERLOAD OVERLOAD OVERLOAD eee CET Ci MOTOR COND LOAD SENSE DOWN COIL 30 n 86 30 2 86 30 86 LC Js DEA Dee s Ing 87 85 87A 85 87 85 LS5 SENSOR UP BOARD 651 I won OO E t lt 1 35 NM secon s 2 CR27D 9 3 E z OVERLOAD E Pi jp 5 9 DOWN DELAY g Bod A 2 5 2 o o x z x lt IU 2 y 8 s s kz ha a L Hn C2 B11 A9 A6 A10 B6 C12 A4 A2 B1 C1 C11 A5 IN IN OUT OUT IN OUT IN IN IN IN IN IN OUT US ELECTRONIC CONTROL MODULE OUT OUT OUT OUT OUT C8 C7 B7 A7 6 OG P U et
5. September 2005 Section 6 Schematics Electrical Schematic REV B CE Models GS 2032 2632 from serial number GS3205 75000 to 75406 GS 2046 2646 3246 from serial number GS4605 75000 to 75437 NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF RD RD 4 4 4 WH WH 3 3 Y 30 s CR48 BL 1 1 yas 2 2 RELAY U5 gr 85 E STOP p 98R T55 54 PS2 Eee PRESSURE DMT SWITCH SWITCH A N O H C 5 CR27A CR27B CR27C OVERLOAD OVERLOAD OVERLOAD eee CET Ci MOTOR COND LOAD SENSE DOWN COIL 30 n 86 30 2 86 30 86 LC 87 85 87A 85 87 85 LS5 SENSOR 4 UP BOARD C57 1 Shirok g m m CR27D 6522 3 E am 8 1 9 ji 2 Q 5 2 o o x z x lt 2 0 r cl ate k C2 B11 A9 A6 A10 B6 C12 A4 A2 B1 C1 11 A5 IN IN OUT OUT IN OUT IN IN IN IN IN IN OUT Us ELECTRONIC CONTROL MODULE OUT OUT OUT OUT OUT C8 B7 AT C6 y s mE m ES Y1 Y4 Y5 Y6 Y9 Y7 Y
6. REVA GS 1530 1532 1930 1932 from serial number GS3004 66987 to GS3005 75999 STEER STEER LEFT RIGHT LEFT RIGHT LEFT RIGHT BRAKE EN BRAKE DRIVE DRIVE MOTOR MOTOR BRAKE E 1 gt M HCL P MANUAL A VI c Cox 1 03 cu in N Fa 19 BRAKE i PUMP RELEASE MANIFOLD a a B1 S1 S2 AC B HP M1 M4 erui mm Z 4 v4 IN X Ya B b ou i 1500psi 1 1 103 ve vs N m TES 0 7 bar FUNCTION MANIFOLD ABBREVIATION LEGEND Item Description A Test port B Check valve steer circuit C Relief valve lift D Check valve brake circuit E Drive forward reverse F Steer left right G Flow regulator relief valve H Platform up Relief valve system J Shuttle valve brake release K Check valve manual brake release L Hand pump manual brake release M Needle valve manual brake release N Platform lowering valve Orifice platform down circuit P Accumulator H Pressure switch platform overload HS0035E S Check valve drive circuit Genie Part No 96316 GS 30 GS 32 GS 46 6 45 Section 6 Schematics Hydraulic Schematic GS 2032 2632 from serial number GS3204 60000 to GS3205 75406
7. a wear pad b outer arm cross tube C chassis deck 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 Section Scheduled Maintenance Procedures CHECKLIST D PROCEDURES GS 2032 GS 2632 GS 2046 GS 2646 and GS 3246 1 Measure the distance between the number one outer arm cross tube and the fork lift tube at the ground controls side of the non steer end of the machine Result The measurement is 0 88 inch 22 4 mm or more Proceed to step 2 Result The measurement is less than 0 88 inch 22 4 mm Replace both wear pads Refer to Repair Procedure 3 3 3 4 or 3 5 How to Replace the Scissor Arm Repair Pads 2 Measure the distance between the number one outer arm cross tube and the fork lift tube at the battery pack side of the non steer end of the machine Result The measurement is 0 88 inch 22 4 mm or more Proceed to step 3 W Result The measurement is less than 0 88 inch 22 4 mm Replace both wear pads Refer to Repair Procedure 3 3 3 4 or 3 5 How to Replace the Scissor Arm Repair Pads a out
8. P1 EMERGENCY S Z xc STOP B ENS OR ELSE N 2 KS1 v key PLATFORM SWITCH CONTROL 4 1 N ALARM MACHINE SHOWN IN THE x STOWED POSITION WITH LN THE POWER OFF 2 0 157 POTHOLE TS66 GUARD PLATFORM SWITCH 1 UP DOWN N C H O 4 CB2 9 c P M CIRCUIT 5 BREAKER 4 LS8 U27 P GUARD 47 mH INDUCTOR NOISE SUPPRESSION SWITH Ed c gt 280 9 RA 22 3 3 m DT 2 E y L30 2 S 5 wonkuenr 2 2 QD1 9 LAAN OPTION ERU E F6 9 275A FUSE A12 B12 B9 B10 IN IN IN OUT IN U9 A8 OUT pa HARGER G A1 OUT U5 ELECTRONIC CONTROL MODULE OUT OUT fm EN AC INPUT Vly U6 9 g O 30 2 CONTROLLER 10 HORN RELAY A H2 OPTION 36 j 913 G6 FB ci DC AC INVERTER HOUR FLASHING 87 55 METER BEACONS OPTION H2 AUTO STYLE HORN u i OPTION ES0142B Genie 6 24 GS 30 GS 32 GS 46 Part No 96316
9. RD RD 4 4 4 WH WH 3 3 juo Y 3 48 CR48 BL 1 1 Jo POWER BK 2 2 M RELAY TO US 8 Eso o N O H C 4 DOWN LIMIT SWITCH NC gt i LEVEL SENSOR I CIRCUIT 1 I BOARD x i zs 3 2 57 2 m gt gt LEVEL 2 21 24 SENSOR z 5 2 z BS EEE gt UU m d 5 052 BK og E 85539 m zh a o z e E m 28 3 zm 982858 1 1 2 I k C2 B11 C12 A10 A4 2 B1 C11 5 IN IN IN IN IN IN IN IN IN OUT ELECTRONIC CONTROL MODULE OUT OUT OUT OUT OUT OUT OUT C8 C7 B7 A7 C6 B6 DE xd scc EN DELL a 2 8 2 x E A Y1 Y4 Y5 Y6 Y9 Y7 Y8 PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM RIGHT LEFT REVERSE FORWARD DOWN DOWN UP GS 3246 L_ L_ L Le L GND ES0141E Genie Part No 96316 GS 30 GS 32 GS 46 6 21 Section 6 Schematics September 2005 Electrical Schematic ANSI CSA and Australia Models REV B GS 2032 2632 from serial number GS3205 75000 to 75406 GS 2046 2646 3246 from serial number GS4605 75000 to 75437 ETE P2 QD
10. Pro GS 1530 0 046 1 17 Q GS 1930 0 037 0 94 mm The lift cylinder orifice is located underneath the fitting on the lift cylinder 1 1 Y8 1800 to 3500 psi I 124 to 241 bar M I 1 3500 psi maximum 241 bar maximum 15 L min 172 bar LL o ce d UNIT lt gt BvPass HS0035C Genie 6 40 GS 30 GS 32 GS 46 Part No 96316 September 2005 Section 6 Schematics Hydraulic Schematic REVA GS 1530 1532 1930 1932 from serial number GS3003 60000 to GS3004 65104 STEER STEER LEFT RIGHT LEFT RIGHT LEFT RIGHT BRAKE BRAKE 4 4 t a a ur a P D HAND _ PUMP RELEASE MANIFOLD 51 52 B Y4 O Ne us 1 1800 Dok 7 PL mE ve N 0 75 f I lt 2 8 L min p
11. ANSI CSA and Australia Models REV GS 1530 1532 1930 1932 from serial number GS3003 60000 to GS3005 74999 2 QD3 EMERGENCY 4 4 BK POWER TO PLATFORM 3 gt 3 RD POWER TO GROUND 1 Lwa emouuwp Loros 2 2 DATALINK HIGH I 5 5 OR DATA LINK LOW SW25 U3 PLATFORM CONTROLS VOLTAGE SWITCH PRINTED CIRCUIT BOARD REGULATOR POUT1 POUT2 POUT3 POUT4 POUT5 POUT6 POUT7 POUT8 POUT9 POUT10 JC1 JOYSTICK HALL EFFECT CONTROLLER BL SW5 SW6 FUNCTION ENABLE T STEER 1 LEFT RIGHT on m 2 4 i RD BK PLATFORM CONTROLS MEMBRANE DECAL POWER LED 119 FAULT LED L25 ts HIGH TORQUE LED 121 BATTERY LEVEL 1 BATTERY LEVEL 2 AAA G7 BATTERY LEVEL 3 BATTERY LEVEL 4 D RAR BATTERY LEVEL5 DRIVE LED L17 LIFT LED L16 PIN1 HIGH TORQUE BN6 PIN2 HORN BN5 PIN3 DRIVE ENABLE BN8 amp PIN4 LIFT ENABLE BN9 POUT11 gt PLATFORM CONTROLLER PIN11 ESO141B Genie GS 30 GS 32 GS 46 Part No 96316 October 2008 Section 6 Schematics This page intentional
12. oj A O BAIN olx wo NIS ANIC n ge cd l lt j eo E zi a a NI io A mi QIN EI ala S o o 2 D O p o m N N A m o a A o o zi a o OLR amp 4009 gt a AININ 92 N AT 91 N a A Apc 85 Section 2 Specifications June 2009 E This page intentionally left blank Genie 2 8 GS 30 GS 32 GS 46 Part No 96316 October 2008 Section Scheduled Maintenance Procedures Scheduled Maintenance Procedures Observe and Obey Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine Scheduled maintenance inspections shall be completed daily quarterly and semi annually annually and every two years as specified on the Maintenance Inspection Report AWARNING 2 to perform each procedure as presented and scheduled could result in death serious injury or substantial damage Immediately tag and remove from service da
13. 6 28 GS 2032 2632 from serial number GS3204 60000 to GS3205 74999 GS 2046 2646 3246 Part No 96316 from serial number GS4604 60000 to GS4605 74999 6 32 GS 2032 2632 from serial number GS3205 75000 to 75406 GS 2046 2646 3246 from serial number GS4605 75000 to 75437 6 36 Genie GS 30 GS 32 GS 46 xi June 2009 TABLE CONTENTS Section 6 Rev Schematics continued Hydraulic Schematics A Component Reference and Hydraulic Symbols Legend 6 39 A Hydraulic Schematic GS 1530 1532 1930 1932 from serial number GS3003 60000 to GS3004 65104 6 40 B Hydraulic Schematic GS 1530 1532 1930 1932 from serial number GS3004 65105 to 66986 6 42 A Hydraulic Schematic GS 1530 1532 1930 1932 from serial number GS3004 66987 to GS3005 75999 6 44 A Hydraulic Schematic GS 2032 2632 from serial number GS3204 60000 to GS3205 75406 6 46 Hydraulic Schematic GS 2046 2646 3246 from serial number GS4604 60000 to GS4604 60878 6 48 Hydraulic Schematic GS 2046 2646 3246 from serial number GS4604 60879 to GS4605 75437 6 50 Genie xii GS 30 GS 32 GS 46 Part No 96316 June 2009 Section
14. 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 specification 3 If required install the valve coil s onto the valve stem Install the coil nut onto the valve stem and torque to specification Genie 4 68 GS 30 GS 32 GS 46 Part No 96316 October 2008 Section 4 Repair Procedures REV C MANIFOLDS O Note alpha numeric callouts refer to corresponding notes on the electrical schematic Note alpha callouts refer to corresponding notes on the hydraulic schematic Genie Part No 96316 GS 30 GS 32 GS 46 4 69 Section 4 Repair Procedures October 2008 MANIFOLDS REV C 6 3 Check Valve Manifold Components GS 1530 GS 1532 GS 1930 and GS 1932 after serial number GS3004 66986 The check valve manifold is mounted on the function manifold Index Schematic No Description Item Function Torque 1 Check valve 200 psi 13 8 bar c TEE Drive 20 ft lbs 27 Nm 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 t
15. d UNIT lt gt BvPass HS0035D Genie 6 42 GS 30 GS 32 GS 46 Part No 96316 September 2005 Section 6 Schematics Hydraulic Schematic REV B GS 1530 1532 1930 1932 from serial number GS3004 65105 to 66986 STEER STEER LEFT RIGHT LEFT RIGHT LEFT RIGHT BRAKE BRAKE DRIVE DRIVE MOTOR MOTOR BRAKE E z z oO i P MANUAL 22 7 Lar BRAKE i PUMP RELEASE MANIFOLD kas ias B XS B1 1 S2 AC B HP M1 M4 Ya X alme 1500 psi 1 1 103 i1 ve M vs a CO wow p 9 d FUNCTION MANIFOLD ABBREVIATION LEGEND Item Description A Test port B Check valve steer circuit C Relief valve lift D Check valve brake circuit E Drive forward reverse F Steer left right G Flow regulator relief valve H Platform up Relief valve system J Shuttle valve brake release K Check valve manual brake release L Hand pump manual brake release M Needle valve manual brake release N Platform lowering valve Orifice platform down circuit P Accumulato
16. REV B CHECKLIST E PROCEDURE 10 Install the hydraulic pump inlet hard line into the tank Install the fitting onto the pump and torque to specification Refer to Section 2 Specifications 11 Install the hydraulic pump return hard line into the tank Install the fitting onto the hydraulic filter head and torque to specification Refer to Section 2 Specifications 12 Fill the tank with hydraulic oil until the fluid is at the FuLL indicator on the hydraulic tank Do not overfill 13 Activate the pump to fill the hydraulic system with oil and bleed the system of air Component damage hazard The pump can be damaged if operated without oil Be careful not to empty the hydraulic tank while in the process of filling the hydraulic system Do not allow the pump to cavitate 14 Repeat steps 12 through 13 until the hydraulic system and tank are both full Genie Part No 96316 GS 30 GS 32 GS 46 3 33 Section Scheduled Maintenance Procedures October 2008 L Y em This page intentionally left blank Genie 3 34 GS 30 GS 32 GS 46 Part No 96316 October 2008 Section 4 Repair Procedures Observe and Obey Repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the m
17. 2 1 Performance 2 2 Flydraulic SpecifiCatiohs reir e rtt tret Reeve 2 3 Manifold Component 2 4 Hydraulic Hose and Fitting Torque Specifications 2 5 SAE and Metric Fasteners Torque Charts 2 7 Section 3 Rev Scheduled Maintenance Procedures ER 3 1 Pre delivery Preparation Report 3 3 Maintenance Inspection 3 5 C Checklist A Procedures A 1 Inspect the Manuals and 3 6 2 Perform Pre operation Inspection uu 3 7 Perform Function Tests l y cere oce e 3 7 4 Perform 30 Day Service 3 8 5 Grease the Steer 3 8 Genie Part No 96316 GS 30 GS 32 GS 46 vii June 2009 TABLE OF CONTENTS Section 3 Rev Scheduled Maintenance Procedures continued Checklist B Procedures viii B 1 Inspect the Batteries ore tice ble tiec ceu rae eun ae 3 9 B 2 Inspect the Electrical 3 11 B 3 Inspect the Tires and Wheels including
18. 37 ioo e fe 38 1001100 e s 1141191 121 40 e s fe A ioo e et 42 100900 19100100 s T el qe pe P 24 s pep p pere 45 10110100 L 45 ej 4r s exe A pel qp L ws Poe 49 loti e or Hii s pe 53 10100 54 10101000 e 85 11001000 2510111600 5 110110001 lt e 5s 11101000 59 oro e fefefe If s 6 1101000 62 11000 p T L Section 4 Repair Procedures June 2009 PLATFORM CONTROLS 1 4 Software Configuration after serial numbers GS3005 74999 GS3205 74999 and GS4605 74999 The Electronic Control Module ECM contains programming for all configurations of the Genie GS 30 GS 32 and GS 46 The machine can be adjusted to a different configuration using the buttons at the platform controls How to Determine the Software Configuration 1 Remove the platform controls from the platform 2 Pull out the red Emergency Stop button to the on position at the ground controls 3 Push in red Emergency Stop butt
19. w EK Y1 4 Y5 YG Y9 Y8 PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM RIGHT LEFT REVERSE FORWARD DOWN DOWN UP GS 3246 ACC aX GND ES0142B Genie Part No 96316 GS 30 GS 32 GS 46 Section 6 Schematics Electrical Schematic CE Models GS 1530 1532 1930 1932 from serial number GS3003 60000 to GS3005 74999 P2 EMERGENCY ss 2 2 BL DATALINK HIGH 24 H OR lre p DATA LINK LOW 4 4 L POWER TO PLATFORM j RD POWER TO GROUND 13 1 1 WH GROUND SW25 DIP SWITCH U3 PLATFORM CONTROLS PRINTED CIRCUIT BOARD VOLTAGE REGULATOR i HALL EFFECT JC1 JOYSTICK CONTROLLER BL SW5 SW6 FUNCTION ENABLE T STEER 1 LEFT RIGHT on m 2 4 i RD BK POUT1 POUT2 a NON q PIN1 POUTS 4 HIGH TORQUE LED 121 ay POUT4 O 2447 BATTERY LEVEL 1 5 BATTERY LEVEL 2 ES US POUT6 4 4 BATTERYLEVEL3 gt 37 POUT7 a BATTERY 4 POUT8 BATTERY LEVEL 5 POUT9 DRIVE LED 117 29 NS PO
20. HS0035C Genie Part No 96316 ABBREVIATION LEGEND Item Description A Test port Check valve steer circuit Relief valve lift Check valve brake circuit Drive forward reverse Steer left right Flow regulator relief valve Platform up I mm o os Relief valve system Shuttle valve brake release Check valve manual brake release Hand pump manual brake release Needle valve manual brake release Platform lowering valve Orifice platform down circuit Accumulator m u O zZ Z lt n Pressure switch platform overload Check valve drive circuit GS 30 GS 32 GS 46 6 41 Section 6 Schematics September 2005 Hydraulic Schematic GS 1530 1532 1930 1932 REV B from serial number GS3004 65105 to 66986 Purond _ 1 OVERLOAD CE MODELS PS2 re Pro GS 1530 0 046 1 17 Q GS 1930 0 037 0 94 mm The lift cylinder orifice is located underneath the fitting on the lift cylinder L m Y8 r 1800 to 3500 psi 1 124 to 241 bar 1 3500 psi maximum 241 bar maximum 15 L min 172 bar LL o ce
21. LEVEL m 2 21 9 28 zz 5 5 SENSOR 9 2 5 2 B L 4 4 5 d g s iB 3 988 LL ll Ll GL ILI gl e et C2 B11 C12 A10 A4 A2 B1 C1 C11 A5 IN IN IN IN IN IN IN IN IN OUT U5 ELECTRONIC CONTROL MODULE OUT OUT OUT OUT OUT OUT OUT C8 B7 AT C6 B6 A6 ee ee oe ee 0 2 7005 2555 2 2 2 8 2 E 8 Y1 Y3 Y4 Y5 Y6 Y9 Y7 Y8 PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM RIGHT LEFT REVERSE FORWARD DOWN DOWN UP GS 3246 ACOX APX APX GND 50141 Genie Part No 96316 GS 30 GS 32 GS 46 6 17 Section 6 Schematics June 2009 Electrical Schematic ANSI CSA and Australia Models REV D GS 2032 2632 from serial number GS3204 60000 to GS3205 74999 GS 2046 2646 3246 from serial number GS4604 60000 to GS4605 74999 E P2 QD3 EMERGENCY 4 4 BK POWER TO PLATFORM 3 A 3 RD POWER TO GROUND 1 Lwa emouuwp Loros 2 2 DATALINK HIGH 5 5 OR LOW SW25 U3 py o DIP PLATFO
22. RD RD 4 4 WH WH 3 3 Y 30 4 85 CR48 BL 1 1 2 2 tu Tw RELAY TO 05 oahs Cs No 4 PSD gt PLATFORM m LS6 PRESSURE _ SWITCH SWITCH e N O H C _ CR27A CR27B CR27C OVERLOAD OVERLOAD OVERLOAD pese eet MOTOR CONT LOAD SENSE DOWN COIL I N C ye 86 2 48 y 4 NC 4 54 85 aza 85 85 LEVEL es IE C5 E BOARD t 4700 uF t S7 5 wt 5 8255 3 BK CR27D amp 25 a 9 OVERLOAD a Ll m DOWN DELAY 2 o c e uL C2 Bi 9 A6 10 B6 C12 A4 2 Bi C11 5 IN IN OUT OUT IN OUT IN IN IN IN IN IN OUT 05 ELECTRONIC CONTROL MODULE OUT OUT OUT OUT OUT C8 C7 B7 A7 C6 y s mE m ES I E E Y1 Y4 Y5 Y6 Y9 Y7 Y8 PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM RIGHT LEFT REVERSE FORWARD DOWN DOWN UP GS 3246 ACOX APX APX L L L 4 L L GND 4 ES0142D Genie Part No 96316 GS 30 GS 32 GS 46 Section 6 Schematics September 2005 Electrical Schematic CE Models REV B GS 1530 1532 1930 1932 from serial number GS3005 75000 to 75999 P2
23. 3 7 S g 95 5 i z 2 od M z 130 g 5 E z 2 QD1 Y OPTION Eus no ms F6 8 9 P 275A FUSE M A12 B12 B9 B10 IN IN IN OUT IN U9 Tee A8 OUT BATTERY fF a WH CHARGER A1 OUT U5 ELECTRONIC CONTROL MODULE OUT OUT m B8 B3 AC INPUT 06 2 motor 2 30 CONTROLLER 10 2 sdy CR5 1 HORN RELAY lo E j E A 3 H2OPTION 488 U13 G6 FB ci DC AC INVERTER HOUR FLASHING Br i OPTION OPTION H2 AUTO STYLE HORN i OPTION ES0142D Genie 6 28 GS 30 GS 32 GS 46 Part No 96316 September 2005 Section Schematics Electrical Schematic REV B CE Models GS 1530 1532 1930 1932 from serial number GS3005 75000 to 75999 NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF
24. REV B Platform Control Box _ 8 vel BK 69 EMERGENCY an PLATFORM V CONTROLS GEN 4 0000 000000 N d JC1 JOYSTICK CONTROLLER 00000000 IV N S BN U3 WH PLATFORM CONTROLS SW25 CIRCUIT BOARD DIP SWITCH WHIBL BITES P2 parom 7 8 GEN 5 Lb EN 6 ee e TO COIL CORD E EE m E EMERGENCY STOP Part No 96316 Genie GS 30 GS 32 GS 46 6 5 October 2008 Section 6 Schematics Limit Switch Legend REV B ALL MODELS X SM y GS 2032 GS 2632 GS 2046 2646 GS GS 3246 GS 1530 GS 1532 GS 1930 GS 1932 Limit Switch Legend maximum height limit switch LS5 CE models down limit switch LS6 a b pothole switches 187 158 G Part No 96316 GS 30 GS 32 GS 46 September 2005 Section 6 Schematics Electrical Symbols Legend REVA eee eee barr _ eae TM 9 Pressure sw
25. CR27D 422455 2 OVERLOAD Lo DOWN DELAY 9 2 Am A o o 2 154 2 Ro 2 3 3 2 99 98 a C2 Bii 9 A6 10 B6 c12 Ad BI CH IN IN OUT OUT IN OUT IN IN IN IN IN IN OUT Us ELECTRONIC CONTROL MODULE OUT OUT OUT OUT OUT C8 C7 B7 A7 c6 rely a T c ds cc EU Rc ee Y1 Y3 Y4 Y5 Y6 Y9 Y7 Y8 PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM RIGHT LEFT REVERSE FORWARD DOWN DOWN UP GS 3246 p L L Le L L GND ES0142B Genie Part No 96316 GS 30 GS 32 GS 46 6 33 Section 6 Schematics June 2009 Electrical Schematic CE Models REV D GS 2032 2632 from serial number GS3204 60000 to GS3205 74999 GS 2046 2646 3246 from serial number GS4604 60000 to GS4605 74999 E P2 QD3 EMERGENCY 4 4 BK POWER TO PLATFORM 3 A 3 RD POWER TO GROUND 1 1 aroun Topics 2 2 DATALINK HIGH 5 5 OR DATA LINK LOW SW25 U3 py o DIP PLATFORM CONTROLS VOLTAGE SWITCH PRINTED CIRCUIT BOARD REGULATOR miim I BN o HALL EFFEC
26. TABLE OF CONTENTS Code Chari nebat Es 5 3 Schematics e ia ME 6 1 Electrical Component and Wire Color 6 2 Pin out Legend toti cir bnnc E ede rr C EE e da n 6 3 Wiring Diagram Ground Controls and Level Sensor Harness 6 4 Wiring Diagram Platform Control 6 5 Limit Switch 6 6 Electrical Symbols 6 7 Electrical Schematics ANSI CSA and Australia Models models without platform overload GS 1530 1532 1930 1932 from serial number GS3003 60000 to GS3005 74999 6 8 GS 1530 1532 1930 1932 from serial number GS3005 75000 to 75999 6 12 GS 2032 2632 from serial number GS3204 60000 to GS3205 74999 GS 2046 2646 3246 from serial number GS4604 60000 to GS4605 74999 6 16 GS 2032 2632 from serial number GS3205 75000 to 75406 GS 2046 2646 3246 from serial number GS4605 75000 to 75437 6 20 Electrical Schematics CE Models models with platform overload GS 1530 1532 1930 1932 from serial number GS3003 60000 to GS3005 74999 6 24 GS 1530 1532 1930 1932 from serial number GS3005 75000 to 75999
27. DIP switches have two positions on and off When reading the DIP switch code in the DIP Switch Code Chart the on and the off are represented by the numbers 1 on and O off How to Determine the DIP Switch Configuration 1 Remove the platform controls from the platform 2 Place the platform controls close to the diagnostic display on the power unit side of the machine 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 Press and hold the lift function enable button OR press the lift function select button 5 Slowly move the joystick in the direction indicated by the blue arrow Result The DIP switch configuration will appear in the diagnostic display Part No 96316 Genie GS 30 GS 32 GS 46 4 9 PLATFORM CONTROLS Machine Option Definitions Motion Beacon The motion beacon option flashes only when operating a function Motion Alarm The motion alarm will sound when operating any function Lift Drive Cut Out This cuts out lift and drive functions when the machine exceeds the rating on the serial plate Configured on all machines Platform Overload This cuts out all functions when the pressure sensor is overloaded The additional weight must be removed from the platform before any function can be resumed Required for CE models Descent Delay This option halts descent at approximately 7 fee
28. GS 32 GS 46 Part No 96316 June 2006 Section Scheduled Maintenance Procedures Checklist D Procedures REV D 1 Check the Scissor Arm Wear Pads Genie requires that this procedure be performed every 1000 hours or annually whichever comes first Maintaining the scissor arm wear pads in good condition is essential to safe machine operation Continued use of worn out wear pads may result in component damage and unsafe operating conditions Note Perform this procedure with the platform in the stowed position GS 1530 GS 1532 GS 1930 and GS 1932 1 Measure the distance between the number one outer arm cross tube and the chassis deck at the ground controls side of the non steer end of the machine Q Result The measurement is 0 90 inch 22 9 mm or more Proceed to step 2 Result The measurement is less than 0 90 inch 22 9 mm Replace both wear pads Refer to Repair Procedure 3 1 or 3 2 How to Replace the Scissor Arm Repair Pads 2 Measure the distance between the number one outer arm cross tube and the chassis deck at the battery pack side of the non steer end of the machine Result The measurement is 0 90 inch 22 9 mm or more Proceed to step 3 Result The measurement is less than 0 90 inch 22 9 mm Replace both wear pads Refer to Repair Procedure 3 1 or 3 2 How to Replace the Scissor Arm Repair Pads Part No 96316 Genie GS 30 GS 32 GS 46
29. Genie A TEREX BRAND Service Manual GS 1530 32 GS 1930 32 GS 2032 GS 2632 GS 2046 GS 2646 GS 3246 Serial Number Range from GS3003 60000 to GS3005 75999 from GS3003 60000 to GS3005 75999 from GS3204 60000 to GS3205 75406 from GS3204 60000 to GS3205 75406 from GS4604 60000 to GS4605 75437 from GS4604 60000 to GS4605 75437 from GS4604 60000 to GS4605 75437 Part No 96316 Rev E5 November 2010 September 2005 Introduction Important Read understand and obey the safety rules and operating instructions in the appropriate Operator s Manual on your machine before attempting any maintenance procedure Basic mechanical hydraulic and electrical skills are required to perform most procedures However several procedures require specialized skills tools lifting equipment and a suitable workshop In these instances we strongly recommend that maintenance and repair be performed at an authorized Genie dealer Service center Technical Publications Genie Industries has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in suggestions for improvement All communications will be carefully considered for future printings of this and all other manuals Contact Us ww
30. 1 mE N 2 KS1 I T key PLATFORM SWITCH CONTROL 1 4 1 i H5 N ALARM MACHINE SHOWN IN THE p 2 3 7 STOWED POSITION WITH N C HO THE POWER OFF CONTROL 7 J 157 POTHOLE TS66 GUARD PLATFORM SWITCH UP DOWN CB2 4 ae Ls 523 PH Of CIRCUIT BREAKER 4 198 POTHOLE 027 GUARD 47 mH INDUCTOR NOISE SUPPRESSION SWITCH m c x gt 3 7 S g 95 5 i z 2 od M z 130 g 5 E z 2 QD1 Y OPTION Eus no ms F6 8 9 P 275A FUSE M A12 B12 B9 B10 IN IN IN OUT IN U9 Tee A8 OUT BATTERY fF a WH CHARGER A1 OUT U5 ELECTRONIC CONTROL MODULE OUT OUT m B8 B3 AC INPUT 06 2 motor 2 30 CONTROLLER 10 2 sdy CR5 1 HORN RELAY lo E j E A 3 H2OPTION 488 U13 G6 FB ci DC AC INVERTER HOUR FLASHING Br i OPTION OPTION H2 AUTO STYLE HORN i OPTION ES0142D Genie 6 36 GS 30 GS 32 GS 46 Part No 96316
31. Bodily injury hazard Keep hands ACAUTION clear of moving parts when lowering the cylinder 59 Attach a lifting strap from an overhead crane to the number 3 inner arm index 23 Raise the arm to a vertical position 60 Remove the retaining fasteners from the number 3 pivot pin at the steer end of the machine index 10 61 Use a soft metal drift to remove the number 3 pivot pin index 10 from the steer end of the machine Remove the number 3 inner arm index 23 from the machine Crushing hazard The number 3 ACAUTION inner arm index 23 may become unbalanced and fall if not properly supported when the pivot pin is removed 62 Remove the cables from the number 2A and 2B cable bridges and lay them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched Part No 96316 October 2008 Section 4 Repair Procedures REV 63 Disconnect the number 2A and 2B cable bridges from the scissor linkset and remove both cable bridges from the machine 64 Attach a lifting strap from an overhead crane to the number 2 outer arm at the ground control side index 26 65 Remove the retaining fasteners from the number 2 center pivot pin index 11 at the ground control side 66 Place a rod through the number 2 center pivot pin at the ground control side index 11 and twist to remove the pin 67 Remove the retaining fasteners from the number 2 pivot pin index 27 at the
32. GS 2632 GS 2046 GS 2646 and GS 3246 REV C The function manifold is mounted behind an inspection door on the ground control side of the machine Index Schematic No Description Item Function Torque m Coil nut items AC AG and All nnne rennen nnne nnns 5 ft lbs 7 Nm Diagnostic nipple Testing 2 Relief valve 3500 psi 241 bar maximum System 1 20 ft lbs 27 Nm 3 Solenoid valve 3 position 4 way AG Laus Steer left right 25 ft lbs 34 Nm 4 anan AD eren Steer circuit 18 ft lbs 24 Nm 5 Solenoid valve 2 position 4 way Logs Drive speed select circuit 25 ft lbs 34 Nm 6 Relief valve 130 PSU 9 Dar sa eere intr tree 2081228 assis Brake release 20 ft lbs 27 Nm Solenoid valve 3 position 5 way AQ ains Drive forward reverse 25 ft lbs 34 Nm Flow regulator and relief valve 0 75 gpm 2 8 L min 1500 psi 103 Dat ciii AH Leine Steer circuit 26 ft lbs 35 Nm 9 Solenoid valve 2 position 4 way Al cet Platform 25 ft lbs 34 Nm 10 Relief valve 1800 to 3500 psi 124 to 241 bar
33. GS 46 Part No 96316 June 2009 Section e Scheduled Maintenance Procedures Maintenance Inspection Report Model Serial number Date Hour meter Machine owner Inspected by print Inspector signature Inspector title Inspector company Instructions Make copies of this report to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hours Inspection A Quarterly or 250 hours Inspection Semi annually or 500 hours Inspection Annually or 1000 hours Inspection 0 Two year 2000 hours Inspection A B C D E Place a check in the appropriate box after each inspection procedure is completed Use the step by step procedures this section to learn how to perform these inspections If any inspection receives N tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable no remove from service repaired Checklist B Rev F Y NR Checklist A Rev C Y NR A 1 Inspect the manuals and decals A 2 Pre operation inspection A 3 Function tests Perform after 40 hours 4 30 day service Perform every 100 hours A 5 Grease steer yokes Comments Genie Part No 96316 B 1 Batteries B 2 Electrical wiring B 3 Tires and wheels B 4 Emer
34. Genie Industries Service Department Genie GS 30 GS 32 GS 46 REV D P2 D EMERGENCY STOP gr w PLATFORM CONTROLS c CIRCUIT BOARD o CONTROLLER il e L _ O m f ws ALARM Gen 4 platform controller joystick controller JC1 red Emergency Stop button P2 DIP switch SW25 circuit board retaining fastener platform controls circuit board U3 alarm H1 JC1 JOYSTICK CONTROLLER x 1 eum PLATFORM CONTROLS CIRCUIT BOARD EMERGENCY 1 STOP gr Gen 5 platform controller joystick controller JC1 alarm H1 platform controls circuit board U3 red Emergency Stop button P2 Part No 96316 June 2009 Section 4 Repair Procedures p M M REV D 1 1 Circuit Boards How to Remove the Platform Controls Circuit Board 1 Push the red Emergency Stop button to the off position at both the ground and platform controls 2 Remove the fasteners securing the platform control box together Open the control box 3 Locate the circuit board mounted to the top half of the platform control box AWARNING Electrocution burn hazar
35. Keep hands ACAUTION clear of moving parts when lowering the scissor arms Genie GS 30 GS 32 GS 46 REV C 55 Secure the ends of the scissor arms together at the steer end of the machine with a strap or other suitable device 56 Secure the ends of the scissor arms together at the non steer end of the machine with a strap or other suitable device 57 Remove the retaining fasteners securing the chassis mount bracket to the chassis 58 Remove the linkset from the machine Bodily injury hazard The number ACAUTION 1 inner and outer arms index 8 and 17 may become unbalanced and fall if not properly supported when removed from the machine Component damage hazard Be sure not to damage the limit switch or level sensor box components when the number 1 inner and outer arms index 8 and 17 is removed from the machine Part No 96316 October 2008 Section 4 Repair Procedures REV How to Replace the Scissor Arm Wear Pads 1 Remove the platform See 2 1 How to Remove the Platform 2 Support and secure the entry ladder to an appropriate lifting device 3 Remove the fasteners from the entry ladder and remove the entry ladder from the machine Crushing hazard The entry ladder ACAUTION may become unbalanced and fall if not properly supported and secured to the lifting device 4 Secure the ends of the scissor arms together at the steer end of the machine with a strap or other suitable
36. MOTOR BRAKE OI 1 T P MANUAL i ly 1 03 CU IN I PN 16 9 cc BRAKE PUMP RELEASE 4 MANIFOLD c B1 1 2 M1 M4 AD ho mi O L jeg 8 4 4 Tm 1500 psi I M AF ve Inl vs 1 4 LT LM 130 psi 1 Leones 9 bar FUNCTION MANIFOLD ABBREVIATION LEGEND Item Description AA Test port AB Relief valve system AC Steer left right AD Check valve steer circuit AE Drive speed AF Relief valve brake release AG Drive forward reverse AH Flow regulator relief valve Platform up AJ Relief valve lift J Shuttle valve brake release K Check valve manual brake release L Hand pump manual brake release M Needle valve manual brake release N Platform lowering valve O Orifice platform down circuit P Accumulator Q Relief valve platform down HS0036G R Pressure switch platform overload Genie Part No 96316 GS 30 GS 32 GS 46 6 47 Section 6 Schematics June 2009 Hydraulic Schematic GS 2046 2646 3246 REV B from serial number GS4604 60000 to GS4604 60878 UPPERLFTCYLINDER PLATFORM urrcvuwpR 1 GS 3246 OVERLOAD CE MODELS Y9 The lift cylinder orifice is The lift cylinder orifice is located underneath the f
37. UPPER LIFT CYLINDER GS 3246 Y9 R 0 037 0 94 mm The lift cylinder orifice is PLATFORM OVERLOAD CE MODELS September 2005 REV urrcuwmpR The lift cylinder orifice is located underneath the fitting on the lift cylinder 7 POWER UNIT LI located underneath the boa fitting on the lift cylinder i 1 LIFT i 2500 psi 172 bar 15 L min 172 bar 71 Y8 1800 to 3500 psi ho 77 124 to 241 bar 1 lt gt E E 1 3500 psi maximum Len 241 bar maximum TANK HS0036G Genie GS 30 GS 32 GS 46 Part No 96316 September 2005 Section 6 Schematics Hydraulic Schematic REVA GS 2032 2632 from serial number GS3204 60000 to GS3205 75406 STEER STEER LEFT RIGHT LEFT RIGHT LEFT RIGHT BRAKE NEN BRAKE DRIVE DRIVE
38. lower the platform to the stowed position and remove all test weight from the platform 23 Calibrate the lift relief valve See 6 4 How to Adjust the Platform Lift Relief Valve Part No 96316 October 2008 Section 4 Repair Procedures REV B TROUBLESHOOTING THE PLATFORM OVERLOAD SYSTEM CONDITION POSSIBLE CAUSE SOLUTION CANNOT LIFT RATED LOAD AT MAX HEIGHT THE PRESSURE SWITCH ALARM CONTINUES TO SOUND AFTER ADJUSTMENT RELIEF VALVE SETTING INCREASE RELIEF VALVE PRESSURE TURN OFF RED EMERGENCY STOP SYSTEM NEEDS TO BE RESET BUTTON WAIT THREE SECONDS AND TURN BACK ON UP LIMIT SWITCH OUT OF ADJUSTMENT LOWER THE UP LIMIT SWITCH SLIGHTLY 2 RATED LOAD FOR HEIGHT BEING CORRECT RATED LOAD IN PLATFORM TURN THE PRESSURE SWITCH NUT INTO PRESSURE SWITCH OUT OF ADJUSTMENT THE HYDRAULIC LINE 1 4 TURN BATTERIES ARE NOT FULLY CHARGED CHARGE BATTERIES OVERLOAD SYSTEM NOT ADJUSTED PROPERLY REPEAT CALIBRATION PROCEDURE SLIDER CHANNEL NOT LUBRICATED LUBRICATE SLIDER CHANNELS AT DOWN LIMIT THE PRESSURE SWITCH ALARM CONTINUES TO SOUND AFTER ADJUSTMENT TURN OFF RED EMERGENCY STOP BUTTON WAIT THREE SECONDS AND TURN BACK ON DOWN LIMIT SWITCH OUT OF ADJUSTMENT RAISE THE DOWN LIMIT SWITCH WRONG RATED LOAD FOR HEIGHT BEING TESTED SYSTEM NEEDS TO BE RESET PUT CORRECT RATED LOAD IN PLATFORM TURN THE PRESSURE SWITCH NUT INTO THE HYDRAULIC LINE 1 4 TURN OR REPEAT CALIBRATION PROCEDURE OV
39. 21 1 mm x 15 cm x 15 cm thick steel block under both wheels at the battery pack side of the machine GS 2032 and GS 2632 Place a 0 8 x 6 x 6 inch 20 3 mm x 15 cm x 15 cm thick steel block under both wheels at the battery pack side of the machine GS 2046 GS 2646 and GS 3246 Place 1 22 x 6 x 6 inch 31 mm x 15 cm x 15 cm thick steel block under both wheels at the battery pack side of the machine 32 Lower the machine onto the blocks 33 Raise the platform 7 to 8 feet 2 1 to 2 4 m O Result The platform should stop and an alarm should sound Result The platform does not stop or the level sensor alarm does not sound Adjust the level sensor until the alarm just begins to sound OR the down limit switch may need to be adjusted 34 Lift the safety arm move it to the center of the Scissor arm and rotate down to a vertical position 35 Lower the scissor arms onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 36 Raise the platform 7 to 8 feet 2 1 to 2 4 m 37 Return the safety arm to the stowed position 38 Lower the platform to the stowed position 39 Raise the machine approximately 2 inches 5 cm 41 Remove the blocks from under both wheels 41 Lower the machine and remove the jack Section 4 Repair Procedures September 2005 Hydraulic Pump 5 1 Function Pump The hydraulic pump is attached to the motor which makes up the h
40. 42 Remove the retaining fasteners from the number 2 center pivot pin index 7 at the ground control side 43 Place a rod through the number 2 center pivot pin at the ground control side index 7 and twist to remove the pin 44 Remove the retaining fasteners from the number 2 pivot pin index 20 at the non steer end Genie GS 30 GS 32 GS 46 REV C 45 Use a soft metal drift to remove the number 2 pivot pin index 420 from the non steer end of the machine Remove the number 2 outer arm at the ground control side index 19 from the machine Crushing hazard The number 2 ACAUTION outer arm at the ground control side index 19 may become unbalanced and fall if not properly supported when the pivot pin is removed 46 Attach a lifting strap from an overhead crane to the number 2 outer arm at the battery side index 19 47 Remove the retaining fasteners from the number 2 center pivot pin index 7 at the battery side 48 Place a rod through the number 2 center pivot pin at the battery side index 7 and twist to remove the pin Crushing hazard The number 2 A CAUTION outer arm index 19 may become unbalanced and fall if not properly supported when the pivot pin is removed 49 Remove the number 2 outer arm index 19 from the machine Crushing hazard The number 2 ACAUTION outer arm index 19 may become unbalanced and fall if not properly supported when removed from the machine Pa
41. 96316 GS 30 GS 32 GS 46 ix June 2009 TABLE OF CONTENTS A Hydraulic Pump 5 1 Function Pump u niiata an A AEEA 4 64 Section 4 Rev Repair Procedures continued C Manifolds 6 1 Function Manifold Components GS 1530 95 1532 95 1930 and GS 1932 4 66 6 2 Function Manifold Components GS 2032 GS 2632 95 2046 GS 2646 and GS 3246 4 68 6 3 Check Valve Manifold Components GS 1530 GS 1532 GS 1930 and GS 1932 after serial number GS3004 66986 4 70 6 4 Valve Adjustments Function Manifold 4 71 6 5 p kin einai bits Aan eee 4 75 B Hydraulic Tank 7 1 Hydraulic 4 77 B Steer Axle Components 8 1 Yokeand Drive Motor eere trei retra rera tendons 4 78 8 2 Steer Cylinder oer Here Einen exuere tee 4 79 8 3 Steer Bellcrank sse nennen 4 80 A Non steer Axle Components 9 1 Drive Brake RES exo au 4 81 A Brake Release Hand Pump Components 10 1 Brake Release Hand Pump Components 4 82 B Platform Overload Components 11 1 Platform Overload siisii titer eiue entera 4 83 Section 5 Rev Fault Codes WTOC Oi uu eL 5 1 Genie x GS 30 GS 32 GS 46 Part No 96316 June 2009 Section 6 Rev gt gt
42. Cables can be damaged if they are kinked or pinched Part No 96316 Genie GS 30 GS 32 GS 46 GS 1532 Cable bridge legend a cable bridge 3 b cable bridge 2 C cable bridge 1 4 Attach a lifting strap from an overhead crane to the number 3 outer arm index 1H 1 5 Remove the external snap rings and retaining fasteners from the number 3 center pivot pins index 2 6 Use a soft metal drift to remove the number 3 center pivot pins index 2 7 Remove the retaining fasteners from the number 3 pivot pin index 12 at the non steer end of the machine 8 Use a soft metal drift to remove the number pivot pin index 12 from the non steer end of the machine Remove the number 3 outer arm index 11 from the machine AWARNING Crushing hazard The number 3 outer arm may become unbalanced and fall if not properly supported when removed from the machine Section 4 Repair Procedures October 2008 SCISSOR COMPONENTS 9 Remove the number 3 cable bridge mounting fasteners and remove the cable bridge from the machine 10 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 11 Remove the pin retaining fasteners from the lift cylinder rod end pivot pin index 3 Use a soft metal drift to remove the pin Bodily injury hazard The cylinder ACAUTION may fall when the rod end pivot pin is remove
43. Figure 2 Note Use the 37 Fittings table on the previous page to determine the correct number of flats for the proper tightening position Note The marks indicate that the correct tightening positions have been determined Use the second mark on the body hex fitting to properly tighten the joint after it has been loosened Figure 2 a body hex fitting b reference mark second mark 4 Tighten the hex nut until the mark on the hex nut is aligned with the second mark on the body hex fitting 5 all machine functions and inspect the hoses and fittings and related components to confirm that there are no leaks Part No 96316 June 2009 Section 2 Specifications REV E SPECIFICATIONS SAE FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual A574 High Strength Grade5 2 Grade8 69 Black Oxide Bolts DRY DRY LUBED Nm_ in lbs Nm Nm inis 5 1 m To LUBED LUBED LUBED m gt muss 13 23 14 257 23 12 26 274 37 66 4 i 745 Go s3 1084 58 s 773 75 1016 60 1084 0 149 03 16 857 s 115 so 12 320 362 15 742 one 12 80 1084 no 149 18 s 122 o 362 1130 T re ro 230 140 s 18 130 376 ro 230 ro 244 240 325 200 271 sa L 10 20 27i 270 366 28
44. GROUND CONTROLS MOTOR CONTROLLER RD 1 2 CB2 KS1 BREAKER MOTOR CONTROLLER WH TERMINAL 1 G6 6 PIN NEUE WH BK N HOUR METER RD ECM PIN B12 J1 TS66 2 PLATFORM UP DOWN ECM PIN A12 J1 3 DOWN TOGGLE SWITCH CR48 TERMINAL 30 PIN A1 J1 P1 1 2 EMERGENCY STOP WH NC NEUE ncc ee LEVEL SENSOR HARNESS ANSI AND CSA MODELS S H5 LS6 MULTI FUNCTION ALARM S7 DOWN LIMIT SWITCH T2 E SHOWN IN STOWED POSITION e ECM PIN B9 LEVEL SENSOR pvo eere 2 d e __ ons TERMINAL 87 13 14 e e WH BK CR48 TERMINAL 87 NORG BK 4 RD BK ECM PIN C12 RD BK WH 222224 e Y ECM PIN BN GROUND To ECM PIN A5 E NOTUSED L 4 LEVEL SENSOR HARNESS CE MODELS AND ANSI CSA MODELS WITH PLATFORM OVERLOAD H5 LS6 MULTI FUNCTION ALARM S7 DOWN LIMIT SWITCH 1 BL SHOWN IN STOWED POSITION e ECM PIN B9 LEVEL SENSOR 1 2 a e _ TERMINAL 87 18 14 l pee MH CR48 TERMINAL 87 Bk 211 422 NCHO 1 BK 4e PBK 2 ON ECM PIN C11 BN GROUND 7e PD ECM PIN A5 5 8 NOTUSED MB CR27D TERMINALS 85 87 AND 87A BK ECM PIN B6 Genie GS 30 GS 32 GS 46 Part No 96316 September 2005 Section 6 Schematics Wiring Diagram
45. GS 32 GS 46 Part No 96316 June 2009 Section Scheduled Maintenance Procedures REV CHECKLIST B PROCEDURES B 10 B 11 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 Part No 96316 Genie GS 30 GS 32 GS 46 3 19 Inspect the Hydraulic Tank Cap Venting System Genie requires that this procedure be performed quarterly or every 250 hours whichever comes first Perform this procedure more often if dusty conditions exist A free breathing hydraulic tank cap is essential for good machine performance and service life A dirty or clogged cap may cause the machine to perform poorly Extremely dirty conditions may require that the cap be inspected more often 1 Remove the breather c
46. Genie GS 30 GS 32 GS 46 SCISSOR COMPONENTS 5 Models with platform overload option Tag and disconnect the wiring from the platform overload switch 6 Loosen the adjustment nuts on the solenoid valve and disconnect the manual lowering cable from the valve Note During assembly the manual platform lowering cable needs to be properly adjusted See 4 1 How to Adjust the Manual Platform Lowering Cable 7 Remove the fasteners securing the manual lowering cable mount bracket to the cylinder Remove the bracket from the cylinder 8 Tag disconnect and plug the hydraulic hoses on the lift cylinder Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 9 Attach a lifting strap from an overhead crane to the rod end of the lift cylinder for support 10 Remove the retaining fasteners from the lift cylinder rod end pivot pin Use a soft metal drift to remove the pin AWARNING Crushing hazard The lift cylinder will fall if not properly supported 11 Lower the cylinder to a horizontal position Bodily injury hazard Keep hands ACAUTION clear of moving parts when lowering the cylinder 4 57 Section 4 Repair Procedures October 2008 SCISSOR COMPONENTS REV C 14 Support and secure the lift cylinder to an appropriat
47. L min 1500 psi 103 bat ain cp Steer circuit 8 Solenoid valve 2 position 4 way Platform up 9 Relief valve 3500 psi 241 bar maximum System relief How to Install a Valve Cartridge 1 Dip the cartridge in clean oil to lube the O rings 2 Screw the cartridge in by hand until the top O ring is met then torque to specification 3 If required install the valve coil s onto the valve stem Install the coil nut onto the valve stem and torque to specification Genie REV C Torque 5 ft lbs 7 Nm 18 ft lbs 24 Nm 20 ft Ibs 27 Nm 20 ft lbs 27 Nm 25 ft lbs 34 Nm 25 ft lbs 34 Nm 26 ft lbs 35 Nm 25 ft lbs 34 Nm 20 ft lbs 27 Nm 4 66 GS 30 GS 32 GS 46 Part No 96316 October 2008 Section 4 Repair Procedures REV MANIFOLDS ey N 2 5 3 SA Ue e ue S i 5 Note alpha callouts refer i tes on to correspon the hydraulic schematic Note alpha numeric callouts f onding notes on the electrical schematic Genie Part No 96316 GS 30 GS 32 GS 46 4 67 Section 4 Repair Procedures October 2008 MANIFOLDS 6 2 Function Manifold Components GS 2032
48. No 96316 PLATFORM CONTROLS Gen 4 platform controller a function enable switch SW5 b joystick controller JC1 with thumb steering rocker SW6 horn button BN5 machine on incline turtle button BN6 lift function select button BN9 drive function select BN8 red Emergency Stop button P2 yellow arrow platform controls diagnostic display Gen 5 platform controller Genie GS 30 GS 32 GS 46 Section 4 Repair Procedures June 2009 PLATFORM CONTROLS How to Adjust the Stowed Drive Speed Tip over hazard Do not adjust the lift and or drive speed higher than specified in this procedure Setting the function speeds greater than specifications could cause the machine to tip over resulting in death or serious injury ADANGER Tip over hazard This procedure must only be performed by a trained service professional Attempting this procedure without the necessary skills will result in death or serious injury Pull out the red Emergency Stop button to the on position at the ground controls 2 Pushin the red Emergency Stop button to the off position at the platform controls Turn the key switch to platform control 4 Atthe platform controls press and hold the lift function select and horn buttons and pull out the red Emergency Stop button to the on position Result The diagnostic display will show PS 5 Re
49. P1 yo EMERGENCY gt DS STOP NAT lt N on zx M I 2 KS1 v key PLATFORM SWITCH CONTROL 1 I NOTE oe H5 MACHINE SHOWN IN THE N Dm STOWED POSITION WITH N C HO THE POWER OFF p Do LS7 TS66 POTHOLE PLATFORM 1 UP DOWN CB2 N CHO 4 circu 2 LS8 BREAKER 4 POTHOLE GUARD SWITCH Do c gt S gs lt gt 9 E 323 B 2 130 5 5 OI MA ERAN 3 F6 P 8 275A FUSE EIL LI de eiman U9 m A8 OUT AER rv SENTI ELECTRONIC CONTROL MODULE OUT OUT mi B8 B3 AC INPUT Ea P lcm E Ow 7 4 CONTROLLER 2 10 4 5 1 2 p HORN RELAY YN H2 OPTION 486 us el Pig DG AC INVERTER 86 ENG Po OPTION BEACONS OPTION H2 AUTO STYLE HORN i OPTION ESO141E Genie 6 20 GS 30 GS 32 GS 46 Part No 96316 September 2005 Section 6 Schematics Electrical Schematic REV B ANSI CSA and Australia Models GS 2032 2632 from serial number GS3205 75000 to 75406 GS 2046 2646 3246 from serial number GS4605 75000 to 75437 NOTE MACHINE SHOWN IN THE STOWED
50. Replace the Hydraulic 3 32 Genie GS 30 GS 32 GS 46 Part No 96316 June 2009 TABLE OF CONTENTS Section 4 Rev Repair Procedures u u 4 1 D Platform Controls 1 1 Circuit Boards 1 enne enne nnns 4 3 1 2 4 4 1 3 Software Configuration before serial numbers GS3005 75000 GS3205 75000 and GS4605 75000 4 9 1 4 Software Configuration after serial numbers GS3005 74999 GS3205 74999 and GS4605 74999 4 12 A Platform Components 21 JPIatfOITI u te ic Garde 4 16 2 2 diosa p 4 17 C Scissor Components 3 1 Scissor Assembly GS 1530 and 95 1532 4 18 3 2 Scissor Assembly GS 1930 and 95 1932 4 24 3 3 Scissor Assembly GS 2032 GS 2046 4 32 3 4 Scissor Assembly GS 2632 95 2646 4 38 3 5 Scissor Assembly GS 3246 4 46 3 6 Lift Cylinder stays ente ben 4 54 Ground Controls 4 1 Manual Platform Lowering Cable 4 59 4 2 Control Relays 4 60 4 3 Level Sensor eene 4 61 Genie Part No
51. SAE Dash size Torque SAE Dash size Thread Size Flats 4 11 ft lbs 14 9 Nm 4 7 16 20 2 6 23 ft lbs 31 2 Nm 6 9 16 18 1 1 4 8 40 ft lbs 54 2 Nm 8 3 4 16 1 10 69 ft lbs 93 6 Nm 10 7 8 14 1 12 93 ft lbs 126 1 Nm 12 1 1 16 12 1 16 139 ft Ibs 188 5 Nm 16 1 5 16 12 1 20 172 ft lbs 233 2 Nm 20 1 5 e 12 1 24 208 ft Ibs 282 Nm 24 1 7 8 12 1 SAE O ring Boss Port tube fitting installed into Steel SAE Dash size Torque 4 16 ft lbs 21 7 Nm 6 35 ft lbs 47 5 Nm 8 60 ft lbs 81 3 Nm 10 105 ft Ibs 142 4 Nm 12 140 ft Ibs 190 Nm 16 210 ft lbs 284 7 Nm 20 260 ft lbs 352 5 Nm 24 315 ft lbs 427 1 Nm Genie Part No 96316 GS 30 GS 32 GS 46 2 5 Section 2 Specifications June 2009 SPECIFICATIONS Torque Procedure JIC 37 fittings 1 Align the tube flare hex nut against the nose of the fitting body body hex fitting and tighten the hex nut to the body hex fitting to hand tight approximately 30 in Ibs 3 4 Nm 2 Make reference mark on one of the flats of the hex nut and continue it on to the body hex fitting with a permanent ink marker Refer to Figure 1 Figure 1 hydraulic hose hex nut reference mark body hex fitting Genie GS 30 GS 32 GS 46 REVE 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
52. all tools and working areas Be sure any forklift overhead crane or d 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 N time use i e cotter pins and self locking nuts are not reused These components may fail if they are used a second time lt Be sure that fasteners intended for one Be sure to properly dispose of old oil or other fluids Use an approved container Please be environmentally safe Be sure that your workshop or work area is properly ventilated and well lit Indicates a potentially hazardous ES situation which if not avoided may result in property damage Be sure to wear protective eye wear and other protective clothing if the situation warrants it Be aware of potential crushing hazards such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Genie vi GS 30 GS 32 GS 46 Part No 96316 June 2009 Table of Contents Introduction Importantinformatl n li Serial Number Inforrmation cuit ree tutte tee pex eedem ed ii Serial Number Legend a ili Section 1 Safety Rules General Safety Rules uu Section 2 Rev Specifications E Machine
53. castle nut torque 3 12 B 4 Test the Emergency 3 12 B 5 the Key Switch ent reete Ear e anka 3 13 6 Automotive style Horn if 3 13 B 7 the Drive 0 24 11111 3 14 B 8 Drive Speed Stowed Position 3 17 B 9 the Drive Speed Raised Position 3 18 B 10 Perform Hydraulic Analysis 3 19 B 11 Inspect the Hydraulic Cap Venting 3 19 B 12 Check the Module Tray Latch Components 3 20 B 13 Inspect the Voltage Inverter if equipped 3 21 B 14 Test the Down Limit Switch and the Pothole Limit Switches 3 22 B 15 Test the Up Limit Switch if equipped 3 25 Checklist C Procedures C 1 the Platform Overload System if equipped 3 26 C 2 Replace the Hydraulic Tank Breather Cap Models with Optional Hydraulic 3 28 Checklist D Procedures D 1 Check the Scissor Arm Wear Pads 3 29 D 2 Replace the Hydraulic Tank Return Filter 3 31 Checklist E Procedure E 1 Testor
54. center pivot pin at the battery side index 2 and twist to remove the pin 16 Remove the number 4 outer arm index 13 from the machine Crushing hazard The number 4 A CAUTION outer arm index 13 may become unbalanced and fall if not properly supported when removed from the machine 17 Attach a lifting strap from an overhead crane to the number 4 inner arm index 12 Raise the arm to a vertical position 18 Remove the retaining fasteners from the number 4 pivot pin at the steer end of the machine index 3 19 Use a soft metal drift to remove the number 4 pivot pin index 3 from the steer end of the machine Remove the number 4 inner arm index 12 from the machine Crushing hazard The number 4 ACAUTION inner arm index 12 may become unbalanced and fall if not properly supported when removed from the machine 20 Remove the cables from the number 3A and 3B cable bridge and lay them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched 21 Disconnect the number 3A and 3B cable bridges from the scissor linkset and remove both cable bridges from the machine Part No 96316 October 2008 Section 4 Repair Procedures REV 22 Attach a lifting strap from an overhead crane to the number 3 outer arm at the ground control side index 16 23 Remove the retaining fasteners from the number 3 center pivot pin index 4 at the ground control side 24 P
55. 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 Part No 96316 October 2008 Section 4 Repair Procedures REV 3 2 Scissor Assembly GS 1930 and GS 1932 How to Disassemble the Scissor Assembly GS 1930 and GS 1932 AWARNING P dily injury hazard The procedures in this section require specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is required Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform See 2 1 How to Remove the Platform 2 Remove the cables from the number 4 outer arm index 13 at the ground controls side Component damage hazard Cables can be damaged if they are kinked or pinched Part No 96316 Genie GS 30 GS 32 GS 46 SCISSOR COMPONENTS _ GS 1930 GS 1932 Cable bridge legend cable bridge 4 cable bridge 3 cable bridge 2 cable bridge 1 3 Remove the cables from the number 4 cable bridge and lay
56. end pivot pin index 5 from the machine Crushing hazard The lift cylinder ACAUTION will fall if not properly supported when the pivot pin is removed 34 Place a 2 x 4 x 10 inch 10 x 10 x 25 cm block onto the number 1 inner arm cylinder plate index 10 35 Lower the cylinder onto the block Bodily injury hazard Keep hands ACAUTION clear of moving parts when lowering the cylinder onto the block 36 Attach a lifting strap from an overhead crane to the number 3 inner arm index 15 Raise the arm to a vertical position 37 Remove the retaining fasteners from the number 3 pivot pin at the steer end of the machine index 6 Section 4 Repair Procedures October 2008 SCISSOR COMPONENTS 38 Use a soft metal drift to remove the number 3 pivot pin index 6 from the steer end of the machine Remove the number 3 inner arm index 15 from the machine Crushing hazard The number 3 ACAUTION inner arm index 15 may become unbalanced and fall if not properly supported when the pivot pin is removed 39 Remove the cables from the number 2A and 2B cable bridge and lay them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched 40 Disconnect the number 2A and 2B cable bridges from the scissor linkset and remove both cable bridges from the machine 41 Attach a lifting strap from an overhead crane to the number 2 outer arm at the ground control side index 19
57. hold the function enable switch 2 SS SG s SS 56 S Ss GS 1530 32 and GS 1930 32 a test port b system relief valve lift relief valve Genie GS 30 GS 32 GS 46 REV C 7 Move and hold the joystick fully in either direction while observing the pressure reading on the pressure gauge Note the pressure Refer to Section 2 Specifications 8 Turn the machine off Hold the system relief valve with a wrench and remove the cap hydraulic schematic item or AB 9 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure ADANGER Tip over hazard Failure to adjust the relief valves to specification could result in the machine tipping over causing death or serious injury Do not adjust the relief valve pressures higher than specifications 10 Install the relief valve cap 11 Repeat steps 4 through 7 to confirm the relief valve pressure 12 Place maximum rated load into the platform Secure the load to the platform Refer to Section 2 Specifications GS 32 and GS 46 test port system relief valve steer relief valve lift relief valve ao oo Part No 96316 October 2008 Section 4 Repair Procedures REV MANIFOLDS 13 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 14 Hold the lift relief valve w
58. 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 Section Scheduled Maintenance Procedures June 2009 CHECKLIST B PROCEDURES B 14 Test the Down Limit Switch and the Pothole Limit Switches Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the limit switches is essential to 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 Perform these procedures with the machine on a firm level surface that is free of obstructi
59. non steer end 68 Use a soft metal drift to remove the number 2 pivot pin index 427 from the non steer end of the machine Remove the number 2 outer arm atthe ground control side index 26 from the machine Crushing hazard The number 2 ACAUTION outer arm at the ground control side index 26 may become unbalanced and fall if not properly supported when the pivot pin is removed 69 Attach a lifting strap from an overhead crane to the number 2 outer arm at the battery side index 26 70 Remove the retaining fasteners from the number 2 center pivot pin index 11 at the battery side 71 Place a rod through the number 2 center pivot pin at the battery side index 11 and twist to remove the pin Crushing hazard The number 2 ACAUTION outer arm index 26 may become unbalanced and fall if not properly supported when the pivot pin is removed Part No 96316 Genie GS 30 GS 32 GS 46 SCISSOR COMPONENTS 72 Remove the number 2 outer arm index 26 from the machine Crushing hazard The number 2 ACAUTION outer arm index 26 may become unbalanced and fall if not properly supported when removed from the machine 73 Attach a lifting strap from an overhead crane to the number 2 inner arm index 25 Raise the arm to a vertical position 74 Remove the retaining fasteners from the number 2 pivot pin at the steer end of the machine index 12 75 Use a soft metal drift to remove the number 2 p
60. number 2 pivot pin index 15 halfway out at the non steer end of the machine Remove the number 2 outer arm index 14 from the ground controls side of the machine Bodily injury hazard The number ACAUTION 2 outer arm at the ground controls side may become unbalanced and fall if not properly supported when removed from the machine 23 Attach a lifting strap from an overhead crane to the number 2 outer arm index 14 at the battery pack side 24 Remove the external snap rings and retaining fasteners from the number 2 center pivot pin index 5 at the battery pack side 25 Use a soft metal drift to remove the number 2 center pivot pin index 5 at the battery pack side Bodily injury hazard The number ACAUTION 2 outer arm at the battery pack side may become unbalanced and fall if not properly supported when removed from the machine Part No 96316 October 2008 Section 4 Repair Procedures REV 26 Use a soft metal drift to tap the number 2 pivot pin index 15 in the other direction at the non steer end Remove the number 2 outer arm index 14 from the battery pack side of the machine Bodily injury hazard The number ACAUTION 2 outer arm at the battery pack side may become unbalanced and fall if not properly supported when removed from the machine 27 Attach a lifting strap from an overhead crane to the number 2 inner arm index 13 28 Remove the retaining fasteners from the number 2
61. or Cable bridge legend serious injury and significant component damage Dealer 2 idi A service is required cable bridge 2B When removing a hose assembly or fitting the O ring on the fitting and or hose end must be 5 Disconnect the number 3 cable bridge from the replaced and then torqued to specification during number 3 outer arm index 11 and remove installation Refer to Section 2 Hydraulic Hose and the cable bridge from the machine Fitting T ifications T U 6 Remove the retaining fasteners from the 1 Remove the platform See 2 1 How to Remove number 4 pivot pin index 1 Me Pakom 7 Usea soft metal drift to remove the number 4 2 Support and secure the entry ladder to an pivot pin index 1 Remove the platform appropriate lifting device mount bracket from the machine 3 Remove the fasteners from the entry ladder and 8 Attach a lifting strap from an overhead crane to remove the entry ladder from the machine the number 3 outer arm at the ground control d Th side index 11 ACAUTION rusning nazara e entry ladder may become unbalanced and fall 9 Remove the retaining fasteners from the if not properly supported and number 3 center pivot pin index 2 at the secured to the lifting device ground control side 4 Remove the cables from the number 3 cable 10 Place a rod through the number 3 center pivot bridge and lay them off to the side pin at the ground control side index 2 and twist to re
62. position Note Any change in software settings will not take effect until the key switch is turned to the off position Part No 96316 GS 30 GS 32 GS 46 4 7 Section 4 Repair Procedures June 2009 PLATFORM CONTROLS How to Adjust the High Torque Drive Speed Tip over hazard Do not adjust the lift and or drive speed higher than specified in this procedure Setting the function speeds greater than specifications could cause the machine to tip over resulting in death or serious injury ADANGER Tip over hazard This procedure must only be performed by a trained service professional Attempting this procedure without the necessary skills will result in death or serious injury This procedure does not apply for the GS 1530 32 and GS 1930 32 models as they are not equipped with the high torque drive speed function 1 Pull out the red Emergency Stop button to the on position at the ground controls 2 Pushin red Emergency Stop button to the off position at the platform controls 3 Turn the key switch to platform control 4 Atthe platform controls press and hold the lift function select and horn buttons and pull out the red Emergency Stop button to the on position Result The diagnostic display will show PS 5 Release the lift function select and horn buttons Result The diagnostic display will show the maximum lift speed percentage 6 Press the drive function sel
63. pressure switch out of the hydraulic line just until the overload alarm sounds Note To allow for the platform overload system delay wait 3 seconds between each quarter turn of the nut or adjustment screw 12 Turn the nut or adjustment screw one quarter turn into the hydraulic line 13 Return the safety arm to the stowed position 14 Using the manual lowering knob lower the platform to the stowed position and remove all test weight from the platform 4 84 Genie GS 30 GS 32 GS 46 REV B 15 Using a suitable lifting device place a test weight in the center of the platform floor Secure the weight to the platform Refer to the chart below GS 1532 272 kg GS 1932 227 kg GS 2032 363 kg GS 2632 227 kg GS 2046 544 kg GS 2646 454 kg GS 3246 317 kg 16 Raise the platform to 25 cm less than full height 17 Lift the safety arm move it to the center of the scissor arm and rotate down to a vertical position 18 Raise the platform in 5 cm increments until the overload alarm sounds Adjust the up limit switch until it actuates just before this point was reached 19 Install the cover onto the platform overload pressure switch and install and tighten the cover retaining fastener s Do not over tighten 20 Apply Sentry Seal to the fastener s securing the cover onto the platform overload pressure switch 21 Return the safety arm to the stowed position 22 Using the machine controls
64. remove may become unbalanced and fall the cable bridge from the machine if not properly supported and secured to the lifting device 6 Remove the retaining fasteners from the number 6 pivot pin index 1 4 Remove the cables from the number 5 cable bridge and lay them off to the side 7 Usea soft metal drift to remove the number 6 pivot pin index 1 Remove the platform Component damage hazard mount bracket from the machine Cables can be damaged if they are kinked or pinched 8 Attach a lifting strap from an overhead crane to the number 5 outer arm at the ground control side index 17 Genie Part No 96316 GS 30 GS 32 GS 46 4 47 Section 4 Repair Procedures October 2008 SCISSOR COMPONENTS 9 Remove the retaining fasteners from the number 5 center pivot pin index 2 at the ground control side 10 Place a rod through the number 5 center pivot pin at the ground control side index 2 and twist to remove the pin 11 Remove the retaining fasteners from the number 5 pivot pin index 18 at the non steer end 12 Use a soft metal drift to remove the number 5 pivot pin index 18 from the non steer end of the machine Remove the number 5 outer arm at the ground control side index 17 from the machine Crushing hazard The number 5 ACAUTION outer arm at the ground control side index 17 may become unbalanced and fall if not properly supported when removed from the machine 13 Attach
65. side 39 Use a soft metal drift to remove the number 2 center pivot pin index 7 at the battery pack side Bodily injury hazard The number ACAUTION 2 outer arm at the battery pack side may become unbalanced and fall if not properly supported when removed from the machine 40 Use a soft metal drift to tap the number 2 pivot pin at the non steer end index 20 in the other direction Remove the number 2 outer arm index 19 from the battery pack side of the machine Bodily injury hazard The number ACAUTION 2 outer arm at the battery pack side may become unbalanced and fall if not properly supported when removed from the machine Genie GS 30 GS 32 GS 46 REV C 41 Remove the number 3 pivot pin index 17 from the non steer end of the machine 42 Attach a lifting strap from an overhead crane to the number 2 inner arm index 18 43 Remove the retaining fasteners from the number 2 pivot pin index 8 at the steer end of the machine 44 Use a soft metal drift to remove the number 2 pivot pin index 48 Remove the number 2 inner arm index 18 from the machine ACAUTION Bodily injury hazard The number 2 inner arm may become unbalanced and fall if not properly supported when removed from the machine 45 Remove the safety arm from the number 2 inner arm index 18 that was just removed 46 Attach a lifting strap from an overhead crane to the number 1 inner arm index 10 47 Raise the nu
66. the machine 5 Raise the machine approximately 6 inches 15 cm Place blocks under the chassis for support AWARNING Crushing hazard The chassis could fall if not properly supported 6 Remove the wheel castle nut Remove the wheel Genie GS 30 GS 32 GS 46 REV B 7 Tag disconnect and plug the hydraulic hoses on the drive motor Cap the fittings on the drive motor AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Component damage hazard Hoses can be damaged if they are kinked or pinched 8 Support and secure the yoke assembly to an appropriate lifting device 9 Remove the retaining fastener from the steer link at the yoke assembly Note While removing the retaining fasteners take note of the quantity and location of the spacers when disconnecting the steer link from the yoke assembly 10 Remove the retaining fastener from the top of the yoke pivot shaft Note The pivot shaft retaining fastener is located above the main deck 11 Lower the yoke assembly out of the chassis Bodily injury hazard The yoke ACAUTION motor assembly may fall if not properly supported when it is removed from the chassis Part No 96316 June 2009 Section 4 Repair Procedures REV B How to Remove a Drive Motor 1 Block the non steer wh
67. the number 3 pivot pin index 17 in the other direction Remove the number 3 outer arm index 16 from the battery pack side of the machine Bodily injury hazard The number ACAUTION 3 outer arm at the battery pack side may become unbalanced and fall if not properly supported when removed from the machine 23 Remove the number 3 pivot pin index 17 from the non steer end of the machine 24 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 25 Remove the pin retaining fasteners from the lift cylinder rod end pivot pin index 5 Use a soft metal drift to remove the pin Bodily injury hazard The cylinder ACAUTION may fall when the rod end pivot pin is removed if not properly supported 26 Lower the cylinder onto the number 1 inner arm index 9 Component damage hazard Cables can be damaged if they are kinked or pinched Part No 96316 Genie GS 30 GS 32 GS 46 SCISSOR COMPONENTS 27 Attach a lifting strap from an overhead crane to the number 3 inner arm index 15 28 Remove the retaining fasteners from the number 3 pivot pin index 6 at the steer end 29 Use a soft metal drift to remove the number 3 pivot pin index 6 Remove the number 3 inner arm index 15 from the machine Bodily injury hazard The number ACAUTION 3 inner arm may become unbalanced and fall if not properly supported when r
68. this procedure be performed x every 250 hours or quarterly whichever comes first 1 Inspect the inverter plug and pigtail for damage or excessive insulation wear Replace as required 2 key switch to the on position and pull out the red Emergency Stop button to the position at both the ground and platform controls x x a rightfault LED b leftfault LED c 25VLED d 21VLED x x Genie Part No 96316 GS 30 GS 32 GS 46 CHECKLIST B PROCEDURES Connect an appropriate power tool to the inverter Activate the tool Result The power tool should operate There may be a brief 0 5 second delay if the power tool has not been used in the previous 10 minutes If the left fault LED REV_POL is illuminated the inverter is connected to batteries with the incorrect polarity Correct the polarity issue with the red wire to battery positive and the black wire to battery negative The inverter will then operate correctly and begin supplying AC power If the right fault LED 123 blinks one time the power draw is too high The tool being used requires too much power to operate or is being used at or near the limit of the inverter for an 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 has been activated A short circuit or partial short exists between the AC
69. wires Scissor arms to platform controls Power to platform wiring 10 Inspect for a liberal coating of dielectric grease in all connections between the ECM and the platform controls 11 Raise the platform and return the safety arm to the stowed position 12 Lower the platform to the stowed position and turn the machine off Section Scheduled Maintenance Procedures June 2009 CHECKLIST B PROCEDURES B 3 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 Checkthe tire surface and sidewalls for cuts cracks punctures and unusual wear 2 Check each wheel for damage bends and cracks 3 Remove the cotter pin and check each castle nut for proper torque Refer to Section 2 Specifications 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 it in place Genie GS 30 GS 32 GS 46 REV F B 4 Test the Emergency Stop Genie requires that this procedure be performed every 250 hou
70. 0 379 380 515 30 433 220 298 300 406 310 420 420 569 so am 9 320 438 430 583 450 60 610 827 50 om a s0 474 40 637 50 678 60 ss 550 759 480 650 60 867 680 92 910 1233 70 104 2 530 76 70 962 750 1016 990 1342 80 1139 N x amp o o 15 s 2 60 908 890 1205 1080 1464 1440 1952 120 1654 T 5 1280 1240 31681 1510 2047 2010 2725 1700 2304 7 16 1460 1979 1950 2643 2370 3218 3160 4284 2670 3620 2 1 2223 2190 2969 2670 3620 3560 4826 3000 4067 METRIC FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual Class 8 8 Class 10 9 Class 12 9 DRY DRY 68 775 ST 103 DRY DRY 2 125 110 147 337 394 T 535 525 713 600 458 622 612 830 536 727 715 970 0 570 562 762 583 791 778 1055 682 925 909 1293 Genie Part No 96316 GS 30 GS 32 GS 46 2 7 iz iz Eh ile 1 4 ee En w O1 Oo A e mE 1 g o A E ak i B z B ile Eh i B O
71. 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 Place 0 66 x 6x 6 inch 16 8 mm x 15 cm x 15 cm thick steel block under both wheels at the ground controls side of the machine GS 2046 GS 2646 and GS 3246 Placea 1x6 x 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 23 Lower the machine onto the blocks 24 Raise the platform 7 to 8 feet 2 1 to 2 4 m Result The level sensor alarm should not sound Result The level sensor alarm does sound Adjust the level sensor retaining fasteners just until the level sensor alarm does not sound 25 Lower the platform to the stowed position 26 Raise the machine approximately 2 inches 5 cm 27 Remove the blocks from under both wheels 28 Lower the machine and remove the jack 29 Center a lifting jack under the drive chassis at the battery pack side of the machine 30 Raise the machine approximately 2 inches 5 cm Part No 96316 Genie GS 30 GS 32 GS 46 GROUND CONTROLS 31 GS 1530 and GS 1930 Place a 0 77 x6 x6 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 6x 6 inch
72. 2 GS 2032 GS 2632 GS 2046 GS 2646 GS 3246 a test port b lift valve coil 2 Tag and disconnect the black and white wires of the up limit switch wire harness from the blue black wires of the manifold wire harness at the lift valve coil on the manifold 3 Securely connect together the terminals of the two blue black wires of the manifold wire harness disconnected from the limit switch wire harness in step 2 4 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls Part No 96316 Genie GS 30 GS 32 GS 46 CHECKLIST C PROCEDURES 5 Fully raise the platform Release the toggle switch Result The alarm should sound Result The alarm does not sound Calibrate the platform overload system Refer to Repair Procedure 11 1 Calibrate the Platform Overload System if equipped 6 Using the manual lowering knob lower the platform to the stowed position 7 Disconnect the two blue black wires of the manifold wire harness at the lift valve coil on the manifold 8 Securely connect the black and white wires of the up limit switch wire harness to the two blue black wires of the manifold wire harness at the lift valve coil on the manifold 9 Fully raise the platform Release the toggle switch Result models with software revision AO and A1 The alarm should not sound and fau
73. 2 GS 46 REV C 13 Remove the cables from the number 3 cable bridge and lay them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched 14 Remove the number 3 cable bridge mounting fasteners and remove the cable bridge from the machine 15 Attach a lifting strap from an overhead crane to the number 3 outer arm index 4 at the ground controls side 16 Remove the external snap rings and retaining fasteners from the number 3 center pivot pins index 4 17 Use a soft metal drift to remove the number 3 center pivot pin index 44 at the ground control side 18 Remove the retaining fasteners from the number 3 pivot pin index 17 at the non steer end of the machine 19 Use a soft metal drift to tap the number 3 pivot pin index 17 halfway out at the non steer end of the machine Remove the number 3 outer arm index 16 at the ground controls side from the machine Bodily injury hazard The number ACAUTION 3 outer arm at the ground controls side may become unbalanced and fall if not properly supported when removed from the machine Part No 96316 October 2008 Section 4 Repair Procedures REV 20 Attach a lifting strap from an overhead crane to the number 3 outer arm index 16 at the battery pack side 21 Use a soft metal drift to remove the number 3 center pivot pin index 4 at the battery pack side of the machine 22 Use a soft metal drift to tap
74. 2 Specifications REV E Machine Specifications Batteries Standard Voltage 6V DC Group GC2 Type T 105 Quantity 4 Battery capacity maximum 225AH Reserve capacity 25 rate 447 minutes Batteries Maintenance free option Voltage DC Group GC2 Type 6V AGM Quantity 4 Battery capacity maximum 200AH Reserve capacity 25 rate 380 minutes Fluid capacities Hydraulic tank 3 75 gallons All models 14 2 liters Hydraulic system including tank 5 gallons GS 3246 19 liters Hydraulic system including tank 4 5 gallons All other models 18 liters For operational specifications refer to the Operator s Manual Part No 96316 Genie Specifications Tires and wheels GS 1530 GS 1532 GS 1930 GS 1932 Tire size solid rubber 12x 4 5 in 30 5 x 11 4 cm Tire contact area 9 sq in 58 cm Castle nut torque dry 300 ft Ibs 406 7 Nm Castle nut torque lubricated 225 ft lbs 305 Nm GS 2032 GS 2632 GS 2046 GS 2646 GS 3246 Tire size solid rubber 15x 5in 38 1 x 12 7 cm Tire contact area 10 sq in 64 5 cm Castle nut torque dry 300 ft Ibs 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 GS 30 GS 32 GS 46 2 1 Section 2 Specifications June 2009 SPECIFICATIONS Performance Speci
75. 21 Tag and disconnect the wire harness from the solenoid valve on the cylinder 22 Remove the cables from the number 4A and 4B cable bridges and lay them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched 23 Disconnect the number 4A and 4B cable bridges from the scissor linkset and remove both cable bridges from the machine 24 Attach a lifting strap from an overhead crane to the lug of the rod end of the upper lift cylinder 25 Remove the retaining fasteners from the upper lift cylinder rod end pivot pin index 3 Part No 96316 October 2008 Section 4 Repair Procedures REV 26 Use a soft metal drift to remove the upper lift cylinder rod end pivot pin index 3 from the machine Crushing hazard The lift cylinder ACAUTION may become unbalanced and fall if not properly supported when the pivot pin is removed 27 Lower the cylinder onto the linkset 28 Attach a lifting strap from an overhead crane to the number 4 outer arm at the ground control side index 20 29 Remove the retaining fasteners from the number 4 center pivot pin index 5 at the ground control side 30 Place a rod through the number 4 center pivot pin at the ground control side index 5 and twist to remove the pin 31 Remove the retaining fasteners from the number 4 pivot pin index 21 at the non steer end 32 Use a soft metal drift to remove the number 4 pivot pin index 21 f
76. 3 EMERGENCY 2 2 1 BL DATALINK HIGH 5 L 5 OR DATA LINK LOW U3 D7 EFFECT JC1 n 7 NGENERATOR JovsriCK Gv CONTROLLER GN PP FUNCTION ENABLE T SW5 SW6 STEER LEFT RIGHT 1 BK PLATFORM CONTROLS MEMBRANE DECAL LIFT LED L16 DRIVE LED L17 HIGH TORQUE LED L21 POUT4 POUT1 fi NC 2 lt G8 PIN1 DIAGNOSTIC DISPLAY HIGH TORQUE BN6 PIN2 HORN BN5 PIN3 PIN4 DRIVE ENABLE BN8 POUT11 LIFT ENABLE BN9 PIN11 PLATFORM CONTROLLER 50141 Genie GS 30 GS 32 GS 46 6 22 Part No 96316 September 2005 Section 6 Schematics _ This page intentionally left blank Genie Part No 96316 GS 30 GS 32 GS 46 6 23 Section 6 Schematics October 2008 Electrical Schematic CE Models REV C GS 1530 1532 1930 1932 from serial number GS3003 60000 to GS3005 74999
77. 7 kg Genie Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice 2 2 GS 30 GS 32 GS 46 Part No 96316 June 2009 Section 2 Specifications REV Hydraulic Specifications Hydraulic Oil Specifications Hydraulic oil type ISO viscosity grade Chevron Rando HD equivalent Multi viscosity Viscosity index 200 Cleanliness level minimum 15 13 Water content maximum 200 ppm Chevron Rando HD oil is fully compatible and mixable with Shell Donax TG Dexron oils Genie specifications require hydraulic oils which are designed to give maximum protection to hydraulic systems have the ability to perform over a wide temperature range and have a minimum viscosity index of 150 They should provide excellent antiwear oxidation corrosion inhibition seal conditioning and foam and aeration suppression properties Optional fluids Petro Canada Environ MV 46 Statoil Hydra Way Bio Pa 32 BP Biohyd SE S Biodegradable Fire resistant UCON Hydrolube HP 5046 Quintolubric 822 Shell Tellus T32 Shell Tellus T46 Chevron Aviation A Mineral based Continued use of Chevron Aviation A hydraulic fluid when ambient temperatures are consistently above 32 F 0 may result in component damage Note Use Chevron Aviation A hydraulic fluid when ambient temperatures consistently below O F 17 C Note Use Shell T
78. 8 PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM RIGHT LEFT REVERSE FORWARD DOWN DOWN UP GS 3246 KD GND ES0142D Genie Part No 96316 GS 30 GS 32 GS 46 Section 6 Schematics September 2005 Electrical Schematic CE Models REV B GS 2032 2632 from serial number GS3205 75000 to 75406 GS 2046 2646 3246 from serial number GS4605 75000 to 75437 TEN P2 QD3 EMERGENCY 2 2 1 BL DATALINK HIGH 5 L 5 OR DATA LINK LOW U3 D7 EFFECT JC1 n 7 NGENERATOR JovsriCK Gv CONTROLLER GN PP FUNCTION ENABLE T SW5 SW6 STEER LEFT RIGHT 1 BK PLATFORM CONTROLS MEMBRANE DECAL LIFT LED L16 DRIVE LED L17 HIGH TORQUE LED L21 POUT4 POUT1 fi NC 2 lt G8 PIN1 DIAGNOSTIC DISPLAY HIGH TORQUE BN6 PIN2 HORN BN5 PIN3 PIN4 DRIVE ENABLE BN8 POUT11 LIFT ENABLE BN9 PIN11 PLATFORM CONTROLLER 01420 Genie GS 30 GS 32 GS 46 Part No 96316 September 2005 Section 6 Schematics REVA Hyd
79. 9 Section 4 Repair Procedures REV D How to Adjust the Lift Speed A DANGER Tip over hazard Do not adjust the lift and or drive speed higher than specified in this procedure Setting the function speeds greater than specifications could cause the machine to tip over resulting in death or serious injury Tip over hazard This procedure must only be performed by a trained service professional Attempting this procedure without the necessary skills will result in death or serious injury Pull out the red Emergency Stop button to the on position at the ground controls Push in the red Emergency Stop button to the off position at the platform controls Turn the key switch to platform control At the platform controls press and hold the lift function select and horn buttons and pull out the red Emergency Stop button to the on position Result The diagnostic display will show PS Release the lift function select and horn buttons Result The diagnostic display will show the maximum lift speed percentage 6 Press the lift function select button 8 Use the steering thumb rocker switch on the joystick to increase or decrease the maximum lift speed percentage Refer to Section 2 Specifications for function speeds Turn the key switch to the off position Note Any change in software settings will not take effect until the key switch is turned to the off position Part
80. DRIVE ENABLE BN8 LIFT ENABLE BN9 POUT11 PIN11 PLATFORM ONTROLLER September 2005 50141 Genie GS 30 GS 32 GS 46 Part No 96316 September 2005 Section 6 Schematics _ This page intentionally left blank Genie Part No 96316 GS 30 GS 32 GS 46 6 15 Section 6 Schematics June 2009 en b Electrical Schematic ANSI CSA and Australia Models REV D GS 2032 2632 from serial number GS3204 60000 to GS3205 74999 GS 2046 2646 3246 from serial number GS4604 60000 to GS4605 74999 EMERGENCY xc STOP NAT B ENS OR 2 r1 KEY PLATFORM SWTCH CONTROL 1 2 H5 N ALARM MACHINE SHOWN IN THE 243 STOWED POSITION WITH LN E N CHO THE POWER OFF SEES Z oJ 157 POTHOLE TS66 GUARD PLATFORM SWITCH 1 UP DOWN CB2 N C H O 4 E 2 PH Of CIRCUIT BREAKER 4 158 POTHOLE GUARD SWITCH pham c C gt 2 28070 9 E 2 3 ios 2 3 E 230 2 5 5 T WORK LIGHT 2 OPTION QD1
81. EMERGENCY alu aL BK POWER TO PLATFORM 4 3 3 RD POWER TO GROUND 1 1 GROUND 2 2 BL DATALINK HIGH I 5 L 5 OR DATA LINK LOW En U3 i PLATFORM CONTROLS VOLTAGE PRINTED CIRCUIT BOARD REGULATOR 1 EFFECT JC1 n 7 NGENERATOR JovsriCK GY CONTROLLER GN FUNCTION ENABLE T STEER 1 LEFT RIGHT SW5 SW6 PLATFORM CONTROLS MEMBRANE DECAL LIFT LED 116 DRIVE LED L17 HIGH TORQUE LED L21 POUT4 DIAGNOSTIC DISPLAY HIGH TORQUE BN6 PIN1 PIN2 HORN BN5 PIN3 DRIVE ENABLE BN8 PIN4 LIFT ENABLE BN9 PLATFORM CONTROLLER POUT11 ES0142D Genie 6 30 GS 30 GS 32 GS 46 Part No 96316 September 2005 Section 6 Schematics _ This page intentionally left blank Genie Part No 96316 GS 30 GS 32 GS 46 6 31 Section 6 Schematics June 2009 S w m Electrical Schematic CE Models REV D GS 2032 2632 from serial number GS3204 60000 to GS3205 74999 GS 2046 2646 3246 from serial number GS4604 60000 to GS4605 74999
82. ERLOAD SYSTEM NOT ADJUSTED PROPERLY Genie Part No 96316 GS 30 GS 32 GS 46 Section 4 Repair Procedures October 2008 M This page intentionally left blank Genie 4 86 GS 30 GS 32 GS 46 Part No 96316 September 2005 Section 5 Fault Codes Observe and Obey Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a firm level surface Platform in the stowed position Key switch in the off position with the key removed The red Emergency Stop button in the off position at both ground and platform controls Wheels chocked All external AC power supply disconnected from the machine Part No 96316 Genie GS 30 GS 32 GS 46 5 1 Fault Codes Before Troubleshooting Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necessary tools and test equipment are available and ready for use Read each appropriate fault code thoroughly Attempting short cuts may prod
83. Function Torque 1 Shuttle valve Jine Brake release circuit 45 50 in lbs 5 Nm 2 Check valve pilot operated Manual brake release circuit 65 70 in Ibs 7 8 Nm 3 Hand Manual brake 30 ft Ibs 41 Nm 4 Needle Manual brake release enable 45 50 in lbs 5 Nm GS 1530 GS 1532 GS 1930 GS 1932 before serial number GS 3004 65105 GS 2032 GS 2632 N before serial number GS 3204 52789 0 GS 2046 05 2646 GS 3246 before serial number GS 4604 60879 Note alpha callouts refer to corresponding notes on the hydraulic schematic GS 1530 GS 1532 GS 1930 GS 1932 after serial number GS 3004 65104 GS 2032 GS 2632 after serial number GS 3204 52788 GS 2046 GS 2646 GS 3246 after serial number GS 4604 60878 Genie 4 82 GS 30 GS 32 GS 46 Part No 96316 October 2008 Section 4 Repair Procedures Platform Overload Components 11 1 6 Using a suitable lifting device place a test Platform Overload System How to Calibrate the Platform Overload System if equipped Perform this procedure after confirming that the maximum height limit switch and the limit switch bracket are not damaged and are functioning correctly 1 Ful
84. G Bodily injury hazard Batteries contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 1 Release the battery pack latch and rotate the battery pack out and away from the chassis 2 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 3 Be sure that the battery retainers and cable connections are tight 4 Fully charge the batteries Allow the batteries to rest 24 hours before performing this procedure to allow the battery cells to equalize 5 Puton protective clothing and eye wear Part No 96316 Genie GS 30 GS 32 GS 46 Models without maintenance free or sealed batteries 6 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results 7 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows Add 0 004 to the reading of each cell for every 10 5 5 C above 80 F 26 7 C 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 P
85. GS 2632 and GS 2646 How to Disassemble the Scissor Assembly GS 2632 and GS 2646 AWARNING Podily injury hazard The procedures in this section require specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is required Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform See 2 1 How to Remove the Platform 2 Support and secure the entry ladder to an appropriate lifting device 3 Remove the fasteners from the entry ladder and remove the entry ladder from the machine Crushing hazard The entry ladder ACAUTION may become unbalanced and fall if not properly supported and secured to the lifting device Part No 96316 Genie SCISSOR COMPONENTS GS 2632 _ 2646 Cable bridge legend a b d e f cable bridge 4 cable bridge 3A cable bridge 3B cable bridge 2A cable bridge 2B cable bridge 1 Remove the cables from the number 4 cable bridge and lay them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched Disconnect the number 4 cable bridge from the number 4 outer arm index 13 and rem
86. OPTION H2 AUTO STYLE HORN i OPTION E ESO141E Genie GS 30 GS 32 GS 46 Part No 96316 September 2005 Section 6 Schematics Electrical Schematic REV B ANSI CSA and Australia Models GS 1530 1532 1930 1932 from serial number GS3005 75000 to 75999 NOTE MACHINE SHOWN IN THE STOWED RD RD 4 4 4 WH WH 3 3 juo Y 4 48 CR48 BL 1 1 Jo POWER BK 2 2 M RELAY TO US 8 eso o N O H C 4 DOWN LIMIT SWITCH NC gt i LEVEL SENSOR I CIRCUIT 1 I BOARD x i zs 3 2 geses 57 2 m So gt gt LEVEL 2 g 21 24 QJ gt gt SENSOR 5 2 z BS EEE gt UU m d 5 BK og E 85539 a o z e E m 28 3 zm 982858 LII l j L L C2 B11 C12 A10 A4 2 B1 C11 5 IN IN IN IN IN IN IN IN IN OUT ELECTRONIC CONTROL MODULE OUT OUT OUT OUT OUT OUT OUT C8 C7 B7 A7 C6 B6 DE xd s
87. Overload 200 j j Lr j 2020 j j J pw j S Ws poe piu 06 4 JL OMNE a NN e J l o e p e s jJ j ee 212 221 22 Ieg qa J ae ee ee Ca Jsf ee Machine Function Code at Diagnostic Display Genie GS 30 GS 32 GS 46 REV D Machine Configuration Code Chart A mark in the four right columns indicates that the machine configuration at left includes this option GS 2032 GS 2632 GS 2046 GS 2646 GS 3246 Machine Motion Lift Drive Platform Descent due Alarm Cut Out Overload Diagnostic Display Part No 96316 June 2009 Section 4 Repair Procedures REV D PLATFORM CONTROLS How to Activate the How to Determine the Battery Battery Drain Alarm Option Voltage 1 Pull out the red Emergency Stop button to the The diagnostic display on the platform controls is on position at the ground controls used to indicate the battery voltage at all times 2 Pushin red Emergency Stop button to the when the machine is in normal operation off position at the platform controls Limp Mode If the battery level falls to less than 3 Turn the key switch to platform control 17 8V DC the single bar in the diagnostic display will be flashing and machine drive speed is limited 4 Atthe pla
88. RM CONTROLS VOLTAGE SWITCH PRINTED CIRCUIT BOARD REGULATOR HALL EFFECT JC1 J GENERATOR JOYSTICK X CONTROLLER I SW5 SW6 FUNCTION ENABLE T STEER 1 LEFT RIGHT l SE 4 i PLATFORM CONTROLS La MEMBRANE DECAL POUT1 g POWER LED L19 POUT2 FAULT LED L25 UO 0 POUT3 lt HIGH TORQUE LED 121 JJ POUT4 O 2447 BATTERY LEVEL 1 5 ES by BATTERY LEVEL 2 POUT6 4 La BATTERY LEVEL3 gt 37 POUT7 a BATTERY LEVEL 4 POUT8 BATTERY LEVELS POUT9 lt DRIVE LED 117 POUT10 4 LIFT LED 116 PIN1 HIGH TORQUE BN6 PIN2 HORN BN5 PIN3 DRIVE ENABLE BN8 PIN4 LIFT ENABLE BN9 POUT11 PLATFORM BK CONTROLLER ES0141B Genie GS 30 GS 32 GS 46 Part No 96316 June 2009 Section 6 Schematics 7 M M This page intentionally left blank Genie Part No 96316 GS 30 GS 32 GS 46 6 19 Section 6 Schematics Electrical Schematic September 2005 ANSI CSA and Australia Models REV B GS 2032 2632 from serial number GS3205 75000 to 75406 GS 2046 2646 3246 from serial number GS4605 75000 to 75437
89. Repair Procedures REV 6 5 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 AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Note If the machine has been in operation allow the coil to cool at least 3 hours before performing this test 1 Tagand disconnect the wiring from the coil to be tested 2 Testthe coil resistance using a multimeter set to resistance Refer to the Valve Coil Resistance Specification table W Result If the resistance is not within the adjusted specification plus or minus 10 replace the coil Part No 96316 Genie GS 30 GS 32 GS 46 MANIFOLDS Valve Coil Resistance Specification Note The following coil r
90. T JC1 GENERATOR 4 2 I SW5 SW6 FUNCTION ENABLE T STEER 1 LEFT RIGHT 2 E 3 PLATFORM CONTROLS E MEMBRANE DECAL POUT1 g POWER LED L19 POUT2 FAULT LED L25 UO re POUT3 4 HIGH TORQUE LED 121 ay POUT4 2447 BATTERY LEVEL 1 POUT5 ES BATTERY LEVEL 2 POUT6 4 La BATTERY LEVEL3 gt 37 POUT7 a BATTERY LEVEL 4 POUT8 BATTERY LEVELS POUT9 lt DRIVE LED 117 POUT10 4 LIFT LED 116 PIN1 HIGH TORQUE BN6 PIN2 HORN BN5 PIN3 DRIVE ENABLE BN8 PIN4 LIFT ENABLE BN9 POUT11 PLATFORM BK I CONTROLLER ES0142B Genie GS 30 GS 32 GS 46 Part No 96316 June 2009 Section 6 Schematics 7 M M This page intentionally left blank Genie Part No 96316 GS 30 GS 32 GS 46 6 35 Section 6 Schematics September 2005 c MM Electrical Schematic CE Models REV B GS 2032 2632 from serial number GS3205 75000 to 75406 GS 2046 2646 3246 from serial number GS4605 75000 to 75437 P1 STOP B
91. UT10 LIFT LED L16 PIN2 PIN3 PIN4 POUT11 PLATFORM CONTROLS MEMBRANE DECAL POWER LED L19 FAULT LED L25 HIGH TORQUE BN6 HORN BN5 DRIVE ENABLE BN8 LIFT ENABLE BN9 PIN11 gt PLATFORM October 2008 CONTROLLER 0142 Genie GS 30 GS 32 GS 46 Part No 96316 October 2008 Section 6 Schematics This page intentionally left blank Genie Part No 96316 GS 30 GS 32 GS 46 6 27 Section 6 Schematics September 2005 Electrical Schematic CE Models REV B GS 1530 1532 1930 1932 from serial number GS3005 75000 to 75999 P1 STOP B 1 22 N 2 KS1 I T key PLATFORM SWITCH CONTROL 1 4 1 i H5 N ALARM MACHINE SHOWN IN THE p 2 3 7 STOWED POSITION WITH N C HO THE POWER OFF CONTROL 7 J 157 POTHOLE TS66 GUARD PLATFORM SWITCH UP DOWN CB2 4 ae Ls 523 PH Of CIRCUIT BREAKER 4 198 POTHOLE 027 GUARD 47 mH INDUCTOR NOISE SUPPRESSION SWITCH m c x gt
92. a lifting strap from an overhead crane to the number 5 outer arm at the battery side index 17 14 Remove the retaining fasteners from the number 5 center pivot pin index 2 at the battery side 15 Place a rod through the number 5 center pivot pin at the battery side index 2 and twist to remove the pin 16 Remove the number 5 outer arm index 17 from the machine Crushing hazard The number 5 ACAUTION outer arm index 17 may become unbalanced and fall if not properly supported when removed from the machine 17 Attach a lifting strap from an overhead crane to the number 5 inner arm index 16 Raise the arm to a vertical position Genie GS 30 GS 32 GS 46 REV C 18 Remove the retaining fasteners from the number 5 pivot pin at the steer end of the machine index 4 19 Use a soft metal drift to remove the number 5 pivot pin index 18 from the steer end of the machine Remove the number 5 inner arm index 16 from the machine Crushing hazard The number 5 ACAUTION inner arm index 16 may become unbalanced and fall if not properly supported when removed from the machine 20 Tag disconnect and plug the hydraulic hose on the upper lift cylinder Cap the fittings on the cylinder AWARNING Sud injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray
93. able switch 47 52 53 Platform joystick fault Forward coil fault Reverse coil fault Joystick potentiometer not centered Malfunctioning coil OR wire disconnected from coil Malfunctioning coil OR wire disconnected from coil Verify potentiometer setting Troubleshoot coil OR inspect wire connection Troubleshoot coil OR inspect wire connection 54 55 Up coil fault Down coil fault Malfunctioning coil OR wire disconnected from coil Malfunctioning coil OR wire disconnected from coil Troubleshoot coil OR inspect wire connection Troubleshoot coil OR inspect wire connection 56 Steer right coil fault Malfunctioning coil OR wire disconnected from coil Troubleshoot coil OR inspect wire connection 57 58 59 Steer left coil fault Brake coil fault Series parallel coil fault Malfunctioning coil OR wire disconnected from coil Malfunctioning coil OR wire disconnected from coil DIP switch settings are incorrect Troubleshoot coil OR inspect wire connection Troubleshoot coil OR inspect wire connection Troubleshoot and correct DIP switch settings 68 88 Low battery voltage ECM has been erased Part No 96316 Batteries discharged Static strap may be missing from the machine Genie Charge batteries Replace static strap GS 30 GS 32 GS 46 Section 5 Fault Codes September 2005 TE This page intent
94. achine Before Repairs Start Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necessary tools and parts are available and ready for use Use only Genie approved replacement parts Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a firm level surface Platform in the stowed position Key switch in the off position with the key removed The red Emergency Stop button in the off position at both ground and platform controls Wheels chocked All external AC power supply disconnected from the machine Part No 96316 Genie GS 30 GS 32 GS 46 Repair Procedures About This Section Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop Select the appropriate repair procedure after troubleshooting the problem Perform disassembly procedures to the point where repairs can be completed Then to re assemble perform the disassembly steps in reverse order Symbols Legend Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible in
95. achine tipping over resulting in death or serious injury Do not raise the platform above the maximum load position of the capacity indicator decal on the side of the platform Note To perform this step the lift relief valve will need to be adjusted 9 Lift the safety arm move it to the center of the Scissor arm and rotate down to a vertical position Section 4 Repair Procedures October 2008 10 Models with round pressure switch Remove the retaining ring securing the cover to the pressure switch and remove the cover Using a flat blade turn the slotted switch adjustment screw of the platform overload pressure switch into the hydraulic line in 90 increments until the overload alarm does not sound Models with box shaped pressure switch Remove the fasteners securing the cover to the pressure switch and remove the cover Using a wrench turn the nut of the platform overload pressure switch into the hydraulic line in 90 increments until the overload alarm does not sound Note To allow the platform overload system to reset the red Emergency Stop button must be cycled after each quarter turn of the nut or slotted Switch adjustment screw Note Turning the nut or slotted switch adjustment screw into the hydraulic line will deactivate the alarm turning the nut or slotted switch adjustment screw out of the hydraulic line will activate the alarm 11 Slowly turn the nut or adjustment screw of the platform overload
96. achine tipping over causing death or serious injury 13 Install the level sensor retaining fasteners through the level sensor and springs and into the mount bracket Tighten the fasteners and measure the distance between the level sensor and the level sensor mount bracket Result The measurement should be approximately 3 inch 10 mm 14 Connect the chassis wire harness to the level sensor wire harness 15 Turn the key switch to the ground control and pull out the red Emergency Stop button to the on position at the ground controls 16 Adjust the level sensor retaining fasteners until the bubble in the top of the level sensor is centered in the circles Result The tilt sensor alarm should not sound 4 62 Genie GS 30 GS 32 GS 46 REV B Steer end EWS m On ORG e Non steer end limit switch level sensor mount bracket level sensor S7 alarm H5 level sensor retaining fastener scissor chassis 17 Raise the platform slightly 18 Return the safety arm to the stowed position 19 Lower the platform to the stowed position 20 Center a lifting jack under the drive chassis at the ground controls side of the machine 21 Raise the machine approximately 2 inches 5 cm Part No 96316 October 2008 Section 4 Repair Procedures REV B 22 GS 1530 and GS 1930 Place a 0 64 x 6x 6 inch 16 2 mm x
97. an penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 59 Tag and disconnect the wire harness from the solenoid valve on the cylinder 60 Tag and disconnect the wires and manual lowering cable from the solenoid valve on the cylinder 61 Models with platform overload option Tag and disconnect the wire harness from the platform overload switch 62 Raise the lift cylinder to a vertical position 63 Remove the pin retaining fasteners from the lift cylinder barrel end pivot pin index 21 Use a soft metal drift to remove the pin Remove the lift cylinder from the machine Crushing hazard The lift cylinder ACAUTION will fall if not properly supported when the pivot pin is removed Component damage hazard Be careful not to damage the valve or fittings on the cylinder while removing it from the machine Section 4 Repair Procedures October 2008 SCISSOR COMPONENTS 64 Remove the cables from the number 1 cable bridge and lay them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched REV C How to Replace the Scissor Arm Wear Pads 1 Remove the platform See 2 1 How to Remove the Platform 65 Disconnect the number 1 cable bridge from the 2 Support and secure the entry ladder to an number 1 outer arm index 22 and remove appropriate lifting device the cabl
98. and an alarm sounds Replace the down limit Switch 16 Raise the platform 7 to 8 feet 2 1 to 2 4 m 17 Lift the safety arm move it to the center of the Scissor arm and rotate down to a vertical position 18 Lower the platform onto the safety arm AMARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform Part No 96316 Genie GS 30 GS 32 GS 46 3 23 CHECKLIST B PROCEDURES 19 Turn the key switch to the off position 20 Disconnect the platform controls from the ECM cable 21 Securely install the connector of the ECM cable into the platform control cable 22 Working at the platform securely install the connector of the platform controls into the platform control cable 23 Enable the down limit switch Loosen the fastener securing the roller arm to the limit Switch and rotate the roller arm 90 degrees in a upwards direction Do not activate the switch contacts 24 Turn the key switch to platform control 25 Raise the platform and return the safety arm to the stowed position 26 Lower the platform to the stowed position Section Scheduled Maintenance Procedures June 2009 CHECKLIST B PROCEDURES Pothole Limit Switches 27 Move the machine onto a grade which exceeds the rating of the level sensor Refer to the serial label on the machine 28 Press the lift function select button Standing on the up hill side of the machine attempt to raise the platfor
99. ap from the hydraulic tank 2 Check for proper venting Result Air passes through the breather cap Result If air does not pass through the cap clean or replace the cap Proceed to step 3 Note When checking for positive tank cap venting air should pass freely through the cap 3 Using a mild solvent carefully wash the cap venting system Dry using low pressure compressed air Repeat step 2 4 Install the breather cap onto the hydraulic tank Section Scheduled Maintenance Procedures June 2009 CHECKLIST B PROCEDURES B 12 Check the Module Tray Latch Components Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the module tray latch components in good condition is essential to good performance and service life Failure to detect worn out latch components may result in module trays opening unexpectedly creating an unsafe operating condition 1 Inspect each module tray rotary latch and related components for wear Tighten any loose fasteners 2 Lubricate each module tray rotary latch Using light oil apply a few drops to each of the springs and to the sides of the rotary latch mechanism 3 20 GS 30 GS 32 GS 46 Genie REV F Part No 96316 June 2009 Section Scheduled Maintenance Procedures REV B 13 3 Inspect the Voltage Inverter if equipped x Genie requires that
100. arm Descent Delay 00 0000000 01 00000101 l L 02 9000100 L 03 0010001 te 04 joorooooof o0 0100000 06 0000101 eis or e 08 ototo fef 99 01000100 fo o0 fefefe pepper 1 3 12 otto ele 13 00101001 eto 14 01010109 15 0100100 Tie 16 7 oomoo fef felei 19 0110001 200100 pelo 21 0900100 tele 22 ooo e 29 24 001100 felelei 25 0101001 fefe T 26 101101000 L 2 01100 282 12142212121 29 01010000 fef fef T 30 oto e e 31 joroon0 Part No 96316 Genie GS 30 GS 32 GS 46 PLATFORM CONTROLS DIP Switch Code Diagnostic Display Code for 2032 2632 2046 Motion Beacon Motion Alarm Lift Drive Cut Out Overload Cut Out Descent Delay Battery Drain Alarm OFF for all models ON 2646 amp 3246 models 32 10000000 33 10010 e tet 34 100100 e ie 35 101000 36 10000 e
101. aulic oil level is at the FuLL Specifications mark on the hydraulic tank Perform this test from the ground with the platform controls Do not stand in the platform 6 Press and hold the steer thumb rocker switch to 1 Locate the steer relief valve on the function the left Allow the wheels to completely turn to manifold schematic item G or AH the left Continue holding the switch while observing the pressure reading on the pressure 2 Connecta 0 to 5000 psi 0 to 350 bar pressure gauge gauge to the test port schematic item A or AA on the function manifold 7 Turnthe machine off Hold the steer relief valve with a wrench and remove the cap schematic 3 Remove the platform controls from the platform item G or AH 8 Adjust the internal hex socket Turn it clockwise 4 Turn the key switch to platform control and pull to increase the pressure or counterclockwise to out the red Emergency Stop button to the on decrease the pressure position at both the ground and platform Component damage hazard controls Do not adjust the relief valve pressures higher than specifications 9 Install the relief valve cap 10 Repeat steps 5 through 6 to confirm the relief valve pressure GS 1530 32 and GS 1930 32 a test port b steer relief valve GS 32 and GS 46 test port System relief valve steer relief valve lift relief valve Genie 4 74 GS 30 GS 32 GS 46 Part No 96316 October 2008 Section 4
102. 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 Note 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 key switch to platform control 3 Checkthe platform up down function from the ground controls Q Result The machine functions should not operate 4 Turn the key switch to ground control 5 Checkthe machine functions from the platform controls Result The machine functions should not operate 6 Turn the key switch to the off position Result No function should operate Part No 96316 Genie GS 30 GS 32 GS 46 CHECKLIST B PROCEDURES B 6 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 personnel An improperly functioning horn will prevent the operator from alerting ground personnel of hazards or unsafe conditions 1 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform c
103. ber 2008 SCISSOR COMPONENTS 3 6 Lift Cylinder How to Remove the Lift Cylinder GS 1530 GS 1532 GS 1930 and GS 1932 AWARNING 2 dlly injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended When removing a hose assembly or fitting the fitting and or hose end must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Raise the platform 7 to 8 feet 2 1 to 2 4 m 2 Liftthe safety arm move it to the center of the Scissor arm and rotate down to a vertical position 3 Lower the platform onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 4 Tag and disconnect the wiring from the solenoid valve coil at the barrel end of the lift cylinder 5 Models with platform overload option Tag and disconnect the wiring from the platform overload switch 4 54 Genie GS 30 GS 32 GS 46 REV C lift cylinder orifice schematic item O connector fitting hydraulic hose manual lowering cable solenoid valve schematic item N g mount bracket 6 Loosen the adjustment nuts on the solenoid valve and disconnect the manual loweri
104. can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Tag and disconnect the hydraulic tank return hard line from the filter Remove the hard line from the machine Cap the fitting on the filter head 4 Tag and disconnect the hydraulic tank hard line from the pump Remove the hard line from the machine Cap the fitting on the pump 5 Remove the hydraulic tank retaining fasteners and remove the hydraulic tank from the machine Torque specifications 35 in Ibs 4Nm Hydraulic tank retaining fasteners dry 26 in lbs 2 9 Nm 40 in lbs 4 5 Nm 30 in Ibs 3 4 Nm Hydraulic tank retaining fasteners lubricated Hydraulic tank drain plug dry Hydraulic tank drain plug lubricated Section 4 Repair Procedures June 2009 Steer Axle Components 8 1 Yoke and Drive Motor How to Remove the Yoke and Drive Motor Assembly When removing a hose assembly or fitting the fitting and or hose end must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Block the non steer wheels 2 Remove the cotter pin from the wheel castle nut Note Always replace the cotter pin with a new one when removing the castle nut 3 Loosen the wheel castle nut Do not remove it 4 Center a lifting jack under the drive chassis at the steer end of
105. cc EN LECCE c 2 8 2 x E A Y1 Y4 Y5 Y6 Y9 Y7 Y8 PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM RIGHT LEFT REVERSE FORWARD DOWN DOWN UP GS 3246 L_ L_ L Le L GND ES0141E Genie Part No 96316 GS 30 GS 32 GS 46 6 13 Section 6 Schematics Electrical Schematic ANSI CSA and Australia Models GS 1530 1532 1930 1932 from serial number GS3005 75000 to 75999 RD BK POWER TO PLATFORM POWER TO GROUND P2 EMERGENCY 1 WH GROUND 2 2 BL DATA LINK HIGH I 5 5 OR DATALINK LOW lm mm pe U3 G8 DIAGNOSTIC DISPLAY POUT4 PIN1 PIN2 PIN3 PIN4 PLATFORM CONTROLS VOLTAGE PRINTED CIRCUIT BOARD REGULATOR 4 cis BN o HALL EFFECT JC n 7 NGENERATOR JovsriCK GY X CONTROLLER GN WH BL SW5 SW6 FUNCTION ENABLE T STEER 1 LEFT RIGHT f z PIN8 PIN10 am BK PLATFORM CONTROLS MEMBRANE DECAL POUT1 LIFT LED L16 POUT2 lt 49 DRIVE LED 117 POUT3 4 HIGH TORQUE LED 121 HIGH TORQUE BN6 HORN BN5
106. ce procedures B 8 Inspect the Tires and Wheels including castle nut torque 0 3 Replace the Hydraulic Tank Return Filter Genie GS 30 GS 32 GS 46 REV C A 5 Grease the Steer Yokes Genie specifications require that this procedure be performed every 100 hours of operation Regular application of lubrication to the steer yokes is essential to good machine performance and service life Continued use of an insufficiently greased steer yoke will result in component damage 1 Locate the grease fitting on the top of the steer yoke 2 Pump multipurpose grease into the steer yoke until the steer yoke is full and grease is being forced past the bearings Repeat this step for the other steer yoke Grease Specification Chevron Ultra duty grease EP NLGI 1 lithium based or equivalent Part No 96316 June 2009 Section 3 Scheduled Maintenance Procedures Checklist B Procedures REV 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 AWARNIN
107. cissor assembly into position and install the chassis mount bracket onto the chassis Securely install and tighten the fasteners Do not overtighten Component damage hazard Be careful not to damage the level sensor or limit switch while moving the scissor assembly Genie Part No 96316 GS 30 GS 32 GS 46 4 45 Section 4 Repair Procedures October 2008 SCISSOR COMPONENTS REV C 9 9 9 Q J oo OOD 9 PT 0 95 3246 a Steer end Non steer end 1 Number 6 pivot pin 16 Number 5 inner arm 2 Number 5 center pivot pin 2 pins 17 Number 5 outer arm 3 Upper lift cylinder rod end pivot pin 18 Number 5 pivot pin non steer end 4 Number 5 pivot pin steer end 19 Number 4 inner arm 5 Number 4 center pivot pin 2 pins 20 Number 4 outer arm 6 Number 4 pivot pin steer end 21 Number 4 pivot pin non steer end 7 Number 3 outer arm 22 Upper lift cylinder barrel end pivot pin 8 Number 3 center pivot pin 2 pins 23 Number 3 inner arm 9 Lower lift cylinder rod end pivot pin 24 Number 3 pivot pin non steer end 10 Number 3 pivot pin steer end 25 Number 2 inner arm 11 Number 2 center pivot pin 2 pins 26 Number 2 outer arm 12 Number 2 pivot pin steer end 27 Number 2 pivo
108. controls PS2 Platform overload pressure switch option QD Quick disconnect QD1 Battery quick disconnect QD3 Control cable to ground 004 Control cable to platform Sw Switch SW5 Function enable SW6 Steer left right SW25 DIP switches S7 Tilt level sensor TS66 Platform up down toggle switch U Electronic component US Platform controls printed circuit board U5 Electronic control module U6 Motor controller U9 Battery charger U13 Voltage inverter option U27 47 mH inductor noise suppression Y Valve coil Y1 Parallel GS 2032 GS 2632 and all GS 46 Steer right 4 Steer left Y5 Drive reverse Y6 Drive forward Y7 Platform down Y8 Platform up Y9 Platform down GS 3246 Genie 6 2 GS 30 GS 32 GS 46 Part No 96316 September 2005 Section 6 Schematics REV C ECM Pin out Legend F eeeee 2 0 PIN OUT LEGEND Item Description A1 Flashing beacon FB1 output A2 Ground from platform controls input White wire at platform controls Plu A4 Power from platform controls to ECM input Red wire at platform controls A5 Level sensor power S7
109. d F6 2 8 275A FUSE l GN A12 B12 B9 B10 A9 OUT IN OUT IN U9 BK ag OUT rz G U5 ELECTRONIC CONTROL MODULE OUT OUT BB B3 AC INPUT UG a scel EE O 30 7 T CONTROLLER 10 2 CR5 HORN RELAY A 59 H2OPTION 85 U13 A at DC AC INVERTER 429 i 85 OPTION METER BEACONS OPTION H2 AUTO STYLE HORN u i OPTION E ES0141B Genie 6 16 GS 30 GS 32 GS 46 Part No 96316 June 2009 Section 6 Schematics Electrical Schematic REVD ANSI CSA and Australia Models GS 2032 2632 from serial number GS3204 60000 to GS3205 74999 GS 2046 2646 3246 from serial number GS4604 60000 to GS4605 74999 NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF RD RD 4 4 4 WH WH 3 3 juo Y 30 CR48 BL 1 1 yes 2 2 M RELAY U5 gr 85 E STOP p o N O H C 4 O LS6 t DOWN LIMIT SWITCH z i em mo gg t 2 2 hi
110. d may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of steps Section Scheduled Maintenance Procedures October 2008 SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend Note The following symbols have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appears at the beginning of a maintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Indicates that a cold motor or pump will be required to perform this procedure Indicates that dealer service will be required to perform this procedure E 4 Genie 3 2 GS 30 GS 32 GS 46 Pre delivery Preparation Report The pre delivery preparation report contains checklists for each type of scheduled inspection Make copies of the Pre delivery Preparation report to use for each inspection Store completed forms as required Maintenance Schedule There are five types of maintenance inspections that must be performed according to a schedule daily quarterly semi annually annually and two year The Schedule
111. d Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Component damage hazard Electrostatic discharge ESD can damage printed circuit board components Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap 4 Carefully disconnect the wire harness connectors from the circuit board 5 Carefully remove the circuit board retaining fasteners and remove the circuit board from the control box Genie Part No 96316 GS 30 GS 32 GS 46 4 3 Section 4 Repair Procedures June 2009 PLATFORM CONTROLS 1 2 Controller Adjustments Platform lift speed stowed drive speed raised drive speed and high torque drive speed are adjustable to compensate for wear in the hydraulic pump and drive motors The function speeds are determined by the percentage of total controller output For further information or assistance consult the Genie Industries Service Department ADANGER Tip over hazard Do not adjust the lift and or drive speed higher than specified in this procedure Setting the function speeds greater than specifications could cause the machine to tip over resulting in death or serious injury ADANGER Tip over hazard This procedure must only be performed by a trained service professional Attempting this procedure without the neces
112. d Maintenance Procedures Section and the Maintenance Inspection Report have been divided into five subsections A B C D and E Use the following chart to determine which group s of procedures are required to perform a scheduled inspection Inspection Checklist Daily or every 8 hours A Quarterly or every 250 hours Semi annually or every 500 hours Annually or every 1000 hours A B C D Two year or every 2000 hours A B C D E Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection Make copies of the Maintenance Inspection Report to use for each inspection Maintain completed forms for a minimum of 4 years or in compliance with your employer jobsite and governmental regulations and requirements Part No 96316 Pre Delivery Preparation Fundamentals It is the responsibility of the dealer to perform the Pre delivery Preparation The Pre delivery Preparation is performed prior to each delivery The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service A damaged or modified machine must never be used If damage or any variation from factory delivered condition is discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications Scheduled maintenance inspectio
113. d if not properly supported 12 Lower the cylinder onto the number 1 inner arm index 8 Component damage hazard Cables can be damaged if they are kinked or pinched 13 Attach a lifting strap from an overhead crane to the number 3 inner arm index 10 14 Remove the retaining fasteners from the number 3 pivot pin index 4 at the steer end 15 Use a soft metal drift to remove the number 3 pivot pin index 4 Remove the number 3 inner arm index 10 from the machine AWARNING Bodily injury hazard The number 3 inner arm may become unbalanced and fall if not properly supported when removed from the machine 16 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 17 Remove the external snap rings and retaining fasteners from the number 2 center pivot pin index 5 at the ground controls side Genie GS 30 GS 32 GS 46 REV C 18 Remove the number 2 cable bridge mounting fasteners and remove the cable bridge from the machine 19 Attach a lifting strap from an overhead crane to the number 2 outer arm index 14 at the ground controls side 20 Use a soft metal drift to remove the number 2 center pivot pin index 5 at the ground controls side 21 Remove the retaining fasteners from the number 2 pivot pin index 15 at the non steer end of the machine 22 Use a soft metal drift to tap the
114. d reconnect the hydraulic hose Torque to specification AWARNING ad injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Part No 96316 September 2005 Section 4 Repair Procedures REVA HYDRAULIC PUMP How to Remove the 6 Tag disconnect and plug the high pressure Hydraulic Pump Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Disconnect the battery pack from the machine AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious 8 injury Remove all rings watches and other jewelry hose at the pump Cap the fitting on the pump AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Remove the hydraulic power unit from the machine Remove the pump mounting bolts Carefully remove the pump 77777777 Tip over hazard After replacing 2 Tagand disconnect the hydraulic power unit ADANGER the hydraulic pump it is critical to cables at the motor controller 3 Disconnect t
115. d result in death or serious injury Remove all rings watches and other jewelry 1 Testthe coil for resistance See 6 5 How to Test a Coil 2 Connect a 100 resistor to the negative terminal of a known good 9V DC battery Connect the other end of the resistor to a terminal on the Coil Note The battery should read 9V DC or more when measured across the terminals Resistor 100 Genie part number 27287 3 Setamultimeter 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 Genie GS 30 GS 32 GS 46 2 AH o 100 RESISTOR BATTERY a A este ET pages a multimeter b 9VDC battery 100 resistor d coil Note Dotted lines in illustration indicate a reversed connection as specified in step 6 5 Momentarily connect the positive lead from the multimeter to the positive terminal on the 9V battery Note and record the current reading 6 Atthe battery or coil terminals reverse the connections Note and record the current reading Result Both current readings are greater than 0 mA and are different by a minimum of 20 The coil is good Result If one or both of the curr
116. device 5 Secure the ends of the scissor arms together at the non steer end of the machine with a strap or other suitable device 6 Remove the retaining fasteners securing the chassis mount bracket to the chassis at the steer end of the machine 7 Attach a lifting strap from an overhead crane to the scissor arm assembly 8 Raise the scissor arm assembly at the steer end with the overhead crane until the chassis mount bracket will clear the level sensor 9 Move the scissor assembly towards the non steer end of the machine slightly and to one side of the machine until one of the scissor arm wear pads is accessible Do not allow both wear pads to slide out of the drive chassis Component damage hazard Be careful not to damage the level sensor or limit switch while moving the scissor assembly Part No 96316 Genie GS 30 GS 32 GS 46 SCISSOR COMPONENTS 10 Remove the old wear pad 11 Install the new wear pad 12 Rotate the scissor assembly towards the other side of the machine until the other scissor arm wear pad is accessible Do not allow both wear pads to slide out of the drive chassis Crushing hazard The scissor ADANGER assembly will fall if both wear pads are allowed to slide out of the drive chassis Component damage hazard Be careful not to damage the level sensor or limit switch while moving the scissor assembly 13 Remove the old wear pad 14 Install the new wear pad 15 Slide t
117. 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 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 3 Lower the platform to the stowed position 4 Press the drive function select button Genie a drive function select button BN8 CHECKLIST B PROCEDURES Choose point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line Continue at full speed and note the time when your reference point on the machine passes over the finish line Refer to Section 2 Specifications Genie Part No 96316 GS 30 GS 32 GS 46 3 17 Section Scheduled Maintenance Procedures June 2009 CHECKLIST B PROCEDURES B 9 Test the Drive Speed Raised Position Genie requires that this procedure be performed every 250 hours or quarterly whichever co
118. e bridge from the machine 3 Remove the fasteners from the entry ladder and 66 Attach a lifting strap from an overhead crane to remove the entry ladder from the machine the number 1 inner arm index 10 ACAUTION Crushing hazard The entry ladder 67 Raise the arm slightly and remove the block may become unbalanced and fall if not properly supported and 68 Lower the arm to the stowed position secured to the lifting device ACAUTION Poy injury hazard Keep hands 4 Secure the ends of the scissor arms together at f i rts wh i i C ear ol paris wien the steer end of the machine with a strap or lowering the scissor arms other suitable device 69 Secure the ends of the scissor arms togetherat 5 Secure the ends of the scissor arms together at the steer end of the machine with a strap or the non steer end of the machine with a strap or other suitable device other suitable device 70 Secure the ends of the scissor arms together at 6 Remove the retaining fasteners securing the the non steer end of the machine with a strap or chassis mount bracket to the chassis at the other suitable device steer end of the machine 71 Remove the retaining fasteners securing the 7 Attach a lifting strap from an overhead crane to chassis mount bracket to the chassis the scissor arm assembly 72 Remove the linkset from the machine 8 Raise the scissor arm assembly at the steer ACAUTION Bodily injury hazard The number end with the overhead crane until the cha
119. e lifting device 15 Remove the lift cylinder through the scissor arms at the steer end of the machine Crushing hazard The lift cylinder ACAUTION may become unbalanced and fall if not properly supported and secured to the lifting device Component damage hazard Be careful not to damage the valve or fittings on the cylinder while removing it from the machine a manifold plug b orifice fitting schematic item Torque specification lift cylind d Sou der Solenoid valve 2 position 2 way N C 20 ft Ibs e hydraulic hose schematic item N 27 Nm f solenoid valve schematic item N g relief valve schematic item Q Relief Valve 20 ft Ibs schematic item Q 27 Nm Note At the upper lift cylinder install the orifice fitting with the large opening of the orifice fitting Coil nut 5 ft lbs closest to the manifold plug 7Nm 12 Attach a lifting strap from an overhead crane or similar lifting device to the barrel end of the lift cylinder for support 13 Remove the retaining fasteners from the lift cylinder barrel end pivot pin Use a soft metal drift to remove the pin AWARNING Crushing hazard The lift cylinder will fall if not properly supported when the pin is removed Genie 4 58 GS 30 GS 32 GS 46 Part No 96316 October 2008 Section 4 Repair Procedures REV B 4 1 Manual Platform Lowering Cable The manual platform lowering cable lowers the platfor
120. e retaining fasteners securing the chassis mount bracket to the chassis 95 Remove the linkset from the machine Bodily injury hazard The number ACAUTION 1 inner and outer arms index 14 and 29 may become unbalanced and fall if not properly supported when removed from the machine Component damage hazard Be sure not to damage the limit switch or level sensor box components when the number 1 inner and outer arms index 14 and 29 is removed from the machine Part No 96316 October 2008 Section 4 Repair Procedures REV How to Replace the Scissor Arm Wear Pads 1 Remove the platform See 2 1 How to Remove the Platform 2 Support and secure the entry ladder to an appropriate lifting device 3 Remove the fasteners from the entry ladder and remove the entry ladder from the machine Crushing hazard The entry ladder ACAUTION may become unbalanced and fall if not properly supported and secured to the lifting device 4 Secure the ends of the scissor arms together at the steer end of the machine with a strap or other suitable device 5 Secure the ends of the scissor arms together at the non steer end of the machine with a strap or other suitable device 6 Remove the retaining fasteners securing the chassis mount bracket to the chassis at the steer end of the machine 7 Attach a lifting strap from an overhead crane to the scissor arm assembly 8 Raise the scissor arm assembly at the steer end wi
121. e the cotter pin from the wheel castle nut Note Always replace the cotter pin with a new one when removing the castle nut 5 Loosen the wheel castle nut Do not remove it 6 Center a lifting jack under the drive chassis at the non steer end Part No 96316 Genie GS 30 GS 32 GS 46 2 inches 5 cm Place blocks under the chassis for support AWARNING Crushing hazard The chassis could fall if not properly supported 8 Remove the wheel castle nut Remove the wheel 9 Tag disconnect and plug the hydraulic hose from the brake Cap the fitting on the brake AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 10 Place a lifting jack under the brake for support 11 Remove the fasteners that attach the brake to the drive chassis Remove the brake Crushing hazard The brake will ACAUTION fall if not properly supported when the mounting fasteners are removed Torque specifications Brake mounting fasteners dry 75 ft lbs 102 Nm Brake mounting fasteners lubricated 56 ft lbs 76 Nm 4 81 Section 4 Repair Procedures September 2005 Brake Release Hand Pump Components REV 10 1 Brake Release Hand Pump Components The brake release hand pump manifold is mounted behind the entry ladder Index Schematic No Description Item
122. ect button Result The diagnostic display will show the stowed drive speed percentage Genie GS 30 GS 32 GS 46 REV D Gen 4 platform controller a function enable switch SW5 b joystick controller JC1 with thumb steering rocker SW6 horn button BN5 machine on incline turtle button BN6 lift function select button BN9 drive function select BN8 red Emergency Stop button P2 yellow arrow platform controls diagnostic display O Gen 5 platform controller 7 Press and hold the machine on incline button Result The diagnostic display will show the stowed high torque drive speed percentage 8 Use the steering thumb rocker switch on the joystick to increase or decrease the stowed high torque drive speed percentage 9 Turn the key switch to the off position Note Any change in software settings will not take effect until the key switch is turned to the off position Part No 96316 June 2009 Section 4 Repair Procedures REV D 1 3 Software Configuration before serial numbers GS3005 75000 GS3205 75000 and GS4605 75000 The ECM Electronic Control Module contains programming for all configurations of the Genie GS 30 GS 32 and GS 46 The machine can be adjusted to a different configuration by changing the toggle settings on the DIP switch The DIP Switch is located on the circuit board inside the platform control box
123. ection is essential to safe machine operation The Pre operation Inspection is a visual inspection performed by the operator prior to each work shift The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The Pre operation Inspection also serves to determine if routine maintenance procedures are required Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine Part No 96316 Genie GS 30 GS 32 GS 46 CHECKLIST A PROCEDURES A 3 Perform Function Tests Completing the function tests is essential to safe machine operation Function tests are designed to discover any malfunctions before the machine is put into service A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from service Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine Section Scheduled Maintenance Procedures October 2008 CHECKLIST A PROCEDURES 4 Perform 30 Day Service The 30 day maintenance procedure is a one time procedure to be performed after the first 30 days or 40 hours of usage After this interval refer to the maintenance tables for continued scheduled maintenance 1 Perform the following maintenan
124. ed from the machine 40 Remove the cables from the number 3A and 3B cable bridges and lay them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched 41 Disconnect the number 3A and 3B cable bridges from the scissor linkset and remove both cable bridges from the machine 42 Attach a lifting strap from an overhead crane to the number 3 outer arm at the ground control side index 7 43 Remove the retaining fasteners from the number 3 center pivot pin index 8 at the ground control side 44 Place a rod through the number 3 center pivot pin at the ground control side index 8 and twist to remove the pin 45 Remove the retaining fasteners from the number 3 pivot pin index 24 at the non steer end Section 4 Repair Procedures October 2008 SCISSOR COMPONENTS 46 Use a soft metal drift to remove the number 3 pivot pin index 24 from the non steer end of the machine Remove the number 3 outer arm at the ground control side index 7 from the machine Crushing hazard The number 3 ACAUTION outer arm at the ground control side index 47 may become unbalanced and fall if not properly supported when removed from the machine 47 Attach a lifting strap from an overhead crane to the number 3 outer arm at the battery side index 7 48 Remove the retaining fasteners from the number 3 center pivot pin index 8 at the battery side 49 Place a rod through the numb
125. eels 2 Remove the cotter pin from the wheel castle nut of the motor to be removed Note Always replace the cotter pin with a new one when removing the castle nut 3 Loosen the wheel castle nut Do not remove it 4 Center a lifting jack under the drive chassis at the steer end of the machine 5 Raise the machine approximately 2 inches 5 cm Place blocks under the chassis for support Crushing hazard The chassis AWARNING could fall if not properly supported 6 Remove the wheel castle nut Remove the wheel 7 Tag disconnect and plug the hydraulic hoses on the drive motor Cap the fittings on the drive motor AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Component damage hazard Hoses can be damaged if they are kinked or pinched 8 Remove the drive motor mounting fasteners Remove the motor Torque specifications STEER AXLE COMPONENTS 8 2 Steer Cylinder How to Remove the Steer Cylinder When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Block the non steer wheels 2 Remove the pin retaining fasteners from the rod end pivot pin Remove the pivot pi
126. ellus T46 hydraulic oil when oil temperatures consistently exceed 205 F 96 Note Genie specifications require additional equipment and special installation instructions for the approved optional fluids Consult the Genie Industries Service Department before use Part No 96316 Genie GS 30 GS 32 GS 46 SPECIFICATIONS Function pump Type Gear Displacement per revolution 0 244 cu in 4cc Flow rate 2500 psi 172 bar 4 gpm 15 L min 10 micron with 25 psi 1 7 bar bypass Hydraulic tank return filter Function manifold System relief valve pressure maximum 3500 psi 241 bar Lift relief valve pressure 1800 to 3500 psi 124 to 241 bar Steer relief valve pressure 1500 psi 103 bar Check valve manifold GS 1530 GS 1532 GS 1930 GS 1932 after serial number GS3004 66986 Check valve pressure maximum 200 psi 13 8 bar Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Section 2 Specifications June 2009 SPECIFICATIONS Manifold Component Specifications Plug torque SAE No 2 50 in Ibs 6 Nm SAE No 4 13 ft lbs 18 Nm SAE No 6 18 ft Ibs 24 Nm SAE No 8 50 ft lbs 68 Nm SAE No 10 55 ft lbs 75 Nm SAE No 12 75 ft lbs 102 Nm 2 4 Genie REV Valve Coil Resistance Note The following coil resistance specifications are at an ambient tempera
127. em is designed to prevent machine operation in the event the machine is overloaded Models equipped with the platform overload option are provided with two additional machine control components the overload pressure switch and a maximum height limit switch The overload pressure switch which is adjustable and located at the barrel end of the lift cylinder is used to determine when the hydraulic lift cylinder requires too much pressure to support the load inside the platform When this occurs the pressure Switch will send a signal to the ECM which will not allow the machine to function until the extra weight is removed from the platform Genie GS 30 GS 32 GS 46 REV C The maximum height limit switch located in the middle of the drive chassis under the scissor arms is used to disable the lift valve coil when the platform is near maximum height When activated the limit switch keeps the lift cylinder from going over lift relief which would cause the pressure Switch to falsely indicate an overload condition R m 74 mi A i a overload pressure switch b maximum height limit switch Part No 96316 April 2006 Section Scheduled Maintenance Procedures REV C 1 Locate the lift valve coil on the function manifold GS 1532 GS 193
128. emoved from the machine 30 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 31 Remove the external snap rings and retaining fasteners from the number 2 center pivot pin index 7 at the ground controls side 32 Remove the number 2 cable bridge mounting fasteners and remove the cable bridge from the machine 33 Attach a lifting strap from an overhead crane to the number 2 outer arm index 19 at the ground controls side 34 Use a soft metal drift to remove the number 2 center pivot pin index 7 at the ground controls side 35 Remove the retaining fasteners from the number 2 pivot pin index 20 at the non steer end of the machine Section 4 Repair Procedures October 2008 SCISSOR COMPONENTS 36 Use a soft metal drift to tap the number 2 pivot pin index 20 halfway out at the non steer end of the machine Remove the number 2 outer arm index 19 from the ground controls side of the machine Bodily injury hazard The number ACAUTION 2 outer arm at the ground controls side may become unbalanced and fall if not properly supported when removed from the machine 37 Attach a lifting strap from an overhead crane to the number 2 outer arm index 19 at the battery pack side 38 Remove the external snap rings and retaining fasteners from the number 2 center pivot pin index 7 at the battery pack
129. ent readings are 0 mA or if the two current readings do not differ by a minimum of 2096 the coil and or its internal diode are faulty and the coil should be replaced Part No 96316 September 2005 Section 4 Repair Procedures REV B 7 1 Hydraulic Tank The primary functions of the hydraulic tank are to cool and deaerate the hydraulic fluid during operation It utilizes internal suction strainers for the pump supply lines and has an external return line filter How to Remove the Hydraulic Tank Component damage hazard The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system When removing a hose assembly or fitting the fitting and or hose end must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications Perform this procedure with the platform in the stowed position 1 Disconnect the battery pack from the machine AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Part No 96316 Genie GS 30 GS 32 GS 46 Hydraulic Tank 2 Remove the drain plug from the hydraulic tank and allow all of the oil from the tank to drain into a suitable container Refer to Section 2 Specifications AWARNING Bodily injury hazard Spraying hydraulic oil
130. epair solved Genie Part No 96316 GS 30 GS 32 GS 46 6 1 Section 6 Schematics September 2005 Electrical Component and Wire Color Legends REV ELECTRICAL COMPONENT LEGEND WIRE COLOR LEGEND Item Description Color Description B5 Battery BK Black BN Button BL Blue BN5 Horn BN Brown BN6 High torque BN8 Drive enable GN Green BN9 Lift enable GY Gray C5 Capacitor 4700 uF OR Orange CB2 Circuit breaker 7A OR BK Orange Black CR Control relay PP Purple 5 Horn relay with H2 option RD Red CR27A Overload motor controller option CR27B Overload load sense option RD BK Red Black CR27C Overload down coil option CR27D Overload down delay option CR48 Power relay to U5 e stop D7 Voltage regulator Platform controls circuit board F6 Fuse 275A FB Flashing beacons G Gauge G6 Hour meter G7 Battery charge indicator GND Ground H Horn or alarm H1 Horn H2 Automotive style horn option H5 Multifunction alarm JC1 Joystick controller Key switch L LED or light L16 Lift L17 Drive L19 Power L21 High torque L25 Fault L30 Work light option LS Limit switch LS5 Platform up option LS6 Platform down LS7 Pothole 188 Pothole M5 Hydraulic power unit NC Normally closed NCHO Normally closed held open NOHC Normally open held closed P Power switch P1 Emergency Stop button at ground controls P2 Emergency Stop button at platform
131. er 3 center pivot pin at the battery side index 8 and twist to remove the pin 50 Remove the number 3 outer arm index 7 from the machine Crushing hazard The number 3 ACAUTION outer arm index 7 may become unbalanced and fall if not properly supported when removed from the machine 51 Attach a lifting strap from an overhead crane to the lug of the rod end of the upper lift cylinder 52 Raise the lift cylinder to a vertical position 53 Remove the pin retaining fasteners from the lift cylinder barrel end pivot pin index 22 Remove the lift cylinder from the machine Crushing hazard The lift cylinder ACAUTION Will fall if not properly supported when the pivot pin is removed Component damage hazard Be careful not to damage the valve or fittings on the cylinder while removing it from the machine Genie GS 30 GS 32 GS 46 REV C 54 Attach a lifting strap from an overhead crane to the lug of the rod end of the lower lift cylinder 55 Remove the retaining fasteners from the lower lift cylinder rod end pivot pin index 9 56 Use a soft metal drift to remove the lower lift cylinder rod end pivot pin index 9 from the machine Crushing hazard The lower lift A CAUTION cylinder will fall if not properly supported when the pivot pin is removed 57 Place a 2 x4 x 10 inch 10 x 10 x 25 cm block onto the number 1 inner arm cylinder plate index 14 58 Lower the cylinder onto the block
132. er arm cross tube b forklift tube wear pad 3 Apply a thin layer of dry film lubricant to the area of the chassis where the scissor arm wear pads make contact Cross tube to chassis specification Measurement minimum 0 88 inch 22 4 mm Genie GS 30 GS 32 GS 46 Part No 96316 June 2006 Section 3 Scheduled Maintenance Procedures REV D 2 Replace the Hydraulic Tank Return Filter Genie requires that this procedure be performed every 1000 hours or annually whichever comes first Replacement of the hydraulic tank return filter is essential for good machine performance and service life A dirty or clogged filter may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter be replaced more often Beware of hot oil Contact with ACAUTION hot oil may cause severe burns Note The hydraulic tank return filter is mounted on the function manifold next to the hydraulic power unit 1 Clean the area around the oil filter Remove the filter with an oil filter wrench 2 Applyathin layer of oil to the new oil filter gasket 3 Install the new filter and tighten it securely by hand 4 Use a permanent ink marker to write the date and number of hours from the hour meter onto the filter Part No 96316 Genie GS 30 GS 32 GS 46 CHECKLIST D PROCEDURES 5 Turn the key switch to ground control and pull o
133. er plug and pigtail for damage or excessive insulation wear Replace as required 15 Connect the battery charger to a properly grounded 115V 60Hz or 230V 60Hz single phase AC power supply Result The charger should operate and begin charging the batteries W If simultaneously the charger alarm sounds and the LEDs blink one time correct the charger connections at the fuse and battery The charger will then operate correctly and begin charging the batteries If simultaneously the charger alarm sounds and the LEDs blink two times the input voltage is too low or too high Correct the voltage issue The charger will then operate correctly and begin charging the batteries If simultaneously the charger alarm sounds and the LEDs blink three times the charger is overheated Allow the charger to cool The charger will then operate correctly and begin charging the batteries Note For best results use an extension of adequate size with a length no longer than 50 feet 15 m Note If you have any further questions regarding the battery charger operation please contact the Genie Industries Scissor Service Department Part No 96316 June 2009 Section Scheduled Maintenance Procedures REV 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 opera
134. er the platform onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform If you are not installing a new level sensor proceed to step 15 7 Turn the key switch to the off position and push in the red Emergency Stop button to the off position at the ground controls 8 Tag and disconnect the level sensor wire harness from the chassis wire harness Note The wire harness connection is located next to the level sensor on top of the chassis at the steer end of the machine 9 Remove the level sensor retaining fasteners Remove the level sensor from the machine 10 Tag and disconnect the level sensor wires from the level sensor connector plug 11 Securely install the wires of the new level sensor into the level sensor connector plug 4 61 Section 4 Repair Procedures October 2008 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 on the level sensor base closest to the short side of the level sensor mount ADANGER Tip over hazard The level sensor must be installed with the X on the level sensor base closest to the long side of the tilt level sensor box and the Y on the level sensor base closest to the short side of the tilt level sensor box Failure to install the tilt level sensor as instructed could result in the m
135. erial number GS4604 60000 to GS4605 75437 Part No 96316 Rev E5 G BRAND
136. es 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 m from the ground 2 Rotate the safety arm away from the machine and let it hang down 3 Lower the platform onto the safety arm AWARNING Cushing hazard Keep hands clear of the safety arm when lowering the platform 4 While raising the platform from the ground controls push the arm of the up limit switch towards the steer end of the machine to activate the limit switch Result The platform stops raising The machine is functioning properly Result The platform continues to raise Adjust or replace the up limit switch Genie Part No 96316 GS 30 GS 32 GS 46 3 25 Section Scheduled Maintenance Procedures April 2006 Checklist C Procedures C 1 Test the Platform Overload System if equipped Genie specifications require that this procedure be performed every 500 hours or six months whichever comes first OR when the machine fails to lift the maximum rated load Testing the platform overload system regularly is essential to safe machine operation Continued use of an improperly operating platform overload system could result in the system not sensing an overloaded platform condition Machine stability could be compromised resulting in the machine tipping over The platform overload syst
137. esistance specifications are at an ambient temperature of 68 F 20 C As valve coil resistance is sensitive to changes in air temperature the coil resistance will typically increase or decrease by 4 for each 18 F 7 7 C that your air temperature increases or decreases from 68 F 20 C Valve Coil Resistance Specifications Description Specification Solenoid valve 3 position 4 way 27 20 20V DC with diode schematic items and AC Solenoid valve 3 position 4 way 190 20V DC with diode schematic item F Solenoid valve 2 position 4 way 190 20V DC with diode schematic item H Solenoid valve 2 position 2 way N C 25Q 20V DC with diode schematic item N Solenoid valve 2 position 4 way 190 20V DC with diode schematic items AE and AI Solenoid valve 3 position 5 way 190 20V DC with diode schematic item AG Section 4 Repair Procedures October 2008 MANIFOLDS REV How to Test a Coil Diode Genie incorporates spike suppressing diodes in all COIL of its coils Properly functioning coil diodes protect MULTI the electrical circuit by suppressing voltage spikes Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil Faulty diodes can fail to protect the electrical system resulting in a tripped circuit breaker or component damage AWARNING Electrocution burn hazard Contact with electrically charged circuits coul
138. ex 14 28 Remove the retaining fasteners from the number 2 center pivot pin index 5 at the ground control side 29 Place a rod through the number 2 center pivot pin at the ground control side index 5 and twist to remove the pin Part No 96316 October 2008 Section 4 Repair Procedures REV 30 Remove the retaining fasteners from the number 2 pivot pin index 15 at the non steer end 31 Use a soft metal drift to remove the number 2 pivot pin index 15 from the non steer end of the machine Remove the number 2 outer arm at the ground control side index 14 from the machine Crushing hazard The number 2 ACAUTION outer arm at the ground control side index 14 may become unbalanced and fall if not properly supported when the pivot pin is removed 32 Attach a lifting strap from an overhead crane to the number 2 outer arm at the battery side index 14 33 Remove the retaining fasteners from the number 2 center pivot pin index 5 at the battery side 34 Place a rod through the number 2 center pivot pin at the battery side index 5 and twist to remove the pin Crushing hazard The number 2 ACAUTION outer arm index 14 may become unbalanced and fall if not properly supported when the pivot pin is removed 35 Remove the number 2 outer arm index 14 from the machine Crushing hazard The number 2 ACAUTION outer arm index 14 may become unbalanced and fall if not properly suppor
139. fications Drive speed maximum GS 1530 GS 1532 GS 1930 GS 1932 Platform stowed 2 5 mph 40 ft 10 7 sec 4 km h 12 2 m 10 7 sec Platform raised 0 5 mph 40 ft 55 sec 0 8 km h 12 2 m 55 sec GS 2032 GS 2632 GS 2046 GS 2646 GS 3246 Platform stowed 2 2 mph 40 ft 12 4 sec 3 5 km h 12 2 m 12 4 sec Platform raised 0 5 mph 40 ft 55 sec 0 8 km h 12 2 m 55 sec Braking distance maximum REV Function speed maximum from platform controls with 1 person in platform GS 1530 GS 1532 Platform up Platform down GS 1930 GS 1932 15 to 17 seconds 16 to 18 seconds Platform up Platform down GS 2032 GS 2046 15 to 17 seconds 22 to 24 seconds Platform up Platform down GS 2632 GS 2646 28 to 32 seconds 26 to 30 seconds Platform up Platform down GS 3246 28 to 32 seconds 22 to 26 seconds Platform up Platform down 55 to 59 seconds 38 to 42 seconds Rated work load at full height maximum GS 1530 and GS 1532 600 Ibs High range on paved surface 24 in 12 in 272 kg 61 cm 30 cm GS 1930 GS 1932 and GS 2632 500 Ibs Gradeability 227 kg GS 1930 GS 2632 and GS 3246 2596 GS 2032 800 105 363 kg GS 1530 GS 2032 GS 2046 and GS 2646 3096 GS 2046 1200 Ibs 544 kg Airborne noise emissions 70 dB Maximum sound level at normal operation workstations GS 2646 1000 Ibs A weighted 454 kg GS 3246 700 Ibs 31
140. from the machine if not properly attached to the overhead crane Component damage hazard Be careful not to damage the valve or fittings on the cylinder while removing it from the machine 54 Place a 4 x 4 x48 inch 10 cm x 10 cm x 1 2 m long block across both sides of the chassis under the number 1 center pivot pin index 11 Part No 96316 Genie GS 30 GS 32 GS 46 SCISSOR COMPONENTS 55 Attach a lifting strap from an overhead crane to the number 1 inner arm index 10 at the non steer end Raise the number 1 inner arm and remove the safety arm Lower the number 1 inner arm index 10 onto the block that was placed across the chassis Bodily injury hazard Keep hands ACAUTION clear of moving parts when lowering the arms onto the block 56 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 57 Support and secure the entry ladder to an appropriate lifting device 58 Remove the fasteners from the entry ladder and remove the entry ladder from the machine Crushing hazard The entry ladder ACAUTION may become unbalanced and fall if not properly supported and secured to the lifting device 59 Attach a lifting strap from an overhead crane to the number 1 outer arm index 22 Do not apply any lifting pressure 60 Remove the external snap rings and retaining fasteners from the number 1 center
141. g cable from the solenoid valve on the cylinder 36 Models with platform overload option Tag and disconnect the wire harness from the platform overload switch 37 Raise the lift cylinder to a vertical position 38 Remove the pin retaining fasteners from the lift cylinder barrel end pin index 16 Use a soft metal drift to remove the pin Remove the lift cylinder from the machine AWARNING Crushing hazard The lift cylinder could become unbalanced and fall when it is removed from the machine if not properly attached to the overhead crane Component damage hazard Be careful not to damage the valve or fittings on the cylinder while removing it from the machine 39 Place a 4 x 4 x 48 inch 10 cm x 10 cm 1 2 m long block across both sides of the chassis under the number 1 center pivot pin index 7 Section 4 Repair Procedures October 2008 SCISSOR COMPONENTS 40 Attach a lifting strap from an overhead crane to the number 1 inner arm index 8 at the non steer end Raise the number 1 inner arm and remove the safety arm Lower the number 1 inner arm index 8 onto the block that was placed across the chassis Bodily injury hazard Keep hands ACAUTION clear of moving parts when lowering the arms onto the block 41 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 42 Support and secure the entr
142. gency stop B 5 Key switch B 6 Horn if equipped B 7 Drive brakes B 8 Drive speed stowed B 9 Drive speed raised B 10 Hydraulic oil analysis B 11 Tank venting system B 12 Latch components B 13 Voltage inverter if equipped B 14 Test the down and pothole limit switches B 15 Test the up limit switch if equipped Checklist C Rev C Y NR C 1 Platform overload if equipped C 2 Breather cap models with optional oil Checklist D Rev C Y NR D 1 Scissor arm wear pads D 2 Hydraulic filter Checklist E Rev B Y NR E 1 Hydraulic oil GS 30 GS 32 GS 46 Section Scheduled Maintenance Procedures October 2008 Checklist A Procedures A 1 Inspect the Manuals and Decals Maintaining the operator s and safety manuals in good condition is essential to safe machine operation Manuals are included with each machine and should be stored in the container provided in the platform An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition In addition maintaining all of the safety and instructional decals in good condition is mandatory for safe machine operation Decals alert operators and 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 per
143. hazard The scissor assembly will fall if not properly supported when removed from the drive chassis Component damage hazard Be careful not to damage the level sensor or limit switch while moving the scissor assembly 10 Remove both old wear pads 11 Install two new wear pads 12 Slide the scissor assembly back into the drive chassis 13 Lower the scissor assembly into position and install the chassis mount bracket onto the chassis Securely install and tighten the fasteners Do not overtighten Component damage hazard Be careful not to damage the level sensor or limit switch while moving the scissor assembly Section 4 Repair Procedures October 2008 SCISSOR COMPONENTS 9 Q C REV C N amp G GG GG GS 1930 a GS 1932 f S Steer End Non steer End O GQ N 9 10 11 Number 5 pivot pin Number 4 center pivot pin 2 pins Number 4 pivot pin steer end Number 3 center pivot pin 2 pins Lift cylinder rod end pivot pin Number 3 pivot pin steer end Number 2 center pivot pin 2 pins Number 2 pivot pin steer end Number 1 center pivot pin 2 pins Number 1 inner arm Number 1 pivot pin Genie GS 30 GS 32 GS 46 12 Number 4 inner arm 13 Number 4 outer arm 14 Number 4 pivot pin non steer
144. he O rings 2 Screw the cartridge in by hand until the top O ring is met then torque to specification 3 If required install the valve coil s onto the valve stem Install the coil nut onto the valve stem and torque to specification Genie 4 70 GS 30 GS 32 GS 46 Part No 96316 October 2008 Section 4 Repair Procedures REV 6 4 Valve Adjustments Function Manifold How to Adjust the System Relief Valve Perform this test from the ground with the platform controls Do not stand in the platform Be sure that the hydraulic oil level is at the FULL mark on the hydraulic tank 1 Locate the system relief valve on the function manifold item 2 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the test port on the function manifold schematic item A or AA 3 Chock both sides of the wheels at the steer end of the machine 4 Remove the platform controls from the platform 5 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls GS 1530 32 and GS 1930 32 a test port b system relief valve Part No 96316 Genie GS 30 GS 32 GS 46 MANIFOLDS 6 Press and hold the function enable switch 7 Move and hold the joystick fully in either direction while observing the pressure reading on the pressure gauge Note the pressure Refer to Section 2 Spec
145. he filter head from the filter head mounting bracket Rotate the filter out and away from the hydraulic power unit 4 Remove the hydraulic power unit retaining fasteners 5 Tag disconnect and plug the hydraulic hard line from the pump Cap the fitting on the pump Genie Part No 96316 GS 30 GS 32 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 GS 46 4 65 Section 4 Repair Procedures October 2008 Manifolds 6 1 Function Manifold Components GS 1530 GS 1532 GS 1930 and GS 1932 The function manifold is mounted under the machine between the module trays Index Schematic No Description Item Function Coil mut E F and tiyu u 1 Diagnostic nipple Testing 2 Check disc Rs Bii Steer circuit Relief valve 1800 to 3500 psi 124 to 241 bar Lift relief 4 Check valve 10 psi 0 7 bar Drive 5 Solenoid valve 3 position 4 way E Drive forward reverse 6 Solenoid valve 3 position 4 way Euntes Steer left right 7 Flow regulator and relief valve 0 75 gpm 2 8
146. he machine crosses the test line 7 Measure the distance between the test line and your machine reference point Refer to Section 2 Specifications Result The machine stops within the specified braking distance No action required Result The machine does not stop within the specified braking distance Proceed to step 8 and determine if the machine is equipped with a dynamic braking valve Note The brakes must be able to hold the machine on any slope it is able to climb 8 Disconnect the battery pack from the machine Electrocution burn hazard Contact AWARNING with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 9 Locate the drive forward reverse valve on the function manifold Refer to Illustrations 2 and 3 GS 1530 GS 1532 GS 1930 GS 1932 Illustration 2 a drive forward reserve valve Part No 96316 June 2009 Section Scheduled Maintenance Procedures REV GS 2032 GS 2632 GS 2046 GS 2646 GS 3246 Illustration 3 a drive forward reverse valve 10 Tag the forward and the reverse valve coils Remove the coils from the valve Note The forward valve coil has white and brown wires attached Note The reverse valve coil has white black and brown wires attached Note For reassembly it will be helpful to leave the wire harness attached to the valve coils F
147. he platform railings to the carriage on the forklift to help support the platform GS 1530 32 and GS 1930 32 Lift the steer end of the platform slightly to clear the platform mount and slide the platform towards the non steer end of the machine until the platform slide blocks at the non steer end of the machine are visible through the access holes in the bottom of the platform 1 k All other models Lift the steer end of the platform slightly to clear the platform mount and slide the platform towards the steer end of the machine until the platform slide blocks at the non steer end of the machine are visible through the access holes in the bottom of the platform AWARNING Crushing hazard The platform will fall if not properly supported 12 Carefully lift the platform off of the machine and place it on a structure capable of supporting it Note Note the position of the wear pads before the platform is removed so when the platform is installed they will be in the correct position Part No 96316 September 2005 REVA 2 2 Platform Extension How to Remove the Platform Extension 1 2 3 Lower the platform to the stowed position Extend the platform approximately 3 feet 1 m Remove the platform controls from the platform and lay them off to the side of the machine Support the platform extension with a forklift at the steer end of the machine Do not apply any lifting pressure Attach a strap from the
148. he scissor assembly back into the drive chassis 16 Lower the scissor assembly into position and install the chassis mount bracket onto the chassis Securely install and tighten the fasteners Do not overtighten Component damage hazard Be careful not to damage the level sensor or limit switch while moving the scissor assembly 4 37 Section 4 Repair Procedures October 2008 SCISSOR COMPONENTS REV C N ped OO GGG 9 GG a O GS 2632 at 264 e GS 2646 C Steer end p Non steer end 1 Number 5 pivot pin 12 Number 4 inner arm 2 Number 4 center pivot pin 2 pins 13 Number 4 outer arm 3 Number 4 pivot pin steer end 14 Number 4 pivot pin non steer end 4 Number 3 center pivot pin 2 pins 15 Number 3 inner arm 5 Lift cylinder rod end pivot pin 16 Number 3 outer arm 6 Number 3 pivot pin steer end 17 Number 3 pivot pin non steer end 7 Number 2 center pivot pin 2 pins 18 Number 2 inner arm 8 Number 2 pivot pin steer end 19 Number 2 outer arm 9 Number 1 center pivot pin 2 pins 20 Number 2 pivot pin non steer end 10 Number 1 inner arm 21 Lift cylinder barrel end pivot pin 11 Number 1 pivot pin 22 Number 1 outer arm Genie 4 38 GS 30 GS 32 GS 46 Part No 96316 October 2008 Section 4 Repair Procedures REV 3 4 Scissor Assembly
149. he steer end 4 Raise the machine approximately 14 inches 36 cm Place blocks under the chassis for support AWARNING Crushing hazard The chassis could fall if not properly supported 5 Turn the yokes to the side so the bellcrank can be removed 6 Remove the bellcrank from the machine Genie GS 30 GS 32 GS 46 REV B Note While removing the bellcrank from the machine take note of the quantity and location of the spacers between the bellcrank and the steer links Note Before re installing the steer bellcrank onto the machine apply a small amount of Loctite onto the threads of the fasteners Torque the fasteners to 31 ft Ibs 42 Nm Apply Loctite to Fasteners Before Securing Into Place Part No 96316 September 2005 Section 4 Repair Procedures Non steer Axle Components 9 1 7 Raisethe machine approximately Drive Brake How to Remove a Drive Brake When removing a hose assembly or fitting the fitting and or hose end must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Support and secure the entry ladder to an appropriate lifting device 2 Remove the entry ladder mounting fasteners Remove the entry ladder from the machine Crushing hazard The entry ladder ACAUTION may become unbalanced and fall if itis not properly supported and secured to the lifting device 3 Block steer wheels 4 Remov
150. ic number 50141 Machine unladen weight 2 714 b 1 231 kg Rated work load including occupants 500 Ib 227 kg G 530 05 z 1 2345 Maximum allowable inclination of the chassis N A aAA Model Sequence number Gradeability N A _ Model year Maximum allowable side force 100 Ib 445 Maximum number of platform occupants 2 Country of manufacture USA This machine complies with ANSI A92 6 1999 B354 2 01 Genie Industries 18340 NE 76th Street Redmond WA 98052 USA 77055 Serial number stamped on chassis Serial number stamped on chassis Genie Part No 96316 GS 30 GS 32 GS 46 iii September 2005 EEF This page intentionally left blank Genie iv GS 30 GS 32 GS 46 Part No 96316 September 2005 Section 1 Safety Rules Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the appropriate Operator s Manual on your machine will result in death or serious injury Many of the hazards identified in the operator s manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless You are trained and qualified to perform maintenance on this machine You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmen
151. ice platform down circuit P Accumulator Q Relief valve platform down HS0036G R Pressure switch platform overload Genie Part No 96316 GS 30 GS 32 GS 46 6 51 Section 6 Schematics September 2005 EIER E This page intentionally left blank Genie 6 52 GS 30 GS 32 GS 46 Part No 96316 Genie Scandinavia Phone 46 31 575100 Fax 46 31 579020 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Iberica Phone 434 93 579 5042 Fax 34 93 579 5059 Genie Germany Phone 0800 180 9017 Phone 49 422 149 1818 Fax 49 422 149 1820 Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 61 7 3375 1002 Genie China Phone 86 21 53852570 Fax 86 21 53852569 Genie Malaysia Phone 65 98 480 775 Fax 65 67 533 544 Genie Japan Phone 81 3 3453 6082 81 3 3453 6083 Genie Korea Phone 82 25 587 267 Fax 82 25 583 910 Genie Phone 44 0 1476 584333 Fax 44 0 1476 584334 Genie Brasil Phone 455 11 41 665 755 Fax 55 11 41 665 754 Genie Mexico City Phone 452 55 5666 5242 Fax 52 55 5666 3241 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566 Service Manual GS 30 GS 32 GS 46 from serial number GS3003 60000 to GS3005 75999 from serial number GS3204 60000 to GS3205 75406 from s
152. ifications 8 Turn the machine off Hold the system relief valve with a wrench and remove the cap schematic item or AB 9 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure 747117112 hazard Failure to adjust the relief valves to specification could result in the machine tipping over causing death or serious injury Do not adjust the relief valve pressures higher than specifications 10 Install the relief valve cap 11 Repeat steps 5 through 7 to confirm the relief valve pressure GS 32 and GS 46 test port system relief valve steer relief valve lift relief valve ao oo Section 4 Repair Procedures October 2008 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 that the hydraulic oil level is at the FULL mark on the hydraulic tank 1 Locate the system relief valve on the function manifold item 2 Connect 0 to 5000 psi 0 to 350 bar pressure gauge to the test port on the function manifold schematic item A or AA 3 Chock both sides of the wheels at the steer end of the machine 4 Remove the platform controls from the platform 5 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls Press and
153. ionally left blank Genie 5 4 GS 30 GS 32 GS 46 Part No 96316 September 2005 Section 6 Schematics Observe and Obey Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Troubleshooting Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necessary tools and test equipment are available and ready for use Schematics About This Section There are two groups of schematics in this section An illustration legend precedes each group of drawings Electrical Schematics AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Hydraulic Schematics Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray General Repair Process Malfunction Identify Troubleshoot discovered symptoms problem still exists Return to Perform service J problem r
154. is less than 17 8V DC Genie Part No 96316 GS 30 GS 32 GS 46 Section 4 Repair Procedures September 2005 Platform Components 2 1 Platform How to Remove the Platform Perform this procedure with the platform extension fully retracted and locked in position 1 Raise the platform to approximately 3 ft 1 m 2 Remove the retaining fasteners securing the platform to the platform mount at the steer end of the machine Lower the platform to the stowed position 4 Disconnect the battery packs from the machine AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 5 Disconnect the platform controls from the control cable at the platform 6 Remove the cover from the AC outlet Tag and disconnect the wiring from the outlet AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 7 Disconnect the wiring from the platform and pull the wiring free of the platform Genie GS 30 GS 32 GS 46 REVA 8 Models with air line to platform option Disconnect the air line from the platform Pull the air line free of the platform 9 Support the platform with a forklift at the non steer end Do not apply any lifting pressure 10 Attach a strap from the lanyard anchorage point on t
155. itch MET 9 normally open ii LH LEVEL z wc 4 ME LL OF 9 D1 evel sensor ME 5 Wire with description Limit switch A1 Motor I X _ Circuits crossing no connection Diode EE Circuits connection Y Connector Z Hour meter Z Light or flashing beacon 4 Inductor noise suppression Button or switch 1 Toggle switch ES 1 Emergency stop button CB2 Circuit breaker 2 30 86 87A ter 85 Control relay mw Fuse Horn or alarm lt LED Part No 96316 Genie Battery charger 6V DC Battery KS1 KEY SWITCH Solenoid valve Solenoid valve with diode T Capacitor PLATFORM CONTROL GROUND CONTROL Sx Key switch E gom es FUNCTION Saepe Pi e Lead a ee sm z asa Joystick JOYSTICK CONTROLLER GS 30 GS 32 GS 46 Section 6 Schematics October 2008 SS Electrical Schematic ANSI CSA and Australia Models REV GS 1530 1532 1930 1932 from serial number GS3003 60000 to GS3005 74999
156. ith a wrench and remove the cap schematic item C or AJ 15 While activating the platform up function adjust the internal hex socket clockwise just until the platform fully raises 16 Fully lower the platform 17 Add an additional 50 pounds 22 7 kg to the platform Secure the additional weight 18 Attempt to raise the platform Result The power unit should not be able to lift the platform Result If the power unit lifts the platform adjust the internal hex socket counterclockwise until the platform will not raise 19 Install the relief valve cap 20 Remove the weight from the platform 21 Bleed the hydraulic system by raising the platform to full height If the pump cavitates or the platform fails to reach full height add hydraulic oil until the pump is functioning correctly Do not overfill the hydraulic tank Component damage hazard Do not continue to operate the machine if the hydraulic pump is cavitating Genie Part No 96316 GS 30 GS 32 GS 46 4 73 Section 4 Repair Procedures October 2008 mmm X MANIFOLDS REV C How to Adjust the Steer Relief 5 Activate the function enable switch and press Valve and hold the steer thumb rocker switch to the right Allow the wheels to completely turn to the right Continue holding the switch while observing the pressure reading on the pressure gauge Note the pressure Refer to Section 2 Be sure that the hydr
157. itting on the lift cylinder 7 located underneath the boa fitting on the lift cylinder i 1 LIFT i 2500 psi 172 bar POWER UNIT LI 15 L min 172 bar E Y8 1800 to 3500 psi ho 777 124 241 1 lt gt E E 1 3500 psi maximum Len 241 bar maximum TANK HS0036F Genie GS 30 GS 32 GS 46 Part No 96316 June 2009 Section 6 Schematics REV B STEER LEFT LEFT RIGHT BRAKE BRAKE PUMP RELEASE HAND OF BRAKE MANUAL RELEASE MANIFOLD Hydraulic Schematic GS 2046 2646 3246 from serial number GS4604 60000 to GS4604 60878 LEFT RIGHT DRIVE DRIVE MOTOR MOTOR OQ Y6 M TL HS0036F ABBREVIATION LEGEND Description Test port Relief valve system Steer left right Check valve steer circuit Drive speed Relief valve brake release Drive forward reverse Flow regulator re
158. ivot pin index 12 from the steer end of the machine Remove the number 2 inner arm index 25 from the machine Crushing hazard The number 2 ACAUTION inner arm index 25 may become unbalanced and fall if not properly supported when the pivot pin is removed 76 Attach a lifting strap from an overhead crane to the number 1 inner arm index 14 77 Raise the number 1 inner arm index 14 approximately 2 feet 60 cm 78 Place a 4 x4 x48 inch 10 cm x 10 cm 1 2 m long block across both sides of the chassis under the number 1 center pivot pin index 13 79 Lower the scissor arms onto the block that was placed across the chassis Bodily injury hazard Keep hands ACAUTION clear of moving parts when lowering the scissor arms 80 Attach a lifting strap from an overhead crane to the lug of the rod end of the lower lift cylinder 4 51 Section 4 Repair Procedures October 2008 SCISSOR COMPONENTS 81 Tag disconnect and plug the hydraulic hose on the lower lift cylinder Cap the fittings on the cylinder AWARNING ew injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 82 Tag and disconnect the wire harness from the solenoid valve on the cylinder 83 Tag and disconnect the wires and manual lowering cable from the solenoid valve on the cylinder 84 Models wi
159. jury or death Indicates an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous ACAUTION situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of steps Section 4 Repair Procedures June 2009 Platform Controls The platform controls used to operate the machine from the platform or while standing on the ground can also be used to tune the performance of the machine Moving the joystick or activating a button sends a signal to the Electronic Control Module ECM When the ECM is in the function mode the platform controls are used to operate the various machine functions When the ECM is in the programming mode PS is shown in the diagnostic display window the platform controls are used to adjust the function speed parameters The platform controls consist of an electronic circuit board joystick membrane decal buttons LEDs and on models with a Gen 5 controller a diagnostic display For further information or assistance consult the
160. l 87a to 30 continuity zero Terminal Number Legend terminal no 87a N C terminal no 85 ground terminal no 30 common terminal no 86 coil terminal no 87 N O Genie GS 30 GS 32 GS 46 Part No 96316 October 2008 Section 4 Repair Procedures REV B 4 3 Level Sensor The Electronic Control Module ECM is programmed to deactivate the lift and drive functions and activate an alarm when a signal is received from the level sensor The tilt alarm sounds when the incline of the chassis exceeds 2 to the side and 3 to the front or rear How to Install and Calibrate the 1 5 Level Sensor DANE Tip over hazard Failure to install ADANGER 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 platform 3 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 4 Raise the platform 7 to 8 feet 2 1 to 2 4 m Part No 96316 Genie GS 30 GS 32 GS 46 GROUND CONTROLS 5 the safety arm move it to the center of the scissor arm and rotate down to a vertical position 6 Low
161. l if not properly supported when removed from the machine Component damage hazard Be sure not to damage the limit switch or level sensor box components when the number 1 inner arm is removed from the machine Part No 96316 October 2008 Section 4 Repair Procedures REV How to Replace the Scissor Arm Wear Pads 1 Remove the platform See 2 1 How to Remove the Platform Support and secure the entry ladder to an appropriate lifting device Remove the fasteners from the entry ladder and remove the entry ladder from the machine ACAUTION Crushing hazard The entry ladder may become unbalanced and fall if not properly supported and secured to the lifting device Secure the ends of the scissor arms together at the steer end of the machine with a strap or other suitable device Secure the ends of the scissor arms together at the non steer end of the machine with a strap or other suitable device Remove the retaining fasteners securing the chassis mount bracket to the chassis at the steer end of the machine Attach a lifting strap from an overhead crane to the scissor arm assembly Raise the scissor arm assembly at the steer end with the overhead crane until the chassis mount bracket will clear the level sensor Part No 96316 Genie GS 30 GS 32 GS 46 4 23 SCISSOR COMPONENTS 9 Remove the scissor assembly from the machine just enough to access both wear pads ADANGER Crushing
162. l the coil nut onto the valve and tighten Torque to 60 in Ibs 7 Nm 16 Connect the battery pack to the machine 17 Replace the brakes and repeat this procedure beginning with step 1 Refer to Repair Procedure 9 1 How to Remove a Drive Brake Repeat this procedure beginning with step 1 18 Contact the Genie Industries Service Parts Department and order kit part number 105457 19 Install the new valve received in the kit and mark the new valve with a white paint pen to identify new valve installation 20 Repeat this procedure beginning with step 1 If the machine fails to stop within the specified stopping distance after installing new brakes please contact the Genie Industries Scissors Service Department 1 800 536 1800 Ext 8710 Section Scheduled Maintenance Procedures June 2009 CHECKLIST B PROCEDURES 21 Remove the drive forward reverse valve from the function manifold Cap the open port of the manifold 22 Carefully inspect the hex portion of the valve for an identification stamp O Result SV10 5905 is stamped on the hex portion of the drive forward reverse valve This indicates the machine is equipped with a dynamic brake valve Proceed to step 23 Wi Result SV10 5905 is not stamped on the hex portion of the drive forward reverse valve This indicates the machine is not equipped with a dynamic brake valve Proceed to step 28 23 Install the drive forward reverse valve removed in step 20 into the f
163. lace a rod through the number 3 center pivot pin at the ground control side index 4 and twist to remove the pin 25 Remove the retaining fasteners from the number 3 pivot pin index 17 at the non steer end 26 Use a soft metal drift to remove the number 3 pivot pin index 17 from the non steer end of the machine Remove the number 3 outer arm at the ground control side index 16 from the machine Crushing hazard The number 3 ACAUTION outer arm at the ground control side index 16 may become unbalanced and fall if not properly supported when removed from the machine 27 Attach a lifting strap from an overhead crane to the number 3 outer arm at the battery side index 16 28 Remove the retaining fasteners from the number 3 center pivot pin index 4 at the battery side 29 Place a rod through the number 3 center pivot pin at the battery side index 4 and twist to remove the pin Part No 96316 Genie GS 30 GS 32 GS 46 SCISSOR COMPONENTS 30 Remove the number 3 outer arm index 16 from the machine Crushing hazard The number 3 ACAUTION outer arm index 16 may become unbalanced and fall if not properly supported when removed from the machine 31 Attach a lifting strap from an overhead crane to the lug of the rod end of the lift cylinder 32 Remove the retaining fasteners from the lift cylinder rod end pivot pin index 5 33 Use a soft metal drift to remove the lift cylinder rod
164. lar lifting device to the barrel end of the lift cylinder for support 4 Tag and disconnect the wiring from the solenoid valve coil at the barrel end of the lift cylinder 13 Remove the retaining fasteners from the lift cylinder barrel end pivot pin Use a soft metal drift to remove the pin AWARNING Crushing hazard The lift cylinder will fall if not properly supported when the pin is removed 14 Support and secure the lift cylinder to an appropriate lifting device 15 Remove the lift cylinder through the scissor arms at the steer end of the machine Crushing hazard The lift cylinder ACAUTION may become unbalanced and fall if not properly supported and secured to the lifting device Component damage hazard Be careful not to damage the valve or fittings on the cylinder while item removing it from the machine c connector fitting d hydraulic hose Torque specification e manuallowering cable f solenoid valve schematic item N Solenoid valve 2 position 2 way N C 20 ft Ibs g cable mount bracket Sm 5 Models with platform overload option Tag Coil nut 5 ft Ibs and disconnect the wiring from the platform 7 Nm overload switch Genie Part No 96316 GS 30 GS 32 GS 46 4 55 Section 4 Repair Procedures October 2008 SCISSOR COMPONENTS 6 Loosen the adjustment nuts on the solenoid valve and disconnect the manual lowering cable from the valve Note During assemb
165. lease the lift function select and horn buttons Result The diagnostic display will show the maximum lift speed percentage 6 Press the drive function select button Result The diagnostic display will show the stowed drive speed percentage Genie REV D Gen 4 platform controller function enable switch SW5 joystick controller JC1 with thumb steering rocker SW6 horn button BN5 d machine on incline turtle button BN6 e lift function select button BN9 f drive function select BN8 9 h i om red Emergency Stop button P2 yellow arrow platform controls diagnostic display Gen 5 platform controller 7 Usethe steering thumb rocker switch on the joystick to increase or decrease the stowed drive speed percentage Refer to Section 2 Specifications for function speeds 8 Turn the key switch to the off position Note Any change in software settings will not take effect until the key switch is turned to the off position 4 6 GS 30 GS 32 GS 46 Part No 96316 June 2009 Section 4 Repair Procedures REV D How to Adjust the Raised Drive Speed A DANGER Tip over hazard Do not adjust the lift and or drive speed higher than specified in this procedure Setting the function speeds greater than specifications could cause the machine to tip over resulting in death or serious injury ADANGER Tip over hazard This procedure must only be
166. lief valve Platform up Relief valve lift Shuttle valve brake release Check valve manual brake release Hand pump manual brake release Needle valve manual brake release Platform lowering valve Orifice platform down circuit Accumulator lt Relief valve platform down Pressure switch platform overload Genie Part No 96316 GS 30 GS 32 GS 46 6 49 Section 6 Schematics September 2005 Hydraulic Schematic GS 2046 2646 3246 REVA from serial number GS4604 60879 to GS4605 75437 WUPPERLFTCYLINDER PLATFORM LIFTCYLINDER GS 3246 OVERLOAD CE MODELS Y9 The lift cylinder orifice is The lift cylinder orifice is located underneath the fitting on the lift cylinder 7 located underneath the boa fitting on the lift cylinder i 1 LIFT i 2500 psi 172 bar POWER UNIT LI 15 L min 172 bar 71 Y8 1800 to 3500 psi ho 2 124 to 241 bar 1 lt gt E E 1 3500 psi maximum Len 241 bar maximum TANK HS0036G Ge
167. lt code 54 should be present in the diagnostic display The system is functioning correctly Result models with software revision A2 and higher The alarm should not sound The system is functioning correctly Result all models The alarm sounds The system is not functioning correctly Troubleshoot the limit switch limit switch wire harness or limit switch mount bracket OR the platform overload system needs to be calibrated Refer to Repair Procedure 11 1 Calibrate the Platform Overload System if equipped Note To determine the software revision level refer to Repair Procedure 1 2 How to Determine the Revision Level 10 Lower the platform to the stowed position Section Scheduled Maintenance Procedures April 2006 CHECKLIST C PROCEDURES 2 Replace the Hydraulic Tank Breather Cap Models with Optional Hydraulic Oil Genie requires that this procedure be performed every 500 hours or semi annually whichever comes first The hydraulic tank is a vented type tank The breather cap has an internal air filter that can become clogged or over time can deteriorate If the breather cap is faulty or improperly installed impurities can enter the hydraulic system which may cause component damage Extremely dirty conditions may require that the cap be inspected more often 1 Remove and discard the hydraulic tank breather cap 2 Install and new cap onto the tank REV C Genie 3 28 GS 30
168. ly the manual platform lowering cable needs to be properly adjusted See 4 1 How to Adjust the Manual Platform Lowering Cable 7 Remove the fasteners securing the manual lowering cable mount bracket to the cylinder Remove the bracket from the cylinder 8 Tag disconnect and plug the hydraulic hoses on the lift cylinder Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 9 Attach a lifting strap from an overhead crane to the rod end of the lift cylinder for support 10 Remove the retaining fasteners from the lift cylinder rod end pivot pin Use a soft metal drift REV C 12 Attach a lifting strap from an overhead crane or similar lifting device to the barrel end of the lift cylinder for support 13 Remove the retaining fasteners from the lift cylinder barrel end pivot pin Use a soft metal drift to remove the pin AWARNING Crushing hazard The lift cylinder will fall if not properly supported when the pin is removed 14 Support and secure the lift cylinder to an appropriate lifting device 15 Remove the lift cylinder through the scissor arms at the steer end of the machine Crushing hazard The lift cylinder ACAUTION may become unbalanced and fall if not properly supported and secured to the lifting device Compone
169. ly charge the batteries and check the hydraulic fluid level Note The hydraulic fluid level must be between the FULL and marks on the hydraulic tank 2 Applyathin layer of dry film lubricant to the area of the chassis where the scissor arm wear pads make contact 3 Chock both sides of the wheels at the steer end of the machine 4 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 5 GS 1532 and GS 1932 Raise the platform approximately 1 5 m Part No 96316 Genie GS 30 GS 32 GS 46 weight corresponding to the maximum load as indicated on the capacity indicator decal in the center of the platform floor Secure the weight to the platform Refer to the chart below GS 1532 484 kg GS 1932 435 kg GS 2032 693 kg GS 2632 479 kg GS 2046 985 kg GS 2646 798 kg GS 3246 699 kg 7 Apply a piece of tape onto the side of the platform at a point which corresponds to the maximum load position of the capacity indicator decal on the side of the platform 8 Raise the platform until the position indicator corresponds to the maximum load position of the capacity indicator decal on the platform Release the toggle switch ER Tip over hazard Raising the platform with maximum load above the maximum load position as shown on the capacity indicator decal on the side of the platform could result in the m
170. ly left blank Genie Part No 96316 GS 30 GS 32 GS 46 6 11 Section 6 Schematics Electrical Schematic September 2005 ANSI CSA and Australia Models REV B GS 1530 1532 1930 1932 from serial number GS3005 75000 to 75999 P1 radi s lt EMERGENCY a ie STOP NAT lt N on 4 4 2 KS1 I T key PLATFORM SWITCH CONTROL 1 I NOTE E Bi H5 ALARM MACHINE SHOWN IN THE t 27128 7 STOWED POSITION WITH N C HO THE POWER OFF p LS7 TS66 POTHOLE PLATFORM UP DOWN CB2 E E N CHO 4 fe 5 circu 2 LS8 BREAKER 4 POTHOLE GUARD SWITCH gt v l S gg 3 9 2 i E 322 2 29 E INL L30 S wonkuenr 2 g QD1 DATA d La ae F6 2 2 275A FUSE LO za DC U9 m A8 OUT OUT U5 ELECTRONIC CONTROL MODULE OUT OUT n B8 B3 AC INPUT U Ea P lcm E 5 Ow T 1 CONTROLLER 2 10 CR5 1 2 p HORN RELAY 39 H2 OPTION m U13 5 55 DG AC INVERTER 86 ENG To 85 OPTION BEACONS
171. m in the event of a main power failure The manual platform lowering cable is attached to the barrel end of the lift cylinder and is activated next to the ground controls How to Adjust the Manual Platform Lowering Cable 1 Raise the platform 7 to 8 feet 2 1 to 2 4 m 2 Liftthe safety arm move it to the center of the Scissor arm and rotate down to a vertical position 3 Lower the platform onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 4 Pull the handle of the manual platform lowering cable out until considerable resistance is felt Release the handle 5 Measure the distance between the base of the handle and cable mounting nut Result The measurement should be no greater than 1 8 inch 3 mm Platform manual lowering cable specification Gap lowering handle to mounting nut 0 to 1 8 inch 0to3mm Genie Part No 96316 GS 30 GS 32 GS 46 Ground Controls Skip to step 8 if the measurement is correct 6 To adjust loosen the upper lock nut on the cable mounting bracket at the cylinder Turn the lower lock nut clockwise to decrease the distance or counterclockwise to increase the distance Tighten the upper lock nut a Z manual lowering cable sheath upper lock nut cable mounting bracket lower lock nut cable mounting nut end of the loweri
172. m to approximately 8 feet 2 4 m O Result The diagnostic display shows code LL an alarm sounds and the machine stops lifting after the pothole guards are deployed The machine is functioning correctly Result The diagnostic display does not show code LL the alarm does not sound and the machine will continue to lift the platform after the pothole guards are deployed Adjust or replace the pothole limit switch 29 Press the drive function select button Standing on the up hill side of the machine attempt to steer and drive the machine O Result The diagnostic display shows code LL an alarm sounds and the machine will not steer or drive The machine is functioning correctly Result The diagnostic display does not show code LL the alarm does not sound and the steer and drive functions operate Adjust or replace the pothole limit switch 30 Lower the platform to the stowed position Move the machine onto a firm level surface 31 Place a wooden block approximately 2 inches 5 cm tall under the right pothole guard Genie GS 30 GS 32 GS 46 REV F 32 Press the lift function select button Attempt to raise the platform approximately 8 feet 2 4 m Result The pothole guard contacts the block and does not fully deploy the diagnostic display shows code 18 an alarm sounds and the platform will lift to 8 feet 2 4 m or beyond The machine is functioning correctly Result The pothole guard co
173. maged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Use only Genie approved replacement parts Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection Unless otherwise specified perform each maintenance procedure with the machine in the following configuration Machine parked on a firm level surface Platform in the stowed position Key switch in the off position with the key removed The red Emergency Stop button in the off position at both ground and platform controls Wheels chocked All external AC power supply disconnected from the machine Part No 96316 Genie GS 30 GS 32 GS 46 1 About This Section This section contains detailed procedures for each scheduled maintenance inspection Each procedure includes a description safety warnings and step by step instructions Symbols Legend Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates an imminently hazardous situation which if not avoided will result in death or serious injury ADANGER AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous ACAUTION situation which if not avoide
174. mber 1 inner arm index 10 approximately 2 feet 60 cm and install the safety arm between the number 1 inner arm index 10 and the number 1 outer arm index 22 at the non steer end of the machine Lower the scissor arms onto the safety arm Bodily injury hazard Keep hands ACAUTION clear of moving parts when lowering the scissor arms onto the safety arm 48 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 3ft 1m Part No 96316 October 2008 Section 4 Repair Procedures REV 49 Tag disconnect and plug the hydraulic hoses on the lift cylinder Cap the fittings on the cylinder AWARNING ew injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 50 Tag and disconnect the wires and manual lowering cable from the solenoid valve on the cylinder 51 Models with platform overload option Tag and disconnect the wire harness from the platform overload switch 52 Raise the lift cylinder to a vertical position 53 Remove the pin retaining fasteners from the lift cylinder barrel end pin index 21 Use a soft metal drift to remove the pin Remove the lift cylinder from the machine AWARNING Crushing hazard The lift cylinder may become unbalanced and fall when it is removed
175. mes 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 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 3 Press the lift function select button 9 o gt lift function select button BN9 b drive function select button BN8 REV Press and hold the function enable switch on the joystick Raise the platform approximately 4 feet 1 2 m from the ground Press the drive function select button 7 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line Continue at full speed and note the time when your reference point on the machine passes over the finish line Refer to Section 2 Specifications Genie 3 18 GS 30
176. move the pin Component damage hazard Cables can be damaged if they 11 Remove the retaining fasteners from the are kinked or pinched number 3 pivot pin index 12 at the non steer end Genie Part No 96316 GS 30 GS 32 GS 46 4 33 Section 4 Repair Procedures October 2008 SCISSOR COMPONENTS 12 Use a soft metal drift to remove the number 3 pivot pin index 12 from the non steer end of the machine Remove the number 3 outer arm at the ground control side index 11 from the machine Crushing hazard The number 3 ACAUTION outer arm at the ground control side index 11 may become unbalanced and fall if not properly supported when removed from the machine 13 Attach a lifting strap from an overhead crane to the number 3 outer arm at the battery side index 11 14 Remove the retaining fasteners from the number 3 center pivot pin index 2 at the battery side 15 Place a rod through the number 3 center pivot pin at the battery side index 42 and twist to remove the pin 16 Remove the number 3 outer arm index 11 from the machine Crushing hazard The number 3 ACAUTION outer arm index 11 may become unbalanced and fall if not properly supported when removed from the machine 17 Attach a lifting strap from an overhead crane to the lug of the rod end of the lift cylinder 18 Remove the retaining fasteners from the lift cylinder rod end pivot pin index 3 19 Use a soft metal drift t
177. n Note While removing the pin retaining fasteners take note of the quantity and location of the spacers when removing the pivot pin 3 Remove the pin retaining fasteners from the barrel end pivot pin Remove the pin Note While removing the pin retaining fasteners take note of the quantity and location of the spacers when removing the pin 4 Remove the steer cylinder from the machine 5 Tag disconnect and plug the hydraulic hoses from the steer cylinder Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Component damage hazard Drive motor mounting fasteners dry 75 ft lbs Hoses can be damaged if they are 101 7 Nm kinked or pinched Drive motor mounting fasteners lubricated 56 ft lbs 76 3 Nm Genie Part No 96316 GS 30 GS 32 GS 46 Section 4 Repair Procedures June 2009 STEER AXLE COMPONENTS 8 3 Steer Bellcrank How to Remove the Steer Bellcrank 1 Remove the steer cylinder See 8 2 How to Remove the Steer Cylinder 2 Remove the retaining fasteners from the steer links at each end of the bellcrank Note While removing the retaining fasteners take note of the quantity and location of the spacers between the bellcrank and the steer links 3 Center a lifting jack under the drive chassis at t
178. ng cable from the valve Note During assembly the manual platform lowering cable needs to be properly adjusted See 4 1 How to Adjust the Manual Platform Lowering Cable 7 Remove the fasteners securing the manual lowering cable mount bracket to the cylinder Remove the bracket from the cylinder 8 Tag disconnect and plug the hydraulic hoses on the lift cylinder Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Part No 96316 October 2008 Section 4 Repair Procedures SCISSOR COMPONENTS 9 Attach a lifting strap from an overhead crane to GS 2032 GS 2632 GS 2046 and GS 2646 the rod end of the lift cylinder for support 1 Raise the platform 7 to 8 feet 2 1 to 2 4 m 10 Remove the retaining fasteners from the lift cylinder rod end pivot pin Use a soft metal drift 2 Lift the safety arm move it to the center of the to remove the pin Scissor arm and rotate down to a vertical position Crushing hazard The lift cylinder AWARNING will fall if not properly supported 3 Lower the platform onto the safety arm 11 Lower the cylinder onto the number 2 inner arm AWARNING Crushing hazard Keep hands clear of the safety arm when 12 Attach a lifting strap from an overhead crane or lowering the platform simi
179. ng cable manual lowering valve hydraulic schematic item N 7 Repeatthis procedure beginning with step 4 8 Raise the platform and rotate the safety arm to the stowed position 9 Pull the manual lowering handle at the ground controls 2 to 3 times to ensure it is functioning correctly Section 4 Repair Procedures October 2008 GROUND CONTROLS 4 2 Control Relays Relays used for single function switching are single pole double throw SPDT relays How to Test a Single Pole Double Throw Relay AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Label and then disconnect all the wiring from the relay to be tested 2 Connectthe leads from an ohmmeter or continuity tester to each terminal combination and check for continuity Terminals 85 and 86 REV B 3 Connect 24V DC and a ground wire to terminals 85 and 86 then test the following terminal combinations Test Desired result terminal 87a to 87 and 30 no continuity infinite terminal 87 to 30 continuity zero Relay schematic deactivated represent the coil and should not be tested in 5 any other combination Test Desired result 85 mr Bra terminal 85 to 86 with resistor 310 to 3300 terminal 87 to 87a and 30 no continuity infinite 0 termina
180. nie GS 30 GS 32 GS 46 Part No 96316 September 2005 Section 6 Schematics Hydraulic Schematic REVA GS 2046 2646 3246 from serial number GS4604 60879 to GS4605 75437 STEER STEER LEFT RIGHT LEFT RIGHT LEFT RIGHT BRAKE NEN BRAKE DRIVE DRIVE MOTOR BRAKE OI 1 P MANUAL i ly 1 03 CU IN I PN 16 9 cc BRAKE PUMP RELEASE 4 MANIFOLD EL LI LL eh wl B1 1 2 M1 M4 AD ho AC lt E LO mn 1500 psi MI Tee AF ve Inl WM vs LA i AH az 130 psi 1 Leones 9 bar FUNCTION MANIFOLD ABBREVIATION LEGEND Item Description AA Test port AB Relief valve system AC Steer left right AD Check valve steer circuit AE Drive speed AF Relief valve brake release AG Drive forward reverse AH Flow regulator relief valve Platform up AJ Relief valve lift J Shuttle valve brake release K Check valve manual brake release L Hand pump manual brake release M Needle valve manual brake release N Platform lowering valve Orif
181. ns shall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual Genie A TEREX BRAND Genie UK The Maltings Wharf Road Grantham Lincolnshire Redmond WA 98073 9730 NG31 6BH England 425 881 1800 44 1476 584333 Copyright 2002 by Genie Industries Genie is a registered trademark of Genie Industries Rev B Genie Industries USA 18340 NE 76th Street PO Box 97030 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 completed no unable to complete repaired Comments Pre Delivery Preparation Y N R Pre operation inspection completed Maintenance items completed Function tests completed Model Serial number Date Machine owner Inspected by print Inspector signature Inspector title Inspector company Section Scheduled Maintenance Procedures October 2008 This page intentionally left blank Genie 3 4 GS 30 GS 32
182. nt damage hazard Be careful not to damage the valve or fittings on the cylinder while removing it from the machine Torque specification Solenoid valve 2 position 2 way N C 20 ft lbs to remove the pin schematic item N 27 Nm AWARNING Crushing hazard The lift cylinder Coil nut 5 ft lbs will fall if not properly supported 7Nm 11 Lower the cylinder onto the number 1 inner arm cylinder plate Bodily injury hazard Keep hands ACAUTION clear of moving parts when lowering the cylinder Genie GS 30 GS 32 GS 46 Part No 96316 October 2008 Section 4 Repair Procedures REV GS 3246 1 Raise the platform 7 to 8 feet 2 1 to 2 4 m 2 Liftthe safety arm move it to the center of the Scissor arm and rotate down to a vertical position 3 Lower the platform onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 4 Tag and disconnect the wiring from the solenoid valve coil at the barrel end of the lift cylinder Skip to step 9 if removing the upper cylinder g Lower Lift Cylinder lift cylinder orifice fitting schematic item O connector fitting hydraulic hose manual lowering cable solenoid valve schematic item N cable mount bracket Note At the lower lift cylinder install the orifice fitting with the small opening of the orifice fitting closest to the supply hose Part No 96316
183. ntacts the block and does not fully deploy the diagnostic display does not show code 18 the alarm does not sound and the machine will continue to lift the platform after the pothole guards are deployed Adjust or replace the pothole limit switch 33 Press the drive function select button Attempt to steer or drive the machine O Result The diagnostic display shows code 18 an alarm sounds and the machine will not steer or drive The machine is functioning correctly Result The diagnostic display does not show code 18 the alarm does not sound and the steer and drive functions operate Adjust or replace the down limit switch 34 Lower the platform to the stowed position and remove the block under the right pothole guard 35 Repeat this procedure beginning with step 31 for the left pothole guard 36 Lower the platform to the stowed position remove the block under the left pothole guard and turn off the machine Part No 96316 June 2009 Section Scheduled Maintenance Procedures REV CHECKLIST B PROCEDURES B 15 Test the Up Limit Switch 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 Perform these procedur
184. o remove the lift cylinder rod end pivot pin index 3 from the machine Crushing hazard The lift cylinder ACAUTION Will fall if not properly supported when the pivot pin is removed 20 Place a 2 x 4 x 10 inch 10 x 10 x 25 cm block onto the number 1 inner arm cylinder plate index 8 4 34 Genie GS 30 GS 32 GS 46 REV C 21 Lower the cylinder onto the block Bodily injury hazard Keep hands ACAUTION clear of moving parts when lowering the cylinder onto the block 22 Attach a lifting strap from an overhead crane to the number 3 inner arm index 10 Raise the arm to a vertical position 23 Remove the retaining fasteners from the number 3 pivot pin at the steer end of the machine index 4 24 Use a soft metal drift to remove the number 3 pivot pin index 4 from the steer end of the machine Remove the number 3 inner arm index 10 from the machine Crushing hazard The number 3 ACAUTION inner arm index 10 may become unbalanced and fall if not properly supported when the pivot pin is removed 25 Remove the cables from the number 2A and 2B cable bridge and lay them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched 26 Disconnect the number 2A and 2B cable bridges from the scissor linkset and remove both cable bridges from the machine 27 Attach a lifting strap from an overhead crane to the number 2 outer arm at the ground control side ind
185. on to the off position at the platform controls 4 Atthe platform controls press and hold the lift function select and speed select buttons and pull out the red Emergency Stop button to the on position Result The diagnostic display at the platform controls and the ECM will show SC REV D e Z w e a lift function select button BN9 b diagnostic display red Emergency Stop button P2 drive function select button BN8 Release the lift function select and speed select buttons Result The diagnostic display will show the current configuration Push in the red Emergency Stop button to the off position at both the ground and platform controls and turn the key switch to the off position Machine Option Definitions Motion Alarm The motion alarm will sound when operating any function Lift Drive Cut Out In addition to an alarm sounding lift and drive functions are disabled when the platform is raised above the down limit switch and the incline of the chassis exceeds the rating on the serial plate Configured on all machines Platform Overload When the platform overload limit switch is tripped signaling an overload condition in the platform all machine functions are disabled The additional weight must be removed from the platform and the power cycled from off to on before any function can be resumed Required for CE models Descen
186. ons Down Limit Switch 1 Remove the platform controls from the platform 2 Raise the platform 7 to 8 feet 2 1 to 2 4 m 3 Liftthe safety arm move it to the center of the Scissor arm and rotate down to a vertical position 4 Lower the platform onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 5 Turn the key switch to the off position 6 Tagand disconnect the platform control box at the platform Genie GS 30 GS 32 GS 46 REV F 7 GS 1530 32 and GS 1930 32 Follow the platform control cable down the scissor stack to the alarm bracket on the chassis deck Tag and disconnect the platform control cable from the ECM cable at the 6 pin Deutsch connector GS 2032 GS 2632 GS 3232 GS 2046 GS 2646 and GS 3246 Follow the platform control cable down the scissor stack to the underside of the chassis deck Tag and disconnect the platform cable from the ECM cable at the 6 pin Deutsch connector under the chassis deck 8 Securely install the platform control box harness plug into the 6 pin Deutsch connector of the ECM cable 9 Disable the down limit switch Loosen the fastener securing the roller arm to the limit switch and rotate the roller arm 90 degrees in a downwards direction Do not activate the switch contacts 10 Turn the key switch to platform control 11 Raise the platform and return the safety arm to the stowed position 12 Working at
187. ontrols 2 Push down the horn button at the platform controls Result The horn should sound Section Scheduled Maintenance Procedures June 2009 CHECKLIST B PROCEDURES B 7 Test the Drive Brakes Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Proper brake action is essential to safe machine operation The drive brake function should operate smoothly free of hesitation jerking and unusual noise Hydraulically released individual wheel brakes can appear to operate normally when not fully operational Perform this procedure with the machine on a firm level surface that is free of obstructions with the platform extension deck fully retracted and the platform in the stowed position 1 Mark a test line on the ground for reference 2 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls Lower the platform to the stowed position Press the drive function select button Genie Illustration 1 a drive function select button BN8 5 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the test line Genie GS 30 GS 32 GS 46 REV F 6 Bring the machine to top drive speed before reaching the test line Release the function enable switch or the joystick when your reference point on t
188. or GS 1530 GS 1532 GS 1930 and GS 1932 all models proceed to step 11 For GS 2032 and GS 2632 before serial number GS3204 51608 proceed to step 11 For GS 2046 GS 2646 and GS 3246 before serial number GS4604 60000 proceed to step 11 For GS 2032 and GS 2632 after serial number GS3204 51607 proceed to step 21 For GS 2046 GS 2646 and GS 3246 after serial number GS4604 59999 proceed to step 21 11 Remove the drive forward reverse valve from the function manifold Cap the open port of the manifold Part No 96316 Genie GS 30 GS 32 GS 46 CHECKLIST B PROCEDURES 12 Carefully inspect the hex portion of the valve for an identification stamp Result SV10 4727 is stamped on the hex portion of the drive forward reverse valve This indicates the machine is equipped with a dynamic brake valve Proceed to step 13 Result SV10 4727 is not stamped on the hex portion of the drive forward reverse valve This indicates the machine is not equipped with a dynamic brake valve Proceed to step 18 13 Install the drive forward reverse valve removed in step 11 into the function manifold and securely tighten Torque to 25 ft lbs 34 Nm 14 In order install the reverse valve coil with white black and brown wires spacer washer and the forward valve coil with white and brown wires onto the valve Note For the machine to function correctly the reverse valve coil must be closest to the manifold 15 Instal
189. output A6 Platform up coil Y8 output 7 Drive reverse coil Y5 output A8 Motor controller U6 terminal 1 A9 Motor controller U6 terminal 3 A10 Overload sensor PS2 input A11 Key switch to platform control input A12 Platform down TS66 input B1 Platform data link high input Blue wire at platform controls B2 Plug B3 ECM ground output B4 Plug B5 Plu B6 Platform down coil Y7 output B7 Steer left coil Y4 output B8 Automotive style horn H2 option output B9 Multi function alarm H5 output B10 Pothole limit switch input B11 Drive enable power up limit switch input B12 Platform up TS66 input C1 Platform data link low input Orange wire at platform controls C2 Power to ECM input C3 Plug C4 Plug C5 Not used 6 Drive forward coil Y6 output C7 Steer right coil Y3 output C8 Parallel coil Y 1 not available on GS 1530 32 and GS 1930 32 C9 Work light L30 option C10 Not used C11 Level sensor signal S7 input C12 Down limit switch 1866 input Genie Part No 96316 GS 30 GS 32 GS 46 Section 6 Schematics June 2009 Wiring Diagram Ground Controls and Level Sensor Harness REV B
190. ove the cable bridge from the machine Remove the retaining fasteners from the number 5 pivot pin index 1 GS 30 GS 32 GS 46 4 39 Section 4 Repair Procedures October 2008 SCISSOR COMPONENTS 7 Use a soft metal drift to remove the number 5 pivot pin index 1 Remove the platform mount bracket from the machine 8 Attach a lifting strap from an overhead crane to the number 4 outer arm at the ground control side index 13 9 Remove the retaining fasteners from the number 4 center pivot pin index 2 at the ground control side 10 Place a rod through the number 4 center pivot pin at the ground control side index 2 and twist to remove the pin 11 Remove the retaining fasteners from the number 4 pivot pin index 15 at the non steer end 12 Use a soft metal drift to remove the number 4 pivot pin index 14 from the non steer end of the machine Remove the number 4 outer arm at the ground control side index 13 from the machine Crushing hazard The number 4 ACAUTION outer arm at the ground control side index 13 may become unbalanced and fall if not properly supported when removed from the machine 13 Attach a lifting strap from an overhead crane to the number 4 outer arm at the battery side index 13 14 Remove the retaining fasteners from the number 4 center pivot pin index 2 at the battery side Genie GS 30 GS 32 GS 46 REV C 15 Place a rod through the number 4
191. performed by a trained service professional Attempting this procedure without the necessary skills will result in death or serious injury Pull out the red Emergency Stop button to the on position at the ground controls 2 Pushin red Emergency Stop button to the off position at the platform controls Turn the key switch to platform control 4 Atthe platform controls press and hold the lift function select and horn buttons and pull out the red Emergency Stop button to the on position Result The diagnostic display will show PS 5 Release the lift function select and horn buttons Result The diagnostic display will show the maximum lift speed percentage 6 Press and hold the horn button Result The diagnostic display will show the raised drive speed percentage Genie PLATFORM CONTROLS Gen 4 platform controller a function enable switch SW5 b joystick controller JC1 with thumb steering rocker SW6 horn button BN5 machine on incline turtle button BN6 lift function select button BN9 drive function select BN8 red Emergency Stop button P2 yellow arrow platform controls diagnostic display UU OOo Gen 5 platform controller 7 Usethe steering thumb rocker switch on the joystick to increase or decrease the maximum lift speed percentage Refer to Section 2 Specifications for function speeds 8 Turn the key switch to the off
192. pivot pin index 6 at the steer end of the machine 29 Use a soft metal drift to remove the number 2 pivot pin index 46 Remove the number 2 inner arm index 13 from the machine Bodily injury hazard The number ACAUTION 2 inner arm may become unbalanced and fall if not properly supported when removed from the machine 30 Remove the safety arm from the number 2 inner arm index 13 that was just removed 31 Attach a lifting strap from an overhead crane to the number 1 inner arm index 8 32 Raise the number 1 inner arm index 8 approximately 2 feet 60 cm and install the safety arm between the number 1 inner arm index 8 and the number 1 outer arm index 17 Lower the scissor arms onto the safety arm Bodily injury hazard Keep hands ACAUTION clear of moving parts when lowering the scissor arms onto the safety arm Part No 96316 Genie GS 30 GS 32 GS 46 SCISSOR COMPONENTS 33 Attach a lifting strap from an overhead crane to the lug on the rod end of the lift cylinder index 3 Raise the lift cylinder approximately 3 ft 1m 34 Tag disconnect and plug the hydraulic hoses on the lift cylinder Cap the fittings on the cylinder AWARNING aan injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 35 Tag and disconnect the wires and manual lowerin
193. pivot pins index 11 61 Remove the number 1 cable bridge from the machine Section 4 Repair Procedures October 2008 62 Use a soft metal drift to remove the number 1 center pivot pins index 9 Bodily injury hazard The number ACAUTION 1 outer arm may become unbalanced and fall if not properly supported when the pin is removed 63 Slide the number 1 outer arm index 22 to the non steer end and remove it from the machine Bodily injury hazard The number ACAUTION 1 outer arm may become unbalanced and fall if not properly supported when removed from the machine 64 Attach the strap from an overhead crane to the number 1 inner arm index 10 Do not lift it 65 Remove the upper fasteners securing the number 1 inner arm pivot bracket to the end of the chassis Loosen the lower fasteners 66 Remove the number 1 inner arm index 10 from the machine Bodily injury hazard The number ACAUTION 1 inner arm may become unbalanced and fall if not properly supported when removed from the machine Component damage hazard Be sure not to damage the limit switch or level sensor box components when the number 1 inner arm is removed from the machine Genie GS 30 GS 32 GS 46 REV C How to Replace the Scissor Arm Wear Pads 1 Remove the platform See 2 1 How to Remove the Platform 2 Support and secure the entry ladder to an appropriate lifting device 3 Remove the fasteners from the en
194. platform extension railings to the carriage on the forklift to help support the platform extension Remove the two retaining fasteners from each platform extension roller bracket assembly Remove each assembly from the machine Note Do not remove the platform roller bolt 2 2 roller bracket assembly b assembly retaining fastener c platform roller bolt Part No 96316 Section 4 Repair Procedures PLATFORM COMPONENTS 7 Remove the platform roller wheels from the machine 8 Carefully slide the platform extension out from the platform and place it on a structure capable of supporting it How to Replace the Platform Extension Wear Pads 1 3 Remove the Platform Extension See 2 2 How to Hemove the Platform Extension Drill out the rivets which hold the wear pads in place Install the new wear pads using new rivets Note When installing new rivets make sure the rivet heads are not above the surface of the wear pad Genie GS 30 GS 32 GS 46 Section 4 Repair Procedures October 2008 Scissor Components REV C O 9 GS 1530 m GS 1532 Steer End Non steer End 1 Number 4 pivot pin 10 Number 3 inner arm 2 Number 3 outer arm 11 Number 3 outer arm 3 Number 3 center pivot pin 2 pins 12 Number 3 pivot pin non stee
195. r Pressure switch platform overload HS0035D S Check valve drive circuit Genie Part No 96316 GS 30 GS 32 GS 46 6 43 Section 6 Schematics September 2005 Hydraulic Schematic GS 1530 1532 1930 1932 REVA from serial number GS3004 66987 to GS3005 75999 1 PLATFORM overtoan CEMODELS ps2 dl Y7 Sac d MN lt N 5 y 65 1930 0 037 0 84 mm 0 037 0 94 e Ii e Q The lift cylinder orifice is located underneath the fitting on the lift cylinder LIFT V FUNCTION MANIFOLD er DO EC 1 nee Y8 1 1800 to 3500 psi M i 124 to 241 bar E E nd x 8800 psi maximum eee 241 bar maximum PRESSURE TANK us 225 mS C D D AL 25psi 1 7 bar POWER BYPASS UNIT d T RE 12 HS0035E Genie GS 30 GS 32 GS 46 Part No 96316 September 2005 Section 6 Schematics Hydraulic Schematic
196. r end 4 Lift cylinder rod end pivot pin 13 Number 2 inner arm 5 Number 3 pivot pin steer end 14 Number 2 outer arm 6 Number 2 center pivot pin 2 pins 15 Number 2 pivot pin non steer end 7 Number 2 pivot pin steer end 16 Lift cylinder barrel end pivot pin 8 Number 1 center pivot pin 2 pins 17 Number 1 outer arm 9 Number 1 pivot pin Genie 4 18 GS 30 GS 32 GS 46 Part No 96316 October 2008 Section 4 Repair Procedures REV C SCISSOR COMPONENTS 3 1 Scissor Assembly GS 1530 and GS 1532 How to Disassemble the Scissor Assembly GS 1530 and GS 1532 AWARNING Podily injury hazard The procedures in this section require specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is required Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform See 2 1 How to Remove the Platform 2 Remove the cables from the number 3 outer arm index 11 at the ground controls side Component damage hazard Cables can be damaged if they are kinked or pinched 3 Remove the cables from the number 3 cable bridge and lay them off to the side Component damage hazard
197. raulic cylinder Relief valve Nol 7 Solenoid operated 2 position 2 way directional valve normally closed 4 Orifice WP PS2 Platform overload pressure switch Function manifold GS 1530 GS 1532 GS 1930 and GS 1932 Variable speed motor Fixed displacement pump 3 Bi directional motor Priority flow regulator lt gt Filter Part No 96316 Component Reference and Hydraulic Symbols Legend T Brake Toa Shuttle valve Solenoid operated 2 position 4 way directional valve Accumulator Check valve Ly Pilot operated check valve with needle valve LA LA fe Solenoid operated 3 position 4 way directional valve Solenoid operated 3 position 4 way directional valve i Lip ne Solenoid operated 3 position 5 way directional valve Function manifold GS 2032 GS 2632 GS 2046 GS 2646 and GS 3246 Genie GS 30 GS 32 GS 46 Section 6 Schematics September 2005 Hydraulic Schematic GS 1530 1532 1930 1932 REVA from serial number GS3003 60000 to GS3004 65104 1 OVERLOAD CE MODELS PS2 re
198. rm control box to the position shown to correctly identify the configuration of the DIP switch settings 4 Locate the DIP switch on the circuit board Move the DIP switch settings to correspond with the configuration of the machine options DIP Switch Legend indicated in the DIP Switch Code Chart 5 Close the lid and install the fasteners 6 Confirm the settings See 1 3 How to Determine the DIP Switch Configuration 7 Pushin red Emergency Stop button to the off position at both the ground and platform controls and turn the key switch to the off position Note Any change in DIP settings will not take effect until the key switch is turned to the off position a OFF for GS 1530 1532 1930 1932 ON for GS 2032 2632 2046 2646 3246 motion beacon motion alarm lift drive cut out platform overload descent delay battery drain alarm OFF for all models p 0 Genie 4 10 GS 30 GS 32 GS 46 Part No 96316 June 2009 Section 4 Repair Procedures REV D DIP Switch Code Chart A mark in the column indicates that the machine configuration includes this option DIP Switch Code Diagnostic Display Code OFF for 1530 1532 1930 amp 1932 models Lift Drive Cut Out Overload Cut Out Battery Drain Alarm OFF for all models Motion Beacon Motion Al
199. roceed to step 8 8 Perform an equalizing charge OR fully charge the batteries and allow the batteries to rest at least 6 hours 9 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results 10 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows Add 0 004 to the reading of each cell for every 10 5 5 C above 80 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 C O Result All battery cells display a specific gravity of 1 277 or greater The battery is fully charged 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 less than 1 177 Replace the battery Section Scheduled Maintenance Procedures June 2009 CHECKLIST B PROCEDURES 11 Check the battery acid level If needed replenish with distilled water to 1 inch 3 mm below the bottom of the battery fill tube Do not overfill 12 Install the vent caps and neutralize any electrolyte that may have spilled U9 Battery Charger a b 9 batteries B5 275A fuse F6 quick disconnect QD1 battery charger U9 Genie GS 30 GS 32 GS 46 REV F All models 13 Check each battery pack and verify that the batteries are wired correctly 14 Inspect the battery charg
200. rom the non steer end of the machine Remove the number 4 outer arm at the ground control side index 20 from the machine Crushing hazard The number 4 ACAUTION outer arm at the ground control side index 20 may become unbalanced and fall if not properly supported when removed from the machine 33 Attach a lifting strap from an overhead crane to the number 4 outer arm at the battery side index 20 34 Remove the retaining fasteners from the number 4 center pivot pin index 5 at the battery side 35 Place a rod through the number 4 center pivot pin at the battery side index 5 and twist to remove the pin Part No 96316 Genie GS 30 GS 32 GS 46 SCISSOR COMPONENTS 36 Remove the number 4 outer arm index 20 from the machine Crushing hazard The number 4 ACAUTION outer arm index 20 may become unbalanced and fall if not properly supported when removed from the machine 37 Attach a lifting strap from an overhead crane to the number 4 inner arm index 19 Raise the arm to a vertical position 38 Remove the retaining fasteners from the number 4 pivot pin at the steer end of the machine index 6 39 Use a soft metal drift to remove the number 4 pivot pin index 6 from the steer end of the machine Remove the number 4 inner arm index 19 from the machine Crushing hazard The number 4 ACAUTION inner arm index 19 may become unbalanced and fall if not properly supported when remov
201. rs Do not over tighten Component damage hazard Be careful not to damage the level sensor or limit switch while moving the scissor assembly Genie Part No 96316 GS 30 GS 32 GS 46 4 31 Section 4 Repair Procedures October 2008 SCISSOR COMPONENTS REV C 5 amp 9 105 2032 1108 2046 Steer end ke Non steer end 1 Number 4 pivot pin 10 Number 3 inner arm 2 Number 3 outer arm 11 Number 3 outer arm 3 Number 3 center pivot pin 2 pins 12 Number 3 pivot pin non steer end 4 Lift cylinder rod end pivot pin 13 Number 2 inner arm 5 Number 3 pivot pin steer end 14 Number 2 outer arm 6 Number 2 center pivot pin 2 pins 15 Number 2 pivot pin non steer end 7 Number 2 pivot pin steer end 16 Lift cylinder barrel end pivot pin 8 Number 1 center pivot pin 2 pins 17 Number 1 outer arm 9 Number 1 pivot pin Genie 4 32 GS 30 GS 32 GS 46 Part No 96316 October 2008 Section 4 Repair Procedures REV SCISSOR COMPONENTS 3 3 Scissor Assembly GS 2032 and GS 2046 How to Disassemble the Scissor Assembly GS 2032 and GS 2046 AWARNING P Cdily injury hazard The procedures in this section require specific repair skills lifting equipment and a suitable GS 2032 workshop Attempting this GS 2046 procedure without these skills and tools could result in death
202. rs or quarterly whichever comes first A properly functioning Emergency Stop is essential for safe machine operation An improperly operating red Emergency Stop button will fail to shut off power and stop all machine functions resulting in a hazardous situation Note As a safety feature selecting and operating the ground controls will override the platform controls except the platform red Emergency Stop button 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Pushin red Emergency Stop button at the ground controls to the off position Result No machine functions should operate 3 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 4 Push down the red Emergency Stop button at the platform controls to the off position Result No machine functions should operate Note The red Emergency Stop button at the ground controls will stop all machine operation even if the key switch is switched to platform control Part No 96316 June 2009 Section Scheduled Maintenance Procedures REV B 5 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
203. rt describe malfunctions and can aid in Return to Perform troubleshooting the machine by pinpointing the service problem repair area or component affected solved Genie 5 2 GS 30 GS 32 GS 46 Part No 96316 September 2005 Section 5 Fault Codes Fault Code Chart Fault Code Problem Possible Causes Solution 01 Internal ECM error EPROM not programmed Replace ECM 02 03 12 18 19 ECM Platform communication error Undefined platform DIP switch settings Chassis up down toggle closed at start up Pothole guard failure Limit switch failure Malfunctioning control cable OR malfunctioning platform controls DIP switch settings incorrect Malfunctioning up down switch Malfunctioning pothole switch OR obstruction in pothole guard linkage Malfunctioning limit switch OR wire disconnected from limit switch Troubleshoot control cable OR troubleshoot platform controls Correct DIP switch settings Troubleshoot up down switch Troubleshoot pothole switch OR remove obstruction Troubleshoot limit switch OR inspect wire connection 42 43 46 Platform left turn switch fault Platform right turn switch fault Platform drive enable switch fault Malfunctioning steer left microswitch Malfunctioning steer right microswitch Malfunctioning drive enable switch Troubleshoot steer left microswitch Troubleshoot steer right microswitch Troubleshoot drive en
204. rt No 96316 October 2008 Section 4 Repair Procedures REV 50 Attach a lifting strap from an overhead crane to the number 2 inner arm index 18 Raise the arm to a vertical position 51 Remove the retaining fasteners from the number 2 pivot pin at the steer end of the machine index 8 52 Use a soft metal drift to remove the number 2 pivot pin index 8 from the steer end of the machine Remove the number 2 inner arm index 18 from the machine Crushing hazard The number 2 ACAUTION inner arm index 18 may become unbalanced and fall if not properly supported when the pivot pin is removed 53 Attach a lifting strap from an overhead crane to the number 1 inner arm index 10 54 Raise the number 1 inner arm index 10 approximately 2 feet 60 cm 55 Place 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 56 Lower the scissor arms onto the block that was placed across the chassis Bodily injury hazard Keep hands ACAUTION clear of moving parts when lowering the scissor arms 57 Attach a lifting strap from an overhead crane to the lug of the rod end of the lower lift cylinder Part No 96316 Genie GS 30 GS 32 GS 46 SCISSOR COMPONENTS 58 Tag disconnect and plug the hydraulic hose on the lower lift cylinder Cap the fittings on the cylinder AWARNING injury hazard Spraying ydraulic oil c
205. sary skills will result in death or serious injury Note Select a test area that is firm level and free 4 x of obstructions 5 How to Determine the Software Revision Level 1 Remove the platform controls from the platform 2 Place the platform controls close to the diagnostic display on the power unit side of the machine 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 6 controls Genie GS 30 GS 32 GS 46 REV D Press the lift function select button sp Genie t eo m m Gen 4 platform controller yellow arrow joystick controller JC1 lift function select button BN9 red Emergency Stop button P2 platform controls diagnostic display O o O Gen 5 platform controller Slowly move the joystick in the direction indicated by the yellow arrow Result The software revision level will appear in the diagnostic display Result If the software revision level does not appear in the diagnostic display turn the key switch to ground control and move the platform lift switch in the down direction The software revision level will appear in the diagnostic display 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 Part No 96316 June 200
206. sonnel of a procedure or hazard and could result in unsafe operating conditions 1 Checkto make sure that the operator s and safety manuals are present and complete in the storage container on the platform 2 Examine the pages of each manual to be sure that they are legible and in good condition Result The operator s manual is appropriate for the machine and all manuals are legible and in good condition Result The operator s manual is not appropriate for the machine or all manuals are not in good condition or is illegible Remove the machine from service until the manual is replaced Genie 3 6 GS 30 GS 32 GS 46 REV C 3 Open operator s manual 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 Industries if replacement manuals or decals are needed Part No 96316 October 2008 Section Scheduled Maintenance Procedures REV A 2 Perform Pre operation Inspection Completing a Pre operation Insp
207. ssis 1 inner and outer arms index 10 mount bracket will clear the level sensor and 22 may become unbalanced 9 Move the scissor assembly towards the and fall if not properly supported non steer end of the machine slightly and to when removed from the machine one side of the machine until one of the scissor Component damage hazard Be arm wear pads is accessible Do not allow both sure not to damage the limit switch wear pads to slide out of the drive chassis or level sensor box components Component damage hazard Be when the number 1 inner and careful not to damage the level outer arms index 10 and 22 is sensor or limit switch while moving removed from the machine the scissor assembly Genie 4 44 GS 30 GS 32 GS 46 Part No 96316 October 2008 Section 4 Repair Procedures SCISSOR COMPONENTS 10 Remove the old wear pad 11 Install the new wear pad 12 Rotate the scissor assembly towards the other side of the machine until the other scissor arm wear pad is accessible Do not allow both wear pads to slide out of the drive chassis ADANGER Crushing hazard The scissor assembly will fall if both wear pads are allowed to slide out of the drive chassis Component damage hazard Be careful not to damage the level sensor or limit switch while moving the scissor assembly 13 Remove the old wear pad 14 Install the new wear pad 15 Slide the scissor assembly back into the drive chassis 16 Lower the s
208. t 2 1 m All controls must be released for 4 to 6 seconds before descent is re enabled Required for CE models Battery Drain Alarm When the machine is turned on and no function is activated for 10 minutes the alarm will sound once every 3 seconds This option can be activated by moving DIP switch 7 to position 1 When this option is configured the flashing dot in the diagnostic display window will remain continuously illuminated when the lift mode is selected and activated Section 4 Repair Procedures June 2009 PLATFORM CONTROLS REV D How to Set the DIP Switch Codes 77777177 Tip over hazard Do not adjust the A DANGER DIP switch settings to other than what is specified in this procedure Exceeding specifications could cause the machine to tip over resulting in death or serious injury If replacing the circuit board note the toggle positions on the DIP switch Set the DIP switch on the new circuit board to the same configuration as the old board co 1 Pushin the red Emergency Stop button to the off position at the ground and platform controls Turn the key switch to the off position DIP switch SW25 platform controls circuit board U3 enlarged view of DIP switch SW25 joystick controller JC1 2 Remove the fasteners securing the top of the platform controls and open the platform control box 3 Rotate the platfo
209. t Delay This option halts descent for 4 to 6 seconds All controls must be released and re engaged before descent is re enabled Required for CE models Battery Drain Alarm When the machine is turned on and in the stowed position and no function is activated for 2 minutes an alarm will sound once every 3 seconds When this option is configured a dot in the diagnostic display window will remain continuously illuminated when the ECM is in the SC mode OR when the platform up function is activated Genie GS 30 GS 32 GS 46 Part No 96316 June 2009 Section 4 Repair Procedures REV D PLATFORM CONTROLS How to Change the Software Configuration t 1 Pull out the red Emergency Stop button to the ZY on position at the ground controls b QT idi 2 2 Pushin red Emergency Stop button to the off position the platform controls 3 Turn the key switch to platform control 4 Atthe platform controls press and hold the lift function select and speed select buttons and pull out the red Emergency Stop button to the on position w joystick controller JC1 with thumb steering rocker SW6 lift function select button BN9 diagnostic display red Emergency Stop button P2 drive function select button BN8 speed select button 6 Result The diagnostic display at the platform controls and the ECM will show SC 5 Release the lift function selec
210. t and speed select 8 Press the speed select button buttons O Result The ones digit setting will be activated O Result The diagnostic display will show the and the current ones setting will flash in the current configuration diagnostic display Use the steering thumb rocker switch on the joystick to increase or 6 Press the lift function select button decrease the value See 1 4 Machine O Result The tens digit setting will be activated Configuration Code Chart configuration and the current tens setting will flash in the settings diagnostic display Use the steering thumb 9 Press and hold the speed select button for a rocker switch on the joystick to increase or minimum of 3 seconds to set the ones value decrease the value See 1 4 Machine Configuration Code Charttor configuration 10 Turn the key switch to the off position settings Note Any change in software settings will not take 7 Press and hold the lift function select button for effect until the key switch is turned to the off a minimum of 3 seconds to set the tens value position Genie Part No 96316 GS 30 GS 32 GS 46 4 13 Section 4 Repair Procedures June 2009 PLATFORM CONTROLS Machine Configuration Code Chart A mark in the four right columns indicates that the machine configuration at left includes this option GS 1530 GS 1532 GS 1930 GS 1932 Motion Lift Drive Platform Descent Alarm Cut Out
211. t pin non steer end 13 Number 1 center pivot pin 2 pins 28 Lower lift cylinder barrel end pivot pin 14 Number 1 inner arm 29 Number 1 outer arm 15 Number 1 pivot pin steer end 2 pins Genie 4 46 GS 30 GS 32 GS 46 Part No 96316 October 2008 Section 4 Repair Procedures REV SCISSOR COMPONENTS 3 5 Scissor Assembly GS 3246 How to Disassemble the Scissor Assembly GS 3246 AWARNING Podily injury hazard The procedures in this section require specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is required Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be GS 3246 replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications Cablo bridge legend a cable bridge 5 1 Remove the platform See 2 1 How to Remove b Dinge 4 the Platform c cable bridge 4B d cable bridge 3A 2 Support and secure the entry ladder to an e cable bridge 3B appropriate lifting device f cable bridge 2A g cable bridge 2B 3 Remove the fasteners from the entry ladder and h cable bridge 1 5 Disconnect the number 5 cable bridge from the ACAUTION Crushing hazard The entry ladder number 5 outer arm index 17 and
212. tal regulations You have the appropriate tools lifting equipment and a suitable workshop Genie Part No 96316 GS 30 GS 32 GS 46 7 Section 1 Safety Rules September 2005 SAFETY RULES Personal Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority Read each procedure thoroughly This manual and the decals on the machine use signal words to identify the following Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death A DANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous situation which if not avoided may cause minor or moderate injury A CAUTION Workplace Safety Be sure to keep sparks flames and lighted tobacco away from flammable and combustible materials like battery gases and engine fuels Always have an approved fire extinguisher within easy reach are properly maintained and ready for use Keep work surfaces clean and free of debris that could get into machine components and cause damage NN Be sure that
213. ted when removed from the machine 36 Attach a lifting strap from an overhead crane to the number 2 inner arm index 13 Raise the arm to a vertical position Part No 96316 Genie GS 30 GS 32 GS 46 SCISSOR COMPONENTS 37 Remove the retaining fasteners from the number 2 pivot pin at the steer end of the machine index 6 38 Use a soft metal drift to remove the number 2 pivot pin index 6 from the steer end of the machine Remove the number 2 inner arm index 13 from the machine Crushing hazard The number 2 ACAUTION inner arm index 13 may become unbalanced and fall if not properly supported when the pivot pin is removed 39 Attach a lifting strap from an overhead crane to the number 1 inner arm index 8 40 Raise the number 1 inner arm index 8 approximately 2 feet 60 cm 41 Place a4 x 4 48 inch 10 cm x 10 cm x 1 2 m long block across both sides of the chassis under the number 1 center pivot pin index 7 42 Lower the scissor arms onto the block that was placed across the chassis Bodily injury hazard Keep hands ACAUTION clear of moving parts when lowering the scissor arms 43 Attach a lifting strap from an overhead crane to the lug of the rod end of the lower lift cylinder 44 Tag disconnect and plug the hydraulic hose on the lower lift cylinder Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen h
214. tform controls press and hold the lift to that of the raised drive speed Refer to Section function select and speed select buttons and 2 Specifications pull out the red Emergency Stop button to the on position Result The diagnostic display at the platform controls and the ECM will show SC 5 Release the lift function select and speed select buttons Result The diagnostic display will show the current configuration 6 Press the speed select button Result The ones digit setting will be activated and the current ones setting will flash in the diagnostic display 7 Press the horn button Result A dot located at the lower right of the diagnostic display window will become illuminated This indicates that the battery drain alarm option has been activated 8 Turn the key switch to the off position Note Any change in software settings will not take effect until the key switch is turned to the off position Note To deactivate the battery drain alarm option on a machine which has the option activated repeat this procedure When the ECM is in the SC mode and the option is deactivated there will not be an illuminated dot in the diagnostic display window OW the battery level is 22 6V DC or higher the battery level is 21 6 to 22 5V DC the battery level is 20 7 to 21 5V DC the battery level is 19 7 to 20 6V DC the battery level is 17 8 to 19 6V DC the battery level
215. th platform overload option Tag and disconnect the wire harness from the platform overload switch 85 Raise the lift cylinder to a vertical position 86 Remove the pin retaining fasteners from the lift cylinder barrel end pivot pin index 28 Use a soft metal drift to remove the pin Remove the lift cylinder from the machine Crushing hazard The lift cylinder ACAUTION Will fall if not properly supported when the pivot pin is removed Component damage hazard Be careful not to damage the valve or fittings on the cylinder while removing it from the machine 87 Remove the cables from the number 1 cable bridge and lay them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched 4 52 Genie GS 30 GS 32 GS 46 REV C 88 Disconnect the number 1 cable bridge from the number 1 outer arm index 29 and remove the cable bridge from the machine 89 Attach a lifting strap from an overhead crane to the number 1 inner arm index 14 90 Raise the arm slightly and remove the block 91 Lower the arm to the stowed position Bodily injury hazard Keep hands ACAUTION clear of moving parts when lowering the scissor arms 92 Secure the ends of the scissor arms together at the steer end of the machine with a strap or other suitable device 93 Secure the ends of the scissor arms together at the non steer end of the machine with a strap or other suitable device 94 Remove th
216. th the overhead crane until the chassis mount bracket will clear the level sensor 9 Move the scissor assembly towards the non steer end of the machine slightly and to one side of the machine until one of the scissor arm wear pads is accessible Do not allow both wear pads to slide out of the drive chassis Component damage hazard Be careful not to damage the level sensor or limit switch while moving the scissor assembly 10 Remove the old wear pad Part No 96316 Genie GS 30 GS 32 GS 46 SCISSOR COMPONENTS 11 Install the new wear pad 12 Rotate the scissor assembly towards the other side of the machine until the other scissor arm wear pad is accessible Do not allow both wear pads to slide out of the drive chassis 777127717 Crushing hazard The scissor A DANGER assembly will fall if both wear pads are allowed to slide out of the drive chassis Component damage hazard Be careful not to damage the level sensor or limit switch while moving the scissor assembly 13 Remove the old wear pad 14 Install the new wear pad 15 Slide the scissor assembly back into the drive chassis 16 Lower the scissor assembly into position and install the chassis mount bracket onto the chassis Securely install and tighten the fasteners Do not over tighten Component damage hazard Be careful not to damage the level sensor or limit switch while moving the scissor assembly Section 4 Repair Procedures Octo
217. the platform controls press the lift function select button Lower the platform to the stowed position Result The diagnostic display will show code 18 an alarm sounds and the lift function should operate The machine is functioning correctly Result The diagnostic display does not show code 18 the alarm does not sound and the lift function should not operate Replace the down limit switch Part No 96316 June 2009 Section e Scheduled Maintenance Procedures REV 13 Press the drive function select button Attempt to drive the machine Result The diagnostic display will show code 18 an alarm sounds and the steer and drive functions should not operate The machine is functioning correctly Result The diagnostic display does not show code 18 the alarm does not sound and the steer and drive functions operate Replace the down limit switch 14 Press the lift function select button Raise the platform approximately 12 inches 0 3 m Result The diagnostic display will show code 18 and an alarm sounds The machine is functioning correctly Result The diagnostic display does not show code 18 and the alarm does not sound Replace the down limit switch 15 Raise the platform until the pothole guards are deployed O Result The diagnostic display does not show code 18 and the alarm does not sound The machine is functioning correctly Result The diagnostic display shows code 18
218. them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched 4 Attach a lifting strap from an overhead crane to the number 4 outer arm index 13 5 Remove the external snap rings and retaining fasteners from the number 4 center pivot pins index 2 Section 4 Repair Procedures October 2008 SCISSOR COMPONENTS 6 Use a soft metal drift to remove the number 4 center pivot pins index 2 7 Remove the retaining fasteners from the number 4 pivot pin index 14 at the non steer end of the machine 8 Use a soft metal drift to remove the number 4 pivot pin index 14 from the non steer end of the machine Remove the number 4 outer arm index 13 from the machine Crushing hazard The number 4 ACAUTION outer arm may become unbalanced and fall if not properly supported when removed from the machine 9 Remove the number 4 cable bridge mounting fasteners and remove the cable bridge from the machine 10 Attach a lifting strap from an overhead crane to the number 4 inner arm index 12 11 Remove the retaining fasteners from the number 4 pivot pin index 3 12 Use a soft metal drift to remove the number 4 pivot pin index 3 at the steer end Remove the number 4 inner arm index 12 from the machine Crushing hazard The number 4 ACAUTION inner arm may become unbalanced and fall if not properly supported when removed from the machine Genie GS 30 GS 3
219. tic REV D CE Models GS 2032 2632 from serial number GS3204 60000 to GS3205 74999 GS 2046 2646 3246 from serial number GS4604 60000 to GS4605 74999 NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF lQD4 _ RD RD 4 4 WH WH 3 3 N 3 4 CR48 BL 1 1 Jo E POWER BK 2 2 RELAY TO US 8 Eso eec mg e No 4 PS2 PLATFORM 156 OVERLOAD CHO Down PRESSURE LIMIT 4 SWITCH j SWITCH A CR27A CR27B CR27C T OVERLOAD OVERLOAD ovEROAD ppeMeeer MOTOR CONT LOAD SENSE DOWN COIL 1 NC 4 30 86 30 86 30 86 LO uni _ JL S8 OF LEVEL f 87 85 87A 85 87 85 SENSOR LS5 CIRCUIT C E i BOARD l l ae SWITCH z 30 86 22 5 3 lt S7 S533 LEVEL SHEE 2 2 5 lt 2822 5 SENSOR 2g fe 85 7 P besje i 2 BK
220. tion and good machine performance Failure to find and replace burnt chafed corroded or pinched wires could result in unsafe operating conditions and may cause component damage Electrocution burn hazard Contact AWARNING with hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Inspect the underside of the chassis for damaged or missing ground strap s 2 Inspect the following areas for burnt chafed corroded and loose wires Ground control panel Hydraulic power unit module tray Battery pack module tray Scissor arms Platform controls 3 Inspect for a liberal coating of dielectric grease in the following locations Between the ECM and platform controls All wire harness connectors Level sensor Part No 96316 Genie GS 30 GS 32 GS 46 CHECKLIST B PROCEDURES 4 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 5 Raise the platform approximately 8 feet 2 4 m from the ground 6 Rotate the safety arm away from the machine and let it hang down 7 Lowerthe platform onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 8 Inspect the center chassis area and scissor arms for burnt chafed and pinched cables 9 Inspect the following areas for burnt chafed corroded pinched and loose
221. try ladder and remove the entry ladder from the machine Crushing hazard The entry ladder ACAUTION may become unbalanced and fall if not properly supported and secured to the lifting device 4 Secure the ends of the scissor arms together at the steer end of the machine with a strap or other suitable device 5 Secure the ends of the scissor arms together at the non steer end of the machine with a strap or other suitable device 6 Remove the retaining fasteners securing the chassis mount bracket to the chassis at the steer end of the machine 7 Attach a lifting strap from an overhead crane to the scissor arm assembly 8 Raise the scissor arm assembly at the steer end with the overhead crane until the chassis mount bracket will clear the level sensor Part No 96316 October 2008 Section 4 Repair Procedures 9 Remove the scissor assembly from the machine just enough to access both wear pads Component damage hazard Be careful not to damage the level sensor or limit switch while moving the scissor assembly Component damage hazard Be CAUTION careful not to damage the level sensor or limit switch while moving the scissor assembly 10 Remove both old wear pads 11 Install two new wear pads 12 Slide the scissor assembly back into the drive chassis 13 Lower the scissor assembly into position and install the chassis mount bracket onto the chassis Securely install and tighten the fastene
222. ts could result in death or serious injury Remove all rings watches and other jewelry 2 Open the power unit module tray REV B Tag and disconnect the hydraulic tank return hard line from the hydraulic filter head and remove the hard line from the tank Cap the fitting on the filter head 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 7 8 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 Install the hydraulic tank and install and 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 lubricated 26 in Ibs 2 9 Nm Genie GS 30 GS 32 GS 46 Part No 96316 September 2005 Section 3 Scheduled Maintenance Procedures p m M M
223. ture 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 E and AC Solenoid valve 3 position 4 way 190 20V DC with diode schematic item F Solenoid valve 2 position 4 way 190 20V DC with diode schematic item H Solenoid valve 2 position 2 way N C 25Q 20V DC with diode schematic item N Solenoid valve 2 position 4 way 190 20V DC with diode schematic item AE and AI Solenoid valve 3 position 5 way 190 20V DC with diode schematic item AG Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice GS 30 GS 32 GS 46 Part No 96316 June 2009 Section 2 Specifications REV SPECIFICATIONS Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with JIC 37 flared fittings and hose ends Genie specifications require that fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed SAE O ring Boss Port JIC 37 Fittings tube fitting installed into Aluminum swivel nut or hose connection
224. uce hazardous conditions Be aware of the following hazards and follow generally accepted safe workshop practices 77771777 Crushing hazard When testing A DANGER or replacing any hydraulic component always support the structure and secure it from movement AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry AWARNING end injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Section 5 Fault Codes September 2005 FAULT CODES About This Section When a malfunction is discovered the fault code charts in this section will help a service professional pinpoint the cause of the problem To use this section basic hand tools and certain pieces of test equipment are required voltmeter ohmmeter pressure gauges General Repair Process Malfunction Identify gt Troubleshoot discovered symptoms LED Diagnostic Readout The diagnostic readout displays numerical codes that provide information about the machine operating status and about malfunctions The dot to the right of the numbers remain on when a fault code is displayed A roblem stil exists The codes listed in the Fault Code Cha
225. unction manifold and securely tighten Torque to 25 ft Ibs 34 Nm 24 order install the reverse valve coil with white black and brown wires spacer washer and the forward valve coil with white and brown wires onto the valve Note For the machine to function correctly the reverse valve coil must be closest to the manifold Genie GS 30 GS 32 GS 46 REV F 25 Install the coil nut onto the valve and tighten Torque to 60 in Ibs 7 Nm 26 Connect the battery pack to the machine 27 Replace the brakes and repeat this procedure beginning with step 1 Refer to Repair Procedure 9 1 How to Remove a Drive Brake Repeat this procedure beginning with step 1 28 Contact the Genie Industries Service Parts Department and order kit part number 105458 29 Install the new valve received in the kit and mark the new valve with a white paint pen to identify new valve installation 30 Repeat this procedure beginning with step 1 If the machine fails to stop within the specified stopping distance after installing new brakes please contact the Genie Industries Scissors Service Department 1 800 536 1800 Ext 8710 Part No 96316 June 2009 Section Scheduled Maintenance Procedures REVF B 8 5 Test the Drive Speed Stowed Position Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Proper drive functions are essential to safe machine operation The
226. ut the red Emergency Stop button to the on position at both the ground and platform controls 6 Activate and hold the platform up toggle switch 7 Inspect the filter and related components to be sure that there are no leaks 8 Clean up any oil that may have spilled Torque specifications Hydraulic tank drain plug dry 40 in lbs 4 5 Nm Hydraulic tank drain plug lubricated 30 in Ibs 3 4 Nm Section Scheduled Maintenance Procedures September 2005 Checklist E Procedure E 1 Test or Replace the Hydraulic Oil Genie requires that this procedure be performed every 2000 hours or every two years whichever comes first Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more often Refer to Section 2 Specifications Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test Note Perform this procedure with the platform in the stowed position 1 Disconnect the battery pack from the machine AWARNING Electrocution burn hazard Contact with hot or live circui
227. w genieindustries com e mail techpub terex com Genie ii GS 30 GS 32 GS 46 Serial Number Information Genie Industries offers the following Service Manuals for these models Title Part No Genie GS 1530 and GS 1930 Service Manual First Edition before serial number 17408 39528 Genie GS 1530 and GS 1930 Service Manual Second Edition from serial number 17408 to 59999 72876 Genie GS 2032 Service Manual First Edition before serial number 17408 46326 Genie GS 2032 and GS 2632 Service Manual Second Edition from serial number 17408 to 59999 72963 Genie GS 2046 GS 2646 and GS 3246 Service Manual First Edition before serial number 17408 48339 Genie GS 2046 GS 2646 and GS 3246 Service Manual Second Edition from serial number 17408 to 59999 72972 Copyright 1997 by Genie Industries 96316 RevE September 2005 Third Edition Fourth Printing Genie is a registered trademark of Genie Industries in the USA and many other countries GS is a trademark of Genie Industries 4 Printed recycled paper Printed in U S A Part No 96316 June 2009 INTRODUCTION Serial Number Legend Genie Model GS 1930 Serial number GS3005 12345 Model year 2005 Manufacture date 04 12 05 Electrical schemat
228. y ladder to an appropriate lifting device 43 Remove the fasteners from the entry ladder and remove the entry ladder from the machine Crushing hazard The entry ladder ACAUTION may become unbalanced and fall if not properly supported and secured to the lifting device 44 Attach a lifting strap from an overhead crane to the number 1 outer arm index 17 Do not apply any lifting pressure 45 Remove the external snap rings and retaining fasteners from the number 1 center pivot pins index 7 46 Remove the number 1 cable bridge from the machine Genie GS 30 GS 32 GS 46 REV C 47 Use a soft metal drift to remove the number 1 center pivot pins index 7 Bodily injury hazard The number ACAUTION 1 outer arm may become unbalanced and fall if not properly supported when the pin is removed 48 Slide the number 1 outer arm index 17 to the non steer end and remove it from the machine Bodily injury hazard The number ACAUTION 1 outer arm may become unbalanced and fall if not properly supported when removed from the machine 49 Attach the strap from an overhead crane to the number 1 inner arm index 8 Do not lift it 50 Remove the upper fasteners securing the number 1 inner arm pivot bracket to the end of the chassis Loosen the lower fasteners 51 Remove the number 1 inner arm index 8 from the machine Bodily injury hazard The number ACAUTION 1 inner arm may become unbalanced and fal
229. ydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 45 Tag and disconnect the wire harness from the solenoid valve on the cylinder Section 4 Repair Procedures October 2008 SCISSOR COMPONENTS 46 Tag and disconnect the wires and manual lowering cable from the solenoid valve on the cylinder 47 Models with platform overload option Tag and disconnect the wire harness from the platform overload switch 48 Raise the lift cylinder to a vertical position 49 Remove the pin retaining fasteners from the lift cylinder barrel end pivot pin index 16 Use a Soft metal drift to remove the pin Remove the lift cylinder from the machine Crushing hazard The lift cylinder ACAUTION Will fall if not properly supported when the pivot pin is removed Component damage hazard Be careful not to damage the valve or fittings on the cylinder while removing it from the machine 50 Remove the cables from the number 1 cable bridge and lay them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched 51 Disconnect the number 1 cable bridge from the number 1 outer arm index 17 and remove the cable bridge from the machine 52 Attach a lifting strap from an overhead crane to the number 1 inner arm index 8 53 Raise the arm slightly and remove the block 54 Lower the arm to the stowed position Bodily injury hazard
230. ydraulic power unit How to Test the Hydraulic Pump When removing a hose assembly or fitting the fitting and or hose end must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Tag disconnect and plug the high pressure hydraulic hose from the hydraulic pump AWARNING 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 2 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the high pressure port on the pump 3 Turn key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 4 64 Genie GS 30 GS 32 GS 46 REVA 4 Activate the platform up function from the ground controls Result If the pressure gauge reads 3200 psi 221 bar immediately stop The pump is good Result If pressure fails to reach 3200 psi 221 bar the pump is bad and will need to be serviced or replaced Component damage hazard There is no relief valve in the hydraulic pump and the pump can be damaged if the pressure is allowed to exceed 3200 psi 221 bar When testing the pump activate the pump in one second intervals until 3200 psi 221 bar is confirmed Do not over pressurize the pump 5 Remove the pressure gauge an

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