Genie GS-1530 User manual

Maintenance Manual -
Scissor Lifts
Slab Scissor Lifts
This manual includes detailed
procedures for each
maintenance
inspection.
Rough Terrain
Scissor Lifts
For Repair procedures, Fault
Codes, Electrical and Hydraulic
Schematics, refer to the
appropriate Service and Repair
Manual for your machine.
Refer
to the inside cover for a list of models
included in this manual.
Part No. 1272215
Rev B2
September 2016

Maintenance Manual September 2016
Introduction
ii Scissor Lifts Part No. 1272215
Intr oduct io n Intr oduct io n
Impor tant Inf ormati on
Important
Read, understand and obey the safety rules and
operating instructions in the appropriate Operator's
Manual on your machine before attempting any
maintenance procedure.
This manual provides detailed scheduled
maintenance information for the machine owner
and user.
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 be performed at an authorized Genie
dealer service center.
Compliance
Machine Classification
Group A/Type 2, 3 as defined by ISO 16368
Machine Design Life
Unrestricted with proper operation, inspection and
scheduled maintenance.
Technical Publications
Genie has endeavored to deliver the highest
degree of accuracy possible. However, continuous
improvement of our products is a Genie policy.
Therefore, product specifications are subject to
change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.
Contact Us:
Internet: www.genielift.com
E-mail: [e-mail]
Copyright © 2016 by Terex Corporation
1272215 Rev B, May 2016
First Edition, Second Printing
Genie is a registered trademark of Terex South Dakota, Inc. in
the U.S.A. and many other countries.
“GS” is a trademark of Terex South Dakota, Inc.

September 2016 Maintenance Manual
Introduction
Part No. 1272215 Scissor Lifts iii
Models included in this manual
Use the following chart to identify the specific serial
number for models included in this manual.
Models
Serial number
GS
-1530 / GS-1532
GS
-1930 / GS-1932
from SN
GS3010A-110000
from SN GS3011C
-10000 to
GS3016C
-23999
from SN GS3014D
-101 to
GS3016D
-607
from SN GS3016P
-151487 to
GS3016P
-160599
from GS30C
-24000
from GS30D
-6080
from GS30P
-160600
GS
-2032/2632/3232
from SN GS3211A
-110000
from SN GS3212C
-10000 to
GS3216C
-17299
from SN GS3216P
-142676 to
GS3216P
-148699
from GS32C
-17300
from GS32P
-148700
GS
-2046/2646/3246
from SN GS4612A
-110000
from SN GS4612C
-10000 to
GS4616C
-18099
from SN GS4614D
-101 to
GS4616D
-5029
from SN GS4616P
-138362 to
GS4616P
-141799
from GS4
6C-18100
from GS46D
-5030
from GS46P
-141800
GS
-2646 AV/2646 AV35
from SN GS4612A
-110000
from SN GS4616P
-138383 to
GS4616P
-141799
GS
-4047
from SN GS4712C
-101 to
GS4716C
-4499
from SN GS4714D
-101 to
GS4716D
-3959
from GS4716P
-101 to
GS4716P
-999
from
GS47C-4500
from GS47D
-3960
from GS47P
-1000
GS
-2669/3369/4069 RT
from SN GS6911
-101
from SN GS6916F
-7897 to
GS69F
-10499
from GS69F
-10500
GS
-2669/3369/4069 DC
from SN GS6912
-1300
from SN GS6916F
-7897 to
GS6916F
-10499
from GS69F
-10500
GS
-2669/3369/4069 BE
from SN GS6914
-5000
from SN GS6916F
-7897 to
GS6916F
-10499
from GS69F
-10500
GS
-3384
from SN GS8413
-42181 to
GS8415
-42382
from SN GS8416F
-42383 to
GS8416F
-45499
from GS84F
-45500
GS
-3390/4390/5390
from SN GS9013
-48427 to
GS9015
-51064
from SN GS9016F
-51064 to
GS9016F
-53299
from GS90F
-53300
Find additional Manuals for your
Model
Go to http://www.genielift.com
Use the links to locate Service Manuals,
Maintenance Manuals, Service and Repair
Manuals, Parts Manuals and Operator's Manuals.

Maintenance Manual September 2016
Introduction
iv Scissor Lifts Part No. 1272215
Identifying the Correct Procedure
for your Model
Unless otherwise noted, each procedure will apply
to all models. Procedures that only apply to specific
models or options will include the information in the
procedure title.
Examples of procedures that apply to specific
models:
•Test the Oscillate Axle - GS-90
•Grease the Steer Yokes - GS-30, GS-32,
GS-46 and GS-47
•Model Abbreviations:
GS-30: GS-1530, GS-1532, GS-1930,
GS-1932
GS-32: GS-2032, GS-2632, GS-3232
GS-46: GS-2046, GS-2646, GS-2646 AV,
2646 AV35, GS-3246
GS-47: GS-4047
GS-69: Unless specified DC, BE or RT
GS-2669 (all models), GS-3369 (all models),
GS-4069 (all models)
GS-84: GS-3384
GS-90: GS-3390, GS-4390, GS-5390
Examples of procedures that apply to all models:
•Test the Drive Speed – Stowed Position
•Inspect the Electrical Wiring
Glossary of terms:
ECM – Electronic Control Module
(GS-69 RT, GS-84, and GS-90)
GCON – Ground Controller. Located at the chassis
ground controls. (GS-30, GS-32, GS-46, GS-47,
GS-69 DC, and GS-69 BE)
PCON – Platform Controller. Located at the
platform. (GS-30, GS-32, GS-46, GS-47, GS-69
DC, and GS-69 BE)
CAT5 Cable – Standard Ethernet cable used for
networking purposes.

September 2016 Maintenance Manual
Introduction
Part No. 1272215 Scissor Lifts v
RevisionHistory
Revision History
Revision
Date
Section
Procedure / Description
A 3/2016 Initial Release
B 5/2016 Specifications Add GM .998L engine
Maintenance Add GM Maintenance intervals
Programmed Maint. Report
Update C-2 and P2-1, Add P0-8
B1 7/2016 Maintenance A-8
B2 9/2016 Introduction Models Included
Reference Examples:
Section – Specifications Electronic Version
Click on any content or procedure in the Table of Contents to view
the update.
Section – Maintenance, (procedure)

Maintenance Manual September 2016
Introduction
vi Scissor Lifts Part No. 1272215
Revision History (continued)
Revision Date Section Procedure / Description
Reference Examples:
Section – Specifications Electronic Version
Click on any content or procedure in the Table of Contents to view
the update.
Section – Maintenance, (procedure)

September 2016 Maintenance Manual
Safety Rules
Part No. 1272215 Scissor Lifts vii
Section 1 Safet y Rul es G eneral Saf ety 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 governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.

Maintenance Manual September 2016
Safety Rules
viii Scissor Lifts Part No. 1272215
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 poss
ible injury or death.
Indicates a imminently hazardous
situation which, if not avoided, will
result in death or serious injury.
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.
Indicates a potentially hazardous
situation which, if not avoided,
may result in property damage.
Be sure to wear protective eye wear and
other protective
clothing if the situation
warrants it.
Be aware of potential crushing hazards
such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved
steel
-toed shoes.
Workplace Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Be sure to keep sparks, flames and
lighted tobacco away from flammable and
combustible materials like
battery gases
and engine fuels. Always have an
approved fire extinguisher within easy
reach.
Be sure that all tools and working areas
are properly maintained and ready for
use. Keep work surfaces clean and free of
debris that could get into machine
com
ponents and cause damage.
Be sure any forklift, overhead crane or
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.
B
e sure that fasteners intended for one
time use (i.e., cotter pins and self
-locking
nuts) are not reused. These components
may fail if they are used a second time.
Be sure to properly dispose of old oil or
other fluids. Use an approved container.
Please
be environmentally safe.
Be sure that your workshop or work area
is properly ventilated and well lit.

September 2016
Table of Contents
Part No. 1272215 Scissor Lifts ix
Introduction Introduction...........................................................................................................ii
Important Information .............................................................................................ii
Models included in this manual............................................................................. iii
Find additional Manuals for your Model ................................................................ iii
Identifying the Correct Procedure for your Model .................................................iv
Glossary of terms: ................................................................................................. iv
Revision History......................................................................................................v
Section 1 Safety Rules........................................................................................................vii
General Safety Rules ........................................................................................... vii
Section 2 Performance Specifications................................................................................1
Function Speeds GS-30, GS-32, GS-46, GS-47....................................................1
Function Speeds GS-69, GS-84, GS-90................................................................2
Drive Speeds..........................................................................................................3
Torque Specifications..........................................................................................4
Tires and Wheels....................................................................................................4
Battery Specifications..........................................................................................5
Battery Specifications - DC and BE Models...........................................................5
Engine Specifications..........................................................................................6
Engine Operator and Maintenance Manuals..........................................................6
Deutz Engine Models .............................................................................................6
Perkins Engine Models...........................................................................................7
Ford Engine Models ...............................................................................................7
Kubota Engine Models ...........................................................................................8
Kohler Engine Models ............................................................................................8
GM Engine Models.................................................................................................9
Hydraulic Specifications....................................................................................10
Hydraulic Relief Valves ........................................................................................10
Hydraulic and Drive Hub Fluid Capacities............................................................12
Hydraulic Oil Specifications..................................................................................13
Hydraulic Hose and Fitting Torque Specifications ...............................................16
Torque Procedure ................................................................................................17

September 2016
Table of Contents
x Scissor Lifts Part No. 1272215
Section 3 Maintenance Procedures ..................................................................................20
Introduction ..........................................................................................................20
Maintenance Schedule ........................................................................................22
Pre-Delivery Preparation Report..........................................................................23
Scheduled Maintenance Inspection Report - Scissor Lifts..................................24
Programmed Maintenance Inspection Report - Scissor Lifts ..............................25
Commissioning Procedures.............................................................................26
C-1 Perform 50 Hour Service...............................................................................26
C-2 Perform Engine Maintenance – 50 Hours.....................................................26
C-3 Perform 150 Hour Service.............................................................................27
Quarterly Maintenance Procedures .................................................................28
Q-1 Check for Open Bulletins and Owner Registration.......................................28
Q-2 Battery Inspection .........................................................................................29
Q-3 Check the Module Tray Latch Components .................................................31
Q-4 Inspect the Battery Balancer - GS-69 DC.....................................................32
Q-5 Inspect the Electrical Wiring..........................................................................33
Q-6 Inspect the Electrical Contactor - GS-30, GS-32, GS-46, GS-47,
GS-69 DC and GS-69 BE ............................................................................34
Q-7 Inspect the Voltage Inverter (if equipped).....................................................34
Q-8 Test the Flashing Beacons (if equipped) ......................................................35
Q-9 Visual Inspection of the Hydraulic Oil ...........................................................36
Q-10 Inspect the Hydraulic Filters........................................................................37
Q-11 Check the Exhaust System - Engine Models..............................................38
Q-12 Inspect the Fuel Tank Check Valve Venting System -
GS-69 RT Gas Models.................................................................................38
Q-13 Test the Fuel Select Operation - Gasoline/LPG Models.............................39
Q-14 Check and Adjust the Engine RPM ............................................................40
Q-15 Inspect the Tires, Wheels and Lug Nut Torque..........................................42
Q-16 Confirm the Proper Brake Configuration - GS-69, GS-84, GS-90..............43
Q-17 Test the Drive Brakes .................................................................................43
Q-18 Test the Drive Speed – Stowed Position ....................................................44
Q-19 Test the Drive Speed - Raised Position......................................................44