Genie GS-1930 User manual

First Edition, Third Printing
Rev C2
Part No. 39528
GS-1930
GS-1530
Technical
Publications
®
Service
Manual
(before serial number 17408)

Genie GS-1530 & GS-1930 Part No. 39528
Service Manual - First Edition
ii
Introduction
Genie North America
Telephone [phone]
Toll Free in U.S.A. 800 536-1800
Toll Free in Canada 800 426-8089
Fax [phone]
E-mail: [email protected]
http://www.genielift.com
Genie Europe
Office Telephone [phone]
Office Fax [phone]
Parts Telephone [phone]
Parts Fax [phone]
®
Copyright © 1997 by Genie Industries
First Edition: First Printing August, 1997
Second Printing February, 1998
Third Printing September, 1999
"Genie" is a registered trademark
of Genie Industries in the U.S.A. and many other
countries. "GS" is a trademark of
Genie Industries.
These machines comply with
ANSI/SIA 92.6-1990.
Printed on recycled paper
Printed in U.S.A.
Important
Read, understand and obey the safety rules and
operating instructions in the appropriate
Genie GS-1530 & Genie GS-1930 Operator’s
Manual before attempting any maintenance or
repair procedure.
This manual provides detailed scheduled
maintenance information for the machine owner
and user. It also provides troubleshooting and
repair procedures for qualified service
professionals.
Basic mechanical, hydraulic and electrical
skills are required to perform most procedures.
However, several procedures require specialized
skills, tools, lifting equipment and a suitable
workshop. In these instances, we strongly
recommend that maintenance and repair be
performed at an authorized Genie dealer
service center.
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 other manuals. Please
write to the technical publications team in care of
Genie Industries, PO Box 97030, Redmond WA
98073-9730 USA.
If you have any questions, please call Genie
Industries.
GS-1930
GS-1530

Part No. 39528 Genie GS-1530 & GS-1930
Service Manual - First Edition
iii
Danger
Failure to obey the instructions and safety rules
in this manual and the appropriate Genie GS-1530
& Genie GS-1930 Operator’s Manual 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.
Safety Rules

Genie GS-1530 & GS-1930 Part No. 39528
Service Manual - First Edition
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.
Red—used to indicate the
presence of an imminently
hazardous situation which, if not
avoided, will result in death or
serious injury.
Orange—used to indicate the
presence of a potentially
hazardous situation which, if not
avoided, could result in death or
serious injury.
Yellow with safety alert symbol—
used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause
minor or moderate injury.
Yellow without safety alert
symbol—used to indicate the
presence of a potentially
hazardous situation which, if not
avoided, may result in property
damage.
Green—used to indicate operation
or maintenance information.
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 and free swinging or
unsecured components when lifting or
placing loads. Always wear approved
steel-toed shoes.
Workplace Safety
Be sure to keep sparks, flames and lighted
tobacco away from flammable and
combustible materials such as battery
gases and engine fuels. Always have an
approved fire extinguisher within easy reach.
Be sure that all tools and working areas are
properly maintained and ready for use.
Keep work surfaces clean and free of
debris that could get into machine
components and cause damage.
Be sure that your workshop or work area
is properly ventilated and well lit.
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.
Be sure that fasteners intended for one time use
(i.e., cotter pins and self-locking nuts) are
not reused. These components may fail if
they are used a second time.
Be sure to properly dispose of old oil or
other fluids. Use an approved container.
Please be environmentally safe .
iv

Part No. 39528 Genie GS-1530 & GS-1930
Service Manual - First Edition
Theory of Operation
Power Source
The Genie GS-1530 and GS-1930 machines are
powered by four six-volt (255 AH) batteries. The
four batteries are wired in series to produce 24
volts.
Hydraulic System
All machine functions are performed by the
hydraulic system. The hydraulic system is powered
by a single-section gear pump. When the pump is
activated, it supplies hydraulic fluid under pressure
to the function manifold, where the control valves
are located. To protect from over-pressurization of
the hydraulic system, the pump is provided with a
pressure relief valve.
Activating a machine function is accomplished by
actuating or moving a switch and/or control handle,
which sends voltage to the ECM. The ECM then
sends the signal to the appropriate directional
control valve. The directional valve determines
which direction the hydraulic fluid will travel.
Computer software determines the volume of fluid
in relation to the proportional valve input voltage.
Electrical System
Limit switches are found in various locations on the
machine. The function of a limit switch is to
communicate the operating position of the machine
to the ECM (Electronic Control Module). When a
change in signal is received from a limit switch, the
ECM responds by limiting the drive speed to 0.5
miles per hour (0.8 km/h), according to the default
settings in the ECM software.
Machine Controls
The GS-1530 and GS-1930 machines are
equipped with operational controls which are found
in two locations: the ground controls, located on
the hydraulic tank side of the machine, and the
platform controls, located in the platform. All lift and
drive functions are available at the platform
controls. Only platform up/down functions are
available at the ground controls.
The ECM uses input from the ground or platform
controls to activate the various machine functions.
The ECM has predetermined settings for the
various machine functions.
The joystick is fitted with a 5000 ohm
potentiometer. With the joystick in the neutral
position, the potentiometer will measure 2730
ohms. These signals are sent to the multiplex card,
then down to the ECM to control the voltage
supplied to the proportional valve. Two
microswitches mounted on the joystick tell the
ECM the drive direction desired. A thumb rocker
switch on the top of the joystick is used for
steering.
Mounted on the platform control box lid of
machines before serial number 17408 are buttons
and a switch that, when activated, sends a signal to
the ECM through the multiplex card. On machines
after serial number 17407, the platform control box
lid has a decal/membrane pad. This is a touch-
activated pad incorporating wiring, switches and
LEDs that are resistant to the environment.
Activating any of the buttons on the pad will send a
signal to the ECM through the multiplex card.
A diagnostic display is located at the battery pack
side of the machine to aid in troubleshooting. If the
machine malfunctions, a fault code will be shown in
the display window.
Washing electronic components is not suggested.
Instead, use compressed air to remove debris from
these components.
Component damage hazard. Avoid
shock or impact to the ECM.
Internal damage may not be visible
from the outside.
v

Genie GS-1530 & GS-1930 Part No. 39528
Service Manual - First Edition
Table of Contents
Introduction
Important Information...................................................................................................... ii
Section One Safety Rules
General Safety Rules..................................................................................................... iii
Theory of Operation ....................................................................................................... v
Section Two Rev Specifications
D Machine Specifications ................................................................................ 2 - 1
D Performance Specifications ......................................................................... 2 - 2
D Hydraulic Specifications ............................................................................... 2 - 2
D Hydraulic Hose and Fitting Torque Specifications ........................................ 2 - 3
Section Three Scheduled Maintenance Inspections
Introduction ............................................................................................................... 3 - 1
Table A ..................................................................................................................... 3 - 2
Table B ..................................................................................................................... 3 - 2
Table C ..................................................................................................................... 3 - 3
Table D ..................................................................................................................... 3 - 3
Maintenance Inspection Report ................................................................................ 3 - 4
Section Four Scheduled Maintenance Procedures
Introduction ............................................................................................................... 4 - 1
A-1 Inspect the Operator’s and Safety Manuals .................................................... 4 - 2
A-2 Inspect the Decals and Placards ..................................................................... 4 - 2
A-3 Inspect for Damage and Loose or Missing Parts ............................................. 4 - 3
A-4 Check the Hydraulic Oil Level ......................................................................... 4 - 3
A-5 Check for Hydraulic Leaks .............................................................................. 4 - 4
A-6 Test the Platform and Ground Controls ........................................................... 4 - 4
A-7 Test the Manual Platform Lowering Operation ................................................ 4 - 5
A-8 Test the Tilt Sensor ......................................................................................... 4 - 6
A-9 Test the Pothole Guards ................................................................................. 4 - 6
A-10 Test the Lift/Drive Select Switch (before serial number 17408) ...................... 4 - 7
A-11 Perform 30 Day Service .................................................................................. 4 - 7
vi

Part No. 39528 Genie GS-1530 & GS-1930
Service Manual - First Edition
TABLE OF CONTENTS
Section Four Scheduled Maintenance Procedures, continued
B-1 Check the Batteries ......................................................................................... 4 - 8
B-2 Inspect the Electrical Wiring ............................................................................ 4 - 9
B-3 Inspect the Tires and Wheels (including castle nut torque) ........................... 4 - 10
B-4 Test the Key Switch ...................................................................................... 4 - 10
B-5 Test the Emergency Stop Buttons ................................................................. 4 - 11
B-6 Test the Service Horn ................................................................................... 4 - 11
B-7 Test the Drive Brakes ................................................................................... 4 - 12
B-8 Test the Drive Speed - Stowed Position ........................................................ 4 - 14
B-9 Test the Drive Speed - Raised Position......................................................... 4 - 14
B-10 Perform Hydraulic Oil Analysis ...................................................................... 4 - 15
B-11 Check the Electrical Contactor (before serial number 6901) ......................... 4 - 15
C-1 Replace the Hydraulic Filter .......................................................................... 4 - 16
D-1 Test or Replace the Hydraulic Oil.................................................................. 4 - 17
vii

Genie GS-1530 & GS-1930 Part No. 39528
Service Manual - First Edition
TABLE OF CONTENTS
Section Five Troubleshooting Flow Charts and Fault Codes
Chart
Number Chart Title Page
Introduction ............................................................................................................................................ 5 - 1
Fault Code Chart Before Serial Number 17408 ........................................................ 5 - 3
Normal Operation Code Chart .................................................................................. 5 - 6
Fault Code Chart After Serial Number 17407 ........................................................... 5 - 8
1 All Functions Will Not Operate .................................................................................. 5 - 9
2 Pump Motor Will Not Operate ................................................................................. 5 - 12
3 All Functions Inoperative, Power Unit Starts and Runs ........................................... 5 - 14
4 Ground Controls Inoperative, Platform Controls Operate Normally......................... 5 - 15
5 Platform Controls Inoperative, Ground Controls Operate Normally......................... 5 - 16
6 Platform Up Function Inoperative ........................................................................... 5 - 18
7 Platform Down Function Inoperative ....................................................................... 5 - 19
8 Steer Left Function Inoperative ............................................................................... 5 - 21
9 Steer Right Function Inoperative ............................................................................ 5 - 23
10 All Drive Functions Inoperative, All Other Functions Operate Normally .................. 5 - 25
10A Brake Release Function Inoperative ....................................................................... 5 - 27
11 Drive Forward Function Inoperative ........................................................................ 5 - 28
12 Drive Reverse Function Inoperative ........................................................................ 5 - 29
13 Machine Will Not Drive At Full Speed ..................................................................... 5 - 30
14 Machine Drives At Full Speed With Platform Raised .............................................. 5 - 32
viii

Part No. 39528 Genie GS-1530 & GS-1930
Service Manual - First Edition
TABLE OF CONTENTS
Section Six Schematics
Introduction ............................................................................................................... 6 - 1
Electrical Components .............................................................................................. 6 - 2
Module Tray Legend ................................................................................................. 6 - 3
Electrical Symbols Legend ....................................................................................... 6 - 4
Electrical Schematic (models before serial number 6901) ........................................ 6 - 5
Electrical Schematic (models from serial number 6901 to 8931) .............................. 6 - 7
Electrical Schematic (models after serial number 8931) ........................................... 6 - 9
Ground Controls and Level Sensor Box Legend ..................................................... 6 - 11
Platform Controls Legend (models before serial number 17408) ............................ 6 - 12
Platform Controls Legend (models after serial number 17407) ............................... 6 - 13
Hydraulic Symbols Legend ..................................................................................... 6 - 14
Hydraulic Schematic ............................................................................................... 6 - 15
ix

Genie GS-1530 & GS-1930 Part No. 39528
Service Manual - First Edition
TABLE OF CONTENTS
Section Seven Repair Procedures
Introduction ............................................................................................................... 7 - 1
Platform Controls
1-1 Platform Controller .......................................................................................... 7 - 2
1-2 Software Configuration .................................................................................... 7 - 3
1-3 Toggle Switches .............................................................................................. 7 - 6
Platform Components
2-1 Platform .......................................................................................................... 7 - 8
2-2 Platform Extension .......................................................................................... 7 - 9
Scissor Components
3-1 Scissor Assembly, GS-1530 (machines before serial number 632) .............. 7 - 10
3-2 Scissor Assembly, GS-1930 (machines before serial number 632) .............. 7 - 16
3-3 Scissor Assembly, GS-1530 (machines after serial number 631) ................. 7 - 22
3-4 Scissor Assembly, GS-1930 (machines after serial number 631) ................. 7 - 28
3-3 Lift Cylinder ................................................................................................... 7 - 34
Ground Controls
4-1 Manual Platform Lowering Cable .................................................................. 7 - 36
4-2 Toggle Switches, See 1-3, Toggle Switches ................................................... 7 - 6
Hydraulic Pump
5-1 Function Pump .............................................................................................. 7 - 37
Manifolds
6-1 Function Manifold Components ..................................................................... 7 - 38
6-2 Valve Adjustment - Function Manifold ........................................................... 7 - 40
Steering Axle Components
7-1 Yoke and Drive Motor ................................................................................... 7 - 42
7-2 Steering Cylinder .......................................................................................... 7 - 43
7-3 Steering Bellcrank (machines before serial nmber 2000) .............................. 7 - 44
7-4 Steering Bellcrank (machines after serial number 1999) ............................... 7 - 44
Non-steering Axle Components
8-1 Drive Brake ................................................................................................... 7 - 45
Brake Release Hand Pump Components
9-1 Brake Release Hand Pump........................................................................... 7 - 46
x