Terex Genie GS-1530 User manual

Service Manual
Part No. 96316
Rev E5
November 2010
from GS3204-60000
to GS3205-75406
Serial Number Range
from GS3003-60000
to GS3005-75999
from GS4604-60000
to GS4605-75437
from GS3003-60000
to GS3005-75999
from GS3204-60000
to GS3205-75406
from GS4604-60000
to GS4605-75437
from GS4604-60000
to GS4605-75437
GS -1530/32
GS -1930/32
GS -2032
GS -2632
GS -2046
GS -2646
GS -3246

September 2005
GS-30 • GS-32 • GS-46 Part No. 96316
ii
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.
Copyright © 1997 by Genie Industries
96316 Rev E 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.
Printed on recycled paper
Printed in U.S.A.
Contact Us:
www.genieindustries.com
e-mail: [email protected]
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
Introduction

June 2009
Part No. 96316 GS-30 • GS-32 • GS-46
iii
INTRODUCTION
Serial Number Legend
PN - 77055
Model:
Model year: Manufacture date:
Maximum allowable inclination of the chassis:
Country of manufacture: USA
This machine complies with:
Serial number:
Rated work load (including occupants):
Genie Industries
18340 NE 76th Street
Redmond, WA 98052
USA
Electrical schematic number:
Gradeability:
Maximum allowable side force :
Maximum number of platform occupants:
Machine unladen weight:
ANSI A92.6-1999
B354.2-01
GS-1930
GS3005-12345
04/12/05
ES0141
2,714 lb / 1,231 kg
500 lb / 227 kg
N/A
N/A
100 lb / 445 N
2
2005
Serial number
(stamped on chassis)
Serial number
(stamped on chassis)
Serial label
GS30 05 - 12345
Model Sequence
number
Model year

September 2005
GS-30 • GS-32 • GS-46 Part No. 96316
This page intentionally left blank.
iv

September 2005
Part No. 96316 GS-30 • GS-32 • GS-46
v
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.
Safety Rules
Section 1 • Safety Rules

September 2005
GS-30 • GS-32 • GS-46 Part No. 96316
vi
SAFETY RULES
Section 1 • Safety Rules
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.
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 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 .
Be sure that your workshop or work area
is properly ventilated and well lit.
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.
Indicates an 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.

June 2009
Part No. 96316 GS-30 • GS-32 • GS-46
Table of Contents
Introduction
Important Information ......................................................................................... ii
Serial Number Information ................................................................................. ii
Serial Number Legend ...................................................................................... iii
Section 1 Safety Rules
General Safety Rules ........................................................................................ v
Section 2 Rev Specifications
E Machine Specifications ................................................................................ 2 - 1
Performance Specifications ......................................................................... 2 - 2
Hydraulic Specifications ............................................................................... 2 - 3
Manifold Component Specifications ............................................................. 2 - 4
Hydraulic Hose and Fitting Torque Specifications ........................................ 2 - 5
SAE and Metric Fasteners Torque Charts ................................................... 2 - 7
Section 3 Rev Scheduled Maintenance Procedures
Introduction .................................................................................................. 3 - 1
Pre-delivery Preparation Report .................................................................. 3 - 3
Maintenance Inspection Report ................................................................... 3 - 5
CChecklist A Procedures
A-1 Inspect the Manuals and Decals ......................................................... 3 - 6
A-2 Perform Pre-operation Inspection ....................................................... 3 - 7
A-3 Perform Function Tests ...................................................................... 3 - 7
A-4 Perform 30 Day Service ..................................................................... 3 - 8
A-5 Grease the Steer Yokes ..................................................................... 3 - 8
vii

June 2009
GS-30 • GS-32 • GS-46 Part No. 96316
TABLE OF CONTENTS
Section 3 Rev Scheduled Maintenance Procedures, continued
FChecklist B Procedures
B-1 Inspect the Batteries ........................................................................... 3 - 9
B-2 Inspect the Electrical Wiring ............................................................. 3 - 11
B-3 Inspect the Tires and Wheels (including castle nut torque) ............... 3 - 12
B-4 Test the Emergency Stop ................................................................. 3 - 12
B-5 Test the Key Switch .......................................................................... 3 - 13
B-6 Test the Automotive-style Horn (if equipped) .................................... 3 - 13
B-7 Test the Drive Brakes ....................................................................... 3 - 14
B-8 Test the Drive Speed - Stowed Position ........................................... 3 - 17
B-9 Test the Drive Speed - Raised Position ............................................ 3 - 18
B-10 Perform Hydraulic Oil Analysis ......................................................... 3 - 19
B-11 Inspect the Hydraulic Cap Venting System....................................... 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
CChecklist C Procedures
C-1 Test the Platform Overload System (if equipped) ............................. 3 - 26
C-2 Replace the Hydraulic Tank Breather Cap -
Models with Optional Hydraulic Oil ................................................... 3 - 28
CChecklist D Procedures
D-1 Check the Scissor Arm Wear Pads .................................................. 3 - 29
D-2 Replace the Hydraulic Tank Return Filter ......................................... 3 - 31
BChecklist E Procedure
E-1 Test or Replace the Hydraulic Oil ..................................................... 3 - 32
viii

June 2009
Part No. 96316 GS-30 • GS-32 • GS-46
TABLE OF CONTENTS
Section 4 Rev Repair Procedures
Introduction .................................................................................................. 4 - 1
DPlatform Controls
1-1 Circuit Boards .................................................................................... 4 - 3
1-2 Controller Adjustments ....................................................................... 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
APlatform Components
2-1 Platform ........................................................................................... 4 - 16
2-2 Platform Extension ........................................................................... 4 - 17
CScissor Components
3-1 Scissor Assembly, GS-1530 and GS-1532 ...................................... 4 - 18
3-2 Scissor Assembly, GS-1930 and GS-1932 ...................................... 4 - 24
3-3 Scissor Assembly, GS-2032 and GS-2046 ...................................... 4 - 32
3-4 Scissor Assembly, GS-2632 and GS-2646 ...................................... 4 - 38
3-5 Scissor Assembly, GS-3246 ............................................................ 4 - 46
3-6 Lift Cylinder ...................................................................................... 4 - 54
BGround Controls
4-1 Manual Platform Lowering Cable ..................................................... 4 - 59
4-2 Control Relays ................................................................................. 4 - 60
4-3 Level Sensor .................................................................................... 4 - 61
ix

June 2009
GS-30 • GS-32 • GS-46 Part No. 96316
AHydraulic Pump
5-1 Function Pump ................................................................................. 4 - 64
Section 4 Rev Repair Procedures, continued
CManifolds
6-1 Function Manifold Components -
GS-1530, GS-1532, GS-1930 and GS-1932 .................................... 4 - 66
6-2 Function Manifold Components -
GS-2032, GS-2632, GS-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 Valve Coils ....................................................................................... 4 - 75
BHydraulic Tank
7-1 Hydraulic Tank ................................................................................. 4 - 77
BSteer Axle Components
8-1 Yoke and Drive Motor ...................................................................... 4 - 78
8-2 Steer Cylinder .................................................................................. 4 - 79
8-3 Steer Bellcrank ................................................................................. 4 - 80
ANon-steer Axle Components
9-1 Drive Brake ...................................................................................... 4 - 81
ABrake Release Hand Pump Components
10-1 Brake Release Hand Pump Components ......................................... 4 - 82
BPlatform Overload Components
11-1 Platform Overload ............................................................................ 4 - 83
Section 5 Rev Fault Codes
Introduction .................................................................................................. 5 - 1
TABLE OF CONTENTS
x

June 2009
Part No. 96316 GS-30 • GS-32 • GS-46
A Fault Code Chart ......................................................................................... 5 - 3
Section 6 Rev Schematics
Introduction .................................................................................................. 6 - 1
A Electrical Component and Wire Color Legends ........................................... 6 - 2
C ECM Pin-out Legend ................................................................................... 6 - 3
B Wiring Diagram - Ground Controls and Level Sensor Harness .................... 6 - 4
B Wiring Diagram - Platform Control Box ........................................................ 6 - 5
B Limit Switch Legend ..................................................................................... 6 - 6
A Electrical Symbols Legend........................................................................... 6 - 7
Electrical Schematics - ANSI, CSA and Australia Models
(models without platform overload)
C GS-1530/1532/1930/1932
(from serial number GS3003-60000 to GS3005-74999) .............................. 6 - 8
B GS-1530/1532/1930/1932
(from serial number GS3005-75000 to 75999) ........................................... 6 - 12
D 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
B 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)
C GS-1530/1532/1930/1932
(from serial number GS3003-60000 to GS3005-74999) ............................ 6 - 24
B GS-1530/1532/1930/1932
(from serial number GS3005-75000 to 75999) ........................................... 6 - 28
D GS-2032/2632
(from serial number GS3204-60000 to GS3205-74999)
GS-2046/2646/3246
(from serial number GS4604-60000 to GS4605-74999) ............................ 6 - 32
B GS-2032/2632 (from serial number GS3205-75000 to 75406)
GS-2046/2646/3246 (from serial number GS4605-75000 to 75437) .......... 6 - 36
TABLE OF CONTENTS
xi

June 2009
GS-30 • GS-32 • GS-46 Part No. 96316
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
B Hydraulic Schematic -
GS-2046/2646/3246
(from serial number GS4604-60000 to GS4604-60878) ............................ 6 - 48
A Hydraulic Schematic -
GS-2046/2646/3246
(from serial number GS4604-60879 to GS4605-75437) ............................ 6 - 50
TABLE OF CONTENTS
xii

REV E
Part No. 96316 GS-30 • GS-32 • GS-46 2 - 1
Section 2 • SpecificationsJune 2009
Machine Specifications
Batteries, Standard
Voltage 6V DC
Group GC2
Type T-105
Quantity 4
Battery capacity, maximum 225AH
Reserve capacity @ 25A rate 447 minutes
Batteries, Maintenance-free (option)
Voltage 6V DC
Group GC2
Type 6V-AGM
Quantity 4
Battery capacity, maximum 200AH
Reserve capacity @ 25A rate 380 minutes
Fluid capacities
Hydraulic tank 3.75 gallons
All models 14.2 liters
Hydraulic system (including tank) 5 gallons
GS-3246 19 liters
Hydraulic system (including tank) 4.5 gallons
All other models 18 liters
For operational specifications, refer to the
Operator's Manual.
Tires and wheels
GS-1530, GS-1532, GS-1930, GS-1932
Tire size (solid rubber) 12 x 4.5 in
30.5 x 11.4 cm
Tire contact area 9 sq in
58 cm2
Castle nut torque, dry 300 ft-lbs
406.7 Nm
Castle nut torque, lubricated 225 ft-lbs
305 Nm
GS-2032, GS-2632, GS-2046, GS-2646, GS-3246
Tire size (solid rubber) 15 x 5 in
38.1 x 12.7 cm
Tire contact area 10 sq in
64.5 cm2
Castle nut torque, dry 300 ft-lbs
406.7 Nm
Castle nut torque, lubricated 225 ft-lbs
305 Nm
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.
Specifications

REV E
2 - 2 GS-30 • GS-32 • GS-46 Part No. 96316
June 2009Section 2 • Specifications
SPECIFICATIONS
Performance Specifications
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
High range on paved surface 24 in ± 12 in
61 cm ± 30 cm
Gradeability
GS-1930, GS-2632 and GS-3246 25%
GS-1530, GS-2032, GS-2046
and GS-2646 30%
Airborne noise emissions <70 dB
Maximum sound level at normal operation workstations
(A-weighted)
Function speed, maximum from platform controls
(with 1 person in platform)
GS-1530, GS-1532
Platform up 15 to 17 seconds
Platform down 16 to 18 seconds
GS-1930, GS-1932
Platform up 15 to 17 seconds
Platform down 22 to 24 seconds
GS-2032, GS-2046
Platform up 28 to 32 seconds
Platform down 26 to 30 seconds
GS-2632, GS-2646
Platform up 28 to 32 seconds
Platform down 22 to 26 seconds
GS-3246
Platform up 55 to 59 seconds
Platform down 38 to 42 seconds
Rated work load at full height, maximum
GS-1530 and GS-1532 600 lbs
272 kg
GS-1930, GS-1932 and GS-2632 500 lbs
227 kg
GS-2032 800 lbs
363 kg
GS-2046 1200 lbs
544 kg
GS-2646 1000 lbs
454 kg
GS-3246 700 lbs
317 kg
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.

REV E
Part No. 96316 GS-30 • GS-32 • GS-46 2 - 3
Section 2 • SpecificationsJune 2009
Hydraulic Specifications
Hydraulic Oil Specifications
Hydraulic oil type Chevron Rando HD equivalent
ISO viscosity grade 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 III) 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
Biodegradable Petro Canada Environ MV 46
Statoil Hydra Way Bio Pa 32
BP Biohyd SE-S
Fire resistant UCON Hydrolube HP-5046
Quintolubric 822
Mineral based Shell Tellus T32
Shell Tellus T46
Chevron Aviation A
Continued use of Chevron
Aviation A hydraulic fluid when
ambient temperatures are
consistently above 32°F / 0°C may
result in component damage.
Note: Use Chevron Aviation A hydraulic fluid
when ambient temperatures consistently below
0°F / -17°C.
Note: Use Shell Tellus T46 hydraulic oil when oil
temperatures consistently exceed 205°F / 96°C.
Note: Genie specifications require additional
equipment and special installation instructions for
the approved optional fluids. Consult the Genie
Industries Service Department before use.
Function pump
Type Gear
Displacement per revolution 0.244 cu in
4 cc
Flow rate @ 2500 psi / 172 bar 4 gpm
15 L/min
Hydraulic tank return filter 10 micron with
25 psi / 1.7 bar bypass
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.
SPECIFICATIONS

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2 - 4 GS-30 • GS-32 • GS-46 Part No. 96316
June 2009Section 2 • Specifications
SPECIFICATIONS
Manifold Component
Specifications
Plug torque
SAE No. 2 50 in-lbs / 6 Nm
SAE No. 4 13 ft-lbs / 18 Nm
SAE No. 6 18 ft-lbs / 24 Nm
SAE No. 8 50 ft-lbs / 68 Nm
SAE No. 10 55 ft-lbs / 75 Nm
SAE No. 12 75 ft-lbs / 102 Nm
Valve Coil Resistance
Note: The following coil resistance specifications are at
an ambient temperature of 68°F / 20°C. As valve coil
resistance is sensitive to 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 27.2Ω
20V DC with diode (schematic item E and AC)
Solenoid valve, 3 position 4 way 19Ω
20V DC with diode (schematic item F)
Solenoid valve, 2 position 4 way 19Ω
20V DC with diode (schematic item H)
Solenoid valve, 2 position 2 way N.C. 25Ω
20V DC with diode (schematic item N)
Solenoid valve, 2 position 4 way 19Ω
20V DC with diode (schematic item AE and AI)
Solenoid valve, 3 position 5 way 19Ω
20V DC with diode (schematic item AG)
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.

REV E
Part No. 96316 GS-30 • GS-32 • GS-46 2 - 5
Section 2 • SpecificationsJune 2009
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.
JIC 37° Fittings
(swivel nut or hose connection)
SAE Dash size Thread Size Flats
-4 7/16-20 2
-6 9/16-18 1 1/4
-8 3/4-16 1
-10 7/8-14 1
-12 1 1/16-12 1
-16 1 5/16-12 1
-20 1 5/8-12 1
-24 1 7/8-12 1
SAE O-ring Boss Port
(tube fitting - installed into Aluminum)
SAE Dash size Torque
-4 11 ft-lbs / 14.9 Nm
-6 23 ft-lbs / 31.2 Nm
-8 40 ft-lbs / 54.2 Nm
-10 69 ft-lbs / 93.6 Nm
-12 93 ft-lbs / 126.1 Nm
-16 139 ft-lbs / 188.5 Nm
-20 172 ft-lbs / 233.2 Nm
-24 208 ft-lbs / 282 Nm
SAE O-ring Boss Port
(tube fitting - installed into Steel)
SAE Dash size Torque
-4 16 ft-lbs / 21.7 Nm
-6 35 ft-lbs / 47.5 Nm
-8 60 ft-lbs / 81.3 Nm
-10 105 ft-lbs / 142.4 Nm
-12 140 ft-lbs / 190 Nm
-16 210 ft-lbs / 284.7 Nm
-20 260 ft-lbs / 352.5 Nm
-24 315 ft-lbs / 427.1 Nm
SPECIFICATIONS

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2 - 6 GS-30 • GS-32 • GS-46 Part No. 96316
June 2009Section 2 • Specifications
a
b
c
b
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
Figure 2.
Note: Use the JIC 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 1
a hydraulic hose
b hex nut
c reference mark
d body hex fitting
b
c
a
d
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-lbs / 3.4 Nm.
2 Make a 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 2
a body hex fitting
b reference mark
c second mark
4 Tighten the hex nut until the mark on the hex
nut is aligned with the second mark on the body
hex fitting.
5 Operate all machine functions and inspect the
hoses and fittings and related components to
confirm that there are no leaks.
SPECIFICATIONS

REV E
Part No. 96316 GS-30 • GS-32 • GS-46 2 - 7
Section 2 • SpecificationsJune 2009
SPECIFICATIONS
Size
(mm)
in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm
516 1.8 21 2.4 41 4.63 54 6.18 58 6.63 78 8.84 68 7.75 91 10.3
619 3.05 36 4.07 69 7.87 93 10.5 100 11.3 132 15 116 13.2 155 17.6
745 5.12 60 6.83 116 13.2 155 17.6 167 18.9 223 25.2 1.95 22.1 260 29.4
ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm
85.4 7.41 7.2 9.88 14 19.1 18.8 25.5 20.1 27.3 26.9 36.5 23.6 32 31.4 42.6
10 10.8 14.7 14.4 19.6 27.9 37.8 37.2 50.5 39.9 54.1 53.2 72.2 46.7 63.3 62.3 84.4
12 18.9 25.6 25.1 34.1 48.6 66 64.9 88 69.7 94.5 92.2 125 81 110 108 147
14 30.1 40.8 40 54.3 77.4 105 103 140 110 150 147 200 129 175 172 234
16 46.9 63.6 62.5 84.8 125 170 166 226 173 235 230 313 202 274 269 365
18 64.5 87.5 86.2 117 171 233 229 311 238 323 317 430 278 377 371 503
20 91 124 121 165 243 330 325 441 337 458 450 610 394 535 525 713
22 124 169 166 225 331 450 442 600 458 622 612 830 536 727 715 970
24 157 214 210 285 420 570 562 762 583 791 778 1055 682 925 909 1233
LUBED DRY L UBED DRYLUBED DRY LUBED DRY
LUBEDDRYLUBED
Cl a ss 12. 9Cl a ss 4. 6
DRYLUBED
M ET RIC FAST ENER T ORQUE CHART
• This chart is to be used as a guide only unless noted elsewhere in this manual •
L UBED DRY
Class 10.9Cl a ss 8. 8
DRY
SIZE THREAD
in-lbs Nm in-lbs N m in-lbs Nm in-lbs Nm in-lbs N m
20 80 9 100 11.3 110 12.4 140 15.8 130 14.7
28 90 10.1 120 13.5 120 13.5 160 18 140 15.8
ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm
18 13 17.6 17 23 18 24 25 33.9 21 28.4
24 14 19 19 25.7 20 27.1 27 36.6 24 32.5
16 23 31.2 31 42 33 44.7 44 59.6 38 51.5
24 26 35.2 35 47.4 37 50.1 49 66.4 43 58.3
14 37 50.1 49 66.4 50 67.8 70 94.7 61 82.7
20 41 55.5 55 74.5 60 81.3 80 108.4 68 92.1
13 57 77.3 75 101.6 80 108.4 110 149 93 126
20 64 86.7 85 115 90 122 120 162 105 142
12 80 108.4 110 149 120 162 150 203 130 176
18 90 122 120 162 130 176 170 230 140 189
11 110 149 150 203 160 217 210 284 180 244
18 130 176 170 230 180 244 240 325 200 271
10 200 271 270 366 280 379 380 515 320 433
16 220 298 300 406 310 420 420 569 350 474
9320 433 430 583 450 610 610 827 510 691
14 350 474 470 637 500 678 670 908 560 759
8480 650 640 867 680 922 910 1233 770 1044
12 530 718 710 962 750 1016 990 1342 840 1139
7590 800 790 1071 970 1315 1290 1749 1090 1477
12 670 908 890 1206 1080 1464 1440 1952 1220 1654
7840 1138 1120 1518 1360 1844 1820 2467 1530 2074
12 930 1260 1240 1681 1510 2047 2010 2725 1700 2304
61460 1979 1950 2643 2370 3213 3160 4284 2670 3620
12 1640 2223 2190 2969 2670 3620 3560 4826 3000 4067
LUBEDDRYLUBED
SAE FASTENER TORQUE CHART
Grade 5
DRYL UBED
• This chart is to be used as a guide only unless noted elsewhere in this manual •
A574 High Strength
Black Oxid e Bol t s
Grade 8
LUBED
1/4
L UBED DRY L UBED DRY
1 1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
5/16
3/8
7/16
1/2
10.9 12.98.84.6

June 2009Section 2 • Specifications
2 - 8 GS-30 • GS-32 • GS-46 Part No. 96316
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