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

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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

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GS-30 • GS-32 • GS-46 Part No. 96316
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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

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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
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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
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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
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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