Terex Genie GS-1532 Installation and operating manual

Service and Repair Manual
Serial Number Rang
e
GS
™
-1530/1532
Refer to t
he
inside cover
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics
GS
™
-1930/1932
GS
™
-2032/2632/3232
GS
™
-2046/2646/3246
GS
™
-4047
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
Part No. 1272217GT
Rev E
March 2021

Service and Repair Manual March 2021
Introduction
iiGS™-30 • 32 • 46 • 47 Part No. 1272217GT
Introducti on Introducti on
Compliance
Machine Classification
Group A/Type 3 as defined by ISO 16368
Machine Design Life
Unrestricted with proper operation, inspection and
scheduled maintenance.
Contact Us:
Internet: www.genielift.com
E-mail: [e-mail]
Find a Manual for this Model
Go to http://www.genielift.com
Service Manuals, Maintenance Manuals, Service
and Repair Manuals, Parts Manuals and
Operator's Manuals.
Copyright © 2016 by Terex Corporation
1272215GT Rev E, March 2021
First Edition, Fifth 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.
Serial Number Range
Use the following chart to identify the specific
serial number for models included in this manual.
GS
-1530, GS-1532, GS-1930, GS-1932
from SNGS3010A-110000 to GS3016A-142280
from SNGS3011C-10000 to GS3016C-23999
from SNGS3014D-101 to GS3016D-6079
from SNGS3016P-151487 to GS3016P-160599
from SN GS30C-24000
from SN GS30D-6080 to GS30D-40100
from SN GS30P-160600 to GS30P-200100
GS-2032, GS-2632, GS-3232
from SNGS3211A-110000 to GS3216A-142675
from SNGS3212C-10000 to GS3216C-17299
from SNGS3216P-142676 toGS3216P-148699
from SN GS32C-17300
from GS32D-101 to GS32D-10100
from SN GS32P-148700 to GS32P-200100
GS
-2046, GS-2646, GS-3246
from SNGS4612A-110000 to GS4616A-138361
from SNGS4612C-10000 to GS4616C-18099
from SNGS4614D-101 to GS4616D-5029
from SNGS4616P-138362 to GS4616P-141799
from SN GS46C-18100
from SN GS46D-5030 to GS46D-20100
from SN GS46P-141800 to GS46P-200100
GS-4047
from SN GS4712C
-101 to GS4716C-4499
from SN GS4714D
-101 to GS4716D-3959
from SN GS4716P
-101 to GS4716P-999
from SN GS47C
-4500
from SN
GS47D-3960
from SN GS47P
-1000

March 2021 Service and Repair Manual
Introduction
Part No. 1272217GT GS™-30 • 32 • 46 • 47 iii
Revision History
Revision Date Section Procedure / Page / Description
A 3/2016 Initial Release
A1 5/2016 Repair Procedures 2-3, 2-4, 9-11
Diagnostics H067 fault
A2 5/2016 Repair Procedure 2-6
Diagnostics Type CXXX and UXXX fault codes
A3 9/2016 Introduction Serial Number Legend
Specifications Add drive speed stowed parameters
B 4/2017 Repair Procedure 11-1
Diagnostics Battery charger and fault codes
B1 12/2017 Schematics GS46, GS47 AS/CE
C 1/2019 All Sections Added GS-1330m
D 8/2019 All Sections Added GS-4655
E 3/2021 Add ending serial break
All Sections Remove GS-1330m, GS-4655
Reference Examples:
Electronic Version
Click on any content or procedure in the Table of Contents to view
the update.
Section – Repair Procedure, 4-2
Section – Fault Codes, All charts
Section – Schematics, Legends and schematics

Service and Repair Manual March 2021
Introduction
iv GS™-30 • 32 • 46 • 47 Part No. 1272217GT
Revision History(continued)
Revision Date Section Procedure / Page / Description
Reference Examples:
Electronic Version
Click on any content or procedure in the Table of Contents to view
the update.
Section – Repair Procedure, 4-2
Section – Fault Codes, All charts
Section – Schematics, Legends and schematics

March 2021 Service and Repair Manual
Introduction
Part No. 1272217GT GS™-30 • 32 • 46 • 47 v
Serial Number Legend
To August 31, 2016
1. Model
2. Model year
3. Facility code
4. Sequence number
5. Serial label located on chassis
6. Serial number (stamped on chassis)
From September 1, 2016
1. Model
2. Facility code
3. Sequence number
4. Serial label located on chassis
5. Serial number (stamped on chassis)

Service and Repair Manual March 2021
Safety Rules
vi GS™-30 • 32 • 46 • 47 Part No. 1272217GT
Section 1 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 governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.

March 2021 Service and Repair Manual
Safety Rules
Part No. 1272217GT GS™-30 • 32 • 46 • 47 vii
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 proced
ure 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 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 pro
tective 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
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
ampl
e capacity.
Be sure that fasteners inte
nded 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.

March 2021
Table of Contents
viii GS™-30 • 32 • 46 • 47 Part No. 1272217GT
Introduction Introduction .......................................................................................................... ii
Find a Manual for this Model...................................................................................ii
Serial Number Range .............................................................................................ii
Revision History .....................................................................................................iii
Serial Number Legend ........................................................................................... v
Section 1 Safety Rules......................................................................................................... vi
General Safety Rules.............................................................................................vi
Section 2 Specifications....................................................................................................... 1
Machine Specifications .......................................................................................... 1
Performance Specifications (models without proportional lift function) ................. 3
Performance Specifications (models with proportional lift).................................... 5
Hydraulic Oil Specifications ................................................................................... 7
Hydraulic Component Specifications ................................................................... 10
Manifold Component Specifications..................................................................... 11
Hydraulic Hose and Fitting Torque Specifications............................................... 12
Torque Procedure ................................................................................................ 13

March 2021
Table of Contents
Part No. 1272217GT GS™-30 • 32 • 46 • 47 ix
Section 3 Repair Procedures .............................................................................................15
Introduction...........................................................................................................15
Platform Controls ...............................................................................................17
1-1 Circuit Board...................................................................................................19
1-2 Joystick...........................................................................................................20
1-3 Platfrom Controls Alarm .................................................................................20
1-4 Platform Emergency Stop Button...................................................................21
Ground Controls.................................................................................................22
2-1 Software Revision Level.................................................................................23
2-2 Machine Setup ...............................................................................................24
2-3 Loading or Updating Machine Software.........................................................25
2-4 Using a Wi-Fi Router to Connect to the SmartLink Web Service Tool ..........30
2-5 Service Override Mode ..................................................................................32
2-6 Level Sensors ................................................................................................34
2-7 Manual Platform Lowering Cable...................................................................49
2-8 Outrigger Calibration ......................................................................................50
Hydraulic Tank....................................................................................................51
3-1 Hydraulic Tank ...............................................................................................51
Hydraulic Pump ..................................................................................................52
4-1 Hydraulic Pump..............................................................................................52
How to Remove the Hydraulic Pump ..............................................................53

March 2021
Table of Contents
x GS™-30 • 32 • 46 • 47 Part No. 1272217GT
Manifolds ............................................................................................................ 54
5-1 Function Manifold Components – GS-1530, GS-1532,
GS-1930 and GS-1932 ................................................................................ 54
5-2 Function Manifold Components – GS-2032, GS-2632, GS-3232,
GS-2046, GS-2646 and GS-3246................................................................ 56
5-3 Function Manifold Components – GS-4047 .................................................. 58
5-4 Check Valve Manifold Components – GS-1530, GS-1532,
GS-1930 and GS-1932 ................................................................................ 60
5-5 Lift Pressure Selector Manifold Components – GS-4047.............................. 61
5-6 Outrigger Function Manifold Components – GS-3232 .................................. 62
5-7 Outrigger Cylinder Manifold Components – GS-3232................................... 63
5-8 Valve Adjustments – Function Manifold ........................................................ 64
5-9 Valve Coils..................................................................................................... 70
Steer Axle Components .................................................................................... 72
6-1 Yoke and Drive Motor .................................................................................... 72
6-2 Steer Cylinder ................................................................................................ 73
6-3 Steer Bellcrank .............................................................................................. 74
Non-Steer Axle Components ............................................................................ 75
7-1 Drive Brake .................................................................................................... 75
Brake Release Hand Pump Components ........................................................ 76
8-1 Brake Release Hand Pump Components...................................................... 76