Genie GS-1530 Installations- und Betriebsanleitung

Service and Repair Manual

GS-1530/32

This manual includes:

Repair procedures

Fault Codes

Electrical and

Hydraulic

Schematics

GS-1930/32

GS-2032

GS-2632

GS-3232

For detailed maintenance

procedures, refer to the

appropriate Maintenance Manual

for your machine.

GS-2046

GS-2646

GS-3246

GS-4047

Refer to the inside cover for a list of models

included in this manual.

Part No. 1272217

Rev A3

September 2016

Service and Repair Manual September 2016

Introduction

ii GS-30 • GS-32 • GS-46 • GS-47 Part No. 1272217

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

procedure.

This manual 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.

Compliance

Machine Classification

Group A/Type 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.

Internet: www.genielift.com

E-mail: awp.techpub@terex.com

Find a Manual for this 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.

1272215 Rev A, June 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 Service and Repair Manual

Introduction

Part No. 1272217 GS-30 • GS-32 • GS-46 • GS-47 iii

Serial Number Range

Use the following chart to identify the specific serial

number for models included in this manual.

Models

Serial number

-1530 / GS-1532

-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

-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

-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

GS46C-18100

from GS46D

-5030

from GS46P

-141800

-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

Service and Repair Manual September 2016

Introduction

iv GS-30 • GS-32 • GS-46 • GS-47 Part No. 1272217

RevisionHistory

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

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

September 2016 Service and Repair Manual

Introduction

Part No. 1272217 GS-30 • GS-32 • GS-46 • GS-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 September 2016

Safety Rules

vi GS-30 • GS-32 • GS-46 • GS-47 Part No. 1272217

Section 1 Safet y Rul es Gener al Safety R ules

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.

September 2016 Service and Repair Manual

Safety Rules

Part No. 1272217 GS-30 • GS-32 • GS-46 • GS-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 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 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 crush

ing 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 extingu

isher 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 an

d 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

viii GS-30 • GS-32 • GS-46 • GS-47 Part No. 1272217

Introduction Introduction...........................................................................................................ii

Important Information .............................................................................................ii

Find a Manual for this Model..................................................................................ii

Serial Number Range............................................................................................ iii

Revision History.....................................................................................................iv

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 Specification ...........................................................................................7

Hydraulic Component Specifications....................................................................10

Manifold Component Specifications.....................................................................11

Hydraulic Hose and Fitting Torque Specifications................................................12

Torque Procedure.................................................................................................13

September 2016

Table of Contents

Part No. 1272217 GS-30 • GS-32 • GS-46 • GS-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......................................................................................51

Hydraulic Tank....................................................................................................52

3-1 Hydraulic Tank ...............................................................................................52

Hydraulic Pump..................................................................................................53

4-1 Hydraulic Pump..............................................................................................53

How to Remove the Hydraulic Pump..............................................................54

September 2016

Table of Contents

x GS-30 • GS-32 • GS-46 • GS-47 Part No. 1272217

Manifolds.............................................................................................................56

5-1 Function Manifold Components – GS-1530, GS-1532, GS-1930 and GS-1932

5-2 Function Manifold Components – GS-2032, GS-2632, GS-3232, GS-2046,

GS-2646 and GS-3246.................................................................................58

5-3 Function Manifold Components – GS-4047...................................................60

5-4 Check Valve Manifold Components – GS-1530, GS-1532, GS-1930 and

GS-1932........................................................................................................62

5-5 Lift Pressure Selector Manifold Components – GS-4047 ..............................63

5-6 Outrigger Function Manifold Components – GS-3232...................................64

5-7 Outrigger Cylinder Manifold Components – GS-3232 ...................................65

5-8 Valve Adjustments – Function Manifold.........................................................66

5-9 Valve Coils......................................................................................................72

Steer Axle Components.....................................................................................74

6-1 Yoke and Drive Motor.....................................................................................74

6-2 Steer Cylinder.................................................................................................75

6-3 Steer Bellcrank...............................................................................................76

Non-Steer Axle Components.............................................................................77

7-1 Drive Brake.....................................................................................................77

Brake Release Hand Pump Components.........................................................78

8-1 Brake Release Hand Pump Components ......................................................78

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