Terex Genie GS-1530 Bedienungsanleitung

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

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.

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.

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

100 lb / 445 N

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.

September 2005

Part No. 96316 GS-30 • GS-32 • GS-46

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

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 .........................................................................................

Serial Number Information .................................................................................

Serial Number Legend ......................................................................................

iii

Section 1 Safety Rules

General Safety Rules ........................................................................................

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

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

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