GS-2032 Service Manual

1 First Edition, Third PrintingREV C1 Part No. 46326GS-2032 TechnicalPublications ServiceManual(before serial number 17408)Genie GS-2032 Part No. 46326 Service Manual - First EditioniiIntroductionGenie North AmericaTelephone (425) 881-1800 Toll free in 800 536-1800 Toll free in Canada 800 426-8089 Fax (425) 882-9260E-mail: EuropeOffice Telephone (44) 01636-605030 Office Fax (44) 01636-611090 Parts Telephone (44) 01636-605002 Parts Fax (44) 01636-611091 Copyright 1997 by Genie IndustriesFirst Edition:First Printing August, 1997 Second Printing March, 1999 Third Printing October, 1999"Genie" is a registered trademarkof Genie Industries in the and many othercountries. "GS" is a trademark ofGenie machines comply withANSI/SIA Printed on recycled paperPrinted in , understand and obey the safety rules andoperating instructions in the Genie GS-2032 &Genie GS-2046 & Genie GS-2646 & GenieGS-3246 Operator s Manual before attempting anymaintenance or repair Manual provides detailed scheduledmaintenance information for the machine ownerand user.

2 It also provides troubleshooting andrepair procedures for qualified mechanical, hydraulic and electricalskills are required to perform most , several procedures require specializedskills, tools, lifting equipment and a suitableworkshop. In these instances, we stronglyrecommend that maintenance and repair beperformed at an authorized Genie dealerservice Industries has endeavored to deliver thehighest degree of accuracy possible. However,continuous improvement of our products is a Geniepolicy. Therefore, product specificationsare subject to change without are encouraged to notify Genie of errorsand send in suggestions for improvement. Allcommunications will be carefully considered forfuture printings of this and other manuals. Pleasewrite to the technical publications team in care ofGenie Industries, PO Box 97030, Redmond WA98073-9730 you have any questions, please call No.

3 46326 Genie GS-2032 Service Manual - First EditioniiiDangerFailure to obey the instructions and safety rulesin this Manual and the Genie GS-2032 & GenieGS-2046 & Genie GS-2646 & Genie GS-3246 Operator s Manual will result in death or of the hazards identified in theoperator s Manual are also safety hazardswhen maintenance and repair proceduresare Not Perform MaintenanceUnless:You are trained and qualified to performmaintenance on this read, understand and obey:- manufacturer s instructions and safety rules- employer s safety rules and worksiteregulations- applicable governmental regulationsYou have the appropriate tools, liftingequipment and a suitable RulesGenie GS-2032 Part No. 46326 Service Manual - First EditionSAFETY RULESP ersonal SafetyAny person working on or around a machine mustbe aware of all known safety hazards.

4 Personalsafety and the continued safe operation of themachine should be your top each procedure thoroughly. Thismanual and the decals on the machineuse signal words to identify the following:Safety alert symbol used to alertpersonnel to potential personalinjury hazards. Obey all safetymessages that follow this symbolto avoid possible injury or used to indicate thepresence of an imminentlyhazardous situation which, if notavoided, will result in death orserious used to indicate thepresence of a potentiallyhazardous situation which, if notavoided, could result in death orserious with safety alert symbol used to indicate the presence of apotentially hazardous situationwhich, if not avoided, may causeminor or moderate without safety alertsymbol used to indicate thepresence of a potentiallyhazardous situation which, if notavoided.

5 May result in used to indicate operationor maintenance sure to wear protective eye wear and otherprotective clothing if the situation aware of potential crushing hazardssuch as moving parts and free swinging orunsecured components when lifting orplacing loads. Always wear approvedsteel-toed SafetyBe sure to keep sparks, flames and lightedtobacco away from flammable andcombustible materials such as batterygases and engine fuels. Always have anapproved fire extinguisher within easy sure that all tools and working areas areproperly maintained and ready for work surfaces clean and free ofdebris that could get into machinecomponents and cause sure that your workshop or work areais properly ventilated and well sure any forklift, overhead crane or other liftingor supporting device is fully capable ofsupporting and stabilizing the weight to belifted.

6 Use only chains or straps that are ingood condition and of ample sure that fasteners intended for one time use( , cotter pins and self-locking nuts) arenot reused. These components may fail ifthey are used a second sure to properly dispose of old oil orother fluids. Use an approved be environmentally safe .ivPart No. 46326 Genie GS-2032 Service Manual - First EditionvPower SourceThe Genie GS-2032 machines are powered byfour six-volt (225 AH) batteries. The four batteriesare wired in series to produce 24 SystemAll machine functions are performed by thehydraulic system. The hydraulic system is poweredby a single-section gear pump. When the pump isactivated, it supplies hydraulic fluid under pressureto the function manifold, where the control valvesare located.

7 To protect from over-pressurization ofthe hydraulic system, the pump is provided with apressure relief a machine function is accomplished byactuating or moving a switch and/or control handle,which sends voltage to the ECM. The ECM thensends the signal to the appropriate directionalcontrol valve. The directional valve determineswhich direction the hydraulic fluid will software determines the volume of fluidin relation to the proportional valve input SystemLimit switches are found in various locations on themachine. The function of a limit switch is tocommunicate the operating position of the machineto the ECM (Electronic Control Module). When achange in signal is received from a limit switch, theECM responds by limiting the drive speed to per hour ( km/h), according to the defaultsettings in the ECM ControlsThe GS-2032 machines are equipped withoperational controls which are found in twolocations: the ground controls, located on thehydraulic tank side of the machine, and theplatform controls, located in the platform.

8 All lift anddrive functions are available at the platformcontrols. Only platform up/down functions areavailable at the ground ECM uses input from the ground or platformcontrols to activate the various machine ECM has predetermined settings for thevarious machine joystick is fitted with a 5000 ohmpotentiometer. With the joystick in the neutralposition, the potentiometer will measure 2730ohms. These signals are sent to the multiplex card,then down to the ECM to control the voltagesupplied to the proportional valve. Twomicroswitches mounted on the joystick tell theECM the drive direction desired. A thumb rockerswitch on the top of the joystick is used on the platform control box lid ofmachines before serial number 17408 are buttonsand a switch that, when activated, sends a signalto the ECM through the multiplex card.

9 Onmachines after serial number 17407, the platformcontrol box lid has a decal/membrane pad. This isa touch-activated pad incorporating wiring,switches and LEDs that are resistant to theenvironment. Activating any of the buttons on thepad will send a signal to the ECM through themultiplex diagnostic display is located at the battery packside of the machine to aid in troubleshooting. If theTheory of OperationGenie GS-2032 Part No. 46326 Service Manual - First EditionTHEORY OF OPERATION vimachine malfunctions, a fault code will be shown inthe display electronic components is not , use compressed air to remove debris fromthese damage shock or impact to the damage may not bevisible from the No. 46326 Genie GS-2032 Service Manual - First EditionTable of ContentsviiIntroductionImportant Information.

10 IiSection OneSafety RulesGeneral Safety Rules ..iiiTheory of Operation ..vSection TwoSpecificationsMachine Specifications .. 2 - 1 Performance 2 - 2 Hydraulic 2 - 2 Hydraulic Hose and Fitting Torque 2 - 3 Section ThreeScheduled Maintenance 3 - 1 Table 3 - 2 Table 3 - 3 Table 3 - 3 Table 3 - 3 Maintenance Inspection Report ..3 - 4 Genie GS-2032 Part No. 46326 Service Manual - First EditionTABLE OF CONTENTS viiiSection FourScheduled Maintenance 4 - 1A-1 Inspect the Operator s and Safety Manuals .. 4 - 2A-2 Inspect the Decals and Placards ..4 - 2A-3 Inspect for Damage and Loose or Missing Parts .. 4 - 3A-4 Check the Hydraulic Oil 4 - 4A-5 Check for Hydraulic 4 - 4A-6 Test the Platform and Ground Controls ..4 - 5A-7 Test the Manual Platform Lowering 4 - 6A-8 Test the Tilt Sensor.