Service Manual - Genielift

1 Service ManualPart No. 96316 Rev E5 November 2010from GS3204-60000to GS3205-75406 Serial Number Rangefrom GS3003-60000to GS3005-75999from GS4604-60000to GS4605-75437from GS3003-60000to GS3005-75999from GS3204-60000to GS3205-75406from GS4604-60000to GS4605-75437from GS4604-60000to GS4605-75437GS -1530/32GS -1930/32GS -2032GS -2632GS -2046GS -2646GS -3246 September 2005GS-30 GS-32 GS-46 Part No. 96316iiImportantRead, understand and obey the safety rules andoperating instructions in the appropriate Operator'sManual on your machine before attempting anymaintenance mechanical, hydraulic and electricalskills are required to perform most , several procedures require specializedskills, tools, lifting equipment and a suitableworkshop.

2 In these instances, we stronglyrecommend that maintenance and repair beperformed at an authorized Genie dealerservice PublicationsGenie 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 all other 1997 by Genie Industries96316 Rev ESeptember 2005 Third Edition, Fourth Printing"Genie" is a registered trademark of GenieIndustries in the USA and many other countries.

3 "GS" is a trademark of Genie Industries. Printed on recycled paperPrinted in : Number InformationGenie Industries offers the following ServiceManuals for these models:TitlePart 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).

4 48339 Genie GS-2046, GS-2646 and GS-3246 Service Manual , Second Edition(from serial number 17408 to 59999)..72972 IntroductionJune 2009 Part No. 96316GS-30 GS-32 GS-46iiiINTRODUCTIONS erial Number LegendPN - 77055 Model:Model year:Manufacture date:Maximum allowable inclination of the chassis:Country of manufacture: USAThis machine complies with:Serial number:Rated work load (including occupants):Genie Industries18340 NE 76th StreetRedmond, WA 98052 USAE lectrical schematic number:Gradeability:Maximum allowable side force :Maximum number of platform occupants:Machine unladen weight.

5 ANSI ,714 lb / 1,231 kg500 lb / 227 kgN/AN/A100 lb / 445 N22005 Serial number(stamped on chassis)Serial number(stamped on chassis)Serial labelGS30 05 - 12345 ModelSequencenumberModel yearSeptember 2005GS-30 GS-32 GS-46 Part No. 96316 This page intentionally left 2005 Part No. 96316GS-30 GS-32 GS-46vDangerFailure to obey the instructions and safety rulesin this Manual and the appropriate Operator'sManual on your machine will result in death orserious 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.

6 - manufacturer s instructions and safety rules- employer s safety rules and worksiteregulations- applicable governmental regulationsYou have the appropriate tools, liftingequipment and a suitable RulesSection 1 Safety RulesSeptember 2005GS-30 GS-32 GS-46 Part No. 96316viSAFETY RULESS ection 1 Safety RulesWorkplace SafetyBe sure to keep sparks, flames andlighted tobacco away from flammable andcombustible materials like battery gasesand engine fuels. Always have an approved fireextinguisher within easy sure that all tools and working areasare properly maintained and ready foruse.

7 Keep work surfaces clean and free ofdebris that could get into machine components andcause sure any forklift, overhead crane orother lifting or supporting device is fullycapable of supporting and stabilizing theweight to be lifted. Use only chains or straps thatare in good condition and of ample sure that fasteners intended for onetime use ( , cotter pins and self-lockingnuts) are not reused. These componentsmay fail if they are used a second sure to properly dispose of old oil orother fluids. Use an approved be environmentally safe .Be sure that your workshop or work areais properly ventilated and well SafetyAny person working on or around a machine mustbe aware of all known safety hazards.

8 Personalsafety and the continued safe operation of themachine should be your top each procedure thoroughly. Thismanual and the decals on the machine,use 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 an imminently hazardoussituation which, if not avoided, willresult in death or serious a potentially hazardoussituation which, if not avoided,could result in death or a potentially hazardoussituation which, if not avoided,may cause minor or a potentially hazardoussituation which, if not avoided,may result in property sure to wear protective eye wear and otherprotective clothing if the situation aware of potential crushing hazardssuch as moving parts.

9 free swinging orunsecured components when lifting orplacing loads. Always wear approvedsteel-toed 2009 Part No. 96316GS-30 GS-32 GS-46 Table of ContentsIntroductionImportant Information ..iiSerial Number Information ..iiSerial Number 1 Safety RulesGeneral Safety Rules ..vSection 2 RevSpecificationsEMachine 2 - 1 Performance 2 - 2 Hydraulic 2 - 3 Manifold Component 2 - 4 Hydraulic Hose and Fitting Torque Specifications .. 2 - 5 SAE and Metric Fasteners Torque Charts .. 2 - 7 Section 3 RevScheduled Maintenance 3 - 1 Pre-delivery Preparation 3 - 3 Maintenance Inspection Report.

10 3 - 5 CChecklist A ProceduresA-1 Inspect the Manuals and Decals ..3 - 6A-2 Perform Pre-operation 3 - 7A-3 Perform Function 3 - 7A-4 Perform 30 Day 3 - 8A-5 Grease the Steer Yokes .. 3 - 8viiJune 2009GS-30 GS-32 GS-46 Part No. 96316 TABLE OF CONTENTSS ection 3 RevScheduled Maintenance Procedures, continuedFChecklist B ProceduresB-1 Inspect the 3 - 9B-2 Inspect the Electrical Wiring .. 3 - 11B-3 Inspect the Tires and Wheels (including castle nut torque) .. 3 - 12B-4 Test the Emergency 3 - 12B-5 Test the Key 3 - 13B-6 Test the Automotive-style Horn (if equipped).