Service Manual - k2dt.com

1 Service ManualPart No. 97385 Rev E5 February 2009from GS3205-75407 Serial Number Rangefrom GS3005A-76000from GS3005B-76000from GS4605-75438from GS3005A-76000from GS3005B-76000from GS3205-75407from GS3205-75407from GS4605-75438from GS4605-75438GS -1530GS -1930GS -2032GS -2632GS -3232GS -2046GS -2646GS -3246 March 2007GS-30 GS-32 GS-46 Part No. 97385iiImportantRead, 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. 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.

2 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 Industries97385 Rev EMarch 2007 Fourth Edition, Fifth Printing" genie " is a registered trademark of GenieIndustries in the USA and many other countries."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-1530 and GS-1930 Service Manual ,Third Edition(from serial number 60000 to 75999) ..96316 genie GS-2032 Service Manual ,First Edition(before serial number 17408).

3 46326 genie GS-2032 and GS-2632 Service Manual ,Second Edition(from serial number 17408 to 59999) ..72963 genie GS-2032 and GS-2632 Service Manual ,Third Edition(from serial number 60000 to 75406) ..96316 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 genie GS-2046, GS-2646 and GS-3246 Service Manual , Third Edition(from serial number 60000 to 75437) ..96316 IntroductionMarch 2007 Part No. 97385GS-30 GS-32 GS-46iiiINTRODUCTIONS erial Number LegendGS30 05 A - 12345 ModelFacility code()used only for model manufacturedin multiple facilitiesSequencenumberPN - 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:ANSI ,714 lb / 1,231 kg500 lb / 227 kgN/AN/A100 lb / 445 N22005 Model yearSerial number(stamped on chassis)Serial number(stamped on chassis)Serial labelMarch 2007GS-30 GS-32 GS-46 Part No.

4 97385 This page intentionally left 2007 Part No. 97385GS-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:- 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 RulesMarch 2007GS-30 GS-32 GS-46 Part No. 97385 Workplace 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.

5 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 RULESS ection 1 Safety RulesPersonal SafetyAny person working on or around a machine mustbe aware of all known safety hazards. 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.

6 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 andother protective clothing if the situationwarrants aware of potential crushing hazardssuch as moving parts, free swinging orunsecured components when lifting orplacing loads. Always wear approved 2009 Part No. 97385GS-30 GS-32 GS-46 Table of ContentsIntroductionImportant Information ..iiSerial Number Information ..iiSerial Number Legend ..iiiSection 1 Safety RulesGeneral Safety Rules ..vSection 2 RevSpecificationsGMachine 2 - 1 Performance 2 - 2 Hydraulic 2 - 3 Manifold Component 2 - 4 Hydraulic Hose and Fitting Torque Specifications.

7 2 - 5 SAE and Metric Fasteners Torque 2 - 7 Section 3 RevScheduled maintenance 3 - 1 Pre-delivery Preparation 3 - 3 maintenance Inspection 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 Service ..3 - 8A-5 Grease the Steer Yokes .. 3 - 8viiFebruary 2009GS-30 GS-32 GS-46 Part No. 97385 TABLE OF CONTENTSS ection 3 RevScheduled maintenance procedures , continuedHChecklist B ProceduresB-1 Inspect the 3 - 9B-2 Inspect the Electrical 3 - 11B-3 Inspect the Tires, Wheels and Castle Nut 3 - 12B-4 Test the Emergency Stop .. 3 - 12B-5 Test the Key 3 - 13B-6 Test the Automotive-style Horn (if equipped).. 3 - 13B-7 Test the Drive Brakes ..3 - 14B-8 Test the Drive Speed - Stowed Position .. 3 - 17B-9 Test the Drive Speed - Raised 3 - 18B-10 Test the Slow Drive Speed.

8 3 - 19B-11 Perform Hydraulic Oil 3 - 20B-12 Inspect the Hydraulic Tank Cap Venting 3 - 20B-13 Check the Module Tray Latch 3 - 21B-14 Inspect the Voltage Inverter (if equipped) .. 3 - 22B-15 Test the Down Limit Switch and the Pothole Limit Switches .. 3 - 23B-16 Test the Up Limit Switch (if equipped)and the Outrigger Limit Switches (if equipped) .. 3 - 26 CChecklist C ProceduresC-1 Test the Platform Overload System (if equipped) ..3 - 27C-2 Replace the Hydraulic Tank Breather Cap -Models with Optional Hydraulic 3 - 29 DChecklist D ProceduresD-1 Check the Scissor Arm Wear Pads ..3 - 30D-2 Replace the Hydraulic Tank Return Filter Element .. 3 - 33 CChecklist E ProcedureE-1 Test or Replace the Hydraulic Oil .. 3 - 34viiiFebruary 2009 Part No. 97385GS-30 GS-32 GS-46 TABLE OF CONTENTSS ection 4 RevRepair 4 - 1 GPlatform Controls1-1 Circuit Boards .. 4 - 21-2 Controller 4 - 41-3 Software 4 - 91-4 Outrigger 4 - 141-5 Outrigger Controls Software 4 - 17 BPlatform 4 - 342-2 Platform 4 - 35 CScissor Components3-1 Scissor Assembly, GS-1530 and 4 - 363-2 Scissor Assembly, GS-1930 and 4 - 423-3 Scissor Assembly, GS-2032 and 4 - 503-4 Scissor Assembly, GS-2632 and 4 - 563-5 Scissor Assembly, GS-3232 and 4 - 643-6 Lift 4 - 723-7 Platform Overload System.

9 4 - 77 DGround Controls4-1 Manual Platform Lowering 4 - 794-2 Level 4 - 80 BHydraulic Pump5-1 Function 4 - 86ixFebruary 2009GS-30 GS-32 GS-46 Part No. 97385 Section 4 RevRepair procedures , continuedFManifolds6-1 Function Manifold Components -GS-1530, GS-1532, GS-1930 and 4 - 886-2 Function Manifold Components -GS-2032, GS-2632, GS-3232, GS-2046, GS-2646 and GS-3246 .. 4 - 906-3 Outrigger Function Manifold Components 4 - 926-4 Outrigger Cylinder Manifold Components 4 - 936-5 Check Valve Manifold Components -GS-1530, GS-1532, GS-1930 and 4 - 946-6 Valve Adjustments - Function 4 - 956-7 Valve 4 - 99 BHydraulic Tank7-1 Hydraulic 4 - 101 BSteer Axle Components8-1 Yoke and Drive 4 - 1028-2 Steer 4 - 1038-3 Steer 4 - 104 ANon-steer Axle Components9-1 Drive 4 - 105 ABrake Release Hand Pump Components10-1 Brake Release Hand Pump Components .. 4 - 106 AOutrigger Components11-1 Outrigger Cylinder.

10 4 - 107 TABLE OF CONTENTSxFebruary 2009 Part No. 97385GS-30 GS-32 GS-46 Section 5 RevFault 5 - 1 CFault Code 5 - 3 BOutrigger Fault Code Chart .. 5 - 5 Section 6 - 1 CElectrical Component Legend .. 6 - 2 BWire Color 6 - 3 DECM Pin-out Legend .. 6 - 4 AOutrigger ECM Pin-out 6 - 5 BWiring Diagram - Ground Controls and Level Sensor 6 - 6 BWiring Diagram - Platform Control Box and Outrigger Control Pad ..6 - 7 CLimit Switch 6 - 8 BElectrical Symbols 6 - 9 Electrical Schematics - ANSI, CSA and Australia ModelsEGS-1530/1532/1930/1932(from serial number GS3005A-76000 to GS3006A-83067)(from serial number GS3005B-76000 to GS3006B-79659) ..6 - 10 CGS-1530/1532/1930/1932(from serial number GS3006A-83068 to GS3007A-87490)(from serial number GS3006B-79660 to GS3007B-82543) ..6 - 14 BGS-1530/1532/1930/1932(from serial number GS3007A-87491 to GS3007A-89537)(from serial number GS3007B-82544 to GS3007B-84599) ..6 - 18 CGS-1530/1532/1930/1932(after serial number GS3007A-89537)(after serial number GS3007B-84599).