Genie GS-2046 & GS-2646 & GS-3246 Lift Service & Repair Manual

Service Manual Part No. 97385 Rev E9 January 2011 from GS3205-75407 from GS3208C-101 Serial Number Range from GS3005A-76000 from GS3005B-76000 from GS3008C-101 from GS4605-75438 from GS3005A-76000 from GS3005B-76000 from GS3008C-101 from GS3205-75407 from GS3208C-101 from GS3205-75407 from GS3208C-101 from GS4605-75438 from GS4605-75438 GS -1530/32 GS -1930/32 GS -2032 GS -2632 GS -3232 GS -2046 GS -2646 GS -3246

January 2011 GS-30 • GS-32 • GS-46 Part No. 97385 ii 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. 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 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. Contact Us: www.genieindustries.com e-mail: techpub@terex.com Copyright © 1997 by Genie Industries 97385 Rev E March 2007 Fourth Edition, Fifth 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. 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-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) ............................... 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 Introduction

January 2011 Part No. 97385 GS-30 • GS-32 • GS-46 iii INTRODUCTION Serial Number Legend GS30 05 A - 12345 Model Facility code ( ) used only for model manufactured in multiple facilities Sequence number 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 GS3005A-12345 04/12/05 ES0141 2,714 lb / 1,231 kg 500 lb / 227 kg N/A N/A 100 lb / 445 N 2 2005 Model year Serial number (stamped on chassis) Serial number (stamped on chassis) Serial label

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January 2011 Part No. 97385 GS-30 • GS-32 • GS-46 v 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

January 2011 GS-30 • GS-32 • GS-46 Part No. 97385 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. vi SAFETY RULES Section 1 • Safety Rules 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.

January 2011 Part No. 97385 GS-30 • GS-32 • GS-46 Table of Contents Introduction Important Information ......................................................................................... ii Serial Number Information ................................................................................. ii Serial Number Legend ...................................................................................... iii Section 1 Safety Rules General Safety Rules ........................................................................................ v Section 2 Rev Specifications G 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 C Checklist 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

January 2011 GS-30 • GS-32 • GS-46 Part No. 97385 TABLE OF CONTENTS Section 3 Rev Scheduled Maintenance Procedures, continued J Checklist B Procedures B-1 Inspect the Batteries ........................................................................... 3 - 9 B-2 Inspect the Electrical Wiring ............................................................. 3 - 11 B-3 Inspect the Tires, Wheels and 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 Test the Slow Drive Speed ............................................................... 3 - 19 B-11 Perform Hydraulic Oil Analysis ......................................................... 3 - 20 B-12 Inspect the Hydraulic Tank Cap Venting System .............................. 3 - 20 B-13 Check the Module Tray Latch Components ...................................... 3 - 21 B-14 Inspect the Voltage Inverter (if equipped) ......................................... 3 - 22 B-15 Test the Down Limit Switch and the Pothole Limit Switches ............. 3 - 23 B-16 Test the Up Limit Switch (if equipped) and the Outrigger Limit Switches (if equipped) ................................. 3 - 26 C Checklist C Procedures C-1 Test the Platform Overload System (if equipped) ............................. 3 - 27 C-2 Replace the Hydraulic Tank Breather Cap - Models with Optional Hydraulic Oil ................................................... 3 - 29 E Checklist D Procedures D-1 Check the Scissor Arm Wear Pads .................................................. 3 - 30 D-2 Replace the Hydraulic Tank Return Filter Element ........................... 3 - 33 C Checklist E Procedure E-1 Test or Replace the Hydraulic Oil ..................................................... 3 - 34 viii

January 2011 Part No. 97385 GS-30 • GS-32 • GS-46 TABLE OF CONTENTS Section 4 Rev Repair Procedures Introduction .................................................................................................. 4 - 1 J Platform Controls 1-1 Circuit Boards .................................................................................... 4 - 2 1-2 Controller Adjustments ....................................................................... 4 - 4 1-3 Software Configuration ....................................................................... 4 - 9 1-4 Outrigger ECM ................................................................................. 4 - 14 1-5 Outrigger Controls Software Update ................................................ 4 - 17 B Platform Components 2-1 Platform ............................................................................................ 4 - 34 2-2 Platform Extension ........................................................................... 4 - 35 C Scissor Components 3-1 Scissor Assembly, GS-1530 and GS-1532 ...................................... 4 - 36 3-2 Scissor Assembly, GS-1930 and GS-1932 ...................................... 4 - 42 3-3 Scissor Assembly, GS-2032 and GS-2046 ...................................... 4 - 50 3-4 Scissor Assembly, GS-2632 and GS-2646 ...................................... 4 - 56 3-5 Scissor Assembly, GS-3232 and GS-3246 ...................................... 4 - 64 3-6 Lift Cylinder ...................................................................................... 4 - 72 3-7 Platform Overload System ............................................................... 4 - 77 D Ground Controls 4-1 Manual Platform Lowering Cable ..................................................... 4 - 79 4-2 Level Sensors .................................................................................. 4 - 80 B Hydraulic Pump 5-1 Function Pump ................................................................................. 4 - 86 ix

January 2011 GS-30 • GS-32 • GS-46 Part No. 97385 Section 4 Rev Repair Procedures, continued F Manifolds 6-1 Function Manifold Components - GS-1530, GS-1532, GS-1930 and GS-1932 .................................... 4 - 88 6-2 Function Manifold Components - GS-2032, GS-2632, GS-3232, GS-2046, GS-2646 and GS-3246 .... 4 - 90 6-3 Outrigger Function Manifold Components - GS-3232 ........................................................................................... 4 - 92 6-4 Outrigger Cylinder Manifold Components - GS-3232 ........................................................................................... 4 - 93 6-5 Check Valve Manifold Components - GS-1530, GS-1532, GS-1930 and GS-1932 .................................... 4 - 94 6-6 Valve Adjustments - Function Manifold ............................................ 4 - 95 6-7 Valve Coils ....................................................................................... 4 - 99 B Hydraulic Tank 7-1 Hydraulic Tank ............................................................................... 4 - 101 B Steer Axle Components 8-1 Yoke and Drive Motor .................................................................... 4 - 102 8-2 Steer Cylinder ................................................................................ 4 - 103 8-3 Steer Bellcrank ............................................................................... 4 - 104 A Non-steer Axle Components 9-1 Drive Brake .................................................................................... 4 - 105 A Brake Release Hand Pump Components 10-1 Brake Release Hand Pump Components ....................................... 4 - 106 A Outrigger Components 11-1 Outrigger Cylinder .......................................................................... 4 - 107 TABLE OF CONTENTS x

Genie GS-2046 & GS-2646 & GS-3246 Lift Service & Repair Manual

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