gs-2032 service manual manual/service46326.pdfservice manual - first edition iii danger failure to...

First Edition, Third PrintingREV C1

Part No. 46326

GS-2032

TechnicalPublications

®

ServiceManual

(before serial number 17408)

Genie GS-2032 Part No. 46326

Service Manual - First Edition

ii

Introduction

Genie North AmericaTelephone (425) 881-1800Toll Free in U.S.A. 800 536-1800Toll Free in Canada 800 426-8089Fax (425) 882-9260E-mail: [email protected]://www.genielift.com

Genie EuropeOffice Telephone (44) 01636-605030Office Fax (44) 01636-611090Parts Telephone (44) 01636-605002Parts Fax (44) 01636-611091

®

Copyright © 1997 by Genie Industries

First Edition: First Printing August, 1997Second Printing March, 1999Third Printing October, 1999

"Genie" is a registered trademarkof Genie Industries in the U.S.A. and many othercountries. "GS" is a trademark ofGenie Industries.

These machines comply withANSI/SIA 92.6-1990.

Printed on recycled paper

Printed in U.S.A.

Important

Read, 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 procedure.

This manual provides detailed scheduledmaintenance information for the machine ownerand user. It also provides troubleshooting andrepair procedures for qualified serviceprofessionals.

Basic mechanical, hydraulic and electricalskills are required to perform most procedures.However, 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 center.

Genie 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 notice.

Readers 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 USA.

If you have any questions, please call GenieIndustries.

GS-2032

Part No. 46326 Genie GS-2032


iii

DangerFailure to obey the instructions and safety rulesin this manual and the Genie GS-2032 & GenieGS-2046 & Genie GS-2646 & Genie GS-3246Operator’s Manual will result in death or seriousinjury.

Many of the hazards identified in theoperator’s manual are also safety hazardswhen maintenance and repair proceduresare performed.

Do Not Perform MaintenanceUnless:

You are trained and qualified to performmaintenance 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, liftingequipment and a suitable workshop.

Safety Rules



SAFETY RULES

Personal 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 priority.

Read 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 death.

Red—used to indicate thepresence of an imminentlyhazardous situation which, if notavoided, will result in death orserious injury.

Orange—used to indicate thepresence of a potentiallyhazardous situation which, if notavoided, could result in death orserious injury.

Yellow with safety alert symbol—used to indicate the presence of apotentially hazardous situationwhich, if not avoided, may causeminor or moderate injury.

Yellow without safety alertsymbol—used to indicate thepresence of a potentiallyhazardous situation which, if notavoided, may result in propertydamage.

Green—used to indicate operationor maintenance information.

Be sure to wear protective eye wear and other

protective clothing if the situation warrantsit.

Be aware of potential crushing hazardssuch as moving parts and free swinging orunsecured components when lifting orplacing loads. Always wear approved

steel-toed shoes.

Workplace SafetyBe sure to keep sparks, flames and lighted

tobacco away from flammable andcombustible materials such as batterygases and engine fuels. Always have an

approved fire extinguisher within easy reach.

Be sure that all tools and working areas areproperly maintained and ready for use.Keep work surfaces clean and free ofdebris that could get into machine

components and cause damage.

Be sure that your workshop or work areais properly ventilated and well lit.

Be sure any forklift, overhead crane or other liftingor supporting device is fully capable ofsupporting and stabilizing the weight to belifted. 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) arenot reused. These components may fail ifthey are used a second time.

Be sure to properly dispose of old oil orother fluids. Use an approved container.Please be environmentally safe .

iv



v

Power SourceThe Genie GS-2032 machines are powered byfour six-volt (225 AH) batteries. The four batteriesare wired in series to produce 24 volts.

Hydraulic 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. To protect from over-pressurization ofthe hydraulic system, the pump is provided with apressure relief valve.

Activating 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 travel.Computer software determines the volume of fluidin relation to the proportional valve input voltage.

Electrical 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 0.5miles per hour (0.8 km/h), according to the defaultsettings in the ECM software.

Machine Controls

The 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. All lift anddrive functions are available at the platformcontrols. Only platform up/down functions areavailable at the ground controls.The ECM uses input from the ground or platformcontrols to activate the various machine functions.The ECM has predetermined settings for thevarious machine functions.

The 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 forsteering.

Mounted 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. 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 card.

A diagnostic display is located at the battery packside of the machine to aid in troubleshooting. If the

Theory of Operation



THEORY OF OPERATION

vi

machine malfunctions, a fault code will be shown inthe display window.

Washing electronic components is not suggested.Instead, use compressed air to remove debris fromthese components.

Component damage hazard.Avoid shock or impact to the ECM.Internal damage may not bevisible from the outside.



Table of Contents

vii

Introduction

Important Information ...................................................................................................... ii

Section One Safety Rules

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

Theory of Operation ....................................................................................................... v

Section Two Specifications

Machine Specifications ............................................................................................. 2 - 1

Performance Specifications ...................................................................................... 2 - 2

Hydraulic Specifications ............................................................................................ 2 - 2

Hydraulic Hose and Fitting Torque Specifications ..................................................... 2 - 3

Section Three Scheduled Maintenance Inspections

Introduction ............................................................................................................... 3 - 1

Table A ..................................................................................................................... 3 - 2

Table B ..................................................................................................................... 3 - 3

Table C ..................................................................................................................... 3 - 3

Table D ..................................................................................................................... 3 - 3

Maintenance Inspection Report ................................................................................ 3 - 4



TABLE OF CONTENTS

viii

Section Four Scheduled Maintenance Procedures

Introduction ............................................................................................................... 4 - 1

A-1 Inspect the Operator’s and Safety Manuals ..................................................... 4 - 2

A-2 Inspect the Decals and Placards ..................................................................... 4 - 2

A-3 Inspect for Damage and Loose or Missing Parts ............................................. 4 - 3

A-4 Check the Hydraulic Oil Level ......................................................................... 4 - 4

A-5 Check for Hydraulic Leaks ............................................................................... 4 - 4

A-6 Test the Platform and Ground Controls ............................................................ 4 - 5

A-7 Test the Manual Platform Lowering Operation ................................................. 4 - 6

A-8 Test the Tilt Sensor ......................................................................................... 4 - 6

A-9 Test the Pothole Guards .................................................................................. 4 - 7

A-10 Test the Lift/Drive Select Switch (before serial number 17408) ....................... 4 - 7

A-11 Perform 30 Day Service .................................................................................. 4 - 8

B-1 Check the Batteries ......................................................................................... 4 - 9

B-2 Inspect the Electrical Wiring .......................................................................... 4 - 10

B-3 Inspect the Tires and Wheels (including castle nut torque) ............................ 4 - 11

B-4 Test the Key Switch ...................................................................................... 4 - 11

B-5 Test the Emergency Stop Buttons ................................................................. 4 - 12

B-6 Test the Service Horn.................................................................................... 4 - 12

B-7 Test the Drive Brakes.................................................................................... 4 - 13

B-8 Test the Drive Speed - Stowed Position ........................................................ 4 - 15

B-9 Test the Drive Speed - Raised Position ......................................................... 4 - 15

B-10 Perform Hydraulic Oil Analysis ...................................................................... 4 - 16

B-11 Check the Electrical Contactor (before serial number 6901) ........................... 4 - 16

B-12 Replace the Hydraulic Return Filter ............................................................... 4 - 17

C-1 Check the Module Tray Latch Components ................................................... 4 - 18

D-1 Test or Replace the Hydraulic Oil .................................................................. 4 - 19



TABLE OF CONTENTS

ix

Section Five Troubleshooting Flow Charts and Fault Codes

ChartNumber Chart Title Page

Introduction ............................................................................................................... 5 - 1

Fault Code Chart Before Serial Number 17408 ........................................................ 5 - 3

Normal Operation Code Chart Before Serial Number 17408 .................................... 5 - 6

Fault Code Chart After Serial Number 17407 ........................................................... 5 - 8

1 All Functions Will Not Operate .................................................................................. 5 - 9

2 Pump Motor Will Not Operate ................................................................................. 5 - 12

3 All Functions Inoperative, Power Unit Starts and Runs ........................................... 5 - 14

4 Ground Controls Inoperative, Platform Controls Operate Normally ......................... 5 - 15

5 Platform Controls Inoperative, Ground Controls Operate Normally ......................... 5 - 16

6 Platform Up Function Inoperative ........................................................................... 5 - 18

7 Platform Down Function Inoperative ....................................................................... 5 - 19

8 Steer Left Function Inoperative ............................................................................... 5 - 21

9 Steer Right Function Inoperative ............................................................................ 5 - 23

10 All Drive Functions Inoperative, All Other Functions Operate Normally .................. 5 - 25

10A Brake Release Function Inoperative ....................................................................... 5 - 27

11 Drive Forward Function Inoperative ........................................................................ 5 - 28

12 Drive Reverse Function Inoperative ........................................................................ 5 - 29

13 Machine Will Not Drive At Full Speed ..................................................................... 5 - 30

14 Machine Drives At Full Speed With Platform Raised .............................................. 5 - 32



TABLE OF CONTENTS

x

Section Six Schematics

Introduction ............................................................................................................... 6 - 1

Electrical Components .............................................................................................. 6 - 2

Module Tray Legend (before serial number 6901) ...................................................... 6 - 4

Module Tray Legend (after serial number 6900) ......................................................... 6 - 5

Electrical Symbols Legend ........................................................................................ 6 - 6

Electrical Schematic (before serial number 6901) ...................................................... 6 - 7

Electrical Schematic (from serial number 6901 to 8931) ............................................ 6 - 9

Electrical Schematic (from serial number 8932 to 17407) ..........................................6 -11

Electrical Schematic (after serial number 17407) ......................................................6 -13

Ground Controls and Level Sensor Box Legend ...................................................... 6 - 15

Platform Controls Legend (before serial number 17408) ........................................... 6 - 16

Platform Controls Legend (after serial number 17407) ............................................. 6 - 17

Hydraulic Symbols Legend ...................................................................................... 6 - 18

Hydraulic Schematic (before serial number 17482) .................................................. 6 - 19

Hydraulic Schematic (after serial number 17481) .................................................... 6 - 20



Section Seven Repair Procedures

Introduction ............................................................................................................... 7 - 1

Platform Controls

1-1 Platform Controller ........................................................................................... 7 - 2

1-2 Software Configuration .................................................................................... 7 - 3

1-3 Toggle Switches .............................................................................................. 7 - 6

Platform Components

2-1 Platform .......................................................................................................... 7 - 8

2-2 Platform Extension .......................................................................................... 7 - 9

Scissor Components

3-1 Scissor Assembly, GS-2032 ......................................................................... 7 - 10

3-2 Lift Cylinder ................................................................................................... 7 - 16

Ground Controls

4-1 Manual Platform Lowering Cable ................................................................... 7 - 18

4-2 Toggle Switches, See 1-3, Toggle Switches .................................................... 7 - 6

Hydraulic Pump

5-1 Hydraulic Pump ............................................................................................. 7 - 19

Manifolds

6-1 Function Manifold Components (before serial number 11501) ........................ 7 - 20

6-2 Function Manifold Components (after serial number 11500) ........................... 7 - 22

6-3 Valve Adjustment - Function Manifold ........................................................... 7 - 24

TABLE OF CONTENTS

xi



Section Seven Repair Procedures, continued

Steering Axle Components

7-1 Yoke and Drive Motor .................................................................................... 7 - 26

7-2 Steering Cylinder ........................................................................................... 7 - 27

7-3 Steering Bellcrank ......................................................................................... 7 - 28

Non-steering Axle Components

8-1 Drive Brake ................................................................................................... 7 - 29

Brake Release Hand Pump Components

9-1 Brake Release Hand Pump Components ....................................................... 7 - 30

TABLE OF CONTENTS

xii

Part No. 46326 Genie GS-2032 2 - 1

Section 2 - SpecificationsService Manual - First Edition

Specifications

Stowed dimensions

Length 96 in 243.8 cm

Length, platform extended 1351/2 in 344.2 cm

Width 32 in 81.3 cm

Height, stowed maximumRails up - CE 827/8 210.3 cm

Height, stowed maximumRails up - ANSI 781/2 in 199.1 cm

Height, stowed maximumRails lowered 761/2 in 193.8 cm

Height, stowed maximumrails removed 39 in 99 cm

Height, guard rail level 39 in 99.1 cm

Weight 3438 lbs 1559 kg

Ground clearance 4.0 in 10.2 cm

Ground clearancePothole guards deployed 7/8 in 2.2 cm

Operational dimensions

Maximum platform height 20 ft 5.8 m

Maximum platformworking height 25.1 ft 6.1 m

Maximum platform extension 39 in 1 m

Wheelbase 73 in 185 cm

Turning raduis, outside 92 in 233.7 cm

Turning raduis, inside 0 in 0 cm

Tires and wheels

Tire size (solid rubber) 15 x 5 x111/4 in38.1 x 12.7 x 28.5 cm

Load range 2,400 lbs 1,089 kg

Tire contact area 8 sq in 20.3 sq cm

Overall tire diameter 15 in 38.1 cm

Wheel diameter 111/4 in 28.5 cm

Wheel width 5 in 12.7 cm

Castle nut torque 300 ft-lbs 406.7 Nm

Platform dimensions

Length 89 in 226.1 cm

Width 311/4 in 65 cm

Extension length 291/2 in 79.4 cm

Maximum load capacity 800 lbs 363 kg

Fluid Capacities

Hydraulic tank capacity 5.5 gallons 20.8 liters

Hydraulic system capacity 6 gallons 22.7 liters(including tank)

Continuous improvement of our products is aGenie policy. Product specifications are subject tochange without notice.

Machine Specifications

2 - 2 Genie GS-2032 Part No. 46326

Section 2 - Specifications Service Manual - First Edition

Performance Specifications

Drive speeds (maximum)

Stowed, maximum 2.2 mph 3.5 km/h40 ft / 12.4 sec 12.2 m / 12.4 sec

Platform raised, 0.5 mph 0.8 km/hmaximum 40 ft / 54.5 sec 12.2 m / 54.5 sec

Gradeability 30%

Function speed, maximumfrom platform controls

Platform up 29 to 31 secondsPlatform down 25 to 27 seconds

SPECIFICATIONS

Hydraulic Specifications

Hydraulic fluid Dexron equivalent

Lift pump

Type: gear

Displacement .244 cu inper revolution 4 cc

Displacement 4 gpm(2500 psi/172 bar) 15 L/min

Hydraulic tank 10 micron with 25 psireturn line filter (1.7 bar) bypass

Function manifold

System relief valve pressure 3500 psi241.3 bar

Steer relief valve pressure 1000 psi69 bar

Part No. 46326 Genie GS-2032 2 - 3

Section 2 - SpecificationsService Manual - First Edition

SPECIFICATIONS

Hydraulic Hose and Fitting Torque SpecificationsYour machine is equipped with either 37° flared fittings and hose ends OR Parker Seal-Lok® fittings andhose ends. Machines that utilize Parker Seal-Lok® hoses and fittings require that the fittings and hoseends be torqued to specification when they are removed and installed or when new hoses or fittings areinstalled. Machines equipped with 37° flared fittings and hose ends do not need to be torqued to thesespecifications.

Torque Procedure1 Replace the O-ring. The O-ring must be

replaced anytime the seal has been broken.The O-ring cannot be re-used if the fitting orhose end has been tightened beyond fingertight.

The O-rings used in the ParkerSeal Lok® fittings and hose endsare a custom-size O-ring. Theyare not a standard SAE sizeO-ring. They are available in theO-ring field service kit (Genie partnumber 49612).

2 Lubricate the O-ring before installation.

Hydraulic Hose and Fitting Torque SpecificationsSAE O-ring Boss Port - tube fitting Seal-Lok® - hose end

SAE Dash Size Installing into... ft. lbs. Nm

SAE Dash Size ft. lbs. Nm

-4 Aluminum 11 14.9 -4 18 24.4Steel 16 21.7 -6 27 36.6

-6 Aluminum 23 31.2 -8 40 54.2Steel 35 47.5 -10 63 85.4

-8 Aluminum 40 54.2 -12 90 122Steel 60 81.3 -16 120 162.7

-10 Aluminum 69 93.6 -20 140 190Steel 105 142.4 -24 165 223.7

-12 Aluminum 93 126.1Steel 140 190

-16 Aluminum 139 188.5Steel 210 284.7

-20 Aluminum 172 233.2Steel 260 352.5

-24 Aluminum 208 282Steel 315 427.1

3 Be sure that the face seal O-ring is seated andretained properly.

4 Position the tube and nut squarely on the faceseal end of the fitting and tighten the nut fingertight.

5 Tighten the nut or fitting to the appropriatetorque per given size as shown in the tableabove.

6 Operate all machine functions and inspect thehoses and fittings and related components tobe sure that there are no leaks.

2 - 4 Genie GS-2032 Part No. 46326

Section 2 - Specifications Service Manual - First Edition

This page intentionally left blank.

Part No. 46326 Genie GS-2032 3 - 1

Section 3 - Scheduled Maintenance InspectionsService Manual - First Edition

Tools arerequired

New partsrequired

Dealerservice

suggested

Scheduled Maintenance Inspections

Observe and Obey:

Maintenance inspections shall be completed bya person trained and qualified on themaintenance of this machine.

Scheduled maintenance inspections shall becompleted daily, quarterly, annually and every2 years as specified on the MaintenanceInspection Report.

Failure to properly complete eachinspection when required maycause death, serious injury orsubstantial machine damage.

Immediately tag and remove from service adamaged or malfunctioning machine.

Repair any machine damage or malfunctionbefore operating machine.

Keep records on all inspections for three years.

Machines that have been out of service for aperiod longer than 3 months must complete thequarterly inspection.

About This SectionThe Schedule

There are four types of maintenance inspectionsthat must be performed according to a schedule—daily, quarterly, annual and two year. To accountfor repeated procedures, the Maintenance Tablesand the Maintenance Inspection Report have beendivided into four subsections—A, B, C, D. Use thefollowing chart to determine which group(s) ofprocedures are required to perform a scheduledinspection.

Inspection Table or Checklist

Daily A

Quarterly A + B

Annual A + B + C

Two year A + B + C + D

Maintenance Tables

The maintenance tables contained in this sectionprovide summary information on the specificphysical requirements for each inspection.

Complete step-by-step instructions for eachscheduled maintenance procedure are provided insection 4, Scheduled Maintenance Procedures.

Maintenance Inspection Report

The maintenance inspection report containschecklists for each type of scheduled inspection.

Make copies of the Maintenance InspectionReport to use for each inspection. Storecompleted forms for three years.

3 - 2 Genie GS-2032 Part No. 46326

Section 3 - Scheduled Maintenance Inspections Service Manual - First Edition

Tools arerequired

New partsrequired

Dealerservice

suggested

Table A

A-1 Inspect the Operator's and Safety Manuals

A-2 Inspect the Decals and Placards

A-3 Inspect for Damage andLoose or Missing Parts

A-4 Check the Hydraulic Oil Level

A-5 Check for Hydraulic Leaks

A-6 Test the Platform and Ground Controls

A-7 Test the Manual Platform Lowering Operation

A-8 Test the Tilt Sensor

A-9 Test the Pothole Guards

A-10 Test the Lift/Drive Select Switch

A-11 Perform 30 Day Service

Table B

B-1 Check the Batteries

B-2 Inspect the Electrical Wiring

B-3 Inspect the Tires and Wheels(including castle nut torque)

Maintenance Tables

Part No. 46326 Genie GS-2032 3 - 3

Section 3 - Scheduled Maintenance InspectionsService Manual - First Edition

Tools arerequired

New partsrequired

Dealerservice

suggested

Table B, continued

B-4 Test the Key Switch

B-5 Test the Emergency Stop Buttons

B-6 Test the Horn

B-7 Test the Drive Brakes

B-8 Test the Drive Speed - Stowed Position

B-9 Test the Drive Speed - Raised Position

B-10 Perform Hydraulic Oil AnalysisSee D-1 Test or Replace the Hydraulic Oil

B-11 Check the Electrical Contactor(before serial number 6901)

Every 250 hours, perform the following enginemaintenance procedure.

B-12 Replace the Hydraulic Return Filter

Table C

C-1 Check the Module Tray latch Components

Table D

D-1 Test or Replace the Hydraulic Oil

MAINTENANCE TABLES

3 - 4 Genie GS-2032 Part No. 46326

Section 3 - Scheduled Maintenance Inspections Service Manual - First Edition

Tools arerequired

New partsrequired

Dealerservice

suggested

Checklist A Y N R

Refer to Table A

A-1 Operator's andSafety manuals

A-2 Decals and placards

A-3 Damage and loose ormissing parts

A-4 Hydraulic oil level

A-5 Hydraulic leaks

A-6 Platform andground controls

A-7 Manual Platform Lowering

A-8 Tilt sensor

A-9 Pothole Guards

A-10 Lift/drive Select Switch

A-11 30 Day Service

Checklist B Y N R

Refer to Table B

B-1 Batteries

B-2 Electrical wiring

B-3 Tires and wheels

B-4 Key Switch

B-5 Emergency Stop

B-6 Horn

B-7 Drive Brakes

B-8 Drive speed - stowed

B-9 Drive speed - raised

B-10 Hydraulic oil analysis

B-11 Electrical contactor(before serial number 6901)

Perform every 250 hours

B-12 Hydraulic Return Filter

Checklist C Y N R

Refer to Table C

C-1 Latch components

Checklist D Y N R

Refer to Table D

D-1 Hydraulic oil

Instructions· Make copies of this page to use for

each inspection.

· Select the appropriate checklist(s) forthe type of inspection to be performed.

Daily Inspection: A

Quarterly Inspection: A+B

Annual Inspection: A+B+C

2 Year Inspection: A+B+C+D

· Place a check in the appropriate boxafter each inspection procedure iscompleted.

· Use the maintenance tables in thissection and the step-by-stepprocedures in section 4 to learn how toperform these inspections.

· If any inspection receives an “N,” tagand remove the machine from service,repair and re-inspect it. After repair,place a check in the “R” box.

LegendY = yes, acceptableN = no, remove from service

R = repaired

Comments

Maintenance Inspection Report

Model

Serial number

Date

Hour meter

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

Part No. 46326 Genie GS-2032 4 - 1

Service Manual - First Edition Section 4 - Scheduled Maintenance Procedures

About This Section

This section contains detailed procedures for eachscheduled maintenance inspection.

Each procedure includes a description, safetywarnings and step-by-step instructions.

Symbols Legend

Safety alert symbol—used to alertpersonnel to potential personalinjury hazards. Obey all safetymessages that follow this symbolto avoid possible injury or death.

Red—used to indicate thepresence of an imminentlyhazardous situation which, if notavoided, will result in death orserious injury.

Orange—used to indicate thepresence of a potentiallyhazardous situation which, if notavoided, could result in death orserious injury.

Yellow with safety alert symbol—used to indicate the presence of apotentially hazardous situationwhich, if not avoided, may causeminor or moderate injury.

Yellow without safety alertsymbol—used to indicate thepresence of a potentiallyhazardous situation which, if notavoided, may result in propertydamage.

Green—used to indicate operationor maintenance information.

Indicates that a specific result is expected afterperforming a series of steps.

Scheduled Maintenance Procedures

Observe and Obey:

Maintenance inspections shall be completed bya person trained and qualified on themaintenance of this machine.

Scheduled maintenance inspections shall becompleted daily, quarterly, annually and every2 years as specified on the MaintenanceInspection Report.

Failure to properly complete eachinspection when required maycause death, serious injury orsubstantial machine damage.


Repair any machine damage or malfunctionbefore operating machine.

Keep records on all inspections for three years.

Unless otherwise specified, perform eachprocedure with the machine in the followingconfiguration:

· Machine parked on a flat level surface

· Platform in the stowed position

· Key switch in the OFF position with the keyremoved

· Wheels chocked

4 - 2 Genie GS-2032 Part No. 46326

Service Manual - First EditionSection 4 - Scheduled Maintenance Procedures

Table A Procedures

A-1Inspect the Operator’s andSafety ManualsMaintaining the operator’s and safety manuals ingood condition is essential to safe machineoperation. Manuals are included with eachmachine and should be stored in the containerprovided in the platform. An illegible or missingmanual will not provide safety and operationalinformation necessary for a safe operatingcondition.

1 Check to be sure the storage container ispresent and in good condition.

2 Check to make sure that the operator’s,responsibilities and safety manuals are presentand complete in the storage container in theplatform.

3 Examine the pages of each manual to be surethat they are legible and in good condition.

4 Always return the manuals to the storagecontainer after use.

Contact your authorized Geniedistributor or Genie Industries ifreplacement manuals are needed.

A-2Inspect theDecals and PlacardsMaintaining all of the safety and instructionaldecals and placards in good condition ismandatory for safe machine operation. Decalsalert operators and personnel to the manypossible hazards associated with using thismachine. They also provide users with operationand maintenance information. An illegible decalwill fail to alert personnel of a procedure or hazardand could result in unsafe operating conditions.

1 Refer to the Decals section in the GenieGS-2032 & Genie GS-2046 & Genie GS-2646& Genie GS-3246 Operator's Manual and usethe decal list and illustrations to determine thatall decals and placards are in place.

2 Inspect all decals for legibility and damage.Replace any damaged or illegible decalimmediately.

Contact your authorized Geniedistributor or Genie Industries ifreplacement decals are needed.

Part No. 46326 Genie GS-2032 4 - 3


TABLE A PROCEDURES

A-3Inspect for Damage and Loose orMissing PartsDaily machine condition inspections are essentialto safe machine operation and good machineperformance. Failure to locate and repair damage,and discover loose or missing parts may result inan unsafe operating condition.

1 Inspect the entire machine for damage andimproperly installed or missing parts including:

· Electrical components, wiring and electricalcables

· Hydraulic power unit, tank, hoses, fittings,cylinders and manifolds

· Battery pack and connections

· Drive motors

· Wear pads

· Tires and wheels

· Limit switches, alarms and horn

· Nut, bolts and other fasteners

· Platform entry chain or gate

· Beacons and alarms (if equipped)

· Brake release components

· Safety arm

· Pothole guards

· Platform extension

· Scissor pins and retaining fasteners

· Platform control joystick

· Inverter (if equipped)

Check the entire machine for:

· Cracks in welds or structural components

· Dents or damage to machine

· Be sure that all structural and other criticalcomponents are present and all associatedfasteners and pins are in place and properlytightened

· Side rails installed and bolts are fastened

· Be sure that the chassis trays are in place,latched and properly connected

4 - 4 Genie GS-2032 Part No. 46326


TABLE A PROCEDURES

A-4Check the Hydraulic Oil LevelMaintaining the hydraulic oil at the proper level isessential to machine operation. Improper hydraulicoil levels can damage hydraulic components. Dailychecks allow the inspector to identify changes inoil level that might indicate the presence ofhydraulic system problems.

Perform this procedure with theplatform in the stowed position.

1 Visually inspect the oil level in the hydraulictank through the sight gauge in the side of thepower unit module.

Result: The hydraulic oil level should be withinthe FULL and ADD marks on the oil level indicatordecal.

2 Add oil if necessary. Do not overfill.

Hydraulic Oil Specifications

Hydraulic oil type Dexron equivalent

Hydraulic tank capacity 5.5 gallons20.8 liters

Hydraulic system 6 gallons(including tank) 22.7 liters

A-5Check for Hydraulic LeaksDetecting hydraulic fluid leaks is essential tooperational safety and good machineperformance. Undiscovered leaks can develop intohazardous situations, impair machine functionsand damage machine components.

1 Inspect for hydraulic oil puddles, dripping orresidue on or around the following areas:

· Hydraulic tank, return filter, fittings and hoses

· Hydraulic power unit, fittings and hoses

· Hydraulic lift cylinder and manuallowering valve

· Function manifold

· The underside of the drive chassis

· Drive motors

· Drive brakes

· Ground area under the machine

Part No. 46326 Genie GS-2032 4 - 5


TABLE A PROCEDURES

A-6Test the Platform andGround ControlsTesting the machine functions and the EmergencyStop buttons for malfunctions is essential for safemachine operation. An unsafe working conditionexists if any function fails to operate properly oreither Emergency Stop button fails to stop all themachine functions. Each function should operatesmoothly and be free of hesitation, jerking andunusual noise.

1 Turn the key switch to ground control and pullout the Emergency Stop button to the ONposition at both the platform and groundcontrols.

2 Activate the platform up function.

Result: The platform should raise.

3 Activate the platform down function.

Result: The platform should lower. The descentalarm should sound while the platform islowering.

4 Push in the ground controls Emergency Stopbutton to the OFF position.

Result: No function should operate.

5 Turn the key switch to platform control and pullout the Emergency Stop button to the ONposition at both the ground and the platformcontrols.

6 Press and hold the lift function enable buttonOR move the lift/drive selector switch to the liftposition.

7 Press and hold the function enable switch on thecontrol handle.

Result: The green power light should come onOR the light below the lift selector buttonshould come on.

8 Slowly move the control handle in the directionindicated by the blue arrow.

Result: The platform should raise. The potholeguards should deploy.

9 Release the control handle.

Result: The platform should stop raising.

10 Press and hold the function enable switch.Slowly move the control handle in the directionindicated by the yellow arrow.

Result: The platform should lower. The descentalarm should sound while the platform islowering.

CE models: When lowering theplatform, the platform should stopwhen it is 6 feet (1.8 m) from theground. Be sure the area belowthe platform is clear of personneland obstructions beforecontinuing. To continue lowering,release the control handle, wait4-6 seconds, then move thecontrol handle again.

11 Push in the Emergency Stop button to the OFFposition.

Result: No function should operate. Themachine should stop.

As a safety feature, selectingand operating the groundcontrols will override theplatform controls, except theEmergency Stop button.

4 - 6 Genie GS-2032 Part No. 46326


TABLE A PROCEDURES

A-7Test the Manual PlatformLowering OperationDetection of Manual Platform Lowering systemmalfunctions is essential for safe machineoperation. An unsafe working condition exists ifthe Manual Platform Lowering function does notoperate in the event of a main power loss.

1 Turn the key switch to ground control and pullout the Emergency Stop button to the ONposition at both the platform and groundcontrols.

2 Raise the platform approximately2 feet (0.6 m).

3 Pull the Manual Platform Lowering handlelocated next to the ground controls.

Result: The platform should lower. The descentalarm will not sound.

A-8Test the Tilt Sensor

Perform this test from the groundwith the platform controls. Do notstand in the platform.

1 Fully lower the platform.

2 Place a 2x4 block or similar piece of woodunder both wheels on one side and drive themachine up onto them.

3 Raise the platform.

Result: When the platform is raised 7 feet(2.1 meters) from the ground, an alarm shouldsound.

4 Lower the platform and remove both pieces ofwood.

Part No. 46326 Genie GS-2032 4 - 7


A-9Test the Pothole Guards

The pothole guards shouldautomatically deploy when theplatform is raised. The potholeguards activate two limit switcheswhich control the machine drivespeed. If the pothole guards donot deploy and the platform israised above 6 feet (1.8 meters),an alarm sounds and the machinewill not drive.

1 Raise the platform.

Result: When the platform is raised 4 feet(1.2 meters) from the ground, the potholeguards should deploy.

2 Press on the pothole guards on one side, andthen the other.

Result: The pothole guards should not move.

3 Lower the platform.

Result: The pothole guards should return to thestowed position.

4 Place a 2x4 block or similar piece of woodunder the pothole guard. Raise the platform.

Result: When the platform is raised above 6feet (1.8 meters), an alarm should sound andthe drive function should not work.

5 Lower the platform and remove the block ofwood.

A-10Test the Lift/Drive Select Switch(before serial number 17408)A properly functioning Lift/Drive Select Switchis essential for safe machine operation. Animproperly operating Lift/Drive Select Switchwill fail to activate the appropriate platform controlwhich may result in a hazardous situation.

1 Turn the key switch to platform control and pullout the Emergency Stop button to the ONposition at both the platform and groundcontrols.

2 Move the lift/drive select switch to the LIFTposition.

3 Press and hold the function enable switch.

Result: The green power light should come on.

4 Slowly move the control handle off center.

Result: The platform should raise or lower.

5 Move the lift/drive select switch to the DRIVEposition.

6 Press and hold the function enable switch.

Result: The green power light should come on.

7 Slowly move the control handle off center.

Result: The drive and steer functions shouldoperate.

TABLE A PROCEDURES

4 - 8 Genie GS-2032 Part No. 46326


A-11Perform 30 Day ServiceThe 30 day maintenance procedure is a one timesequence of procedures to be performed after thefirst 30 days or 50 hours of usage. After thisinterval, refer to the maintenance tables forcontinued scheduled maintenance.

1 Perform the following maintenance procedures:· B-3 Inspect Tires and Wheels· B-12 Replace the Hydraulic Return Filter

TABLE A PROCEDURES

Part No. 46326 Genie GS-2032 4 - 9


Table B Procedures

B-1Check the BatteriesProper battery condition is essential to goodmachine performance and operational safety.Improper fluid levels or damaged cables andconnections can result in component damage andhazardous conditions.

Bodily injury hazard. Batteriescontain acid. Avoid spilling orcontacting battery acid. Neutralizebattery acid spills with bakingsoda and water.

Electrocution hazard. Contactwith hot or live circuits mayresult in death or serious injury.Remove all rings, watches andother jewelry.

Perform this test after fullycharging the batteries.

1 Put on protective clothing and eye wear.

2 Be sure that the battery cable connections arefree of corrosion.

3 Be sure that the battery hold downs and cableconnections are tight.

4 Remove the battery vent caps and check thespecific gravity of each battery cell with ahydrometer.

Result: If any battery cell displays a specificgravity of less than 1.098, the battery must bereplaced.

5 Check the battery acid level of each battery. Ifneeded, replenish with distilled water to thebottom of the battery fill tube. Do not overfill.

6 Install the battery vent caps.

7 Check each battery pack and verify that thebatteries are wired correctly.

4 - 10 Genie GS-2032 Part No. 46326


B-2Inspect the Electrical WiringMaintaining electrical wiring in good condition isessential to safe operation and good machineperformance. Failure to find and replace burnt,chafed, corroded or pinched wires could result inunsafe operating conditions and may causecomponent damage.

Electrocution hazard. Contactwith hot or live circuits mayresult in death or serious injury.Remove all rings, watches andother jewelry.

1 Inspect the following areas for burnt, chafed,corroded and loose wires:

· Ground control panel

· Hydraulic power unit module tray

· Battery pack module tray

· Scissor arms

· Platform controls

2 Turn the key switch to ground control and pullout the Emergency Stop button to the ONposition.

3 Raise the platform approximately 8 feet (2.4 m)from the ground.

4 Lift the safety arm, move to the center of thescissor arm and rotate down to a verticalposition.

5 Lower the platform onto the safety arm.

Crushing hazard. Keep hands clearof the safety arm when loweringthe platform.

6 Inspect the center chassis area and scissorarms for burnt, chafed and pinched cables.

7 Inspect the following areas for burnt, chafed,corroded, pinched and loose wires:

· ECM to platform controls

· Power to platform wiring

8 Raise the platform and return the safety arm tothe stowed position.

9 Lower the platform to the stowed position andturn the machine off.

TABLE B PROCEDURES

Part No. 46326 Genie GS-2032 4 - 11


TABLE B PROCEDURES

B-3Inspect the Tires and Wheels(including castle nut torque)Maintaining the tires and wheels in goodcondition is essential to safe operation and goodperformance. Tire and/or wheel failure could resultin a machine tip-over. Component damage mayalso result if problems are not discovered andrepaired in a timely fashion.

1 Check the tire surface and sidewalls for cuts,cracks or unusual wear.

2 Check each wheel for damage, bends andcracks.

3 Remove the cotter pin and check each castlenut for proper torque.

4 Install a new cotter pin.

Always replace the cotter pin witha new one when removing thecastle nut or when checking thetorque of the castle nut.

Tires and wheels

Castle nut torque, dry 300 ft-lbs 406.7 Nm

Castle nut torque, lubricated 225 ft-lbs 305 Nm

B-4Test the Key SwitchProper key switch action and response is essentialto safe machine operation. The machine can beoperated from the ground or platform controls andthe activation of one or the other is accomplishedwith the key switch. Failure of the key switch toactivate the appropriate control panel could causea hazardous operating situation.

1 Pull out the Emergency Stop button to the ONposition at both the ground and platformcontrols.

2 Turn the key switch to platform control.

3 Check the platform up/down function from theground controls.

Result: The machine functions should notoperate.

4 Turn the key switch to ground control.

5 Check the machine functions from theplatform controls.

Result: The machine functions should notoperate.

6 Turn the key switch to the OFF position.

Result: No function should operate.

4 - 12 Genie GS-2032 Part No. 46326


TABLE B PROCEDURES

B-5Test the Emergency StopButtonsProperly functioning Emergency Stop buttonsare essential for safe machine operation. Animproperly operating Emergency Stop buttonwill fail to shut off power and stop all machinefunctions resulting in a hazardous situation.

As a safety feature, selectingand operating the ground controlswill override the platform controls,except the platform EmergencyStop button.

1 Turn the key switch to ground control and pullout the Emergency Stop button to the ONposition at both the ground and platformcontrols.

2 Push in the Emergency Stop button at theground controls to the OFF position.

Result: No functions should operate.

3 Turn the key switch to platform control and pullout the Emergency Stop button to the ONposition at both the ground and platformcontrols.

4 Push down the Emergency Stop button at theplatform controls to the OFF position.

Result: No machine functions should operate.

The ground control EmergencyStop button will stop all machineoperation, even if the key switchis switched to platform control.

B-6Test the HornA functioning horn is essential to safe machineoperation. The horn is activated at the platformcontrols and sounds at the ground as a warning toground personnel. An improperly functioning hornwill prevent the operator from alerting groundpersonnel of hazards or unsafe conditions.

1 Turn the key switch to platform control andpull out the Emergency Stop button to theON position at both the ground andplatform controls.

2 Push down the horn button at the platformcontrols.

Result: The horn should sound.

The standard machine uses themultifunction alarm to emit thehorn sound. The optional horn willsound like an automotive typehorn.

Part No. 46326 Genie GS-2032 4 - 13


B-7Test the Drive BrakesProper brake action is essential to safe machineoperation. The drive brake function should operatesmoothly, free of hesitation, jerking and unusualnoise. Hydraulically released individual wheelbrakes can appear to operate normally when notfully operational.

Perform this procedure with themachine on a firm, level surfacethat is free of obstructions.

Be sure the platform extensiondeck is fully retracted and theplatform is in the stowed position.

1 Mark a test line on the ground for reference.


3 Lower the platform to the stowed position.

4 Move the drive select toggle switch down fornormal drive operation OR press the drivespeed selector button until the indicator light isOFF.

5 Choose a point on the machine; i.e., contactpatch of a tire, as a visual reference for usewhen crossing the test line.

6 Bring the machine to full drive speed beforereaching the test line. Release the functionenable switch or the joystick on the platformcontrols when your reference point on themachine crosses the test line.

TABLE B PROCEDURES

7 Measure the distance between the test line andyour machine reference point.

Braking: paved surface

Stopping distance 2 ft 0.6 m

Result: The machine stops within the specifiedbraking distance. No action required.

Result: The machine does not stop within thespecified braking distance. Proceed to step 8and determine if the machine is equipped witha dynamic braking valve.

The brakes must be able to holdthe machine on any slope it is ableto climb.

8 Disconnect the battery pack from the machine.

Electrocution hazard. Contact withelectrically charged circuits couldresult in death or serious injury.Remove all rings, watches andother jewelry.

9 Locate the drive forward/reverse valve on thefunction manifold. Refer to Illustrations 2 and 3.

a drive forward/reserve valve

a

4 - 14 Genie GS-2032 Part No. 46326


10 Tag the forward and the reverse valve coils.Remove the coils from the valve.

The forward valve coil has whiteand brown wires attached.

The reverse valve coil haswhite/black and brown wiresattached.

For reassembly, it will be helpful toleave the wire harness attached tothe valve coils.

11 Remove the drive forward/reverse valve from thefunction manifold. Cap the open port of themanifold.

12 Carefully inspect the hex portion of the valve foran identification stamp.

Result: SV10-4727 is stamped on the hexportion of the drive forward/reverse valve. Thisindicates the machine is equipped with adynamic brake valve. Proceed to step 13.

Result: SV10-4727 is not stamped on the hexportion of the drive forward/reverse valve. Thisindicates the machine is not equipped with adynamic brake valve. Proceed to step 18.

13 Install the drive forward/reverse valve removedin step 11 into the function manifold andsecurely tighten. Torque to 25 ft-lbs / 34 Nm.

14 In order, install the reverse valve coil (withwhite/black and brown wires), spacer washerand the forward valve coil (with white and brownwires) onto the valve.

For the machine to functioncorrectly, the reverse valve coilmust be closest to the manifold.

15 Install the coil nut onto the valve and tighten.Torque to 60 in-lbs / 7 Nm.

16 Connect the battery pack to the machine.

17 Replace the brakes and repeat this procedurebeginning with step 1. Refer to Repair Procedure8-1, How to Remove a Drive Brake.

18 Contact the Genie Industries Service PartsDepartment and order kit part number 105457.

19 Install the new valve received in the kit andmark the new valve with a white paint pen toidentify new valve installation.

20 Repeat this procedure beginning with step 1.

If the machine fails to stop within the specifiedstopping distance after installing new brakes,please contact the Genie Industries ScissorsService Department, 1-800-536-1800 Ext. 8710.

TABLE B PROCEDURES

Part No. 46326 Genie GS-2032 4 - 15


B-8Test the Drive Speed -Stowed PositionProper drive functions are essential to safemachine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free of hesitation,jerking and unusual noise over the entireproportionally controlled speed range.

Select a test area that is firm, leveland free of obstructions.

1 Create start and finish lines by marking two lineson the ground 40 feet (12.2 m) apart.


3 Lower the platform to the stowed position.

4 Move the drive select toggle switch down fornormal drive operation OR press the drivespeed selector button until the indicator light isOFF.

5 Choose a point on the machine; i.e., contactpatch of a tire, as a visual reference for usewhen crossing the start and finish lines.

6 Bring the machine to maximum drive speedbefore reaching the start line. Begin timingwhen your reference point on the machinecrosses the start line.

7 Continue at full speed and note the time whenthe machine reference point passes over thefinish line. Return the control handle to center.

Drive speed:

Stowed position 40 ft/ 12.4 sec 12.2 m/12.4 sec

B-9Test the Drive Speed -Raised PositionProper drive functions are essential to safemachine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free of hesitation,jerking and unusual noise over the entireproportionally controlled speed range.

Select a test area that is firm,level and free of obstructions.

1 Create start and finish lines by marking twolines on the ground 40 feet (12.2 m) apart.


3 Raise the platform approximately 6 feet (2 m).

4 Move the drive select toggle switch down fornormal drive operation OR press the drive speedselector button until the indicator light is OFF.

5 Choose a point on the machine; i.e., contactpatch of a tire, as a visual reference for usewhen crossing the start and finish lines.

6 Bring the machine to maximum drive speedbefore reaching the start line. Begin timingwhen your reference point on the machinecrosses the start line.

7 Continue at full speed and note the time whenthe machine reference point passes over thefinish line. Return the control handle to center.

Drive speed (maximum):

Platform raised 40 ft / 54.5 sec 12.2 m / 54.5 sec

TABLE B PROCEDURES

4 - 16 Genie GS-2032 Part No. 46326


TABLE B PROCEDURES

B-10Perform Hydraulic Oil AnalysisSee D-1, Test or Replace the Hydraulic Oil.

B-11Check the Electrical Contactor -(before serial number 6901)Maintaining the electrical contactor in goodcondition is essential to safe machine operation.Failure to locate a worn or damaged contactorcould result in an unsafe working condition andcomponent damage.

1 Open the hydraulic power unit module andlocate the electrical contactor mounted abovethe hydraulic power unit.

2 Visually inspect the contact points of eachcontactor for the following items:

· Excessive burns

· Excessive arcs

· Excessive pitting

Replace the contactor if anydamage is found.

Part No. 46326 Genie GS-2032 4 - 17


TABLE B PROCEDURES

B-12Replace the Hydraulic ReturnFilterReplacement of the hydraulic filter isessential for good machine performance andservice life. A dirty or clogged filter may cause themachine to perform poorly and continued use maycause component damage. Extremely dirtyconditions may require that the filter be replacedmore often.

Beware of hot oil. Contact withhot oil may cause severe burns.

The hydraulic filter is mounted onthe function manifold next to thehydraulic power unit.

1 Clean the area around the oil filter, thenremove the filter with an oil filter wrench.

2 Apply a thin layer of oil to the new oil filtergasket.

3 Install the new filter (Genie part number 55616)and tighten it securely by hand. Clean up anyoil that may have spilled during thereplacement procedure.

4 Turn the key switch to ground control and pullout the Emergency Stop button to the ONposition at both the ground and platformcontrols. Activate and hold the platform uptoggle switch.

5 Inspect the filter and related components tobe sure that there are no leaks.

4 - 18 Genie GS-2032 Part No. 46326


Table C Procedure

C-1Check the Module Tray LatchComponentsMaintaining the module tray latch components ingood condition is essential to good performanceand service life. Failure to detect worn out latchcomponents may result in module trays openingunexpectedly, creating an unsafe operatingcondition.


1 Lubricate each module tray latch. Using lightoil, apply a few drops to the side of the latchpin.

2 Inspect each module tray latch pad (ifequipped). Replace any worn pad before thelatch will fail to securely hold the module trayclosed.

Part No. 46326 Genie GS-2032 4 - 19


D-1Test or Replace the Hydraulic OilReplacement or testing of the hydraulic oil isessential for good machine performance andservice life. Dirty oil and suction strainer maycause the machine to perform poorly andcontinued use may cause component damage.Extremely dirty conditions may require oil changesto be performed more often.

This machine uses Dexronequivalent hydraulic oil. Beforereplacing the hydraulic oil, the oilmay be tested by an oil distributorfor specific levels of contaminationto verify that changing the oil isnecessary. If the hydraulic oilis not replaced at the two yearinspection, test the oilquarterly. Replace the oil whenit fails the test.


1 Disconnect the battery pack from the machine.

2 Open the power unit compartment and place adrain pan or other suitable container under thehydraulic tank.

3 Remove the drain plug from the hydraulic tank.

Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.

4 Completely drain the tank into a suitablecontainer. See capacity specifications listed atright.

5 Remove the return filter mounting bracketfasteners from the manifold. Push the filter andaccumulator out of the way.

6 Remove the motor controller mounting bracketretaining fasteners and move the motorcontroller to the side.

7 Remove the hydraulic tank from the machine.

8 Remove the suction strainer and clean it usinga mild solvent.

9 Clean the inside of the hydraulic tank using amild solvent.

10 Install the suction strainer using thread sealeron the threads.

11 Install the drain plug using thread sealer on thethreads.

Table D Procedure

4 - 20 Genie GS-2032 Part No. 46326


12 Install the hydraulic filter bracket and the motorcontroller bracket.

Electrocution hazard. Theconnectors on the motor controllerwill short out to ground if themotor controller mounting bracketis not installed before the batterypack is connected.

13 Install the hydraulic tank.

14 Fill the tank with hydraulic oil until the fluid iswithin the FULL and ADD marks on the oil levelindicator decal. Do not overfill.

15 Clean up any oil that may have spilled. Properlydispose of the oil.

16 Operate all machine functions through a fullcycle and check for leaks.

Hydraulic oil type - Dexron equivalent

Hydraulic tank capacity 5.5 gallons20.8 liters

Hydraulic system 6 gallons(including tank) 22.7 liters

TABLE D PROCEDURE

Part No. 46326 Genie GS-2032 5 - 1

Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

Before Troubleshooting:

Read, understand and obey the safety rulesand operating instructions printed in theGenie GS-2032 & Genie GS-2046 & GenieGS-2646 & Genie GS-3246 Operator’sManual.

Be sure that all necessary tools and testequipment are available and ready for use.

Read each appropiate flow chart thoroughly.Attempting shortcuts may produce hazardousconditions.

Be aware of the following hazards and followgenerally accepted safe workshop practices.

Crushing hazard. When testingor replacing any hydrauliccomponent, always supportthe structure and secure itfrom movement.

Electrocution hazard. Contactwith electrically charged circuitsmay result in death or seriousinjury. Remove all rings, watchesand other jewelry.

Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.

Perform all troubleshooting on afirm level surface.

Two persons will be required tosafely perform sometroubleshooting procedures.

Troubleshooting Flow Charts

Observe and Obey:

Troubleshooting and repair procedures shall becompleted by a person trained and qualified onthe repair of this machine.


Repair any machine damage or malfunctionbefore operating the machine.

Unless otherwise specified, perform eachrepair procedure with the machine in thefollowing configuration:

· Machine parked on a flat level surface

· Platform in stowed position

· Key switch in the OFF position with the key removed

· Wheels chocked

5 - 2 Genie GS-2032 Part No. 46326

Service Manual - First EditionSection 5 - Troubleshooting Flow Charts

General Repair Process

TROUBLESHOOTING FLOW CHARTS

About This SectionWhen a malfunction is discovered, the flow chartsin this section will help a service professionalpinpoint the cause of the problem. To use thissection, basic hand tools and certain pieces of testequipment are required—voltmeter, ohmmeter andpressure gauges.

The location of terminals mentioned in this sectioncan be found on the appropriate electrical orhydraulic schematics provided in Section 6,Schematics.

Since various degrees of a particular functionloss may occur, selecting the appropriate flowchart may be troublesome. When a function willnot operate with the same speed or power as amachine in good working condition, refer to theflow chart which most closely describes theproblem.

Malfunctiondiscovered

Identifysymptoms

Troubleshoot

Performrepair

Return toservice problem

solved

problemstill exists

Inspectand test

LED Diagnostic ReadoutThe diagnostic readout displays numerical codesthat provide information about the machineoperating status and about malfunctions. Thedot to the right of the numbers will blink duringnormal operation codes and remain on with faultcodes.

The codes listed in the Operation Code Chartare common operational status codes andmalfunction codes that can be cleared easily.

The codes listed in the Fault Code Chartdescribe malfunctions and can aid introubleshooting the machine by pinpointing thearea or component affected.

Part No. 46326 Genie GS-2032 5 - 3


Fault Code ChartBefore Serial Number 17408

Notes

Continued on next page

Fault Code Problem Possible Causes Solution

00 Reset the ECM. If problem remains, replace the ECM.

18

Alarm sounds continuously. Error indicator light on at the platform controls when function enable switch is engaged. Machine will not drive. Machine is not level.

Pothole guard may be blocked or pothole limit switches may not be activating or there is a bad wire connection.

Remove obstruction to pothole guard OR check pothole limit switch wiring for open connections OR check pothole limit switch for proper adjustment and activation.

19

Alarm sounds continuously. Error indicator light on at the platform controls when function enable switch is engaged. Machine will not drive. Machine is level.

Pothole guard may be blocked or pothole limit switches may not be activating or there is a bad wire connection.

Remove obstruction to pothole guard OR check pothole limit switch wiring for open connections OR check pothole limit switch for proper adjustment and activation.

33Machine will not operate. Error indicator light on at the platform controls.

Joystick initialization OK but function enable switch is tied down.

Release the function enable switch OR check the switch for continuity in the joystick controller box (see Repair Section).

34Machine unit will not operate. Error indicator light on at the platform controls.

ECM does not recognize the platform controls.

Replace joystick controller box main circuit board OR replace the coil cord.

35Machine unit will not operate. Error indicator light on at the platform controls.

ECM does not recognize the platform controls.

Replace joystick controller box main circuit board.

51

Only the platform down function operates; no other functions operate. Error indicator light on at the platform controls when the function enable switch is engaged.

No power output from ECM to the motor contactor.

Check wiring and terminal at motor contactor ckt A9-Curtis terminal 3 OR check wiring and terminal at control ECM pin A9, ckt A9-Curtis terminal 3.

5 - 4 Genie GS-2032 Part No. 46326



FAULT CODE CHART(BEFORE SERIAL NUMBER 17408)

Notes


52

Machine will not drive forward. Pump motor starts. Error indicator light on at the platform controls when the function enable switch is engaged.

No power output from ECM to the drive forward coil.

Check wiring and terminal at the forward coil, ckt C6-Forward coil OR check wiring and terminal at control ECM pin C6, ckt C6 Forward coil.

53

Machine will not drive in reverse. Pump motor starts. Error indicator light on at the platform controls when the function enable switch is engaged.

No power output from ECM to the drive reverse coil.

Check wiring and terminal at the reverse coil, ckt A7-Reverse coil OR check wiring and terminal at ECM pin A7, ckt A7 Reverse coil.

54

Platform will not raise. Pump motor starts. Error indicator light on at the platform controls when the function enable switch is engaged.

No power output from ECM to the platform up coil.

Check wiring and terminal at the platform up coil, ckt A6-Up coil OR check wiring and terminal at ECM pin A6, ckt A6 Up coil.

55Platform will not lower. Error indicator light on at the platform controls when the function enable switch is engaged.

No power output from ECM to the platform lowering coil.

Check wiring and terminal at the platform lowering coil, ckt B6-Down coil OR check wiring and terminal at ECM pin B6, ckt B6 Down coil.

56

Machine will not steer right. Pump motor starts. Error indicator light on at the platform controls when the function enable switch is engaged.

No power output from ECM to steer right coil.

Check wiring and terminal at the steer right coil, ckt C7 Right coil OR check wiring and terminal at ECM pin C7, C7 Right coil.

57

Machine will not steer left. Pump motor starts. Error indicator light on at the platform controls when the function enable switch is engaged.

No power output from ECM to steer left coil.

Check wiring and terminal at the steer left coil, ckt B7 Left coil OR check wiring and terminal at ECM pin B7, B7 Left coil.

Part No. 46326 Genie GS-2032 5 - 5



FAULT CODE CHART(BEFORE SERIAL NUMBER 17408)

Notes


58 Machine will not drive but platform will still raise.No power output from ECM to the brake orifice coil.

Check wiring and terminal at the orifice coil, ckt C9 orifice coil OR check wiring and terminal at ECM pin C9, C9 orifice coil OR replace Coil.

60Machine will not operate. Error indicator light on at the platform controls.

Lift/drive switch is turned "off" or in a neutral position.

Check switch position OR Replace switch.

63Machine will not operate. Flashing green LED at the platform controls.

Lift/drive switch turned from lift to drive or drive to lift while the function enable switch is engaged.

Release function enable switch and move lift/drive switch to either lift or drive.

88 Machine will not operate. ECM cannot be reset. EPROM not programmed. Replace ECM.

no code available

Green flashing LED at the platform controls.

Function enable switch held for more than 10 seconds without activating any function.

Release function enable switch OR check the function enable microswitch for continuity in the joystick controller box. Reset controller and check for fault code 33 at power up.

no code available

Machine drive speed reduces to off limit drive speed OR platform raises slowly. Red flashing LED at the platform controls while function enable switch is activated.

Low Voltage Cut Back (LVCB) is activated because battery supply voltage is 18.5V DC or less.

Charge batteries.

5 - 6 Genie GS-2032 Part No. 46326


Normal Operation Code ChartBefore Serial Number 17408

edoC noitidnoC noitanalpxE

02gnihsalf

.lortnocmroftalpothctiwsyeK.teef6evobadednetxemroftalP

tuodellupsnottubpotSycnegremEmroftalpdnalortnocdnuorG.noitisopnoehtot

ycnegremEmroftalpehtneht,yllamrongnitareposawenihcaMotdenrutsawhctiwsyekehtdnanidehsupsawnottubpotS

otdenrutsihctiwsyeklitnuffooglliwmralA.lortnocdnuorgdellupsinottubpotSycnegremEmroftalpehtrolortnocmroftalp

.tuo

12gnihsalf

.lortnocmroftalpothctiwsyeK.teef6evobadednetxemroftalP

tuodellupsnottubpotSycnegremEmroftalpdnalortnocdnuorG.noitisopnoehtot

.noitarepolamroN

22gnihsalf

.lortnocdnuorgothctiwsyeKnoehtottuodellupnottubpotSycnegremElortnocdnuorG

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Part No. 46326 Genie GS-2032 5 - 7


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5 - 8 Genie GS-2032 Part No. 46326


Notes

Fault Code ChartAfter Serial Number 17407


— — Normal operation

01 Machine will not operate. ECM cannot be reset. EPROM not programmed. Replace ECM.

02 Platform ECM error. Defective control cable OR platform controls.Troubleshoot cable OR platform controls.

03 Undefined platform DIP switch settings. DIP switch settings incorrect. Correct DIP switch settings.

12 Chassis up/down switch closed at start up. Malfunctioning up/down switch. Troubleshoot up/down switch.

18 Pothole guard failure.Malfunctioning pothole switch OR obstruction in pothole guard linkage.

Troubleshoot pothole switch OR remove obstruction.

42 Platform left turn switch closed at start up.Malfunctioning steer left microswitch.

Troubleshoot steer left microswitch.

43 Platform right turn switch closed at start up.Malfunctioning steer right microswitch.

Troubleshoot steer right microswitch.

45 Platform lift enable switch closed at start up.Malfunctioning lift enable switch.

Troubleshoot lift enable switch.

46 Platform drive enable switch closed at start up.Malfunctioning drive enable switch.

Troubleshoot drive enable switch.

47 Platform joystick off neutral at start up.Joystick potentiometer not centered.

Verify potentiometer setting.

52 Forward coil error. Malfuctioning coil OR wire disconnected from coil.Troubleshoot coil OR inspect wire connection.

53 Reverse coil error. Malfuctioning coil OR wire disconnected from coil.Troubleshoot coil OR inspect wire connection.

54 Up coil error. Malfuctioning coil OR wire disconnected from coil.Troubleshoot coil OR inspect wire connection.

55 Down coil error. Malfuctioning coil OR wire disconnected from coil.Troubleshoot coil OR inspect wire connection.

56 Right coil error. Malfuctioning coil OR wire disconnected from coil.Troubleshoot coil OR inspect wire connection.

57 Left coil error. Malfuctioning coil OR wire disconnected from coil.Troubleshoot coil OR inspect wire connection.

58 Brake coil error. Malfuctioning coil OR wire disconnected from coil.Troubleshoot coil OR inspect wire connection.

68 Low Voltage. Batteries discharged. Charge batteries.

Part No. 46326 Genie GS-2032 5 - 9


All FunctionsWill Not Operate

Be sure the circuitbreaker and fuse arenot tripped or blown.

Be sure the batteriesare properly connected.

Be sure the batteriesare fully charged.

Be sure bothEmergency Stopswitches are pulled outto the ON position.

Chart 1

0V

Charge batteries ORcheck battery conditionand replace badbatteries OR check forshort circuits OR checkbattery cables OR checkfor open in negativebattery cable frombatteries to ground pointon module tray.

24V or more

Replace 275A fuse.

Continued on the nextpage.

24V

Check voltage on inputside of 275A (F1) fuseinside battery moduletray.

Check voltage on outputside of 275A fuse insidethe battery module tray.

less than24V

Before serial number6901: Check voltage onthe input side of themotor contactor (K1).After serial number6900: check voltage onterminal B+ on the motorcontroller.

Repair open in 24Vsupply cable from 275Afuse to Anderson plugORBefore serial number6901: repair open in24V supply cable fromAnderson plug to motorcontactor (K1).After serial number6900: repair open in24V supply cable fromAnderson plug toterminal B+ on the motorcontroller.

24V

Check continuity from B-terminal on motorcontroller to the negativebattery cable at theAnderson plug.

nocontinuity

fullcontinuity

Repair open in negativebattery cable from B-terminal on motorcontroller to Andersonplug.

Turn key switch toplatform control andpress and hold thefunction enable switch.Visually inspect thepower-on LED.

light is on

light is not on

Troubleshoot groundand platform controlsystems separately ORconsult the GenieIndustries ServiceDepartment.

0V

5 - 10 Genie GS-2032 Part No. 46326


CHART 1

Continued from theprevious page.

Check voltage at inputside of each contact atthe key switch S2.

Repair open in wht wirefrom Emergency StopSwitch to key switch ORrepair open in wht wirejumper to each contactOR replace contact onEmergency Stop SwitchOR replace EmergencyStop Switch.

24V

Turn key switch toground control positionand check output side ofcontact.

Check cam on keyswitch.

bad Repair or replace keyswitch.

good

Replace contact ORrefer to Ground ControlsInoperative, Chart 5 ORconsult Genie IndustriesService Department.24V

Check voltage at inputside of 7A circuitbreaker F2.

0V

24V

Before serial number6900:Repair open in whtwire from input side ofmotor contactor to inputside of 7A circuitbreaker (24f-circuitbreaker to relay).After serial number6901: repair open inwire from motorcontroller to 7A circuitbreaker.

Check voltage at whtwire at input side ofEmergency Stop SwitchS1.

24V

Repair open in wht wirefrom output side of 7Acircuit breaker OR resetor replace 7A circuitbreaker.


0V

0V

0V

Part No. 46326 Genie GS-2032 5 - 11


CHART 1

Turn key switch toplatform control positionand check output side ofeach contact.

Check cam on keyswitch.

Repair or replace keyswitch.

good

Replace bad contact ORrefer to PlatformControls Inoperative,Chart 6 OR consult theGenie Industries ServiceDepartment.

24V

Refer to Chart 2, PumpMotor Will Not OperateOR repair open in whtwire (C2 estop chassis)OR consult the GenieIndustries ServiceDepartment.


0V bad

5 - 12 Genie GS-2032 Part No. 46326


Chart 2

Pump MotorWill Not Operate

Be sure the circuitbreaker and fuse arenot tripped or blown.

Be sure the batteriesare properly connected.

Be sure the batteriesare fully charged.

Activate lift function fromthe ground controls andcheck voltage at positiveterminal on pump motorM1.

24V ormore

Check continuity onground cable from pumpmotor to M- terminal onmotor controller.

nocontinuity

continuity

Replace ground cableon pump motor.

less than 24V


Activate lift function andcheck voltage atterminal 1 on the motorcontroller.

24V

Replace negative cablefrom B- terminal oncontroller to theAnderson plug.

Check continuity from B-terminal on controller tothe negative batterycable at the Andersonplug AP1.

continuity

nocontinuity

Before serial number6901: Repair open inwht wire (A8-motor)from K1 contact tocontroller.After serial number6900: Repair open inwht wire (A8-motor)from ECM.

Activate lift function andcheck voltage atterminal 3 on controller.

Before serial number8932: Repair open inwht wire (A9-mtr contterminal 3) from ECM tocontroller OR replaceECM OR consult GenieIndustries ServiceDepartment.After serial number8931: Repair open inwht wire (A9-mtr contterminal 3) OR relpace1k ohm potentiometeron controller.

0V

5V

Replace pump motorOR consult the GenieIndustries ServiceDepartment.

Check voltage on B+terminal on motorcontroller U2.

less than24V

Replace positive batterycable from pump to B+terminal on motorcontroller.

24V

Activate lift function andcheck voltage at M-terminal on controller.

24V

0V

Replace controller orcontact Genie IndustriesService Department.

less than24V

Part No. 46326 Genie GS-2032 5 - 13


CHART 2


Activate lift function andcheck voltage on theoutput side of motorcontroller relay K1.

less than 24V

24V ormore

0V

Check continuity on thebrown ground wire onthe coil of the motorcontroller relay to theground point on thechassis.

Check voltage on theoutput side of the 275Afuse.

Activate lift function andcheck voltage on theinput side of motorcontroller relay.

Activate lift function andcheck voltage on thewht wire on the coil ofthe motor controllerrelay.

24V

nocontinui

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