Genie GS-1530 Maintenance Manual
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Genie GS-1530 Maintenance Manual

Scissor lifts
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See also: Service & Repair Manual , Service Manual
Maintenance Manual -
Scissor Lifts
Slab Scissor Lifts
Rough Terrain
Scissor Lifts
Refer to the inside cover for a list of models
included in this manual.
This manual includes detailed
procedures for each
maintenance inspection.
For Repair procedures, Fault
Codes, Electrical and Hydraulic
Schematics, refer to the
appropriate Service and Repair
Manual for your machine.
Part No. 1272215
Rev B2
September 2016

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Summary of Contents for Genie GS-1530

  • Page 1 Maintenance Manual - Scissor Lifts Slab Scissor Lifts This manual includes detailed procedures for each maintenance inspection. Rough Terrain For Repair procedures, Fault Codes, Electrical and Hydraulic Scissor Lifts Schematics, refer to the appropriate Service and Repair Manual for your machine. Part No.
  • Page 2 Copyright © 2016 by Terex Corporation 1272215 Rev B, May 2016 First Edition, Second Printing Genie is a registered trademark of Terex South Dakota, Inc. in the U.S.A. and many other countries. “GS” is a trademark of Terex South Dakota, Inc.

  • Page 3: Models Included In This Manual

    GS-2669/3369/4069 DC from SN GS6912-1300 Models Serial number from SN GS6916F-7897 to GS6916F-10499 GS-1530 / GS-1532 from SN GS3010A-110000 from GS69F-10500 GS-1930 / GS-1932 from SN GS3011C-10000 to GS3016C-23999 GS-2669/3369/4069 BE from SN GS6914-5000...

  • Page 4: Glossary Of Terms

    • Test the Oscillate Axle - GS-90 • Grease the Steer Yokes - GS-30, GS-32, GS-46 and GS-47 • Model Abbreviations: GS-30: GS-1530, GS-1532, GS-1930, GS-1932 GS-32: GS-2032, GS-2632, GS-3232 GS-46: GS-2046, GS-2646, GS-2646 AV, 2646 AV35, GS-3246 GS-47: GS-4047...

  • Page 5: Revision History

    September 2016 Maintenance Manual Introduction Revision His tory Revision History Revision Date Section Procedure / Description 3/2016 Initial Release 5/2016 Specifications Add GM .998L engine Maintenance Add GM Maintenance intervals Programmed Maint. Report Update C-2 and P2-1, Add P0-8 7/2016 Maintenance 9/2016 Introduction...
  • Page 6 Maintenance Manual September 2016 Introduction Revision History (continued) Revision Date Section Procedure / Description Reference Examples: Electronic Version Section – Specifications Click on any content or procedure in the Table of Contents to view Section – Maintenance, (procedure) the update. Scissor Lifts Part No.

  • Page 7: Safety Rules

    September 2016 Maintenance Manual Safety Rules Gener al Safety R ules Section 1 Safety R ules 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.
  • Page 8 Maintenance Manual September 2016 Safety Rules Personal Safety Workplace Safety Any person working on or around a machine must Any person working on or around a machine must be aware of all known safety hazards. Personal be aware of all known safety hazards. Personal safety and the continued safe operation of the safety and the continued safe operation of the machine should be your top priority.

  • Page 9: Table Of Contents

    September 2016 Table of Contents Introduction Introduction ......................ii Important Information ..................... ii Models included in this manual ................iii Find additional Manuals for your Model ..............iii Identifying the Correct Procedure for your Model ..........iv Glossary of terms: ....................iv Revision History......................
  • Page 10 September 2016 Table of Contents Section 3 Maintenance Procedures .................. 20 Introduction ......................20 Maintenance Schedule ..................22 Pre-Delivery Preparation Report ................23 Scheduled Maintenance Inspection Report - Scissor Lifts ........24 Programmed Maintenance Inspection Report - Scissor Lifts ......25 Commissioning Procedures ................
  • Page 11 September 2016 Table of Contents Q-20 Test the Down Limit Switch, Level Sensor and Pothole Limit Switches - GS-30, GS-32, GS-46 and GS-47 ..............45 Q-21 Test the Platform Gate Proximity Switches and the Extension Deck Limit Switch - GS-2646 AV, GS-2646 AV35 ............49 Annual Maintenance Procedures..............

  • Page 12: Performance Specifications

    Function speed, maximum from platform controls Function speed, maximum from platform controls (with 1 person in platform) (with maximum rated load in platform) GS-1530, GS-1532, GS-1930 and GS-1932 GS-1530, GS-1532, GS-1930 and GS-1932 Platform up 15 to 17 seconds Platform up (fast mode)
  • Page 13 Maintenance Manual September 2016 Performance Specifications Function Speeds GS-69, GS-84, GS- 90 Function Speeds Function speed, maximum from platform controls (with maximum rated load in platform) GS-2669 DC, GS-2669 BE, GS-2669 RT Platform up 29 to 39 seconds Platform down 26 to 36 seconds GS-3369 DC, GS-3369 BE, GS-3369 RT Platform up...

  • Page 14: Drive Speeds

    Model Stowed position Elevated Braking distance, Gradeability position maximum High range on paved surface GS-1530, GS-1532 10.9 seconds 55 seconds 1 - 3 ft 40 ft / 12.2 m 40 ft / 0.3 - 0.9 m 12.2 m GS-1930, GS-1932 10.9 seconds...

  • Page 15: Torque Specifications

    Torque values are listed as lubricated unless otherwise noted. Lug nuts must be coated with a mineral based lubricant when removed and replaced on the machine. Model GS-1530, GS-1532, GS-1930, GS-1932, GS-2032, GS-2632, GS-3232, GS-2046, GS-2646, GS-3246, GS-4047, GS-2646AV Castle nut torque...

  • Page 16: Battery Specifications

    September 2016 Maintenance Manual Battery Specifications Batter y Specification s Battery Specific ations - DC and BE Models GS-1530, GS-1532, GS-1930, GS-1932, GS-2669, GS-3369, GS-4069 (standard) (standard) GS-2032, GS-2632, GS-3232, GS-2046, (DC and BE models) GS-2646, GS-3246, GS-2646 AV Voltage...

  • Page 17: Engine Specifications

    Deutz Engine Models Engine Operator and Maintenance Manuals D2011 L03i Low idle 1500 rpm Deutz D2011L03i 313 Hz Genie part number 139320 High idle 2500 rpm Deutz D 2.9 L4 522 Hz Genie part number 1251561 Oil capacity (including filter) 9.5 quarts...

  • Page 18: Perkins Engine Models

    September 2016 Maintenance Manual Engine Specifications Perki ns Engine M odels Ford Engi ne Models Perkins Engine Models Ford Engine Models 403D-11 MSG-425 Low idle 1500 rpm Low idle 1600 rpm 150 Hz 53.3 Hz High idle 3000 rpm High idle 2500 rpm 300 Hz 83.3 Hz...

  • Page 19: Kubota Engine Models

    Maintenance Manual September 2016 Engine Specifications Kubota Engine M odels Kohler Engi ne Model s Kubota Engine Models Kohler Engine Models D1105-E3B, D1105-E4B KD350 Low idle 1500 rpm High idle 3600/3000 rpm 250 Hz Oil capacity (including filter) 1.3 quarts High idle 3000 rpm 1.2 liters...

  • Page 20: Gm Engine Models

    September 2016 Maintenance Manual Engine Specifications GM Engine M odels GM Engine Models .998L Low idle 1100 rpm 36.6 Hz High idle 3000 rpm 100 Hz Oil capacity (including filter) 3.2 quarts 3.0 liters Engine coolant capacity 5 quarts 4.7 liters Spark plug gap 0.039 to 0.047 inches 1.0 to 1.2 mm...

  • Page 21: Hydraulic Specifications

    Model System relief Lift relief Steer relief Outrigger Oscillate Traction relief relief Manifold Hot oil relief GS-1530, GS-1532 3700 psi 1800 to 1500 psi GS-1930, GS-1932 255 bar 3700 psi 103 bar GS-2032, GS-2632 142 to 255 bar GS-2046, GS-2646,...
  • Page 22 2900 to 3100 psi 1950 to 2250 psi 3500 psi 280 psi 200 to 214 bar 135 to 155 bar 241 bar 19.3 bar GS-1530, GS-1532 200 psi GS-1930, GS-1932 14 bar Check valve manifold GS-2646 AV 750 psi Extension deck...

  • Page 23: Hydraulic And Drive Hub Fluid Capacities

    Drive hub oil type: SAE 90 multipurpose hypoid gear oil API service classification GL5 Model Drive hubs Hydraulic tank Hydraulic system (including tank) GS-1530, GS-1532, GS-1930, GS-1932 3.4 gallons 3.8 gallons 12.9 liters 14.2 liters GS-2032, GS-2632, GS-2046, GS-2646, GS-2646 AV 3.4 gallons...

  • Page 24: Hydraulic Oil Specifications

    Hydraulic fluids may be incompatible due to the Hydraulic Fluid Specifications differences in base additive Genie specifications require hydraulic oils which are chemistry. When incompatible designed to give maximum protection to hydraulic fluids are mixed, insoluble systems, have the ability to perform over a wide...
  • Page 25 Maintenance Manual September 2016 Hydraulic Specifications Chevron Rando HD Premium Oil Chevron 5606A Hydraulic Oil MV Fluid Properties Fluid Properties ISO Grade ISO Grade Viscosity index Viscosity index Kinematic Viscosity Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 200°F / 100°C cSt @ 104°F / 40°C 33.5 cSt @ 104°F / 40°C...
  • Page 26 September 2016 Maintenance Manual Hydraulic Specifications Petro-Canada Environ MV 46 UCON Hydrolube HP-5046 Fluid Fluid Properties Properties ISO Grade ISO Grade Viscosity index Viscosity index Kinematic Viscosity Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 149°F / 65°C cSt @ 104°F / 40°C 44.4 cSt @ 104°F / 40°C cSt @ 0°F / -18°C...

  • Page 27: Hydraulic Hose And Fitting Torque Specifications

    Your machine is equipped with Parker Seal-Lok™ SAE Dash Size Torque ORFS or 37° JIC fittings and hose ends. Genie 14 ft-lbs / 19 Nm specifications require that fittings and hose ends be torqued to specification when they are removed 23 ft-lbs / 31.2 Nm...

  • Page 28: Torque Procedure

    Note: The O-ring in Parker Seal Lok™ fittings and hose end are custom-size O-rings. They are not standard size O-rings. They are available in the O-ring field service kit (Genie part number 49612). Lubricate the O-ring before installation. Be sure the O-ring face seal is seated and retained properly.
  • Page 29 Maintenance Manual September 2016 Hydraulic Specifications Working clockwise on the body hex fitting, make a second mark with a permanent ink marker to indicate the proper tightening position. Refer to Illustration 2. Note: Use the JIC 37° Fitting table in this section to determine the correct number of flats, for the proper tightening position.
  • Page 30 September 2016 Maintenance Manual This page intentionally left blank. Part No. 1272215 Scissor Lifts...

  • Page 31: Maintenance Procedures

     Repair any machine damage or malfunction before operating the machine.  Use only Genie approved replacement parts.  Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection.
  • Page 32 September 2016 Maintenance Manual Maintenance Procedures Maintenance Symbols Legend About This Section Note: The following symbols have been used in this This section contains detailed procedures for each manual to help communicate the intent of the scheduled maintenance inspection. instructions. When one or more of the symbols Each procedure includes a description, safety appear at the beginning of a maintenance warnings and step-by-step instructions.

  • Page 33: Maintenance Schedule

    Maintenance Manual September 2016 Maintenance Procedures Maintenanc e Schedul e Maintenance Schedule Programmed Example (under 1000 HRS): The maintenance procedures have been divided into subsections that include: Commissioning, Quarterly, Annually and Programmed maintenance intervals. The maintenance inspection report has been divided into general areas of the machine that include: Drive Chassis, Platform, Functions and Controls, Engine and Electrical.

  • Page 34: Pre-Delivery Preparation Report

    September 2016 Maintenance Manual Pre-Delivery Preparation Report Pre-Deliv ery Prepar ati on Repor t Fundamentals Instructions It is the responsibility of the owner or dealer to Use the operator’s manual on your machine. perform the Pre-delivery Preparation. The Pre-delivery Preparation consists of The Pre-delivery Preparation is performed prior to completing the Pre-operation Inspection, the each delivery.

  • Page 35: Scheduled Maintenance Inspection Report - Scissor Lifts

    September 2016 Scheduled Maintenance Inspection Report – Scissor Lifts Model Hour meter Date Serial number Inspector company Machine owner Inspected by (print) Inspector signature Inspection Type Legend Make copies of this report to use for each inspection. Select the appropriate procedures for the type of Q = quarterly or frequent inspections Y = yes, acceptable inspection(s) to perform.

  • Page 36: Programmed Maintenance Inspection Report - Scissor Lifts

    September 2016 Programmed Maintenance Inspection Report – Scissor Lifts Model Hour meter Date Serial number Inspector company Machine owner Inspected by (print) Inspector signature Programmed maintenance will be completed based on machine Legend Make copies of this report to use for each hours.

  • Page 37: Commissioning Procedures

    Maintenance Manual September 2016 Commissioning Procedures Commissionin g Procedur es C-2 Perform Engine M aintenanc e – 50 Hours C-1 Perform 50 H our Service Perform Engine Maintenance - 50 Perform 50 Hour Service Hours The 50 hour maintenance procedure is a one time sequence of procedures to be performed after the The 50 hour maintenance procedure is a one time first 50 hours of usage.

  • Page 38: Perform 150 Hour Service

    September 2016 Maintenance Manual Commissioning Procedures C-3 Perform 150 H our Servic e Perform 150 Hour Service The 150 hour maintenance procedure is a one time sequence of procedures to be performed after the first 150 hours of usage. After this interval, refer to the maintenance tables for continued scheduled maintenance.

  • Page 39: Quarterly Maintenance Procedures

    Select "Customer Login" to login or select your machine has no open bulletins is to frequently "Request New Access" to create a new check the serial number of your Genie machine account. against our bulletin database. Using the links below you can view any open bulletins for your machine(s) At the homepage, select "Unit Configuration"...

  • Page 40: Battery Inspection

    Check the ambient air temperature and adjust the specific gravity reading for each cell as follows: Genie specifications require that this procedure be performed quarterly. • Add 0.004 to the reading of each cell for every 10° F / 5.5° C above 80° F / 26.7° C.
  • Page 41 Maintenance Manual September 2016 Quarterly Maintenance Procedures GS-30, GS-32, GS-46, GS-47 and GS-69 DC: Perform an equalizing charge OR fully charge the battery(s) and allow the battery(s) to rest at Check each battery pack and verify that the least 6 hours. batteries are wired correctly.

  • Page 42: Check The Module Tray Latch Components

    Maintenance Manual Quarterly Maintenance Procedures Check the Module Tray Latch Components Genie specifications require that this procedure be performed quarterly. Maintaining the module tray latch components in good condition is essential to good performance and service life. Failure to detect worn out latch...

  • Page 43: Inspect The Battery Balancer - Gs-69 Dc

    Quarterly Maintenance Procedures Q-4 Ins pect the Battery Bal anc er - GS- 69 DC Inspect the Battery Balancer - GS-69 DC Genie specifications require that this procedure be performed quarterly. Open the battery compartment and locate the fuse box.

  • Page 44: Inspect The Electrical Wiring

    Inspect the Electrical Wiring • Battery charger • Scissor arms • All wire harness connectors to platform Genie specifications require that this procedure be control box performed quarterly. • ECM (GCON) to platform controls (PCON) Maintaining electrical wiring in good condition is •...

  • Page 45: Inspect The Electrical Contactor

    Inspect the Voltage Inverter GS-30, GS-32, GS-46, GS-47, (if equipped) GS-69 DC and GS-69 BE Genie specifications require that this procedure be performed quarterly. Genie specifications require that this procedure be performed quarterly. Perform this procedure more often if dusty conditions exist.

  • Page 46: Test The Flashing Beacons (If Equipped)

    Test the Flashing Beacons (if Result: The power tool should operate. There equipped) may be a brief (0.5 second) delay if the power Genie specifications require that this procedure be tool has not been used in the previous performed quarterly. 10 minutes.

  • Page 47: Visual Inspection Of The Hydraulic Oil

    • Color: oil should be a clear, light-honey colored • Appearance, oil should be clear and not Genie specifications require that this procedure be cloudy or visibly distorts the view through performed quarterly. the sight glass or container •...

  • Page 48: Inspect The Hydraulic Filters

    Models without Filter Condition Indicator: Inspect the Hydraulic Filters Note: Models without a filter condition indicator cannot be inspected. At the required maintenance Genie specifications require that this procedure be interval, replace the filters. performed quarterly. Hydraulic Tank Cap (if equipped):...

  • Page 49: Check The Exhaust System - Engine Models

    Inspect the Fuel Tank Check Engine Models Valve Venting System - GS-69 RT Gas Models Genie specifications require that this procedure be performed quarterly. Maintaining the exhaust system is essential to good engine performance and service life. Note: For machines located in the United States,...

  • Page 50: Test The Fuel Select Operation - Gasoline/Lpg Models

    Press the LPG operation button. Result: The LPG indicator light should be on. Start the engine and allow it to run at low idle. Genie specifications require that this procedure be Press high idle button to allow the engine to performed quarterly.

  • Page 51: Check And Adjust The Engine Rpm

    ECM and can only be adjusted by moves freely. re-programming the ECM. If RPM or service is required, please contact Genie Product Support. Hold the throttle lever against the low idle adjustment screw. Ford Models: MSG-425 EFI Turn the adjustment screw clockwise to Deutz Models: D 2.9 L4...
  • Page 52 September 2016 Maintenance Manual Quarterly Maintenance Procedures Tighten the lock nut. All other engine models: Low rpm idle adjustment: Loosen the lock nut on the low idle adjustment screw. Turn the adjustment screw clockwise to increase low rpm or counterclockwise to decrease low rpm.

  • Page 53: Inspect The Tires, Wheels And Lug Nut Torque

    Q-15 Ins pec t the Tires , W heels and Lug Nut T orque Q-15 Inspect the Tires and Wheels Deutz D2011L03i (including torque) Genie specifications require that this procedure be performed quarterly. Maintaining the tires and wheels, including proper wheel fastener torque, is essential to safe operation and good performance. Tire and/or wheel failure could result in a machine tip-over.

  • Page 54: Confirm The Proper Brake Configuration - Gs-69, Gs-84, Gs-90

    Confirm the Proper Brake Test the Drive Brakes Configuration - GS-69, GS-84, GS-90 Genie specifications require that this procedure be performed quarterly. Proper brake action is essential to safe machine Genie specifications require that this procedure be operation. The drive brake function should operate performed quarterly.

  • Page 55: Test The Drive Speed - Stowed Position

    Test the Drive Speed - Stowed Test the Drive Speed - Raised Position Position Genie specifications require that this procedure be Genie specifications require that this procedure be performed quarterly. performed quarterly. Proper drive function is essential to safe machine Proper drive function is essential to safe machine operation.

  • Page 56: Test The Down Limit Switch, Level Sensor And Pothole Limit Switches

    Do not activate the switch contacts. 10 Turn the selector/key switch to platform control. Genie specifications require that this procedure be 11 Raise the platform and return the safety arm to performed quarterly. the stowed position. Maintaining the limit switches is essential to safe 12 Working at the platform controls, lower the operation and good machine performance.
  • Page 57 Maintenance Manual September 2016 Quarterly Maintenance Procedures 13 Attempt to drive and steer the machine. 15 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. Result: The ground controls LCD displays 16 Lift the safety arm, move it to the center of the "PHS: POTHOLE GUARDS STUCK"...
  • Page 58 September 2016 Maintenance Manual Quarterly Maintenance Procedures 25 Standing on the up-hill side of the machine, Level Sensor attempt to drive and steer the machine. 23 Move the machine onto a grade which Result: The ground controls LCD displays "LL: exceeds the rating of the level sensor.
  • Page 59 Maintenance Manual September 2016 Quarterly Maintenance Procedures 28 Attempt to raise the platform to approximately 29 Attempt to drive and steer the machine. 8 feet / 2.4 m. Result: The ground controls LCD displays Result: The pothole guard contacts the block "PHS: POTHOLE GUARDS STUCK"...

  • Page 60: Test The Platform Gate Proximity Switches And The Extension Deck Limit Switch - Gs-2646 Av, Gs-2646 Av35

    The ground controls LCD displays "Fd: FUNCTION DISABLED" and the platform controls LED displays "Ld". The machine is functioning properly. Genie specifications require that this procedure be Result: The platform up and down functions performed quarterly. operate.The ground controls LCD does not display "Fd: FUNCTION DISABLED"...
  • Page 61 Maintenance Manual September 2016 Quarterly Maintenance Procedures Extension Deck Limit Switch Attempt to drive and steer the machine. Result: The drive and steer functions do not 11 Deploy the manual extension deck or the operate.The ground controls LCD displays "Fd: powered extension deck (if equipped), FUNCTION DISABLED"...

  • Page 62: Annual Maintenance Procedures

    Check the Drive Hub Oil Level and GS-69 BE and GS-69 DC Fastener Torque - GS-69, GS-84 and GS-90 Genie specifications require that this procedure be performed annually. Genie specifications require that this procedure be performed quarterly. Proper pump function is essential to safe oscillate operation and machine function.

  • Page 63: Test The Oscillate Axle - Gs-90

    Test the Oscillate Axle - GS-90 Result: The time to fully elevate the platform is at or less than the table shown below. The efficiency of the function pump is good. Genie specifications require that this procedure be GS-2669 55 seconds performed annually.
  • Page 64 September 2016 Maintenance Manual Annual Maintenance Procedures Test the down limit switch and relay K11 Using a volt meter, check for voltage by connecting the positive lead to relay K11, Note: Perform this test using the platform controls terminal 87 and connecting the negative lead while standing on the ground as described below.
  • Page 65 K12, terminal 30. this procedure. Movement of the Oscillate operates in the incorrect direction. machine could result in death or Do not proceed. Contact Genie Product serious injury. Support. Result: The volt meter should read 12V DC or Note: Remove the jumper wire from relay K12 and greater.

  • Page 66: Test The Down Limit Switch Descent Delay - Gs-69, Gs-84 And

    19 Close the ground control panel and secure GS-69, GS-84 and GS-90 using the fasteners removed in Step 3 and securely tighten. Genie specifications require that this procedure be performed annually. 20 Disconnect the platform controller from the control cable and securely connect the control cable to the ground control plug.
  • Page 67 Maintenance Manual September 2016 Annual Maintenance Procedures Check the Descent Delay Check the Down Limit Switch Function Height GS-69: Raise the platform approximately 10 ft GS-69: Raise the platform approximately 10 ft / 3 m. / 3 m. GS-84 and GS-90: Raise the platform GS-84 and GS-90: Raise the platform approximately 15 ft / 4.6 m.

  • Page 68: Test The Platform Overload Pressure Transducer And Platform Height Sensor - Gs-30, Gs-32, Gs-46 And Gs-47 (If Equipped)

    Emergency Stop button to the off position. Pressure Transducer Genie specifications require that this procedure be Working at the barrel end of the lift cylinder, performed annually OR when the machine fails to follow the pressure transducer cable down the lift the maximum rated load.
  • Page 69 Maintenance Manual September 2016 Annual Maintenance Procedures Platform Height Sensor Turn the key switch to ground controls and pull out the ground controls red Emergency Stop 13 Working at platform height sensor assembly, button to the on position. follow the platform height sensor cable to its end point at the chassis deck.
  • Page 70 September 2016 Maintenance Manual Annual Maintenance Procedures 17 Using the multimeter, measure the voltage reading of the pressure transducer at pin C and B. Result: The voltage reading of the platform height sensor is between 1V and 4V. The platform height sensor is functioning properly. Result: The voltage reading of the platform height sensor is 0V or above 5V.

  • Page 71: (If Equipped)

    Note: The overload system will not measure loads at or below the height of the Down Limit Switch. Genie specifications require that this procedure be performed annually OR when the machine fails to lift the maximum rated load.
  • Page 72 September 2016 Maintenance Manual Annual Maintenance Procedures Press and hold the ground control scroll up Press the Enter button. and scroll down buttons. Result: The ground controls LCD display will show the following: Press the Enter button. Result: The ground controls LCD display will show the following: Ground Control Menu Buttons 1 scroll down button...

  • Page 73: Test The Platform Overload System - Gs-69 (If Equipped)

    Result: The ground controls LCD display will System - GS-69 (if equipped) show the following: Genie specifications require that this procedure be performed annually OR when the machine fails to lift the maximum rated load. Result: Fault code with description is Testing the platform overload system regularly is essential to safe machine operation.
  • Page 74 September 2016 Maintenance Manual Annual Maintenance Procedures Lift the safety arm, move it to the center of the 11 GS-69 BE and GS-69 DC: Turn the key switch scissor arm and rotate down to a vertical to ground control and fully raise the platform. position.

  • Page 75: Test The Platform Overload System - Gs-84 And Gs-90 (If Equipped)

    How to Calibrate the to Repair Procedure, Platform Overload System (if equipped) Genie specifications require that this procedure be performed annually OR when the machine fails to GS-69 RT: Start the machine and fully raise lift the maximum rated load.
  • Page 76 September 2016 Maintenance Manual Annual Maintenance Procedures Tag and disconnect the platform controls wire 11 Raise the platform until the position indicator harness from the ECM wire harness. corresponds to the maximum load position of the capacity indicator decal. Securely connect the platform controls to the Result: The engine stops and an audible alarm ECM wire harness.

  • Page 77: Programmed Maintenance Procedures

    Securely install the filter element into the canister. Install the gasket and baffle (if equipped), and Genie specifications require that this procedure be end cap onto the air cleaner canister. performed every 40 hours or weekly, whichever Note: Be sure the dust discharge valve is facing comes first.

  • Page 78: P0-2 Grease The Steer Yokes - Gs-30, Gs-32, Gs-46 And Gs-47

    P0- 2 Gr ease the Steer Yok es - GS- 30, GS-32, GS-46 and GS- 47 P0-2 Grease the Steer Yokes - GS-30, GS-32, GS-46 and GS-47 Genie specifications require that this procedure be performed every 100 hours of operation. Regular application of lubrication to the steer yokes is essential to good machine performance and service life.

  • Page 79: P0-3 Deutz Engine Maintenance - Under 1000 Hours

    Maintenance Manual September 2016 Programmed Maintenance Procedures P0- 3 D eutz Engine M aintenanc e – U nder 1000 H ours P0-3 Deutz Engine Maintenance – Under 1000 Hours Programmed Maintenance Inspection Report Additional engine maintenance is required. Refer to the the specific intervals that apply.

  • Page 80: P0-4 Ford Engine Maintenance - Under 1000 Hours

    September 2016 Maintenance Manual Programmed Maintenance Procedures P0- 4 F ord Engi ne Mai ntenance – Under 1000 H ours P0-4 Ford Engine Maintenance – Under 1000 Hours Programmed Maintenance Inspection Report Additional engine maintenance is required. Refer to the the specific intervals that apply.

  • Page 81: P0-5 Kohler Engine Maintenance - Under 1000 Hours

    Maintenance Manual September 2016 Programmed Maintenance Procedures P0- 5 Kohler Engi ne Mai ntenance – Under 1000 H ours P0-5 Kohler Engine Maintenance – Under 1000 Hours Programmed Maintenance Inspection Report Additional engine maintenance is required. Refer to the the specific intervals that apply. Required maintenance procedures and additional engine information are available in the manufacturer's manuals.

  • Page 82: P0-6 Kubota Engine Maintenance - Under 1000 Hours

    September 2016 Maintenance Manual Programmed Maintenance Procedures P0- 6 Kubota Engi ne Mai ntenanc e – U nder 1000 Hours P0-6 Kubota Engine Maintenance – Under 1000 Hours Programmed Maintenance Inspection Report Additional engine maintenance is required. Refer to the the specific intervals that apply.

  • Page 83: P0-7 Perkins Engine Maintenance - Under 1000 Hours

    Maintenance Manual September 2016 Programmed Maintenance Procedures P0- 7 Perki ns Engine M aintenanc e – U nder 1000 H ours P0-7 Perkins Engine Maintenance – Under 1000 Hours Programmed Maintenance Inspection Report Additional engine maintenance is required. Refer to the the specific intervals that apply.

  • Page 84: P0-8 Gm Engine Maintenance - Under 1000 Hours

    September 2016 Maintenance Manual Programmed Maintenance Procedures P0- 8 GM Engi ne Mai ntenanc e – U nder 1000 Hours P0-8 GM Engine Maintenance – Under 1000 Hours Programmed Maintenance Inspection Report Additional engine maintenance is required. Refer to the the specific intervals that apply.

  • Page 85: P1-1 Perform Engine Maintenance - 1000 Hours

    Maintenance Manual September 2016 Programmed Maintenance Procedures P1- 1 Perform Engine M aintenanc e – 1000 H ours P1-1 Perkins Models Perform Engine Maintenance – • Alternator and fan belts - replace 1000 Hours • Engine valve lash – inspect/adjust •...

  • Page 86: P1-2 Replace The Drive Hub Oil - Gs-69, Gs-84 And Gs-90

    September 2016 Maintenance Manual Programmed Maintenance Procedures P1- 2 R epl ace the Drive H ub Oil - GS-69, GS- 84 and GS-90 P2- 1 Perform Engine M aintenanc e – 2000 H ours P1-2 P2-1 Replace the Drive Hub Oil - GS-69, Perform Engine Maintenance –...

  • Page 87: P2-2 Replace The Hydraulic Filters

    Maintenance Manual September 2016 Programmed Maintenance Procedures P2- 2 R epl ace the Hy draulic Filters P2-2 Kubota Models Replace the Hydraulic Filters D1105, WG972 • Radiator coolant (L.L.C.) - replace • Battery - replace Engine specifications require that this procedure be •...

  • Page 88: P2-3 Check The Free-Wheel Configuration - Gs-84 And Gs-90

    Locate the medium and high pressure filter(s). Remove the filter housing using a wrench on the nut provided on the bottom of the housing. Genie requires that this procedure be performed every 2000 hours. Remove the filter element from the housing.
  • Page 89 Maintenance Manual September 2016 Programmed Maintenance Procedures Disengage the drive hubs by turning over the Lift the wheels off the ground and then place drive hub disconnect caps on each non-steer jack stands under the drive chassis for wheel hub. support.

  • Page 90: P2-4 Check The Scissor Arm Wear Pads (And Slider Blocks, If Equipped)

    22.9 mm or more. Proceed to step 3. Result: The measurement is less than 0.90 inch / 22.9 mm. Replace both wear pads. Genie requires that this procedure be performed Refer to Repair Procedure in the appropriate every 2000 hours.
  • Page 91 Maintenance Manual September 2016 Programmed Maintenance Procedures GS-2032, GS-2632, GS-3232, GS-2046, GS-2646, GS-3246 and GS-4047: Measure the distance between the number one outer arm cross tube and the fork lift tube at the ground controls side of the non-steer end of the machine. Refer to Illustration 2. Result: The measurement is 0.88 inch / 22.4 mm or more.
  • Page 92 September 2016 Maintenance Manual Programmed Maintenance Procedures GS-2669 (all models), GS-3369 (all models), GS-3384, GS-3390, GS-4390, GS-5390 GS-4069 (all models) Measure the thickness of each chassis wear Measure the thickness of each platform pad at the steer end of the machine. scissor arm slider blocks at the non-steer end Result: The measurement is 5/16 inch / 8 mm of the machine.

  • Page 93: P2-5 Grease The Steer Axle Wheel Bearings - Gs-69 Be And Gs-69 Dc

    Result:  There is side to side or up and down down movement. Proceed to step 10. movement Proceed to step 6. Genie requires that this procedure be performed Remove the dust cap from the hub. Remove every 2000 hours. the cotter pin from the castle nut.

  • Page 94: P2-6 Test Or Replace The Hydraulic Oil

    14 Pack both bearings with clean, fresh grease. 15 Place the large inner bearing into the rear of Genie requires that this procedure be performed the hub. every 2000 hours. 16 Install a new bearing grease seal into the hub...

  • Page 95: P3-1 Perform Engine Maintenance - 3000 Hours

    Maintenance Manual September 2016 Programmed Maintenance Procedures P3- 1 Perform Engine M aintenanc e – 3000 H ours P3-1 Testing the oil: Perform Engine Maintenance – Complete the hydraulic oil testing with an oil 3000 Hours distributor. If the hydraulic oil passes testing at the 2000 hour maintenance interval, the oil must be tested every quarter by an oil distributor Engine specifications require that this procedure be...
  • Page 96 September 2016 Maintenance Manual This page intentionally left blank. Sciss or Lifts Part No. 1272215 Maintenanc e M anual September 2016 Part No. 1272215 Scissor Lifts...

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