Terex Genie GS-1330m Maintenance Manual
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Terex Genie GS-1330m Maintenance Manual

Scissor lifts
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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.
Original Instructions
Part No. 1305686GT
Rev A
November 2021

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Summary of Contents for Terex Genie GS-1330m

  • 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. Refer to the inside cover for a list of models Original Instructions included in this manual.
  • Page 2 Copyright © 2016 by Terex Corporation 1305686GT Rev A, November 2021 Second Edition, First 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 November 2021 Maintenance Manual Introduction Models included in this manual Identifying the Correct Procedure for your Model Use the following chart to identify the specific serial number for models included in this manual. Unless otherwise noted, each procedure will apply to all models.
  • Page 4 Maintenance Manual November 2021 Introduction Revision History Revision Date Section Procedure / Description 10/2021 Initial Release Reference Examples: Section – Specifications Electronic Version Click on any content or procedure in the Table of Contents to view Section – Maintenance, (procedure) the update.
  • Page 5 November 2021 Maintenance Manual Safety Rules Secti on 1 Safety Rul es Danger Failure to obey the instructions and safety rules in this manual and the appropriate Operator's Manual on your machine will result in death or serious injury. Many of the hazards identified in the operator's manual are also safety hazards when maintenance and repair procedures are performed.
  • Page 6 Maintenance Manual November 2021 Safety Rules Personal Safety Workplace Safety Any person working on or around a machine Any person working on or around a machine must be aware of all known safety hazards. must be aware of all known safety hazards. Personal safety and the continued safe Personal safety and the continued safe operation of the machine should be your top...
  • Page 7 November 2021 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 ..........iii Glossary of terms: ..................... iii Revision History ....................

  • Page 8: Table Of Contents

    November 2021 Table of Contents Section 2 Performance Specifications ................1 Function Speeds GS-30, GS-32, GS-46, GS-47, GS-55 ........1 Function Speeds GS-69, GS-84, GS-90 ............. 2 Drive Speeds ..................... 3 Torque Specifications ..................4 Tires and Wheels ....................4 Battery Specifications..................
  • Page 9 November 2021 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 10 November 2021 Table of Contents Annual Maintenance Procedures ..............51 A-1 Check the Drive Hub Oil Level and Fastener Torque ........51 A-2 Test the Function Pump - GS-69 BE and GS-69 DC ........52 A-3 Test the Oscillate Axle - GS-90 ..............53 A-4 Test the Down Limit Switch Descent Delay - GS-69, GS-84 and GS-90 (if equipped).............

  • Page 11: Performance Specifications

    November 2021 Maintenance Manual Performance Specifications Secti on 2 Perfor man ce Speci ficatio ns Function Speeds Function speed, maximum from platform controls (with 1 person in platform) Function speed, maximum from platform controls (with 1 person in platform) GS-2046 Models with hydraulic drive Platform up 34 to 41 seconds...

  • Page 12: Function Speeds Gs-69, Gs-84, Gs-90

    Maintenance Manual November 2021 Performance Specifications 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 - 39 seconds Platform down 26 - 46 seconds GS-3369 DC, GS-3369 BE, GS-3369 RT Platform up 34 - 44 seconds Platform down...

  • Page 13: Drive Speeds

    November 2021 Maintenance Manual Performance Specifications Drive Speeds Model Stowed position Elevated position Braking distance, maximum High range on paved surface GS-1330m, GS-4655 10.9 seconds 55 seconds 1 - 3 ft 40 ft / 12,2 m 40 ft / 12,2 m 0,3 - 0,9 m GS-1530, GS-1532 10.9 seconds...

  • Page 14: Torque Specifications

    Maintenance Manual November 2021 Torque Specifications Tires and Wheels Model GS-2669 / 3369 / 4069 (DC and BE models) Torque values are listed as lubricated unless Castle nut torque 150 ft-lbs otherwise noted. Lug nuts must be coated with a (steer end) 203 Nm mineral based lubricant when removed and...

  • Page 15: Battery Specifications

    November 2021 Maintenance Manual Battery Specifications GS-1330m GS-1530 / 1532 (standard) (standard) GS-1930 / 1932 / 1932 XH Voltage 12V DC GS-2032 / 2632 Group Models with hydraulic drive Voltage 6V DC Type 24TMX Group Quantity Battery capacity, maximum Type T-105 85AH Quantity...
  • Page 16 Maintenance Manual November 2021 Battery Specifications GS-1530 / 1532 GS-2669, GS-3369, GS-4069 (optional) (standard) GS-1930 / 1932 / 1932 XH (DC and BE models) GS-2032 / 2632 / 3232 Voltage 6V DC GS-2046 / 2646 / 3246 Group GS-2646 XH / 3246 XH Models with electric drive Type T-105...

  • Page 17: Engine Specifications

    November 2021 Maintenance Manual Engine Specifications Deutz Engine Models Engine Operator and Maintenance Manuals D2011 L03i Low idle 1500 rpm Deutz D2011L03i 313 Hz Genie part number 139320GT High idle 2500 rpm Deutz TD 2.2 L3 522 Hz Genie part number 1305687GT Oil capacity (including filter) 9.5 quarts...

  • Page 18: Perkins Engine Models

    Maintenance Manual November 2021 Engine Specifications 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 Oil capacity (including filter) Oil capacity (including filter) 4.6 quarts 6.7 quarts...

  • Page 19: Kubota Engine Models

    November 2021 Maintenance Manual Engine Specifications 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 500 Hz Unit ships with 15W-40. Extreme operating Oil capacity (including filter) 5.4 quarts temperatures may require the use of alternative...

  • Page 20: Gm Engine Models

    Maintenance Manual November 2021 Engine Specifications 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 Engine coolant Ethylene Glycol Spark plug gap 0.039 - 0.047 inches 1,0 - 1,2 mm...

  • Page 21: Hydraulic Specifications

    November 2021 Maintenance Manual Hydraulic Specifications Hydraulic Relief Valve Pressure Manifold Relief Valve Pressure / Bar System Outrigger Oscillate Traction Model Lift relief Steer relief relief relief relief Manifold Hot oil relief GS-1330m 2250 psi 1600 psi 155 bar 110 bar 1800 psi GS-1432m 124 bar...
  • Page 22 Maintenance Manual November 2021 Hydraulic Specifications Manifold Relief Valve Pressure / Bar Outrigger Oscillate Traction Model System relief Lift relief Steer relief relief relief Manifold Hot oil relief GS-2669 RT 3500 psi 3100 psi 3300 psi 2500 psi 241 bar 214 bar 228 bar 172 bar...

  • Page 23: Hydraulic And Drive Hub Fluid Capacities

    November 2021 Maintenance Manual Hydraulic Specifications Hydraulic and Drive Hub Fluid Capacities Model Drive hubs Hydraulic tank Hydraulic system (including tank) GS-1330m 1.06 gallons 1.5 gallons 4 liters 5,68 liters GS-1432m / 1932m / 1932m Lite / 1932m XH 10 fl oz 1.06 gallons 1.5 gallons 300 cc...

  • Page 24: Hydraulic Oil Specifications

    Maintenance Manual November 2021 Hydraulic Specifications Hydraulic Oil Specifications Do not top off with incompatible hydraulic fluids. 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 November 2021 Maintenance Manual 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 cSt @ 104°F / 40°C 15.0...
  • Page 26 Maintenance Manual November 2021 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 cSt @ 104°F / 40°C 44.4 cSt @ 0°F / -18°C...

  • Page 27: Hydraulic Hose And Fitting Torque Specifications

    November 2021 Maintenance Manual Hydraulic Specifications Hydraulic Hose and Fitting SAE O-ring Boss Port Torque Specifications (tube fitting - installed into Aluminum) (all types) Your machine is equipped with Parker Seal-Lok™ ORFS or 37° JIC fittings and hose ends. Genie SAE Dash Size Torque specifications require that fittings and hose ends...

  • Page 28: Torque Procedure

    Maintenance Manual November 2021 Hydraulic Specifications Torque Procedure Seal-Lok™ fittings 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 or hose end has been tightened beyond finger tight.
  • Page 29 November 2021 Maintenance Manual Hydraulic Specifications JIC 37° fittings Working clockwise on the body hex fitting, make a second mark with a permanent ink Align the tube flare (hex nut) against the nose marker to indicate the proper tightening of the fitting body (body hex fitting) and position.

  • Page 30: Maintenance Procedures

    Maintenance Manual November 2021 Maintenance Procedures Machine Configuration: Secti on 3 Maint enan ce Pro ced ures Unless otherwise specified, perform each  procedure with the machine in the following configuration: • Machine parked on a firm, level surface • Key switch in the off position with the key Observe and Obey: removed Maintenance inspections shall be completed...
  • Page 31 November 2021 Maintenance Manual Maintenance Procedures About This Section Maintenance Symbols Legend Note: The following symbols have been used in This section contains detailed procedures for each this 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 32: Maintenance Schedule

    Maintenance Manual November 2021 Maintenance Procedures 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 33: Pre-Delivery Preparation Report

    November 2021 Maintenance Manual Pre-Delivery Preparation Report 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 34: Scheduled Maintenance Inspection Report - Scissor Lifts

    Scheduled November 2021 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 35: Programmed Maintenance Inspection Report - Scissor Lifts

    Programmed November 2021 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 36: Commissioning Procedures

    Maintenance Manual November 2021 Commissioning Procedures 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 37: Perform 150 Hour Service

    November 2021 Maintenance Manual Commissioning Procedures 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 38: Quarterly Maintenance Procedures

    Maintenance Manual November 2021 Quarterly Maintenance Procedures Machines purchased in ASIA, North America and Latin America: Check for Open Bulletins and Owner Registration Go to ASIA, North America and Latin America Bulletins (https://www.gogenielift.com/) Genie specifications require that this procedure be performed quarterly.

  • Page 39: Battery Inspection

    November 2021 Maintenance Manual Quarterly Maintenance Procedures Models without maintenance-free or sealed batteries: Battery Inspection Put on protective clothing and eye wear. Remove the battery vent caps and check the specific gravity of each battery cell with a Genie specifications require that this procedure be hydrometer.
  • Page 40 Maintenance Manual November 2021 Quarterly Maintenance Procedures 10 Check the ambient air temperature and adjust GS-30m, GS-30, GS-32m, GS-32, GS-46, GS-55, the specific gravity reading for each cell as GS-69 DC/BE: follows: Verify that the batteries are wired correctly. • Add 0.004 to the reading of each cell for every 10°...

  • Page 41: Check The Module Tray Latch Components

    November 2021 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 components may result in module trays opening unexpectedly, creating an unsafe operating 275A Fuse...

  • Page 42: Inspect The Battery Balancer - Gs-69 Dc

    Maintenance Manual November 2021 Quarterly Maintenance Procedures 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. Locate the LED indicator under the fuse box and watch the LED for 5 seconds to verify the battery balancer condition.

  • Page 43: Inspect The Electrical Wiring

    November 2021 Maintenance Manual Quarterly Maintenance Procedures • Battery tray(s) 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 44: Inspect The Electrical Contactor - Gs-30M, Gs-30, Gs-32M

    Maintenance Manual November 2021 Quarterly Maintenance Procedures Inspect the Electrical Contactors Inspect the Voltage Inverter (if - GS-30m, GS-30, GS-32m, GS-32, equipped) GS-46, GS-55, GS-69 DC, GS-69 BE Genie specifications require that this procedure be performed quarterly. Perform this procedure more often if dusty Genie specifications require that this procedure be conditions exist.
  • Page 45 November 2021 Maintenance Manual Quarterly Maintenance Procedures Inverter type 2: Result: The power tool should operate. There may be a brief (0.5 second) delay if the power tool has not been used in the previous 10 minutes. If the left fault LED (REV_POL) is illuminated, the inverter is connected to batteries with the incorrect polarity.

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

    Maintenance Manual November 2021 Quarterly Maintenance Procedures Test the Flashing Beacons (if Visual Inspection of the Hydraulic equipped) Genie specifications require that this procedure be performed quarterly. Genie specifications require that this procedure be Flashing beacons are used to alert operators and performed quarterly.

  • Page 47: Inspect The Hydraulic Filters

    November 2021 Maintenance Manual Quarterly Maintenance Procedures Q-10 Collect a sample of hydraulic oil and place in a clear container. Visually inspect the Inspect the Hydraulic Filters hydraulic oil for the following: Genie specifications require that this procedure be • Color: oil should be a clear, light-honey performed quarterly.

  • Page 48: Check The Exhaust System - Engine Models

    Maintenance Manual November 2021 Quarterly Maintenance Procedures Q-11 Models without Filter Condition Indicator: Check the Exhaust System - Note: Models without a filter condition indicator Engine Models cannot be inspected. At the required maintenance interval, replace the filters. Genie specifications require that this procedure be Hydraulic Tank Cap (if equipped): performed quarterly.

  • Page 49: Inspect The Fuel Tank Check Valve Venting System - Gs-69 Rt Gas Models

    November 2021 Maintenance Manual Quarterly Maintenance Procedures Q-12 Q-13 Inspect the Fuel Tank Check Test the Fuel Select Operation - Valve Venting System - GS-69 RT Gasoline/LPG Models Gas Models Genie specifications require that this procedure be performed quarterly. Note: For machines located in the United States, EPA Certificate 40 CFR Part 1060 requires that The ability to select and switch between gasoline the check valve be in proper working condition.

  • Page 50: Check And Adjust The Engine Rpm

    Maintenance Manual November 2021 Quarterly Maintenance Procedures Q-14 Press the engine stop button. Check and Adjust the Engine Result: The engine should stop. RPM - GS-69 RT, GS-84, GS-90 Press the LPG operation button. Result: The LPG indicator light should be on. Start the engine and allow it to run at low idle.
  • Page 51 November 2021 Maintenance Manual Quarterly Maintenance Procedures Tighten the lock nut. Start the engine from the ground controls. Press and hold the start button or hold the start toggle switch and check the engine RPM on the diagnostic display. Result: Low idle rpm is correct. Result: Low idle rpm is not correct.
  • Page 52 Maintenance Manual November 2021 Quarterly Maintenance Procedures All other engine models: Deutz D2011L03i 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. Tighten the lock nut.

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

    November 2021 Maintenance Manual Quarterly Maintenance Procedures Q-15 Q-16 Inspect the Tires and Wheels Confirm the Proper Brake (including torque) Configuration - GS-69, GS-84, GS-90 Genie specifications require that this procedure be performed quarterly. Genie specifications require that this procedure be performed quarterly.

  • Page 54: Test The Drive Brakes

    Maintenance Manual November 2021 Quarterly Maintenance Procedures Q-17 Q-18 Test the Drive Brakes Test the Drive Speed – Stowed Position Genie specifications require that this procedure be performed quarterly. Genie specifications require that this procedure be performed quarterly. Proper brake action is essential to safe machine operation.

  • Page 55: Test The Drive Speed - Raised Position

    November 2021 Maintenance Manual Quarterly Maintenance Procedures Q-19 Q-20 Test the Drive Speed - Raised Test the Down Limit Switch, Position Level Sensor and Pothole Limit Switches - GS-30, GS-32, GS-46, GS-55 Genie specifications require that this procedure be performed quarterly. Proper drive function is essential to safe machine Genie specifications require that this procedure be operation.
  • Page 56 Maintenance Manual November 2021 Quarterly Maintenance Procedures Tag and disconnect the platform control box at the platform. Down Limit Switch Follow the platform control cable down the Disable the down limit switch. Loosen the scissor stack to the alarm bracket on the fastener securing the roller arm to the limit chassis deck.
  • Page 57 November 2021 Maintenance Manual Quarterly Maintenance Procedures 13 Attempt to drive and steer the machine. 15 GS-55: Raise the platform approximately 13 feet / 4 m. Result: The ground controls LCD displays "PHS: POTHOLE GUARDS STUCK" and the All other models: Raise the platform 7 to platform controls LED displays "PHS".
  • Page 58 Maintenance Manual November 2021 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 exceeds the rating of the level sensor. Refer "LL: MACHINE TILTED"...
  • Page 59 November 2021 Maintenance Manual Quarterly Maintenance Procedures Pothole Limit Switches Result: The pothole guard contacts the block and does not fully deploy. The ground 27 Place a wooden block approximately 2 inches controls LCD does not display "PHS: / 5 cm tall under the right pothole guard. POTHOLE GUARDS STUCK"...
  • Page 60 Maintenance Manual November 2021 Quarterly Maintenance Procedures 31 Repeat this procedure beginning with step 30 for the left pothole guard. 32 Lower the platform to the stowed position, remove the block under the left pothole guard. 33 GS-55: Raise the platform approximately 13 feet / 4 m.

  • Page 61: Annual Maintenance Procedures

    November 2021 Maintenance Manual Annual Maintenance Procedures Install the plug(s) into the drive hub. Check the torque of the drive hub mounting Check the Drive Hub Oil Level fasteners. Refer to Torque Specifications, and Fastener Torque Tires and Wheels. Repeat this procedure for each drive hub. Torque specifications GS-1530 / 1532 / 1930 / 1932 33 ft-lbs...

  • Page 62: Test The Function Pump - Gs-69 Be And Gs-69 Dc

    Maintenance Manual November 2021 Annual Maintenance Procedures Test the Function Pump GS-69 BE and GS-69 DC Genie specifications require that this procedure be performed annually. Proper pump function is essential to safe oscillate operation and machine function. Note: Perform this procedure on a firm, level surface with the platform in the stowed position and the platform extension deck fully retracted.

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

    November 2021 Maintenance Manual Annual Maintenance Procedures Test relay K11 Test the Oscillate Axle - GS-90 Note: Perform this test using the platform controls while standing on the ground as described below. At the ground controls, turn the key switch to platform controls and pull out the red Genie specifications require that this procedure be Emergency Stop button.
  • Page 64 Maintenance Manual November 2021 Annual Maintenance Procedures Oscillate Float Test Using a volt meter, check for voltage by connecting the positive lead to relay K11, Note: The following procedure will require two terminal 87 and connecting the negative lead people. to the ground strip terminal.
  • Page 65 November 2021 Maintenance Manual Annual Maintenance Procedures 15 Using the jumper wire, jump from relay K12, 18 Push in the red Emergency Stop button on terminal 87A to terminal D4 below the blue the platform controller and on the ground wire.

  • Page 66: Test The Down Limit Switch Descent Delay - Gs-69, Gs-84 And Gs-90 (If Equipped)

    Maintenance Manual November 2021 Annual Maintenance Procedures Test the Descent Delay Check the Down Limit Height (if equipped) GS-69, GS-84, GS-90 GS-69: Raise the platform approximately 10 feet / 3 m. Genie specifications require that this procedure be GS-84, GS-90: Raise the platform performed annually.

  • Page 67: Test The Platform Overload Pressure Transducer And Platform Height Sensor

    November 2021 Maintenance Manual Annual Maintenance Procedures Lower the platform onto the safety arm. Test the Platform Overload Crushing hazard. Keep hands Pressure Transducer and clear of the safety arm when lowering the platform. Platform Height Sensor At the ground controls, turn the key switch to the off position and push in the red Emergency Stop button to the off position.
  • Page 68 Maintenance Manual November 2021 Annual Maintenance Procedures Turn the key switch to ground controls and Platform Height Sensor pull out the ground controls red Emergency Stop button to the on position. 13 Working at platform height sensor assembly, follow the platform height sensor cable to its 10 Using the multimeter, measure the voltage end point at the chassis deck.
  • Page 69 November 2021 Maintenance Manual Annual Maintenance Procedures GS-69, GS-84, GS-90 17 Using the multimeter, measure the voltage reading of the platform height sensor. Note: Perform this procedure with the machine on a firm, level surface that is free of obstructions. Result: The voltage reading of the platform height sensor is between 1V and 4V.
  • Page 70 Maintenance Manual November 2021 Annual Maintenance Procedures Lower the platform onto the safety arm. Turn the key switch to ground controls and pull out the ground controls red Emergency Crushing hazard. Keep hands Stop button to the on position. clear of the safety arm when Using the multimeter, measure the voltage lowering the platform.
  • Page 71 November 2021 Maintenance Manual Annual Maintenance Procedures 17 Using the multimeter, measure the voltage Platform Height Sensor reading of the platform height sensor. 13 Working at platform height sensor assembly, Result: The voltage reading of the platform follow the platform height sensor cable to its height sensor is between 0.5V and 4.5V.
  • Page 72 Maintenance Manual November 2021 Annual Maintenance Procedures 19 At the ground controls, turn the key switch to the off position and push in the red Emergency Stop button to the off position. 20 Remove the test leads. 21 Turn the key switch to ground controls and pull out the ground controls red Emergency Stop button to the on position.

  • Page 73: Test The Platform Overload System

    November 2021 Maintenance Manual Annual Maintenance Procedures The platform height sensor, located at the steer end of the chassis, is used to determine the height Test the Platform Overload of the platform. System - GS-30m, GS-30, The overload pressure transducer and the platform GS-32m, GS-32, GS-46, GS-55 height sensor provide the GCON with necessary information to determine the load in the platform.
  • Page 74 Maintenance Manual November 2021 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 75: Test The Platform Overload System - Gs-69 (If Equipped)

    November 2021 Maintenance Manual Annual Maintenance Procedures Follow the menu structure to complete the NO LOAD calibration procedure. Test the Platform Overload Result: The ground controls LCD display will System - GS-69, GS-84, GS-90 show the following: Genie specifications require that this procedure be performed annually OR when the machine fails to lift the maximum rated load.
  • Page 76 Maintenance Manual November 2021 Annual Maintenance Procedures Raise the platform. Pull out the platform red Emergency Stop button to the on position. Result: The platform fully raises, the overload indicator light is off and there is no audible Note: Start the engine if equipped. alarm.

  • Page 77: Check The Steer Yoke King Pin Fastener Torque

    November 2021 Maintenance Manual Annual Maintenance Procedures Check the Steer Yoke King Pin Fastener Torque - GS-84, GS-90 Genie specifications require that this procedure be performed annually. Maintaining proper torque is essential to safe machine operation. Improper bolt torque could result in an unsafe operating condition and component damage.

  • Page 78: Programmed Maintenance Procedures

    Maintenance Manual November 2021 Programmed Maintenance Procedures P0-1 Inspect the air filter element. If needed, blow from the inside out using low pressure dry Inspect the Engine Air Filter - compressed air, or carefully tap out dust. GS-69 RT Securely install the filter element into the canister.

  • Page 79: P0-2 Grease The Steer Yokes - Gs-30M, Gs-30, Gs-32, Gs-46, Gs-55

    November 2021 Maintenance Manual Programmed Maintenance Procedures P0-2 P0-3 Grease the Steer Yokes - Replace the Drive Hub Oil - GS-30m, GS-30, GS-32, GS-46, GS-30, GS-32m, GS-32, GS-46, GS-55 GS-55 Genie specifications require that this procedure be Drive hub specifications require that this procedure be performed after the first 50 hours of operation.

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

    Maintenance Manual November 2021 Programmed Maintenance Procedures P0-4 Deutz Engine Maintenance – Under 1000 Hours Additional engine maintenance is required. Refer to the Programmed Maintenance Inspection Report for the specific intervals that apply. Required maintenance procedures and additional engine information are available in the manufacturer's manuals.

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

    November 2021 Maintenance Manual Programmed Maintenance Procedures P0-5 Ford Engine Maintenance – Under 1000 Hours Additional engine maintenance is required. Refer to the Programmed Maintenance Inspection Report for the specific intervals that apply. Required maintenance procedures and additional engine information are available in the manufacturer's manuals.

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

    Maintenance Manual November 2021 Programmed Maintenance Procedures P0-6 Kohler Engine Maintenance – Under 1000 Hours Additional engine maintenance is required. Refer to the Programmed Maintenance Inspection Report for the specific intervals that apply. Required maintenance procedures and additional engine information are available in the manufacturer's manuals.

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

    November 2021 Maintenance Manual Programmed Maintenance Procedures P0-7 Kubota Engine Maintenance – Under 1000 Hours Additional engine maintenance is required. Refer to the Programmed Maintenance Inspection Report for the specific intervals that apply. Required maintenance procedures and additional engine information are available in the manufacturer's manuals.

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

    Maintenance Manual November 2021 Programmed Maintenance Procedures P0-8 Perkins Engine Maintenance – Under 1000 Hours Additional engine maintenance is required. Refer to the Programmed Maintenance Inspection Report for the specific intervals that apply. Required maintenance procedures and additional engine information are available in the manufacturer's manuals.

  • Page 85: P0-9 Gm Engine Maintenance - Under 1000 Hours

    November 2021 Maintenance Manual Programmed Maintenance Procedures P0-9 GM Engine Maintenance – Under 1000 Hours Additional engine maintenance is required. Refer to the Programmed Maintenance Inspection Report for the specific intervals that apply. Required maintenance procedures and additional engine information are available in the manufacturer's manuals.

  • Page 86: P1-1 Perform Engine Maintenance - 1000 Hours

    Maintenance Manual November 2021 Programmed Maintenance Procedures P1-1 Perkins Models Perform Engine Maintenance – • Alternator and fan belts - replace 1000 Hours • Engine valve lash – inspect/adjust • Engine crankcase breather - replace Kubota Models Engine specifications require that this procedure be performed every 1000 hours.

  • Page 87: P1-2 Replace The Drive Hub Oil - Gs-69, Gs-84, Gs-90

    November 2021 Maintenance Manual Programmed Maintenance Procedures P1-2 P2-1 Replace the Drive Hub Oil - GS- Perform Engine Maintenance – 69, GS-84, GS-90 2000 Hours Drive hub specifications require that this procedure Engine specifications require that this procedure be performed after the first 50 hours of operation. be performed every 2000 hours.

  • Page 88: P2-2 Replace The Hydraulic Filters

    Maintenance Manual November 2021 Programmed Maintenance Procedures P2-2 Kubota Models Replace the Hydraulic Filters All Models: • Radiator coolant (L.L.C.) - replace • Battery - replace Genie specifications require that this procedure be • Radiator hoses and clamp bands - replace performed every 2000 hours.
  • Page 89 November 2021 Maintenance Manual Programmed Maintenance Procedures GS-30m, GS-1432m/1932m, GS-1530/1532, GS-69, GS-84, GS-90 GS-1930/1932, GS-32, GS-46 Replace the Medium and High Pressure Hydraulic Filter(s) Models with electric drive Locate the medium and high pressure filter(s). Clean the area around the return filter. Remove the filter housing using a wrench on Locate the drain port on the function manifold the nut at the bottom of the housing.

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

    Maintenance Manual November 2021 Programmed Maintenance Procedures P2-3 Disengage the drive hubs by turning over the drive hub disconnect caps on each non-steer Check the Free-wheel wheel hub. Configuration - GS-84, GS-90 Genie requires that this procedure be performed every 2000 hours. Proper use of the free-wheel configuration is essential to safe machine operation.

  • Page 91: P2-4 Check The Scissor Arm Wear Pads (And Slider Blocks, If Equipped)

    November 2021 Maintenance Manual Programmed Maintenance Procedures P2-4 Lift the wheels off the ground and then place jack stands under the drive chassis for Check the Scissor Arm Wear support. Pads 10 Disengage the drive hubs by turning over the (and Slider Blocks, if equipped) drive hub disconnect caps on each steer wheel hub.
  • Page 92 Maintenance Manual November 2021 Programmed Maintenance Procedures GS-2032, GS-2632, GS-3232, GS-2046, GS-2646, Measure the distance between the number GS-3246: one inner arm cross tube and the chassis deck at the battery pack side of the non-steer Measure the distance between the number end of the machine.
  • Page 93 November 2021 Maintenance Manual Programmed Maintenance Procedures GS-4655: Measure the thickness of each chassis wear pad at the non-steer end of the machine. Result: The measurement is 4.89 inch / 12.42 cm or more. Proceed to step 2. Result: The measurement is less than 4.89 inch / 12.42 cm.

  • Page 94: P2-5 Grease The Steer Axle Wheel Bearings - Gs-69 Be And Gs-69 Dc

    Maintenance Manual November 2021 Programmed Maintenance Procedures P2-5 GS-3384, GS-3390, GS-4390, GS-5390: Grease the Steer Axle Wheel Measure the thickness of each chassis wear Bearings - GS-69 BE, GS-69 DC pad at the steer end of the machine. Result: The measurement is 5/16 inch / 8 mm or more.
  • Page 95 November 2021 Maintenance Manual Programmed Maintenance Procedures Check for wheel bearing wear by attempting 13 Place the hub on a flat surface and gently pry to move the wheel hub side to side, then up the bearing seal out of the hub. Remove the and down.

  • Page 96: P2-6 Test Or Replace The Hydraulic Oil

    Maintenance Manual November 2021 Programmed Maintenance Procedures P2-6 Testing the oil: Test or Replace the Hydraulic Oil Complete the hydraulic oil testing with an oil distributor. If the hydraulic oil passes testing at the 2000 hour maintenance interval, the oil must Genie requires that this procedure be performed be tested every quarter by an oil distributor every 2000 hours.

  • Page 97: P3-1 Perform Engine Maintenance - 3000 Hours

    November 2021 Maintenance Manual Programmed Maintenance Procedures P3-1 Perkins Models Perform Engine Maintenance – • Water pump - inspect 3000 Hours • Fuel Injector - test/change • Cooling system coolant (Heavy Duty) - change Engine specifications require that this procedure Kubota Models be performed every 3000 hours.

  • Page 98: P5-1 Perform Engine Maintenance - 5000 Hours

    Maintenance Manual November 2021 Programmed Maintenance Procedures P5-1 P6-1 Perform Engine Maintenance – Perform Engine Maintenance – 5000 Hours 6000 Hours Engine specifications require that this procedure Engine specifications require that this procedure be performed every 5000 hours. be performed every 6000 hours. Required maintenance procedures and additional Required maintenance procedures and additional engine information are available in the...

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Genie gs-1432mGenie gs-1932mGenie gs-1932m liteGenie gs-1932m xhGenie gs-1530Genie gs-1532 ... Show all

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