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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. 1272215GT
Rev E1
June 2022
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Table of Contents
Related Manuals for Terex Genie GS-2646 AV
Summary of Contents for Terex Genie GS-2646 AV
- 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 Group A/Type 3 as defined by ISO 16368 First Edition, Fifth Printing Machine Design Life Genie is a registered trademark of Terex South Dakota, Inc. in the U.S.A. and many other countries. Unrestricted with proper operation, inspection and “GS” is a trademark of Terex South Dakota, Inc.
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Page 3: Models Included In This Manual
June 2022 Maintenance Manual Introduction Models included in this manual GS-2669/3369/4069 RT from SN GS6911-101 from SN GS6916F-7897 to GS69F-10499 Use the following chart to identify the specific from GS69F-10500 to serial number for models included in this manual. GS69F-17999 Models Serial number GS-2669/3369/4069 DC from SN GS6912-1300... -
Page 4: Glossary Of Terms
Maintenance Manual June 2022 Introduction Find additional Manuals for your Identifying the Correct Procedure Model for your Model Go to http://www.genielift.com Unless otherwise noted, each procedure will apply to all models. Procedures that only apply to Use the links to locate Service Manuals, specific models or options will include the Maintenance Manuals, Service and Repair information in the procedure title. -
Page 5: Revision History
June 2022 Maintenance Manual Introduction Revision Hist ory Revision History Revision Date Section Procedure / Description 3/2016 Initial Release 5/2016 Specifications GM .998L Maintenance Programmed Maint. Report C-2, P2-1, P0-8 7/2016 Annual 9/2016 Introduction Models Included 1/2019 All Sections GS-1330m 6/2019 All Sections GS-4655... - Page 6 Maintenance Manual June 2022 Introduction Revision History (continued) Revision Date Section Procedure / Description Reference Examples: Section – Specifications Electronic Version Click on any content or procedure in the Table of Contents to view Section – Maintenance, (procedure) the update. Scissor Lifts Part No.
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Page 7: Safety Rules
June 2022 Maintenance Manual Safety Rules Gene ral Saf ety Rul es 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. - Page 8 Maintenance Manual June 2022 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...
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Page 9: Table Of Contents
June 2022 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 June 2022 Table of Contents Section 3 Maintenance Procedures ................19 Introduction ...................... 19 Maintenance Schedule ..................21 Pre-Delivery Preparation Report ............... 22 Scheduled Maintenance Inspection Report - Scissor Lifts ......... 23 Programmed Maintenance Inspection Report - Scissor Lifts ......24 Commissioning Procedures ................
- Page 11 June 2022 Table of Contents Q-11 Check the Exhaust System - Engine Models ..........38 Q-12 Inspect the Fuel Tank Check Valve Venting System - GS-69 RT Gas Models ................39 Q-13 Test the Fuel Select Operation - Gasoline/LPG Models ......39 Q-14 Check and Adjust the Engine RPM ............
- Page 12 June 2022 Table of Contents Programmed Maintenance Procedures............61 P0-1 Inspect the Engine Air Filter - GS-69 RT ..........61 P0-2 Grease the Steer Yokes - GS-30, GS-32, GS-46, GS-47 ......62 P0-3 Deutz Engine Maintenance – Under 1000 Hours ........63 P0-4 Ford Engine Maintenance –...
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Page 13: Performance Specifications
June 2022 Maintenance Manual Performance Specifications Function Speeds Secti on 2 Perfor man ce Speci ficatio ns Function Speeds Functi on Sp eeds GS-30 , GS-3 2, GS -46, GS-4 7, GS- 55 (models with proportional lift) (models without proportional lift) Function speed, maximum from platform controls Function speed, maximum from platform controls (with 1 person in platform) - Page 14 Maintenance Manual June 2022 Performance Specifications Functi on Sp eeds GS-69 , GS-8 4, 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 - 39 seconds Platform down 26 - 46 seconds GS-3369 DC, GS-3369 BE, GS-3369 RT...
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Page 15: Drive Speeds
June 2022 Maintenance Manual Performance Specifications Drive Spe eds Drive Speeds Model Stowed position Elevated position Braking distance, Gradeability 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 / 12.2 m 0.3 - 0.9 m GS-1930, GS-1932... -
Page 16: Torque Specifications
Maintenance Manual June 2022 Torque Specifications Tor q ue S peci fic ati on s Tires and Wheels Tires and Wheels 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. -
Page 17: Battery Specifications
June 2022 Maintenance Manual Battery Specifications Batter y Spec ific ati on s Battery Sp ecificati ons - DC a nd BE M odels GS-1530, GS-1532, GS-1930, GS-1932, GS-4047 (standard) (standard) GS-2032, GS-2632, GS-3232, GS-2046, Voltage 12V DC GS-2646, GS-3246, GS-2646 AV Group Voltage 6V DC... -
Page 18: Engine Specifications
Maintenance Manual June 2022 Engine Specifications Engi ne Sp eci fica tio ns Deutz Engi ne Mod els Deutz Engine Models Engine Operator and Engine O per ato r an d M ainte nanc e M anu als Maintenance Manuals D2011 L03i Low idle 1500 rpm... -
Page 19: Perkins Engine Models
June 2022 Maintenance Manual Engine Specifications Perkins Engi ne Mod els Perkins Engine Models For d Engin e M odels 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... -
Page 20: Kubota Engine Models
Maintenance Manual June 2022 Engine Specifications Kubota En gine Mo dels Kubota Engine Models Kohler En gine Mod els 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 21: Gm Engine Models
June 2022 Maintenance Manual Engine Specifications GM Engi ne 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 Engine coolant Ethylene Glycol... -
Page 22: Hydraulic Specifications
Maintenance Manual June 2022 Hydraulic Specifications Hydr au lic Sp eci fica ti ons Hydraulic Relief Valve Pressure Hydraulic Relief Valv es Manifold Relief Valve Pressure / Bar Outrigger Oscillate Traction Model System relief Lift relief Steer relief relief relief Manifold Hot oil relief GS-1530, GS-1532... - Page 23 June 2022 Maintenance Manual Hydraulic Specifications Manifold Relief Valve Pressure / Bar Outrigger Oscillate Traction Model System relief Lift relief Steer relief relief relief Manifold Hot oil relief GS-3384 2700 to 2900 psi 2700 to 2900 psi 280 psi 186 to 200 bar 186 to 200 bar 19.3 bar GS-3390...
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Page 24: Hydraulic And Drive Hub Fluid Capacities
Maintenance Manual June 2022 Hydraulic Specifications Hydraulic and Drive Hub Fluid C apa cities Hydraulic and Drive Hub Fluid Capacities Note: Hydraulic system includes hydraulic tank capacity. Drive hub oil type: SAE 90 multipurpose hypoid gear oil API service classification GL5 Hydraulic system Model Drive hubs... -
Page 25: Hydraulic Oil Specifications
June 2022 Maintenance Manual Hydraulic Specifications Hydraulic Oil Specific ations 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. - Page 26 Maintenance Manual June 2022 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 27 June 2022 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 cSt @ 104°F / 40°C 44.4 cSt @ 0°F / -18°C...
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Page 28: Hydraulic Hose And Fitting Torque Specifications
Maintenance Manual June 2022 Hydraulic Specifications Hydraulic Hose and Fitti ng Tor que Sp ecificati ons 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™ SAE Dash Size Torque ORFS or 37°... -
Page 29: Torque Procedure
June 2022 Maintenance Manual Hydraulic Specifications Tor que P roce dur e Torque Procedure JIC 37° fittings Align the tube flare (hex nut) against the nose Seal-Lok™ fittings of the fitting body (body hex fitting) and tighten the hex nut to the body hex fitting to Replace the O-ring. - Page 30 Maintenance Manual June 2022 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.
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Page 31: Maintenance Procedures
June 2022 Maintenance Manual Maintenance Procedures Machine Configuration: Secti on 3 Maint enan ce Pro ced ures Intro ductio n Unless otherwise specified, perform each procedure with the machine in the following configuration: • Machine parked on a firm, level surface •... - Page 32 Maintenance Manual June 2022 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.
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Page 33: Maintenance Schedule
June 2022 Maintenance Manual Maintenance Procedures Maint enan ce Sche dule 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
Maintenance Manual June 2022 Pre-Delivery Preparation Report Pre-Delive ry Pr epa ratio n Rep ort 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
Scheduled June 2022 Maintenance Inspection Report – Scissor Lifts Schedule d M ainte nanc e Ins pecti on Re port - Scisso r Lif ts 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. -
Page 36: Programmed Maintenance Inspection Report - Scissor Lifts
Programmed June 2022 Maintenance Inspection Report – Scissor Lifts Progr amm ed Maint ena nce I nspe ction R epo rt - 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
June 2022 Maintenance Manual Commissioning Procedures Com m issio ni ng Pr o ce dur es C-2 Per for m Engin e M ainte nanc e – 50 H ours C-1 Per for m 50 Hou r Servic e Perform Engine Maintenance - 50 Perform 50 Hour Service Hours The 50 hour maintenance procedure is a one time... -
Page 38: Perform 150 Hour Service
Maintenance Manual June 2022 Commissioning Procedures C-3 Per for m 15 0 Ho ur Se rvice 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
June 2022 Maintenance Manual Quarterly Maintenance Procedures Quar ter l y Ma in ten an ce Pr oc ed ur es Q-1 Ch eck f or O pen B ulletins and Owne r Re gistra tion Machines purchased in ASIA, North America and Latin America: Check for Open Bulletins and Owner Registration... -
Page 40: Battery Inspection
Maintenance Manual June 2022 Quarterly Maintenance Procedures Remove the battery vent caps and check the Q-2 Bat tery Insp ection specific gravity of each battery cell with a Battery Inspection hydrometer. Note the results. Check the ambient air temperature and adjust the specific gravity reading for each cell as follows: Genie specifications require that this procedure be... - Page 41 June 2022 Maintenance Manual Quarterly Maintenance Procedures 11 Check the battery acid level. If needed, Perform an equalizing charge OR fully charge replenish with distilled water to 1/8 inch / the battery(s) and allow the battery(s) to rest 3 mm below the bottom of the battery fill tube. at least 6 hours.
- Page 42 Maintenance Manual June 2022 Quarterly Maintenance Procedures GS-30, GS-32, GS-46, GS-47, GS-69 DC: Check each battery pack and verify that the batteries are wired correctly. GS-47 1 batteries B5 2 275A fuse F6 275A Fuse 3 quick disconnect QD1 GS-30, GS-32, GS-46 1 batteries B5 2 275A fuse F6 3 quick disconnect QD1...
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Page 43: Check The Module Tray Latch Components
June 2022 Maintenance Manual Quarterly Maintenance Procedures Q-3 Ch eck t he M odul e T ray Latc h Com pon ents 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. -
Page 44: Inspect The Battery Balancer - Gs-69 Dc
Maintenance Manual June 2022 Quarterly Maintenance Procedures Q-4 I nspec t the Batte ry Bala ncer - 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 45: Inspect The Electrical Wiring
June 2022 Maintenance Manual Quarterly Maintenance Procedures Q-5 I nspec t the Electric al Wiring • 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. -
Page 46: Inspect The Electrical Contactor
Maintenance Manual June 2022 Quarterly Maintenance Procedures Q-6 I nspec t the Electric al Cont acto r - GS-30 , GS- 32, GS -46, GS-4 7, GS- 69 DC, GS-69 BE Q-7 I nspec t the Voltag e Inv ert er (if eq uipp ed) Inspect the Electrical Contactors Inspect the Voltage Inverter - GS-30, GS-32, GS-46, GS-47,... - Page 47 June 2022 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.
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Page 48: Test The Flashing Beacons (If Equipped)
Maintenance Manual June 2022 Quarterly Maintenance Procedures Q-8 Test the Flashi ng Be acons (if equip ped ) Q-9 Visu al Insp ectio n of the Hy dra ulic Oil Test the Flashing Beacons (if Visual Inspection of the Hydraulic equipped) Genie specifications require that this procedure be performed quarterly. -
Page 49: Inspect The Hydraulic Filters
June 2022 Maintenance Manual Quarterly Maintenance Procedures Q-10 Insp ect th e Hyd raulic Filte rs 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 •... -
Page 50: Check The Exhaust System - Engine Models
Maintenance Manual June 2022 Quarterly Maintenance Procedures Q-11 C heck the Ex haust System - En gine Mod els 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. -
Page 51: Inspect The Fuel Tank Check Valve Venting System - Gs-69 Rt Gas Models
June 2022 Maintenance Manual Quarterly Maintenance Procedures Q-12 Insp ect th e Fuel Tank Check Valve Ve nting Sys tem - GS- 69 R T G as M odels Q-12 Q-13 Tes t the Fu el Select Ope rati on - Gas oline/ LPG Mo dels Q-13 Inspect the Fuel Tank Check Test the Fuel Select Operation -... -
Page 52: Check And Adjust The Engine Rpm
Maintenance Manual June 2022 Quarterly Maintenance Procedures Q-14 C heck and A djust t he En gine RP M 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. - Page 53 June 2022 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. Continue with step 3.
- Page 54 Maintenance Manual June 2022 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.
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Page 55: Inspect The Tires, Wheels And Lug Nut Torque
June 2022 Maintenance Manual Quarterly Maintenance Procedures Q-15 Insp ect th e Tires, Wheels an d Lu g Nut To rqu e Q-15 Q-16 C onfi rm t he Pr ope r Brak e Con figu ratio n - GS-69, GS-8 4, GS- 90 Q-16 Inspect the Tires and Wheels Confirm the Proper Brake... -
Page 56: Test The Drive Brakes
Maintenance Manual June 2022 Quarterly Maintenance Procedures Q-17 Tes t the Drive Brakes Q-17 Q-18 Tes t the Drive Spee d – Stow ed Positi on Q-18 Test the Drive Brakes Test the Drive Speed – Stowed Position Genie specifications require that this procedure be performed quarterly. -
Page 57: Test The Drive Speed - Raised Position
June 2022 Maintenance Manual Quarterly Maintenance Procedures Q-19 Tes t the Drive Spee d - R aised Po sition Q-19 Q-20 Tes t the Down Limit Switc h, L evel Sen sor and Pothol e Li mit Switches - GS -30, GS-3 2, GS- 46, GS -47 Q-20 Test the Drive Speed - Raised Test the Down Limit Switch,... - Page 58 Maintenance Manual June 2022 Quarterly Maintenance Procedures 13 Attempt to drive and steer the machine. Down Limit Switch Result: The ground controls LCD displays Disable the down limit switch. Loosen the "PHS: POTHOLE GUARDS STUCK" and the fastener securing the roller arm to the limit platform controls LED displays "PHS".
- Page 59 June 2022 Maintenance Manual Quarterly Maintenance Procedures 15 Raise the platform 7 to 8 feet / 2,1 to 2,4 m. Level Sensor 16 Lift the safety arm, move it to the center of the 23 Move the machine onto a grade which scissor arm and rotate down to a vertical exceeds the rating of the level sensor.
- Page 60 Maintenance Manual June 2022 Quarterly Maintenance Procedures 25 Standing on the up-hill side of the machine, 28 Attempt to raise the platform to approximately 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 "LL: MACHINE TILTED"...
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Page 61: Test The Platform Gate Proximity Switches And The Extension Deck Limit Switch - Gs-2646 Av, Gs-2646 Av35
June 2022 Maintenance Manual Quarterly Maintenance Procedures Q-21 Tes t the Platfo rm Gate P roximi ty Switches an d the Extensi on De ck Limi t Switch - GS-2 646 AV, GS-26 46 AV35 Q-21 29 Attempt to drive and steer the machine. Test the Platform Gate Proximity Result: The ground controls LCD displays "PHS: POTHOLE GUARDS STUCK"... - Page 62 Maintenance Manual June 2022 Quarterly Maintenance Procedures Attempt to raise the platform for Attempt to drive and steer the machine. approximately 2 seconds and release. Result: The drive and steer functions do not Attempt to lower the platform for operate.The ground controls LCD displays approximately 2 seconds and release.
- Page 63 June 2022 Maintenance Manual Quarterly Maintenance Procedures Extension Deck Limit Switch 11 Deploy the manual extension deck or the powered extension deck (if equipped), approximately 2 ft / 0.6 m. 12 Attempt to raise the platform for approximately 2 seconds and release. Attempt to lower the platform for approximately 2 seconds and release.
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Page 64: Annual Maintenance Procedures
Maintenance Manual June 2022 Annual Maintenance Procedures Ann ual Mai nte na nc e Pr oce dur e s A-1 Check the Drive H ub Oil Lev el an d F asten er To rque - GS -69, GS-8 4, GS- 90 Install the plug(s) into the drive hub. -
Page 65: Test The Function Pump - Gs-69 Be And Gs-69 Dc
June 2022 Maintenance Manual Annual Maintenance Procedures A-2 T est th e F uncti on Pu mp - GS-6 9 BE and GS-6 9 DC A-3 T est th e Oscilla te Axle - GS- 90 Test the Function Pump Test the Oscillate Axle - GS-90 GS-69 BE and GS-69 DC Genie specifications require that this procedure be... - Page 66 Maintenance Manual June 2022 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 67 June 2022 Maintenance Manual Annual Maintenance Procedures Oscillate Float Test 15 Using the jumper wire, jump from relay K12, terminal 87A to terminal D4 below the blue Note: The following procedure will require two wire. people. Result: The left steer end oscillate cylinder will 13 Using a volt meter, check for voltage by extend causing the machine to tilt away from connecting the positive lead to terminals D2,...
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Page 68: Test The Down Limit Switch Descent Delay
Maintenance Manual June 2022 Annual Maintenance Procedures A-4 T est th e Down Limit Switch Des cent D elay - GS- 69, GS -84 and GS-9 0 (if equip ped ) 18 Push in the red Emergency Stop button on the platform controller and on the ground Test the Down Limit Switch controls. - Page 69 June 2022 Maintenance Manual Annual Maintenance Procedures Check the Descent Delay Check the Down Limit Switch Function Height GS-69: Raise the platform approximately GS-69: Raise the platform approximately 10 feet / 3 m. 10 feet / 3 m. GS-84 and GS-90: Raise the platform GS-84 and GS-90: Raise the platform approximately 15 ft / 4.6 m.
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Page 70: Test The Platform Overload Pressure Transducer And Platform Height Sensor - Gs-30, Gs-32, Gs-46, Gs-47 (If Equipped)
Maintenance Manual June 2022 Annual Maintenance Procedures A-5 T est th e Platf orm Ove rload Press ure Tr ansd ucer an d Platfo rm H eight Senso r - GS-3 0, GS- 32, GS -46, GS-4 7 (if equi ppe d) Lower the platform onto the safety arm. - Page 71 June 2022 Maintenance Manual 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.
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Page 72: Check The Steer Yoke King Pin Fastener Torque
Maintenance Manual June 2022 Annual Maintenance Procedures A-6 Check the Stee r Yoke Kin g Pin Faste ner To rqu e 17 Using the multimeter, measure the voltage reading of the pressure transducer at pin C Check the Steer Yoke King Pin and B. -
Page 73: Programmed Maintenance Procedures
June 2022 Maintenance Manual Programmed Maintenance Procedures Pr ogr am m ed M ain te nan ce Pr o ced ur es P0-1 P0-1 In spect the E ngine Air Filt er - GS- 69 R T Inspect the air filter element. If needed, blow from the inside out using low pressure dry Inspect the Engine Air Filter - GS- compressed air, or carefully tap out dust. -
Page 74: P0-2 Grease The Steer Yokes - Gs-30, Gs-32, Gs-46, Gs-47
Maintenance Manual June 2022 Programmed Maintenance Procedures P0-2 G reas e th e Stee r Yokes - GS -30, GS-3 2, GS- 46, GS -47 P0-2 Grease the Steer Yokes - GS-30, GS-32, GS-46, GS-47 Genie specifications require that this procedure be performed every 100 hours of operation. -
Page 75: P0-3 Deutz Engine Maintenance - Under 1000 Hours
June 2022 Maintenance Manual Programmed Maintenance Procedures P0-3 De utz Engi ne Maint ena nce – Und er 1 000 Hou rs P0-3 Deutz Engine Maintenance – Under 1000 Hours Additional engine maintenance is required. Refer to the Programmed Maintenance Inspection Report for the specific intervals that apply. -
Page 76: P0-4 Ford Engine Maintenance - Under 1000 Hours
Maintenance Manual June 2022 Programmed Maintenance Procedures P0-4 For d Engin e M ainte nanc e – U nde r 10 00 H ours P0-4 Ford Engine Maintenance – Under 1000 Hours Additional engine maintenance is required. Refer to the Programmed Maintenance Inspection Report for the specific intervals that apply. -
Page 77: P0-5 Kohler Engine Maintenance - Under 1000 Hours
June 2022 Maintenance Manual Programmed Maintenance Procedures P0-5 Kohl er En gine Maint ena nce – Und er 100 0 Hou rs P0-5 Kohler Engine Maintenance – Under 1000 Hours Additional engine maintenance is required. Refer to the Programmed Maintenance Inspection Report for the specific intervals that apply. -
Page 78: P0-6 Kubota Engine Maintenance - Under 1000 Hours
Maintenance Manual June 2022 Programmed Maintenance Procedures P0-6 Kub ota En gine Main ten ance – Un der 100 0 Hou rs P0-6 Kubota Engine Maintenance – Under 1000 Hours Additional engine maintenance is required. Refer to the Programmed Maintenance Inspection Report for the specific intervals that apply. -
Page 79: P0-7 Perkins Engine Maintenance - Under 1000 Hours
June 2022 Maintenance Manual Programmed Maintenance Procedures P0-7 Per kins Engi ne Maint ena nce – Und er 1 000 Hou rs P0-7 Perkins Engine Maintenance – Under 1000 Hours Additional engine maintenance is required. Refer to the Programmed Maintenance Inspection Report for the specific intervals that apply. -
Page 80: P0-8 Gm Engine Maintenance - Under 1000 Hours
Maintenance Manual June 2022 Programmed Maintenance Procedures P0-8 G M Engin e M ainte nanc e – U nde r 1 000 H ours P0-8 GM Engine Maintenance – Under 1000 Hours Additional engine maintenance is required. Refer to the Programmed Maintenance Inspection Report for the specific intervals that apply. -
Page 81: P1-1 Perform Engine Maintenance - 1000 Hours
June 2022 Maintenance Manual Programmed Maintenance Procedures P1-1 Per for m Engi ne Maint ena nce – 100 0 Ho urs P1-1 Perkins Models Perform Engine Maintenance – • Alternator and fan belts - replace 1000 Hours • Engine valve lash – inspect/adjust •... -
Page 82: P1-2 Replace The Drive Hub Oil - Gs-69, Gs-84, Gs-90
Maintenance Manual June 2022 Programmed Maintenance Procedures P1-2 Re place the D rive H ub Oil - GS- 69, GS -84, GS-9 0 P1-2 P2-1 Per for m Engi ne Maint ena nce – 200 0 Ho urs P2-1 Replace the Drive Hub Oil - GS- Perform Engine Maintenance –... -
Page 83: P2-2 Replace The Hydraulic Filters
June 2022 Maintenance Manual Programmed Maintenance Procedures P2-2 Re place the Hy dra ulic Filt ers P2-2 Kubota Models Replace the Hydraulic Filters D1105, WG972 • Radiator coolant (L.L.C.) - replace • Battery - replace Genie specifications require that this procedure be •... -
Page 84: P2-3 Check The Free-Wheel Configuration - Gs-84 And Gs-90
Maintenance Manual June 2022 Programmed Maintenance Procedures P2-3 Ch eck th e F ree -whe el Con figu ratio n - GS-84 and GS-9 0 P2-3 GS-69, GS-84, GS-90 Check the Free-wheel Replace the Medium and High Pressure Configuration - GS-84 and GS-90 Hydraulic Filter(s) Locate the medium and high pressure filter(s). - Page 85 June 2022 Maintenance Manual 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.
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Page 86: P2-4 Check The Scissor Arm Wear Pads (And Slider Blocks, If Equipped)
Maintenance Manual June 2022 Programmed Maintenance Procedures P2-4 Ch eck th e Scisso r Arm W ear Pads (an d Slider Blocks, if equi ppe d) P2-4 Measure the distance between the number one inner arm cross tube and the chassis Check the Scissor Arm Wear deck at the battery pack side of the non-steer Pads... - Page 87 June 2022 Maintenance Manual Programmed Maintenance Procedures GS-2032, GS-2632, GS-3232, GS-2046, GS-2646, GS-3246, 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 88 Maintenance Manual June 2022 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.
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Page 89: P2-5 Grease The Steer Axle Wheel Bearings - Gs-69 Be And Gs-69 Dc
June 2022 Maintenance Manual Programmed Maintenance Procedures P2-5 G reas e th e Stee r Axle Wh eel Bea rings - GS -69 BE a nd GS -69 DC P2-5 Check for wheel bearing wear by attempting to move the wheel hub side to side, then up Grease the Steer Axle Wheel and down. -
Page 90: P2-6 Test Or Replace The Hydraulic Oil
Maintenance Manual June 2022 Programmed Maintenance Procedures P2-6 Test or Re place the H ydr aulic Oil P2-6 13 Place the hub on a flat surface and gently pry the bearing seal out of the hub. Remove the Test or Replace the Hydraulic Oil rear bearing. -
Page 91: P3-1 Perform Engine Maintenance - 3000 Hours
June 2022 Maintenance Manual Programmed Maintenance Procedures P3-1 Per for m Engi ne Maint ena nce – 300 0 Ho urs 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...