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Terex Genie GS-1330m User Manual

Terex Genie GS-1330m
261 pages
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Service and Repair Manual
Serial Number Range
GS
-1330m
Refer to inside cover
GS
-1432m/1932m
GS
-1932m Lite/1932m XH
GS
-1530/1532
GS
-1930/1932/1932 XH
GS
-3032/2632/3232
GS
-2046/2646/3246/4046
GS
-2646 XH/3246 XH
GS
-4655

Table of Contents

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Terex Genie GS-1330m Specifications

General IconGeneral
BrandTerex
ModelGenie GS-1330m
CategoryLifting Systems
LanguageEnglish

Summary

Introduction

Find a Manual for this Model

Provides instructions on how to locate specific machine manuals online.

Serial Number Range

Explains how to identify the serial number range for models covered in the manual.

Revision History

Initial Release

Details the initial release of the manual, including version and date.

Revision B

Notes the addition of specific models in revision B of the manual.

Serial Number Legend

Model Identification

Explains the meaning of each part of the serial number for model identification.

Safety Rules

Personal Safety

Outlines essential safety precautions for individuals working on or around the machine.

Workplace Safety

Details safety practices for the work environment, including fire prevention and tool maintenance.

Specifications

Machine Specifications

Lists detailed specifications for various machine models, including battery types and capacities.

Fluid capacities

Provides fluid capacities for hydraulic systems and tanks across different models.

Tires and wheels

Details tire sizes, contact areas, and castle nut torque specifications.

Performance Specifications

Lists performance data such as drive speed, function speed, and braking distance.

Hydraulic Oil Specifications

Specifies required hydraulic oil properties and lists recommended and optional fluids.

Hydraulic Component Specifications

Details specifications for hydraulic pumps, manifolds, and related components for various models.

Manifold Component Specifications

Provides plug torque and valve coil resistance specifications for manifold components.

Hydraulic Hose and Fitting Torque Specifications

Lists torque specifications for Seal-Lok™ and JIC 37° fittings and SAE O-ring Boss Ports.

Torque Procedure

Outlines the procedure for correctly applying torque to hydraulic hose and fittings.

Repair Procedures

Observe and Obey

Emphasizes the importance of trained personnel and proper safety protocols before starting repairs.

Before Repairs Start

Lists critical steps to follow before commencing repair procedures, including safety and tool readiness.

Machine Configuration

Specifies the required machine configuration for performing repair procedures safely and correctly.

About This Section

Describes the scope of the repair procedures section and the need for professional execution.

Symbols Legend

Explains the meaning of various symbols used to denote hazards and expected results in procedures.

Platform Controls

Details the components and operation of the platform control system.

1-1 Circuit Board

Details how to remove the platform controls circuit board, including safety precautions.

1-2 Joystick

Provides instructions on how to remove the joystick assembly from the platform controls.

1-3 Platform Controls Alarm

Explains the procedure for removing the platform controls alarm component.

1-4 Platform Emergency Stop Button

Outlines the steps for removing the platform emergency stop button assembly.

Ground Controls

Describes the functionality and components of the ground control system.

2-1 Software Revision Level

Describes how to determine the machine software revision level using the ground controls display.

2-2 Machine Setup

Details how to set up machine parameters like model, options, and speed from the ground controls.

2-3 Loading or Updating Machine Software

Explains procedures for updating machine software via Bootloader or Machine Application Mode.

2-4 Using a Wi-Fi Router to Connect to the SmartLink Web Service Tool

Guides users on connecting to the SmartLink Web Service Tool using a Wi-Fi router for software updates.

2-5 Service Override Mode

Explains the procedure for entering and using Service Override mode for specific maintenance tasks.

2-6 Level Sensors

Details how to install and calibrate the level sensor, crucial for machine stability.

2-7 Manual Platform Lowering Cable

Describes how to adjust the manual platform lowering cable for proper operation.

2-8 Outrigger Calibration - GS-3232

Provides a step-by-step guide for calibrating the outrigger system on the GS-3232 model.

3-1 Hydraulic Tank

Details the procedure for removing the hydraulic tank, including safety precautions.

4-1 Function Pump

Explains how to remove the hydraulic pump, including model-specific instructions.

Manifolds

Covers manifold components, installation procedures, and valve adjustments for various models.

5-1 Function Manifold Components – GS-1330m

Lists components and torque values for the function manifold on the GS-1330m.

5-2 Function Manifold Components – GS-1432m, GS-1932m, GS-1932m Lite, GS-1932m XH

Details function manifold components and torque for specific GS models.

5-3 Function Manifold Components – GS-3232

Lists components and torque specifications for the GS-3232 function manifold.

5-4 Function Manifold Components – GS-4655

Details function manifold components and torque for the GS-4655 model.

5-5 Function Manifold Components – Models with electric drive, All other models

Lists function manifold components for electric drive models and other specified types.

5-8 Function Manifold Components – Models with hydraulic drive, GS-2032, GS-2632

Details function manifold components for hydraulic drive models GS-2032 and GS-2632.

5-9 Outrigger Manifold Components – GS-3232

Lists components for the GS-3232 outrigger manifold.

5-10 Outrigger Cylinder Manifold Components – GS-3232

Details outrigger cylinder manifold components for the GS-3232 model.

5-11 Valve Adjustments - Function Manifold

Provides instructions for adjusting system relief valves on electric and hydraulic drive models.

5-12 Valve Coils

Explains how to test valve coils and their diodes, including resistance specifications.

Steer Axle Components

Covers components related to the steer axle, including removal procedures.

6-1 Yoke Assembly

Details the procedure for removing the yoke assembly, including safety precautions.

6-2 Drive Motors

Provides instructions on how to remove drive motors for both electric and hydraulic drive models.

6-3 Steer Cylinder

Explains the process for removing the steer cylinder, emphasizing hydraulic safety.

6-4 Steer Bellcrank

Details the procedure for removing the steer bellcrank, referencing the steer cylinder removal.

6-5 Manual Brake Release - Models with electric drive

Outlines the procedure for manually releasing electric brakes, emphasizing safety for trained personnel.

6-6 Thrust Washers - GS-1432m, GS-1932m, GS-1932m Lite, GS-1932m XH

Describes how to remove thrust washers from the king pin for specific GS models.

Non-Steer Axle Components

Covers components related to the non-steer axle, including drive brake removal.

7-1 Drive Brake - Models with hydraulic drive

Details the procedure for removing the drive brake for hydraulic drive models, including safety warnings.

8-1 Brake Release Hand Pump Components - Models with hydraulic drive

Lists components of the brake release hand pump system for hydraulic drive models.

Scissor Components

Covers the various scissor assemblies and their disassembly procedures for different GS models.

9-1 Scissor Assembly - GS-1330m

Details the disassembly procedure for the GS-1330m scissor assembly, including safety warnings.

9-2 Scissor Assembly - GS-1432m

Provides instructions for disassembling the scissor assembly for the GS-1432m model.

9-3 Scissor Assembly - GS-1530, GS-1532

Outlines the disassembly procedure for the scissor assembly of GS-1530 and GS-1532 models.

9-4 Scissor Assembly - GS-1930, GS-1932, GS-1932 XH

Details the disassembly process for the scissor assembly of GS-1930, GS-1932, and GS-1932 XH models.

9-5 Scissor Assembly - GS-1932m, GS-1932m Lite, GS-1932m XH

Explains the disassembly procedure for the scissor assembly of GS-1932m, Lite, and XH models.

9-6 Scissor Assembly - GS-2032, GS-2046

Provides disassembly instructions for the scissor assembly of GS-2032 and GS-2046 models.

9-7 Scissor Assembly - GS-2632, GS-2646, GS-2646 XH

Details the disassembly procedure for scissor assemblies of GS-2632, GS-2646, and GS-2646 XH models.

9-8 Scissor Assembly - GS-3232, GS-3246, GS-3246 XH

Outlines the disassembly process for scissor assemblies of GS-3232, GS-3246, and GS-3246 XH models.

9-9 Scissor Assembly - GS-4046

Provides disassembly instructions for the scissor assembly of the GS-4046 model.

9-10 Scissor Assembly - GS-4655

Details the disassembly procedure for the scissor assembly of the GS-4655 model.

9-11 Scissor Arm Wear Pads

Explains how to replace scissor arm wear pads for specific GS models and all other models.

9-12 Platform Height Sensor

Details the procedure for disassembling the platform height sensor assembly for various GS models.

9-13 Lift Cylinders

Provides instructions on how to remove the lift cylinder for multiple GS models, including safety precautions.

Platform Overload System

Explains how to calibrate the platform overload system, including full and no-load procedures.

Platform Overload Recovery Message

Guides on how to clear the platform overload recovery message from the ground controls LCD.

Outdoor Height Limiting

Details the procedure for calibrating the outdoor height limiting system for specific models.

Platform

Outlines the procedure for removing the platform assembly from the machine for specific GS models.

Platform Extension Deck

Describes how to remove and replace wear pads on the platform extension deck.

Diagnostics

Observe and Obey

Emphasizes safety and proper procedures for all diagnostic and repair tasks.

Before Troubleshooting

Lists essential preparations and precautions before starting any troubleshooting.

About This Section

Introduces the diagnostics section, highlighting required tools and the purpose of fault code charts.

Definitions

Defines key terms and acronyms used within the diagnostics section, such as GSDS, ECM, and DTC.

GCON LCD Diagnostic Readout

Explains the alpha-numeric codes displayed on the GCON LCD for status and malfunction information.

Genie® SmartLink™ Diagnostic System

Describes the GSDS, its function in indicating malfunctions via OIC and DTC, and where codes are displayed.

GCON ECM Connector Layout

Illustrates the connector layout on the Ground Controls ECM for models with and without outriggers.

GCON I/O Map - Models without outriggers

Details the pin assignments, circuit functions, I/O types, and wire colors for the GCON ECM.

GCON I/O Map - Models with outriggers, (continued)

Continues the GCON I/O map details, specifically for models equipped with outriggers.

Operational Indicator Codes (OIC)

Explains the meaning of various OICs displayed on the platform controls, indicating machine status.

Diagnostic Trouble Codes (DTC)

Defines DTCs and categorizes them by type (HXXX, PXXX, UXXX, FXXX, CXXX) based on potential causes.

Troubleshooting "HXXX" and "PXXX" Faults

Provides a diagnostic chart and wiring diagram for troubleshooting HXXX and PXXX fault types.

Fault Inspection Procedure

Outlines a systematic procedure for inspecting devices and harnesses to diagnose circuit faults.

Type "HXXX" Faults

Lists specific HXXX fault codes, their messages, descriptions, possible causes, and failure modes.

Type "PXXX" Faults

Details PXXX fault codes, including messages, descriptions, possible causes, and failure modes.

Type "UXXX" Faults

Covers UXXX fault codes related to switch issues, their causes, and resulting failure modes.

Type "FXXX" Faults

Lists FXXX fault codes associated with machine feedback devices like sensors and transducers.

Type "CXXX" Faults

Explains CXXX fault codes related to control system issues, such as ECM communication errors.

Battery Charger

Charger Fault Codes

Lists specific charger fault codes (F-0-0-x) with their descriptions, possible causes, and solutions.

Charger Error Codes

Details charger error codes (E-0-x-x) indicating issues like voltage problems, timeouts, or software failures.

Schematics

Electrical Schematics

Introduces electrical diagrams for understanding machine circuitry and component connections.

Hydraulic Schematics

Introduces hydraulic diagrams illustrating fluid power systems for various machine models.

Electrical Component and Wire Color Legends

Provides a legend for electrical components and wire color coding used throughout the schematics.

Wiring Diagram Ground and Platform Controls

Shows the wiring diagram for both ground and platform control systems, illustrating connections.

Limit Switch Legend

Illustrates the location and identification of limit switches used on different machine models.

Electrical Symbol Legend

Explains the standard electrical symbols used in the schematics for clarity.

Hydraulic Symbols Legend

Provides a legend for hydraulic symbols used in the hydraulic schematics.

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