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Terex Genie GS-1532 User Manual

Terex Genie GS-1532
341 pages
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Service and Repair Manual
Serial Number Rang
e
GS
-1530/1532
Refer to t
he
inside cover
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics
GS
-1930/1932
GS
-2032/2632/3232
GS
-2046/2646/3246
GS
-4047
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
Part No. 1272217GT
Rev E
March 2021

Table of Contents

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Terex Genie GS-1532 Specifications

General IconGeneral
Power SourceElectric
Gradeability25%
Battery Voltage24 V
Tire TypeSolid non-marking
Overall Width32 in

Summary

Introduction

Compliance

Machine classification and design life details.

Contact Us

Contact information for Genie.

Find a Manual for this Model

Instructions on how to find other manuals.

Serial Number Range

Identifies serial number ranges for included models.

Revision History

Lists revisions made to the manual.

Serial Number Legend

Safety Rules

Danger

Indicates imminent hazards, death or serious injury.

Do Not Perform Maintenance Unless:

Lists conditions for performing maintenance.

Personal Safety

General safety advice for individuals.

Workplace Safety

Safety advice for the work environment.

Specifications

Machine Specifications

General machine specifications.

Tires and wheels

Specifications for tires and wheels, including torque.

Performance Specifications (models without proportional lift)

Performance data for models without proportional lift.

Performance Specifications (models with proportional lift)

Performance data for models with proportional lift.

Hydraulic Oil Specifications

Requirements and types of hydraulic oil.

Hydraulic Component Specifications

Specifications for hydraulic pumps and manifolds.

Manifold Component Specifications

Torque and coil resistance specifications for manifold components.

Hydraulic Hose and Fitting Torque Specifications

Torque specifications for Seal-Lok™ and JIC 37° fittings.

Torque Procedure

Detailed procedures for applying torque to fittings.

Repair Procedures

Observe and Obey:

General safety and operational rules.

Before Repairs Start:

Pre-repair checks and preparations.

Machine Configuration:

Required machine configuration for repairs.

Platform Controls

Operation and components of platform controls.

Operational Indicator Codes

Explains codes displayed on the platform control LED readout.

1-1 Circuit Board

Procedure for removing the platform controls circuit board.

1-2 Joystick

Procedure for removing the joystick.

1-3 Platform Controls Alarm

Procedure for removing the platform controls alarm.

1-4 Platform Emergency Stop Button

Procedure for removing the platform emergency stop button.

Ground Controls

2-1 Software Revision Level

Procedure to determine the machine software revision level.

2-2 Machine Setup

Procedure to set up the machine from ground controls.

2-3 Loading or Updating Machine Software

Procedures for loading or updating machine software.

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

Instructions for connecting to the SmartLink tool using a Wi-Fi router.

2-5 Service Override Mode

Procedure for operating the machine in service override mode.

2-6 Level Sensors

Information about level sensors and their function.

How to Install and Calibrate the Level Sensor - Procedure 1

Step-by-step guide for installing and calibrating level sensor.

How to Install and Calibrate the Level Sensor - Procedure 2

Step-by-step guide for installing and calibrating level sensor.

How to Install and Calibrate the Level Sensor - Procedure 3

Step-by-step guide for installing and calibrating level sensor.

Outrigger Level Sensor - GS-3232 Models

Specific instructions for GS-3232 outrigger level sensor.

How to Calibrate the Outrigger System

Procedure for calibrating the outrigger system.

2-7 Manual Platform Lowering Cable

Procedure for adjusting the manual platform lowering cable.

How to Adjust the Manual Platform Lowering Cable

Detailed steps for adjusting the manual platform lowering cable.

2-8 Outrigger Calibration

Procedure for calibrating the outrigger system.

Hydraulic Tank

How to Remove the Hydraulic Tank

Step-by-step guide to remove the hydraulic tank.

Hydraulic Pump

4-1 Function Pump

Information about the function pump.

How to Test the Hydraulic Pump

Procedure for testing the hydraulic pump.

How to Remove the Hydraulic Pump

Step-by-step guide to remove the hydraulic pump.

Manifolds

How to Install a Valve Cartridge

Procedure for installing a valve cartridge.

5-3 Function Manifold Components – GS-4047

Specifications for the GS-4047 function manifold.

5-5 Lift Pressure Selector Manifold Components – GS-4047

Components of the lift pressure selector manifold.

5-6 Outrigger Function Manifold Components – GS-3232

Components of the outrigger function manifold.

5-7 Outrigger Cylinder Manifold Components – GS-3232

Components of the outrigger cylinder manifold.

5-8 Valve Adjustments - Function Manifold

Procedures for adjusting system relief valves.

How to Adjust the System Relief Valve

Steps to adjust the system relief valve.

How to Adjust the Platform Lift Relief Valve

Procedure to adjust the platform lift relief valve.

How to Adjust the Steer Relief Valve

Procedure to adjust the steer relief valve.

5-9 Valve Coils

Procedures for testing valve coils.

How to Test a Coil

Method for testing coil resistance and functionality.

How to Test a Coil Diode

Procedure for testing coil diodes.

Steer Axle Components

6-1 Yoke and Drive Motor

Procedure for removing the yoke and drive motor.

How to Remove a Drive Motor

Steps to remove the drive motor.

6-2 Steer Cylinder

Procedures for removing the steer cylinder.

How to Remove the Steer Cylinder

Steps to remove the steer cylinder.

6-3 Steer Bellcrank

Procedure for removing the steer bellcrank.

How to Remove the Steer Bellcrank

Steps to remove the steer bellcrank.

Non-Steer Axle Components

7-1 Drive Brake

Procedure for removing the drive brake.

How to Remove the Drive Brake

Steps to remove the drive brake.

Brake Release Hand Pump Components

8-1 Brake Release Hand Pump Components

List of components for the hand pump.

Scissor Components

9-1 Scissor Assembly, GS-1530 and GS-1532

Procedure for disassembling the scissor assembly.

9-2 Scissor Assembly, GS-1930 and GS-1932

Procedure for disassembling the scissor assembly.

9-3 Scissor Assembly, GS-2032 and GS-2046

Procedure for disassembling the scissor assembly.

9-4 Scissor Assembly, GS-2632 and GS-2646

Procedure for disassembling the scissor assembly.

9-5 Scissor Assembly, GS-3232 and GS-3246

Procedure for disassembling the scissor assembly.

9-6 Scissor Assembly, GS-4047

Procedure for disassembling the scissor assembly.

9-7 Scissor Arm Wear Pads

Procedure for replacing scissor arm wear pads.

9-8 Platform Height Sensor (if equipped)

Procedure for disassembling the platform height sensor assembly.

9-9 Lift Cylinders

Procedures for removing lift cylinders.

Platform Components

10-1 Platform

Procedure for removing the platform.

10-2 Platform Extension Deck

Procedures for removing and replacing platform extension deck wear pads.

Battery Charger

11-1 Battery Charger

Description of the battery charger and its functions.

Charger status indicators

Indicators on the charger and their meanings.

Remote charger status indicators

Remote status indicators for the charger.

Charger Fault Codes

Lists charger fault codes, descriptions, causes, and solutions.

Charger Error Codes

Lists charger error codes, descriptions, conditions, and causes.

Selecting a Charge Profile

Procedure for selecting the appropriate battery charge profile.

Diagnostics

Observe and Obey:

General safety and operational rules for diagnostics.

Before Troubleshooting:

Pre-troubleshooting checks and prerequisites.

About This Section

Overview of the diagnostics section and required tools.

GCON LCD Diagnostic Readout

Explains diagnostic codes displayed on the GCON LCD.

Genie® SmartLink™ Diagnostic System

Overview of the GSDS and its use in troubleshooting.

GCON I/O Map without Load Sense (all models except GS-3232)

Pinout and function details for GCON I/O without load sense.

GCON I/O Map with Load Sense (GS-3232 only)

Pinout and function details for GCON I/O with load sense.

Operational Indicator Codes (OIC)

Explains operational indicator codes and their meanings.

Diagnostic Trouble Codes (DTC)

Explains types of diagnostic trouble codes and their causes.

Troubleshooting "HXXX" and "PXXX" Faults

Diagnostic chart and wiring diagram for HXXX and PXXX faults.

Fault Inspection Procedure

General procedure for inspecting faults.

Type "HXXX" Faults

Lists HXXX fault codes, descriptions, causes, and failure modes.

Type "PXXX" Faults

Lists PXXX fault codes, descriptions, causes, and failure modes.

Type "UXXX" Faults

Lists UXXX fault codes, descriptions, causes, and failure modes.

Type "FXXX" Faults

Lists FXXX fault codes, descriptions, causes, and failure modes.

Type "CXXX" Faults

Lists CXXX fault codes, descriptions, causes, and failure modes.

Schematics

About This Section

Overview of the schematics section.

Electrical Schematics

Information on electrical schematics.

Hydraulic Schematics

Information on hydraulic schematics.

Electrical Component and Wire Color Legends

Legends for electrical components and wire colors.

Wiring Diagram Ground and Platform Controls

Wiring diagram for ground and platform controls.

Limit Switch Legend

Legend for limit switch symbols and locations.

Electrical Symbol Legend

Legend for common electrical symbols used in schematics.

Hydraulic Symbols Legend

Legend for common hydraulic symbols used in schematics.

Hydraulic Component Abbreviation Legend

Legend for hydraulic component abbreviations.

Electrical Schematics – ANSI / CSA Models

Electrical schematics for ANSI/CSA models.

Hydraulic Schematic, GS-1530 / 1532 / 1930 / 1932

Hydraulic schematic for specific serial number range.

Electrical Schematic, GS-3246, AS / CE (from serial number GS4616P-146463)

Electrical schematic for a specific serial number.

Electrical Schematics – CE and Australia Models

Electrical schematics for CE and Australia models.

Electrical Schematic, GS-3232, AS / CE (from serial number GS3216P-146463)

Electrical schematic for a specific serial number.

Electrical Schematic, GS-3246, AS / CE (from serial number GS4616P-146463)

Electrical schematic for a specific serial number.

Electrical Schematic, GS-4047, AS / CE (from serial number GS4716D-3102)

Electrical schematic for a specific serial number.

Electrical Schematic • Foot Switch (option) All Models

Electrical schematic for the optional foot switch.

Electrical Schematic, GS-4047, AS / CE (from serial number GS4716D-3102)

Electrical schematic for a specific serial number.

Electrical Schematic • Foot Switch (option) All Models

Electrical schematic for the optional foot switch.

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