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Terex Genie GS-4046 Service And Repair Manual
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Service and
Rep
air Manual
S
e
ria
l N
u
mb
er R
an
g
e
GS
™
-
1330m
Re
f
er t
o in
s
ide
cov
er
This m
anual includ
es:
Repair proce
dur
es
Fault
Codes
Electr
ical and
Hydr
aulic S
chematics
GS
™
-
1432m/
1932m
GS
™
-
1932m L
ite
/1932
m XH
GS
™
-
1530/
1532
GS
™
-
1930/
1932/
1932
XH
For detailed m
aintenance
procedur
es, ref
er to the
appropriate Maintenance
Manual for your machine.
GS
™
-
2
032
/2
632
/3
232
GS
™
-
2046/
2646/
3246
/4046
GS
™
-
2646 X
H/32
46 XH
GS
™
-
4655
Par
t No. 1309020GT
Rev B
Augu
st 2021
2
Table of Contents
Table of Contents
8
Find a Manual for this Model
2
Serial Number Range
2
Revision History
3
Serial Number Legend
5
Safety Rules
6
Table of Contents
8
Specifications
15
Machine Specifications
15
Performance Specifications
18
Hydraulic Oil Specifications
19
Hydraulic Component Specifications
23
Manifold Component Specifications
26
Hydraulic Hose and Fitting Torque Specifications
27
Torque Procedure
28
Repair Procedures
30
Introduction
30
Observe and Obey
30
Read, Understand and Obey the Safety Rules and Operating Instructions in the Appropriate Operator's Manual on Your Machine
30
Platform Controls
32
Circuit Board
34
Joystick
35
Platfrom Controls Alarm
35
Platform Emergency Stop Button
36
Ground Controls
37
Software Revision Level
38
Machine Setup
39
Loading or Updating Machine Software
40
Using a Wi-Fi Router to Connect to the Smartlink Web Service Tool
45
Service Override Mode
47
Level Sensors
49
Manual Platform Lowering Cable
54
Outrigger Calibration - GS-3232
56
Hydraulic Tank
57
Hydraulic Pump
59
Manifolds
61
Function Manifold Components - GS-1330M
61
Function Manifold Components - GS-1432M, GS-1932M, GS-1932M Lite, GS-1932M XH
62
Function Manifold Components - GS-3232
63
Function Manifold Components - GS-4655
64
Function Manifold Components - Models with Electric Drive, All Other Models
65
Function Manifold Components - Models with Hydraulic Drive, GS-1530, GS-1532, GS-1930, GS-1932, GS-1932 XH
66
Check Valve Manifold Components - Models with Hydraulic Drive, GS-1530, GS-1532, GS-1930, GS-1932, GS-1932 XH
68
Function Manifold Components - Models with Hydraulic Drive, GS-2032, GS-2632
69
Outrigger Manifold Components - GS-3232
71
Outrigger Cylinder Manifold Components - GS-3232
72
Valve Adjustments - Function Manifold
73
How to Adjust the System Relief Valve - Models with Electric Drive
73
How to Adjust the System Relief Valve - Models with Hydraulic Drive
74
How to Adjust the Platform Lift Relief Valve - Models with Hydraulic Drive
75
How to Adjust the Steer Relief Valve - Models with Hydraulic Drive (Includes GS-1330M Electric Drive)
77
Valve Coils
78
Steer Axle Components
81
Yoke Assembly
81
Drive Motors
82
Steer Cylinder
83
Steer Bellcrank
83
Manual Brake Release - Models with Electric Drive
84
Thrust Washers - GS-1432M, GS-1932M, GS-1932M Lite, GS-1932M XH
85
Non-Steer Axle Components
86
Drive Brake - Models with Hydraulic Drive
86
Brake Release Hand Pump Components
87
Brake Release Hand Pump Components - Models with Hydraulic Drive
87
Scissor Components
88
Scissor Assembly - GS-1330M
89
Scissor Assembly - GS-1432M
97
Scissor Assembly - GS-1530, GS-1532
100
Scissor Assembly - GS-1930, GS-1932, GS-1932 XH
106
Scissor Assembly - GS-1932M, GS-1932M Lite, GS-1932M XH
114
Scissor Assembly - GS-2032, GS-2046
117
Scissor Assembly - GS-2632, GS-2646, GS-2646 XH
124
Scissor Assembly - GS-3232, GS-3246, GS-3246 XH
131
Scissor Assembly - GS-4046
140
Scissor Assembly - GS-4655
149
Scissor Arm Wear Pads
153
How to Replace the Scissor Arm Wear Pad - GS-1432M, GS-1932M, GS-1932M Lite, GS-1932M XH
153
How to Replace the Scissor Arm Wear Pad - All Other Models
154
Platform Height Sensor
156
How to Disassemble the Platform Height Sensor Assembly - GS-1432M, GS-1932M, GS-1932M Lite, GS-1932M XH
156
How to Disassemble the Platform Height Sensor Assembly - All Other Models
157
Lift Cylinder
159
Pressure Transducer
171
Platform Overload System
172
Platform Overload Recovery
177
Outdoor Height Limiting
179
Platform Components
181
Platform
181
How to Remove the Platform - GS-1432M, GS-1932M, GS-1932M Lite, GS-1932M XH
181
How to Remove the Platform - All Other Models
182
Platform Extension Deck
183
Battery Charger
184
Selecting a Charge Profile
185
How to Replace a Drive Motor Power Cable
186
GS-1432M, GS-1932M, GS-1932M Lite, GS-1932M XH
186
Drive Morot Power Cables
186
Power Cables
186
Repair any Machine Damage or Malfunction before Operating the Machine
189
Electrocution/Burn Hazard
189
Be Sure that All Necessary Tools and Test Equipment Are Available and Ready for Use
189
Before Troubleshooting
189
About this Section
189
Damaged or Malfunctioning Machine
189
Immediately Tag and Remove from Service a
189
Troubleshooting and Repair Procedures Shall be Completed by a Person Trained and Qualified on the Repair of this Machine
189
Introduction
189
Diagnostics
189
GCON I/O Map - Models Without Outriggers
192
GCON I/O Map - Models with Outriggers
193
Operation Indicator Codes (OIC)
195
Diagnostic Trouble Codes (DTC)
196
Troubleshooting "HXXX" and "PXXX" Faults
197
Fault Inspection Procedure
198
Type "HXXX" Faults
200
Type "PXXX" Faults
204
Type "UXXX" Faults
207
Type "FXXX" Faults
210
Type "CXXX" Faults
213
Battery Charger
215
Charger Fault Codes
216
Charger Error Codes
217
Schematics
221
Introduction
221
Electrical Component and Wire Color Legends
222
Wiring Diagram Ground and Platform Controls
224
Limit Switch Legend
225
Electrical Symbol Legend
227
Hydraulic Symbols Legend
228
Hydraulic Schematics
229
Hydraulic Schematic, GS-1330M (from GS30MD-101)
230
Hydraulic Schematic, GS-1432M, GS-1932M, GS-1932M Lite
231
GS-1932M XH (from GS32MD-101)
232
Hydraulic Schematic, Models with Electric Drive GS-1530, GS-1532, GS-1930, GS-1932, GS-1932 XH (from GS30D-40101, GS30P-200101)
234
(From GS30D-40101, GS30P-200101)
235
Hydraulic Schematic, Models with Electric Drive GS-2032, GS-2632
237
(From GS32D-10101, GS32P-200101, GS46D-20101, GS46P-200101)
238
Hydraulic Schematic, Models with Hydraulic Drive GS-2032, GS-2632 (from GS32D-10101, GS32P-200101)
239
Hydraulic Schematic, Outriggers GS3232 (from GS32D-10101, GS32P-200101)
242
Hydraulic Schematic, GS-4046 (from GS46D-20101, GS46P-200101)
243
Hydraulic Schematic, GS-4655 (from GS55D-101)
246
Electrical Schematics
247
Electrical Schematic, GS-1330M (from GS30MD-40101)
248
Electrical Schematic, GS-1432M, GS-1932M
249
GS-1932M Lite, GS-1932M XH (from GS32MD-101)
249
Electrical Schematic, GS-3232 (from GS32D-10101, GS32P-200101)
252
Electrical Schematic, GS-4655 (from GS55D-10101)
253
Electrical Schematic, All Other Models Models with Electric Drive
256
Gs32P-200101, Gs32Md-101, Gs46D-20101, Gs46P-200101)
256
(From GS30D-40101, GS30P-200101, GS32D-10101, GS32P-200101)
257
Electrical Schematic, All Other Models Models with Hydraulic Drive
257
Electrical Schematics - Options
259
Electrical Schematic, Options
260
Other manuals for Terex Genie GS-4046
Operator's Manual
107 pages
Maintenance Manual
99 pages
4
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Terex Genie GS-4046 Specifications
General
Brand
Terex
Model
Genie GS-4046
Category
Scissor Lifts
Language
English
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