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Technical
Publications

GS-1530
GS-1930
Service
Manual
(before serial number 17408)

First Edition, Third Printing


Rev C2
Part No. 39528
GS-1530
GS-1930
Genie North America
Important

Genie Europe
Safety Rules

Danger

Do Not Perform Maintenance


Unless:
Personal Safety

Workplace Safety
Service Manual - First Edition

Theory of Operation
Power Source controls to activate the various machine functions.
The ECM has predetermined settings for the
The Genie GS-1530 and GS-1930 machines are various machine functions.
powered by four six-volt (255 AH) batteries. The
four batteries are wired in series to produce 24 The joystick is fitted with a 5000 ohm
volts. potentiometer. With the joystick in the neutral
position, the potentiometer will measure 2730
Hydraulic System ohms. These signals are sent to the multiplex card,
then down to the ECM to control the voltage
All machine functions are performed by the supplied to the proportional valve. Two
hydraulic system. The hydraulic system is powered microswitches mounted on the joystick tell the
by a single-section gear pump. When the pump is ECM the drive direction desired. A thumb rocker
activated, it supplies hydraulic fluid under pressure switch on the top of the joystick is used for
to the function manifold, where the control valves steering.
are located. To protect from over-pressurization of
the hydraulic system, the pump is provided with a Mounted on the platform control box lid of
pressure relief valve. machines before serial number 17408 are buttons
and a switch that, when activated, sends a signal to
Activating a machine function is accomplished by the ECM through the multiplex card. On machines
actuating or moving a switch and/or control handle, after serial number 17407, the platform control box
which sends voltage to the ECM. The ECM then lid has a decal/membrane pad. This is a touch-
sends the signal to the appropriate directional activated pad incorporating wiring, switches and
control valve. The directional valve determines LEDs that are resistant to the environment.
which direction the hydraulic fluid will travel. Activating any of the buttons on the pad will send a
Computer software determines the volume of fluid signal to the ECM through the multiplex card.
in relation to the proportional valve input voltage.
A diagnostic display is located at the battery pack
Electrical System side of the machine to aid in troubleshooting. If the
machine malfunctions, a fault code will be shown in
Limit switches are found in various locations on the the display window.
machine. The function of a limit switch is to
communicate the operating position of the machine Washing electronic components is not suggested.
to the ECM (Electronic Control Module). When a Instead, use compressed air to remove debris from
change in signal is received from a limit switch, the these components.
ECM responds by limiting the drive speed to 0.5
Component damage hazard. Avoid
miles per hour (0.8 km/h), according to the default
shock or impact to the ECM.
settings in the ECM software.
Internal damage may not be visible
from the outside.
Machine Controls
The GS-1530 and GS-1930 machines are
equipped with operational controls which are found
in two locations: the ground controls, located on
the hydraulic tank side of the machine, and the
platform controls, located in the platform. All lift and
drive functions are available at the platform
controls. Only platform up/down functions are
available at the ground controls.
The ECM uses input from the ground or platform

Part No. 39528 Genie GS-1530 & GS-1930 v


Service Manual - First Edition

Table of Contents

Introduction
Important Information ...................................................................................................... ii

Section One Safety Rules


General Safety Rules ..................................................................................................... iii
Theory of Operation ....................................................................................................... v

Section Two Rev Specifications


D Machine Specifications ................................................................................ 2 - 1
D Performance Specifications ......................................................................... 2 - 2
D Hydraulic Specifications ............................................................................... 2 - 2
D Hydraulic Hose and Fitting Torque Specifications ........................................ 2 - 3

Section Three Scheduled Maintenance Inspections


Introduction ............................................................................................................... 3 - 1
Table A ..................................................................................................................... 3 - 2
Table B ..................................................................................................................... 3 - 2
Table C ..................................................................................................................... 3 - 3
Table D ..................................................................................................................... 3 - 3
Maintenance Inspection Report ................................................................................ 3 - 4

Section Four Scheduled Maintenance Procedures


Introduction ............................................................................................................... 4 - 1
A-1 Inspect the Operator’s and Safety Manuals .................................................... 4 - 2
A-2 Inspect the Decals and Placards ..................................................................... 4 - 2
A-3 Inspect for Damage and Loose or Missing Parts ............................................. 4 - 3
A-4 Check the Hydraulic Oil Level ......................................................................... 4 - 3
A-5 Check for Hydraulic Leaks .............................................................................. 4 - 4
A-6 Test the Platform and Ground Controls ........................................................... 4 - 4
A-7 Test the Manual Platform Lowering Operation ................................................ 4 - 5
A-8 Test the Tilt Sensor ......................................................................................... 4 - 6
A-9 Test the Pothole Guards ................................................................................. 4 - 6
A-10 Test the Lift/Drive Select Switch (before serial number 17408) ...................... 4 - 7
A-11 Perform 30 Day Service .................................................................................. 4 - 7

vi Genie GS-1530 & GS-1930 Part No. 39528


Service Manual - First Edition

TABLE OF CONTENTS

Section Four Scheduled Maintenance Procedures, continued


B-1 Check the Batteries ......................................................................................... 4 - 8
B-2 Inspect the Electrical Wiring ............................................................................ 4 - 9
B-3 Inspect the Tires and Wheels (including castle nut torque) ........................... 4 - 10
B-4 Test the Key Switch ...................................................................................... 4 - 10
B-5 Test the Emergency Stop Buttons ................................................................. 4 - 11
B-6 Test the Service Horn ................................................................................... 4 - 11
B-7 Test the Drive Brakes ................................................................................... 4 - 12
B-8 Test the Drive Speed - Stowed Position ........................................................ 4 - 14
B-9 Test the Drive Speed - Raised Position......................................................... 4 - 14
B-10 Perform Hydraulic Oil Analysis ...................................................................... 4 - 15
B-11 Check the Electrical Contactor (before serial number 6901) ......................... 4 - 15
C-1 Replace the Hydraulic Filter .......................................................................... 4 - 16
D-1 Test or Replace the Hydraulic Oil .................................................................. 4 - 17

Part No. 39528 Genie GS-1530 & GS-1930 vii


Section Five Troubleshooting Flow Charts and Fault Codes
Section Six Schematics
Section Seven Repair Procedures

Platform Controls

Platform Components

Scissor Components

Ground Controls

Hydraulic Pump

Manifolds

Steering Axle Components

Non-steering Axle Components

Brake Release Hand Pump Components


Service Manual - First Edition Section 2 - Specifications

REV D
Specifications

Machine Specifications Operational dimensions

Maximum platform height 15 ft 19 ft


Model GS-1530 GS-1930 4.6 m 5.8 m

Stowed dimensions Maximum platform working height 21 ft 25.1 ft


6.4 m 7.7 m
Length 72 in 72 in
183 cm 183 cm Maximum platform extension 391/4 in 391/4 in
1m 1m
Length, platform extended 1011/2 in 1011/2 in
257.8 cm 257.8 cm Wheelbase 52 in 52 in
132.1 cm 132.1cm
Width 30 in 30 in
76.2 cm 76.2 cm Turning raduis, outside 61 in 61 in
154.9 cm 154.9 cm
Height, stowed maximum 801/4 821/2
Rails up - CE 203.7 cm 209.6 cm Turning raduis, inside 0 in 0 in
0 cm 0 cm
Height, stowed maximum 75 7/8 in 781/4 in
Rails up - ANSI 192.8 cm 198.6 cm Tires and wheels
Height, stowed maximum 74 in 76 5/16in Tire size (solid rubber) 12 x 4.5 x 8.6 in
Rails lowered 188 cm 193.8 cm 30.5 x 11.4 x 21.8 cm
Height, stowed maximum 361/2 in 381/2 in Load range 2,400 lbs
rails removed 93 cm 98 cm 1,089 kg
Height, guard rail level 40 in 40 in Tire contact area 9 sq in 58 sq cm
102 cm 102 cm
Overall tire diameter 12 in 30.5 cm
Weight 2563 lbs 2963 lbs
1163 kg 1344 kg Wheel diameter 8.6 in 21.8 cm

Ground clearance 2 7/8 2 7/8 Wheel width 4.5 in 11.4 cm


6.8 cm 6.8 cm
Castle nut torque 300 ft-lbs 406.7 Nm
Ground clearance 7/8in 7/8in
Pothole guards deployed 2.2 cm 2.2 cm Platform dimensions

Continuous improvement of our products is a Genie


Length 621/4 in 158 cm
policy. Product specifications are subject to change
without notice.
Width 251/2 in 65 cm

Extension length 291/2 in 74.9 cm

Maximum load capacity 600 lbs 500 lbs


272 kg 227 kg

Fluid Capacities

Hydraulic tank capacity 5 gallons 18.9 liters

Hydraulic system capacity 51/2 gallons 20.8 liters


(including tank)

Part No. 39528 Genie GS-1530 & Genie GS-1930 2-1


Section 2 - Specifications Service Manual - First Edition

SPECIFICATIONS REV D

Performance Specifications Hydraulic Specifications


Model GS-1530 GS-1930 Hydraulic fluid Dexron equivalent

Drive speeds (maximum) Lift pump

Stowed, maximum 2.5 mph 4 km/h Type: gear


40 ft / 10.7 sec 12.2 m / 10.7 sec
Displacement .244 cu in
Platform raised, 0.5 mph 0.7 km/h per revolution 4 cc
maximum 40 ft / 55 sec 12.2 m / 55 sec
Displacement 4 gallons per minute
Gradeability 15 liters per minute
GS-1530 30% (2500 psi/172 bar)
GS-1930 30%
Hydraulic tank 10 micron with 25 psi
Function speed, maximum return line filter (1.7 bar) bypass
from platform controls
Function manifold
Platform up 16 to 18 seconds 16 to 18 seconds
Platform down 16 to 17 seconds 22 to 23 seconds
Model GS-1530 GS-1930

System relief valve pressure


GS-1530 3000 psi 207 bar
GS-1930 3500 psi 241 bar

Steer relief valve pressure 1200 psi 82.8 bar

2-2 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 2 - Specifications

REV D SPECIFICATIONS

Hydraulic Hose and Fitting Torque Specifications


Your machine is equipped with either 37° flared fittings and hose ends OR Parker Seal-Lok® fittings and
hose ends. Machines that utilize Parker Seal-Lok® hoses and fittings require that the fittings and hose
ends be torqued to specification when they are removed and installed or when new hoses or fittings are
installed. Machines equipped with 37° flared fittings and hose ends do not need to be torqued to these
specifications.

Hydraulic Hose and Fitting Torque Specifications


SAE O-ring Boss Port - tube fitting Seal-Lok® - hose end
SAE Dash SAE Dash
Size Installing into... ft. lbs. Nm Size ft. lbs. Nm
-4 Aluminum 11 14.9 -4 18 24.4
Steel 16 21.7 -6 27 36.6
-6 Aluminum 23 31.2 -8 40 54.2
Steel 35 47.5 -10 63 85.4
-8 Aluminum 40 54.2 -12 90 122
Steel 60 81.3 -16 120 162.7
-10 Aluminum 69 93.6 -20 140 190
Steel 105 142.4 -24 165 223.7
-12 Aluminum 93 126.1
Steel 140 190
-16 Aluminum 139 188.5
Steel 210 284.7
-20 Aluminum 172 233.2
Steel 260 352.5
-24 Aluminum 208 282
Steel 315 427.1

Torque Procedure
1 Replace the O-ring. The O-ring must be 2 Lubricate the O-ring before installation.
replaced anytime the seal has been broken.
3 Be sure that the face seal O-ring is seated and
The O-ring cannot be re-used if the fitting or
retained properly.
hose end has been tightened beyond finger
tight. 4 Position the tube and nut squarely on the face
The O-rings used in the Parker seal end of the fitting and tighten the nut finger
Seal Lok® fittings and hose ends tight.
are a custom-size O-ring. They 5 Tighten the nut or fitting to the appropriate
are not a standard SAE size torque per given size as shown in the table
O-ring. They are available in the above.
O-ring field service kit (Genie part
number 49612). 6 Operate all machine functions and inspect the

Part No. 39528 Genie GS-1530 & Genie GS-1930 2-3


Section 2 - Specifications Service Manual - First Edition

This page intentionally left blank.

2-4 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 3 - Scheduled Maintenance Inspections

Scheduled Maintenance Inspections


About This Section
Dealer
Tools are New parts service
required required suggested
The Schedule

There are four types of maintenance inspections


that must be performed according to a schedule—
daily, quarterly, annual and two year. To account
for repeated procedures, the Maintenance Tables
Observe and Obey: and the Maintenance Inspection Report have been
divided into four subsections—A, B, C, D. Use the
Maintenance inspections shall be completed by following chart to determine which group(s) of
a person trained and qualified on the procedures are required to perform a scheduled
maintenance of this machine. inspection.
Scheduled maintenance inspections shall be
completed daily, quarterly, annually and every Inspection Table or Checklist
2 years as specified on the Maintenance
Inspection Report. Daily A

Failure to properly complete each Quarterly A+B


inspection when required may
cause death, serious injury or Annual A+B+C
substantial machine damage.
Two year A+B+C+D
Immediately tag and remove from service a
damaged or malfunctioning machine.
Maintenance Tables
Repair any machine damage or malfunction
before operating machine. The maintenance tables contained in this section
provide summary information on the specific
Keep records on all inspections for three years.
physical requirements for each inspection.
Machines that have been out of service for a
period longer than 3 months must complete the Complete step-by-step instructions for each
quarterly inspection. scheduled maintenance procedure are provided in
section 4, Scheduled Maintenance Procedures.

Maintenance Inspection Report


The maintenance inspection report contains
checklists for each type of scheduled inspection.

Make copies of the Maintenance Inspection


Report to use for each inspection. Store
completed forms for three years.

Part No. 39528 Genie GS-1530 & Genie GS-1930 3-1


Section 3 - Scheduled Maintenance Inspections Service Manual - First Edition

Maintenance Tables

Table A Tools are New parts


Dealer
service
required required suggested

A-1 Inspect the Operator's and Safety Manuals

A-2 Inspect the Decals and Placards

A-3 Inspect for Damage, Loose or Missing Parts

A-4 Check the Hydraulic Oil Level

A-5 Check for Hydraulic Leaks

A-6 Test the Platform and Ground Controls

A-7 Test the Manual Platform Lowering Operation

A-8 Test the Tilt Sensor

A-9 Test the Pothole Guards

A-10 Test the Lift/Drive Select Switch


(before serial number 17408)

A-11 Perform 30 Day Service

Table B

B-1 Check the Batteries

B-2 Inspect the Electrical Wiring

B-3 Inspect the Tires and Wheels


(including castle nut torque)

B-4 Test the Key Switch

3-2 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 3 - Scheduled Maintenance Inspections

MAINTENANCE TABLES

Table B, continued Tools are New parts


Dealer
service
required required suggested

B-5 Test the Emergency Stop Buttons

B-6 Test the Horn

B-7 Test the Drive Brakes

B-8 Test the Drive Speed - Stowed Position

B-9 Test the Drive Speed - Raised Position

B-10 Perform Hydraulic Oil Analysis


See D-1 Test or Replace the Hydraulic Oil

B-11 Check the Electrical Contactor


(before serial number 6901)

Table C

C-1 Replace the Hydraulic Filter

Table D

D-1 Test or Replace the Hydraulic Oil

Part No. 39528 Genie GS-1530 & Genie GS-1930 3-3


Section 3 - Scheduled Maintenance Inspections Service Manual - First Edition

Maintenance Inspection Report


Model Checklist A Y N R Checklist C Y N R
Dealer
Tools are New parts Refer toservice
Table C
Refer to Table A
Serial number required required suggested
A-1 Operator's and C-6 Hydraulic filter
Date Safety manuals
A-2 Decals and placards Checklist D Y N R
Hour meter A-3 Damage, loose or Refer to Table D
missing parts
Machine owner D-1 Hydraulic oil
A-4 Hydraulic oil level
Inspected by (print) A-5 Hydraulic leaks
A-6 Platform and
Inspector signature ground controls
A-7 Manual Platform Lowering
Inspector title
A-8 Tilt sensor
Inspector company A-9 Pothole Guards
A-10 Lift/drive Select Switch
Instructions
(before serial number 17408)
· Make copies of this page to use for
each inspection. A-11 30 Day Service
· Select the appropriate checklist(s) for
the type of inspection to be performed. Checklist B Y N R

Daily Inspection: A Refer to Table B

Quarterly Inspection: A+B B-1 Batteries

Annual Inspection: A+B+C B-2 Electrical wiring


B-3 Tires and wheels
2 Year Inspection: A+B+C+D
B-4 Key Switch
· Place a check in the appropriate box
B-5 Emergency Stop
after each inspection procedure is
completed. B-6 Horn
· Use the maintenance tables in this B-7 Drive Brakes
section and the step-by-step B-8 Drive speed - stowed
procedures in section 4 to learn how to
perform these inspections. B-9 Drive speed - raised

· If any inspection receives an “N,” tag B-10 Hydraulic oil analysis


and remove the machine from service, B-11 Electrical contactor
repair and re-inspect it. After repair, (before serial number 6901)
place a check in the “R” box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
Comments

3-4 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 4 - Scheduled Maintenance Procedures

Scheduled Maintenance Procedures


About This Section
This section contains detailed procedures for each
scheduled maintenance inspection.

Each procedure includes a description, safety


warnings and step-by-step instructions.
Observe and Obey: Symbols Legend

Maintenance inspections shall be completed by Safety alert symbol—used to alert


a person trained and qualified on the personnel to potential personal
maintenance of this machine. injury hazards. Obey all safety
messages that follow this symbol
Scheduled maintenance inspections shall be to avoid possible injury or death.
completed daily, quarterly, annually and every
2 years as specified on the Maintenance Red—used to indicate the
Inspection Report. presence of an imminently
hazardous situation which, if not
Failure to properly complete each avoided, will result in death or
inspection when required may serious injury.
cause death, serious injury or
substantial machine damage. Orange—used to indicate the
presence of a potentially
Immediately tag and remove from service a hazardous situation which, if not
damaged or malfunctioning machine. avoided, could result in death or
serious injury.
Repair any machine damage or malfunction
before operating machine. Yellow with safety alert symbol—
used to indicate the presence of a
Keep records on all inspections for three years. potentially hazardous situation
Unless otherwise specified, perform each which, if not avoided, may cause
procedure with the machine in the following minor or moderate injury.
configuration: Yellow without safety alert
· Machine parked on a flat level surface symbol—used to indicate the
presense of a potentially
· Platform in the stowed position hazardous situation which, if not
· Key switch in the OFF position with the key avoided, may result in property
removed damage.

· Wheels chocked Green—used to indicate operation


or maintenance information.
Indicates that a specific result is expected after
performing a series of steps.

Part No. 39528 Genie GS-1530 & Genie GS-1930 4-1


Section 4 - Scheduled Maintenance Procedures Service Manual - First Edition

Table A Procedures
A-1 A-2
Inspect the Operator’s and Inspect the
Safety Manuals Decals and Placards
Maintaining the operator’s and safety manuals in Maintaining all of the safety and instructional
good condition is essential to safe machine decals and placards in good condition is
operation. Manuals are included with each mandatory for safe machine operation. Decals
machine and should be stored in the container alert operators and personnel to the many
provided in the platform. An illegible or missing possible hazards associated with using this
manual will not provide safety and operational machine. They also provide users with operation
information necessary for a safe operating and maintenance information. An illegible decal
condition. will fail to alert personnel of a procedure or hazard
and could result in unsafe operating conditions.
1 Check to be sure the storage container is
present and in good condition. 1 Refer to the Decals section in the appropriate
Genie GS-1530 & Gemie GS-1930 Operator's
2 Check to make sure that the operator’s,
Manual and use the decal list and illustrations
responsibilities and safety manuals are present
to determine that all decals and placards are in
and complete in the storage container in the
place.
platform.
2 Inspect all decals for legibility and damage.
3 Examine the pages of each manual to be sure
Replace any damaged or illegible decal
that they are legible and in good condition.
immediately.
4 Always return the manuals to the storage
Contact your authorized Genie
container after use.
distributor or Genie Industries if
Contact your authorized Genie replacement decals are needed.
distributor or Genie Industries if
replacement manuals are needed.

4-2 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 4 - Scheduled Maintenance Procedures

TABLE A PROCEDURES

A-3 A-4
Inspect for Damage and Loose or Check the Hydraulic Oil Level
Missing Parts Maintaining the hydraulic oil at the proper level is
Daily machine condition inspections are essential essential to machine operation. Improper hydraulic
to safe machine operation and good machine oil levels can damage hydraulic components. Daily
performance. Failure to locate and repair damage, checks allow the inspector to identify changes in
and discover loose or missing parts may result in oil level that might indicate the presence of
an unsafe operating condition. hydraulic system problems.

1 Inspect the entire machine for damage and Perform this procedure with the
improperly installed or missing parts including: platform in the stowed position.

· Electrical components, wiring and electrical 1 Visually inspect the oil level in the hydraulic
cables tank through the sight gauge in the side of the
power unit module.
· Hydraulic power unit, tank, hoses, fittings,
cylinders and manifolds Result: The hydraulic oil level should be within
· Drive motors the FULL and ADD marks on the oil level indicator
decal.
· Pothole guards
2 Add oil if necessary. Do not overfill.
· Scissor pins and retaining fasteners
· Scissor components and wear pads Hydraulic Oil Specifications
· Dents or damage to machine
Hydraulic oil type Dexron equivalent
· Tires and wheels
· Limit switches, level sensor and alarm Hydraulic tank capacity 5.5 gallons
20.8 liters
· Optional horn (if equipped)
· Beacons (if equipped) Hydraulic system 6 gallons
· Manual brake release components (including tank) 22.7 liters

· Platform entry chain or gate


· Safety arm
· Cracks in welds or structural components
· Battery pack and connections
· Platform extension
· Platform control joystick
· Platform railings

Part No. 39528 Genie GS-1530 & Genie GS-1930 4-3


Section 4 - Scheduled Maintenance Procedures Service Manual - First Edition

TABLE A PROCEDURES

A-5 A-6
Check for Hydraulic Leaks Test the Platform and
Detecting hydraulic fluid leaks is essential to Ground Controls
operational safety and good machine Testing the machine functions and the Emergency
performance. Undiscovered leaks can develop into Stop buttons for malfunctions is essential for safe
hazardous situations, impair machine functions machine operation. An unsafe working condition
and damage machine components. exists if any function fails to operate properly or
1 Inspect for hydraulic oil puddles, dripping or either Emergency Stop button fails to stop all the
residue on or around the following areas: machine functions. Each function should operate
smoothly and be free of hesitation, jerking and
· Hydraulic tank—filter, fittings and hoses unusual noise.
· Hydraulic power unit, fittings and hoses
1 Turn the key switch to ground control and pull
· Hydraulic lift cylinder and manual out the Emergency Stop button to the ON
lowering valve position at both the platform and ground
· Function manifold controls.
· The underside of the drive chassis 2 Activate the platform up function.
· Drive motors Result: The platform should raise.
· Drive brakes
3 Activate the platform down function.
· Ground area under the machine
Result: The platform should lower. The descent
alarm should sound while the platform is
lowering.
4 Push in the ground controls Emergency Stop
button to the OFF position.
Result: No function should operate.
5 Turn the key switch to platform control and pull
out the Emergency Stop button to the ON
position at both the ground and the platform
controls.
6 Press and hold the lift function enable button
OR move the lift/drive selector switch to the lift
position.
7 Press and hold the function enable switch on
the control handle.
Result: The green power light should come on.

4-4 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 4 - Scheduled Maintenance Procedures

TABLE A PROCEDURES

8 Slowly move the control handle in the direction A-7


indicated by the blue arrow.
Test the Manual Platform
Result: The platform should raise. The pothole
Lowering Operation
guards should deploy.
Detection of Manual Platform Lowering system
9 Release the control handle.
malfunctions is essential for safe machine
Result: The platform should stop raising. operation. An unsafe working condition exists if
the Manual Platform Lowering function does not
10 Press and hold the function enable switch. operate in the event of a main power loss.
Slowly move the control handle in the direction
indicated by the yellow arrow. 1 Turn the key switch to ground control and pull
out the Emergency Stop button to the ON
Result: The platform should lower. The descent position at both the platform and ground
alarm should sound while the platform is controls.
lowering.
2 Raise the platform approximately
CE models: When lowering the 2 feet (0.6 m).
platform, the platform should stop
when it is 7 feet (2.1 m) from the 3 Pull the Manual Platform Lowering handle
ground. Be sure the area below located next to the ground controls.
the platform is clear of personnel Result: The platform should lower. The descent
and obstructions before alarm will not sound.
continuing. To continue lowering,
release the control handle, wait 5
seconds, then move the control
handle again.
As a safety feature, selecting
and operating the ground
controls will override the
platform controls, except
the platform Emergency Stop
button.

Part No. 39528 Genie GS-1530 & Genie GS-1930 4-5


Section 4 - Scheduled Maintenance Procedures Service Manual - First Edition

TABLE A PROCEDURES

A-8 A-9
Test the Tilt Sensor Test the Pothole Guards
Perform this test from the ground The pothole guards should
with the platform controls. Do not automatically deploy when the
stand in the platform. platform is raised. The pothole
guards activate two limit switches
1 Fully lower the platform.
which control the machine drive
2 Place a 2x4 block or similar piece of wood speed. If the pothole guards do
under both wheels on one side and drive the not deploy and the platform is
machine up onto them. raised above 6 feet (1.8 meters),
an alarm sounds and the machine
3 Raise the platform. will not drive.
Result: When the platform is raised 7 feet 1 Raise the platform.
(2.1 meters) from the ground, an alarm should
sound. Result: When the platform is raised 4 feet
(1.2 meters) from the ground, the pothole guards
4 Lower the platform and remove both pieces of should deploy.
wood.
2 Press on the pothole guards on one side, and
then the other.
Result: The pothole guards should not move.
3 Lower the platform.
Result: The pothole guards should return to the
stowed position.
4 Place a 2x4 block or similar piece of wood under
the pothole guard. Raise the platform.
Result: When the platform is raised
approximately 7 to 8 feet (2.1 to 2.4 meters),
an alarm should sound and the drive function
should not work.
5 Lower the platform and remove the 2x4 block.

4-6 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 4 - Scheduled Maintenance Procedures

TABLE A PROCEDURES

A-10 A-11
Test the Lift/Drive Select Switch Perform 30 Day Service
(before serial number 17408) The 30 day maintenance procedure is a onetime
A properly functioning Lift/Drive Select Switch sequence of procedures to be performed after the
is essential for safe machine operation. An first 30 days or 50 hours of usage. After this
improperly operating Lift/Drive Select Switch interval, refer to the maintenance tables for
will fail to activate the appropriate platform control continued scheduled maintenance.
which may result in a hazardous situation. 1 Perform the following maintenance procedures:
1 Turn the key switch to platform control and pull · B-3 Inspect Tires and Wheels
out the Emergency Stop button to the ON · C-1 Replace the Hydraulic Filter
position at both the platform and ground
controls.
2 Move the lift/drive select switch to the LIFT
position.
3 Press and hold the function enable switch.
Result: The green power light should come on.
4 Slowly move the control handle off center.
Result: The platform should raise or lower.
5 Move the lift/drive select switch to the DRIVE
position.
6 Press and hold the function enable switch.
Result: The green power light should come on.
7 Slowly move the control handle off center.
Result: The drive and steer functions should
operate.

Part No. 39528 Genie GS-1530 & Genie GS-1930 4-7


Section 4 - Scheduled Maintenance Procedures Service Manual - First Edition

Table B Procedures
B-1 7 Check each battery pack and verify that the
batteries are wired correctly.
Check the Batteries
Proper battery condition is essential to good
machine performance and operational safety.
Improper fluid levels or damaged cables and
connections can result in component damage and
hazardous conditions.

Bodily injury hazard. Batteries


contain acid. Avoid spilling or
contacting battery acid. Neutralize
battery acid spills with baking
soda and water.
Electrocution hazard. Contact
with hot or live circuits may
result in death or serious injury.
Remove all rings, watches and
other jewelry.
Perform this test after fully
charging the batteries.
1 Put on protective clothing and eye wear.
2 Be sure that the battery cable connections are
free of corrosion.
3 Be sure that the battery hold downs and cable
connections are tight.
4 Remove the battery vent caps and check the
specific gravity of each battery cell with a
hydrometer.
Result: If any battery cell displays a specific
gravity of less than 1.098, the battery must be
replaced.
5 Check the battery acid level of each battery. If
needed, replenish with distilled water to the
bottom of the battery fill tube. Do not overfill.
6 Install the battery vent caps.

4-8 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 4 - Scheduled Maintenance Procedures

TABLE B PROCEDURES

B-2 6 Inspect the center chassis area and scissor


arms for burnt, chafed and pinched cables.
Inspect the Electrical Wiring
7 Inspect the following areas for burnt, chafed,
Maintaining electrical wiring in good condition is corroded, pinched and loose wires:
essential to safe operation and good machine
performance. Failure to find and replace burnt, · ECM to platform controls
chafed, corroded or pinched wires could result in · Power to platform wiring
unsafe operating conditions and may cause
8 Raise the platform and return the safety arm to
component damage.
the stowed position.
Electrocution hazard. Contact 9 Lower the platform to the stowed position and
with hot or live circuits may turn the machine off.
result in death or serious injury.
Remove all rings, watches and
other jewelry.
1 Inspect the following areas for burnt, chafed,
corroded and loose wires:
· Ground control panel
· Hydraulic power unit module tray
· Battery pack module tray
· Scissor arms
· Platform controls
2 Turn the key switch to ground control and pull
out the Emergency Stop button to the ON
position.
3 Raise the platform approximately 8 feet (2.4 m)
from the ground.
4 Rotate the safety arm away from the machine
and let it hang down.
5 Lower the platform onto the safety arm.
Crushing hazard. Keep hands
clear of the safety arm when
lowering the platform.

Part No. 39528 Genie GS-1530 & Genie GS-1930 4-9


Section 4 - Scheduled Maintenance Procedures Service Manual - First Edition

TABLE B PROCEDURES

B-3 B-4
Inspect the Tires and Wheels Test the Key Switch
(including castle nut torque) Proper key switch action and response is essential
Maintaining the tires and wheels in good to safe machine operation. The machine can be
condition is essential to safe operation and good operated from the ground or platform controls and
performance. Tire and/or wheel failure could result the activation of one or the other is accomplished
in a machine tip-over. Component damage may with the key switch. Failure of the key switch to
also result if problems are not discovered and activate the appropriate control panel could cause
repaired in a timely fashion. a hazardous operating situation.

1 Check the tire surface and sidewalls for cuts, 1 Pull out the Emergency Stop button to the ON
cracks, punctures and unusual wear. position at both the ground and platform
controls.
2 Check each wheel for damage, bends and
cracks. 2 Turn the key switch to platform control.

3 Remove the cotter pin and check each castle 3 Check the platform up/down function from the
nut for proper torque. ground controls.

4 Install a new cotter pin. Result: The machine functions should not
operate.
Always replace the cotter pin with
a new one when removing the 4 Turn the key switch to ground control.
castle nut or when checking the 5 Check the machine functions from the
torque of the castle nut. platform controls.

Tires and wheels Result: The machine functions should not


operate.
Castle nut torque, dry 300 ft-lbs 406.7 Nm
6 Turn the key switch to the OFF position.
Castle nut torque, lubricated 225 ft-lbs 305 Nm
Result: No function should operate.

4 - 10 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 4 - Scheduled Maintenance Procedures

TABLE B PROCEDURES

B-5 B-6
Test the Emergency Stop Buttons Test the Horn
Properly functioning Emergency Stop buttons A functioning horn is essential to safe machine
are essential for safe machine operation. An operation. The horn is activated at the platform
improperly operating Emergency Stop button controls and sounds at the ground as a warning to
will fail to shut off power and stop all machine ground personnel. An improperly functioning horn
functions resulting in a hazardous situation. will prevent the operator from alerting ground
personnel of hazards or unsafe conditions.
As a safety feature, selecting
and operating the ground controls 1 Turn the key switch to platform control and
will override the platform controls, pull out the Emergency Stop button to the
except the platform Emergency ON position at both the ground and
Stop button. platform controls.
1 Turn the key switch to ground control and pull 2 Push down the horn button at the platform
out the Emergency Stop button to the ON controls.
position at both the ground and platform
controls. Result: The horn should sound.

2 Push in the Emergency Stop button at the


ground controls to the OFF position.
Result: No functions should operate.
3 Turn the key switch to platform control and pull
out the Emergency Stop button to the ON
position at both the ground and platform
controls.
4 Push down the Emergency Stop button at the
platform controls to the OFF position.
Result: No machine functions should operate.
The ground control Emergency
Stop button will stop all machine
operation, even if the key switch
is switched to platform control.

Part No. 39528 Genie GS-1530 & Genie GS-1930 4 - 11


Section 4 - Scheduled Maintenance Procedures Service Manual - First Edition

TABLE B PROCEDURES

B-7 7 Measure the distance between the test line and


your machine reference point.
Test the Drive Brakes
Proper brake action is essential to safe machine Braking: paved surface
operation. The drive brake function should operate
smoothly, free of hesitation, jerking and unusual Stopping distance 2 ft 0.6 m
noise. Hydraulically-released individual wheel
brakes can appear to operate normally when not
fully operational. Result: The machine stops within the specified
braking distance. No action required.
Perform this procedure with the
machine on a firm, level surface Result: The machine does not stop within the
that is free of obstructions. specified braking distance. Proceed to step 8
and determine if the machine is equipped with
Be sure the platform extension a dynamic braking valve.
deck is fully retracted and the
platform is in the stowed position. The brakes must be able to hold
the machine on any slope it is able
1 Mark a test line on the ground for reference. to climb.
2 Turn the key switch to platform control and pull 8 Disconnect the battery pack from the machine.
out the Emergency Stop button to the ON
position at both the ground and platform Electrocution hazard. Contact with
controls. electrically charged circuits could
result in death or serious injury.
3 Lower the platform to the stowed position. Remove all rings, watches and
4 Move the lift/drive selector switch to the drive other jewelry.
position (if equipped). 9 Locate the drive forward/reverse valve on the
5 Choose a point on the machine; i.e., contact function manifold. Refer to Illustrations 1.
patch of a tire, as a visual reference for use
when crossing the test line.
6 Bring the machine to full drive speed before
reaching the test line. Release the function
enable switch or the joystick on the platform
controls when your reference point on the
machine crosses the test line.

a drive forward/reserve valve

4 - 12 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 4 - Scheduled Maintenance Procedures

TABLE B PROCEDURES

10 Tag the forward and the reverse valve coils. 15 Install the coil nut onto the valve and tighten.
Remove the coils from the valve. Torque to 60 in-lbs / 7 Nm.
The forward valve coil has white 16 Connect the battery pack to the machine.
and brown wires attached.
7 Replace the brakes and repeat this procedure
The reverse valve coil has beginning with step 1. Refer to Repair Procedure
white/black and brown wires 8-1, How to Remove a Drive Brake.
attached.
18 Contact the Genie Industries Service Parts
For reassembly, it will be helpful to Department and order kit part number 105457.
leave the wire harness attached to
19 Install the new valve received in the kit and
the valve coils.
mark the new valve with a white paint pen to
11 Remove the drive forward/reverse valve from the identify new valve installation.
function manifold. Cap the open port of the
20 Repeat this procedure beginning with step 1.
manifold.
If the machine fails to stop within the specified
12 Carefully inspect the hex portion of the valve for
stopping distance after installing new brakes,
an identification stamp.
please contact the Genie Industries Scissors
Result: SV10-4727 is stamped on the hex Service Department, 1-800-536-1800 Ext. 8710.
portion of the drive forward/reverse valve. This
indicates the machine is equipped with a
dynamic brake valve. Proceed to step 13.
Result: SV10-4727 is not stamped on the hex
portion of the drive forward/reverse valve. This
indicates the machine is not equipped with a
dynamic brake valve. Proceed to step 18.
13 Install the drive forward/reverse valve removed
in step 11 into the function manifold and
securely tighten. Torque to 25 ft-lbs / 34 Nm.
14 In order, install the reverse valve coil (with
white/black and brown wires), spacer washer
and the forward valve coil (with white and brown
wires) onto the valve.
For the machine to function
correctly, the reverse valve coil
must be closest to the manifold.

Part No. 39528 Genie GS-1530 & Genie GS-1930 4 - 13


Section 4 - Scheduled Maintenance Procedures Service Manual - First Edition

TABLE B PROCEDURES

B-8 B-9
Test the Drive Speed - Test the Drive Speed -
Stowed Position Raised Position
Proper drive functions are essential to safe Proper drive functions are essential to safe
machine operation. The drive function should machine operation. The drive function should
respond quickly and smoothly to operator control. respond quickly and smoothly to operator control.
Drive performance should also be free of hesitation, Drive performance should also be free of hesitation,
jerking and unusual noise over the entire jerking and unusual noise over the entire
proportionally controlled speed range. proportionally controlled speed range.

Select a test area that is firm, level Select a test area that is firm, level
and free of obstructions. and free of obstructions.
1 Create start and finish lines by marking two lines 1 Create start and finish lines by marking two lines
on the ground 40 feet (12.2 m) apart. on the ground 40 feet (12.2 m) apart.
2 Turn the key switch to platform control and pull 2 Turn the key switch to platform control and pull
out the Emergency Stop button to the ON out the Emergency Stop button to the ON
position at both the ground and platform position at both the ground and platform
controls. controls.
3 Lower the platform to the stowed position. 3 Raise the platform approximately 6 feet (2 m).
4 Choose a point on the machine; i.e., contact 4 Choose a point on the machine; i.e., contact
patch of a tire, as a visual reference for use patch of a tire, as a visual reference for use
when crossing the start and finish lines. when crossing the start and finish lines.
5 Bring the machine to maximum drive speed 5 Bring the machine to maximum drive speed
before reaching the start line. Begin timing before reaching the start line. Begin timing
when your reference point on the machine when your reference point on the machine
crosses the start line. crosses the start line.
6 Continue at full speed and note the time when 6 Continue at full speed and note the time when
the machine reference point passes over the the machine reference point passes over the
finish line. Return the control handle to center. finish line. Return the control handle to center.

Drive speed: Drive speed (maximum):

Stowed position 40 ft/ 10.1 sec 12.2 m/10.1 sec Platform raised 40 ft / 55 sec 12.2 m / 55 sec

4 - 14 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 4 - Scheduled Maintenance Procedures

TABLE B PROCEDURES

B-10 B-11
Perform Hydraulic Oil Analysis Check the Electrical Contactor -
See D-1, Test or Replace the Hydraulic Oil. (before serial number 6901)
Maintaining the electrical contactor in good
condition is essential to safe machine operation.
Failure to locate a worn or damaged contactor could
result in an unsafe working condition and
component damage.

1 Open the hydraulic power unit module and locate


the electrical contactor mounted above the
hydraulic power unit.
2 Visually inspect the contact points of each
contactor for the following items:
· Excessive burns
· Excessive arcs
· Excessive pitting
Replace the contactor if any
damage is found.

Part No. 39528 Genie GS-1530 & Genie GS-1930 4 - 15


Section 4 - Scheduled Maintenance Procedures Service Manual - First Edition

Table C Procedure
C-1
Replace the Hydraulic Filter
Replacement of the hydraulic filter is
essential for good machine performance and
service life. A dirty or clogged filter may cause the
machine to perform poorly and continued use may
cause component damage. Extremely dirty
conditions may require that the filter be replaced
more often.

Beware of hot oil. Contact with


hot oil may cause severe burns.
The hydraulic filter is mounted on
the function manifold next to the
hydraulic power unit.
1 Clean the area around the oil filter, then
remove the filter with an oil filter wrench.
2 Apply a thin layer of oil to the new oil filter
gasket.
3 Install the new filter (Genie part number 44788)
and tighten it securely by hand. Clean up any
oil that may have spilled during the
replacement procedure.
4 Turn the key switch to ground control and pull
out the Emergency Stop button to the ON
position at both the ground and platform
controls. Activate and hold the platform up
toggle switch.
5 Inspect the filter and related components to
be sure that there are no leaks.

4 - 16 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 4 - Scheduled Maintenance Procedures

Table D Procedure
D-1 6 Remove the motor controller mounting bracket
retaining fasteners and move the motor
Test or Replace the Hydraulic Oil controller to the side.
Replacement or testing of the hydraulic oil is 7 Remove the hydraulic tank from the machine.
essential for good machine performance and
service life. Dirty oil and suction strainer may 8 Remove the suction strainer and clean it using
cause the machine to perform poorly and a mild solvent.
continued use may cause component damage. 9 Clean the inside of the hydraulic tank using a
Extremely dirty conditions may require oil changes mild solvent.
to be performed more often.
10 Install the suction strainer using thread sealer
This machine uses Dexron on the threads.
equivalent hydraulic oil. Before
replacing the hydraulic oil, the oil 11 Install the drain plug using thread sealer on the
may be tested by an oil distributor threads.
for specific levels of contamination 12 Install the hydraulic filter bracket and the Curtis
to verify that changing the oil is motor controller bracket.
necessary. If the hydraulic oil
is not replaced at the two year Electrocution hazard. The
inspection, test the oil connectors on the motor controller
quarterly. Replace the oil when will short out to ground if the
it fails the test. motor controller mounting bracket
is not installed before the battery
Perform this procedure with the pack is connected.
platform in the stowed position.
13 Install the hydraulic tank.
1 Disconnect the battery pack from the machine.
14 Fill the tank with hydraulic oil until the fluid is
2 Open the power unit compartment and place a within the FULL and ADD marks on the oil level
drain pan or other suitable container under the indicator decal. Do not overfill.
hydraulic tank.
15 Clean up any oil that may have spilled. Properly
3 Remove the drain plug from the hydraulic tank. discard of oil.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and Hydraulic oil type - Dexron equivalent
burn skin. Loosen hydraulic
connections very slowly to allow Hydraulic tank capacity 5 gallons
the oil pressure to dissipate 18.9 liters
gradually. Do not allow oil to squirt
Hydraulic system 5.5 gallons
or spray.
(including tank) 20.8 liters
4 Completely drain the tank into a suitable
container. See capacity specifications listed
above.
5 Remove the return filter mounting bracket
fasteners from the manifold. Push the filter and
accumulator out of the way.

Part No. 39528 Genie GS-1530 & Genie GS-1930 4 - 17


Section 4 - Scheduled Maintenance Procedures Service Manual - First Edition

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4 - 18 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

Troubleshooting Flow Charts


Before Troubleshooting:
Read, understand and obey the safety rules
and operating instructions printed in the
Genie GS-1530 & Genie GS-1930 Operator’s
Manual.
Be sure that all necessary tools and test
Observe and Obey: equipment are available and ready for use.

Troubleshooting and repair procedures shall be Read each appropiate flow chart thoroughly.
completed by a person trained and qualified on Attempting shortcuts may produce hazardous
the repair of this machine. conditions.

Immediately tag and remove from service a Be aware of the following hazards and follow
damaged or malfunctioning machine. generally accepted safe workshop practices.

Repair any machine damage or malfunction Crushing hazard. When testing


before operating the machine. or replacing any hydraulic
component, always support
Unless otherwise specified, perform each the structure and secure it
repair procedure with the machine in the from movement.
following configuration:
Electrocution hazard. Contact
· Machine parked on a flat level surface
with electrically charged circuits
· Platform in stowed position may result in death or serious
· Key switch in the OFF position with the injury. Remove all rings, watches
key removed and other jewelry.
· Wheels chocked Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
Perform all troubleshooting on a
firm level surface.
Two persons will be required to
safely perform some
troubleshooting procedures.

Part No. 39528 Genie GS-1530 & Genie GS-1930 5-1


Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

TROUBLESHOOTING FLOW CHARTS

About This Section General Repair Process

When a malfunction is discovered, the flow charts


in this section will help a service professional Malfunction Identify Troubleshoot
pinpoint the cause of the problem. To use this discovered symptoms
section, basic hand tools and certain pieces of test
equipment are required—voltmeter, ohmmeter,
pressure gauges. problem
still exists
The location of terminals mentioned in this section
can be found on the appropriate electrical or Return to Inspect Perform
hydraulic schematics provided in Section 6, service problem and test repair
Schematics. solved

Since various degrees of a particular function


loss may occur, selecting the appropriate flow
chart may be troublesome. When a function will
not operate with the same speed or power as a
machine in good working condition, refer to the
flow chart which most closely describes the
problem.

LED Diagnostic Readout


The diagnostic readout displays numerical codes
that provide information about the machine
operating status and about malfunctions. The
dot to the right of the numbers will blink during
normal operation codes and remain on with fault
codes.
The codes listed in the Operation Code Chart
are common operational status codes and
malfunction codes that can be cleared easily.

The codes listed in the Fault Code Chart


describe malfunctions and can aid in
troubleshooting the machine by pinpointing the
area or component affected.

5-2 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

Fault Code Chart


(Before Serial Number 17408)

Fault Code Problem Possible Causes Solution

Reset the ECM. If problem


00 remains, replace the ECM.

Alarm sounds continuously. Remove obstruction to pothole


Error indicator light on at the Pothole guard may be blocked guard OR check pothole limit
platform controls when function or pothole limit switches may switch wiring for open
18 enable switch is engaged. not be activating or there is a connections OR check pothole
Machine will not drive. Machine bad wire connection. limit switch for proper
is not level. adjustment and activation.

Alarm sounds continuously. Remove obstruction to pothole


Error indicator light on at the Pothole guard may be blocked guard OR check pothole limit
platform controls when function or pothole limit switches may switch wiring for open
19 enable switch is engaged. not be activating or there is a connections OR check pothole
Machine will not drive. Machine bad wire connection. limit switch for proper
is level. adjustment and activation.

Release the function enable


Machine will not operate. Error Joystick initialization OK but switch OR check the switch for
33 indicator light on at the platform function enable switch is tied continuity in the joystick
controls. down. controller box (see Repair
Section).
Machine unit will not operate. Replace joystick controller box
ECM does not recognize the
34 Error indicator light on at the
platform controls.
main circuit board OR replace
platform controls. the coil cord.
Machine unit will not operate.
ECM does not recognize the Replace joystick controller box
35 Error indicator light on at the
platform controls. main circuit board.
platform controls.

Only the platform down


Check wiring and terminal at
function operates no other
motor contactor ckt A9-Curtis
functions operate. Error No power output from ECM to
51 indicator light on at the platform the motor contactor.
terminal 3 OR check wiring and
terminal at control ECM pin A9,
controls when the function
ckt A9-Curtis terminal 3.
enable switch is engaged.

Notes

Continued on next page

Part No. 39528 Genie GS-1530 & Genie GS-1930 5-3


Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

FAULT CODE CHART


(BEFORE SERIAL NUMBER 17408)

Fault Code Problem Possible Causes Solution

Machine will not drive forward. Check wiring and terminal at


Pump motor starts. Error the forward coil, ckt C6-
No power output from ECM to
52 indicator light on at the platform
the drive forward coil.
Forward coil OR check wiring
controls when the function and terminal at control ECM
enable switch is engaged. pin C6, ckt C6 Forward coil.

Machine will not drive in


Check wiring and terminal at
reverse. Pump motor starts.
the reverse coil, ckt A7-
Error indicator light on at the No power output from ECM to
53 platform controls when the the drive reverse coil.
Reverse coil OR check wiring
and terminal at ECM pin A7,
function enable switch is
ckt A7 Reverse coil.
engaged.
Platform will not raise. Pump Check wiring and terminal at
motor starts. Error indicator the platform up coil, ckt A6-Up
No power output from ECM to
54 light on at the platform controls
the platform up coil.
coil OR check wiring and
when the function enable terminal at ECM pin A6, ckt A6
switch is engaged. Up coil.
Check wiring and terminal at
Platform will not lower. Error
the platform lowering coil, ckt
indicator light on at the platform No power output from ECM to
55 controls when the function the platform lowering coil.
B6-Down coil OR check wiring
and terminal at ECM pin B6,
enable switch is engaged.
ckt B6 Down coil.

Machine will not steer right. Check wiring and terminal at


Pump motor starts. Error the steer right coil, ckt C7
No power output from ECM to
56 indicator light on at the platform
steer right coil.
Right coil OR check wiring and
controls when the function terminal at ECM pin C7, C7
enable switch is engaged. Right coil.

Machine will not steer left. Check wiring and terminal at


Pump motor starts. Error the steer left coil, ckt B7 Left
No power output from ECM to
57 indicator light on at the platform
steer left coil.
coil OR check wiring and
controls when the function terminal at ECM pin B7, B7
enable switch is engaged. Left coil.

Check wiring and terminal at


the orifice coil, ckt C9 orifice
Machine will not drive but No power output from ECM to
58 platform will still raise. the brake orifice coil.
coil OR check wiring and
terminal at ECM pin C9, C9
orifice coil OR replace Coil.

Notes
Continued on next page

5-4 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

FAULT CODE CHART


(BEFORE SERIAL NUMBER 17408)

Fault Code Problem Possible Causes Solution

Machine will not operate. Error


Lift/drive switch is turned "off" Check switch position OR
60 indicator light on at the platform
or in a neutral position. Replace switch.
controls.
Lift/drive switch turned from lift
Machine will not operate. Release function enable switch
to drive or drive to lift while the
63 Flashing green LED at the
function enable switch is
and move lift/drive switch to
platform controls. either lift or drive.
engaged.
Machine will not operate. ECM
88 cannot be reset.
EPROM not programmed. Replace ECM.

Release function enable switch


OR check the function enable
no code Green flashing LED at the
Function enable switch held for
more than 10 seconds without
microswitch for continuity in
available platform controls.
activating any function.
the joystick controller box.
Reset controller and check for
fault code 33 at power up.

Machine drive speed reduces


to off limit drive speed OR Low Voltage Cut Back (LVCB)
no code platform raises slowly. Red is activated because battery
Charge batteries.
available flashing LED at the platform
controls while function enable
supply voltage is 18.5V DC or
less.
switch is activated.

Notes

Continued on next page

Part No. 39528 Genie GS-1530 & Genie GS-1930 5-5


Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

Normal Operation Code Chart


(Before Serial Number 17408)

Code Condition Explanation

Machine was operating normally, then the platform Emergency


Key switch to platform control.
Stop button was pushed in and the key switch was turned to
Platform extended above 6 feet.
20 ground control. Alarm will go off until key switch is turned to
Ground control and platform Emergency Stop buttons pulled out
flashing platform control or the platform Emergency Stop button is pulled
to the on position.
out.

Key switch to platform control.


Platform extended above 6 feet.
21 Normal operation.
Ground control and platform Emergency Stop buttons pulled out
flashing
to the on position.

Key switch to ground control.


Ground control Emergency Stop button pulled out to the on
To clear this code, be sure joystick is properly connected or pull
22 position.
the platform Emergency Stop button out to the on position.
flashing Platform control Emergency Stop button pushed in to the off
position.

Key switch to ground control.


Ground control and platform Emergency Stop buttons pulled out
23 Turn key switch to platform control.
to the on position.
flashing
Error indicator light at platform controls is on.

Key switch to ground control.


Ground control Emergency Stop button pulled out to the on
position. To clear this code, be sure joystick is properly connected or pull
24
Platform control Emergency Stop button pushed in to the off the platform Emergency Stop button out to the on position.
flashing
position.
Platform extended less than 6 feet.

Key switch to ground control.


Ground control and platform Emergency Stop buttons pulled
25 out to the on position. Turn key switch to platform control.
flashing Error indicator light at platform controls is on.
Platform extended less than 6 feet.

Key switch to platform control.


31 Ground control and platform Emergency Stop buttons pulled out Normal operation.
flashing to the on position.

Key switch to platform control.


Ground control Emergency Stop button pulled out to the on
To clear this code, be sure joystick is properly connected or pull
32 position.
the platform Emergency Stop button out to the on position.
flashing Platform control Emergency Stop button pushed in to the off
position.

Up function selected.
Key switch to platform control.
Note: if joystick controller is returned to center position before
Ground control and platform Emergency Stop buttons pulled out
36 function enable button is released, code 31 flashing will appear. If
to the on position.
flashing function enable button is released first, code 36 flashing will
Lift/drive switch to lift position.
remain until another function is selected.

Down function selected.


Key switch to platform control.
Note: if joystick controller is returned to center position before
Ground control and platform Emergency Stop buttons pulled out
37 function enable button is released, code 31 flashing will appear. If
to the on position.
flashing function enable button is released first, code 37 flashing will
Lift/drive switch to lift position.
remain until another function is selected.

Drive in blue direction function selected.


Key switch to platform control.
Note: if joystick controller is returned to center position before
Ground control and platform Emergency Stop buttons pulled out
38 function enable button is released, code 31 flashing will appear. If
to the on position.
flashing function enable button is released first, code 38 flashing will
Lift/drive switch to drive position.
remain until another function is selected.

Drive in yellow direction function selected.


Key switch to platform control.
Note: if joystick controller is returned to center position before
Ground control and platform Emergency Stop buttons pulled out
39 function enable button is released, code 31 flashing will appear. If
to the on position.
flashing function enable button is released first, code 39 flashing will
Lift/drive switch to drive position.
remain until another function is selected.

Key switch to platform control.


Horn is being pressed.
Ground control and platform Emergency Stop buttons pulled out
40 Note: Horn will operate without code 40 flashing if function enable
to the on position.
flashing switch is not pressed in.
Function enable switch pressed.

5-6 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

This page intentionally left blank.

Part No. 39528 Genie GS-1530 & Genie GS-1930 5-7


Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

Fault Code Chart


(After Serial Number 17407)

Fault Code Problem Possible Causes Solution

Machine will not operate. ECM


01 cannot be reset.
EPROM not programmed. Replace ECM.

02 Platform ECM error. EPROM not programmed. Replace ECM.


Undefined platform DIP switch
03 settings.
DIP switch settings incorrect. Correct DIP switch settings.

Chassis up/down switch closed


12 at start up.
Malfunctioningup/down switch. Troubleshoot up/down switch.

Malfunctioning pothole switch


Troubleshoot pothole switch
18 Pothole guard failure. OR obstruction in pothole
OR remove obstruction.
guard linkage.
Platform left turn switch closed Malfunctioning steer left Troubleshoot steer left
42 at start up. microswitch. microswitch.
Platform right turn switch Malfunctioning steer right Troubleshoot steer right
43 closed at start up. microswitch. microswitch.
Platform lift enable switch Malfunctioning lift enable
45 closed at start up. switch.
Troubleshoot lift enable switch.

Platform drive enable switch Malfunctioning drive enable Troubleshoot drive enable
46 closed at start up. switch. switch.
Platform joystick off neutral at Joystick potentiometer not
47 start up. centered.
Verify potentiometer setting.

Malfuctioning coil OR wire Troubleshoot coil OR inspect


52 Forward coil error.
disconnected from coil. wire connection.
Malfuctioning coil OR wire Troubleshoot coil OR inspect
53 Reverse coil error.
disconnected from coil. wire connection.
Malfuctioning coil OR wire Troubleshoot coil OR inspect
54 Up coil error.
disconnected from coil. wire connection.
Malfuctioning coil OR wire Troubleshoot coil OR inspect
55 Down coil error.
disconnected from coil. wire connection.
Malfuctioning coil OR wire Troubleshoot coil OR inspect
56 Right coil error.
disconnected from coil. wire connection.
Malfuctioning coil OR wire Troubleshoot coil OR inspect
57 Left coil error.
disconnected from coil. wire connection.
Malfuctioning coil OR wire Troubleshoot coil OR inspect
58 Brake coil error.
disconnected from coil. wire connection.

68 Low Voltage. Batteries discharged. Charge batteries.

Notes

5-8 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

Chart 1
All Functions Turn keyswitch to Troubleshoot ground
platform control and light is on and platform control
Will Not Operate press and hold the systems separately OR
function enable switch. consult Genie Industries
Visually inspect the Service Department.
power-on LED.

light is not on
Be sure the circuit
breaker and fuse are less than Charge batteries OR
Check voltage on input
not tripped or blown. side of 275A (F1) fuse 24V check battery condition
and replace bad
inside battery module batteries OR check for
Be sure the batteries tray. short circuits OR check
are properly connected. battery cables OR check
for open in negative
Be sure the batteries battery cable from
24V or more batteries to ground point
are fully charged. on module tray.
Be sure both
Emergency Stop 0V
Check voltage on output Replace 275A fuse.
switches are pulled out side of 275A fuse inside
to the ON position. the battery module tray.

24V

Check continuity from B- no Repair open in negative


terminal on motor continuity battery cable from B-
controller to the negative terminal on Curtis motor
battery cable at the controller to Anderson
Anderson plug. plug.
full
continuity
Before serial number 0V Repair open in 24V
6901: Check voltage on supply cable from 275A
the input side of the fuse to Anderson plug
motor contactor (K1). OR
After serial number Before serial number
6900: check voltage on 6901: repair open in
terminal B+ on the motor 24V supply cable from
controller. Anderson plug to motor
contactor (K1).
After serial number
6900: repair open in
24V supply cable from
Anderson plug to
24V terminal B+ on the motor
controller.

Continued on the next


page.

Part No. 39528 Genie GS-1530 & Genie GS-1930 5-9


Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

CHART 1

Continued from the After serial number Before serial number


6901: Check voltage at 0V 6900:Repair open in wht
previous page. input side of 7A circuit wire from input side of
breaker F2. motor contactor to input
Before serial number side of 7A circuit
6900:(wire 24F- circuit breaker (24f-circuit
breaker to relay). breaker to relay).
After serial number
6901: repair open in
wire from motor
controller to 7A circuit
24V breaker.

Check voltage at wht Repair open in wht wire


wire at input side of 0V from output side of 7A
Emergency Stop Switch circuit breaker OR reset
S1. or replace 7A circuit
breaker.
24V

Check voltage at input 0V Repair open in wht wire


side of each contact at from Emergency Stop
the key switch S2. Switch to key switch OR
repair open in wht wire
jumper to each contact
OR replace contact on
Emergency Stop Switch
24V OR replace Emergency
Stop Switch.

Turn key switch to 0V Check cam on key bad Repair or replace key
ground control position switch. switch.
and check output side of
contact.
good

Replace contact OR
refer to Ground Controls
Inoperative, Chart 5 OR
consult Genie Industries
24V Service Department.

Continued on the next


page.

5 - 10 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

CHART 1

Continued from the Turn key switch to 0V Check cam on key bad Repair or replace key
platform control position switch. switch.
previous page. and check output side of
each contact.
good

Replace bad contact OR


refer to Platform
Controls Inoperative,
24V Chart 6 OR consult the
Genie Industries Service
Department.

Refer to Chart 2, Pump


Motor Will Not Operate
OR repair open in wht
wire (C2 estop chassis)
OR consult the Genie
Industries Service
Department.

Part No. 39528 Genie GS-1530 & Genie GS-1930 5 - 11


Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

Chart 2
Pump Motor Activate lift function from
24V or
more Check voltage on B+ less than Replace positive battery
the ground controls and terminal on motor 24V cable from pump to B+
Will Not Operate check voltage at positive controller. terminal on motor
terminal on pump motor. controller.
24V
no
Check continuity on continuity Replace ground cable
Be sure the circuit ground cable from pump on lift pump motor.
breaker and fuse are motor to M- terminal on
controller.
not tripped or blown.
continuity
Be sure the batteries
are properly connected. Check continuity from B- no Replace negative cable
terminal on controller to continuity from B- terminal on
Be sure the batteries the negative battery controller to the
are fully charged. cable at the Anderson Anderson plug.
plug (AP1).

continuity
less than
Activate lift function and 24V Before serial number
check voltage at 6900: Repair open in
terminal 1 on controller. wht wire (A8-motor)
from K 1 contact to
controller.
After serial number
6901: Repair open in
less than 24V 24V wht wire (A8-motor)
from ECU.

Activate lift function and Before serial number


0V 8931: Repair open in
check voltage at
terminal 3 on controller. wht wire (A9-mtr cont
terminal 3) from ECU to
controller OR replace
ECU OR consult Genie
Industries Service
Department.
After serial number
8932: Repair open in
5V wht wire (A9-mtr cont
terminal 3) OR
relpace1k ohm
potentiometer on
controller.

Activate lift function and 24V Replace controller or


check voltage at M- contact Genie Industries
terminal on controller. Service Department.

0V
Continued on the next
page. Replace pump motor
OR consult Genie
Industries Service
Department.

5 - 12 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

CHART 2

Activate lift function and 24V or Replace positive cable


Continued from the check voltage on the more from PR1 to Curtis
previous page. output side of PR1. controller OR replace
positive cable from
curtis controller to pump
motor.
less than 24V

Activate lift function and 24V or Activate lift function and Repair open in wht wire
check voltage on the more check voltage on the 0V (A8-motor) from ECM to
input side of K1. white wire on the coil of K1 OR replace ECM OR
K1. conult Genie Industries
Service Department.
24V
continuity
Check continuity on the Repair or replace K1.
brn ground wire on the
coil of K1 to the ground
point on the chassis.

0V no
continuity
Repair open in brn
ground wire from K1 to
the ground point on
chassis.

Check voltage on the 0V Replace 275A fuse OR


output side of the 275A replace positive cable
fuse. from 275A fuse to
battery switch OR
consult Genie Industries
Service Department.
24V

Replace positive battery


cables from output side
of 275A fuse to
Anderson plug (AP1)
OR replace positive
battery cables from
Anderson plug to K1 OR
Consult Genie Industries
Service Department.

Part No. 39528 Genie GS-1530 & Genie GS-1930 5 - 13


Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

Chart 3
All Functions Check hydraulic fluid low Fill with Dexron II
level. equivalent hydraulic
Inoperative, fluid.
Power Unit OK
Starts and Runs
Check for a positive no good Replace pump coupling
connection between OR replace pump OR
electric motor and replace motor.
pump by removing
Be sure, if the Error pump from motor,
Indicator light is on at leaving all hoses
the platform controls, connected. Visually
check coupling
you refer to the specific connection.
chart that relates to the
error code that is good
displayed on the ECM.
no good
Test the hydraulic pump. Replace the pump.
Be sure the circuit See Repair section.
breaker and fuse are
not tripped or blown. good

Be sure the batteries Consult the Genie


are properly connected. Industries Service
Department.
Be sure the batteries
are fully charged.

5 - 14 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

Chart 4
Ground With key switch in Repair open in wht wire
ground position and the jumper from the platform
Controls Emergency Stop buttons
0V
control contact to the
pulled out to the ON ground control contact
Inoperative, position at both the at the key switch (S2).
Platform ground and platform
controls, check voltage
Controls on the contact at the
input side of the key
Operate switch at the ground
controls (S2).
Normally
24V or more

Check voltage at output Check if key switch Replace key switch


Be sure, if the Error side of contact.
0V
internal cam is activating
yes
contact for ground
Indicator light is on at ground control contact. controls.
the platform controls,
you refer to the specific no
chart that relates to the 24V
error code that is Replace key switch.
displayed on the ECM.
Be sure the circuit
breaker and fuse are Check voltage at the Repair open in wht wire
center terminal of the 0V jumper from the key
not tripped or blown. platform up/down toggle switch to the center
switch (S3) at the terminal on toggle
Be sure the batteries ground controls. switch.
are properly connected.
24V
Be sure the batteries
are fully charged. Test or replace the
platform up/down toggle
switch S3 (See Repair
Section) OR repair open
in wht wire from the
toggle switch to the
ECM (B12-up switch)
OR repair open in wht
wire from the toggle
switch to the ECM (A12-
down switch) OR
consult the Genie
Industries Service
Department.

Part No. 39528 Genie GS-1530 & Genie GS-1930 5 - 15


Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

Chart 5
Platform Turn the key switch to Repair open in wht wire
platform control and jumper from the
Controls make sure both 0V Emergency Stop contact
Emergency Stop buttons to the platform control
Inoperative, are pulled out to the ON contact at the key switch
Ground position at both the (S2).
ground and platform
Controls controls. Check voltage
at the input side of the
Operate platform controls contact
on the key switch (S2).
Normally
24V or more

Check voltage at the Check if the key switch Replace the key switch
Be sure, if the Error output side of contact.
0V
internal cam is activating
yes
contact for platform
Indicator light is on at platform control contact. controls.
the platform controls,
you refer to the specific no
chart that relates to the 24V
error code that is Replace key switch.
displayed on the ECM.
Be sure the circuit
breaker and fuse are Check voltage at 0V Repair open in wht wire
terminal A11 at the (A11-key sw) from the
not tripped or blown. ECM. key switch to A11 at
ECM.
Be sure the batteries
are properly connected. 24V

Be sure the batteries Check voltage at


0V
Replace ECM.
are fully charged. terminal B2 at the ECM.

24V

Turn the key switch to 0V Replace control cable


platform controls and, from the ECM to the
Before serial number platform controls.
6091: check voltage at
terminal 4 on the main
circuit board at the
platform controls.
After serial number
6900: check voltage at
the input side of the
Emergency Stop button
(S9).

24V

Continued on the next


page.

5 - 16 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

CHART 5

Before serial number 0V Replace the main circuit


Continued from the 6091: Check voltage at board.
previous page. the input side of the
Emergency Stop switch
at the platform controls.

24V

Check voltage at output 0V Replace contact on


side of platform Emergency Stop switch
Emergency Stop switch. OR replace Emergency
Stop switch.
24V

Check voltage at Before serial number


terminal 5 on the main 0V 6091: replace the main
circuit board at the circuit board.
platform controls. After serial number
6900: repair open in the
wire from terminal 22 to
terminal 5 on the main
24V control board.

Check voltage at 0V Replace control cable


terminal A4 at the ECM. from the ECM to the
platform controls.
24V

Replace the ECM OR


consult the Genie
Industries Service
Department.

Part No. 39528 Genie GS-1530 & Genie GS-1930 5 - 17


Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

Chart 6
Platform Up With the key switch in Connect the positive Repair open in the wht
platform position and lead from a volt meter to wire (A6-up coil) from
Function both Emergency Stop the coil on the platform the platform up
buttons pulled out to the up directional valve directional valve coil to
Inoperative ON position and the lift/ light is (item G) wire terminal
0V
the ECM (see Repair
drive selector switch in on without disconnecting Section) OR replace
the lift position, activate the wire and the ECM OR consult the
the controller in the UP negative lead of the volt Genie Industries Service
Be sure all other direction and check to meter to the ground Department.
functions operate see if the error indicator point on the manifold.
light at the platform Activate the controller in
normally. controls is on. the UP direction and
check the voltage.
Be sure the circuit
breaker and fuse are 24V
not tripped or blown. 0 or
infinite
Disconnect the wire ohms Replace the platform up
Be sure the batteries from the platform up directional valve coil
are properly connected. directional valve coil on (item G).
the function manifold
(item G) and check the
Be sure the batteries resistance. See Repair
are fully charged. Section.
light is not on
18-20 ohms

Repair or replace the


platform up directional
valve cartridge (item G)
OR consult the Genie
Industries Service
Department.

Install a 0 to 3500 PSI 3000 Check for mechanical


pressure gauge at the PSI or restrictions keeping
quick disconnect more platform up function
coupling on the function from moving OR repair
manifold and activate or replace platform lift
the platform up function. cylinder OR consult the
Genie Industries Service
Department.
less than
3000 PSI

Adjust the relief valve


OR repair or replace the
platform lift cylinder OR
the platform lowering
valve may be stuck
open OR the function
manifold could have an
internal defect. Consult
the Genie Industries
Service Department.

5 - 18 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

Chart 7
Platform Down With the key switch in With the platform raised Repair open in the wht
the platform position and and the safety arm wire (B6-down coil) from
Function the platform raised installed, connect the the platform lowering
slightly and the leads of a volt meter to valve coil (item R) to the
Inoperative Emergency Stop buttons the wires on the platform ECM OR repair open in
pulled out to the ON light is lowering coil on the 0V the brown ground wire
position at both the on cylinder without circuit from the coil to
ground and platform removing the wires. With the battery module tray
Be sure all other controls and the lift/drive the key switch in the OR replace the ECM
functions operate switch in the lift position, platform position and the OR consult the Genie
activate the controller in lift/drive toggle switch in Industries Service
normally. the DOWN direction and the lift position, activate Department.
check to see if the error the controller in the
Be sure the circuit indicator light is on. DOWN direction and
breaker and fuse are check the voltage.
not tripped or blown.
24V
Be sure the batteries 0 or
are properly connected. Label and disconnect infinite
the wires from the coil ohms Replace platform
on the platform lowering lowering valve coil
Be sure the batteries valve (item R) at the (item R).
are fully charged. platform lift cylinder and
check the resistance
(See Repair Section).
23 to 25
ohms
With the platform raised platform
Repair or replace the
and the safety arm lowers platform lowering valve
removed, pull the cartridge (item R).
manual platform
lowering handle at the
light is not on ground controls.
platform does
not lower
Check for mechanical
restrictions keeping the
platform from lowering
OR repair or replace the
platform lowering valve
cartridge (item R) OR
repair or replace the lift
cylinder OR consult the
Genie Industries Service
Department.

Continued on the next


page.

Part No. 39528 Genie GS-1530 & Genie GS-1930 5 - 19


Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

CHART 7

switch
Label and disconnect bad Replace the lift/drive
Continued from the
the wires from the lift/ toggle switch.
previous page.
drive toggle switch at
the platform controls
and troubleshoot the
toggle switch (see
Repair Section).

good

Replace the platform


controls OR replace the
ECM OR consult the
Genie Industries Service
Department.

5 - 20 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

Chart 8
Steer Left With the key switch in Connect the positive Repair open in the wht
platform position and lead from a volt meter to wire (B7-left coil) from
Function both Emergency Stop the steer left directional the coil on the steer left
buttons pulled out to the light is valve coil (item F) wire directional valve (item F)
Inoperative ON position, activate the on terminal without to the ECM OR repair
steer rocker switch in disconnecting the wire, 0V open in the brown
the LEFT direction and and the negative lead of ground wire circuit from
check to see if the error the volt meter to the the manifold to the
Be sure all other indicator light at the brown ground wire on battery module tray OR
functions operate platform controls is on. the manifold. Activate replace the ECM OR
the steer rocker switch consult the Genie
normally. in the LEFT direction and Industries Service
check the voltage. Department.
Be sure the circuit
breaker and fuse are 24V
not tripped or blown.
0 or
Disconnect the wires infinite
Be sure the batteries from the coil on the ohms
are properly connected. steer left directional Replace the coil.
valve on the function
manifold (item F) and
Be sure the batteries check the resistance of
are fully charged. the valve coil (See
light is not on Repair Section).

26 to 28
ohms Repair or replace the
steer directional valve
cartridge (item F) OR
consult the Genie
Industries Service
Department.

Activate the steer left no Check continuity of the bad Replace the steer left/
function. Does the motor steer microswitch. right micro switch inside
turn on? the drive controller
handle.
good

Check for wire continuity


from the steer
yes microswitch to the
terminal strip OR
replace the main circuit
board at the platform
controls.

Continued on the next


page.

Part No. 39528 Genie GS-1530 & Genie GS-1930 5 - 21


Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

CHART 8

Install a 0 to 2000 psi Check for mechanical


Continued from the pressure gauge at the 1200 restrictions keeping the
previous page. quick disconnect psi steer left function from
coupling on the function moving OR repair or
manifold and activate replace the steer
the steer left function. cylinder OR consult the
Genie Industries Service
Department.
less than
1200 psi

Reset the steer relief


valve pressure (item C)
on the function manifold
to 1200 psi OR replace
the relief valve.

1200 psi

Repair or replace the


steer cylinder OR
replace the steer left/
right valve cartridge OR
the function manifold
could have an internal
defect. Consult the
Genie Industries Service
Department.

5 - 22 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

Chart 9
Steer Right With the key switch in Connect the positive Repair open in the wht
platform position and lead from a volt meter to wire (wire C7-rt coil)
Function both Emergency Stop the steer right directional from the steer right
buttons pulled out to the light is valve coil (item F) wire directional valve coil
Inoperative ON position, activate the on terminal without (item F) to the ECM OR
steer rocker switch in disconnecting the wire, 0V repair open in brown
the LEFT direction and and the negative lead of ground wire circuit from
check to see if the error the volt meter to the the manifold to the
Be sure all other indicator light at the brown ground wire on battery module tray OR
functions operate platform controls is on. the the function replace the ECM OR
manifold. Activate the consult the Genie
normally. steer rocker switch in Industries Service
the RIGHT direction and Department.
Be sure the circuit check the voltage.
breaker and fuse are
not tripped or blown. 24V
0 or
Be sure the batteries Disconnect the wires infinite
are properly connected. from the steer right ohms
directional valve coil on Replace the coil.
the function manifold
Be sure the batteries (item F) and check the
are fully charged. resistance of the valve
light is not on
coil. See Repair Section.

26 to 28
ohms Repair or replace the
steer directional valve
(item F) OR consult the
Genie Industries Service
Department.

Activate the steer right no Check continuity of the bad Replace the steer left/
function. Does the motor steer microswitch. right micro switch inside
turn on? the drive controller
handle.
good

Check for wire continuity


from the steer
microswitch to the main
circuit board OR replace
main circuit board at the
yes platform controls.

Continued on the next


page.

Part No. 39528 Genie GS-1530 & Genie GS-1930 5 - 23


Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

CHART 9

Install a 0 to 2000 psi Check for mechanical


Continued from the pressure gauge at the 1200 restrictions keeping the
previous page. quick disconnect psi steer right function from
coupling on the function moving OR repair or
manifold and activate replace the steer
the steer right function. cylinder OR consult the
Genie Industries Service
Department.
less than
1200 psi

Repair or replace the


steer cylinder OR
replace the steer left/
right valve cartridge OR
the function manifold
could have an internal
defect. Consult the
Genie Industries Service
Department.

5 - 24 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

Chart 10
All Drive error
indicator
With the key switch in Reset the ECM by Refer to the chart(s) that
Functions platform position and the pushing in the platform light is are related to the error
Emergency Stop buttons Emergency Stop button on code that is displayed
Inoperative, All pulled out to the ON to the OFF position, on the ECM OR consult
position at both the light is switch the lift/drive the Genie Industries
Other Functions ground and platform flashing selector switch to the Service Department.
controls, activate drive drive position and pull
Operate forward and drive the Emergency Stop
reverse functions. button up to the ON
Normally Check to see if the position. Check the
green indicator light is lights at the platform
flashing at the platform controls.
controls.
Be sure, if the Error
green light is
Indicator light is on at flashing
the platform controls,
you refer to the specific Test the lift/drive toggle bad Replace lift/drive toggle
chart that relates to the switch S7 (see Repair switch.
Section). Is switch
error code that is good?
displayed on the ECM.
light is not good
Be sure the circuit flashing
breaker and fuse are Replace the main circuit
not tripped or blown. board OR replace the
ECM OR Consult the
Be sure the batteries Genie Industries Service
Department.
are properly connected.

Be sure the batteries


are fully charged.
Is the error indicator yes Refer to chart(s) that are
light on at the platform related to the error code
controls? that is displayed on the
ECM OR consult the
Genie Industries Service
Department.
no

Does the power unit no Replace the joystick


run? controller OR replace
the main circuit board
OR replace the ECM
OR consult the Genie
Industries Service
Department.
yes

Continued on the next


page.

Part No. 39528 Genie GS-1530 & Genie GS-1930 5 - 25


Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

CHART 10

See Chart 3. Is the no Replace or repair


Continued from the coupler between the coupler, motor, and/or
previous page.
motor and pump in good pump.
condition?

yes
3000 psi
Chock both sides of the or more See Chart 10A, Brake
front drive wheels. Release Function
Connect a 0 to 5000 psi Inoperative.
(0 to 345 bar) pressure
gauge to the test port on
the function manifold
and drive the machine in
either the forward or
reverse direction.

less than
3000 psi

Repair or replace the


drive forward/reverse
valve cartridge OR
rebuild or replace the
drive motors OR the
manifold may have an
internal defect. Consult
the Genie Industries
Service Department.

5 - 26 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

Chart 10A
Brake Release Chock the wheels at the wheels Turn the brake release wheels Rebuild or replace the
steer end. Jack the non turn valve (item N) clockwise turn brakes OR replace the
Function steer end of the all the way and try to brake release valve
Inoperative machine up rotate the wheels. (item N) OR consult the
approximately 4 inches Genie Industries Service
(10 cm) and place jack Department.
stands under the
machine for support.
Be sure, if the Error Turn the brake release
Indicator light is on at knob (item N)
counterclockwise all the
the platform controls, way and pump the hand wheels
you refer to the specific pump fully 13-15 times do not
chart that relates to the or until much resistance turn
is felt. Turn each wheel
error code that is by hand. Each wheel
displayed on the ECM. should turn freely
without much effort.
Be sure the circuit
breaker and fuse are
not tripped or blown.
Attempt to drive the If machine still does not
Be sure the batteries machine in either wheels drive at full speed with
direction and have an turn the platform in the
are properly connected. assistant try to rotate the stowed position, replace
non steer wheels. This the joystick controller
Be sure the batteries will require 2 people. OR replace the main
are fully charged. circuit board at the
wheels platform controls OR
do not replace the ECM OR
turn consult the Genie
wheels Industries Service
do not Department.
turn

Plumb a 0 to 500 psi 200 to Pressure is good.


(34.5 bar) gauge into the 300 psi Replace the brakes OR
hose from the function consult the Genie
manifold to the brake. Industries Service
Attempt to drive the Department.
machine in either
direction and read the
pressure on the gauge.
less
than
200 psi
Replace the shuttle
valve (item O) OR the
0.025" orifice (item E)
may be plugged OR
replace the brake
release valve (item N)
OR the function
manifold or brake
release manifold may
have an internal defect
OR consult the Genie
Industries Service
Department.

Part No. 39528 Genie GS-1530 & Genie GS-1930 5 - 27


Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

Chart 11
Drive Forward With the key switch in Connect the positive Repair open in the wht
platform position and the lead from a volt meter to wire (C6-forward coil)
Function Emergency Stop buttons the drive forward from the drive forward
pulled out to the ON directional valve coil directional valve coil to
Inoperative position at both the light is (item J) wire terminal the ECM OR repair
0V
ground and platform on without disconnecting open in the brown
controls, activate drive the wire, and the ground wire circuit from
controller in the forward negative lead of the volt the manifold to the
Be sure all other direction and check to meter to the brown battery module tray OR
functions operate see if the error indicator ground wire on the replace the ECM OR
light at the platform manifold. Activate drive consult the Genie
normally. controls is on. in the forward direction Industries Service
and check the voltage. Department.
Be sure the circuit
breaker and fuse are 24V
not tripped or blown.
0 or
Disconnect the wires infinite Replace the drive
Be sure the batteries from the drive forward ohms forward directional valve
are properly connected. light is not on directional valve coil coil (item J).
(item J) and check the
resistance. See Repair
Be sure the batteries Section.
are fully charged.

Replace the drive


forward/reverse valve
cartridge (item J) OR 18 to 20
consult the Genie ohms
Industries Service
Department.

Repair or replace the


drive forward directional
valve (item J) OR
consult the Genie
Industries Service
Department.

5 - 28 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

Chart 12
Drive Reverse With the key switch in Connect the positive Repair open in the wht
platform position and the lead from a volt meter to wire from the drive
Function Emergency Stop buttons the drive reverse reverse directional valve
pulled out to the ON directional valve coil coil (A7-reverse coil) to
Inoperative position at both the light is (item J) wire terminal the ECM OR repair
ground and platform on without disconnecting 0V open in the brown
controls, activate the the wire, and the ground wire circuit from
drive controller in the negative lead of the volt the manifold to the
Be sure all other reverse direction and meter to the brown battery module tray OR
functions operate check to see if the error ground wire on the replace the ECM OR
indicator light at the function manifold. consult the Genie
normally. platform controls is on. Activate drive in the Industries Service
reverse direction and Department.
Be sure the circuit check the voltage.
breaker and fuse are
not tripped or blown. 24V
0 or
Be sure the batteries Disconnect the wires infinite Replace the drive
are properly connected. light is not from the drive reverse ohms reverse directional valve
on directional valve coil coil (item J).
(item J) and check the
Be sure the batteries resistance. See Repair
are fully charged. Section.

Replace the drive


forward/reverse valve
cartridge (item J) OR 18 to 20
consult the Genie ohms
Industries Service
Department.

Repair or replace the


drive reverse directional
valve (item J) OR
consult the Genie
Industries Service
Department.

Part No. 39528 Genie GS-1530 & Genie GS-1930 5 - 29


Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

Chart 13
Machine Will With the key switch in Raise the platform Raise the platform more
platform position and the light is approximately 3 feet than 6 feet (1.8 m) and
Not Drive At Emergency Stop buttons not on (0.9 m) and drive yes drive the machine. If the
pulled out to the ON machine. Does the machine does not drive
Full Speed position at both the machine drive at a and an alarm sounds,
ground and platform reduced speed? the machine is operating
controls, and the normally. Check the
platform in the stowed pothole guards for
no
Be sure the circuit position, drive the obstructions OR test the
machine in either pothole guard limit
breaker and fuse are direction. Is the error Consult the Genie switches (see Repair
not tripped or blown. indicator light on at the Industries Service section).
platform controls? Department.
Be sure the batteries
light
are properly connected. is on
Be sure the batteries Check voltage at the wht 0V Repair open in the wht
are fully charged. wire (39C-pothole sw) at wire (39C-pothole sw)
S5. from S5 to the multi-
function alarm to the key
switch.
24V

Raise the platform Adjust the limit switch


approximately 3 feet 0V S5 so the pothole arm
(0.9 m) and check the activates the switch OR
voltage at the output replace the limit switch
side of S5. contact OR replace the
limit switch S5.
24V

Check voltage at the wht 0V Repair open in the wht


wire (21B-pothole sw)on wire jumper (21B-
the input side of S6. pothole jumper) from the
output side of S5 to the
input side of S6.
24V

Check voltage on the 0V Adjust limit switch S6 so


output side of S6. the pothole arm
activates the switch OR
replace the limit switch
contact OR replace the
limit switch S6.

24V

Continued on the next


page.

5 - 30 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

CHART 13

Repair open in the wht


Continued from the wire (B10-pothole
previous page. switch) from the output
side of S6 to the ECM
OR replace the ECM.

Chock both sides of the Reset the relief valve


front drive wheels. less pressure OR replace the
Install a 0 to 5000 psi than relief valve OR rebuild
(0 to 345 bar) pressure 3000 psi or replace the drive
gauge to the test port on motors OR the function
the function manifold manifold may have an
and drive the machine in internal defect. Consult
either the forward or the Genie Industries
reverse direction. Service Department.
more
than
3000 psi
one or
Chock the wheels at the both
non steer end. Jack the wheels
steer end of machine up do not Repair or replace drive
approximately 4 inches turn
(10 cm) and place jack motor(s) OR consult the
stands under the Genie Industries Service
machine for support. Department.
With the lift/drive
selector switch in the
drive position, move the
joystick controller to the
full speed forward or
reverse position.
both
wheels
turn
See Chart 10A, Brake
Release Function
Inoperative.

Part No. 39528 Genie GS-1530 & Genie GS-1930 5 - 31


Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

Chart 14
Machine With the key switch in light is
Consult the Genie
platform position and the not on
Drives At Emergency Stop buttons
Industries Service
Department.
pulled out to the ON
Full Speed position at both the
With Platform ground and platform
controls, and the
Raised platform in the stowed
position, drive the
machine in either
direction. Is the error
indicator light on at the
Be sure the circuit platform controls?
breaker and fuse
light
are not tripped or is on
blown.
See Chart 13 OR
Be sure the remove the obstruction
from the pothole guard
batteries are OR consult the Genie
properly connected. Industries Service
Department.
Be sure the
batteries are fully
charged.

5 - 32 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 6 - Schematics

Schematics
About This Section
There are two groups of schematics in this section.
An illustration legend precedes each group of
drawings.

Electrical Schematics

Observe and Obey: Electrocution hazard. Contact with


electrically charged circuits may
Troubleshooting and repair procedures shall be result in death or serious injury.
completed by a person trained and qualified on Remove all rings, watches and
the repair of this machine. other jewelry.
Immediately tag and remove from service a Hydraulic Schematics
damaged or malfunctioning machine.
Bodily injury hazard. Spraying
Repair any machine damage or malfunction hydraulic oil can penetrate and
before operating the machine. burn skin. Loosen hydraulic
connections very slowly to allow
Before Troubleshooting: the oil pressure to dissipate
Read, understand and obey the safety rules gradually. Do not allow oil to squirt
and operating instructions printed in the or spray.
Genie GS-1530 & Genie GS-1930 Operator's General Repair Process
Manual.
Be sure that all necessary tools and test
Malfunction Identify Troubleshoot
equipment are available and ready for use. discovered symptoms

problem
still exists

Return to Inspect Perform


service problem and test repair
solved

Part No. 39528 Genie GS-1530 & Genie GS-1930 6-1


Section 6 - Schematics Service Manual - First Edition

Electrical Components

Item Description Genie Part Manufacturer Manufacturer Qty


Part Number Part Number
AP1 ................ Anderson connector ............ 19436 ............. Anderson ............................. 6325-G1 ......................... 2

B1 ................... Alarm, steady tone .............. 39540 ............. Floyd Bell Inc. ...................... UC-09628-Q .................. 1

B2 ................... Alarm, intermittent ............... 18963 ............. Floyd Bell Inc. ...................... XB-09-630-Q .................. 1

F1 ................... Fuse, 275 amp .................... 13104 ............. Buss ..................................... ANN-275 ........................ 1

F2 ................... Circuit breaker ..................... 47811 ............. ETA ...................................... 45-700-IG1-P10 ............. 2

FB1 ................ Flashing beacon .................. 39676 ............. ECCO Electronic Controls ... 6220A ............................. 2

G1 .................. Battery, 255AH, 6V DC ....... 46265 ............. Dyno Battery Co. ................. GC2B, dry ...................... 8

H1 .................. Hour meter ........................... 19506 ............. ENM Corporation ................. T40A4508 ...................... 1

K1 ................... Relay, 180 amp ................... 19550 ............. Curtis Instruments ............... 13220544 ....................... 1

P2 ................... Level sensor, Dual Axis ....... 40836 ............. Power Comp. of Midwest .... L36 ................................. 1

R1 .................. Resistor, 75 Ohm ................ 51590 ............. Dale ..................................... RS-10-38, 75 Ohm ........ 1

S1 ................... Contact, N.C. ....................... 29732 ............. Telemecanique .................... ZB2-BE102 .................... 1

S2 ................... Contact - key switch, N.O. .. 45081 ............. Telemecanique .................... ZB2-BE101 .................... 1

S3 ................... Toggle switch, SPDT


3 position momentary .......... 13037 ............. Microswitch Control Inc. ...... 1NT1-7 ........................... 1

S4, S5, S6 ...... Contact - limit switch,


N.C.H.O. .............................. 19491 ............. Telemecanique .................... XESP2051 ..................... 3

S7 ................... Toggle switch, DPDT


2 position maintained .......... 44987 ............. ITT Schadow. ...................... 220536 ........................... 1

S9 ................... Contact, N.C. ....................... 44990 ............. Telemecanique .................... ZA2-BZ1026 ................... 1

S10 ................. Contact, N.O. ....................... 44989 ............. Telemecanique .................... ZA2-BZ1016 ................... 1

U2 .................. Motor controller,


48V, 275 amp ...................... 39472 ............. Curtis Instruments ............... 1204-036 ........................ 1

Y2, Y3, Y4 ...... Coil, 20V DC with diode ....... 39347 ............. Hydra Power Systems ......... 6309757 ......................... 3

Y5, Y6, Y8 ...... Coil, 20V DC with diode ....... 44176 ............. Hydra Power Systems ......... 6359752 ......................... 3

Y7 ................... Coil, 20V DC ........................ 44787 ............. Hydra Power Systems ......... 10166-25 ........................ 1

6-2 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 6 - Schematics

Module Tray Legend

Module Tray
Legend
(models before
serial number
6901)

Module Tray
Legend
(models after
serial number
6900)

Part No. 39528 Genie GS-1530 & Genie GS-1930 6-3


Section 6 - Schematics Service Manual - First Edition

Electrical Symbols Legend

6-4 Genie GS-1530 & Genie GS-1930 Part No. 39528


Section 6 - Schematics Service Manual

Electrical Schematic
(models before serial number 6901)
A B C D E F G H I J K L M N

6-5 Genie GS-1530 & GS-1930 Part No. 39528


Service Manual Section 6 - Schematics

Electrical Schematic
(models before serial number 6901)
N M L K J I H G F E D C B A

Part No. 39528 Genie GS-1530 & GS-1930 6-6


Service Manual Section 6 - Schematics

Electrical Schematic
(models before serial number 6901)
Section 6 - Schematics Service Manual

Electrical Schematic
(models from serial number 6901 to 8931)
A B C D E F G H I J K L M N

6-7 Genie GS-1530 & GS-1930 Part No. 39528


Service Manual Section 6 - Schematics

Electrical Schematic
(models from serial number 6901 to 8931)
N M L K J I H G F E D C B A

Part No. 39528 Genie GS-1530 & GS-1930 6-8


Service Manual Section 6 - Schematics

Electrical Schematic
(models from serial number 6901 to 8931)
Section 6 - Schematics Service Manual

Electrical Schematic
(models after serial number 8931)
A B C D E F G H I J K L M N

6-9 Genie GS-1530 & GS-1930 Part No. 39528


Service Manual Section 6 - Schematics

Electrical Schematic
(models after serial number 8931)
N M L K J I H G F E D C B A

Part No. 39528 Genie GS-1530 & GS-1930 6 - 10


Service Manual Section 6 - Schematics

Electrical Schematic
(models after serial number 8931)
Service Manual - First Edition Section 6 - Schematics

Ground Controls and Level Sensor Box Legend

Part No. 39528 Genie GS-1530 & Genie GS-1930 6 - 11


Section 6 - Schematics Service Manual - First Edition

Platform Controls Legend


(models before serial number 17408)

6 - 12 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 6 - Schematics

Platform Controls Legend


(models after serial number 17407)

Part No. 39528 Genie GS-1530 & Genie GS-1930 6 - 13


Section 6 - Schematics Service Manual - First Edition

Hydraulic Symbols Legend

6 - 14 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual Section 6 - Schematics

Hydraulic Schematic

N M L K J I H G F E D C B A

Part No. 39528 Genie GS-1530 & GS-1930 6 - 15


Service Manual Section 6 - Schematics

Hydraulic Schematic
Service Manual - First Edition Section 7 - Repair Procedures

Repair Procedures
About This Section
Most of the procedures in this section should only
be performed by a trained service professional
in a suitably equipped workshop. Select the
appropriate repair procedure after troubleshooting
the problem.

Observe and Obey: Perform disassembly procedures to the point


where repairs can be completed. Then to
Repair procedures shall be completed by a re-assemble, perform the disassembly steps in
person trained and qualified on the repair of reverse order.
this machine.
Symbols Legend
Immediately tag and remove from service a
damaged or malfunctioning machine. Safety alert symbol—used to alert
personnel to potential personal
Repair any machine damage or malfunction injury hazards. Obey all safety
before operating the machine. messages that follow this symbol
to avoid possible injury or death.
Before Repairs Start:
Red—used to indicate the
Read, understand and obey the safety rules presence of an imminently
and operating instructions in the Genie hazardous situation which, if not
GS-1530 & Genie GS-1930 Operator's Manual. avoided, will result in death or
serious injury.
Be sure that all necessary tools and parts are
available and ready for use. Orange—used to indicate the
presence of a potentially
Read each procedure completely and adhere to
hazardous situation which, if not
the instructions. Attempting shortcuts may
avoided, could result in death or
produce hazardous conditions.
serious injury.
Unless otherwise specified, perform each repair
Yellow with safety alert symbol—
procedure with the machine in the following
used to indicate the presence of a
configuration:
potentially hazardous situation
· Machine parked on a flat level surface which, if not avoided, may cause
minor or moderate injury.
· Platform in the stowed position
Yellow without safety alert
· Key switch in the OFF position with the key symbol—used to indicate the
removed presence of a potentially
· Wheels chocked hazardous situation which, if not
avoided, may result in property
damage.
Green—used to indicate operation
or maintenance information.
Indicates that a specific result is expected after
performing a series of steps.

Part No. 39528 Genie GS-1530 & Genie GS-1930 7-1


Section 7 - Repair Procedures Service Manual - First Edition

Platform Controls
1-1
Platform Controller
The platform controller is controlled by an ECM
(Electronic Control Module) located in the battery
pack module tray. It is a fully self-contained unit
which is capable of recognizing machine
malfunctions with on-board diagnostics and
displays a fault code on a digital display on the
ECM. This aids in troubleshooting the machine by
pinpointing the fault or malfunction. See the
Troubleshooting section of this manual for a list of
fault codes and additional information. The ECM is
not user-serviceable. For further information or
assistance, consult the Genie Industries Service
Department.

Platform Controller Platform Controller


(before serial number 17408) (after serial number 17407)

a b

e d

f
a Main circuit board a Main circuit board
b Lift/drive selector toggle switch b Emergency stop button
c Horn button c Joystick controller
d Emergency stop button d Alarm
e LED circuit board
f Joystick controller

7-2 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 7 - Repair Procedures

PLATFORM CONTROLS

1-2 How to Determine the Revision


Software Configuration Level
1 Remove the platform controls from the
The ECM (Electronic Control Module) contains
platform.
programming for all configurations of the GS-1530
and GS-1930. The platform controls can be 2 Turn the key switch to platform control and pull
adjusted to a different configuration by changing the out the Emergency Stop buttons to the ON
combination of the DIP switch settings. The DIP position at both the ground and platform
switch is located on the circuit board inside the controls.
platform control box.
DIP switches have two positions - ON or OFF. When 3 Press and hold the lift enable button and the
reading the DIP switch code in the DIP Switch function enable switch. Move the joystick
Code Chart, the ON and OFF are represented by the handle to the UP position to raise the platform.
numbers 1 (ON) and 0 (OFF). Observe the code shown in the LED display
window, located on the battery pack side of the
Select a test area that is firm, level machine.
and free of obstructions.
Result: The configuration code of the DIP
Models before serial number 17408 switch will appear in the LED display window.
were not adjustable when they
4 Press and hold the lift enable button and the
were shipped from the factory. If
function enable switch. Move the joystick
the ECM (Electronic Control
handle to the DOWN position to lower the
Module) has been updated to
platform. Observe the code shown in the LED
revision "b0" or later, or if the
display window, located on the battery pack
model's serial number is after
side of the machine.
17407, you can access the
revision level of the ECM by using Result: The software revision level will appear
the following procedure: in the LED display window. If revision level "b0"
appears in the display window, the procedure
under How to Set the DIP Switch Codes on the
next page will apply. If revision level "A" is
displayed, the procedure will not apply.
5 Push in the Emergency Stop button to the OFF
position at both the ground and platform
controls and turn the key switch to the OFF
position.

Part No. 39528 Genie GS-1530 & Genie GS-1930 7-3


Section 7 - Repair Procedures Service Manual - First Edition

PLATFORM CONTROLS

How to Set the DIP Switch Codes 4 Open the controller box lid and locate the DIP
switch on the circuit board. Move the DIP
Tip-over hazard. Do not adjust the switch settings to correspond with the
DIP switch settings to other than configuration of the machine options, indicated
what is specified in this procedure. in the DIP Switch Code Chart.
Exceeding specifications will
cause death or serious injury. a

If replacing the circuit board, note b


the toggle positions on the DIP
switch. Set the DIP switch on the c
new circuit board to the same d
configuration of the old one.
e
1 Push in the Emergency Stop button to the OFF
position at the ground and platform controls. f
Turn the key switch to the OFF position.
2 Remove the fasteners securing the top of the
controller to the controller case.
3 Rotate the platform controller box in the
position shown to correctly identify the
configuration of the DIP switch settings.
a DIP switch
b Emergency stop button
c Circuit boards
d Joystick controller
e Controller box
f Enlarged view of DIP switch

5 Close the lid and install the fasteners.


6 Confirm the settings. See 1-2, How to
Determine the Revision Level.
7 Push in the Emergency Stop button to the OFF
position at both the ground and platform
controls and turn the key switch to the OFF
position.
Any change in DIP settings will
not take effect until the key switch
is turned to the OFF position.

7-4 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 7 - Repair Procedures

PLATFORM CONTROLS

DIP Switch Code Chart DIP Switch Function Definitions


A mark in the column indicates that the machine Motion Beacon: The motion beacon option flashes
configuration includes this option. only when operating a function.

Motion Alarm: The motion alarm will beep when

Lift Drive Cut Out

Overload Cutout
operating any function.
Motion Beacon

Descent Delay
Motion Alarm
Diagnostic Dip Switch Lift/Drive Cut Out: This cuts out lift and drive
Display Code Code functions when the machine goes out of level.
Required for Europe and Australia.

Overload: This cuts out lift when the cylinder is


00 00000000 overloaded. Required for France.
01 00000100 •
02 00001000 • Descent Delay: This option halts descent for 4
03 00010000 • seconds at approximately 6 feet (2 m). Required for
04 00100000 • Europe.
05 01000000 •
06 00001100 • •
07 00010100 • •
08 00100100 • •
09 01000100 • •
10 00011100 • • •
11 00101100 • • •
12 01001100 • • •
13 00110100 • • •
14 01010100 • • •
15 01100100 • • •
16 00111100 • • • •
17 01011100 • • • •
18 01101100 • • • •
19 01110100 • • • •
20 01111100 • • • • •
21 00011000 • •
22 00101000 • •
23 01001000 • •
24 00111000 • • •
25 01011000 • • •
26 01101000 • • •
27 01111000 • • • •
28 00110000 • •
29 01010000 • •
30 01110000 • • •
31 01100000 • •

Part No. 39528 Genie GS-1530 & Genie GS-1930 7-5


Section 7 - Repair Procedures Service Manual - First Edition

PLATFORM CONTROLS

1-3 Test Desired result


Toggle Switches Left position

Toggle switches used for single function switching terminal 1 to 2, 3, 4, 5 & 6 no continuity
are single pole double throw (SPDT) switches. Dual (infinite W)
function switching requires a double pole double terminal 2 to 3 continuity
throw (DPDT) switch. (zero W)

How to Test a Toggle Switch terminal 2 to 4, 5 & 6 no continuity

Continuity is the equivalent of 0 to terminal 3 to 4, 5 & 6 no continuity


3 ohms. A simple continuity tester terminal 4 to 5 & 6 no continuity
may not accurately test the switch.
terminal 5 to 6 continuity
This procedure covers fundamental switch testing
and does not specifically apply to all varieties of Center position There are no terminal
toggle switches. combinations that will produce
continuity (infinite W)
1 Turn the key switch to the OFF position. Tag
and disconnect all wiring from the toggle switch Right position
to be tested.
terminal 1 to 2 continuity
The toggle switch at the platform (zero Ω)
controls requires that the wires are
terminal 1 to 3, 4, 5 & 6 no continuity
unplugged from the main circuit (infinite Ω)
board before testing.
terminal 2 to 3, 4, 5 & 6 no continuity
2 Connect the leads of an ohmmeter to the switch
terminals in the following combinations listed terminal 3 to 4, 5 & 6 no continuity
below to check for continuity.
terminal 4 to 5 continuity

terminal 4 to 6 no continuity
Left Center Right
terminal 5 to 6 no continuity

1 3 1 3 1 3
2 2 2

Single pole
double throw
1 2 3 1 2 3 1 2 3
(SPDT)
4 5 6 4 5 6 4 5 6

Double pole
double throw
(DPDT)
1 2 3 1 2 3 1 2 3

7-6 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 7 - Repair Procedures

This page intentionally left blank.

Part No. 39528 Genie GS-1530 & Genie GS-1930 7-7


Section 7 - Repair Procedures Service Manual - First Edition

Platform Components
2-1 11 Lift the steer end of the platform slightly to clear
the scissor arms and slide the platform towards
Platform the non-steer end of the machine until the non-
steer end platform pivot pins are visible through
How to Remove the Platform the access holes in the side of the platform.

Perform this procedure with the 12 Remove the retaining fasteners from the scissor
platform extension fully retracted platform pivot pins at the non-steer end of the
and locked in position. machine.

1 Lower the platform to the stowed position. 13 Use a slide hammer to remove the pins.

2 Remove the retaining fastener that holds the Crushing hazard. The platform will
platform controls quick disconnect plug to the fall if it is not properly supported.
bottom of the platform. 14 Carefully lift the platform off of the machine and
3 Twist to disconnect the plug from the platform place it on a structure capable of supporting it.
controls. Note the position of the wear pads
4 Remove the cover to the 110V AC outlet. Label before the platform is removed so
and disconnect the wiring from the outlet. when the platform is installed they
will be in the correct position.
Electrocution hazard. Contact with
electrically charged circuits may
result in death or serious injury.
Remove all rings, watches and
other jewelry.
5 Pull the wiring through the platform tube.
If your machine is equipped with
an air line to platform option, the
air line must be disconnected from
the platform before removal.
6 Support the platform with a forklift at the
non-steer end. Do not lift it.
7 Attach a strap from the platform railings to the
carriage on the forklift to help support the
platform.
8 Remove the retaining fasteners from the
scissor platform pivot pins at the steer end of
the machine.
9 Use a slide hammer to remove the pins.
Crushing hazard. The platform will
fall if it is not properly supported.
10 Remove the plugs from the access holes in the
side of the platform.

7-8 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 7 - Repair Procedures

PLATFORM COMPONENTS

2-2
Platform Extension

How to Remove the


Platform Extension
1 Lower the platform to the stowed position.
2 Extend the platform approximately 3 feet (1 m).
3 Remove the platform controls from the platform
and lay them off to the side of the machine.
4 Support the platform extension with a forklift at
the steer end. Do not lift it.
5 Attach a strap from the platform extension
railings to the carriage on the forklift to help
support the platform extension.
6 Remove the mounting fasteners from all four of
the platform extension roller supports.
7 Remove the roller supports and the roller
wheels.
8 Carefully slide the platform extension out from
the platform and place it on a structure capable
of supporting it.

How to Replace the Platform


Extension Wear Pads
1 Remove the Platform Extension. See 2-2, How
to Remove the Platform Extension.
2 Drill out the rivets which hold the wear pads in
place.
3 Install the new wear pad using new rivets.
When installing new rivets, make
sure the rivet heads are not above
the surface of the wear pad.

Part No. 39528 Genie GS-1530 & Genie GS-1930 7-9


Section 7 - Repair Procedures Service Manual - First Edition

Scissor Components (before serial number 632)

1 12

3 13

5 14

15
7

8 16

17

10 18

11

GS-1530
Steer End Non-steer End
1 Number 4 pivot pin (steer-end) 10 Number 1 inner arm
2 Number 3 center pivot pin 11 Number 1 pivot pin (steer-end)
3 Lift cylinder rod end pivot pin 12 Number 4 pivot pin (non-steer end)
4 Number 3 inner arm 13 Number 3 outer arm
5 Number 3 pivot pin (steer-end) 14 Number 3 pivot pin (non-steer end)
6 Number 2 center pivot pin 15 Number 2 outer arm
7 Number 2 inner arm 16 Number 2 pivot pin (non-steer end)
8 Number 2 pivot pin (steer-end) 17 Lift cylinder barrel end pivot pin
9 Number 1 center pivot pin 18 Number 1 outer arm

7 - 10 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 7 - Repair Procedures

SCISSOR COMPONENTS

3-1 5 Remove the pin retaining fasteners from the


number 3 pivot pin (index #14) at the ground
Scissor Assembly, controls side.
GS-1530 Models 6 Remove the external snap rings. Use a slide
(before serial number 632) hammer to remove the pins.
7 Repeat steps 4 through 6 for the battery pack
How to Disassemble the side of the machine.
Scissor Assembly 8 Remove the number 3 outer arm (index #13)
GS-1530 Models from the machine.

(before serial number 632) Bodily injury hazard. The number 3


outer arm (index #12) may become
The procedures in this section unbalanced and fall if not properly
require specific repair skills, lifting supported when it is removed from
equipment and a suitable the machine.
workshop. Attempting this
9 Remove the fasteners from the lower cable tray
procedure without these skills and
support at the steer end.
tools may result in death or
serious injury and significant 10 Remove the pin retaining fasteners from the
component damage. Dealer number 2 center pivot pin (index #6). Do not
service is required. remove the pin.
Follow the disassembly steps to the point required 11 Slide the cable tray towards the battery pack
to complete the repair. Then re-assemble the side of the machine and remove it from the
scissor assembly by following the disassembly machine and lay it off to the side.
steps in reverse order. Component damage hazard.
Cables can be damaged if they are
1 Remove the platform. See 2-1, How to Remove
kinked or pinched.
the Platform.
2 Remove the cables from the side of the number 12 Attach a lifting strap from an overhead crane to
3 outer arm (index #13) at the ground controls lug on the rod-end of the lift cylinder.
side. 13 Remove the external snap ring from the cylinder
Component damage hazard. rod-end pivot pin (index #3). Use a soft metal
Cables can be damaged if they drift to remove the pin.
are kinked or pinched. Bodily injury hazard. The cylinder
may fall if not properly supported
3 Attach a lifting strap from an overhead crane to
when the pin is removed.
the number 3 outer arm (index #13).
4 Remove the pin retaining fasteners from the
number 3 center pivot pin (index #2) at the
ground controls side.

Part No. 39528 Genie GS-1530 & Genie GS-1930 7 - 11


Section 7 - Repair Procedures Service Manual - First Edition

SCISSOR COMPONENTS

14 Lower the cylinder onto the number 1 center 24 Repeat steps 20 through 23 for the battery pack
pivot pin (index #9). side of the machine. Remove the arm from the
machine.
15 Attach a lifting strap from an overhead crane to
number 3 inner arm (index #4). Bodily injury hazard. The number
16 Remove the pin retaining fasteners from the 2 outer arm (index #15) may
number 3 pivot pin (index #5). Do not remove become unbalanced and fall if not
the pin. properly supported when the pins
are removed.
17 Remove the external snap ring. Use a slide
hammer to remove the pin. 25 Attach a lifting strap from an overhead crane to
the number 2 inner arm (index #7).
18 Repeat steps 16 and 17 for the battery pack
side. 26 Remove the pin retaining fasteners from the
number 2 pivot pin (index #8).
Bodily injury hazard. The number
3 inner arm (index #4) may 27 Remove the external snap ring. Use a slide
become unbalanced and fall if not hammer to remove the pin.
properly supported when the pins
are removed. 28 Repeat steps 26 and 27 for the battery pack
side of the machine. Remove the arm from the
19 Attach a strap from an overhead crane to the machine.
number 2 outer arm (index #15).
Bodily injury hazard. The number
20 Remove the pin retaining fasteners from the 2 inner arm (index #7) may
number 2 center pivot pin (index #6) at the become unbalanced and fall if not
ground controls side. properly supported when the pins
are removed.
21 Remove the external snap ring. Use a slide
hammer to remove the pin. 29 Remove the retaining fasteners on the safety
arm from the number 2 inner arm (index #7)
22 Remove the pin retaining fasteners from the
that was just removed.
number 2 pivot pin (index #16) at the ground
controls side. 30 Attach the strap from the crane to the number 1
inner arm (index #10).
23 Remove the external snap ring. Use a slide
hammer to remove the pin. 31 Raise the number 1 inner arm (index #10)
approximately 2 feet (0.6 m) and insert the
safety arm between the number 1 inner arm
(index #10) and the number 1 outer arm
(index #18).
Bodily injury hazard. Keep hands
clear of moving parts when
inserting the safety arm.

7 - 12 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 7 - Repair Procedures

SCISSOR COMPONENTS

32 Disconnect and plug the hydraulic hose on the 37 Attach the strap from the crane to the number 1
lift cylinder. Cap the fitting on the cylinder. inner arm (index #10). Raise the inner arm
slightly and remove the safety arm. Lower the
Bodily injury hazard. Spraying
arms on to the block.
hydraulic oil can penetrate and
burn skin. Loosen hydraulic Bodily injury hazard. Keep hands
connections very slowly to allow clear of moving parts when
the oil pressure to dissipate lowering the arms onto the block.
gradually. Do not allow oil to squirt
38 Remove the cables from the number 1 inner
or spray.
arm (index #10) and lay off to the side.
33 Tag and disconnect the wires from the solenoid
Component damage hazard.
valve on the cylinder.
Cables can be damaged if they
34 Attach the strap from the crane to the lug on are kinked or pinched.
the rod end of the cylinder.
39 Attach the overhead crane to the number 1 outer
35 Remove the external snap ring from the arm (index #17). Do not lift it.
cylinder barrel-end pin (index #17). Use a soft
40 Remove the pin retaining fasteners from the
metal drift to remove the pin. Remove the
number 1 center pivot pin (index #9) at the
cylinder from the machine.
ground controls side.
Crushing hazard. If the overhead
41 Remove the external snap ring. Use a slide
crane is not properly attached, the
hammer to remove the pin.
cylinder may become unbalanced
and fall when it is removed from 42 Repeat steps 40 and 41 for the battery pack
the machine. side.
Component damage hazard. Be Bodily injury hazard. The number
careful not to damage the valve or 1 outer arm (index #17) may
fittings on the cylinder while become unbalanced and fall if not
removing it from the machine. properly supported when the pins
are removed.
36 Place a 4 x 4 x 32 inch (10 x 10 x 81 cm) long
block across both sides of the chassis under 43 Slide the arm to the non-steer end and remove
the number 1 center pivot pin (index number the outer base scissor arm from the machine.
#9).
Note the position of the wear pads
before the arm is removed so
when the scissor is assembled
they will be in the correct position.

Part No. 39528 Genie GS-1530 & Genie GS-1930 7 - 13


Section 7 - Repair Procedures Service Manual - First Edition

SCISSOR COMPONENTS

44 Attach the overhead crane to the number 1 inner How to Replace the Scissor Arm
arm (index #10). Do not lift it.
Wear Pads
45 Remove the pin retaining fasteners from the
number 1 pivot pin at the ground controls side.
(before serial number 632)
Use a slide hammer to remove the pin. 1 Remove the platform. See 2-1, How to Remove
46 Repeat step 45 for the battery pack side. the Platform.
Remove the number 1 inner arm (index #10) 2 Carefully slide the forks from a forklift under the
from the machine. scissor arms at the non-steer end of the
machine.
Bodily injury hazard. The number 1
inner arm (index #10) may become 3 Attach a strap from the scissor arms to the
unbalanced and fall if not properly carriage on the forklift for support.
supported when the pins are 4 Remove the pin retaining fasteners from the
removed. number 1 inner arm pivot pins. Use a slide
hammer to remove the pins.
5 Remove the fasteners from the level sensor
box. Remove the box.
6 Remove the fasteners from the level sensor.
Remove the level sensor.
7 Slide the scissor assembly towards the non-
steer end of the machine approximately 18
inches (45.7 cm).
8 Remove the mounting fasteners from the
stationary wear pads on the platform and at the
steer end of the chassis.
Note the position of the old wear
pads before they are removed so
when the new ones are installed
they will be in the correct position.
9 Install the new wear pads with new fasteners.
10 Slide the movable wear pads off of the number 3
inner arm (index #3) and the number 1 outer arm
(index #16). Install the new wear pads.
11 Re-assemble machine in reverse order in which
it was disassembled.

7 - 14 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 7 - Repair Procedures

SCISSOR COMPONENTS

This page intentionally left blank.

Part No. 39528 Genie GS-1530 & Genie GS-1930 7 - 15


Section 7 - Repair Procedures Service Manual - First Edition

SCISSOR COMPONENTS

1 15

3 16

4 17

6 18
7
19
8

10 20

11 21

22
12
23
13

14

GS-1930
Steer End Non-steer End
1 Number 5 pivot pin (steer-end) 13 Number 1 inner arm
2 Number 4 center pivot pin 14 Number 1 pivot pin (steer-end)
3 Number 4 inner arm 15 Number 5 pivot pin (non-steer end)
4 Number 4 pivot pin (steer-end) 16 Number 4 outer arm
5 Number 3 center pivot pin 17 Number 4 pivot pin (non-steer end)
6 Lift cylinder rod end pivot pin 18 Number 3 outer arm
7 Number 3 inner arm 19 Number 3 pivot pin (non-steer end)
8 Number 3 pivot pin (steer-end) 20 Number 2 outer arm
9 Number 2 center pivot pin 21 Number 2 pivot pin (non-steer end)
10 Number 2 inner arm 22 Lift cylinder barrel end pivot pin
11 Number 2 pivot pin (steer-end) 23 Number 1 outer arm
12 Number 1 center pivot pin

7 - 16 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 7 - Repair Procedures

SCISSOR COMPONENTS

3-2 5 Attach a lifting strap from an over head crane to


the steer-end outer platform support arm (index
Scissor Assembly, #16).
GS-1930 Models 6 Remove the external snap ring from the number
(before serial number 632) 4 center pivot pin (index #2) at the ground
controls side. Use a slide hammer to remove
How to Disassemble the the pin.

Scissor Assembly 7 Remove the pin retaining fasteners from the


number 4 pivot pin (index #17) at the non-steer
GS-1930 Models end the machine at the ground controls side.
(before serial number 632) 8 Remove the external snap ring from the number
The procedures in this section 4 pivot pin (index #17) at the ground controls
require specific repair skills, lifting side. Use a slide hammer to remove the pin.
equipment and a suitable
9 Repeat steps 6 through 8 for the battery pack
workshop. Attempting this
side of the machine.
procedure without these skills and
tools may result in death or 10 Remove the arm from the machine.
serious injury and significant
Bodily injury hazard. The number
component damage. Dealer
4 outer arm (index #16) may
service is required.
become unbalanced and fall if not
Follow the disassembly steps to the point required properly supported when it is
to complete the repair. Then re-assemble the removed from the machine.
scissor assembly by following the disassembly
11 Attach a lifting strap from an overhead crane to
steps in reverse order.
the number 4 inner arm (index #3).
1 Remove the platform. See 2-1, How to Remove 12 Remove the pin retaining fasteners from the
the Platform. number 4 pivot pin (index #4) at both sides of
2 Remove the cables from the side of the outer the machine.
platform support arm (index #16) at the ground 13 Remove the external snap ring from the
controls side. number 4 pivot pin (index #4). Use a slide
3 Remove the retaining fasteners from the center hammer to remove the pin.
pivot pins (index #2) at both the ground 14 Repeat steps 11 and 12 for the battery pack
controls side and the battery pack side. Do not side of the machine.
remove the pins.
Bodily injury hazard. The number
4 Remove the upper cable tray and lay off to the 4 inner arm (index #3) may
side. become unbalanced and fall if not
Component damage hazard. properly supported when it is
Cables can be damaged if they are removed.
kinked or pinched.

Part No. 39528 Genie GS-1530 & Genie GS-1930 7 - 17


Section 7 - Repair Procedures Service Manual - First Edition

SCISSOR COMPONENTS

15 Attach a lifting strap from an overhead crane to 24 Attach a lifting strap from an overhead crane to
the number 3 outer arm (index #18). lug on the rod end of the lift cylinder to support
it.
16 Remove the pin retaining fasteners from the
number 3 center pivot pin (index #5) at the 25 Remove the external snap ring from the
ground controls side. cylinder rod-end pivot pin (index #6). Use a soft
metal drift to remove the pin.
17 Remove the external snap ring. Use a slide
hammer to remove the pin. Bodily injury hazard. The cylinder
may fall if not properly supported
Bodily injury hazard. The number
when the pin is removed.
3 outer arm (index #18) may
become unbalanced and fall if not 26 Lower the cylinder onto the number 1 center
properly supported when the pivot pin (index #12).
center pivot pin is removed.
27 Attach a lifting strap from an overhead crane to
18 Remove the pin retaining fasteners from the the number 3 inner arm (index #7).
number 3 pivot pin (index #19) at the non-steer
28 Remove the pin retaining fasteners from the
end.
number 3 pivot pin (index #8) at the steer end
19 Remove the external snap ring. Use a slide of the machine at the ground controls side.
hammer to remove the pin.
29 Remove the external snap ring. Use a slide
Bodily injury hazard. The number hammer to remove the pin.
3 outer arm (index #18) may
Bodily injury hazard. The number 3
become unbalanced and fall if not
inner arm (index #7) may fall if not
properly supported when it is
properly supported when the pins
removed.
are removed.
20 Repeat steps 16 through 19 for the battery
30 Repeat steps 28 and 29 for the battery pack
pack side of the machine.
side.
21 Remove the fasteners from the lower cable tray
31 Attach a strap from an overhead crane to the
support at the steer end.
number 2 outer arm (index #20) at the ground
22 Remove the pin retaining fasteners from the controls side.
number 2 center pivot pin (index #9) at the
32 Remove the pin retaining fasteners from the
ground controls side. Do not remove the pin.
number 2 center pivot pin (index #9) at the
23 Slide the cable tray towards the battery pack ground controls side.
side of the machine and remove it from the
33 Remove the external snap ring. Use a slide
machine and lay it off to the side.
hammer to remove the pin.
Component damage hazard.
Cables can be damaged if they
are kinked or pinched.

7 - 18 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 7 - Repair Procedures

SCISSOR COMPONENTS

34 Remove the pin retaining fasteners from the 43 Raise the number 1 inner arm (index #13)
number 2 pivot pin (index #21) at the ground approximately 2 feet (0.6 m) and insert the
controls side. safety arm between the number 1 inner arm
(index #13) and the number 1 outer arm
35 Remove the external snap ring. Use a slide
(index #23) at the steer end of the machine.
hammer to remove the pin.
Bodily injury hazard. Keep hands
36 Repeat steps 32 through 35 for the battery
clear of moving parts when
pack side of the machine.
inserting the safety arm.
Bodily injury hazard. The number
44 Disconnect and plug the hydraulic hose on the
2 outer arm (index #20) may
lift cylinder. Cap the fitting on the cylinder.
become unbalanced and fall if not
properly supported when the pins Bodily injury hazard. Spraying
are removed. hydraulic oil can penetrate and
burn skin. Loosen hydraulic
37 Attach a lifting strap from an over head crane
connections very slowly to allow
to the number 2 inner arm (index #10).
the oil pressure to dissipate
38 Remove the pin retaining fasteners from the gradually. Do not allow oil to squirt
number 2 pivot pin (index #11) at the ground or spray.
controls side.
45 Tag and disconnect the wires from the solenoid
39 Remove the external snap ring. Use a slide valve on the cylinder.
hammer to remove the pin.
46 Attach the strap from the crane to the lug on
40 Repeat steps 38 and 39 for the battery pack the rod end of the cylinder.
side of the machine.
47 Remove the external snap ring from the cylinder
Bodily injury hazard. The number 2 barrel-end pivot pin (index #22). Use a soft
inner arm (index #10) may become metal drift to remove the pin. Remove the
unbalanced and fall if not properly cylinder from the machine.
supported when the pins are
Crushing hazard. If the overhead
removed.
crane is not properly attached, the
41 Remove the retaining fasteners on the safety cylinder may become unbalanced
arm from the number 2 inner arm (index #10) and fall when it is removed from
that was just removed. the machine.
42 Attach the strap from the crane to the number Component damage hazard. Be
1 inner arm (index #13). careful not to damage the valve or
fittings on the cylinder while
removing it from the machine.

Part No. 39528 Genie GS-1530 & Genie GS-1930 7 - 19


Section 7 - Repair Procedures Service Manual - First Edition

SCISSOR COMPONENTS

48 Place a 4 x 4 x 32 inch (10 x 10 x 81 cm) long 56 Attach the overhead crane to the number 1 inner
block across both sides of the chassis under arm (index #13). Do not lift it.
the number 1 center pivot pin (index #12).
57 Remove the pin retaining fasteners from the
49 Attach the strap from the crane to the number 1 number 1 pivot pin (index #14) at the ground
inner arm (index #13) at the non-steer end. controls side. Use a slide hammer to remove
Raise the arm slightly and remove the safety the pin.
arm. Lower the arm on to the block.
58 Repeat step 57 for the battery pack side.
Bodily injury hazard. Keep hands Remove the number 1 inner arm (index #13)
clear of moving parts when from the machine.
lowering the arms onto the block.
Bodily injury hazard. The number
50 Remove the cables from the number 1 inner 1 inner arm (index #13) may
arm (index #13) and lay off to the side. become unbalanced and fall if not
properly supported when the pins
Component damage hazard.
are removed.
Cables can be damaged if they
are kinked or pinched.
51 Attach the overhead crane to the number 1
outer arm (index #23). Do not lift it.
52 Remove the pin retaining fasteners from the
number 1 center pivot pin (index #1) at the
ground controls side.
53 Remove the external snap ring. Use a slide
hammer to remove the pin.
54 Repeat steps 52 and 53 for the battery pack
side.
Bodily injury hazard. The number 1
outer arm (index #23) may become
unbalanced and fall if not properly
supported when the pins are
removed.
55 Slide the arm to the non-steer end and remove
the number 1 outer arm (index #23) from the
machine.
Note the position of the wear pads
before the arm is removed so
when the scissor is assembled
they will be in the correct position.

7 - 20 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 7 - Repair Procedures

SCISSOR COMPONENTS

How to Replace the Scissor Arm


Wear Pads
(before serial number 632)
1 Remove the platform. See 2-1, How to Remove
the Platform.
2 Carefully slide the forks from a forklift under the
scissor arms at the non-steer end of the
machine.
3 Attach a strap from the scissor arms to the
carriage on the forklift for support.
4 Remove the pin retaining fasteners from the
number 1 inner arm pivot pins. Use a slide
hammer to remove the pins.
5 Remove the fasteners from the level sensor
box. Remove the box.
6 Remove the fasteners from the level sensor.
Remove the level sensor.
7 Slide the scissor assembly towards the non-
steer end of the machine approximately 18
inches (45.7 cm).
8 Remove the mounting fasteners from the
stationary wear pads on the platform and at the
steer end of the chassis.
Note the position of the old wear
pads before they are removed so
when the new ones are installed
they will be in the correct position.
9 Install the new wear pads with new fasteners.
10 Slide the movable wear pads off of the number
4 inner arm (index #3) and the number 1 outer
arm (index #21). Install the new wear pads.
11 Re-assemble machine in reverse order in which
it was disassembled.

Part No. 39528 Genie GS-1530 & Genie GS-1930 7 - 21


Section 7 - Repair Procedures Service Manual - First Edition

Scissor Components (after serial number 631)


1 12

3 13

5 14

15
7

8 16

17

10 18

11

GS-1530

Steer End Non-steer End


1 Number 4 pivot pin (steer-end) 10 Number 1 inner arm
2 Number 3 center pivot pin 11 Number 1 pivot pin (steer-end)
3 Lift cylinder rod-end pin 12 Number 4 pivot pin (non-steer end)
4 Number 3 inner arm 13 Number 3 outer arm
5 Number 3 pivot pin (steer-end) 14 Number 3 pivot pin (non-steer end)
6 Number 2 center pivot pin (2 pins) 15 Number 2 outer arm
7 Number 2 inner arm 16 Number 2 pivot pin (non-steer end)
8 Number 2 pivot pin (steer-end) 17 Lift cylinder barrel-end pin
9 Number 1 center pivot pin 18 Number 1 outer arm

7 - 22 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 7 - Repair Procedures

SCISSOR COMPONENTS

3-3 5 Use a soft metal drift to remove the number 3


center pivot pin (index #2).
Scissor Assembly,
6 Remove the external snap rings from the
GS-1530 Models number 3 pivot pin (index #14).
(after serial number 631)
7 Use a soft metal drift to remove the number 3
pivot pin (index #14). Remove the number 3
How to Disassemble the outer arm (index #13) from the machine.
Scissor Assembly Bodily injury hazard. The number
GS-1530 Models 3 outer arm (index #13) may
become unbalanced and fall if not
(after serial number 631) properly supported when it is
This procedure requires specific removed from the machine.
repair skills, lifting equipment and
8 Remove the cable clamps from the number 3
a suitable workshop. Attempting
inner arm (index #4).
this procedure without these skills
and tools may result in death or 9 Remove the mounting fasteners from the cable
serious injury and significant tray support at the steer end.
component damage. Dealer
10 Remove the external snap rings from the
service is required.
number 2 center pivot pin (index #6) at the
When removing a hose assembly ground controls side. Do not remove the pin.
or fitting, the O-ring on the fitting
11 Slide the cable tray towards the battery pack
and/or hose end must be replaced
side of the machine and remove it from the
and then torqued to specification
machine and lay it off to the side.
during installation. Refer to
Section Two, Hydraulic Hose and Component damage hazard.
Fitting Torque Specifications. Cables can be damaged if they
are kinked or pinched.
1 Remove the platform. See 2-1, How to Remove
the Platform. 12 Attach a lifting strap from an overhead crane to
lug on the rod end of the lift cylinder.
2 Remove the cables from the side of the number
3 outer arm (index #13) at the ground controls 13 Remove the pin retaining fasteners from the
side. cylinder rod-end pivot pin (index #3). Use a soft
metal drift to remove the pin.
Component damage hazard.
Cables can be damaged if they Bodily injury hazard. The cylinder
are kinked or pinched. may fall if not properly supported
when the pin is removed.
3 Attach a lifting strap from an overhead crane to
the number 3 outer arm (index #13).
4 Remove the external snap rings from the
number 3 center pivot pin (index #2).

Part No. 39528 Genie GS-1530 & Genie GS-1930 7 - 23


Section 7 - Repair Procedures Service Manual - First Edition

SCISSOR COMPONENTS

14 Lower the cylinder onto the number 1 center 23 Attach a lifting strap from an overhead crane to
pivot pin (index #9). the number 2 inner arm (index #7).
15 Attach a lifting strap from an overhead crane to 24 Remove the external snap rings from the
number 3 inner arm (index #4). number 2 pivot pin (index #8).
16 Remove the external snap rings from the 25 Use a soft metal drift to remove the number 2
number 3 pivot pin (index #5). pivot pin (index #8). Remove the number 2
inner arm (index #7) from the machine.
17 Use a soft metal drift to remove the number 3
pivot pin (index #5). Remove the number 3 Bodily injury hazard. The number
inner arm (index #4) from the machine. 2 inner arm (index #7) may
become unbalanced and fall if not
Bodily injury hazard. The number
properly supported when it is
3 inner arm (index #4) may
removed from the machine.
become unbalanced and fall if not
properly supported when it is 26 Remove the safety arm from the number 2
removed from the machine. inner arm (index #7) that was just removed.
18 Attach a lifting strap from an overhead crane to 27 Attach the strap from the overhead crane to the
the number 2 outer arm (index #15). number 1 inner arm (index #10).
19 Remove the external snap rings from the 28 Raise the number 1 inner arm (index #10)
number 2 center pivot pin (index #6) at the approximately 2 feet (0.6 m) and insert the
battery pack side. safety arm between the number 1 inner arm
(index #10) and the number 1 outer arm
20 Use a soft metal drift to remove both of the
(index #18).
number 2 center pivot pins (index #6).
Bodily injury hazard. Keep hands
21 Remove the external snap rings from the
clear of moving parts when
number 2 pivot pin (index #16).
inserting the safety arm.
22 Use a soft metal drift to remove the number 2
29 Disconnect and plug the hydraulic hose on the
pivot pin (index #16). Remove the number 2
lift cylinder. Cap the fitting on the cylinder.
outer arm (index #15) from the machine.
Bodily injury hazard. Spraying
Bodily injury hazard. The number
hydraulic oil can penetrate and
2 outer arm (index #15) may
burn skin. Loosen hydraulic
become unbalanced and fall if not
connections very slowly to allow
properly supported when it is
the oil pressure to dissipate
removed from the machine.
gradually. Do not allow oil to squirt
or spray.

7 - 24 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 7 - Repair Procedures

SCISSOR COMPONENTS

30 Tag and disconnect the wires from the solenoid 36 Attach the strap from the overhead crane to the
valve on the cylinder. number 1 outer arm (index #18). Do not lift it.
31 Attach the strap from an overhead crane to the 37 Remove the external snap rings from the
lug on the rod end of the lift cylinder. number 1 center pivot pin (index #9).
32 Remove the pin retaining fasteners from the 38 Use a soft metal drift to remove the number 1
cylinder barrel-end pivot pin (index #17). Use a center pivot pin (index #9).
soft metal drift to remove the pin. Remove the
Bodily injury hazard. The number
cylinder from the machine.
1 outer arm (index #18) may
Crushing hazard. If the overhead become unbalanced and fall if not
crane is not properly attached, the properly supported when the pin is
cylinder may become unbalanced removed.
and fall when it is removed from
39 Slide the number 1 outer arm (index #18) to the
the machine.
non-steer end and remove it from the machine.
Component damage hazard. Be
Bodily injury hazard. The number 1
careful not to damage the valve or
outer arm (index #18) may become
fittings on the cylinder while
unbalanced and fall if not properly
removing it from the machine.
supported when removing it from
33 Place a 4 x 4 x 32 (10 x 10 x 81 cm) inch long the machine.
block across both sides of the chassis under
Note the position of the wear pads
the number 1 center pivot pin (index #9).
before the arm is removed so when
34 Attach the strap from the overhead crane to the the scissor is assembled they will
number 1 inner arm (index #10). Raise the be in the correct position.
inner arm slightly and remove the safety arm.
40 Attach the strap from an overhead crane to the
Lower the arms on to the block.
number 1 inner arm (index #10). Do not lift it.
Bodily injury hazard. Keep hands
41 Remove the pin retaining fasteners from both
clear of moving parts when
of the number 1 pivot pins (index #10) at the
lowering the arms onto the block.
steer end of the machine. Use a slide hammer
35 Remove the cables from the number 1 inner to remove the pins.
arm (index #10) and lay off to the side.
42 Remove the number 1 inner arm (index #10)
Component damage hazard. from the machine.
Cables can be damaged if they
Bodily injury hazard. The number 1
are kinked or pinched.
inner arm (index #10) may become
unbalanced and fall if not properly
supported when removed from the
machine.

Part No. 39528 Genie GS-1530 & Genie GS-1930 7 - 25


Section 7 - Repair Procedures Service Manual - First Edition

SCISSOR COMPONENTS

How to Replace the Scissor Arm 11 Remove the fasteners from the level sensor box
and slide it towards the non-steer end of the
Wear Pads machine as far as it will go.
(after serial number 631) Component damage hazard. Be
1 Remove the platform. See 2-1, How to Remove careful not to damage the level
the Platform. sensor box, limit switch, level
sensor or wiring while moving the
2 Remove the mounting fasteners from the level sensor box.
stationary wear pads on the platform.
12 Secure the ends of the scissor arms together at
Note the position of the old wear both ends of the machine with a tie down strap
pads before they are removed so or other appropriate device.
when the new ones are installed
they will be in the correct position. 13 Remove the pin retaining fasteners from the
number 1 inner arm pivot pins at the steer end
3 Remove the fasteners from the entry ladder and of the machine. Use a slide hammer to remove
remove the entry ladder. the pins.
4 Raise the platform approximately 7 to 8 feet (2.1 14 Attach a strap from an overhead crane to the
to 2.4 m). steer end of the scissor arms.
5 Rotate the safety arm away from the machine. 15 Carefully slide the forks from a forklift under the
6 Lower the platform onto the safety arm. scissor arms at the non-steer end of the
machine.
7 Mark the mounting position of the level sensor
box on the drive chassis. 16 Raise the scissor arms up until the number 1
inner arm will clear the level sensor box.
8 Remove the level sensor box lid.
Component damage hazard. Be
9 Mark the mounting position of the level sensor careful not to damage the level
on the level sensor box. sensor box, limit switch or level
10 Remove the mounting fasteners from the level sensor while moving the scissor
sensor. assembly.
17 Move the scissor assembly towards the non-
steer end of the machine slightly and to one
side of the machine until one of the scissor arm
wear pads are accessible. Do not allow both
wear pads to slide out of the drive chassis.
The scissor assembly will fall if
both wear pads are allowed to
slide out of the drive chassis.

7 - 26 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 7 - Repair Procedures

18 Install the new wear pad.


Note the position of the old wear
pad before it is removed so when
the new one is installed it will be in
the correct position.
19 Move the scissor assembly towards the other
side of the machine until the other scissor arm
wear pad is accessible.
The scissor assembly will fall if
both wear pads are allowed to
slide out of the drive chassis.
20 Install the new wear pad.
Note the position of the old wear
pad before it is removed so when
the new one is installed it will be in
the correct position.
21 Slide the scissor assembly back into the drive
chassis.
22 Lower the scissor assembly into position and
install the pivot pins.
Component damage hazard. Be
careful not to damage the level
sensor box, limit switch or level
sensor while installing the scissor
assembly.

Part No. 39528 Genie GS-1530 & Genie GS-1930 7 - 27


Section 7 - Repair Procedures Service Manual - First Edition

SCISSOR COMPONENTS

1 15

3 16

4 17

6 18

7
19
8

10 20

11 21

22
12
23
13

14

GS-1930
Steer End Non-steer End
1 Number 5 pivot pin (steer-end) 13 Number 1 inner arm
2 Number 4 center pivot pin 14 Number 1 pivot pin (steer-end)
3 Number 4 inner arm 15 Number 5 pivot pin (non-steer end)
4 Number 4 pivot pin (steer-end) 16 Number 4 outer arm
5 Number 3 center pivot pin 17 Number 4 pivot pin (non-steer end)
6 Lift cylinder rod-end pin 18 Number 3 outer arm
7 Number 3 inner arm 19 Number 3 pivot pin (non-steer end)
8 Number 3 pivot pin (steer-end) 20 Number 2 outer arm
9 Number 2 center pivot pin (2 pins) 21 Number 2 pivot pin (non-steer end)
10 Number 2 inner arm 22 Lift cylinder barrel-end pin
11 Number 2 pivot pin (steer-end) 23 Number 1 outer arm
12 Number 1 center pivot pin

7 - 28 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 7 - Repair Procedures

SCISSOR COMPONENTS

3-4 3 Attach a lifting strap from an overhead crane to


the number 4 outer arm (index #16).
Scissor Assembly,
4 Remove the external snap rings from the
GS-1930 Models number 4 center pivot pin (index #2).
(after serial number 631)
5 Use a soft metal drift to remove the number 4
center pivot pin (index #2).
How to Disassemble the
6 Remove the external snap rings from the
Scissor Assembly number 4 pivot pin (index #17).
GS-1930 Models 7 Use a soft metal drift to remove the number 4
(after serial number 631) pivot pin (index #17). Remove the number 4
outer arm (index #16) from the machine.
This procedure requires specific
repair skills, lifting equipment and Bodily injury hazard. The number
a suitable workshop. Attempting 4 outer arm (index #16) may
this procedure without these skills become unbalanced and fall if not
and tools may result in death or properly supported when it is
serious injury and significant removed from the machine.
component damage. Dealer
8 Remove the cable clamps from the upper cable
service is required.
tray on the number 4 inner arm (index #3).
When removing a hose assembly
9 Remove the mounting fasteners from the upper
or fitting, the O-ring on the fitting
cable tray supports.
and/or hose end must be replaced
and then torqued to specification 10 Remove the upper cable tray from the scissor
during installation. Refer to assembly. Lay the cables off to the side of the
Section Two, Hydraulic Hose and machine.
Fitting Torque Specifications.
Component damage hazard.
1 Remove the platform. See 2-1, How to Remove Cables can be damaged if they
the Platform. are kinked or pinched.
2 Remove the cables from the side of the number 11 Attach a lifting strap from an overhead crane to
4 outer arm (index #16) at the ground controls the number 4 inner arm (index #3).
side.
12 Remove the external snap rings from the
Component damage hazard. number 4 pivot pin (index #4) at the steer end of
Cables can be damaged if they the machine.
are kinked or pinched.

Part No. 39528 Genie GS-1530 & Genie GS-1930 7 - 29


Section 7 - Repair Procedures Service Manual - First Edition

SCISSOR COMPONENTS

13 Use a soft metal drift to remove the number 4 20 Remove the pin retaining fasteners from the
pivot pin (index #4) at the steer end. Remove cylinder rod-end pivot pin (index #6). Use a soft
the number 4 inner arm (index #3) from the metal drift to remove the pin.
machine.
Bodily injury hazard. The cylinder
Bodily injury hazard. The number 4 may fall if not properly supported
inner arm (index #3) may become when the pin is removed.
unbalanced and fall if not properly
21 Lower the cylinder onto the number 1 center
supported when it is removed from
pivot pin (index #12).
the machine.
22 Remove the cables from the number 3 inner
14 Attach a lifting strap from an overhead crane to
arm (index #7) and lay them off to the side.
the number 3 outer arm (index #18).
23 Attach a lifting strap from an overhead crane to
15 Remove the external snap rings from the
number 3 inner arm (index #7).
number 3 center pivot pin (index #5).
24 Remove the external snap rings from the
16 Use a soft metal drift to remove the number 3
number 3 pivot pin at the steer end (index #8).
center pivot pin (index #5).
25 Use a soft metal drift to remove the number 3
17 Remove the external snap rings from the
pivot pin (index #8). Remove the number 3
number 3 pivot pin (index #19) from the non-
inner arm (index #7) from the machine.
steer end of the machine.
Bodily injury hazard. The number
18 Use a soft metal drift to remove the number 3
3 inner arm (index #7) may
pivot pin (index #19) from the non-steer end of
become unbalanced and fall if not
the machine. Remove the number 3 outer arm
properly supported when it is
(index #18) from the machine.
removed from the machine.
Bodily injury hazard. The number
26 Remove the cable clamps from the lower cable
3 outer arm (index #18) may
tray. Lay the cables off to the side of the
become unbalanced and fall if not
machine.
properly supported when it is
removed from the machine. Component damage hazard.
Cables can be damaged if they
19 Attach a lifting strap from an overhead crane to
are kinked or pinched.
lug on the rod end of the lift cylinder.
27 Attach a strap from an overhead crane to the
number 2 outer arm (index #20).
28 Remove the mounting fasteners from the lower
cable tray supports.

7 - 30 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 7 - Repair Procedures

SCISSOR COMPONENTS

29 Remove the external snap rings from the 37 Remove the safety arm from the number 2 inner
number 2 center pivot pin (index #9) at the arm (index #10) that was just removed.
ground controls side.
38 Attach the strap from the overhead crane to the
30 Remove the external snap rings from the number 1 inner arm (index #13).
number 2 center pivot pin (index #9) at the
39 Raise the number 1 inner arm (index #13)
battery pack side.
approximately 2 feet (0.6 m) and insert the
31 Use a soft metal drift to remove both of the safety arm between the number 1 inner arm
number 2 center pivot pins (index #9). (index #13) and the number 1 outer arm
(index #23).
32 Remove the external snap rings from the
number 2 pivot pin (index #21) at the non-steer Bodily injury hazard. Keep hands
end of the machine. clear of moving parts when
inserting the safety arm.
33 Use a soft metal drift to remove the number 2
pivot pin (index #21). Remove the number 2 40 Disconnect and plug the hydraulic hose on the
outer arm (index #20) from the machine. lift cylinder. Cap the fitting on the cylinder.
Bodily injury hazard. The number Bodily injury hazard. Spraying
2 outer arm (index #20) may hydraulic oil can penetrate and
become unbalanced and fall if not burn skin. Loosen hydraulic
properly supported when it is connections very slowly to allow
removed from the machine. the oil pressure to dissipate
gradually. Do not allow oil to squirt
34 Attach a lifting strap from an overhead crane to
or spray.
the number 2 inner arm (index #10).
41 Tag and disconnect the wires from the solenoid
35 Remove the external snap rings from the
valve on the cylinder.
number 2 pivot pin (index #11) at the steer end
of the machine. 42 Attach the strap from an overhead crane to the
lug on the rod end of the lift cylinder.
36 Use a soft metal drift to remove the number 2
pivot pin (index #11). Remove the number 2 43 Remove the pin retaining fasteners from the
inner arm (index #10) from the machine. cylinder barrel-end pivot pin (index #22). Use a
soft metal drift to remove the pin. Remove the
Bodily injury hazard. The number
cylinder from the machine.
2 inner arm (index #10) may
become unbalanced and fall if not Crushing hazard. If the overhead
properly supported when it is crane is not properly attached, the
removed from the machine. cylinder may become unbalanced
and fall when it is removed from
the machine.

Part No. 39528 Genie GS-1530 & Genie GS-1930 7 - 31


Section 7 - Repair Procedures Service Manual - First Edition

SCISSOR COMPONENTS

Component damage hazard. Be 51 Slide the number 1 outer arm (index #23) to the
careful not to damage the valve or non-steer end and remove it from the machine.
fittings on the cylinder while
Bodily injury hazard. The number
removing it from the machine.
1 outer arm (index #23) may
44 Place a 4 x 4 x 32 inch (10 x 10 x 81 cm) long become unbalanced and fall if not
block across both sides of the chassis under properly supported when removing
the number 1 center pivot pin (index it from the machine.
number #12).
Note the position of the wear pads
45 Attach the strap from the overhead crane to the before the arm is removed so
number 1 inner arm (index #13). Raise the when the scissor is assembled
inner arm slightly and remove the safety arm. they will be in the correct position.
Lower the arms on to the block. 52 Attach the strap from an overhead crane to the
Bodily injury hazard. Keep hands number 1 inner arm (index #13). Do not lift it.
clear of moving parts when 53 Remove the pin retaining fasteners from both of
lowering the arms onto the block. the number 1 pivot pins (index #14) at the steer
46 Remove the cables from the number 1 inner end of the machine. Use a slide hammer to
arm (index #13) and lay them off to the side. remove the pins.

Component damage hazard. 54 Remove the number 1 inner arm (index #13)
Cables can be damaged if they from the machine.
are kinked or pinched. Bodily injury hazard. The number 1
47 Remove the fasteners from the entry ladder inner arm (index #13) may become
and remove the entry ladder. unbalanced and fall if not properly
supported when removed from the
48 Attach the strap from the overhead crane to the machine.
number 1 outer arm (index #23). Do not lift it.
Component damage hazard. Be
49 Remove the external snap rings from the sure not to damage the limit switch
number 1 center pivot pin (index #12). or level sensor box components
50 Use a soft metal drift to remove the number 1 when the number 1 inner arm
center pivot pin (index #12). (index #13) is removed from the
machine.
Bodily injury hazard. The number
1 outer arm (index #23) may
become unbalanced and fall if not
properly supported when the pin is
removed.

7 - 32 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 7 - Repair Procedures

SCISSOR COMPONENTS

How to Replace the Scissor Arm 11 Remove the fasteners from the level sensor box
and slide it towards the non-steer end of the
Wear Pads machine as far as it will go.
(after serial number 631) Component damage hazard. Be
1 Remove the platform. See 2-1, How to Remove careful not to damage the level
the Platform. sensor box, limit switch, level
sensor or wiring while moving the
2 Remove the mounting fasteners from the level sensor box.
stationary wear pads on the platform.
12 Secure the ends of the scissor arms together at
Note the position of the old wear both ends of the machine with a tie down strap
pads before they are removed so or other appropriate device.
when the new ones are installed
they will be in the correct position. 13 Remove the pin retaining fasteners from the
number 1 inner arm pivot pins at the steer end
3 Remove the fasteners from the entry ladder and of the machine. Use a slide hammer to remove
remove the entry ladder. the pins.
4 Raise the platform approximately 7 to 8 feet (2.1 14 Attach a strap from an overhead crane to the
to 2.4 m). steer end of the scissor arms.
5 Rotate the safety arm away from the machine. 15 Carefully slide the forks from a forklift under the
6 Lower the platform onto the safety arm. scissor arms at the non-steer end of the
machine.
7 Mark the mounting position of the level sensor
box on the drive chassis. 16 Raise the scissor arms up until the number 1
inner arm will clear the level sensor box.
8 Remove the level sensor box lid.
Component damage hazard. Be
9 Mark the mounting position of the level sensor careful not to damage the level
on the level sensor box. sensor box, limit switch or level
10 Remove the mounting fasteners from the level sensor while moving the scissor
sensor. assembly.
17 Move the scissor assembly towards the non-
steer end of the machine slightly and to one
side of the machine until one of the scissor arm
wear pads are accessible. Do not allow both
wear pads to slide out of the drive chassis.
The scissor assembly will fall if
both wear pads are allowed to
slide out of the drive chassis.

Part No. 39528 Genie GS-1530 & Genie GS-1930 7 - 33


Section 7 - Repair Procedures Service Manual - First Edition

SCISSOR COMPONENTS

18 Install the new wear pad. 3-5


Note the position of the old wear Lift Cylinder
pad before it is removed so when
the new one is installed it will be in
the correct position.
How to Remove the Lift Cylinder
19 Move the scissor assembly towards the other This procedure requires specific
side of the machine until the other scissor arm repair skills, lifting equipment and
wear pad is accessible. a suitable workshop. Attempting
this procedure without these skills
The scissor assembly will fall if and tools may result in death or
both wear pads are allowed to serious injury and significant
slide out of the drive chassis. component damage. Dealer
service is strongly recommended.
20 Install the new wear pad.
When removing a hose assembly
Note the position of the old wear
or fitting, the O-ring on the fitting
pad before it is removed so when
and/or hose end must be replaced
the new one is installed it will be in
and then torqued to specification
the correct position.
during installation. Refer to
21 Slide the scissor assembly back into the drive Section Two, Hydraulic Hose and
chassis. Fitting Torque Specifications.
22 Lower the scissor assembly into position and 1 Raise the platform approximately 7 to 8 feet
install the pivot pins. (2.1 to 2.4 m).
Component damage hazard. Be 2 Rotate the safety arm away from the machine.
careful not to damage the level
3 Lower the platform onto the safety arm.
sensor box, limit switch or level
sensor while installing the scissor Crushing hazard. Keep hands
assembly. clear of the safety arm when
lowering the platform.
4 Tag and disconnect the wiring from the
solenoid at the barrel end of the lift cylinder.
5 Loosen the adjustment nuts on the solenoid,
then disconnect the manual lowering cable from
the solenoid.
During assembly, the manual
platform lowering cable needs to
be properly adjusted. Refer to 4-1,
How to Adjust the Manual Platform
Lowering Cable.
6 Remove the mounting fasteners from the
manual lowering cable mounting bracket.
Remove the bracket from the cylinder.

7 - 34 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 7 - Repair Procedures

SCISSOR COMPONENTS

7 Disconnect and plug the hydraulic hardline from How to Check the Resistance
the lift cylinder. Cap the fitting on the cylinder.
of a Valve Coil
Bodily injury hazard. Spraying
hydraulic oil can penetrate and 1 Turn the key switch to the OFF position and
burn skin. Loosen hydraulic disconnect the wires from the valve coil to be
connections very slowly to allow tested.
the oil pressure to dissipate 2 Connect the positive lead from the ohmmeter to
gradually. Do not allow oil to squirt the valve coil terminal, then connect the
or spray. negative lead from the ohmmeter to the internal
8 Remove the hardline retaining strap from the ring of the valve coil.
cylinder.
Platform lowering valve coil specifications
9 Attach a strap from an overhead crane or
similar lifting device to the rod end of the lift 2 position 2 way N.C. solenoid valve - 20V 23 - 259
cylinder for support. (schematic item R)

10 Remove the external snap ring from the lift


cylinder rod-end pivot pin. Then use a soft
metal drift to remove the pin.
Crushing hazard. The lift cylinder
will fall if not properly supported.
Component damage hazard. Be
careful not to damage the level
sensor box, limit switch or level
sensor while lowering the cylinder.
11 Lower the cylinder.
12 Remove the fasteners from the entry ladder
and remove the entry ladder.
13 Support the barrel end of the lift cylinder with a
lifting device.
14 Remove the external snap ring from the lift
cylinder barrel-end pivot pin. Then use a soft
metal drift to remove the pin.
Crushing hazard. The lift cylinder
will fall if not properly supported.
15 Carefully pull the cylinder out the non-steer end
of the machine through the scissor arms.

Part No. 39528 Genie GS-1530 & Genie GS-1930 7 - 35


Section 7 - Repair Procedures Service Manual - First Edition

Ground Controls
4-1 10 Raise the platform and rotate the safety arm to
the storage position.
Manual Platform Lowering Cable
11 Pull the manual lowering handle at the ground
The manual platform lowering cable lowers the controls 2 to 3 times to ensure it is functioning
platform in the event of a main power failure. The correctly.
manual platform lowering cable is attached to the
Cable distance 3/16 to 1/4 inch
barrel end of the lift cylinder and is activated next
4.7 to 6.4 mm
to the ground controls.

How to Adjust the Manual a


Platform Lowering Cable
1 Raise the platform approximately 7 to 8 feet a manual lowering cable
b
sheath
(2.1 to 2.4 m). b upper lock nut
c cable mounting
2 Rotate the safety arm away from the machine. bracket
c
d lower lock nut
3 Lower the platform onto the safety arm. e cable mounting nut
d f end of the lowering
Crushing hazard. Keep hands
cable
clear of the safety arm when g manual lowering valve
lowering the platform.
e
4 Push the handle on the manual platform lowering
cable all the way in.
5 Disconnect the cable mounting nut from the f
lowering valve at the barrel end of the lift
cylinder.
6 Pull the cable tight and measure the distance g
between the end of the lowering cable and the R
end of the lowering valve.
Result: The measurement should be 3/16 to
1
/4 inch (4.7 to 6.4 mm).
4-2
7 To adjust, loosen the upper lock nut on the
cable mounting bracket. Turn the lower lock nut Toggle Switches
clockwise to decrease the distance or
counterclockwise to increase the distance. See 1-3, Toggle Switches.

8 Tighten the upper lock nut and re-measure the


distance between the end of the lowering cable
and the end of the lowering valve. Re-adjust if
needed.
9 Install the cable mounting nut onto the lowering
valve.

7 - 36 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 7 - Repair Procedures

Hydraulic Pump
5-1 How to Remove the
Function Pump Hydraulic Pump
When removing a hose assembly
The hydraulic pump is attached to the motor which
or fitting, the O-ring on the fitting
makes up the Hydraulic Power Unit.
and/or hose end must be replaced
How to Test the Hydraulic Pump and then torqued to specification
during installation. Refer to
When removing a hose assembly Section Two, Hydraulic Hose and
or fitting, the O-ring on the fitting Fitting Torque Specifications.
and/or hose end must be replaced
1 Remove the mounting fasteners from the
and then torqued to specification
hydraulic filter bracket at the function manifold.
during installation. Refer to
Push the filter off to the side.
Section Two, Hydraulic Hose and
Fitting Torque Specifications. 2 Tag, disconnect and cap the hydraulic hoses
on the pump.
1 Disconnect and plug the high pressure hydraulic
hose from the hydraulic pump. Bodily injury hazard. Spraying
hydraulic oil can penetrate and
Bodily injury hazard. Spraying
burn skin. Loosen hydraulic
hydraulic oil can penetrate and
connections very slowly to allow
burn skin. Loosen hydraulic
the oil pressure to dissipate
connections very slowly to allow
gradually. Do not allow oil to squirt
the oil pressure to dissipate
or spray.
gradually. Do not allow oil to squirt
or spray. 3 Remove the pump mounting bolts. Carefully
remove the pump.
2 Connect a 0 to 5000 psi (0 to 350 bar) pressure
gauge to the high pressure port on the pump.
3 Turn the key switch to ground control and pull
the Emergency Stop button to the ON position.
4 Activate the platform up function from the
ground controls.
Result: If the pressure gauge reads 3700 psi
(255 bar), immediately stop. The pump is good.
Result: If pressure fails to reach 3700 psi
(255 bar), the pump is bad and will need to be
serviced or replaced.
5 Remove the pressure gauge and reconnect the
hydraulic hose.

Part No. 39528 Genie GS-1530 & Genie GS-1930 7 - 37


Section 7 - Repair Procedures Service Manual - First Edition

Function Manifold
6-1
Function Manifold Components
The function manifold is mounted inside the hydraulic power unit module.
Index Schematic
No. Description Item Function Torque

1 Flow regulator, 0.5 gpm (1.9 L/min) .. A ........... Steer circuit ....................................... 35-40 ft-lbs (47-54 Nm)
2 Orifice washer, 0.040 in (1 mm) ....... B ........... Steer circuit
3 Relief valve, 1200 psi (82.7 bar) ....... C ........... Steering relief .................................... 25-30 ft-lbs (34-41 Nm)
4 Relief valve,
GS-1530, 3200 psi (220.6 bar) ......... D ........... System relief ..................................... 25-30 ft-lbs (34-41 Nm)
GS-1930, 3700 psi (255.1 bar) ......... D ........... System relief ..................................... 25-30 ft-lbs (34-41 Nm)
5 Orifice plug, 0.025 in (0.6 mm) ......... E ........... Brake circuit
6 3 position 4 way solenoid valve ......... F ........... Steer left/right ................................... 18-20 ft-lbs (24-27 Nm)
7 2 position 4 way solenoid valve ......... G ........... Platform up ....................................... 23-25 ft-lbs (31-34 Nm)
8 Orifice washer, 0.060 in (1.5 mm) .... H ........... Brake circuit
9 2 position 2 way solenoid valve,
N. O. .................................................. I ............ Brake circuit ...................................... 18-20 ft-lbs (24-27 Nm)
10 3 position 4 way solenoid valve ......... J ............ Drive forward/reverse ....................... 18-20 ft-lbs (24-27 Nm)
11 Check valve ....................................... K ........... Brake circuit ...................................... 35-40 ft-lbs (47-54 Nm)
12 Check valve (machines after
serial number 1885 only) ................... L ........... Steer circuit ....................................... 35-40 ft-lbs (47-54 Nm)
13 Diagnostic fitting ................................ M .......... Testing

Plug Torque Specifications


Description Hex Size Torque Description Hex Size Torque

SAE No. 2 1/ 8 50 in-lbs / 6 Nm SAE No. 8 5/16 50 ft-lbs / 68 Nm

SAE No. 4 3/16 13 ft-lbs / 18 Nm SAE No. 10 9/16 55 ft-lbs / 75 Nm

SAE No. 6 1/ 4 18 ft-lbs / 24 Nm SAE No. 12 5/8 75 ft-lbs / 102 Nm

7 - 38 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 7 - Repair Procedures

FUNCTION MANIFOLD

Part No. 39528 Genie GS-1530 & Genie GS-1930 7 - 39


Section 7 - Repair Procedures Service Manual - First Edition

FUNCTION MANIFOLD

6-2 10 Bleed the hydraulic system by raising the


platform to full height. If the pump cavitates or
Valve Adjustments - platform fails to reach full height, add hydraulic
Function Manifold oil until the pump is functioning correctly. Do
not overfill the hydraulic reservoir.
How to Adjust the Function Component damage hazard. Do
Relief Valve not continue to operate the
machine if the hydraulic pump is
Be sure that the hydraulic oil level cavitating.
is between the FULL and ADD marks
on the oil level indicator decal.
1 Open the hydraulic power unit module tray and
How to Adjust the Steering Relief
locate the function relief valve on the function Valve
manifold.
1 Open the hydraulic power unit module tray and
2 Place maximum rated load into the platform. locate the steering relief valve on the function
Secure the load to the platform. manifold.
Maximum Capacity 2 Connect a 0 to 5000 psi (0 to 350 bar) pressure
gauge to the test port on the function manifold.
GS-1530 600 lbs 272 kg
GS-1930 500 lbs 227 kg 3 Turn the key switch to ground control and pull
out the Emergency Stop button to the ON
position at both the ground and platform
3 Hold the function relief valve with a wrench and controls.
remove the cap (item 4, function manifold).
4 Activate the function enable switch and press
4 While activating the platform up function, adjust and hold the steer thumb rocker switch to the
the internal hex socket clockwise, just until the right. Allow the wheels to completely turn to the
platform begins to raise. right, then continue holding the switch while
5 Fully lower the platform. observing the pressure reading on the pressure
gauge. Note the pressure.
6 Add an additional 50 pounds (22.7 kg) to the
platform. Secure the additional weight. 5 Press and hold the steer thumb rocker switch to
the left. Allow the wheels to completely turn to
7 Raise the platform slightly. the left, then continue holding the switch while
8 The power unit should not be able to lift the observing the pressure reading on the pressure
platform. If the power unit lifts the platform, gauge.
adjust the internal hex socket counterclockwise 6 Turn the machine off. Hold the steer relief valve
until the adjustment is correct. with a wrench and remove the cap
9 Install the relief valve cap. (item 3, function manifold).

7 - 40 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 7 - Repair Procedures

FUNCTION MANIFOLD

7 Adjust the internal hex socket. Turn it clockwise


to increase the pressure or counterclockwise to
decrease the pressure. Install the relief valve
cap.
Tip-over hazard. Do not adjust
the relief valves higher than
recommended.
8 Repeat steps 3 through 6 to recheck the valve
pressure.

Steering relief valve specification

Pressure 1200 psi 82.8 bar

How to Check the Resistance


of a Valve Coil
1 Turn the key switch to the OFF position and
disconnect the wire from the valve coil to be
tested.
2 Connect the positive lead from the ohmmeter to
the valve coil terminal, then connect the
negative lead from the ohmmeter to the internal
ring of the valve coil.

Function manifold valve coil specifications

3 position 4 way solenoid valve 26 - 28W


(schematic item F)

2 position 2 way solenoid valve 26 - 28W


(schematic item I)

2 position 4 way solenoid valve 18 - 20W


(schematic item G)

3 position 4 way solenoid valve 18 - 20W


(schematic item J)

Part No. 39528 Genie GS-1530 & Genie GS-1930 7 - 41


Section 7 - Repair Procedures Service Manual - First Edition

Steering Axle Components


7-1 7 Support the yoke assembly with a lifting device.
Yoke and Drive Motor 8 Remove the retaining fastener that fastens the
steer link to the bellcrank.
How to Remove the Yoke Note the quantity and location of
and Drive Motor the spacers when disconnecting
the steer link from the bellcrank.
When removing a hose assembly
9 Remove the retaining fastener from the top of
or fitting, the O-ring on the fitting
the yoke pivot shaft.
and/or hose end must be replaced
and then torqued to specification 10 Lower the yoke assembly out of the chassis.
during installation. Refer to
Section Two, Hydraulic Hose and Bodily injury hazard. The yoke/
Fitting Torque Specifications. motor assembly may fall if not
properly supported when it is
1 Block the non-steer wheels and center a lifting removed from the chassis.
jack under the drive chassis at the steer end.
Torque specifications
2 Remove the cotter pin from the wheel castle
nut. Castle nut 300 ft-lbs
406.7 Nm
Always replace the cotter pin with
a new one when removing the
castle nut.
How to Remove a Drive Motor
3 Loosen the wheel castle nut. Do not
remove it. 1 Block the non-steer wheels and center a lifting
jack under the drive chassis at the steer end.
4 Raise the machine approximately 14 inches
(35.6 cm). Place blocks under the chassis for 2 Remove the cotter pin on the wheel lug nut of
support. the motor to be removed.

Crushing hazard. The chassis will Always replace the cotter pin with
fall if it is not properly supported. a new one when removing the
castle nut.
5 Remove the castle nut, then remove the wheel.
3 Loosen the wheel castle nut. Do not remove it.
6 Tag, disconnect and cap the hydraulic hoses
on the drive motor.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to
allow the oil pressure to
dissipate gradually. Do not
allow oil to squirt or spray.

7 - 42 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 7 - Repair Procedures

STEERING AXLE COMPONENTS

4 Raise the machine approximately 2 inches 7-2


(5.1 cm). Place blocks under the chassis for
support. Steering Cylinder
5 Remove the castle nut, then remove the wheel.
How to Remove the
6 Tag, disconnect and cap the hydraulic hoses on Steering Cylinder
the drive motor.
When removing a hose assembly
Bodily injury hazard. Spraying
or fitting, the O-ring on the fitting
hydraulic oil can penetrate and
and/or hose end must be replaced
burn skin. Loosen hydraulic
and then torqued to specification
connections very slowly to
during installation. Refer to
allow the oil pressure to
Section Two, Hydraulic Hose and
dissipate gradually. Do not
Fitting Torque Specifications.
allow oil to squirt or spray.
1 Tag, disconnect and plug the hydraulic hoses
7 Remove the drive motor mounting fasteners,
from the steering cylinder. Cap the fittings on
then remove the motor.
the cylinder.
Torque specifications Bodily injury hazard. Spraying
hydraulic oil can penetrate and
Castle nut 300 ft-lbs
406.7 Nm burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
2 Remove the pin retaining fasteners from the
barrel-end pivot pin. Remove the pivot pin.
Note the quantity and location of
the spacers when removing the
barrel-end pivot pin.
3 Remove the pin retaining fasteners from the rod-
end pivot pin. Remove the pin.
Note the quantity and location of
the spacers when removing the
rod-end pivot pin.
4 Remove the steering cylinder from the machine.

Part No. 39528 Genie GS-1530 & Genie GS-1930 7 - 43


Section 7 - Repair Procedures Service Manual - First Edition

STEERING AXLE COMPONENTS

7-3 7-4
Steering Bellcrank Steering Bellcrank
(before serial number 2000) (after serial number 1999)
1 Remove the steering cylinder. See 7-2, How to When removing a hose assembly
Remove the Steering Cylinder. or fitting, the O-ring on the fitting
and/or hose end must be replaced
2 Remove the pin retaining fastener from the
and then torqued to specification
bellcrank center pivot pin. Remove the pin.
during installation. Refer to
3 Support one drive yoke/motor assembly with a Section Two, Hydraulic Hose and
lifting device. Fitting Torque Specifications.
4 Remove the retaining fastener from the yoke 1 Tag, disconnect and plug the hydraulic hoses
pivot shaft. from the steering cylinder. Cap the fittings on
the cylinder.
5 Place a block under the yoke/motor assembly
that is being removed. Lower the yoke Bodily injury hazard. Spraying
assembly approximately 3 inches (7.6 cm) to hydraulic oil can penetrate and
allow the steer link to clear the pivot shaft on burn skin. Loosen hydraulic
the yoke. connections very slowly to
allow the oil pressure to
Bodily injury hazard. The yoke/ dissipate gradually. Do not
motor assembly may fall if not allow oil to squirt or spray.
properly supported when it is
lowered from the chassis. 2 Remove the pin retaining fasteners from the rod-
end pivot pin of the steer cylinder. Remove the
6 Lower the yoke assembly on to the block for pin.
support.
Note the quantity and location of
Component damage hazard. When the spacers when removing the
the bellcrank is installed, be sure rod-end pivot pin.
the steering cylinder hoses are
placed between the bellcrank and 3 Remove the retaining fastener from the center
the bottom of the drive chassis. pivot pin of the bellcrank.
7 Remove the pin retaining fasteners from the Note the quantity and the location
bellcrank pivot pin. Remove the pin. of the spacers on the bellcrank.
8 Repeat steps 4 through 7 for other yoke/motor 4 Remove the retaining fasteners from the steer
assembly. Remove the bellcrank. links at each end of the bellcrank. Remove the
bellcrank from the machine.
Note the quantity and the location
of the spacers in between the
bellcrank and the steer links.

7 - 44 Genie GS-1530 & Genie GS-1930 Part No. 39528


Service Manual - First Edition Section 7 - Repair Procedures

Non-steering Axle Components


8-1 9 Remove the fasteners that attach the brake to
the drive chassis, then remove the brake.
Drive Brake
Crushing hazard. The brake will fall
if it is not properly supported when
How to Remove a Drive Brake the mounting fasteners are
When removing a hose assembly removed.
or fitting, the O-ring on the fitting
and/or hose end must be replaced Torque specifications
and then torqued to specification Castle nut 300 ft-lbs
during installation. Refer to 406.7 Nm
Section Two, Hydraulic Hose and
Fitting Torque Specifications.
1 Remove the fasteners from the entry ladder and
remove the entry ladder.
2 Block the steer wheels and center a lifting jack
under the drive chassis at the non-steer end.
3 Remove the cotter pin from the wheel castle nut.
Always replace the cotter pin with
a new one when removing the
castle nut.
4 Loosen the wheel castle nut. Do not remove it.
5 Raise the machine 2 inches (5.1 cm) and place
blocks under the drive chassis for support.
6 Remove the wheel castle nut, then remove the
wheel.
7 Disconnect the hydraulic hose from the brake
and plug it. Cap the fitting on the brake.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to
allow the oil pressure to
dissipate gradually. Do not
allow oil to squirt or spray.
8 Place a second lifting jack under the brake for
support.

Part No. 39528 Genie GS-1530 & Genie GS-1930 7 - 45


Section 7 - Repair Procedures Service Manual - First Edition

9-1
Brake Release Hand Pump Components
The brake release handpump manifold is mounted behind the entry ladder next to the battery charger.
Index Schematic
No. Description Item Function Torque

1 Check valve, pilot operated ............... N ........... Manual brake release ....................... 25-30 ft-lbs (34-41 Nm)
2 Shuttle valve ...................................... O ........... Brake release .................................... 8-10 ft-lbs (11-14 Nm)
3 Hand pump ........................................ P ........... Manual brake release ....................... 25-30 ft-lbs (34-41 Nm)

Plug Torque Specifications


Description Hex Size Torque Description Hex Size Torque

SAE No. 2 1/ 8 50 in-lbs / 6 Nm SAE No. 8 5/16 50 ft-lbs / 68 Nm

SAE No. 4 3/16 13 ft-lbs / 18 Nm SAE No. 10 9/16 55 ft-lbs / 75 Nm

SAE No. 6 1/ 4 18 ft-lbs / 24 Nm SAE No. 12 5/8 75 ft-lbs / 102 Nm

7 - 46 Genie GS-1530 & Genie GS-1930 Part No. 39528