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Service Manual

Serial Number Range

GS -1530/32 from GS3005A-76000


from GS3005B-76000
from GS3008C-101

GS -1930/32 from GS3005A-76000


from GS3005B-76000
from GS3008C-101

GS -2032 from GS3205-75407


from GS3208C-101

GS -2632 from GS3205-75407


from GS3208C-101

GS -3232 from GS3205-75407


from GS3208C-101

GS -2046 from GS4605-75438

GS -2646 from GS4605-75438

GS -3246 from GS4605-75438

Part No. 97385


Rev E9
January 2011
January 2011

Introduction

Important Serial Number Information


Read, understand and obey the safety rules and Genie Industries offers the following Service
operating instructions in the appropriate Operator's Manuals for these models:
Manual on your machine before attempting any
maintenance procedure. Title Part No.

Basic mechanical, hydraulic and electrical Genie GS-1530 and GS-1930 Service Manual,
skills are required to perform most procedures. First Edition
However, several procedures require specialized (before serial number 17408) ............................... 39528
skills, tools, lifting equipment and a suitable Genie GS-1530 and GS-1930 Service Manual,
workshop. In these instances, we strongly Second Edition
recommend that maintenance and repair be (from serial number 17408 to 59999) ................... 72876
performed at an authorized Genie dealer Genie GS-1530 and GS-1930 Service Manual,
service center. Third Edition
(from serial number 60000 to 75999) ................... 96316

Compliance
Genie GS-2032 Service Manual,
Machine Classification First Edition
Group A/Type 3 as defined by ISO 16368 (before serial number 17408) ............................... 46326
Genie GS-2032 and GS-2632 Service Manual,
Machine Design Life
Second Edition
Unrestricted with proper operation, inspection and (from serial number 17408 to 59999) ................... 72963
scheduled maintenance.
Genie GS-2032 and GS-2632 Service Manual,
Third Edition
Technical Publications (from serial number 60000 to 75406) ................... 96316

Genie Industries has endeavored to deliver the


highest degree of accuracy possible. However, Genie GS-2046, GS-2646 and GS-3246
Service Manual, First Edition
continuous improvement of our products is a Genie
(before serial number 17408) ............................... 48339
policy. Therefore, product specifications
are subject to change without notice. Genie GS-2046, GS-2646 and GS-3246
Service Manual, Second Edition
Readers are encouraged to notify Genie of errors (from serial number 17408 to 59999) ................... 72972
and send in suggestions for improvement. All Genie GS-2046, GS-2646 and GS-3246
communications will be carefully considered for Service Manual, Third Edition
future printings of this and all other manuals. (from serial number 60000 to 75437) ................... 96316

Contact Us:
Copyright © 1997 by Genie Industries
www.genieindustries.com
e-mail: techpub@terex.com 97385 Rev E March 2007
Fourth Edition, Fifth Printing

"Genie" is a registered trademark of Genie


Industries in the USA and many other countries.
"GS" is a trademark of Genie Industries.

Printed on recycled paper

Printed in U.S.A.

ii GS-30 • GS-32 • GS-46 Part No. 97385


January 2011

INTRODUCTION

Serial Number Legend

Model: GS-1930
Serial number: GS3005A-12345
Model year: 2005 Manufacture date: 04/12/05
Electrical schematic number: ES0141
Machine unladen weight: 2,714 lb / 1,231 kg

Rated work load (including occupants): 500 lb / 227 kg GS30 05 A - 12345


Maximum allowable inclination of the chassis:
N/A
Model Sequence
Gradeability: N/A number
Model year
Maximum allowable side force : 100 lb / 445 N
Maximum number of platform occupants: 2
Facility code
(used only for model manufactured
Country of manufacture: USA in multiple facilities )
This machine complies with:

ANSI A92.6-1999
B354.2-01

Genie Industries
18340 NE 76th Street
Redmond, WA 98052
USA

PN - 77055

Serial label

Serial number
(stamped on chassis)
Serial number
(stamped on chassis)

Part No. 97385 GS-30 • GS-32 • GS-46 iii


January 2011

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iv GS-30 • GS-32 • GS-46 Part No. 97385


January 2011 Section 1 • Safety Rules

Safety Rules

Danger
Failure to obey the instructions and safety rules
in this manual and the appropriate Operator's
Manual on your machine will result in death or
serious injury.
Many of the hazards identified in the
operator’s manual are also safety hazards
when maintenance and repair procedures
are performed.

Do Not Perform Maintenance


Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
- manufacturer’s instructions and safety rules
- employer’s safety rules and worksite
regulations
- applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.

Part No. 97385 GS-30 • GS-32 • GS-46 v


Section 1 • Safety Rules January 2011

SAFETY RULES

Personal Safety Workplace Safety


Any person working on or around a machine must Be sure to keep sparks, flames and
be aware of all known safety hazards. Personal lighted tobacco away from flammable and
safety and the continued safe operation of the combustible materials like battery gases
machine should be your top priority. and engine fuels. Always have an approved fire
extinguisher within easy reach.

Read each procedure thoroughly. This Be sure that all tools and working areas
manual and the decals on the machine, are properly maintained and ready for
use signal words to identify the following: use. Keep work surfaces clean and free of
debris that could get into machine components and
Safety alert symbol—used to alert cause damage.
personnel to potential personal
injury hazards. Obey all safety Be sure any forklift, overhead crane or
messages that follow this symbol other lifting or supporting device is fully
to avoid possible injury or death. capable of supporting and stabilizing the
weight to be lifted. Use only chains or straps that
Indicates an imminently hazardous
are in good condition and of ample capacity.
situation which, if not avoided, will
result in death or serious injury. Be sure that fasteners intended for one
Indicates a potentially hazardous time use (i.e., cotter pins and self-locking
situation which, if not avoided, nuts) are not reused. These components
could result in death or serious may fail if they are used a second time.
injury. Be sure to properly dispose of old oil or
Indicates a potentially hazardous other fluids. Use an approved container.
situation which, if not avoided, Please be environmentally safe .
may cause minor or moderate Be sure that your workshop or work area
injury. is properly ventilated and well lit.
Indicates a potentially hazardous
situation which, if not avoided,
may result in property damage.
Be sure to wear protective eye wear and
other protective clothing if the situation
warrants it.

Be aware of potential crushing hazards


such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved steel-toed
shoes.

vi GS-30 • GS-32 • GS-46 Part No. 97385


January 2011

Table of Contents

Introduction
Important Information ......................................................................................... ii
Serial Number Information ................................................................................. ii
Serial Number Legend ...................................................................................... iii

Section 1 Safety Rules


General Safety Rules ........................................................................................ v

Section 2 Rev Specifications


G Machine Specifications ................................................................................ 2 - 1
Performance Specifications ......................................................................... 2 - 2
Hydraulic Specifications ............................................................................... 2 - 3
Manifold Component Specifications ............................................................. 2 - 4
Hydraulic Hose and Fitting Torque Specifications ........................................ 2 - 5
SAE and Metric Fasteners Torque Charts ................................................... 2 - 7

Section 3 Rev Scheduled Maintenance Procedures


Introduction .................................................................................................. 3 - 1
Pre-delivery Preparation Report .................................................................. 3 - 3
Maintenance Inspection Report ................................................................... 3 - 5
C Checklist A Procedures
A-1 Inspect the Manuals and Decals ......................................................... 3 - 6
A-2 Perform Pre-operation Inspection ....................................................... 3 - 7
A-3 Perform Function Tests ...................................................................... 3 - 7
A-4 Perform 30 Day Service ..................................................................... 3 - 8
A-5 Grease the Steer Yokes ..................................................................... 3 - 8

Part No. 97385 GS-30 • GS-32 • GS-46 vii


January 2011

TABLE OF CONTENTS

Section 3 Rev Scheduled Maintenance Procedures, continued


J Checklist B Procedures
B-1 Inspect the Batteries ........................................................................... 3 - 9
B-2 Inspect the Electrical Wiring ............................................................. 3 - 11
B-3 Inspect the Tires, Wheels and Castle Nut Torque ............................ 3 - 12
B-4 Test the Emergency Stop ................................................................. 3 - 12
B-5 Test the Key Switch .......................................................................... 3 - 13
B-6 Test the Automotive-style Horn (if equipped) .................................... 3 - 13
B-7 Test the Drive Brakes ....................................................................... 3 - 14
B-8 Test the Drive Speed - Stowed Position ........................................... 3 - 17
B-9 Test the Drive Speed - Raised Position ............................................ 3 - 18
B-10 Test the Slow Drive Speed ............................................................... 3 - 19
B-11 Perform Hydraulic Oil Analysis ......................................................... 3 - 20
B-12 Inspect the Hydraulic Tank Cap Venting System .............................. 3 - 20
B-13 Check the Module Tray Latch Components ...................................... 3 - 21
B-14 Inspect the Voltage Inverter (if equipped) ......................................... 3 - 22
B-15 Test the Down Limit Switch and the Pothole Limit Switches ............. 3 - 23
B-16 Test the Up Limit Switch (if equipped)
and the Outrigger Limit Switches (if equipped) ................................. 3 - 26
C Checklist C Procedures
C-1 Test the Platform Overload System (if equipped) ............................. 3 - 27
C-2 Replace the Hydraulic Tank Breather Cap -
Models with Optional Hydraulic Oil ................................................... 3 - 29
E Checklist D Procedures
D-1 Check the Scissor Arm Wear Pads .................................................. 3 - 30
D-2 Replace the Hydraulic Tank Return Filter Element ........................... 3 - 33
C Checklist E Procedure
E-1 Test or Replace the Hydraulic Oil ..................................................... 3 - 34

viii GS-30 • GS-32 • GS-46 Part No. 97385


January 2011

TABLE OF CONTENTS

Section 4 Rev Repair Procedures


Introduction .................................................................................................. 4 - 1
J Platform Controls
1-1 Circuit Boards .................................................................................... 4 - 2
1-2 Controller Adjustments ....................................................................... 4 - 4
1-3 Software Configuration ....................................................................... 4 - 9
1-4 Outrigger ECM ................................................................................. 4 - 14
1-5 Outrigger Controls Software Update ................................................ 4 - 17
B Platform Components
2-1 Platform ............................................................................................ 4 - 34
2-2 Platform Extension ........................................................................... 4 - 35
C Scissor Components
3-1 Scissor Assembly, GS-1530 and GS-1532 ...................................... 4 - 36
3-2 Scissor Assembly, GS-1930 and GS-1932 ...................................... 4 - 42
3-3 Scissor Assembly, GS-2032 and GS-2046 ...................................... 4 - 50
3-4 Scissor Assembly, GS-2632 and GS-2646 ...................................... 4 - 56
3-5 Scissor Assembly, GS-3232 and GS-3246 ...................................... 4 - 64
3-6 Lift Cylinder ...................................................................................... 4 - 72
3-7 Platform Overload System ............................................................... 4 - 77
D Ground Controls
4-1 Manual Platform Lowering Cable ..................................................... 4 - 79
4-2 Level Sensors .................................................................................. 4 - 80
B Hydraulic Pump
5-1 Function Pump ................................................................................. 4 - 86

Part No. 97385 GS-30 • GS-32 • GS-46 ix


January 2011

TABLE OF CONTENTS

Section 4 Rev Repair Procedures, continued


F Manifolds
6-1 Function Manifold Components -
GS-1530, GS-1532, GS-1930 and GS-1932 .................................... 4 - 88
6-2 Function Manifold Components -
GS-2032, GS-2632, GS-3232, GS-2046, GS-2646 and GS-3246 .... 4 - 90
6-3 Outrigger Function Manifold Components -
GS-3232 ........................................................................................... 4 - 92
6-4 Outrigger Cylinder Manifold Components -
GS-3232 ........................................................................................... 4 - 93
6-5 Check Valve Manifold Components -
GS-1530, GS-1532, GS-1930 and GS-1932 .................................... 4 - 94
6-6 Valve Adjustments - Function Manifold ............................................ 4 - 95
6-7 Valve Coils ....................................................................................... 4 - 99
B Hydraulic Tank
7-1 Hydraulic Tank ............................................................................... 4 - 101
B Steer Axle Components
8-1 Yoke and Drive Motor .................................................................... 4 - 102
8-2 Steer Cylinder ................................................................................ 4 - 103
8-3 Steer Bellcrank ............................................................................... 4 - 104
A Non-steer Axle Components
9-1 Drive Brake .................................................................................... 4 - 105
A Brake Release Hand Pump Components
10-1 Brake Release Hand Pump Components ....................................... 4 - 106
A Outrigger Components
11-1 Outrigger Cylinder .......................................................................... 4 - 107

x GS-30 • GS-32 • GS-46 Part No. 97385


January 2011

TABLE OF CONTENTS

Section 5 Rev Fault Codes


Introduction .................................................................................................. 5 - 1
C Fault Code Chart ......................................................................................... 5 - 3
B Outrigger Fault Code Chart .......................................................................... 5 - 5

Section 6 Rev Schematics


Introduction .................................................................................................. 6 - 1
C Electrical Component Legend ...................................................................... 6 - 2
B Wire Color Legend ....................................................................................... 6 - 3
D ECM Pin-out Legend ................................................................................... 6 - 4
A Outrigger ECM Pin-out Legend .................................................................... 6 - 5
B Wiring Diagram - Ground Controls and Level Sensor Harness .................... 6 - 6
B Wiring Diagram - Platform Control Box and Outrigger Control Pad .............. 6 - 7
C Limit Switch Legend ..................................................................................... 6 - 8
B Electrical Symbols Legend ........................................................................... 6 - 9
Electrical Schematics - ANSI, CSA and Australia Models
E GS-1530/1532/1930/1932
(from serial number GS3005A-76000 to GS3006A-83067)
(from serial number GS3005B-76000 to GS3006B-79659) ........................ 6 - 10
C GS-1530/1532/1930/1932
(from serial number GS3006A-83068 to GS3007A-87490)
(from serial number GS3006B-79660 to GS3007B-82543) ........................ 6 - 14
B GS-1530/1532/1930/1932
(from serial number GS3007A-87491 to GS3007A-89537)
(from serial number GS3007B-82544 to GS3007B-84599) ........................ 6 - 18
C GS-1530/1532/1930/1932
(after serial number GS3007A-89537)
(after serial number GS3007B-84599) ....................................................... 6 - 22
E GS-2032/2632
(from serial number GS3205-75407 to GS3206-79991)
GS-2046/2646/3246
(from serial number GS4605-75438 to GS4606-78915) ............................ 6 - 26
C GS-2032/2632
(from serial number GS3206-79992 to GS3207-83650)
GS-2046/2646/3246
(from serial number GS4606-78916 to GS4607-82535) ............................. 6 - 30

Part No. 97385 GS-30 • GS-32 • GS-46 xi


January 2011

TABLE OF CONTENTS

Section 6 Rev Schematics, continued


B GS-2032/2632
(from serial number GS3207-83651 to GS3207-84866)
GS-2046/2646/3246
(from serial number GS4607-82536 to GS4607-84839) ............................ 6 - 34
C GS-2032/2632/3232
(after serial number GS3207-84866)
GS-2046/2646/3246
(after serial number GS4607-84839) ......................................................... 6 - 38
Electrical Schematics - CE Models
E GS-1530/1532/1930/1932
(from serial number GS3005A-76000 to GS3005A-76388)
(from serial number GS3005B-76000 to GS3005B-76030) ........................ 6 - 42
E GS-1530/1532/1930/1932
(from serial number GS3005A-76389 to GS3005A-79394)
(from serial number GS3005B-76031 to GS3005B-76920) ........................ 6 - 46
D GS-1530/1532/1930/1932
(from serial number GS3005A-79395 to GS3006A-83067)
(from serial number GS3005B-76921 to GS3006B-79659) ........................ 6 - 50
C GS-1530/1532/1930/1932
(from serial number GS3006A-83068 to GS3007A-87490)
(from serial number GS3006B-79660 to GS3007B-82543) ........................ 6 - 54
B GS-1530/1532/1930/1932
(from serial number GS3007A-87491 to GS3007A-89537)
(from serial number GS3007B-82544 to GS3007B-84599) ........................ 6 - 58
F GS-1530/1532/1930/1932
(after serial number GS3007A-89537 and GS3007B-84599)
(from serial number GS3008C-101) ........................................................... 6 - 62
E GS-2032/2632
(from serial number GS3205-75407 to GS3205-77290)
GS-2046/2646/3246
(from serial number GS4605-75438 to GS4605-76734) ............................ 6 - 66
D GS-2032/2632
(from serial number GS3205-77291 to GS3206-79991)
GS-2046/2646/3246
(from serial number GS4605-76735 to GS4606-78915) ............................. 6 - 70

xii GS-30 • GS-32 • GS-46 Part No. 97385


January 2011

TABLE OF CONTENTS

Section 6 Rev Schematics, continued


C GS-2032/2632
(from serial number GS3206-79992 to GS32007-83650)
GS-2046/2646/3246
(from serial number GS4606-78916 to GS4607-82535) ............................ 6 - 74
B GS-2032/2632
(from serial number GS3207-83651 to GS32007-84866)
GS-2046/2646/3246
(from serial number GS4607-82536 to GS4607-84839) ............................ 6 - 78
F GS-2032/2632/GS-3232
(after serial number GS32007-84866 and from GS3208C-101)
GS-2046/2646/3246
(after serial number GS4607-84839 and from GS4609C-101) ................... 6 - 82
Hydraulic Schematics
B Component Reference and Hydraulic Symbols Legend ............................. 6 - 86
B GS-1530/1532/1930/1932
(from serial number GS3005A-76000 to 76491)
(from serial number GS3005B-76000 to 76084) ........................................ 6 - 88
D GS-1530/1532/1930/1932
(after serial number GS3005A-76491)
(after serial number GS3005B-76084)
(from serial number GS3008C-101) ........................................................... 6 - 89
D GS-2032/2632
(from serial number GS3205-75407 to GS3206-80131)
GS-2046/2646/3246
(from serial number GS4605-75438 to GS4606-79027) ............................. 6 - 90
A GS-2032/2632
(from serial number GS3206-80132 to GS3207-84866)
GS-2046/2646/3246
(form serial number GS4606-79028 to GS4607-84839) ............................ 6 - 91
D GS-2032/2632/3232
(after serial number GS3207-84866 and from GS3208C-101)
GS-2046/2646/3246
(after serial number GS4607-84839 and from GS4609-101) ..................... 6 - 92
D GS-3232
(from serial number GS3207-84867)
(from serial number GS3208C-101) ........................................................... 6 - 93

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January 2011

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GS-30 • GS-32 • GS-46 Part No. 97385


February 2009 Section 2 • Specifications

REV G
Specifications
Machine Specifications Tires and wheels

Batteries, Standard GS-1530, GS-1532, GS-1930, GS-1932

Voltage 6V DC Tire size (solid rubber) 12 x 4.5 in


30.5 x 11.4 cm
Group GC2
Tire contact area 9 sq in
Type T-105 58 cm2

Quantity 4 Castle nut torque, dry 300 ft-lbs


406.7 Nm
Battery capacity, maximum 225AH
Castle nut torque, lubricated 225 ft-lbs
Reserve capacity @ 25A rate 447 minutes 305 Nm
Weight, each 62 lbs GS-2032, GS-2632, GS-3232, GS-2046, GS-2646,
28 kg GS-3246
Batteries, Maintenance-free (option) Tire size (solid rubber) 15 x 5 in
38.1 x 12.7 cm
Voltage 6V DC
Tire contact area 15 sq in
Group GC2 96.7 cm2
Type 6V-AGM Castle nut torque, dry 300 ft-lbs
Quantity 4 406.7 Nm

Battery capacity, maximum 200AH Castle nut torque, lubricated 225 ft-lbs
305 Nm
Reserve capacity @ 25A rate 380 minutes

Weight, each 62 lbs Continuous improvement of our products is a


28 kg Genie policy. Product specifications are
Fluid capacities subject to change without notice.

Hydraulic tank 3.75 gallons


All models 14.2 liters

Hydraulic system (including tank) 5 gallons


GS-3232 and GS-3246 19 liters

Hydraulic system (including tank) 4.5 gallons


All other models 18 liters

For operational specifications, refer to the


Operator's Manual.

Part No. 97385 GS-30 • GS-32 • GS-46 2-1


Section 2 • Specifications February 2009

SPECIFICATIONS REV G

Performance Specifications Function speed, maximum from platform controls


(with 1 person in platform)
Drive speed, maximum
GS-1530 and GS-1532
GS-1530, GS-1532, GS-1930 and GS-1932
Platform up 15 to 17 seconds
Platform stowed, fast 2.5 mph Platform down 16 to 18 seconds
40 ft / 10.7 sec
4 km/h GS-1930 and GS-1932
12.2 m / 10.7 sec Platform up 15 to 17 seconds
Platform stowed, slow 1.1 mph Platform down 22 to 24 seconds
40 ft / 24.8 sec GS-2032 and GS-2046
1.8 km/h
12.2 m / 24.8 sec Platform up 28 to 32 seconds
Platform down 26 to 30 seconds
Platform raised 0.5 mph
40 ft / 55 sec GS-2632 and GS-2646
0.8 km/h
12.2 m / 55 sec Platform up 28 to 32 seconds
Platform down 22 to 26 seconds
GS-2032, GS-2632, GS-3232, GS-2046, GS-2646 and
GS-3246 GS-3232 and GS-3246

Platform stowed, fast 2.2 mph Platform up 55 to 59 seconds


40 ft / 12.4 sec Platform down 38 to 42 seconds
3.5 km/h
12.2 m / 12.4 sec Rated work load at full height, maximum

Platform stowed, slow 1.1 mph GS-1530 and GS-1532 600 lbs
40 ft / 24.8 sec 272 kg
1.8 km/h GS-1930, GS-1932, GS-2632 and GS-3232 500 lbs
12.2 m / 24.8 sec 227 kg
Platform raised 0.5 mph GS-2032 800 lbs
40 ft / 55 sec 363 kg
0.8 km/h
12.2 m / 55 sec GS-2046 1200 lbs
544 kg
Braking distance, maximum
GS-2646 1000 lbs
High range on paved surface 24 in ± 12 in 454 kg
61 cm ± 30 cm
GS-3246 700 lbs
Gradeability 317 kg
GS-1930, GS-1932, GS-2632, GS-3232 Outrigger leveling capacity, maximum
GS-3232 and GS-3246 25%
Side to side 5°
GS-1530, GS-1532, GS-2032, Front to rear 3°
GS-2046 and GS-2646 30%

Airborne noise emissions <70 dB Continuous improvement of our products is a


Maximum sound level at normal operation workstations Genie policy. Product specifications are
(A-weighted) subject to change without notice.

2-2 GS-30 • GS-32 • GS-46 Part No. 97385


February 2009 Section 2 • Specifications

REV G SPECIFICATIONS

Hydraulic Specifications Function pump

Hydraulic Oil Specifications Type Gear

Hydraulic oil type Chevron Rando HD equivalent Displacement per revolution 0.244 cu in
Viscosity grade Multi-viscosity 4 cc
Viscosity index 200 Flow rate @ 2500 psi / 172 bar 4 gpm
Cleanliness level, minimum 15/13 15 L/min

Water content, maximum 200 ppm Hydraulic tank return filter 10 micron with
25 psi / 1.7 bar bypass
Chevron Rando HD oil is fully compatible and
mixable with Shell Donax TG (Dexron III) oils. Function manifold
Genie specifications require hydraulic oils which are System relief valve pressure, maximum 3700 psi
designed to give maximum protection to hydraulic 255 bar
systems, have the ability to perform over a wide
temperature range, and the viscosity index should Lift relief valve pressure 1800 to 3700 psi
exceed 140. They should provide excellent antiwear, 124 to 241 bar
oxidation, corrosion inhibition, seal conditioning, and
foam and aeration suppression properties. Steer relief valve pressure 1500 psi
103 bar
Optional fluids
Outrigger manifold
Biodegradable Petro Canada Environ MV 46
Statoil Hydra Way Bio Pa 32 Relief valve pressure, maximum 3500 psi
BP Biohyd SE-S 241 bar

Fire resistant UCON Hydrolube HP-5046 Check valve manifold -


Quintolubric 822 GS-1530, GS-1532, GS-1930, GS-1932

Mineral based Shell Tellus T32 Check valve pressure, maximum 200 psi
Shell Tellus T46 13.8 bar
Chevron Aviation A

Continuous improvement of our products is a


Continued use of Chevron Genie policy. Product specifications are
Aviation A hydraulic fluid when subject to change without notice.
ambient temperatures are
consistently above 32°F / 0°C may
result in component damage.
Note: Use Chevron Aviation A hydraulic fluid
when ambient temperatures consistently below
0°F / -17°C.

Note: Use Shell Tellus T46 hydraulic oil when oil


temperatures consistently exceed 205°F / 96°C.
Note: Genie specifications require additional
equipment and special installation instructions for
the approved optional fluids. Consult the Genie
Industries Service Department before use.

Part No. 97385 GS-30 • GS-32 • GS-46 2-3


Section 2 • Specifications February 2009

SPECIFICATIONS REV G

Manifold Component Valve Coil Resistance


Specifications Note: The following coil resistance specifications are at
an ambient temperature of 68°F / 20°C. As valve coil
Plug torque resistance is sensitive to changes in air temperature,
the coil resistance will typically increase or decrease by
SAE No. 2 50 in-lbs / 6 Nm 4% for each 18°F / -7.7°C that your air temperature
SAE No. 4 13 ft-lbs / 18 Nm increases or decreases from 68°F / 20°C.

SAE No. 6 18 ft-lbs / 24 Nm Description Specification

SAE No. 8 50 ft-lbs / 68 Nm Solenoid valve, 3 position 4 way 27.2Ω


20V DC with diode (schematic items F and AC)
SAE No. 10 55 ft-lbs / 75 Nm
Solenoid valve, 3 position 4 way 19Ω
SAE No. 12 75 ft-lbs / 102 Nm 20V DC with diode (schematic item E)

Solenoid valve, 2 position 4 way 19Ω


20V DC with diode (schematic item H and AI)

Solenoid valve, 2 position 2 way N.C. 25Ω


20V DC with diode (schematic item N)

Solenoid valve, 2 position 4 way 19Ω


20V DC with diode (schematic items AE)

Solenoid valve, 3 position 5 way 19Ω


20V DC with diode (schematic item AG)

Solenoid valve, 2 position 2 way 27.2Ω


20V DC with diode (schematic item CA, CB, CC
and CD)

Solenoid valve, 3 position 4 way 19Ω


20V DC with diode (schematic item BA)

Continuous improvement of our products is a


Genie policy. Product specifications are
subject to change without notice.

2-4 GS-30 • GS-32 • GS-46 Part No. 97385


February 2009 Section 2 • Specifications

REV G SPECIFICATIONS

Hydraulic Hose and Fitting


Torque Specifications
Your machine is equipped with JIC 37° flared
fittings and hose ends. Genie specifications require
that fittings and hose ends be torqued to
specification when they are removed and installed
or when new hoses or fittings are installed.

SAE O-ring Boss Port JIC 37° Fittings


(tube fitting - installed into Aluminum) (swivel nut or hose connection)

SAE Dash size Torque SAE Dash size Thread Size Flats

-4 11 ft-lbs / 14.9 Nm -4 7/16-20 2

-6 23 ft-lbs / 31.2 Nm -6 9/16-18 1 1/4

-8 40 ft-lbs / 54.2 Nm -8 3/4-16 1

-10 69 ft-lbs / 93.6 Nm -10 7/8-14 1

-12 93 ft-lbs / 126.1 Nm -12 1 1/16-12 1

-16 139 ft-lbs / 188.5 Nm -16 1 5/16-12 1

-20 172 ft-lbs / 233.2 Nm -20 1 5/8-12 1

-24 208 ft-lbs / 282 Nm -24 1 7/8-12 1

SAE O-ring Boss Port


(tube fitting - installed into Steel)

SAE Dash size Torque

-4 16 ft-lbs / 21.7 Nm

-6 35 ft-lbs / 47.5 Nm

-8 60 ft-lbs / 81.3 Nm

-10 105 ft-lbs / 142.4 Nm

-12 140 ft-lbs / 190 Nm

-16 210 ft-lbs / 284.7 Nm

-20 260 ft-lbs / 352.5 Nm

-24 315 ft-lbs / 427.1 Nm

Part No. 97385 GS-30 • GS-32 • GS-46 2-5


Section 2 • Specifications February 2009

SPECIFICATIONS REV G

Torque Procedure 3 Working clockwise on the body hex fitting, make


a second mark with a permanent ink marker to
JIC 37° fittings indicate the proper tightening position. Refer to
Figure 2.
1 Align the tube flare (hex nut) against the nose of
the fitting body (body hex fitting) and tighten the Note: Use the JIC 37° Fittings table on the
hex nut to the body hex fitting to hand-tight, previous page to determine the correct number of
approximately 30 in-lbs / 3.4 Nm. flats for the proper tightening position.
2 Make a reference mark on one of the flats of the Note: The marks indicate that the correct tightening
hex nut, and continue it on to the body hex positions have been determined. Use the second
fitting with a permanent ink marker. Refer to mark on the body hex fitting to properly tighten the
Figure 1. joint after it has been loosened.
a

b
b
a
c
d c
b

Figure 1 Figure 2

a hydraulic hose a body hex fitting


b hex nut b reference mark
c reference mark c second mark
d body hex fitting
4 Tighten the hex nut until the mark on the hex
nut is aligned with the second mark on the body
hex fitting.
5 Operate all machine functions and inspect the
hoses and fittings and related components to
confirm that there are no leaks.

2-6 GS-30 • GS-32 • GS-46 Part No. 97385


February 2009 Section 2 • Specifications

REV G SPECIFICATIONS

SAE FASTENER TORQUE CHART


• This chart is to be used as a guide only unless noted elsewhere in this manual •
A574 High Strength
SIZE THREAD Grade 5 Grade 8 Black Oxide Bolts
LUBED DRY LUBED DRY LUBED
in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm
1/4 20 80 9 100 11.3 110 12.4 140 15.8 130 14.7
28 90 10.1 120 13.5 120 13.5 160 18 140 15.8
LUBED DRY LUBED DRY LUBED
ft - lbs Nm f t - lbs Nm f t - lbs Nm f t - lbs Nm f t - lbs Nm
5/16 18 13 17.6 17 23 18 24 25 33.9 21 28.4
24 14 19 19 25.7 20 27.1 27 36.6 24 32.5
3/8 16 23 31.2 31 42 33 44.7 44 59.6 38 51.5
24 26 35.2 35 47.4 37 50.1 49 66.4 43 58.3
7/16 14 37 50.1 49 66.4 50 67.8 70 94.7 61 82.7
20 41 55.5 55 74.5 60 81.3 80 108.4 68 92.1
1/2 13 57 77.3 75 101.6 80 108.4 110 149 93 126
20 64 86.7 85 115 90 122 120 162 105 142
9/16 12 80 108.4 110 149 120 162 150 203 130 176
18 90 122 120 162 130 176 170 230 140 189
5/8 11 110 149 150 203 160 217 210 284 180 244
18 130 176 170 230 180 244 240 325 200 271
3/4 10 200 271 270 366 280 379 380 515 320 433
16 220 298 300 406 310 420 420 569 350 474
7/8 9 320 433 430 583 450 610 610 827 510 691
14 350 474 470 637 500 678 670 908 560 759
8 480 650 640 867 680 922 910 1233 770 1044
1
12 530 718 710 962 750 1016 990 1342 840 1139
7 590 800 790 1071 970 1315 1290 1749 1090 1477
1 1/8
12 670 908 890 1206 1080 1464 1440 1952 1220 1654
7 840 1138 1120 1518 1360 1844 1820 2467 1530 2074
1 1/4
12 930 1260 1240 1681 1510 2047 2010 2725 1700 2304
6 1460 1979 1950 2643 2370 3213 3160 4284 2670 3620
1 1/2
12 1640 2223 2190 2969 2670 3620 3560 4826 3000 4067

METRIC FASTENER TORQUE CHART


• This chart is to be used as a guide only unless noted elsewhere in this manual •

Size Class 4.6 4.6 Class 8.8 8.8 Class 10.9 10.9 Class 12.9 12.9

(m m ) LUBED DRY LUBED DRY LUBED DRY LUBED DRY


in- lbs Nm in- lbs Nm in-lbs Nm in-lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm
5 16 1.8 21 2.4 41 4.63 54 6.18 58 6.63 78 8.84 68 7.75 91 10.3
6 19 3.05 36 4.07 69 7.87 93 10.5 100 11.3 132 15 116 13.2 155 17.6
7 45 5.12 60 6.83 116 13.2 155 17.6 167 18.9 223 25.2 1.95 22.1 260 29.4
LUBED DRY LUBED DRY LUBED DRY LUBED DRY
f t- lbs Nm f t- lbs Nm f t -lbs Nm f t -lbs Nm f t - lbs Nm f t - lbs Nm f t - lbs Nm ft - lbs Nm
8 5.4 7.41 7.2 9.88 14 19.1 18.8 25.5 20.1 27.3 26.9 36.5 23.6 32 31.4 42.6
10 10.8 14.7 14.4 19.6 27.9 37.8 37.2 50.5 39.9 54.1 53.2 72.2 46.7 63.3 62.3 84.4
12 18.9 25.6 25.1 34.1 48.6 66 64.9 88 69.7 94.5 92.2 125 81 110 108 147
14 30.1 40.8 40 54.3 77.4 105 103 140 110 150 147 200 129 175 172 234
16 46.9 63.6 62.5 84.8 125 170 166 226 173 235 230 313 202 274 269 365
18 64.5 87.5 86.2 117 171 233 229 311 238 323 317 430 278 377 371 503
20 91 124 121 165 243 330 325 441 337 458 450 610 394 535 525 713
22 124 169 166 225 331 450 442 600 458 622 612 830 536 727 715 970
24 157 214 210 285 420 570 562 762 583 791 778 1055 682 925 909 1233

Part No. 97385 GS-30 • GS-32 • GS-46 2-7


Section 2 • Specifications February 2009

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2-8 GS-30 • GS-32 • GS-46 Part No. 97385


April 2008 Section 3 • 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 a person trained and qualified on the Safety alert symbol—used to alert
maintenance of this machine. personnel to potential personal
injury hazards. Obey all safety
Scheduled maintenance inspections shall be messages that follow this symbol
completed daily, quarterly, semi-annually, to avoid possible injury or death.
annually and every 2 years as specified on the
Maintenance Inspection Report. Indicates an imminently hazardous
situation which, if not avoided, will
Failure to properly complete each result in death or serious injury.
inspection when required may
cause death, serious injury or Indicates a potentially hazardous
substantial machine damage. situation which, if not avoided,
could result in death or serious
Immediately tag and remove from service a injury.
damaged or malfunctioning machine.
Indicates a potentially hazardous
Repair any machine damage or malfunction situation which, if not avoided,
before operating the machine. may cause minor or moderate
injury.
Use only Genie approved replacement parts.
Indicates a potentially hazardous
Machines that have been out of service for a situation which, if not avoided,
period longer than 3 months must complete the may result in property damage.
quarterly inspection.
Indicates that a specific result is expected after
Unless otherwise specified, perform each performing a series of steps.
procedure with the machine in the following
configuration: Indicates that an incorrect result has occurred
after performing a series of steps.
· Machine parked on a firm, level surface
· Platform in the stowed position
· Key switch in the off position with the key
removed
· The red Emergency Stop button in the off
position at both ground and platform controls
· Wheels chocked
· All external AC power supply disconnected
from the machine

Part No. 97385 GS-30 • GS-32 • GS-46 3-1


Section 3 • Scheduled Maintenance Procedures April 2008

SCHEDULED MAINTENANCE PROCEDURES

Maintenance Symbols Legend Pre-delivery Preparation Report


Note: The following symbols have been used in The pre-delivery preparation report contains
this manual to help communicate the intent of the checklists for each type of scheduled inspection.
instructions. When one or more of the symbols
appears at the beginning of a maintenance Make copies of the Pre-delivery Preparation report
procedure, it conveys the meaning below. to use for each inspection. Store completed forms
as required.

Maintenance Schedule
Indicates that tools will be required to
perform this procedure. There are five types of maintenance inspections
that must be performed according to a schedule—
daily, quarterly, semi-annually, annually, and
two year. The Scheduled Maintenance Procedures
Indicates that new parts will be required
Section and the Maintenance Inspection Report
to perform this procedure.
have been divided into five subsections—A, B, C,
D, and E. Use the following chart to determine
which group(s) of procedures are required to
Indicates that a cold motor or pump will perform a scheduled inspection.
be required to perform this procedure.
Inspection Checklist

Indicates that dealer service will be Daily or every 8 hours A


required to perform this procedure.
Quarterly or every 250 hours A+B

Semi-annually or every 500 hours A+B+C

Annually or every 1000 hours A+B+C+D

Two year or every 2000 hours A+B+C+D+E

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. Maintain completed
forms for a minimum of 4 years or in compliance
with your employer, jobsite and governmental
regulations and requirements.

3-2 GS-30 • GS-32 • GS-46 Part No. 97385


Pre-Deliver
Pre-Deliveryy Preparation
April 2008 Section 3 • Scheduled Maintenance Procedures

Fundamentals Instructions
It is the responsibility of the dealer to perform the Use the operator’s manual on your machine.
Pre-delivery Preparation.
The Pre-delivery Preparation consists of completing
The Pre-delivery Preparation is performed prior to the Pre-operation Inspection, the Maintenance items
each delivery. The inspection is designed to discover if and the Function Tests.
anything is apparently wrong with a machine before it
is put into service. Use this form to record the results. Place a check in
the appropriate box after each part is completed.
A damaged or modified machine must never be used. Follow the instructions in the operator’s manual.
If damage or any variation from factory delivered
condition is discovered, the machine must be tagged If any inspection receives an N, remove the machine
and removed from service. from service, repair and re-inspect it. After repair,
place a check in the R box.
Repairs to the machine may only be made by a
qualified service technician, according to the Legend
manufacturer's specifications. Y = yes, completed
Scheduled maintenance inspections shall be N = no, unable to complete
performed by qualified service technicians, according R = repaired
to the manufacturer's specifications and the Comments
requirements listed in the responsibilities manual.

Pre-Delivery Preparation Y N R
Pre-operation inspection
completed
Maintenance items completed
Function tests completed

Model

Serial number

Date

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

Genie Industries USA Genie UK


18340 NE 76th Street The Maltings, Wharf Road
PO Box 97030 Grantham, Lincolnshire
Redmond, WA 98073-9730 NG31- 6BH England
(425) 881-1800 (44) 1476-584333
Copyright © 2002 by Genie Industries. Genie® is a registered trademark of Genie
Industries. Rev B
Part No. 97385 GS-30 • GS-32 • GS-46 3-3
Section 3 • Scheduled Maintenance Procedures November 2008

This page intentionally left blank.

3-4 GS-30 • GS-32 • GS-46 Part No. 97385


June 2009 Section 3 • Scheduled Maintenance Procedures

Maintenance Inspection Report


Model Checklist A - Rev C Y N R Checklist B - Rev J Y N R
A-1 Inspect the manuals B-1 Batteries
Serial number and decals B-2 Electrical wiring
Date A-2 Pre-operation B-3 Tires and wheels
inspection
B-4 Emergency stop
Hour meter A-3 Function tests
B-5 Key switch
Perform after 40 hours:
Machine owner B-6 Horn (if equipped)
A-4 30 day service
B-7 Drive brakes
Inspected by (print) Perform every 100 hours:
B-8 Drive speed - stowed
A-5 Grease steer yokes
B-9 Drive speed - raised
Inspector signature
B-10 Drive speed - slow
Inspector title B-11 Hydraulic oil analysis
B-12 Tank venting system
Inspector company
B-13 Latch components

Instructions B-14 Voltage inverter


(if equipped)
· Make copies of this report to use for
each inspection. B-15 Test the down and
pothole limit switches
· Select the appropriate checklist(s) for
the type of inspection to be B-16 Test the up and
performed. outrigger limit switches
(if equipped)
Daily or 8 hours
Inspection: A
Checklist C - Rev C Y N R
Quarterly or 250 hours C-1 Platform overload
Inspection: A+B (if equipped)
Semi-annually or C-2 Breather cap - models
500 hours with optional oil
Inspection: A+B+C
Annually or
Checklist D - Rev E Y N R
1000 hours
Inspection: A+B+C+D D-1 Scissor arm wear pads

Two year or D-2 Hydraulic filter


2000 hours
Inspection: A+B+C+D+E Checklist E - Rev C Y N R
· Place a check in the appropriate box E-1 Hydraulic oil
after each inspection procedure is
completed.
Comments
· Use the step-by-step procedures in
this section to learn how to perform
these inspections.
· If any inspection receives an “N”, tag
and remove the machine from service,
repair and re-inspect it. After repair,
place a check in the “R” box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired

Part No. 97385 GS-30 • GS-32 • GS-46 3-5


Section 3 • Scheduled Maintenance Procedures March 2007

Checklist A Procedures REV C

A-1 3 Open the operator's manual to the decals


inspection section. Carefully and thoroughly
Inspect the Manuals and Decals inspect all decals on the machine for legibility
Maintaining the operator’s and safety manuals in and damage.
good condition is essential to safe machine Result: The machine is equipped with all
operation. Manuals are included with each required decals, and all decals are legible and
machine and should be stored in the container in good condition.
provided in the platform. An illegible or missing
manual will not provide safety and operational Result: The machine is not equipped with all
information necessary for a safe operating required decals, or one or more decals are
condition. illegible or in poor condition. Remove the
machine from service until the decals are
In addition, maintaining all of the safety and replaced.
instructional decals in good condition is mandatory
for safe machine operation. Decals alert operators 4 Always return the manuals to the storage
and personnel to the many possible hazards container after use.
associated with using this machine. They also Note: Contact your authorized Genie distributor or
provide users with operation and maintenance Genie Industries if replacement manuals or decals
information. An illegible decal will fail to alert are needed.
personnel of a procedure or hazard and could
result in unsafe operating conditions.
1 Check to make sure that the operator's and
safety manuals are present and complete in the
storage container on the platform.
2 Examine the pages of each manual to be sure
that they are legible and in good condition.
Result: The operator's manual is appropriate for
the machine and all manuals are legible and in
good condition.
Result: The operator's manual is not
appropriate for the machine or all manuals are
not in good condition or is illegible. Remove the
machine from service until the manual is
replaced.

3-6 GS-30 • GS-32 • GS-46 Part No. 97385


March 2007 Section 3 • Scheduled Maintenance Procedures

REV C CHECKLIST A PROCEDURES

A-2 A-3
Perform Pre-operation Inspection Perform Function Tests
Completing a Pre-operation Inspection is essential Completing the function tests is essential to safe
to safe machine operation. The Pre-operation machine operation. Function tests are designed to
Inspection is a visual inspection performed by the discover any malfunctions before the machine is
operator prior to each work shift. The inspection is put into service. A malfunctioning machine must
designed to discover if anything is apparently never be used. If malfunctions are discovered, the
wrong with a machine before the operator performs machine must be tagged and removed from
the function tests. The Pre-operation Inspection service.
also serves to determine if routine maintenance
procedures are required. Complete information to perform this procedure is
available in the appropriate operator's manual.
Complete information to perform this procedure is Refer to the Operator's Manual on your machine.
available in the appropriate operator's manual.
Refer to the Operator's Manual on your machine.

Part No. 97385 GS-30 • GS-32 • GS-46 3-7


Section 3 • Scheduled Maintenance Procedures March 2007

CHECKLIST A PROCEDURES REV C

A-4 A-5
Perform 30 Day Service Grease the Steer Yokes

The 30 day maintenance procedure is a one time Genie specifications require that this procedure be
procedure to be performed after the first 30 days or performed every 100 hours of operation.
40 hours of usage. After this interval, refer to the
maintenance tables for continued scheduled Regular application of lubrication to the steer yokes
maintenance. is essential to good machine performance and
service life. Continued use of an insufficiently
1 Perform the following maintenance procedures: greased steer yoke will result in component
damage.
· B-3 Inspect the Tires, Wheels and
Castle Nut Torque 1 Locate the grease fitting on the top of the steer
· D-2 Replace the Hydraulic Tank yoke.
Return Filter Element 2 Pump multipurpose grease into the steer yoke
until the steer yoke is full and grease is being
forced past the bearings. Repeat this step for
the other steer yoke.

Grease Specification

Chevron Ultra-duty grease, EP NLGI 1 (lithium based)


or equivalent

3-8 GS-30 • GS-32 • GS-46 Part No. 97385


June 2009 Section 3 • Scheduled Maintenance Procedures

REV J
Checklist B Procedures
B-1 Models without maintenance-free or sealed
batteries:
Inspect the Batteries
6 Remove the battery vent caps and check the
specific gravity of each battery cell with a
hydrometer. Note the results.
Genie requires that this procedure be performed 7 Check the ambient air temperature and adjust
every 250 hours or quarterly, whichever comes the specific gravity reading for each cell as
first. follows:
Proper battery condition is essential to good • Add 0.004 to the reading of each cell for
machine performance and operational safety. every 10° / 5.5° C above 80° F / 26.7° C.
Improper fluid levels or damaged cables and
• Subtract 0.004 from the reading of each cell for
connections can result in component damage and
every 10° / 5.5° C below 80° F / 26.7° C.
hazardous conditions.
Result: All battery cells display an adjusted
Electrocution/burn hazard. Contact specific gravity of 1.277 or higher. The battery
with electrically charged circuits is fully charged. Proceed to step 11.
could result in death or serious
injury. Remove all rings, watches Result: One or more battery cells display a
and other jewelry. specific gravity of 1.217 or below. Proceed to
step 8.
Bodily injury hazard. Batteries
contain acid. Avoid spilling or 8 Perform an equalizing charge OR fully charge
contacting battery acid. Neutralize the batteries and allow the batteries to rest at
battery acid spills with baking soda least 6 hours.
and water. 9 Remove the battery vent caps and check the
1 Release the battery pack latch and rotate the specific gravity of each battery cell with a
battery pack out and away from the chassis. hydrometer. Note the results.

2 Be sure that the battery cable connections are 10 Check the ambient air temperature and adjust
free of corrosion. the specific gravity reading for each cell as
follows:
Note: Adding terminal protectors and a corrosion
preventative sealant will help eliminate corrosion • Add 0.004 to the reading of each cell for
on the battery terminals and cables. every 10° / 5.5° C above 80° F / 26.7° C.

3 Be sure that the battery retainers and cable • Subtract 0.004 from the reading of each cell for
connections are tight. every 10° / 5.5° C below 80° F / 26.7° C.

4 Fully charge the batteries. Allow the batteries to Result: All battery cells display a specific gravity
rest 24 hours before performing this procedure of 1.277 or greater. The battery is fully charged.
to allow the battery cells to equalize. Proceed to step 11.

5 Put on protective clothing and eye wear. Result: The difference in specific gravity
readings between cells is greater than 0.1 OR
the specific gravity of one or more cells is less
than 1.177. Replace the battery.

Part No. 97385 GS-30 • GS-32 • GS-46 3-9


Section 3 • Scheduled Maintenance Procedures June 2009

CHECKLIST B PROCEDURES REV J

11 Check the battery acid level. If needed, All models:


replenish with distilled water to 1/8 inch / 3 mm
below the bottom of the battery fill tube. Do not 13 Check each battery pack and verify that the
overfill. batteries are wired correctly.

12 Install the vent caps and neutralize any 14 Inspect the battery charger plug and pigtail for
electrolyte that may have spilled. damage or excessive insulation wear. Replace
as required.
+

15 Connect the battery charger to a properly


grounded 115V/60Hz or 230V/60Hz single
phase AC power supply.
- -
Result: The charger should operate and begin
charging the batteries.
- -
If, simultaneously, the charger alarm sounds
a and the LEDs blink one time, correct the
charger connections at the fuse and battery.
The charger will then operate correctly and
+

begin charging the batteries.


b
F6 If, simultaneously, the charger alarm sounds
275A Fuse
and the LEDs blink two times, the input voltage
+ -

QD1 c
is too low or too high. Correct the voltage issue.
The charger will then operate correctly and
BK RD begin charging the batteries.
U9
Battery Charger d If, simultaneously, the charger alarm sounds
and the LEDs blink three times, the charger is
overheated. Allow the charger to cool. The
charger will then operate correctly and begin
a batteries B5
b 275A fuse F6 charging the batteries.
c quick disconnect QD1
d battery charger U9
Note: For best results, use an extension of
adequate size with a length no longer than
50 feet / 15 m.

Note: If you have any further questions regarding


the battery charger operation, please contact the
Genie Industries Scissor Service Department.

3 - 10 GS-30 • GS-32 • GS-46 Part No. 97385


June 2009 Section 3 • Scheduled Maintenance Procedures

REV J CHECKLIST B PROCEDURES

B-2 4 Turn the key switch to ground control and pull


out the red Emergency Stop button to the on
Inspect the Electrical Wiring position at both the ground and platform
controls.
5 Raise the platform approximately 8 feet / 2.4 m
from the ground.
Genie requires that this procedure be performed
every 250 hours or quarterly, whichever comes 6 Rotate the safety arm away from the machine
first. and let it hang down.

Maintaining electrical wiring in good condition is 7 Lower the platform onto the safety arm.
essential to safe operation and good machine Crushing hazard. Keep hands
performance. Failure to find and replace burnt, clear of the safety arm when
chafed, corroded or pinched wires could result in lowering the platform.
unsafe operating conditions and may cause
component damage. 8 Inspect the center chassis area and scissor
arms for burnt, chafed and pinched cables.
Electrocution/burn hazard. Contact
with electrically charged circuits 9 Inspect the following areas for burnt, chafed,
could result in death or serious corroded, pinched and loose wires:
injury. Remove all rings, watches · Scissor arms
and other jewelry.
· ECM to platform controls
1 Inspect the underside of the chassis for
· Power to platform wiring
damaged or missing ground strap(s).
10 Inspect for a liberal coating of dielectric grease
2 Inspect the following areas for burnt, chafed, in all connections between the ECM and the
corroded and loose wires: platform controls.
· Ground control panel 11 Raise the platform and return the safety arm to
· Hydraulic power unit module tray the stowed position.
· Battery pack module tray 12 Lower the platform to the stowed position and
· Scissor arms turn the machine off.
· Platform controls
3 Inspect for a liberal coating of dielectric grease
in the following locations:
· Between the ECM and platform controls
· All wire harness connectors
· Level sensor

Part No. 97385 GS-30 • GS-32 • GS-46 3 - 11


Section 3 • Scheduled Maintenance Procedures June 2009

CHECKLIST B PROCEDURES REV J

B-3 B-4
Inspect the Tires and Wheels Test the Emergency Stop
(including castle nut torque) Genie requires that this procedure be performed
every 250 hours or quarterly, whichever comes
first.

A properly functioning Emergency Stop is essential


Genie requires that this procedure be performed for safe machine operation. An improperly
every 250 hours or quarterly, whichever comes operating red Emergency Stop button will fail to
first. shut off power and stop all machine functions,
Maintaining the tires and wheels in good resulting in a hazardous situation.
condition is essential to safe operation and good As a safety feature, selecting and operating the
performance. Tire and/or wheel failure could result ground controls will override the platform controls,
in a machine tip-over. Component damage may except the platform red Emergency Stop button.
also result if problems are not discovered and
repaired in a timely fashion. 1 Turn the key switch to ground control and pull
out the red Emergency Stop button to the on
1 Check the tire surface and sidewalls for cuts, position at both the ground and platform
cracks, punctures and unusual wear. controls.
2 Check each wheel for damage, bends and 2 Push in the red Emergency Stop button at the
cracks. ground controls to the off position.
3 Remove the cotter pin and check each castle
Result: No machine functions should operate.
nut for proper torque. Refer to Section 2,
Specifications. 3 Turn the key switch to platform control and pull
out the red Emergency Stop button to the on
Note: Always replace the cotter pin with a new one
position at both the ground and platform
when removing the castle nut or when checking
controls.
the torque of the castle nut.
4 Push down the red Emergency Stop button at
4 Install a new cotter pin. Bend the cotter pin to
the platform controls to the off position.
lock it in place.
Result: No machine functions should operate.
Note: The red Emergency Stop button at the
ground controls will stop all machine operation,
even if the key switch is switched to platform
control.

3 - 12 GS-30 • GS-32 • GS-46 Part No. 97385


June 2009 Section 3 • Scheduled Maintenance Procedures

REV J CHECKLIST B PROCEDURES

B-5 B-6
Test the Key Switch Test the Automotive-style Horn
Genie requires that this procedure be performed (if equipped)
every 250 hours or quarterly, whichever comes Genie requires that this procedure be performed
first. every 250 hours or quarterly, whichever comes
Proper key switch action and response is essential first.
to safe machine operation. The machine can be The horn is activated at the platform controls and
operated from the ground or platform controls and sounds at the ground as a warning to ground
the activation of one or the other is accomplished personnel. An improperly functioning horn will
with the key switch. Failure of the key switch to prevent the operator from alerting ground
activate the appropriate control panel could cause personnel of hazards or unsafe conditions.
a hazardous operating situation.
1 Turn the key switch to platform control and
Perform this procedure from the ground using the pull out the red Emergency Stop button to the
platform controls. Do not stand in the platform. on position at both the ground and
1 Pull out the red Emergency Stop button to the platform controls.
on position at both the ground and platform 2 Push down the horn button at the platform
controls. controls.
2 Turn the key switch to platform control. Result: The horn should sound.
3 Check the platform up/down function from the
ground controls.
Result: The machine functions should not
operate.
4 Turn the key switch to ground control.
5 Check the machine functions from the platform
controls.
Result: The machine functions should not
operate.
6 Turn the key switch to the off position.
Result: No function should operate.

Part No. 97385 GS-30 • GS-32 • GS-46 3 - 13


Section 3 • Scheduled Maintenance Procedures June 2009

CHECKLIST B PROCEDURES REV J

B-7 6 Bring the machine to top drive speed before


reaching the test line. Release the function
Test the Drive Brakes enable switch or the joystick when your
reference point on the machine crosses the
test line.
7 Measure the distance between the test line and
Genie requires that this procedure be performed your machine reference point. Refer to Section
every 250 hours or quarterly, whichever comes 2, Specifications.
first.
Result: The machine stops within the specified
Proper brake action is essential to safe machine braking distance. No action required.
operation. The drive brake function should operate
smoothly, free of hesitation, jerking and unusual Result: The machine does not stop within the
noise. Hydraulically-released individual wheel specified braking distance. Proceed to step 8
brakes can appear to operate normally when not and determine if the machine is equipped with
fully operational. a dynamic braking valve.

Perform this procedure with the machine on a firm Note: The brakes must be able to hold the machine
level surface that is free of obstructions, with the on any slope it is able to climb.
platform extension deck fully retracted and the 8 Disconnect the battery pack from the machine.
platform in the stowed position.
Electrocution/burn hazard. Contact
1 Mark a test line on the ground for reference. with electrically charged circuits
2 Turn the key switch to platform control and pull could result in death or serious
out the red Emergency Stop button to the on injury. Remove all rings, watches
position at both the ground and platform and other jewelry.
controls. 9 Locate the drive forward/reverse valve on the
3 Lower the platform to the stowed position. function manifold. Refer to Illustrations 2 and 3.

4 Press the drive function select button. Refer to


a
Illustration 1.

Illustration 1

a drive function select button BN8

5 Choose a point on the machine; i.e., contact GS-1530 • GS-1532 • GS-1930 • GS-1932
patch of a tire, as a visual reference for use
Illustration 2
when crossing the test line.
a drive forward/reserve valve

3 - 14 GS-30 • GS-32 • GS-46 Part No. 97385


June 2009 Section 3 • Scheduled Maintenance Procedures

REV J CHECKLIST B PROCEDURES

12 Carefully inspect the hex portion of the valve for


an identification stamp.
Result: SV10-4727 is stamped on the hex
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.
a
13 Install the drive forward/reverse valve removed
GS-2032 • GS-2632 • GS-3232 in step 11 into the function manifold and torque
GS-2046 • GS-2646 • GS-3246 to 25 ft-lbs / 34 Nm.
Illustration 3
14 In order, install the reverse valve coil (with
a drive forward/reverse valve white/black and brown wires), spacer washer
and the forward valve coil (with white and
10 Tag the forward and the reverse valve coils.
brown wires) onto the valve.
Remove the coils from the valve.
Note: For the machine to function correctly, the
Note: The forward valve coil has white and brown
reverse valve coil must be closest to the manifold.
wires attached.
15 Install the coil nut onto the valve and torque to
Note: The reverse valve coil has white/black and
60 in-lbs / 7 Nm.
brown wires attached.
16 Connect the battery pack to the machine.
Note: For reassembly, it will be helpful to leave the
wire harness attached to the valve coils. 17 Replace the brakes and repeat this procedure
beginning with step 1. Refer to Repair
For GS-1530, GS-1532, GS-1930 and GS-1932 Procedure 9-1, How to Remove a Drive Brake.
(all models) proceed to step 11. Repeat this procedure beginning with step 1.
For GS-2032 and GS-2632 before serial number 18 Contact the Genie Industries Service Parts
GS3204-51608 proceed to step 11. Department and order kit part number 105457.
For GS-2046, GS-2646 and GS-3246 before 19 Install the new valve received in the kit and
serial number GS4604-60000 proceed to mark the new valve with a white paint pen to
step 11. identify new valve installation.

For GS-2032 and GS-2632 after serial number 20 Repeat this procedure beginning with step 1.
GS3204-51607 and from GS3208C-101 proceed If the machine fails to stop within the specified
to step 21. stopping distance after installing new brakes,
For GS-2046, GS-2646 and GS-3246 after please contact the Genie Industries Scissors
serial number GS4604-59999 and from Service Department, 1-800-536-1800 Ext. 8710.
GS4609-101 proceed to step 21.

11 Remove the drive forward/reverse valve from


the function manifold. Plug the open port of the
manifold.

Part No. 97385 GS-30 • GS-32 • GS-46 3 - 15


Section 3 • Scheduled Maintenance Procedures June 2009

CHECKLIST B PROCEDURES REV J

21 Remove the drive forward/reverse valve from 25 Install the coil nut onto the valve and torque to
the function manifold. Plug the open port of the 60 in-lbs 7 Nm.
manifold.
26 Connect the battery pack to the machine.
22 Carefully inspect the hex portion of the valve for
27 Replace the brakes and repeat this procedure
an identification stamp.
beginning with step 1. Refer to Repair
Result: SV10-5905 is stamped on the hex Procedure 9-1, How to Remove a Drive Brake.
portion of the drive forward/reverse valve. Repeat this procedure beginning with step 1.
This indicates the machine is equipped with
28 Contact the Genie Industries Service Parts
a dynamic brake valve. Proceed to step 23.
Department and order kit part number 105458.
Result: SV10-5905 is not stamped on the hex
29 Install the new valve received in the kit and
portion of the drive forward/reverse valve. This
mark the new valve with a white paint pen to
indicates the machine is not equipped with a
identify new valve installation.
dynamic brake valve. Proceed to step 28.
30 Repeat this procedure beginning with step 1.
23 Install the drive forward/reverse valve removed
in step 21 into the function manifold and torque If the machine fails to stop within the specified
to 25 ft-lbs / 34 Nm. stopping distance after installing new brakes,
please contact the Genie Industries Scissors
24 In order, install the reverse valve coil (with
Service Department, 1-800-536-1800 Ext. 8710.
white/black and brown wires), spacer washer
and the forward valve coil (with white and
brown wires) onto the valve.
Note: For the machine to function correctly, the
reverse valve coil must be closest to the manifold.

3 - 16 GS-30 • GS-32 • GS-46 Part No. 97385


June 2009 Section 3 • Scheduled Maintenance Procedures

REV J CHECKLIST B PROCEDURES

B-8 5 Choose a point on the machine; i.e., contact


patch of a tire, as a visual reference for use
Test the Drive Speed - when crossing the start and finish lines.
Stowed Position 6 Bring the machine to top drive speed before
reaching the start line. Begin timing when your
reference point on the machine crosses the
start line.
Genie requires that this procedure be performed
7 Continue at full speed and note the time when
every 250 hours or quarterly, whichever comes
your reference point on the machine passes
first.
over the finish line. Refer to Section 2,
Proper drive functions are essential to safe Specifications.
machine operation. The drive function should
respond quickly and smoothly to operator control.
Drive performance should also be free of
hesitation, jerking and unusual noise over the
entire proportionally controlled speed range.

Perform this procedure with the machine on a firm,


level surface that is free of obstructions.
1 Create start and finish lines by marking two
lines on the ground 40 feet / 12.2 m apart.
2 Turn the key switch to platform control and pull
out the red Emergency Stop button to the on
position at both the ground and platform
controls.
3 Lower the platform to the stowed position.
4 Press the drive function select button.

a drive function select button BN8

Part No. 97385 GS-30 • GS-32 • GS-46 3 - 17


Section 3 • Scheduled Maintenance Procedures June 2009

CHECKLIST B PROCEDURES REV J

B-9 4 Press and hold the function enable switch on


the joystick.
Test the Drive Speed -
5 Raise the platform approximately 4 feet / 1.2 m
Raised Position from the ground.
6 Press the drive function select button.
7 Choose a point on the machine; i.e., contact
Genie requires that this procedure be performed patch of a tire, as a visual reference for use
every 250 hours or quarterly, whichever comes when crossing the start and finish lines.
first.
8 Bring the machine to top drive speed before
Proper drive functions are essential to safe reaching the start line. Begin timing when your
machine operation. The drive function should reference point on the machine crosses the
respond quickly and smoothly to operator control. start line.
Drive performance should also be free of
9 Continue at full speed and note the time when
hesitation, jerking and unusual noise over the
your reference point on the machine passes
entire proportionally controlled speed range.
over the finish line. Refer to Section 2,
Perform this procedure with the machine on a firm, Specifications.
level surface that is free of obstructions.
1 Create start and finish lines by marking two
lines on the ground 40 feet / 12.2 m apart.
2 Turn the key switch to platform control and pull
out the red Emergency Stop button to the on
position at both the ground and platform
controls.
3 Press the lift function select button.

a b

a lift function select button BN9


b drive function select button BN8

3 - 18 GS-30 • GS-32 • GS-46 Part No. 97385


June 2009 Section 3 • Scheduled Maintenance Procedures

REV J CHECKLIST B PROCEDURES

B-10 5 Choose a point on the machine; i.e., contact


patch of a tire, as a visual reference for use
Test the Slow Drive Speed when crossing the start and finish lines.
6 Bring the machine to top drive speed before
reaching the start line. Begin timing when your
reference point on the machine crosses the
Genie requires that this procedure be performed start line.
every 250 hours or quarterly, whichever comes
first. 7 Continue at full speed and note the time when
your reference point on the machine passes
Proper drive functions are essential to safe over the finish line. Refer to Section 2,
machine operation. The drive function should Specifications.
respond quickly and smoothly to operator control.
Drive performance should also be free of
hesitation, jerking and unusual noise over the
entire proportionally controlled speed range.

Perform this procedure with the machine on a firm,


level surface that is free of obstructions.

1 Create start and finish lines by marking two


lines on the ground 40 feet / 12.2 m apart.
2 Turn the key switch to platform control and pull
out the red Emergency Stop button to the on
position at both the ground and platform
controls.
3 Lower the platform to the stowed position.
4 Press the slow speed select button.

a slow speed select button BN6

Part No. 97385 GS-30 • GS-32 • GS-46 3 - 19


Section 3 • Scheduled Maintenance Procedures June 2009

CHECKLIST B PROCEDURES REV J

B-11 B-12
Perform Hydraulic Oil Analysis Inspect the Hydraulic Tank Cap
Venting System

Genie requires that this procedure be performed


every 250 hours or quarterly, whichever comes Genie requires that this procedure be performed
first. quarterly or every 250 hours, whichever comes
Replacement or testing of the hydraulic oil is first. Perform this procedure more often if dusty
essential for good machine performance and conditions exist.
service life. Dirty oil may cause the machine to A free-breathing hydraulic tank cap is essential for
perform poorly and continued use may cause good machine performance and service life. A dirty
component damage. Extremely dirty conditions or clogged cap may cause the machine to perform
may require oil changes to be performed more poorly. Extremely dirty conditions may require that
often. Refer to Section 2, Specifications. the cap be inspected more often.
Before replacing the hydraulic oil, the oil may be 1 Remove the breather cap from the hydraulic
tested by an oil distributor for specific levels of tank.
contamination to verify that changing the oil is
necessary. 2 Check for proper venting.
If the hydraulic oil is not replaced at the two
Result: Air passes through the breather cap.
year inspection, test the oil quarterly. Replace
the oil when it fails the test. See E-1, Test or Result: If air does not pass through the cap,
Replace the Hydraulic Oil. clean or replace the cap. Proceed to step 3.
Note: When checking for positive tank cap venting,
air should pass freely through the cap.

3 Using a mild solvent, carefully wash the cap


venting system. Dry using low pressure
compressed air. Repeat step 2.
4 Install the breather cap onto the hydraulic tank.

3 - 20 GS-30 • GS-32 • GS-46 Part No. 97385


June 2009 Section 3 • Scheduled Maintenance Procedures

REV J CHECKLIST B PROCEDURES

B-13
Check the Module Tray Latch
Components

Genie requires that this procedure be performed


every 250 hours or quarterly, whichever comes
first.
Maintaining the module tray latch components in
good condition is essential to good performance
and service life. Failure to detect worn out latch
components may result in module trays opening
unexpectedly, creating an unsafe operating
condition.

1 Inspect each module tray rotary latch and


related components for wear. Tighten any loose
fasteners.
2 Lubricate each module tray rotary latch. Using
light oil, apply a few drops to each of the
springs and to the sides of the rotary latch
mechanism.

Part No. 97385 GS-30 • GS-32 • GS-46 3 - 21


Section 3 • Scheduled Maintenance Procedures June 2009

CHECKLIST B PROCEDURES REV J

B-14 3 Connect an appropriate power tool to the


inverter. Activate the tool.
Inspect the Voltage Inverter
Result: The power tool should operate. There
(if equipped)
may be a brief (0.5 second) delay if the power
tool has not been used in the previous 10
minutes.

Genie requires that this procedure be performed If the left fault LED (REV_POL) is illuminated,
every 250 hours or quarterly, whichever comes the inverter is connected to batteries with the
first. incorrect polarity. Correct the polarity issue with
the red wire to battery positive and the black
1 Inspect the inverter plug and pigtail for damage wire to battery negative. The inverter will then
or excessive insulation wear. Replace as operate correctly and begin supplying AC
required. power.
2 Turn the key switch to the on position and pull If the right fault LED (123) blinks one time, the
out the red Emergency Stop button to the on power draw is too high. The tool being used
position at both the ground and platform requires too much power to operate or is being
controls. used at or near the limit of the inverter for an
extended period of time. Reduce the power
b a
draw. The inverter will then operate correctly
and begin supplying AC power.
If the right fault LED (123) blinks two times, the
Ground Fault Interrupt (GFI) has been
activated. A short circuit or partial short exists
FAUL
T OUT
between the AC hot and ground in the tool or
PUT
POW
ER IN outlet. Check the tool for burnt, chafed,
c VERT
ER
25V corroded and loose wires, and inspect the tool
24V-2
21V
2V for internal moisture. Correct the short circuit or
d moisture issue OR inspect the wiring in the
PART
N UM
BER
XXX
power-to-platform box. The inverter will then
operate correctly and begin supplying AC
power.
If right fault LED (123) blinks three times, the
inverter is overheated. Allow the inverter to
a right fault LED cool. The inverter will then operate correctly
b left fault LED
and begin supplying AC power.
c 25V LED
d 21V LED If the battery 25 volt fault LED (25V) blinks one
time, the battery voltage is over 30V. Operate
the machine to lower the voltage level. The
inverter will then operate correctly and begin
supplying AC power.
If the battery 21 volt fault LED (21V) blinks one
time, the battery voltage is less than 20V DC.
The inverter will continue to operate until the
battery voltage falls to 17.8V DC.

3 - 22 GS-30 • GS-32 • GS-46 Part No. 97385


June 2009 Section 3 • Scheduled Maintenance Procedures

REV J CHECKLIST B PROCEDURES

B-15 7 GS-1530/32 and GS-1930/32: Follow the


platform control cable down the scissor stack to
Test the Down Limit Switch and the alarm bracket on the chassis deck. Tag and
the Pothole Limit Switches disconnect the platform control cable from the
ECM cable at the 6-pin Deutsch connector.
GS-2032, GS-2632, GS-3232, GS-2046,
GS-2646 and GS-3246: Follow the platform
Genie requires that this procedure be performed control cable down the scissor stack to the
every 250 hours or quarterly, whichever comes underside of the chassis deck. Tag and
first. disconnect the platform cable from the ECM
cable at the 6-pin Deutsch connector under
Maintaining the limit switches is essential to safe the chassis deck.
operation and good machine performance. 8 Securely install the platform control box harness
Operating the machine with a faulty limit switch plug into the 6-pin Deutsch connector of the
could result in reduced machine performance and ECM cable.
a potentially unsafe operating condition.
9 Disable the down limit switch. Loosen the
Perform these procedures with the machine on a
fastener securing the roller arm to the limit
firm, level surface that is free of obstructions.
switch, and rotate the roller arm 90 degrees in a
Down Limit Switch downwards direction. Do not activate the switch
contacts.
1 Remove the platform controls from the platform.
10 Turn the key switch to platform control.
2 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
11 Raise the platform and return the safety arm to
3 Lift the safety arm, move it to the center of the the stowed position.
scissor arm and rotate down to a vertical
position. 12 Working at the platform controls, press the lift
function select button. Lower the platform to the
4 Lower the platform onto the safety arm. stowed position.
Crushing hazard. Keep hands Result: The diagnostic display will show code
clear of the safety arm when 18, an alarm sounds and the lift function should
lowering the platform. operate. The machine is functioning properly.
5 Turn the key switch to the off position. Result: The diagnostic display does not show
6 Tag and disconnect the platform control box at code 18, the alarm does not sound and the lift
the platform. function should not operate. Replace the down
limit switch.

Part No. 97385 GS-30 • GS-32 • GS-46 3 - 23


Section 3 • Scheduled Maintenance Procedures June 2009

CHECKLIST B PROCEDURES REV J

13 Press the drive function select button. Attempt 19 Turn the key switch to the off position.
to drive the machine.
20 Disconnect the platform controls from the ECM
Result: The diagnostic display will show code cable.
18, an alarm sounds, and the steer and drive
21 Securely install the connector of the ECM cable
functions should not operate. The machine is
into the platform control cable.
functioning properly.
22 Working at the platform, securely install the
Result: The diagnostic display does not show
connector of the platform controls into the
code 18, the alarm does not sound, and the
platform control cable.
steer and drive functions operate. Replace the
down limit switch. 23 Enable the down limit switch. Loosen the
fastener securing the roller arm to the limit
14 Press the lift function select button. Raise the
switch, and rotate the roller arm 90 degrees in
platform approximately 12 inches / 0.3 m.
a upwards direction. Do not activate the switch
Result: The diagnostic display will show code contacts.
18 and an alarm sounds. The machine is
24 Turn the key switch to platform control.
functioning properly.
25 Raise the platform and return the safety arm to
Result: The diagnostic display does not show
the stowed position.
code 18 and the alarm does not sound.
Replace the down limit switch. 26 Lower the platform to the stowed position.
15 Raise the platform until the pothole guards are
deployed.
Result: The diagnostic display does not show
code 18 and the alarm does not sound. The
machine is functioning properly.
Result: The diagnostic display shows code 18
and an alarm sounds. Replace the down limit
switch.
16 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
17 Lift the safety arm, move it to the center of the
scissor arm and rotate down to a vertical
position.
18 Lower the platform onto the safety arm.
Crushing hazard. Keep hands
clear of the safety arm when
lowering the platform.

3 - 24 GS-30 • GS-32 • GS-46 Part No. 97385


June 2009 Section 3 • Scheduled Maintenance Procedures

REV J CHECKLIST B PROCEDURES

Pothole Limit Switches 32 Press the lift function select button. Attempt to
raise the platform approximately 8 feet / 2.4 m.
27 Move the machine onto a grade which exceeds
the rating of the level sensor. Refer to the serial Result: The pothole guard contacts the block
label on the machine. and does not fully deploy, the diagnostic display
shows code 18, an alarm sounds and the
28 Press the lift function select button. Standing on platform will lift to 8 feet / 2.4 m or beyond. The
the up-hill side of the machine, attempt to raise machine is functioning properly.
the platform to approximately 8 feet / 2.4 m.
Result: The pothole guard contacts the block
Result: The diagnostic display shows code LL, and does not fully deploy, the diagnostic display
an alarm sounds, and the machine stops lifting does not show code 18, the alarm does not
after the pothole guards are deployed. The sound and the machine will continue to lift the
machine is functioning properly. platform after the pothole guards are deployed.
Result: The diagnostic display does not show Adjust or replace the pothole limit switch.
code LL, the alarm does not sound and the 33 Press the drive function select button. Attempt
machine will continue to lift the platform after to steer or drive the machine.
the pothole guards are deployed. Adjust or
replace the pothole limit switch. Result: The diagnostic display shows code 18,
an alarm sounds, and the machine will not steer
29 Press the drive function select button. Standing or drive. The machine is functioning properly.
on the up-hill side of the machine, attempt to
steer and drive the machine. Result: The diagnostic display does not show
code 18, the alarm does not sound and the
Result: The diagnostic display shows code LL, steer and drive functions operate. Adjust or
an alarm sounds, and the machine will not steer replace the down limit switch.
or drive. The machine is functioning properly.
34 Lower the platform to the stowed position and
Result: The diagnostic display does not show remove the block under the right pothole guard.
code LL, the alarm does not sound and the
steer and drive functions operate. Adjust or 35 Repeat this procedure beginning with step 31
replace the pothole limit switch. for the left pothole guard.

30 Lower the platform to the stowed position. Move 36 Lower the platform to the stowed position,
the machine onto a firm, level surface. remove the block under the left pothole guard.
31 Place a wooden block approximately 37 Turn off the machine.
2 inches / 5 cm tall under the right pothole
guard.

Part No. 97385 GS-30 • GS-32 • GS-46 3 - 25


Section 3 • Scheduled Maintenance Procedures June 2009

CHECKLIST B PROCEDURES REV J

B-16 Outrigger Limit Switches (if equipped)


Test the 5 Lower the platform onto the safety arm.
Up Limit Switch (if equipped) and 6 While raising the platform from the ground
the Outrigger Limit Switches controls and working with the outrigger limit
switch at the battery side of the machine, push
(if equipped) the arm of the outrigger limit switch towards the
steer end of the machine to activate the limit
switch.
Result: The platform stops raising. The machine
Genie requires that this procedure be performed
is functioning properly.
every 250 hours or quarterly, whichever comes
first. Result: The platform continues to raise. Adjust
or replace the outrigger limit switch.
Maintaining the limit switches is essential to safe
Note: Repeat this procedure for the outrigger limit
operation and good machine performance.
switch at ground controls side of the machine.
Operating the machine with a faulty limit switch
could result in reduced machine performance and 7 Return the safety arm to the stowed position.
a potentially unsafe operating condition.
8 Lower the platform to the stowed position and
Perform these procedures with the machine on a turn off the machine.
firm, level surface that is free of obstructions.

Up Limit Switch (if equipped)

1 Turn the key switch to ground control and raise


the platform approximately 8 feet / 2.4 m from
the ground.
2 Rotate the safety arm away from the machine
and let it hang down.
3 Lower the platform onto the safety arm.
Crushing hazard. Keep hands
clear of the safety arm when
lowering the platform.
4 While raising the platform from the ground
controls, push the arm of the up limit switch
towards the steer end of the machine to
activate the limit switch.
Result: The platform stops raising. The machine
is functioning properly.
Result: The platform continues to raise. Adjust
or replace the up limit switch.

3 - 26 GS-30 • GS-32 • GS-46 Part No. 97385


March 2007 Section 3 • Scheduled Maintenance Procedures

REV C
Checklist C Procedures
C-1 The maximum height limit switch, located in the
middle of the drive chassis under the scissor arms,
Test the is used to disable the lift valve coil when the
Platform Overload System platform is near maximum height. When activated,
the limit switch keeps the lift cylinder from going
(if equipped) over lift relief which would cause the pressure
switch to falsely indicate an overload condition.

Genie specifications require that this procedure be


performed every 500 hours or six months,
whichever comes first OR when the machine fails
to lift the maximum rated load.
Testing the platform overload system regularly is
essential to safe machine operation. Continued
use of an improperly operating platform overload
system could result in the system not sensing an
overloaded platform condition. Machine stability a
could be compromised resulting in the machine
tipping over.
b
The platform overload system is designed to
prevent machine operation in the event the
platform is overloaded. Models equipped with the
platform overload option are provided with two
additional machine control components: the
overload pressure switch and a maximum height a overload pressure switch
limit switch. b maximum height limit switch

The overload pressure switch, which is adjustable


and located at the barrel-end of the lift cylinder, is
used to determine when the hydraulic lift cylinder
requires too much pressure to support the load
inside the platform. When this occurs, the pressure
switch will send a signal to the ECM, which will not
allow the machine to function until the extra weight
is removed from the platform.

Part No. 97385 GS-30 • GS-32 • GS-46 3 - 27


Section 3 • Scheduled Maintenance Procedures March 2007

CHECKLIST C PROCEDURES REV C

1 Locate the lift valve coil on the function 5 Fully raise the platform. Release the toggle
manifold. switch.
a Result: The alarm should sound.
Result: The alarm does not sound. Calibrate the
platform overload system. Refer to Repair
• GS-1532 Procedure 3-7, Calibrate the Platform Overload
• GS-1932 System (if equipped).
b
6 Using the manual lowering knob, lower the
platform to the stowed position.
7 Disconnect the two blue/black wires of the
manifold wire harness at the lift valve coil on the
manifold.

• GS-2032 8 Securely connect the black and white wires of


• GS-2632 the up limit switch wire harness to the two
a
• GS-3232 blue/black wires of the manifold wire harness at
• GS-2046 the lift valve coil on the manifold.
• GS-2646 9 Fully raise the platform. Release the toggle
• GS-3246 switch.
b
Result - models with software revision A0 and
a test port
b lift valve coil
A1: The alarm should not sound and fault code
54 should be present in the diagnostic display.
2 Tag and disconnect the black and white wires of The system is functioning correctly.
the up limit switch wire harness from the
Result - models with software revision A2 and
blue/black wires of the manifold wire harness at
higher: The alarm should not sound. The
the lift valve coil on the manifold.
system is functioning correctly.
3 Securely connect together the terminals of the
Result - all models: The alarm sounds. The
two blue/black wires of the manifold wire
system is not functioning correctly.
harness, disconnected from the limit switch wire
Troubleshoot the limit switch, limit switch wire
harness in step 2.
harness or limit switch mount bracket OR the
4 Turn the key switch to ground control and pull platform overload system needs to be
out the red Emergency Stop button to the on calibrated. Refer to Repair Procedure 3-7,
position at both the ground and platform Calibrate the Platform Overload System (if
controls. equipped).
Note: To determine the software revision level,
refer to Repair Procedure 1-2, How to Determine
the Revision Level.
10 Lower the platform to the stowed position.

3 - 28 GS-30 • GS-32 • GS-46 Part No. 97385


March 2007 Section 3 • Scheduled Maintenance Procedures

REV C CHECKLIST C PROCEDURES

C-2
Replace the
Hydraulic Tank Breather Cap -
Models with Optional Hydraulic Oil

Genie requires that this procedure be performed


every 500 hours or semi-annually, whichever
comes first.
The hydraulic tank is a vented-type tank. The
breather cap has an internal air filter that can
become clogged or, over time, can deteriorate. If
the breather cap is faulty or improperly installed,
impurities can enter the hydraulic system which
may cause component damage. Extremely dirty
conditions may require that the cap be inspected
more often.

1 Remove and discard the hydraulic tank breather


cap.
2 Install a new cap onto the tank.

Part No. 97385 GS-30 • GS-32 • GS-46 3 - 29


Section 3 • Scheduled Maintenance Procedures June 2009

Checklist D Procedures REV E

D-1
Check the
Scissor Arm Wear Pads

Genie requires that this procedure be performed


every 1000 hours or annually, whichever comes
first.
Maintaining the condition of the scissor arm
wearpads is essential to safe machine operation.
Continued use of worn out wear pads may result in
component damage and unsafe operating
conditions.

Perform this procedure with the platform in the


stowed position.

GS-1530, GS-1532, GS-1930 and GS-1932:


1 From serial numbers GS3003A-60000 to a b c
GS3006A-85006 and from GS3005B-76000 to Illustration 1
GS3006B-80468: Measure the distance
a wear pad
between the number one outer arm cross tube b outer arm cross tube
and the chassis deck at the ground controls c chassis deck
side of the non-steer end of the machine.
Refer to illustration 1.
After serial numbers GS3006A-85006,
GS3006B-80468 and GS3008C-101: Measure
the distance between the number one inner arm
cross tube and the chassis deck at the ground
controls side of the non-steer end of the
machine.
Refer to illustration 2.
Result: The measurement is
0.90 inch / 22.9 mm or more. Proceed to step 2.
Result: The measurement is less than
0.90 inch / 22.9 mm. Replace both wear pads.
Refer to Repair Procedure 3-1 or 3-2, How to
Replace the Scissor Arm Wear Pads. c b a

Illustration 2

a wear pad
b inner arm cross tube
c chassis deck

3 - 30 GS-30 • GS-32 • GS-46 Part No. 97385


June 2009 Section 3 • Scheduled Maintenance Procedures

REV E CHECKLIST D PROCEDURES

2 From serial numbers GS3003A-60000 to


GS3006A-85006 and from GS3005B-76000 to
GS3006B-80468: Measure the distance
between the number one outer arm cross tube
and the chassis deck at the battery pack side of
the non-steer end of the machine.
Refer to illustration 1.
After serial numbers GS3006A-85006,
GS3006B-80468 and GS3008C-101: Measure
the distance between the number one inner arm
cross tube and the chassis deck at the battery
pack side of the non-steer end of the machine.
Refer to illustration 2.
Result: The measurement is
0.90 inch / 22.9 mm or more. Proceed to step 3.
Result: The measurement is less than
0.90 inch / 22.9 mm. Replace both wear pads.
Refer to Repair Procedure 3-1 or 3-2, How to
Replace the Scissor Arm Wear Pads.
3 Apply a thin layer of dry film lubricant to the a b c
area of the chassis where the scissor arm wear Illustration 1
pads make contact.
a wear pad
b outer arm cross tube
Cross tube to chassis specification c chassis deck

Measurement, minimum 0.90 inch


22.9 mm

c b a
Illustration 2

a wear pad
b inner arm cross tube
c chassis deck

Part No. 97385 GS-30 • GS-32 • GS-46 3 - 31


Section 3 • Scheduled Maintenance Procedures June 2009

CHECKLIST D PROCEDURES REV E

GS-2032, GS-2632, GS-3232, GS-2046, GS-2646


and GS-3246:
1 Measure the distance between the number one
outer arm cross tube and the fork lift tube at the
ground controls side of the non-steer end of the
machine.
Result: The measurement is
0.88 inch / 22.4 mm or more. Proceed to step 2.
Result: The measurement is less than
0.88 inch / 22.4 mm. Replace both wear pads.
Refer to Repair Procedure 3-3, 3-4 or 3-5, How
to Replace the Scissor Arm Wear Pads.
2 Measure the distance between the number one
outer arm cross tube and the fork lift tube at the
battery pack side of the non-steer end of the
machine.
Result: The measurement is
0.88 inch / 22.4 mm or more. Proceed to step 3.
Result: The measurement is less than
0.88 inch / 22.4 mm. Replace both wear pads.
Refer to Repair Procedure 3-3, 3-4 or 3-5, How
to Replace the Scissor Arm Wear Pads.
3 Apply a thin layer of dry film lubricant to the
area of the chassis where the scissor arm wear
pads make contact.

Cross tube to chassis specification a b c

Measurement, minimum 0.88 inch a outer arm cross tube


b fork lift tube
22.4 mm
c wear pad

3 - 32 GS-30 • GS-32 • GS-46 Part No. 97385


June 2009 Section 3 • Scheduled Maintenance Procedures

REV E CHECKLIST D PROCEDURES

D-2 5 Turn the key switch to ground control and pull


out the red Emergency Stop button to the on
Replace the Hydraulic Tank position at both the ground and platform
Return Filter Element controls.
6 Activate and hold the platform up toggle switch.
7 Inspect the filter and related components to
be sure that there are no leaks.
Genie requires that this procedure be performed
every 1000 hours or annually, whichever comes 8 Clean up any oil that may have spilled.
first.
Torque specifications
Replacement of the hydraulic tank return filter is
essential for good machine performance and Hydraulic tank drain plug, dry 40 in-lbs
service life. A dirty or clogged filter may cause the 4.5 Nm
machine to perform poorly and continued use may Hydraulic tank drain plug, lubricated 30 in-lbs
cause component damage. Extremely dirty 3.4 Nm
conditions may require that the filter be replaced
more often.

Beware of hot oil. Contact with


hot oil may cause severe burns.
Note: The hydraulic tank return filter is mounted on
the function manifold next to the hydraulic power
unit.

1 Clean the area around the oil filter. 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 and tighten it securely by
hand.
4 Use a permanent ink marker to write the date
and number of hours from the hour meter onto
the filter.

Part No. 97385 GS-30 • GS-32 • GS-46 3 - 33


Section 3 • Scheduled Maintenance Procedures April 2008

Checklist E Procedure REV C

E-1 3 Tag and disconnect the hydraulic tank return


hard line from the hydraulic filter head and
Test or Replace the Hydraulic Oil remove the hard line from the tank. Cap the
fitting on the filter head.
4 Tag and disconnect the hydraulic pump inlet
hard line and remove the hard line from the
Genie requires that this procedure be performed tank. Cap the fitting on the pump.
every 2000 hours or every two years, whichever
comes first. 5 Remove the hydraulic tank retaining fasteners
and remove the hydraulic tank from the
Replacement or testing of the hydraulic oil is machine.
essential for good machine performance and
service life. Dirty oil may cause the machine to 6 Drain all of the oil into a suitable container.
perform poorly and continued use may cause Refer to Section 2, Specifications, for capacity
component damage. Extremely dirty conditions information.
may require oil changes to be performed more Bodily injury hazard. Spraying
often. Refer to Section 2, Specifications. hydraulic oil can penetrate and
burn skin. Loosen hydraulic
Before replacing the hydraulic oil, the oil may be
connections very slowly to allow
tested by an oil distributor for specific levels of
the oil pressure to dissipate
contamination to verify that changing the oil is
gradually. Do not allow oil to squirt
necessary.
or spray.
If the hydraulic oil is not replaced at the two
year inspection, test the oil quarterly. Replace 7 Clean up any oil that may have spilled. Properly
the oil when it fails the test. discard the used oil.
Note: Perform this procedure with the platform in 8 Clean the inside of the hydraulic tank using a
the stowed position. mild solvent. Allow the tank to dry completely.

1 Disconnect the battery pack from the machine. 9 Install the hydraulic tank and install and tighten
the hydraulic tank retaining fasteners. Torque to
Electrocution/burn hazard. Contact specification.
with electrically charged circuits
could result in death or serious
Torque specifications
injury. Remove all rings, watches
and other jewelry. Hydraulic tank retaining fasteners, dry 35 in-lbs
4 Nm
2 Open the power unit module tray.
Hydraulic tank retaining fasteners, lubricated 26 in-lbs
2.9 Nm

3 - 34 GS-30 • GS-32 • GS-46 Part No. 97385


April 2008 Section 3 • Scheduled Maintenance Procedures

REV C CHECKLIST E PROCEDURE

10 Install the hydraulic pump inlet hard line into the


tank. Install the fitting onto the pump and torque
to specification. Refer to Section 2,
Specifications.
11 Install the hydraulic pump return hard line into
the tank. Install the fitting onto the hydraulic
filter head and torque to specification. Refer to
Section 2, Specifications.
12 Fill the tank with hydraulic oil until the fluid is at
the FULL indicator on the hydraulic tank. Do not
overfill.
13 Activate the pump to fill the hydraulic system
with oil and bleed the system of air.
Component damage hazard. The
pump can be damaged if operated
without oil. Be careful not to empty
the hydraulic tank while in the
process of filling the hydraulic
system. Do not allow the pump to
cavitate.
14 Repeat steps 12 through 13 until the hydraulic
system and tank are both full.

Part No. 97385 GS-30 • GS-32 • GS-46 3 - 35


Section 3 • Scheduled Maintenance Procedures March 2007

This page intentionally left blank.

3 - 36 GS-30 • GS-32 • GS-46 Part No. 97385


March 2007 Section 4 • 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
Repair procedures shall be completed by a where repairs can be completed. Then to
person trained and qualified on the repair of this re-assemble, perform the disassembly steps in
machine. reverse order.
Immediately tag and remove from service a Symbols Legend
damaged or malfunctioning machine.
Safety alert symbol—used to alert
Repair any machine damage or malfunction personnel to potential personal
before operating the machine. injury hazards. Obey all safety
messages that follow this symbol
Before Repairs Start: to avoid possible injury or death.
Read, understand and obey the safety rules Indicates an imminently hazardous
and operating instructions in the appropriate situation which, if not avoided, will
operator's manual on your machine. result in death or serious injury.
Be sure that all necessary tools and parts are Indicates a potentially hazardous
available and ready for use. situation which, if not avoided,
could result in death or serious
Use only Genie approved replacement parts.
injury.
Read each procedure completely and adhere to
Indicates a potentially hazardous
the instructions. Attempting shortcuts may
situation which, if not avoided,
produce hazardous conditions.
may cause minor or moderate
Unless otherwise specified, perform each repair injury.
procedure with the machine in the following
Indicates a potentially hazardous
configuration:
situation which, if not avoided,
· Machine parked on a firm, level surface may result in property damage.
· Platform in the stowed position Indicates that a specific result is expected after
· Key switch in the off position with the key performing a series of steps.
removed Indicates that an incorrect result has occurred
· The red Emergency Stop button in the off after performing a series of steps.
position at both ground and platform controls
· Wheels chocked
· All external AC power supply disconnected
from the machine

Part No. 97385 GS-30 • GS-32 • GS-46 4-1


Section 4 • Repair Procedures October 2009

Platform Controls REV J

The platform controls, used to operate the machine 1-1


from the platform or while standing on the ground,
can also be used to tune the performance of the Circuit Boards
machine.
How to Remove the Platform
Moving the joystick or activating a button sends a
signal to the Electronic Control Module (ECM). Controls Circuit Board
When the ECM is in the function mode, the
1 Push in the red Emergency Stop button to the
platform controls are used to operate the various
off position at both the ground and platform
machine functions. When the ECM is in the
controls.
programming mode (PS is shown in the diagnostic
display window), the platform controls are used to 2 Remove the fasteners securing the platform
adjust the function speed parameters. control box together. Open the control box.

The platform controls consist of an electronic 3 Locate the circuit board mounted to the top half
circuit board, joystick, membrane decal, buttons, of the platform control box.
LEDs and a diagnostic display. Electrocution/burn hazard. Contact
For further information or assistance, consult the with electrically charged circuits
Genie Industries Service Department. could result in death or serious
injury. Remove all rings, watches
and other jewelry.
Component damage hazard.
a Electrostatic discharge (ESD) can
JC1 damage printed circuit board
JOYSTICK
CONTROLLER components. Maintain firm contact
b H1
ALARM
with a metal part of the machine
that is grounded at all times when
handling printed circuit boards OR
U3
c PLATFORM CONTROLS
CIRCUIT BOARD
use a grounded wrist strap.
4 Remove the alarm and the red Emergency Stop
button assemblies from the control box.
P2
d EMERGENCY
STOP 5 Carefully disconnect the wire harness
connectors from the circuit board.
a joystick controller JC1
6 Carefully remove the circuit board retaining
b alarm H1
c platform controls circuit board U3 fasteners and remove the circuit board from the
d red Emergency Stop button P2 control box.

4-2 GS-30 • GS-32 • GS-46 Part No. 97385


October 2009 Section 4 • Repair Procedures

REV J PLATFORM CONTROLS

The outrigger control pad is used to operate the How to Remove the Outrigger
outriggers from the platform or while standing on
the ground and can also be used to calibrate the Control Pad Circuit Board
outrigger ECM and the outrigger level sensor. 1 Push in the red Emergency Stop button to the
off position at both the ground and platform
Activating buttons on the outrigger control pad controls.
sends a signal to the outrigger Electronic Control
Module (ECM). When the outrigger ECM receives 2 Remove the fasteners securing the outrigger
a signal, it enables the outrigger control pad to control pad to the outrigger control pad bracket.
extend, retract or autolevel the outriggers. When Set the fasteners to the side.
calibrating the outrigger ECM and the outrigger 3 Carefully remove the top half of the control pad
level sensor, the outrigger control pad buttons are and set to the side.
used in a specific sequence to achieve calibration.
4 Locate the circuit board mounted to the bottom
The outrigger control pad consist of an electronic half of the outrigger control pad.
circuit board, membrane decal, buttons and LEDs.
Electrocution/burn hazard. Contact
For further information or assistance, consult the with electrically charged circuits
Genie Industries Service Department. could result in death or serious
injury. Remove all rings, watches
a and other jewelry.

U36 b Component damage hazard.


OUTRIGGER
PLATFORM CONTROL
CIRCUIT BOARD
Electrostatic discharge (ESD) can
c
damage printed circuit board
j d components. Maintain firm contact
e with a metal part of the machine
that is grounded at all times when
f
handling printed circuit boards OR
use a grounded wrist strap.
5 Carefully disconnect the wire harness
connectors from the circuit board.
i h g 6 Carefully remove the circuit board retaining
fasteners and remove the circuit board from the
Outrigger Control Pad control pad.
a lift enable L69 (solid green light)
b lift error L70
(flashing red or solid red light)
c right front outrigger L52
(solid green or solid red light)
d left front outrigger L51
(solid green or solid red light)
e right rear outrigger L54
(solid green or solid red light)
f left rear outrigger L53
(solid green or solid red light)
g outrigger extend BN105
h function enable BN106
i outrigger retract BN107
j outrigger control circuit board U36

Part No. 97385 GS-30 • GS-32 • GS-46 4-3


Section 4 • Repair Procedures October 2009

PLATFORM CONTROLS REV J

1-2 3 Turn the key switch to platform control and pull


out the red Emergency Stop button to the on
Controller Adjustments position at both the ground and platform
controls.
Platform lift speed, stowed drive speed, raised
drive speed and high torque drive speed are
adjustable to compensate for wear in the hydraulic
a
pump and drive motors. d

The function speeds are determined by the


percentage of total controller output.
b
For further information or assistance, consult the
Genie Industries Service Department.
c
Tip-over hazard. Do not adjust the
lift and/or drive speed higher than a joystick controller JC1
specified in this procedure. Setting b lift function select button BN9
c red Emergency Stop button P2
the function speeds greater than d yellow arrow
specifications could cause the
machine to tip over resulting in 4 Press the lift function select button.
death or serious injury.
5 Slowly move the joystick in the direction
Tip-over hazard. This procedure indicated by the yellow arrow.
must only be performed by a
Result: The software revision level will appear
trained service professional.
in the diagnostic display.
Attempting this procedure without
the necessary skills will result in 6 Push in the red Emergency Stop button to the
death or serious injury. off position at both the ground and platform
controls and turn the key switch to the off
Note: Select a test area that is firm, level and free
position.
of obstructions.

How to Determine the


Software Revision Level
1 Remove the platform controls from the platform.
2 Place the platform controls close to the
diagnostic display on the power unit side of the
machine.

4-4 GS-30 • GS-32 • GS-46 Part No. 97385


October 2009 Section 4 • Repair Procedures

REV J PLATFORM CONTROLS

How to Adjust the Lift Speed


Tip-over hazard. Do not adjust the a
lift and/or drive speed higher than
specified in this procedure. Setting b g
the function speeds greater than
specifications could cause the c f
machine to tip over resulting in d
death or serious injury.
e
Tip-over hazard. This procedure
must only be performed by a a joystick controller JC1 with thumb
trained service professional. steering rocker SW6
Attempting this procedure without b horn button BN5
c lift function select button BN9
the necessary skills will result in d diagnostic display G8
death or serious injury. e red Emergency Stop button P2
f drive function select BN8
1 Pull out the red Emergency Stop button to the g speed select button BN6
on position at the ground controls.
7 Use the steering thumb rocker switch on the
2 Push in the red Emergency Stop button to the joystick to increase or decrease the maximum
off position at the platform controls. lift speed percentage. Refer to Section 2,
3 Turn the key switch to platform control. Specifications, for function speeds.

4 At the platform controls, press and hold the lift 8 Turn the key switch to the off position.
function select and horn buttons and pull out Note: Any change in software settings will not take
the red Emergency Stop button to the on effect until the key switch is turned to the off
position. position.
Result: The diagnostic display will show "PS."
5 Release the lift function select and horn
buttons.
Result: The diagnostic display will show the
maximum lift speed percentage.
6 Press the lift function select button.

Part No. 97385 GS-30 • GS-32 • GS-46 4-5


Section 4 • Repair Procedures October 2009

PLATFORM CONTROLS REV J

How to Adjust the Stowed Drive


Speed a
Tip-over hazard. Do not adjust the b g
lift and/or drive speed higher than
specified in this procedure. Setting
c f
the function speeds greater than
specifications could cause the d
machine to tip over resulting in e
death or serious injury.
a joystick controller JC1 with thumb
Tip-over hazard. This procedure steering rocker SW6
must only be performed by a b horn button BN5
trained service professional. c lift function select button BN9
d diagnostic display G8
Attempting this procedure without e red Emergency Stop button P2
the necessary skills will result in f drive function select BN8
death or serious injury. g speed select button BN6

On machines with software revision A4 and higher, 6 Press the drive function select button.
setting the raised drive speed percentage to zero
will result in the steer function being disabled when Result: The diagnostic display will show the
the platform is above the down limit switch. stowed drive speed percentage.
Refer to 1-2, How to Determine the Software 7 Use the steering thumb rocker switch on the
Revision Level. joystick to increase or decrease the stowed
drive speed percentage. Refer to Section 2,
1 Pull out the red Emergency Stop button to the
Specifications, for drive speeds.
on position at the ground controls.
8 Turn the key switch to the off position.
2 Push in the red Emergency Stop button to the
off position at the platform controls. Note: Any change in software settings will not take
effect until the key switch is turned to the off
3 Turn the key switch to platform control.
position.
4 At the platform controls, press and hold the lift
function select and horn buttons and pull out
the red Emergency Stop button to the on
position.
Result: The diagnostic display will show "PS."
5 Release the lift function select and horn
buttons.
Result: The diagnostic display will show the
maximum lift speed percentage.

4-6 GS-30 • GS-32 • GS-46 Part No. 97385


October 2009 Section 4 • Repair Procedures

REV J PLATFORM CONTROLS

How to Adjust the Raised Drive


Speed a
Tip-over hazard. Do not adjust the b g
lift and/or drive speed higher than
specified in this procedure. Setting
c f
the function speeds greater than
specifications could cause the d
machine to tip over resulting in e
death or serious injury.
a joystick controller JC1 with thumb
Tip-over hazard. This procedure steering rocker SW6
must only be performed by a b horn button BN5
c lift function select button BN9
trained service professional. d diagnostic display G8
Attempting this procedure without e red Emergency Stop button P2
the necessary skills will result in f drive function select BN8
death or serious injury. g speed select button BN6

On machines with software revision A4 and higher, 6 Press the drive function select button.
setting the raised drive speed percentage to zero 7 Press and hold the horn button.
will result in the steer function being disabled when
the platform is above the down limit switch. Result: The diagnostic display will show the
Refer to 1-2, How to Determine the Software raised drive speed percentage.
Revision Level. 8 Use the steering thumb rocker switch on the
1 Pull out the red Emergency Stop button to the joystick to increase or decrease the raised drive
on position at the ground controls. speed percentage. Refer to Section 2,
Specifications, for drive speeds.
2 Push in the red Emergency Stop button to the
off position at the platform controls. 9 Turn the key switch to the off position.

3 Turn the key switch to platform control. Note: Any change in software settings will not take
effect until the key switch is turned to the off
4 At the platform controls, press and hold the lift position.
function select and horn buttons and pull out
the red Emergency Stop button to the on
position.
Result: The diagnostic display will show "PS."
5 Release the lift function select and horn
buttons.
Result: The diagnostic display will show the
maximum lift speed percentage.

Part No. 97385 GS-30 • GS-32 • GS-46 4-7


Section 4 • Repair Procedures October 2009

PLATFORM CONTROLS REV J

How to Adjust the Slow or High


Torque Drive Speed a
Tip-over hazard. Do not adjust the b g
lift and/or drive speed higher than
specified in this procedure. Setting
c f
the function speeds greater than
specifications could cause the d
machine to tip over resulting in e
death or serious injury.
a joystick controller JC1 with thumb
Tip-over hazard. This procedure steering rocker SW6
must only be performed by a b horn button BN5
trained service professional. c lift function select button BN9
Attempting this procedure without d diagnostic display G8
e red Emergency Stop button P2
the necessary skills will result in f drive function select BN8
death or serious injury. g speed select button BN6

On machines with software revision A4 and higher, 6 Press the drive function select button.
setting the raised drive speed percentage to zero
will result in the steer function being disabled when Result: The diagnostic display will show the
the platform is above the down limit switch. stowed drive speed percentage.
Refer to 1-2, How to Determine the Software 7 Press and hold the speed select button.
Revision Level.
Result: The diagnostic display will show the
1 Pull out the red Emergency Stop button to the stowed high torque drive speed percentage.
on position at the ground controls.
8 Use the steering thumb rocker switch on the
2 Push in the red Emergency Stop button to the joystick to increase or decrease the stowed
off position at the platform controls. high torque drive speed percentage.
3 Turn the key switch to platform control. 9 Turn the key switch to the off position.
4 At the platform controls, press and hold the lift Note: Any change in software settings will not take
function select and horn buttons and pull out effect until the key switch is turned to the off
the red Emergency Stop button to the on position.
position.
Result: The diagnostic display will show "PS."
5 Release the lift function select and horn
buttons.
Result: The diagnostic display will show the
maximum lift speed percentage.

4-8 GS-30 • GS-32 • GS-46 Part No. 97385


October 2009 Section 4 • Repair Procedures

REV J PLATFORM CONTROLS

1-3
Software Configuration
The Electronic Control Module (ECM) contains
programming for all configurations of the Genie a d
GS-30, GS-32 and GS-46. The machine can be
adjusted to a different configuration using the
b
buttons at the platform controls.
c
How to Determine the a lift function select button BN9
Software Configuration b diagnostic display
c red Emergency Stop button P2
1 Remove the platform controls from the platform. d speed select button BN6

2 Pull out the red Emergency Stop button to the 5 Release the lift function select and speed select
on position at the ground controls. buttons.
3 Push in the red Emergency Stop button to the Result: The diagnostic display will show the
off position at the platform controls. current configuration.
4 At the platform controls, press and hold the lift 6 Push in the red Emergency Stop button to the
function select and speed select buttons, and off position at both the ground and platform
pull out the red Emergency Stop button to the controls and turn the key switch to the off
on position. position.
Result: The diagnostic display, at the platform
controls and the ECM, will show "SC."

Machine Option / Feature Definitions


Motion Alarm: The motion alarm will sound when operating any function.

Lift/Drive Cut Out: In addition to an alarm sounding, lift and drive functions are disabled when the
platform is raised above the down limit switch and the incline of the chassis exceeds the rating on the
serial plate. Configured on all machines.
Platform Overload: When the platform overload limit switch is tripped, signaling an overload condition
in the platform, all machine functions are disabled. The additional weight must be removed from the
platform and the power cycled from off to on before any function can be resumed. Required for CE
models.

Descent Delay: This option halts descent for 4 to 6 seconds. All controls must be released and re-
engaged before descent is re-enabled. Required for CE models.

Battery Drain Alarm: When the machine is turned on and in the stowed position, and no function is
activated for 2 minutes, an alarm will sound once every 3 seconds.
When this option is configured, a dot in the diagnostic display window will remain continuously
illuminated when the ECM is in the 'SC' mode OR when the platform up function is activated.

Part No. 97385 GS-30 • GS-32 • GS-46 4-9


Section 4 • Repair Procedures October 2009

PLATFORM CONTROLS REV J

How to Change the


Software Configuration a
1 Pull out the red Emergency Stop button to the f
on position at the ground controls. b
2 Push in the red Emergency Stop button to the e
off position at the platform controls. c
3 Turn the key switch to platform control. d

4 At the platform controls, press and hold the lift


a joystick controller JC1 with thumb
function select and speed select buttons, and steering rocker SW6
pull out the red Emergency Stop button to the b lift function select button BN9
on position. c diagnostic display
d red Emergency Stop button P2
Result: The diagnostic display, at the platform e drive function select button BN8
controls and the ECM, will show "SC." f speed select button BN6

5 Release the lift function select and speed select 8 Press the speed select button.
buttons. Result: The 'ones' digit setting will be activated
Result: The diagnostic display will show the and the current 'ones' setting will flash in the
current configuration. diagnostic display. Use the steering thumb
rocker switch on the joystick to increase or
6 Press the lift function select button. decrease the value. See 1-3, Machine
Result: The 'tens' digit setting will be activated Configuration Code Chart for configuration
and the current 'tens' setting will flash in the settings.
diagnostic display. Use the steering thumb 9 Press and hold the speed select button for a
rocker switch on the joystick to increase or minimum of 3 seconds to set the 'ones' value.
decrease the value. See 1-3, Machine
Configuration Code Chart for configuration 10 Turn the key switch to the off position.
settings. Note: Any change in software settings will not take
7 Press and hold the lift function select button for effect until the key switch is turned to the off
a minimum of 3 seconds to set the 'tens' value. position.

4 - 10 GS-30 • GS-32 • GS-46 Part No. 97385


October 2009 Section 4 • Repair Procedures

REV J PLATFORM CONTROLS

Machine Configuration Code Chart Machine Configuration Code Chart


(before serial numbers GS3007A-89468 (after serial numbers GS3007A-89467
and GS3007B-84527) and GS3007B-84526) (from serial
number GS3008C-101)
A mark in the four right columns indicates the
machine configuration code, in the left column, A mark in the four right columns indicates the
includes this feature. machine configuration code, in the left column,
GS-1530 • GS-1532 • GS-1930 • GS-1932 includes this feature.
(ECMs with software revisins A0 to A4) GS-1530 • GS-1532 • GS-1930 • GS-1932
(ECMs with software revisions A5 and higher)
Machine
Function Machine
Motion Lift/Drive Platform Descent
Code at Function
Alarm Cut Out Overload Delay Motion Lift/Drive Platform Descent
Diagnostic Code at
Display Alarm Cut Out Overload Delay
Diagnostic
Display
00
01 • 00 •
02 • 01 • •
03 • 02 • •
04 • 03 •
06 • • 04 • •
07 • • 06 • • •
08 • • 07 • •
10 • • • 08 • • •
11 • • • 10 • • •
13 • • • 11 • • • •
16 • • • • 13 • • •
21 • • 16 • • • •
22 • • 21 • •
24 • • • 22 • • •
28 • • 24 • • •
28 • •

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 11


Section 4 • Repair Procedures October 2009

PLATFORM CONTROLS REV J

Machine Configuration Code Chart Machine Configuration Code Chart


(before serial numbers (after serial numbers GS3207-85152
GS3207-85153 and GS4607-84772) and GS4607-84771)
(from serial numbers GS3208C-101 and
A mark in the four right columns indicates that the
machine configuration code, in the left column,
GS4609C-101)
includes this feature.
A mark in the four right columns indicates that the
GS-2032 • GS-2632 machine configuration code, in the left column,
GS-2046 • GS-2646 • GS-3246 includes this feature.
(ECMs with software revisins A0 to A4)
GS-2032 • GS-2632 • GS-3232
Machine
GS-2046 • GS-2646 • GS-3246
Function (ECMs with software revisions A5 and higher)
Motion Lift/Drive Platform Descent
Code at
Alarm Cut Out Overload Delay Machine
Diagnostic
Function
Display Motion Lift/Drive Platform Descent
Code at
Alarm Cut Out Overload Delay
32 Diagnostic
Display
33 •
34 •
32 •
35 •
33 • •
36 • 34 • •
38 • • 35 •
39 • •
36 • •
40 • •
38 • • •
42 • • • 39 • •
43 • • •
40 • • •
45 • • • 42 • • •
48 • • • • 43 • • • •
53 • • 45 • • •
54 • •
48 • • • •
56 • • •
53 • •
60 • • 54 • • •
56 • • •
60 • •

4 - 12 GS-30 • GS-32 • GS-46 Part No. 97385


October 2009 Section 4 • Repair Procedures

REV J PLATFORM CONTROLS

How to Activate the How to Determine the Battery


Battery Drain Alarm Option Voltage
1 Pull out the red Emergency Stop button to the The diagnostic display on the platform controls is
on position at the ground controls. used to indicate the battery voltage at all times
when the machine is in normal operation.
2 Push in the red Emergency Stop button to the
off position at the platform controls. Limp Mode: If the battery level falls to less than
3 Turn the key switch to platform control. 17.8V DC, the single bar in the diagnostic display
will be flashing and machine drive speed is limited
4 At the platform controls, press and hold the lift to that of the raised drive speed. Refer to Section
function select and speed select buttons, and 2, Specifications.
pull out the red Emergency Stop button to the
on position.
the battery level is 22.6V DC or higher
Result: The diagnostic display, at the platform
controls and the ECM, will show "SC."
5 Release the lift function select and speed select the battery level is 21.6 to 22.5V DC
buttons.
Result: The diagnostic display will show the
current configuration. the battery level is 20.7 to 21.5V DC
6 Press the speed select button.
Result: The 'ones' digit setting will be activated
and the current 'ones' setting will flash in the the battery level is 19.7 to 20.6V DC
diagnostic display.
7 Press the horn button.
the battery level is 17.8 to 19.6V DC
Result: A dot, located at the lower right of the
diagnostic display window, will become
illuminated. This indicates that the battery drain
alarm option has been activated. the battery level is less than 17.8V DC

8 Press and hold the speed select button for a


minimum of 3 seconds or until the 'ones' setting
stops flashing.
9 Turn the key switch to the off position.
Note: To deactivate the battery drain alarm option
on a machine which has the option activated,
repeat this procedure. When the ECM is in the 'SC'
mode and the option is deactivated, there will not
be an illuminated dot in the diagnostic display
window.

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 13


Section 4 • Repair Procedures October 2009

PLATFORM CONTROLS REV J

1-4 6 Continue to hold the function enable, outrigger


extend and outrigger retract buttons.
Outrigger ECM
Result: After approximately 3 seconds at the
The Electronic Control Module (ECM) is outrigger control pad, the right rear outrigger
programmed to deactivate the drive and steer and left front outrigger lights turn red. The right
functions while the outriggers are deployed and front outrigger and left rear outrigger lights turn
activate an alarm when a signal is received from green, and the lift error light remains red.
the outrigger level sensor, indicating the outriggers 7 Continue to hold the outrigger extend and
are not deployed or the machine is out of level. outrigger retract buttons. Release the function
The ECM is also used to calibrate the outrigger enable button.
level sensor to achieve a levelness of 0° +/- 0.5° Result: After approximately 5 seconds at the
front to back and side to side, while the outriggers outrigger control pad, the lift enable, right rear
are deployed. outrigger and left front outrigger lights turn
green. The right front outrigger and left rear
For further information or assistance, consult the
outrigger lights remain green.
Genie Industries Service Department.
Result: All lights turn red on the outrigger
How to Calibrate the Outrigger control pad and the alarm sounds
Level Sensor continuously. The outrigger level sensor is
installed incorrectly OR the machine is not on
1 Move the machine to a firm level surface that a level surface. Check the levelness of the
is free of obstructions. Use a digital level to surface and inspect the digital level sensor to
confirm. ensure the bubble at the top of the level sensor
is centered in the circles. Repeat this
2 Turn the key switch to platform control.
procedure beginning with step 3.
3 Pull out the red Emergency Stop button to the
8 Push in the Red Emergency Stop button at the
on position at the ground controls.
platform controls. The outrigger level sensor
4 Push in the red Emergency Stop button to the is now calibrated.
off position at the platform controls.
Note: After installing a new outrigger level sensor,
5 Press and hold the function enable, extend and the new outrigger level sensor must be calibrated.
retract buttons on the outrigger control pad and
pull out the red Emergency Stop button to the
on position at the platform controls.
Result: The lift error light turns red on the
outrigger control pad.

4 - 14 GS-30 • GS-32 • GS-46 Part No. 97385


October 2009 Section 4 • Repair Procedures

REV J PLATFORM CONTROLS

How to Calibrate the Outrigger


a Pressure Transducers
b Note: For best performance, calibrate the
pressure transducers when the ambient
temperature is 32°F / 0°C, or above.

i c 1 Move the machine to a firm level surface that


is free of obstructions. Use a digital level to
h d confirm.
2 Turn the key switch to platform control.
3 Pull out the red Emergency Stop button to the
on position at the ground controls.
g e
4 Push in the red Emergency Stop button to the
f off position at the platform controls.

Outrigger Control Pad 5 Press and hold the outrigger extend and retract
buttons and pull out the red Emergency Stop
a lift enable
b lift error
button to the on position at the platform
c right front outrigger controls.
d right rear outrigger
e outrigger extend Result: The lift error light turns red at the
f function enable outrigger control pad.
g outrigger retract
h left rear outrigger 6 Continue to hold the outrigger extend and
i left front outrigger retract buttons.
Result: After approximately 3 seconds at the
outrigger control pad, the right front outrigger,
right rear outrigger, left rear outrigger and left
front outrigger lights turn red. The lift error light
remains red.
7 Continue to hold the outrigger retract button
and release the outrigger extend button.
Result: After approximately 5 seconds at the
outrigger control pad, the lift enable light turns
green. The right front outrigger, right rear
outrigger, left rear outrigger and left front
outrigger lights remain red.

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 15


Section 4 • Repair Procedures October 2009

PLATFORM CONTROLS REV J

8 Press and hold the function enable and How to Activate the
outrigger extend buttons until the outriggers
are fully extended. Continue to hold the Outrigger Motion Alarm Option
outrigger extend button and release the 1 Turn the key switch to platform control.
function enable button.
3 Pull out the red Emergency Stop button to the
Result: After approximately 5 seconds at the on position at the ground controls.
outrigger control pad, the right front outrigger,
right rear outrigger, left rear outrigger and left 4 Push in the red Emergency Stop button to the
front outrigger lights turn green. off position at the platform controls.
Result: The outrigger controls alarm will sound 5 Press and hold the outrigger extend button and
for approximately 1 second. pull out the red Emergency Stop button to the
on position at the platform controls.
9 Press and hold the function enable and
outrigger retract buttons until the outriggers Result: After approximately 5 seconds, the
are fully retracted. Push in the red Emergency outrigger controls alarm will sound twice. The
Stop button to the off position at the platform outrigger motion alarm is now activated.
controls. The pressure transducers are now
calibrated. How to Deactivate the
Note: After installing a new cylinder or pressure
Outrigger Motion Alarm Option
transducer, the pressure transducers on the 1 Turn the key switch to platform control.
machine must be calibrated.
3 Pull out the red Emergency Stop button to the
on position at the ground controls.
a 4 Push in the red Emergency Stop button to the
off position at the platform controls.
b
5 Press and hold the outrigger extend button and
pull out the red Emergency Stop button to the
on position at the platform controls.
i c
Result: After approximately 5 seconds, the
h d outrigger controls alarm will sound twice. The
outrigger motion alarm is now deactivated.

g e

Outrigger Control Pad

a lift enable
b lift error
c right front outrigger
d right rear outrigger
e outrigger extend
f function enable
g outrigger retract
h left rear outrigger
i left front outrigger

4 - 16 GS-30 • GS-32 • GS-46 Part No. 97385


October 2009 Section 4 • Repair Procedures

REV J PLATFORM CONTROLS

1-5 4 Remove the fasteners securing the outrigger


control pad to the outrigger control pad
Outrigger Controls Software bracket. Set the fasteners to the side. Refer to
Update Illustration 1.
Component damage hazard. After
Periodically the outrigger controls system is removing the fasteners securing
updated to improve system performance. When the control pad assembly to the
an update is available for the outrigger controls control pad bracket, the control
system, the system can be updated with the pad assembly may slide away
latest software revision. Updates to the outrigger from the bracket. Use caution
controls system include updating the outrigger when removing the fasteners.
ECM and/or the outrigger control pad.
a
Prior to updating the outrigger controls system,
the software programmer, hardware and firmware
must be acquired through the Genie Industries
Service Department.

Note: Perform this procedure with the machine on


a firm, level surface.
Note: Failure to update the firmware on the
outrigger ECM and/or the outrigger control pad
when updating the outrigger controls system, may
result in abnormal operation of the outrigger
controls system.

How to Remove and Disassemble


the Outrigger Control Pad
1 Disconnect the battery pack from the machine.
Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings, b
watches and other jewelry.
2 Push in the red Emergency Stop button to the c
off position at both the ground and platform d
controls.
Illustration 1
3 Tag and disconnect the outrigger controls coil
a control pad
cord from the outrigger controls cable. b control pad bracket
c washer
d screw

5 Carefully remove the outrigger control pad


from the outrigger control pad bracket. Refer
to Illustration 1.

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 17


Section 4 • Repair Procedures October 2009

PLATFORM CONTROLS REV J

6 Remove the top enclosure of the control pad 8 Using a set of pliers, grasp the connector of
and set to the side. Refer to Illustration 2. the coil cord and slowly pull the coil cord away
from the printed circuit board. Refer to
Component damage hazard.
Illustration 3.
Electrostatic discharge (ESD) can
damage printed circuit board Component damage hazard.
components. Maintain firm Attempting to disconnect the coil
contact with a metal part of the cord from the printed circuit board
machine that is grounded at all at the cord wires, may result in
times when handling printed the cord wires pulling out of the
circuit boards OR use a grounded connector.
wrist strap.
a
a

c b
c
Illustration 3
f
a coil cord
d
b coil cord connector
c printed circuit board
e
9 Proceed to step 16 to update the firmware.
Illustration 2

a top enclosure
b coil cord
c bottom enclosure
d printed circuit board
e control pad decal (hidden from view)
f button cap

7 Locate the printed circuit board mounted to the


bottom enclosure of the outrigger control pad
and remove the button caps. Refer to
Illustration 2.

4 - 18 GS-30 • GS-32 • GS-46 Part No. 97385


October 2009 Section 4 • Repair Procedures

REV J PLATFORM CONTROLS

How to Remove and Disassemble


the Outrigger ECM
10 At the battery pack side of the machine,
open the access door to the ECM. Refer to
Illustration 4.
f a

Illustration 4

a outrigger ECM

11 Tag and disconnect the wire harness from the b


Outrigger ECM. d

12 Remove the fasteners securing the outrigger


ECM to the mounting bracket and remove the
ECM from the machine. Set the fasteners to
the side. c

13 Remove the fasteners securing the bottom


cover to the ECM enclosure. Set the cover and Illustration 5
the fasteners to the side. Refer to Illustration
a ECM enclosure
5. b printed circuit board
c torx screw
14 Carefully remove the printed circuit board from d bottom cover
the ECM enclosure. Refer to Illustration 5. e mounting bracket
f ECM decal
Component damage hazard.
Electrostatic discharge (ESD) can
damage printed circuit board
components. Maintain firm
contact with a metal part of the
machine that is grounded at all
times when handling printed
circuit boards OR use a grounded
wrist strap.
15 Proceed to step 16 to update the firmware.

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 19


Section 4 • Repair Procedures October 2009

PLATFORM CONTROLS REV J

How to Update the Firmware 17 Plug the PSoc MiniProg cable into the printed
circuit board of the ECM or the control pad,
Note: The PSoC Programmer (Genie part number making sure the "VDD" on the PSoC MiniProg
125324), updated Hex files for the outrigger cable line up with the "+" on the printed circuit
control pad (Genie part number 125132) and the board. Refer to Illustration 6.
updated Hex files for the outrigger ECM (Genie
part number 125131) must be installed on a PC or
laptop.

16 Plug the USB end of the PSoC MiniProg cable GREEN


LED1

into a PC or laptop. R14

MTG1 MTG2

Note: A window may ask to find a driver for the RED J1


TP11
LIFT
PSoC MiniProg cable. Click "Yes" until finished. C9
LED0

R20
1 4

VDD
JP1

C7 C8

U2
TP17
TP12
TP11 TP1
TP16 D1

+ R C D 24V
TP7

LED5 LED4
R17
D2

Illustration 6

18 Open the PSoC Programmer on a PC or


laptop.

4 - 20 GS-30 • GS-32 • GS-46 Part No. 97385


October 2009 Section 4 • Repair Procedures

REV J PLATFORM CONTROLS

19 Select "MINIProg1/048E47470618" from the Result: All the boxes in the lower right corner
"Port" drop down menu. of the "PSoC Programmer" window should
have a green background and show as being
"Connected."

Red
Background
Green
Background

Idle Not Connected

All Green
Backgrounds

Not Powered Idle Connected

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 21


Section 4 • Repair Procedures October 2009

PLATFORM CONTROLS REV J

20 Click the "File Load" button.

All Green
Backgrounds

Not Powered Idle Connected

4 - 22 GS-30 • GS-32 • GS-46 Part No. 97385


October 2009 Section 4 • Repair Procedures

REV J PLATFORM CONTROLS

21 Browse the folder containing the appropriate Note: To ensure the correct file is selected for
.hex file, select the file and click "Open." either the ECM or control pad update, refer to
the decals located in Illustrations 2 and 5. An
Result: All the boxes in the lower right hand
example of the firmware file number and revision
corner of the "PSoC Programmer" window
level can be found on the decals as shown below.
should have a green background.

ECU P/N: 109954 REV: A PCON P/N: 105627 REV: A

DESCRIPTION: ECU O/R CONTROLS, GS3232P DESCRIPTION: PCON, O/R CONTROLS, GS3232P

FIRMWARE FILE: 125131.hex REV: A1 FIRMWARE FILE: 125132.hex REV: A1

DATE CODE: DATE CODE:

SERIAL #: 125320 A
SERIAL #:
125321 A

FIRMWARE FILE NUMBER FIRMWARE FILE NUMBER

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 23


Section 4 • Repair Procedures October 2009

PLATFORM CONTROLS REV J

22 With the background of all boxes in the lower


right corner of the PSoc Programmer window
green in color, locate the "Device Family" drop
down menu and select "29x66."

All Green
Backgrounds

Not Powered Pass Idle Connected

4 - 24 GS-30 • GS-32 • GS-46 Part No. 97385


October 2009 Section 4 • Repair Procedures

REV J PLATFORM CONTROLS

Note: The ECM printed circuit board will be Note: The control pad printed circuit board will be
labeled with Genie part number 105368 and will labeled with Genie part number 105370 and will
serve as the identifier when for selecting "29x66" serve as the identifier when for selecting "29x66"
from the "Device Family" drop-down menu. Refer from the "Device Family" drop-down menu. Refer
to Illustration 7. to Illustration 8.

L1

PCBA P / N: 105368 REV: A


C7

C14
MTG1
PCB P / N: 105369 REV: A
PCBA P / N: 105370 REV: A
C1
C9
LIFT
PCB P / N: 105367 REV: A

C9 C2
JP1
C8
U1

C7
U2

L2
VCC TP12
R98 R101

+ - R C D TP7

LED5
R90

D6

GREEN
LED1

R14

MTG1 MTG2
PCB P/N: 105369 REV: A
PCBA P/N: 105370 REV: RED J1

C9
LIFT LED0 1 4
R20

J1 D5
D1

F1 F2
JP1

C7 C8

D3
U2
SGND TP17
A12 TP12

CONTROL PAD
TP11 TP1
TP16 D1
A1 D2

+ - R C D 24V
B12 B1 TP7

C1
C12 LED5 LED4
R17
D2

C6
GND

D44 D45 D46 D47 D40 D41

D42 D43 D29 D30 D27 D28 D25 D26 D23 D24 D37 D38 D35 D36 D33 D34 D31 D32
L1

PRINTED CIRCUIT BOARD R18

LF TP6
TP13
C11
TP14

C12 C13 RF
R87

R67

R70

R12
U4 U5 C14
U3
PCBA P/N: 105368 REV:
U14

U11
U13

U12

R6 R7

L1
C10

C7
R4 R8
24VCC_A

C5 R9 TP15
24VCC_C 24VCC_B R19
D4 D49 D48
C4 C33 C5 C14 R3

TP10

LR
R10 R11 Q2 R13
C1
C6
C34
C8
RR C3

R16 R15
R75 R74 R71 R72 R82 R81 R77 R78 R38 R37 R40 R41 R44 R43 R47 R48 R53 R52 R56 R57 R60 R59 R63 R64

ECM
D22
C9 C2
R2 Q3
C1
PCB P/N: 105367 REV A
U1
R76

R83 R79 R73 R84 R86 R85 R80 R39 R45 R49 R42 R46 R51 R54 R50 R55 R61 R65 R58 R62 R68 R69 R66
LED3 LED2
D5
L2 R5
VCC D6
D39 D21 LS1
R101

D50
C2
R7

U1
R98
C12

R14

R88

PRINTED CIRCUIT BOARD


U4 R89 U10
LED1 C11
R6
R12
R91
U7

U8

R8
U3

L2
C10

R99 R90
R13

D6
C21

D7 TP4
R5
R11 D7
R100
C20

R4 R3
LED2 C16
C19 JP1
R9 R10
ENABLE
R1

C15 S2 S3 S1
U9

U5

C4
U2

C18
R2

TP8
U6

TP9
C13 D4 D3
C3

VCC
C17 + - R C D
R29

R27
R28
R17

R16
R96

R94

R19

R18

R26
R30

R15

R25

R92

SGND
D18

D17

D11

D51
D53

D13

D20

D16

D15
C31 D19

D10
D12

D14
D52

C30

MTG4 MTG3
C29
C26
C37

C25

C28

C27

C35
C22
C36

C23
C32
R22 C24

RETRACT TP5 EXTEND


R21

R32

R31

R1
R97

R95

R24

R36

R35

R34

R33

R93
R20
R23

D9 D8 TP3 TP2

Illustration 7 Illustration 8

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 25


Section 4 • Repair Procedures October 2009

PLATFORM CONTROLS REV J

23 At the "Device" drop-down menu select


CY8C29666 if the outrigger ECM firmware is
being updated OR select CY8C29466 if the
outrigger control pad firmware is being
updated.

All Green
Backgrounds

Not Powered Pass Idle Connected

4 - 26 GS-30 • GS-32 • GS-46 Part No. 97385


October 2009 Section 4 • Repair Procedures

REV J PLATFORM CONTROLS

24 At "Programming Mode", select the "Reset"


bullet.

All Green
Backgrounds

Not Powered Pass Idle Connected

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 27


Section 4 • Repair Procedures October 2009

PLATFORM CONTROLS REV J

25 Click the "Toggle Device Power" button. 26 Click the "Program" button to update the
firmware of either the ECM or the control pad.
Result: A portion of the lower right hand corner
in the "PSoC Programmer" window should now Result: The main "PSoC Programmer" window
be red and show as being "Powered". will indicate a successful program.
Result: The red light labeled "Target Power" on
the MiniProg cable should be on.

Red Green
Background Backgrounds

Powered Pass Idle Connected

4 - 28 GS-30 • GS-32 • GS-46 Part No. 97385


October 2009 Section 4 • Repair Procedures

REV J PLATFORM CONTROLS

27 Click the "Toggle Device Power" button to 28 Carefully disconnect the "MiniProg" cable from
power down the printed circuit board. the printed circuit board.
Result: All the boxes in the lower right hand Component damage hazard.
corner of the "PSoC Programmer" window Electrostatic discharge (ESD) can
should have a green background and should damage printed circuit board
indicate "Not Powered." components. Maintain firm
contact with a metal part of the
machine that is grounded at all
times when handling printed
circuit boards OR use a grounded
wrist strap.
Note: Repeat this procedure beginning with step
16 if updates are required of the outrigger ECM
AND the outrigger control pad.

All Green
Backgrounds

Not Powered Pass Idle Connected

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 29


Section 4 • Repair Procedures October 2009

PLATFORM CONTROLS REV J

How to Assemble and Install the 33 Install the control pad onto the control pad
bracket and secure using the fasteners
Outrigger Control Pad removed in step 4. Do not over tighten the
30 Carefully connect the control pad coil cord to fasteners. Refer to Illustration 1.
the control pad printed circuit board. Refer to a
Illustration 2.
31 Install the button caps removed in step 7 onto
the buttons of the control pad printed circuit
board. Refer to Illustration 2.
Component damage hazard.
Electrostatic discharge (ESD) can
damage printed circuit board
components. Maintain firm
contact with a metal part of the
machine that is grounded at all
times when handling printed
circuit boards OR use a grounded
wrist strap.
32 Install the control pad top enclosure onto the
control pad bottom enclosure. Refer to
Illustration 2.
a

c
d
c
Illustration 1
f a control pad
d b control pad bracket
c washer
d screw
e

Illustration 2
34 Connect the outrigger controls coil cord to the
outrigger controls cable.
a top enclosure
b coil cord
c bottom enclosure
d printed circuit board
e control pad decal (hidden from view)
f button cap

4 - 30 GS-30 • GS-32 • GS-46 Part No. 97385


October 2009 Section 4 • Repair Procedures

REV J PLATFORM CONTROLS

How to Assemble and Install the


Outrigger ECM
35 Insert the ECM printed circuit board into the
ECM enclosure. Refer to Illustration 5.
Component damage hazard. f a
Electrostatic discharge (ESD) can
damage printed circuit board
components. Maintain firm
contact with a metal part of the
machine that is grounded at all
times when handling printed
circuit boards OR use a grounded
wrist strap.
36 Using the fasteners removed in step 13, e
securely install the ECM bottom cover to the
ECM enclosure. Do not over tighten. Refer to
Illustration 5.

b
d

Illustration 5

a ECM enclosure
b printed circuit board
c torx screw
d bottom cover
e mounting bracket
f ECM decal

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 31


Section 4 • Repair Procedures October 2009

PLATFORM CONTROLS REV J

37 Using the fasteners removed in step 12, How to Finish the Outrigger
securely install the ECM assembly onto the
ECM bracket. Do not over tighten. Refer to Controls Software Update
Illustration 9. 40 Connect the battery pack to the machine.
Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.
41 Calibrate the outrigger level sensor. See 1-4,
How to Calibrate the Outrigger Level Sensor.
42 Calibrate the outrigger pressure transducers.
See 1-4, How to Calibrate the Outrigger
Pressure Transducers.
43 Perform the function tests. Refer to the
Operator's Manual on your machine.
44 Return the machine to service.
If you have any further questions regarding these
instructions or need assistance, please contact
the Genie Industries Scissors Service
Department,
1-800-536-1800 Ext. 8710

Illustration 9

a ECM assembly
b ECM bracket

38 Connect the ECM harness to the ECM.


39 Close the access door and secure in place.

4 - 32 GS-30 • GS-32 • GS-46 Part No. 97385


June 2009 Section 4 • Repair Procedures

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Part No. 97385 GS-30 • GS-32 • GS-46 4 - 33


Section 4 • Repair Procedures April 2008

Platform Components REV B

2-1 8 Models with air line to platform option:


Disconnect the air line from the platform. Pull
Platform the air line free of the platform.
9 Support the platform with a forklift at the
How to Remove the Platform non-steer end. Do not apply any lifting
Perform this procedure with the platform extension pressure.
fully retracted and locked in position. 10 Attach a strap from the lanyard anchorage point
1 Raise the platform to approximately 3 ft / 1 m. on the platform railings to the carriage on the
forklift to help support the platform.
2 Remove the retaining fasteners securing the
platform to the platform mount at the steer end 11 GS-1530/32 and GS-1930/32: Lift the steer end
of the machine. of the platform slightly to clear the platform
mount and slide the platform towards the non-
3 Lower the platform to the stowed position. steer end of the machine until the platform slide
4 Disconnect the battery packs from the machine. blocks at the non-steer end of the machine are
visible through the access holes in the bottom
Electrocution/burn hazard. Contact of the platform.
with electrically charged circuits
could result in death or serious All other models: Lift the steer end of the
injury. Remove all rings, watches platform slightly to clear the platform mount and
and other jewelry. slide the platform towards the steer end of the
machine until the platform slide blocks at the
5 Disconnect the platform controls from the non-steer end of the machine are visible
control cable at the platform. through the access holes in the bottom of the
platform.
6 Remove the cover from the AC outlet. Tag and
disconnect the wiring from the outlet. Crushing hazard. The platform will
fall if not properly supported.
Electrocution hazard. Contact with
electrically charged circuits could 12 Carefully lift the platform off of the machine and
result in death or serious injury. place it on a structure capable of supporting it.
Remove all rings, watches and
other jewelry. Note: Take notice of the wear pad position before
the platform is removed, so when the platform is
7 Disconnect the wiring from the platform and pull installed they will be in the correct position.
the wiring free of the platform.

4 - 34 GS-30 • GS-32 • GS-46 Part No. 97385


April 2008 Section 4 • Repair Procedures

REV B PLATFORM COMPONENTS

2-2 7 Remove the platform roller wheels from the


machine.
Platform Extension
8 Carefully slide the platform extension out from
the platform and place it on a structure capable
How to Remove the of supporting it.
Platform Extension
How to Replace the Platform
1 Lower the platform to the stowed position.
Extension Wear Pads
2 Extend the platform approximately 3 feet / 1 m.
1 Remove the Platform Extension. See 2-2, How
3 Remove the platform controls from the platform to Remove the Platform Extension.
and lay them off to the side of the machine.
2 Drill out the rivets which hold the wear pads in
4 Support the platform extension with a forklift at place.
the steer end of the machine. Do not apply any
lifting pressure. 3 Install the new wear pads using new rivets.
When installing the new rivets, make sure the
5 Attach a strap from the platform extension rivet heads are not above the surface of the
railings to the carriage on the forklift to help wear pad.
support the platform extension.
6 Remove the two retaining fasteners from each
platform extension roller bracket assembly.
Remove each assembly from the machine.
Note: Do not remove the platform roller bolt.

a roller bracket assembly


b assembly retaining fastener
c platform roller bolt

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 35


Section 4 • Repair Procedures March 2007

Scissor Components REV C

10
2

3 11

4 12

13
5
14
6 15

7 16

8 17

GS-1530
GS-1532
Steer End Non-steer End
1 Number 4 pivot pin 10 Number 3 inner arm
2 Number 3 center pivot pin (2 pins) 11 Number 3 outer arm
3 Lift cylinder rod-end pivot pin 12 Number 3 pivot pin (non-steer end)
4 Number 3 pivot pin (steer end) 13 Number 2 inner arm
5 Number 2 center pivot pin (2 pins) 14 Number 2 outer arm
6 Number 2 pivot pin (steer end) 15 Number 2 pivot pin (non-steer end)
7 Number 1 center pivot pin (2 pins) 16 Lift cylinder barrel-end pivot pin
8 Number 1 inner arm 17 Number 1 outer arm
9 Number 1 pivot pin

4 - 36 GS-30 • GS-32 • GS-46 Part No. 97385


March 2007 Section 4 • Repair Procedures

REV C SCISSOR COMPONENTS

3-1
Scissor Assembly,
GS-1530 and GS-1532 a

How to Disassemble the


b
Scissor Assembly,
GS-1530 and GS-1532
c
Bodily injury hazard. The
procedures in this section require
specific repair skills, lifting
equipment and a suitable GS-1530
workshop. Attempting this GS-1532
procedure without these skills and
tools could result in death or Cable bridge legend
serious injury and significant
a cable bridge 3
component damage. Dealer
b cable bridge 2
service is required. c cable bridge 1
When removing a hose assembly or fitting, the 5 Remove the external snap rings and retaining
O-ring on the fitting and/or hose end must be fasteners from the number 3 center pivot pin at
replaced and then torqued to specification during the ground control side of the machine (index
installation. Refer to Section 2, Hydraulic Hose and #2).
Fitting Torque Specifications.
6 Use a soft metal drift to remove the number 3
1 Remove the platform. See 2-1, How to Remove center pivot pin at the ground control side of the
the Platform. machine (index #2).
2 Remove the cables from the number 3 outer 7 Remove the retaining fasteners from the
arm (index #11) at the ground controls side. number 3 pivot pin (index #12) at the non-steer
Component damage hazard. end of the machine.
Cables can be damaged if they 8 Use a soft metal drift to remove the number 3
are kinked or pinched. pivot pin (index #12) from the non-steer end of
3 Remove the cables from the number 3 cable the machine. Remove the number 3 outer arm
bridge and lay them off to the side. at the ground control side (index #11) from the
machine.
Component damage hazard.
Cables can be damaged if they Crushing hazard. The number 3
are kinked or pinched. outer arm may become
unbalanced and fall if not properly
Models with dual supported when removed from the
number 3 outer arms: machine.
4 Attach a lifting strap from an overhead crane to 9 Attach a lifting strap from an overhead crane to
the number 3 outer arm at the ground controls the number 3 outer arm at the battery pack side
side of the machine (index #11). of the machine (index #11).

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 37


Section 4 • Repair Procedures March 2007

SCISSOR COMPONENTS REV C

10 Remove the external snap rings and retaining 20 Remove the pin retaining fasteners from the lift
fasteners from the number 3 center pivot pin at cylinder rod-end pivot pin (index #3). Use a soft
the battery pack side of the machine (index #2). metal drift to remove the pin.
11 Use a soft metal drift to remove the number 3 Bodily injury hazard. The cylinder
center pivot pin at the battery pack side of the may fall when the rod-end pivot
machine (index #2). pin is removed if not properly
supported.
12 Remove the number 3 outer arm at the battery
pack side (index #11) from the machine. 21 Lower the cylinder onto the number 1 inner arm
(index #8).
Crushing hazard. The number 3
outer arm may become Component damage hazard.
unbalanced and fall if not properly Cables can be damaged if they
supported when removed from the are kinked or pinched.
machine.
22 Attach a lifting strap from an overhead crane to
Models with a single the number 3 inner arm (index #10).
number 3 outer arm assembly:
23 Remove the retaining fasteners from the
13 Attach a lifting strap from an overhead crane to number 3 pivot pin (index #4) at the steer end.
the number 3 outer arm (index #11).
24 Use a soft metal drift to remove the number 3
14 Remove the external snap rings and retaining pivot pin (index #4). Remove the number 3
fasteners from the number 3 center pivot pins inner arm (index #10) from the machine.
(index #2).
Bodily injury hazard. The number
15 Use a soft metal drift to remove the number 3 3 inner arm may become
center pivot pins (index #2). unbalanced and fall if not properly
supported when removed from the
16 Remove the retaining fasteners from the machine.
number 3 pivot pin (index #12) at the non-steer
end of the machine. 25 Remove the cables from the number 2 cable
bridge and lay them off to the side.
17 Use a soft metal drift to remove the number 3
pivot pin (index #12) from the non-steer end of Component damage hazard.
the machine. Remove the number 3 outer arm Cables can be damaged if they
(index #11) from the machine. are kinked or pinched.

Crushing hazard. The number 3 26 Remove the external snap rings and retaining
outer arm may become fasteners from the number 2 center pivot pin
unbalanced and fall if not properly (index #5) at the ground controls side.
supported when removed from the 27 Remove the number 2 cable bridge mounting
machine. fasteners and remove the cable bridge from the
All models: machine.

18 Remove the number 3 cable bridge mounting 28 Attach a lifting strap from an overhead crane to
fasteners and remove the cable bridge from the the number 2 outer arm (index #14) at the
machine. ground controls side.

19 Attach a lifting strap from an overhead crane to 29 Use a soft metal drift to remove the number 2
the lug on the rod end of the lift cylinder for center pivot pin (index #5) at the ground
support. Do not apply any lifting pressure. controls side.

4 - 38 GS-30 • GS-32 • GS-46 Part No. 97385


March 2007 Section 4 • Repair Procedures

REV C SCISSOR COMPONENTS

30 Remove the retaining fasteners from the 38 Use a soft metal drift to remove the number 2
number 2 pivot pin (index #15) at the non-steer pivot pin (index #6). Remove the number 2
end of the machine. inner arm (index #13) from the machine.
31 Use a soft metal drift to tap the number 2 pivot Bodily injury hazard. The number
pin (index #15) halfway out at the non-steer end 2 inner arm may become
of the machine. Remove the number 2 outer unbalanced and fall if not properly
arm (index #14) from the ground controls side supported when removed from the
of the machine. machine.
Bodily injury hazard. The number 39 Remove the safety arm from the number 2 inner
2 outer arm at the ground controls arm (index #13) that was just removed.
side may become unbalanced and
40 Attach a lifting strap from an overhead crane to
fall if not properly supported when
the number 1 inner arm (index #8).
removed from the machine.
41 Raise the number 1 inner arm (index #8)
32 Attach a lifting strap from an overhead crane to
approximately 2 feet / 60 cm and install the
the number 2 outer arm (index #14) at the
safety arm between the number 1 inner arm
battery pack side.
(index #8) and the number 1 outer arm (index
33 Remove the external snap rings and retaining #17). Lower the scissor arms onto the safety
fasteners from the number 2 center pivot pin arm.
(index #5) at the battery pack side.
Bodily injury hazard. Keep hands
34 Use a soft metal drift to remove the number 2 clear of moving parts when
center pivot pin (index #5) at the battery pack lowering the scissor arms onto the
side. safety arm.
Bodily injury hazard. The number 42 Attach a lifting strap from an overhead crane to
2 outer arm at the battery pack the lug on the rod end of the lift cylinder
side may become unbalanced and (index #3). Raise the lift cylinder approximately
fall if not properly supported when 3 ft / 1 m.
removed from the machine.
43 Tag, disconnect and plug the hydraulic hoses
35 Use a soft metal drift to tap the number 2 pivot on the lift cylinder. Cap the fittings on the
pin (index #15) in the other direction at the non- cylinder.
steer end. Remove the number 2 outer arm
Bodily injury hazard. Spraying
(index #14) from the battery pack side of the
hydraulic oil can penetrate and
machine.
burn skin. Loosen hydraulic
Bodily injury hazard. The number connections very slowly to allow
2 outer arm at the battery pack the oil pressure to dissipate
side may become unbalanced and gradually. Do not allow oil to squirt
fall if not properly supported when or spray.
removed from the machine.
44 Tag and disconnect the wires and manual
36 Attach a lifting strap from an overhead crane to lowering cable from the solenoid valve on the
the number 2 inner arm (index #13). cylinder.
37 Remove the retaining fasteners from the 45 Models with platform overload option: Tag
number 2 pivot pin (index #6) at the steer end and disconnect the wire harness from the
of the machine. platform overload switch.

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 39


Section 4 • Repair Procedures March 2007

SCISSOR COMPONENTS REV C

46 Raise the lift cylinder to a vertical position. 53 Attach a lifting strap from an overhead crane to
the number 1 outer arm (index #17). Do not
47 Remove the pin retaining fasteners from the lift
apply any lifting pressure.
cylinder barrel-end pin (index #16). Use a soft
metal drift to remove the pin. Remove the lift 54 Remove the external snap rings and retaining
cylinder from the machine. fasteners from the number 1 center pivot pins
(index #7).
Crushing hazard. The lift cylinder
could become unbalanced and fall 55 Remove the number 1 cable bridge from the
when it is removed from the machine.
machine if not properly attached to
56 Use a soft metal drift to remove the number 1
the overhead crane.
center pivot pins (index #7).
Component damage hazard. Be
Bodily injury hazard. The number
careful not to damage the valve or
1 outer arm may become
fittings on the cylinder while
unbalanced and fall if not properly
removing it from the machine.
supported when the pin is
48 Place a 4 x 4 x 48 inch / 10 cm x 10 cm x 1.2 m removed.
long block across both sides of the chassis
57 Slide the number 1 outer arm (index #17) to the
under the number 1 center pivot pin
non-steer end and remove it from the machine.
(index #7).
Bodily injury hazard. The number
49 Attach a lifting strap from an overhead crane to
1 outer arm may become
the number 1 inner arm (index #8) at the non-
unbalanced and fall if not properly
steer end. Raise the number 1 inner arm and
supported when removed from the
remove the safety arm. Lower the number 1
machine.
inner arm (index #8) onto the block that was
placed across the chassis. 58 Attach the strap from an overhead crane to the
number 1 inner arm (index #8). Do not lift it.
Bodily injury hazard. Keep hands
clear of moving parts when 59 Remove the upper fasteners securing the
lowering the arms onto the block. number 1 inner arm pivot bracket to the end of
the chassis. Loosen the lower fasteners.
50 Remove the cables from the number 1 cable
bridge and lay them off to the side. 60 Remove the number 1 inner arm (index #8)
from the machine.
Component damage hazard.
Cables can be damaged if they Bodily injury hazard. The number
are kinked or pinched. 1 inner arm may become
unbalanced and fall if not properly
51 Support and secure the entry ladder to an
supported when removed from the
appropriate lifting device.
machine.
52 Remove the fasteners from the entry ladder and
Component damage hazard. Be
remove the entry ladder from the machine.
sure not to damage the limit switch
Crushing hazard. The entry ladder or level sensor box components
may become unbalanced and fall if when the number 1 inner arm is
not properly supported and removed from the machine.
secured to the lifting device.

4 - 40 GS-30 • GS-32 • GS-46 Part No. 97385


March 2007 Section 4 • Repair Procedures

REV C SCISSOR COMPONENTS

How to Replace the Scissor Arm 9 Remove the scissor assembly from the
machine just enough to access both wear pads.
Wear Pads
Crushing hazard. The scissor
1 Remove the platform. See 2-1, How to Remove assembly will fall if not properly
the Platform. supported when removed from the
2 Support and secure the entry ladder to an drive chassis.
appropriate lifting device. Component damage hazard. Be
3 Remove the fasteners from the entry ladder and careful not to damage the level
remove the entry ladder from the machine. sensor or limit switch while moving
the scissor assembly.
Crushing hazard. The entry ladder
may become unbalanced and fall if 10 Remove both old wear pads.
not properly supported and 11 Install two new wear pads.
secured to the lifting device.
12 Slide the scissor assembly back into the drive
4 Secure the ends of the scissor arms together at chassis.
the steer end of the machine with a strap or
other suitable device. 13 Lower the scissor assembly into position and
install the chassis mount bracket onto the
5 Secure the ends of the scissor arms together at chassis. Securely install and tighten the
the non-steer end of the machine with a strap or fasteners. Do not overtighten.
other suitable device.
Component damage hazard. Be
6 Remove the retaining fasteners securing the careful not to damage the level
chassis mount bracket to the chassis at the sensor or limit switch while moving
steer end of the machine. the scissor assembly.
7 Attach a lifting strap from an overhead crane to
the scissor arm assembly.
8 Raise the scissor arm assembly at the steer
end with the overhead crane until the chassis
mount bracket will clear the level sensor.

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 41


Section 4 • Repair Procedures March 2007

SCISSOR COMPONENTS REV C

12
2
13

3 14

4 15

5 16

6 17

18
7
19

8 20

9 21

10 22

11

GS-1930
GS-1932
Steer End Non-steer End
1 Number 5 pivot pin 12 Number 4 inner arm
2 Number 4 center pivot pin (2 pins) 13 Number 4 outer arm
3 Number 4 pivot pin (steer end) 14 Number 4 pivot pin (non-steer end)
4 Number 3 center pivot pin (2 pins) 15 Number 3 inner arm
5 Lift cylinder rod-end pivot pin 16 Number 3 outer arm
6 Number 3 pivot pin (steer end) 17 Number 3 pivot pin (non-steer end)
7 Number 2 center pivot pin (2 pins) 18 Number 2 inner arm
8 Number 2 pivot pin (steer end) 19 Number 2 outer arm
9 Number 1 center pivot pin (2 pins) 20 Number 2 pivot pin (non-steer end)
10 Number 1 inner arm 21 Lift cylinder barrel-end pivot pin
11 Number 1 pivot pin 22 Number 1 outer arm

4 - 42 GS-30 • GS-32 • GS-46 Part No. 97385


March 2007 Section 4 • Repair Procedures

REV C SCISSOR COMPONENTS

3-2
Scissor Assembly,
a
GS-1930 and GS-1932
b
How to Disassemble the
Scissor Assembly,
GS-1930 and GS-1932
Bodily injury hazard. The
c
procedures in this section require
specific repair skills, lifting
equipment and a suitable d
workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant GS-1930
component damage. Dealer GS-1932
service is required.
Cable bridge legend
When removing a hose assembly or fitting, the
O-ring on the fitting and/or hose end must be a cable bridge 4
replaced and then torqued to specification during b cable bridge 3
c cable bridge 2
installation. Refer to Section 2, Hydraulic Hose and d cable bridge 1
Fitting Torque Specifications.
Models with dual
1 Remove the platform. See 2-1, How to Remove number 4 outer arms:
the Platform.
4 Attach a lifting strap from an overhead crane to
2 Remove the cables from the number 4 outer
the number 4 outer arm at the ground controls
arm (index #13) at the ground controls side.
side of the machine (index #13).
Component damage hazard.
5 Remove the external snap rings and retaining
Cables can be damaged if they
fasteners from the number 4 center pivot pin at
are kinked or pinched.
the ground control side of the machine (index
3 Remove the cables from the number 4 cable #2).
bridge and lay them off to the side.
6 Use a soft metal drift to remove the number 4
Component damage hazard. center pivot pin at the ground control side of the
Cables can be damaged if they machine (index #2).
are kinked or pinched.
7 Remove the retaining fasteners from the
number 4 pivot pin (index #14) at the non-steer
end of the machine.

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 43


Section 4 • Repair Procedures March 2007

SCISSOR COMPONENTS REV C

8 Use a soft metal drift to remove the number 4 16 Remove the retaining fasteners from the
pivot pin (index #14) from the non-steer end of number 4 pivot pin (index #14) at the non-steer
the machine. Remove the number 4 outer arm end of the machine.
at the ground control side (index #13) from the
17 Use a soft metal drift to remove the number 4
machine.
pivot pin (index #14) from the non-steer end of
Crushing hazard. The number 3 the machine. Remove the number 4 outer arm
outer arm may become (index #13) from the machine.
unbalanced and fall if not properly
Crushing hazard. The number 4
supported when removed from the
outer arm may become
machine.
unbalanced and fall if not properly
9 Attach a lifting strap from an overhead crane to supported when removed from the
the number 4 outer arm at the battery pack side machine.
of the machine (index #13).
All models:
10 Remove the external snap rings and retaining
fasteners from the number 4 center pivot pin at 18 Remove the number 4 cable bridge mounting
the battery pack side of the machine (index #2). fasteners and remove the cable bridge from the
machine.
11 Use a soft metal drift to remove the number 4
center pivot pin at the battery pack side of the 19 Attach a lifting strap from an overhead crane to
machine (index #2). the number 4 inner arm (index #12).

12 Remove the number 4 outer arm at the battery 20 Remove the retaining fasteners from the
pack side (index #13) from the machine. number 4 pivot pin (index #3).

Crushing hazard. The number 4 21 Use a soft metal drift to remove the number 4
outer arm may become pivot pin (index #3) at the steer end. Remove
unbalanced and fall if not properly the number 4 inner arm (index #12) from the
supported when removed from the machine.
machine. Crushing hazard. The number 4
Models with a single inner arm may become
number 4 outer arm assembly: unbalanced and fall if not properly
supported when removed from the
13 Attach a lifting strap from an overhead crane to machine.
the number 4 outer arm (index #13).
22 Remove the cables from the number 3 cable
14 Remove the external snap rings and retaining bridge and lay them off to the side.
fasteners from the number 4 center pivot pins
Component damage hazard.
(index #2).
Cables can be damaged if they
15 Use a soft metal drift to remove the number 4 are kinked or pinched.
center pivot pins (index #2).
23 Remove the number 3 cable bridge mounting
fasteners and remove the cable bridge from the
machine.

4 - 44 GS-30 • GS-32 • GS-46 Part No. 97385


March 2007 Section 4 • Repair Procedures

REV C SCISSOR COMPONENTS

24 Attach a lifting strap from an overhead crane to 32 Remove the number 3 pivot pin (index #17)
the number 3 outer arm (index #4) at the from the non-steer end of the machine.
ground controls side.
33 Attach a lifting strap from an overhead crane to
25 Remove the external snap rings and retaining the lug on the rod end of the lift cylinder for
fasteners from the number 3 center pivot pins support. Do not apply any lifting pressure.
(index #4).
34 Remove the pin retaining fasteners from the lift
26 Use a soft metal drift to remove the number 3 cylinder rod-end pivot pin (index #5). Use a soft
center pivot pin (index #4) at the ground control metal drift to remove the pin.
side.
Bodily injury hazard. The cylinder
27 Remove the retaining fasteners from the may fall when the rod-end pivot
number 3 pivot pin (index #17) at the non-steer pin is removed if not properly
end of the machine. supported.
28 Use a soft metal drift to tap the number 3 pivot 35 Lower the cylinder onto the number 1 inner arm
pin (index #17) halfway out at the non-steer end (index #9).
of the machine. Remove the number 3 outer
Component damage hazard.
arm (index #16) at the ground controls side
Cables can be damaged if they
from the machine.
are kinked or pinched.
Bodily injury hazard. The number
36 Attach a lifting strap from an overhead crane to
3 outer arm at the ground controls
the number 3 inner arm (index #15).
side may become unbalanced and
fall if not properly supported when 37 Remove the retaining fasteners from the
removed from the machine. number 3 pivot pin (index #6) at the steer end.
29 Attach a lifting strap from an overhead crane to 38 Use a soft metal drift to remove the number 3
the number 3 outer arm (index #16) at the pivot pin (index #6). Remove the number 3
battery pack side. inner arm (index #15) from the machine.
30 Use a soft metal drift to remove the number 3 Bodily injury hazard. The number
center pivot pin (index #4) at the battery pack 3 inner arm may become
side of the machine. unbalanced and fall if not properly
supported when removed from the
31 Use a soft metal drift to tap the number 3 pivot
machine.
pin (index #17) in the other direction. Remove
the number 3 outer arm (index #16) from the 39 Remove the cables from the number 2 cable
battery pack side of the machine. bridge and lay them off to the side.
Bodily injury hazard. The number Component damage hazard.
3 outer arm at the battery pack Cables can be damaged if they
side may become unbalanced and are kinked or pinched.
fall if not properly supported when
removed from the machine. 40 Remove the external snap rings and retaining
fasteners from the number 2 center pivot pin
(index #7) at the ground controls side.

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 45


Section 4 • Repair Procedures March 2007

SCISSOR COMPONENTS REV C

41 Remove the number 2 cable bridge mounting 49 Use a soft metal drift to tap the number 2 pivot
fasteners and remove the cable bridge from the pin at the non-steer end (index #20) in the other
machine. direction. Remove the number 2 outer arm
(index #19) from the battery pack side of the
42 Attach a lifting strap from an overhead crane to
machine.
the number 2 outer arm (index #19) at the
ground controls side. Bodily injury hazard. The number
2 outer arm at the battery pack
43 Use a soft metal drift to remove the number 2
side may become unbalanced and
center pivot pin (index #7) at the ground
fall if not properly supported when
controls side.
removed from the machine.
44 Remove the retaining fasteners from the
50 Remove the number 3 pivot pin (index #17)
number 2 pivot pin (index #20) at the non-steer
from the non-steer end of the machine.
end of the machine.
51 Attach a lifting strap from an overhead crane to
45 Use a soft metal drift to tap the number 2 pivot
the number 2 inner arm (index #18).
pin (index #20) halfway out at the non-steer end
of the machine. Remove the number 2 outer 52 Remove the retaining fasteners from the
arm (index #19) from the ground controls side number 2 pivot pin (index #8) at the steer end
of the machine. of the machine.
Bodily injury hazard. The number 53 Use a soft metal drift to remove the number 2
2 outer arm at the ground controls pivot pin (index #8). Remove the number 2
side may become unbalanced and inner arm (index #18) from the machine.
fall if not properly supported when
Bodily injury hazard. The number
removed from the machine.
2 inner arm may become
46 Attach a lifting strap from an overhead crane to unbalanced and fall if not properly
the number 2 outer arm (index #19) at the supported when removed from the
battery pack side. machine.
47 Remove the external snap rings and retaining 54 Remove the safety arm from the number 2 inner
fasteners from the number 2 center pivot pin arm (index #18) that was just removed.
(index #7) at the battery pack side.
55 Attach a lifting strap from an overhead crane to
48 Use a soft metal drift to remove the number 2 the number 1 inner arm (index #10).
center pivot pin (index #7) at the battery pack
56 Raise the number 1 inner arm (index #10)
side.
approximately 2 feet / 60 cm and install the
Bodily injury hazard. The number safety arm between the number 1 inner arm
2 outer arm at the battery pack (index #10) and the number 1 outer arm (index
side may become unbalanced and #22) at the non-steer end of the machine.
fall if not properly supported when Lower the scissor arms onto the safety arm.
removed from the machine.
Bodily injury hazard. Keep hands
clear of moving parts when
lowering the scissor arms onto the
safety arm.

4 - 46 GS-30 • GS-32 • GS-46 Part No. 97385


March 2007 Section 4 • Repair Procedures

REV C SCISSOR COMPONENTS

57 Attach a lifting strap from an overhead crane to 64 Attach a lifting strap from an overhead crane to
the lug on the rod end of the lift cylinder the number 1 inner arm (index #10) at the non-
(index #5). Raise the lift cylinder approximately steer end. Raise the number 1 inner arm and
3 ft / 1 m. remove the safety arm. Lower the number 1
inner arm (index #10) onto the block that was
58 Tag, disconnect and plug the hydraulic hoses
placed across the chassis.
on the lift cylinder. Cap the fittings on the
cylinder. Bodily injury hazard. Keep hands
clear of moving parts when
Bodily injury hazard. Spraying
lowering the arms onto the block.
hydraulic oil can penetrate and
burn skin. Loosen hydraulic 65 Remove the cables from the number 1 cable
connections very slowly to allow bridge and lay them off to the side.
the oil pressure to dissipate
Component damage hazard.
gradually. Do not allow oil to squirt
Cables can be damaged if they
or spray.
are kinked or pinched.
59 Tag and disconnect the wires and manual
66 Support and secure the entry ladder to an
lowering cable from the solenoid valve on the
appropriate lifting device.
cylinder.
67 Remove the fasteners from the entry ladder and
60 Models with platform overload option: Tag
remove the entry ladder from the machine.
and disconnect the wire harness from the
platform overload switch. Crushing hazard. The entry ladder
may become unbalanced and fall if
61 Raise the lift cylinder to a vertical position.
not properly supported and
62 Remove the pin retaining fasteners from the lift secured to the lifting device.
cylinder barrel-end pin (index #21). Use a soft
68 Attach a lifting strap from an overhead crane to
metal drift to remove the pin. Remove the lift
the number 1 outer arm (index #22). Do not
cylinder from the machine.
apply any lifting pressure.
Crushing hazard. The lift cylinder
69 Remove the external snap rings and retaining
may become unbalanced and fall
fasteners from the number 1 center pivot pins
when it is removed from the
(index #11).
machine if not properly attached to
the overhead crane. 70 Remove the number 1 cable bridge from the
machine.
Component damage hazard. Be
careful not to damage the valve or 71 Use a soft metal drift to remove the number 1
fittings on the cylinder while center pivot pins (index #9).
removing it from the machine.
Bodily injury hazard. The number
63 Place a 4 x 4 x 48 inch / 10 cm x 10 cm x 1.2 m 1 outer arm may become
long block across both sides of the chassis unbalanced and fall if not properly
under the number 1 center pivot pin supported when the pin is
(index #11). removed.

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 47


Section 4 • Repair Procedures March 2007

REV C

72 Slide the number 1 outer arm (index #22) to the How to Replace the Scissor Arm
non-steer end and remove it from the machine.
Wear Pads
Bodily injury hazard. The number
1 outer arm may become 1 Remove the platform. See 2-1, How to Remove
unbalanced and fall if not properly the Platform.
supported when removed from the 2 Support and secure the entry ladder to an
machine. appropriate lifting device.
73 Attach the strap from an overhead crane to the 3 Remove the fasteners from the entry ladder and
number 1 inner arm (index #10). Do not lift it. remove the entry ladder from the machine.
74 Remove the upper fasteners securing the Crushing hazard. The entry ladder
number 1 inner arm pivot bracket to the end of may become unbalanced and fall if
the chassis. Loosen the lower fasteners. not properly supported and
75 Remove the number 1 inner arm (index #10) secured to the lifting device.
from the machine. 4 Secure the ends of the scissor arms together at
Bodily injury hazard. The number the steer end of the machine with a strap or
1 inner arm may become other suitable device.
unbalanced and fall if not properly 5 Secure the ends of the scissor arms together at
supported when removed from the the non-steer end of the machine with a strap or
machine. other suitable device.
Component damage hazard. Be 6 Remove the retaining fasteners securing the
sure not to damage the limit switch chassis mount bracket to the chassis at the
or level sensor box components steer end of the machine.
when the number 1 inner arm is
removed from the machine. 7 Attach a lifting strap from an overhead crane to
the scissor arm assembly.
8 Raise the scissor arm assembly at the steer
end with the overhead crane until the chassis
mount bracket will clear the level sensor.

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March 2007 Section 4 • Repair Procedures

REV C

9 Remove the scissor assembly from the


machine just enough to access both wear pads.
Crushing hazard. The scissor
assembly will fall if not properly
supported when removed from the
drive chassis.
Component damage hazard. Be
careful not to damage the level
sensor or limit switch while moving
the scissor assembly.
10 Remove both old wear pads.
11 Install two new wear pads.
12 Slide the scissor assembly back into the drive
chassis.
13 Lower the scissor assembly into position and
install the chassis mount bracket onto the
chassis. Securely install and tighten the
fasteners. Do not over tighten.
Component damage hazard. Be
careful not to damage the level
sensor or limit switch while moving
the scissor assembly.

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 49


Section 4 • Repair Procedures March 2007

SCISSOR COMPONENTS REV C

10
2

3 11

4 12

13
5
14
6 15

7 16

8 17

GS-2032
Steer end
GS-2046
Non-steer end
1 Number 4 pivot pin 10 Number 3 inner arm
2 Number 3 center pivot pin (2 pins 11 Number 3 outer arm
3 Lift cylinder rod-end pivot pin 12 Number 3 pivot pin (non-steer end)
4 Number 3 pivot pin (steer end) 13 Number 2 inner arm
5 Number 2 center pivot pin (2 pins) 14 Number 2 outer arm
6 Number 2 pivot pin (steer end 15 Number 2 pivot pin (non-steer end)
7 Number 1 center pivot pin (2 pins) 16 Lift cylinder barrel-end pivot pin
8 Number 1 inner arm 17 Number 1 outer arm
9 Number 1 pivot pin

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March 2007 Section 4 • Repair Procedures

REV C SCISSOR COMPONENTS

3-3
Scissor Assembly,
a
GS-2032 and GS-2046
b
How to Disassemble the
c
Scissor Assembly,
GS-2032 and GS-2046
d
Bodily injury hazard. The
procedures in this section require
specific repair skills, lifting
equipment and a suitable GS-2032
workshop. Attempting this GS-2046
procedure without these skills and
tools could result in death or Cable bridge legend
serious injury and significant
a cable bridge 3
component damage. Dealer
b cable bridge 2A
service is required. c cable bridge 2B
d cable bridge 1

When removing a hose assembly or fitting, the 5 Disconnect the number 3 cable bridge from the
O-ring on the fitting and/or hose end must be number 3 outer arm (index #11) and remove
replaced and then torqued to specification during the cable bridge from the machine.
installation. Refer to Section 2, Hydraulic Hose and
Fitting Torque Specifications. 6 Remove the retaining fasteners from the
number 4 pivot pin (index #1).
1 Remove the platform. See 2-1, How to Remove
7 Use a soft metal drift to remove the number 4
the Platform.
pivot pin (index #1). Remove the platform
2 Support and secure the entry ladder to an mount bracket from the machine.
appropriate lifting device.
8 Attach a lifting strap from an overhead crane to
3 Remove the fasteners from the entry ladder and the number 3 outer arm at the ground control
remove the entry ladder from the machine. side (index #11).
Crushing hazard. The entry ladder 9 Remove the retaining fasteners from the
may become unbalanced and fall if number 3 center pivot pin (index #2) at the
not properly supported and ground control side.
secured to the lifting device.
10 Place a rod through the number 3 center pivot
4 Remove the cables from the number 3 cable pin at the ground control side (index #2) and
bridge and lay them off to the side. twist to remove the pin.
Component damage hazard. 11 Remove the retaining fasteners from the
Cables can be damaged if they number 3 pivot pin (index #12) at the non-steer
are kinked or pinched. end.

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 51


Section 4 • Repair Procedures March 2007

SCISSOR COMPONENTS REV C

12 Use a soft metal drift to remove the number 3 21 Lower the cylinder onto the block.
pivot pin (index #12) from the non-steer end of
Bodily injury hazard. Keep hands
the machine. Remove the number 3 outer arm
clear of moving parts when
at the ground control side (index #11) from the
lowering the cylinder onto the
machine.
block.
Crushing hazard. The number 3
22 Attach a lifting strap from an overhead crane to
outer arm at the ground control
the number 3 inner arm (index #10). Raise the
side (index #11) may become
arm to a vertical position.
unbalanced and fall if not properly
supported when removed from the 23 Remove the retaining fasteners from the
machine. number 3 pivot pin at the steer end of the
machine (index #4).
13 Attach a lifting strap from an overhead crane to
the number 3 outer arm at the battery side 24 Use a soft metal drift to remove the number 3
(index #11). pivot pin (index #4) from the steer end of the
machine. Remove the number 3 inner arm
14 Remove the retaining fasteners from the
(index #10) from the machine.
number 3 center pivot pin (index #2) at the
battery side. Crushing hazard. The number 3
inner arm (index #10) may
15 Place a rod through the number 3 center pivot
become unbalanced and fall if not
pin at the battery side (index #2) and twist to
properly supported when the pivot
remove the pin.
pin is removed.
16 Remove the number 3 outer arm (index #11)
25 Remove the cables from the number 2A and 2B
from the machine.
cable bridge and lay them off to the side.
Crushing hazard. The number 3
Component damage hazard.
outer arm (index #11) may
Cables can be damaged if they
become unbalanced and fall if not
are kinked or pinched.
properly supported when removed
from the machine. 26 Disconnect the number 2A and 2B cable
bridges from the scissor linkset and remove
17 Attach a lifting strap from an overhead crane to
both cable bridges from the machine.
the lug of the rod end of the lift cylinder.
27 Attach a lifting strap from an overhead crane to
18 Remove the retaining fasteners from the lift
the number 2 outer arm at the ground control
cylinder rod end pivot pin (index #3).
side (index #14).
19 Use a soft metal drift to remove the lift cylinder
28 Remove the retaining fasteners from the
rod end pivot pin (index #3) from the machine.
number 2 center pivot pin (index #5) at the
Crushing hazard. The lift cylinder ground control side.
will fall if not properly supported
29 Place a rod through the number 2 center pivot
when the pivot pin is removed.
pin at the ground control side (index #5) and
20 Place a 2 x 4 x 10 inch / 10 x 10 x 25 cm block twist to remove the pin.
onto the number 1 inner arm cylinder plate
(index #8).

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March 2007 Section 4 • Repair Procedures

REV C SCISSOR COMPONENTS

30 Remove the retaining fasteners from the 37 Remove the retaining fasteners from the
number 2 pivot pin (index #15) at the non-steer number 2 pivot pin at the steer end of the
end. machine (index #6).
31 Use a soft metal drift to remove the number 2 38 Use a soft metal drift to remove the number 2
pivot pin (index #15) from the non-steer end of pivot pin (index #6) from the steer end of the
the machine. Remove the number 2 outer arm machine. Remove the number 2 inner arm
at the ground control side (index #14) from the (index #13) from the machine.
machine.
Crushing hazard. The number 2
Crushing hazard. The number 2 inner arm (index #13) may
outer arm at the ground control become unbalanced and fall if not
side (index #14) may become properly supported when the pivot
unbalanced and fall if not properly pin is removed.
supported when the pivot pin is
39 Attach a lifting strap from an overhead crane to
removed.
the number 1 inner arm (index #8).
32 Attach a lifting strap from an overhead crane to
40 Raise the number 1 inner arm (index #8)
the number 2 outer arm at the battery side
approximately 2 feet / 60 cm.
(index #14).
41 Place a 4 x 4 x 48 inch / 10 cm x 10 cm x 1.2 m
33 Remove the retaining fasteners from the
long block across both sides of the chassis
number 2 center pivot pin (index #5) at the
under the number 1 center pivot pin (index #7).
battery side.
42 Lower the scissor arms onto the block that was
34 Place a rod through the number 2 center pivot
placed across the chassis.
pin at the battery side (index #5) and twist to
remove the pin. Bodily injury hazard. Keep hands
clear of moving parts when
Crushing hazard. The number 2
lowering the scissor arms.
outer arm (index #14) may
become unbalanced and fall if not 43 Attach a lifting strap from an overhead crane to
properly supported when the pivot the lug of the rod end of the lower lift cylinder.
pin is removed.
44 Tag, disconnect and plug the hydraulic hose on
35 Remove the number 2 outer arm (index #14) the lower lift cylinder. Cap the fittings on the
from the machine. cylinder.
Crushing hazard. The number 2 Bodily injury hazard. Spraying
outer arm (index #14) may hydraulic oil can penetrate and
become unbalanced and fall if not burn skin. Loosen hydraulic
properly supported when removed connections very slowly to allow
from the machine. the oil pressure to dissipate
gradually. Do not allow oil to squirt
36 Attach a lifting strap from an overhead crane to
or spray.
the number 2 inner arm (index #13). Raise the
arm to a vertical position. 45 Tag and disconnect the wire harness from the
solenoid valve on the cylinder.

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 53


Section 4 • Repair Procedures March 2007

SCISSOR COMPONENTS REV C

46 Tag and disconnect the wires and manual 54 Lower the arm to the stowed position.
lowering cable from the solenoid valve on the
Bodily injury hazard. Keep hands
cylinder.
clear of moving parts when
47 Models with platform overload option: Tag lowering the scissor arms.
and disconnect the wire harness from the
55 Secure the ends of the scissor arms together at
platform overload switch.
the steer end of the machine with a strap or
48 Raise the lift cylinder to a vertical position. other suitable device.
49 Remove the pin retaining fasteners from the lift 56 Secure the ends of the scissor arms together at
cylinder barrel-end pivot pin (index #16). Use a the non-steer end of the machine with a strap or
soft metal drift to remove the pin. Remove the other suitable device.
lift cylinder from the machine.
57 Remove the retaining fasteners securing the
Crushing hazard. The lift cylinder chassis mount bracket to the chassis.
will fall if not properly supported
58 Remove the linkset from the machine
when the pivot pin is removed.
Bodily injury hazard. The number
Component damage hazard. Be
1 inner and outer arms (index #8
careful not to damage the valve or
and #17) may become unbalanced
fittings on the cylinder while
and fall if not properly supported
removing it from the machine.
when removed from the machine.
50 Remove the cables from the number 1 cable
Component damage hazard. Be
bridge and lay them off to the side.
sure not to damage the limit switch
Component damage hazard. or level sensor box components
Cables can be damaged if they when the number 1 inner and
are kinked or pinched. outer arms (index #8 and #17) is
removed from the machine.
51 Disconnect the number 1 cable bridge from the
number 1 outer arm (index #17) and remove
the cable bridge from the machine.
52 Attach a lifting strap from an overhead crane to
the number 1 inner arm (index #8).
53 Raise the arm slightly and remove the block.

4 - 54 GS-30 • GS-32 • GS-46 Part No. 97385


March 2007 Section 4 • Repair Procedures

REV C SCISSOR COMPONENTS

How to Replace the Scissor Arm 9 Move the scissor assembly towards the
non-steer end of the machine slightly and to
Wear Pads one side of the machine until one of the scissor
1 Remove the platform. See 2-1, How to Remove arm wear pads is accessible. Do not allow both
the Platform. wear pads to slide out of the drive chassis.

2 Support and secure the entry ladder to an Component damage hazard. Be


appropriate lifting device. careful not to damage the level
sensor or limit switch while moving
3 Remove the fasteners from the entry ladder and the scissor assembly.
remove the entry ladder from the machine.
10 Remove the old wear pad.
Crushing hazard. The entry ladder
may become unbalanced and fall if 11 Install the new wear pad.
not properly supported and 12 Rotate the scissor assembly towards the other
secured to the lifting device. side of the machine until the other scissor arm
4 Secure the ends of the scissor arms together at wear pad is accessible. Do not allow both wear
the steer end of the machine with a strap or pads to slide out of the drive chassis.
other suitable device. Crushing hazard. The scissor
5 Secure the ends of the scissor arms together at assembly will fall if both wear pads
the non-steer end of the machine with a strap or are allowed to slide out of the drive
other suitable device. chassis.

6 Remove the retaining fasteners securing the Component damage hazard. Be


chassis mount bracket to the chassis at the careful not to damage the level
steer end of the machine. sensor or limit switch while moving
the scissor assembly.
7 Attach a lifting strap from an overhead crane to
the scissor arm assembly. 13 Remove the old wear pad.

8 Raise the scissor arm assembly at the steer 14 Install the new wear pad.
end with the overhead crane until the chassis 15 Slide the scissor assembly back into the drive
mount bracket will clear the level sensor. chassis.
16 Lower the scissor assembly into position and
install the chassis mount bracket onto the
chassis. Securely install and tighten the
fasteners. Do not overtighten.
Component damage hazard. Be
careful not to damage the level
sensor or limit switch while moving
the scissor assembly.

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 55


Section 4 • Repair Procedures March 2007

SCISSOR COMPONENTS REV C

12
2
13

3 14

4 15

5 16

6 17

18
7
19

8 20

9 21

10 22

11

GS-2632
Steer end
GS-2646
Non-steer end
1 Number 5 pivot pin 12 Number 4 inner arm
2 Number 4 center pivot pin (2 pins) 13 Number 4 outer arm
3 Number 4 pivot pin (steer end) 14 Number 4 pivot pin (non-steer end)
4 Number 3 center pivot pin (2 pins) 15 Number 3 inner arm
5 Lift cylinder rod end pivot pin 16 Number 3 outer arm
6 Number 3 pivot pin (steer end) 17 Number 3 pivot pin (non-steer end)
7 Number 2 center pivot pin (2 pins) 18 Number 2 inner arm
8 Number 2 pivot pin (steer end) 19 Number 2 outer arm
9 Number 1 center pivot pin (2 pins) 20 Number 2 pivot pin (non-steer end)
10 Number 1 inner arm 21 Lift cylinder barrel-end pivot pin
11 Number 1 pivot pin 22 Number 1 outer arm

4 - 56 GS-30 • GS-32 • GS-46 Part No. 97385


March 2007 Section 4 • Repair Procedures

REV C SCISSOR COMPONENTS

3-4
Scissor Assembly,
a
GS-2632 and GS-2646
b
How to Disassemble the
c
Scissor Assembly,
GS-2632 and GS-2646
d
Bodily injury hazard. The
e
procedures in this section require
specific repair skills, lifting
equipment and a suitable f
workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant GS-2632
component damage. Dealer GS-2646
service is required.
Cable bridge legend
When removing a hose assembly or fitting, the
O-ring on the fitting and/or hose end must be a cable bridge 4
replaced and then torqued to specification during b cable bridge 3A
c cable bridge 3B
installation. Refer to Section 2, Hydraulic Hose and d cable bridge 2A
Fitting Torque Specifications. e cable bridge 2B
f cable bridge 1
1 Remove the platform. See 2-1, How to Remove
the Platform. 4 Remove the cables from the number 4 cable
bridge and lay them off to the side.
2 Support and secure the entry ladder to an
appropriate lifting device. Component damage hazard.
Cables can be damaged if they
3 Remove the fasteners from the entry ladder and are kinked or pinched.
remove the entry ladder from the machine.
5 Disconnect the number 4 cable bridge from the
Crushing hazard. The entry ladder number 4 outer arm (index #13) and remove
may become unbalanced and fall if the cable bridge from the machine.
not properly supported and
secured to the lifting device. 6 Remove the retaining fasteners from the
number 5 pivot pin (index #1).

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 57


Section 4 • Repair Procedures March 2007

SCISSOR COMPONENTS REV C

7 Use a soft metal drift to remove the number 5 15 Place a rod through the number 4 center pivot
pivot pin (index #1). Remove the platform pin at the battery side (index #2) and twist to
mount bracket from the machine. remove the pin.
8 Attach a lifting strap from an overhead crane to 16 Remove the number 4 outer arm (index #13)
the number 4 outer arm at the ground control from the machine.
side (index #13).
Crushing hazard. The number 4
9 Remove the retaining fasteners from the outer arm (index #13) may
number 4 center pivot pin (index #2) at the become unbalanced and fall if not
ground control side. properly supported when removed
from the machine.
10 Place a rod through the number 4 center pivot
pin at the ground control side (index #2) and 17 Attach a lifting strap from an overhead crane to
twist to remove the pin. the number 4 inner arm (index #12). Raise the
arm to a vertical position.
11 Remove the retaining fasteners from the
number 4 pivot pin (index #15) at the non-steer 18 Remove the retaining fasteners from the
end. number 4 pivot pin at the steer end of the
machine (index #3).
12 Use a soft metal drift to remove the number 4
pivot pin (index #14) from the non-steer end of 19 Use a soft metal drift to remove the number 4
the machine. Remove the number 4 outer arm pivot pin (index #3) from the steer end of the
at the ground control side (index #13) from the machine. Remove the number 4 inner arm
machine. (index #12) from the machine.
Crushing hazard. The number 4 Crushing hazard. The number 4
outer arm at the ground control inner arm (index #12) may
side (index #13) may become become unbalanced and fall if not
unbalanced and fall if not properly properly supported when removed
supported when removed from the from the machine.
machine.
20 Remove the cables from the number 3A and 3B
13 Attach a lifting strap from an overhead crane to cable bridge and lay them off to the side.
the number 4 outer arm at the battery side
Component damage hazard.
(index #13).
Cables can be damaged if they
14 Remove the retaining fasteners from the are kinked or pinched.
number 4 center pivot pin (index #2) at the
21 Disconnect the number 3A and 3B cable
battery side.
bridges from the scissor linkset and remove
both cable bridges from the machine.

4 - 58 GS-30 • GS-32 • GS-46 Part No. 97385


March 2007 Section 4 • Repair Procedures

REV C SCISSOR COMPONENTS

22 Attach a lifting strap from an overhead crane to 30 Remove the number 3 outer arm (index #16)
the number 3 outer arm at the ground control from the machine.
side (index #16).
Crushing hazard. The number 3
23 Remove the retaining fasteners from the outer arm (index #16) may
number 3 center pivot pin (index #4) at the become unbalanced and fall if not
ground control side. properly supported when removed
from the machine.
24 Place a rod through the number 3 center pivot
pin at the ground control side (index #4) and 31 Attach a lifting strap from an overhead crane to
twist to remove the pin. the lug of the rod end of the lift cylinder.
25 Remove the retaining fasteners from the 32 Remove the retaining fasteners from the lift
number 3 pivot pin (index #17) at the non-steer cylinder rod end pivot pin (index #5).
end.
33 Use a soft metal drift to remove the lift cylinder
26 Use a soft metal drift to remove the number 3 rod end pivot pin (index #5) from the machine.
pivot pin (index #17) from the non-steer end of
Crushing hazard. The lift cylinder
the machine. Remove the number 3 outer arm
will fall if not properly supported
at the ground control side (index #16) from the
when the pivot pin is removed.
machine.
34 Place a 2 x 4 x 10 inch / 10 x 10 x 25 cm block
Crushing hazard. The number 3
onto the number 1 inner arm cylinder plate
outer arm at the ground control
(index #10).
side (index #16) may become
unbalanced and fall if not properly 35 Lower the cylinder onto the block.
supported when removed from the
machine. Bodily injury hazard. Keep hands
clear of moving parts when
27 Attach a lifting strap from an overhead crane to lowering the cylinder onto the
the number 3 outer arm at the battery side block.
(index #16).
36 Attach a lifting strap from an overhead crane to
28 Remove the retaining fasteners from the the number 3 inner arm (index #15). Raise the
number 3 center pivot pin (index #4) at the arm to a vertical position.
battery side.
37 Remove the retaining fasteners from the
29 Place a rod through the number 3 center pivot number 3 pivot pin at the steer end of the
pin at the battery side (index #4) and twist to machine (index #6).
remove the pin.

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 59


Section 4 • Repair Procedures March 2007

SCISSOR COMPONENTS REV C

38 Use a soft metal drift to remove the number 3 45 Use a soft metal drift to remove the number 2
pivot pin (index #6) from the steer end of the pivot pin (index #20) from the non-steer end of
machine. Remove the number 3 inner arm the machine. Remove the number 2 outer arm
(index #15) from the machine. at the ground control side (index #19) from the
machine.
Crushing hazard. The number 3
inner arm (index #15) may Crushing hazard. The number 2
become unbalanced and fall if not outer arm at the ground control
properly supported when the pivot side (index #19) may become
pin is removed. unbalanced and fall if not properly
supported when the pivot pin is
39 Remove the cables from the number 2A and 2B
removed.
cable bridge and lay them off to the side.
46 Attach a lifting strap from an overhead crane to
Component damage hazard.
the number 2 outer arm at the battery side
Cables can be damaged if they
(index #19).
are kinked or pinched.
47 Remove the retaining fasteners from the
40 Disconnect the number 2A and 2B cable
number 2 center pivot pin (index #7) at the
bridges from the scissor linkset and remove
battery side.
both cable bridges from the machine.
48 Place a rod through the number 2 center pivot
41 Attach a lifting strap from an overhead crane to
pin at the battery side (index #7) and twist to
the number 2 outer arm at the ground control
remove the pin.
side (index #19).
Crushing hazard. The number 2
42 Remove the retaining fasteners from the
outer arm (index #19) may
number 2 center pivot pin (index #7) at the
become unbalanced and fall if not
ground control side.
properly supported when the pivot
43 Place a rod through the number 2 center pivot pin is removed.
pin at the ground control side (index #7) and
49 Remove the number 2 outer arm (index #19)
twist to remove the pin.
from the machine.
44 Remove the retaining fasteners from the
Crushing hazard. The number 2
number 2 pivot pin (index #20) at the non-steer
outer arm (index #19) may
end.
become unbalanced and fall if not
properly supported when removed
from the machine.

4 - 60 GS-30 • GS-32 • GS-46 Part No. 97385


March 2007 Section 4 • Repair Procedures

REV C SCISSOR COMPONENTS

50 Attach a lifting strap from an overhead crane to 58 Tag, disconnect and plug the hydraulic hose on
the number 2 inner arm (index #18). Raise the the lower lift cylinder. Cap the fittings on the
arm to a vertical position. cylinder.
51 Remove the retaining fasteners from the Bodily injury hazard. Spraying
number 2 pivot pin at the steer end of the hydraulic oil can penetrate and
machine (index #8). burn skin. Loosen hydraulic
connections very slowly to allow
52 Use a soft metal drift to remove the number 2
the oil pressure to dissipate
pivot pin (index #8) from the steer end of the
gradually. Do not allow oil to squirt
machine. Remove the number 2 inner arm
or spray.
(index #18) from the machine.
59 Tag and disconnect the wire harness from the
Crushing hazard. The number 2
solenoid valve on the cylinder.
inner arm (index #18) may
become unbalanced and fall if not 60 Tag and disconnect the wires and manual
properly supported when the pivot lowering cable from the solenoid valve on the
pin is removed. cylinder.
53 Attach a lifting strap from an overhead crane to 61 Models with platform overload option: Tag
the number 1 inner arm (index #10). and disconnect the wire harness from the
platform overload switch.
54 Raise the number 1 inner arm (index #10)
approximately 2 feet / 60 cm. 62 Raise the lift cylinder to a vertical position.
55 Place a 4 x 4 x 48 inch / 10 cm x 10 cm x 1.2 m 63 Remove the pin retaining fasteners from the lift
long block across both sides of the chassis cylinder barrel-end pivot pin (index #21). Use a
under the number 1 center pivot pin (index #9). soft metal drift to remove the pin. Remove the
lift cylinder from the machine.
56 Lower the scissor arms onto the block that was
placed across the chassis. Crushing hazard. The lift cylinder
will fall if not properly supported
Bodily injury hazard. Keep hands
when the pivot pin is removed.
clear of moving parts when
lowering the scissor arms. Component damage hazard. Be
careful not to damage the valve or
57 Attach a lifting strap from an overhead crane to
fittings on the cylinder while
the lug of the rod end of the lower lift cylinder.
removing it from the machine.

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 61


Section 4 • Repair Procedures March 2007

SCISSOR COMPONENTS REV C

64 Remove the cables from the number 1 cable How to Replace the Scissor Arm
bridge and lay them off to the side.
Wear Pads
Component damage hazard.
Cables can be damaged if they 1 Remove the platform. See 2-1, How to Remove
are kinked or pinched. the Platform.

65 Disconnect the number 1 cable bridge from the 2 Support and secure the entry ladder to an
number 1 outer arm (index #22) and remove appropriate lifting device.
the cable bridge from the machine. 3 Remove the fasteners from the entry ladder and
66 Attach a lifting strap from an overhead crane to remove the entry ladder from the machine.
the number 1 inner arm (index #10). Crushing hazard. The entry ladder
67 Raise the arm slightly and remove the block. may become unbalanced and fall if
not properly supported and
68 Lower the arm to the stowed position. secured to the lifting device.
Bodily injury hazard. Keep hands 4 Secure the ends of the scissor arms together at
clear of moving parts when the steer end of the machine with a strap or
lowering the scissor arms. other suitable device.
69 Secure the ends of the scissor arms together at 5 Secure the ends of the scissor arms together at
the steer end of the machine with a strap or the non-steer end of the machine with a strap or
other suitable device. other suitable device.
70 Secure the ends of the scissor arms together at 6 Remove the retaining fasteners securing the
the non-steer end of the machine with a strap or chassis mount bracket to the chassis at the
other suitable device. steer end of the machine.
71 Remove the retaining fasteners securing the 7 Attach a lifting strap from an overhead crane to
chassis mount bracket to the chassis. the scissor arm assembly.
72 Remove the linkset from the machine 8 Raise the scissor arm assembly at the steer
Bodily injury hazard. The number end with the overhead crane until the chassis
1 inner and outer arms (index #10 mount bracket will clear the level sensor.
and #22) may become unbalanced 9 Move the scissor assembly towards the
and fall if not properly supported non-steer end of the machine slightly and to
when removed from the machine. one side of the machine until one of the scissor
Component damage hazard. Be arm wear pads is accessible. Do not allow both
sure not to damage the limit switch wear pads to slide out of the drive chassis.
or level sensor box components Component damage hazard. Be
when the number 1 inner and careful not to damage the level
outer arms (index #10 and 22) is sensor or limit switch while moving
removed from the machine. the scissor assembly.

4 - 62 GS-30 • GS-32 • GS-46 Part No. 97385


March 2007 Section 4 • Repair Procedures

REV C SCISSOR COMPONENTS

10 Remove the old wear pad.


11 Install the new wear pad.
12 Rotate the scissor assembly towards the other
side of the machine until the other scissor arm
wear pad is accessible. Do not allow both wear
pads to slide out of the drive chassis.
Crushing hazard. The scissor
assembly will fall if both wear pads
are allowed to slide out of the drive
chassis.
Component damage hazard. Be
careful not to damage the level
sensor or limit switch while moving
the scissor assembly.
13 Remove the old wear pad.
14 Install the new wear pad.
15 Slide the scissor assembly back into the drive
chassis.
16 Lower the scissor assembly into position and
install the chassis mount bracket onto the
chassis. Securely install and tighten the
fasteners. Do not overtighten.
Component damage hazard. Be
careful not to damage the level
sensor or limit switch while moving
the scissor assembly.

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 63


Section 4 • Repair Procedures March 2007

SCISSOR COMPONENTS REV C

2 16

3 17

4 18

19
5
20
6
21
7

8 22

9 23

10 24

25
11

26

12 27

13 28

14 29

15

GS-3232
Steer end GS-3246 Non-steer end
1 Number 6 pivot pin 16 Number 5 inner arm
2 Number 5 center pivot pin (2 pins) 17 Number 5 outer arm
3 Upper lift cylinder rod-end pivot pin 18 Number 5 pivot pin (non-steer end)
4 Number 5 pivot pin (steer end) 19 Number 4 inner arm
5 Number 4 center pivot pin (2 pins) 20 Number 4 outer arm
6 Number 4 pivot pin (steer end) 21 Number 4 pivot pin (non-steer end)
7 Number 3 outer arm 22 Upper lift cylinder barrel-end pivot pin
8 Number 3 center pivot pin (2 pins) 23 Number 3 inner arm
9 Lower lift cylinder rod-end pivot pin 24 Number 3 pivot pin (non-steer end)
10 Number 3 pivot pin (steer end) 25 Number 2 inner arm
11 Number 2 center pivot pin (2 pins) 26 Number 2 outer arm
12 Number 2 pivot pin (steer end) 27 Number 2 pivot pin (non-steer end)
13 Number 1 center pivot pin (2 pins) 28 Lower lift cylinder barrel-end pivot pin
14 Number 1 inner arm 29 Number 1 outer arm
15 Number 1 pivot pin (steer end) (2 pins)

4 - 64 GS-30 • GS-32 • GS-46 Part No. 97385


March 2007 Section 4 • Repair Procedures

REV C SCISSOR COMPONENTS

3-5
Scissor Assembly, a

GS-3232 and GS-3246


b
How to Disassemble the
Scissor Assembly, c

GS-3232 and GS-3246


d
Bodily injury hazard. The e
procedures in this section require
specific repair skills, lifting
equipment and a suitable f
workshop. Attempting this g
procedure without these skills and
tools could result in death or
serious injury and significant h
component damage. Dealer
service is required.
When removing a hose assembly or fitting, the GS-3232
O-ring on the fitting and/or hose end must be GS-3246
replaced and then torqued to specification during
installation. Refer to Section 2, Hydraulic Hose and Cable bridge legend
Fitting Torque Specifications.
a cable bridge 5
1 Remove the platform. See 2-1, How to Remove b cable bridge 4A
the Platform. c cable bridge 4B
d cable bridge 3A
2 Support and secure the entry ladder to an e cable bridge 3B
appropriate lifting device. f cable bridge 2A
g cable bridge 2B
3 Remove the fasteners from the entry ladder and h cable bridge 1
remove the entry ladder from the machine. 5 Disconnect the number 5 cable bridge from the
Crushing hazard. The entry ladder number 5 outer arm (index #17) and remove
may become unbalanced and fall if the cable bridge from the machine.
not properly supported and 6 Remove the retaining fasteners from the
secured to the lifting device. number 6 pivot pin (index #1).
4 Remove the cables from the number 5 cable 7 Use a soft metal drift to remove the number 6
bridge and lay them off to the side. pivot pin (index #1). Remove the platform
Component damage hazard. mount bracket from the machine.
Cables can be damaged if they 8 Attach a lifting strap from an overhead crane to
are kinked or pinched. the number 5 outer arm at the ground control
side (index #17).

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 65


Section 4 • Repair Procedures March 2007

SCISSOR COMPONENTS REV C

9 Remove the retaining fasteners from the 18 Remove the retaining fasteners from the
number 5 center pivot pin (index #2) at the number 5 pivot pin at the steer end of the
ground control side. machine (index #4).
10 Place a rod through the number 5 center pivot 19 Use a soft metal drift to remove the number 5
pin at the ground control side (index #2) and pivot pin (index #18) from the steer end of the
twist to remove the pin. machine. Remove the number 5 inner arm
(index #16) from the machine.
11 Remove the retaining fasteners from the
number 5 pivot pin (index #18) at the non-steer Crushing hazard. The number 5
end. inner arm (index #16) may
become unbalanced and fall if not
12 Use a soft metal drift to remove the number 5
properly supported when removed
pivot pin (index #18) from the non-steer end of
from the machine.
the machine. Remove the number 5 outer arm
at the ground control side (index #17) from the 20 Tag, disconnect and plug the hydraulic hose on
machine. the upper lift cylinder. Cap the fittings on the
cylinder.
Crushing hazard. The number 5
outer arm at the ground control Bodily injury hazard. Spraying
side (index #17) may become hydraulic oil can penetrate and
unbalanced and fall if not properly burn skin. Loosen hydraulic
supported when removed from the connections very slowly to allow
machine. the oil pressure to dissipate
gradually. Do not allow oil to squirt
13 Attach a lifting strap from an overhead crane to
or spray.
the number 5 outer arm at the battery side
(index #17). 21 Tag and disconnect the wire harness from the
solenoid valve on the cylinder.
14 Remove the retaining fasteners from the
number 5 center pivot pin (index #2) at the 22 Remove the cables from the number 4A and 4B
battery side. cable bridges and lay them off to the side.
15 Place a rod through the number 5 center pivot Component damage hazard.
pin at the battery side (index #2) and twist to Cables can be damaged if they
remove the pin. are kinked or pinched.
16 Remove the number 5 outer arm (index #17) 23 Disconnect the number 4A and 4B cable
from the machine. bridges from the scissor linkset and remove
both cable bridges from the machine.
Crushing hazard. The number 5
outer arm (index #17) may 24 Attach a lifting strap from an overhead crane to
become unbalanced and fall if not the lug of the rod end of the upper lift cylinder.
properly supported when removed
25 Remove the retaining fasteners from the upper
from the machine.
lift cylinder rod end pivot pin (index #3).
17 Attach a lifting strap from an overhead crane to
the number 5 inner arm (index #16). Raise the
arm to a vertical position.

4 - 66 GS-30 • GS-32 • GS-46 Part No. 97385


March 2007 Section 4 • Repair Procedures

REV C SCISSOR COMPONENTS

26 Use a soft metal drift to remove the upper lift 36 Remove the number 4 outer arm (index #20)
cylinder rod end pivot pin (index #3) from the from the machine.
machine.
Crushing hazard. The number 4
Crushing hazard. The lift cylinder outer arm (index #20) may
may become unbalanced and fall if become unbalanced and fall if not
not properly supported when the properly supported when removed
pivot pin is removed. from the machine.
27 Lower the cylinder onto the linkset. 37 Attach a lifting strap from an overhead crane to
the number 4 inner arm (index #19). Raise the
28 Attach a lifting strap from an overhead crane to
arm to a vertical position.
the number 4 outer arm at the ground control
side (index #20). 38 Remove the retaining fasteners from the
number 4 pivot pin at the steer end of the
29 Remove the retaining fasteners from the
machine (index #6).
number 4 center pivot pin (index #5) at the
ground control side. 39 Use a soft metal drift to remove the number 4
pivot pin (index #6) from the steer end of the
30 Place a rod through the number 4 center pivot
machine. Remove the number 4 inner arm
pin at the ground control side (index #5) and
(index #19) from the machine.
twist to remove the pin.
Crushing hazard. The number 4
31 Remove the retaining fasteners from the
inner arm (index #19) may
number 4 pivot pin (index #21) at the non-steer
become unbalanced and fall if not
end.
properly supported when removed
32 Use a soft metal drift to remove the number 4 from the machine.
pivot pin (index #21) from the non-steer end of
40 Remove the cables from the number 3A and 3B
the machine. Remove the number 4 outer arm
cable bridges and lay them off to the side.
at the ground control side (index #20) from the
machine. Component damage hazard.
Cables can be damaged if they
Crushing hazard. The number 4
are kinked or pinched.
outer arm at the ground control
side (index #20) may become 41 Disconnect the number 3A and 3B cable
unbalanced and fall if not properly bridges from the scissor linkset and remove
supported when removed from the both cable bridges from the machine.
machine.
42 Attach a lifting strap from an overhead crane to
33 Attach a lifting strap from an overhead crane to the number 3 outer arm at the ground control
the number 4 outer arm at the battery side side (index #7).
(index #20).
43 Remove the retaining fasteners from the
34 Remove the retaining fasteners from the number 3 center pivot pin (index #8) at the
number 4 center pivot pin (index #5) at the ground control side.
battery side.
44 Place a rod through the number 3 center pivot
35 Place a rod through the number 4 center pivot pin at the ground control side (index #8) and
pin at the battery side (index #5) and twist to twist to remove the pin.
remove the pin.
45 Remove the retaining fasteners from the
number 3 pivot pin (index #24) at the non-steer
end.

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 67


Section 4 • Repair Procedures March 2007

SCISSOR COMPONENTS REV C

46 Use a soft metal drift to remove the number 3 54 Attach a lifting strap from an overhead crane to
pivot pin (index #24) from the non-steer end of the lug of the rod end of the lower lift cylinder.
the machine. Remove the number 3 outer arm
55 Remove the retaining fasteners from the lower
at the ground control side (index #7) from the
lift cylinder rod end pivot pin (index #9).
machine.
56 Use a soft metal drift to remove the lower lift
Crushing hazard. The number 3
cylinder rod end pivot pin (index #9) from the
outer arm at the ground control
machine.
side (index #7) may become
unbalanced and fall if not properly Crushing hazard. The lower lift
supported when removed from the cylinder will fall if not properly
machine. supported when the pivot pin is
removed.
47 Attach a lifting strap from an overhead crane to
the number 3 outer arm at the battery side 57 Place a 2 x 4 x 10 inch / 10 x 10 x 25 cm block
(index #7). onto the number 1 inner arm cylinder plate
(index #14).
48 Remove the retaining fasteners from the
number 3 center pivot pin (index #8) at the 58 Lower the cylinder onto the block.
battery side.
Bodily injury hazard. Keep hands
49 Place a rod through the number 3 center pivot clear of moving parts when
pin at the battery side (index #8) and twist to lowering the cylinder.
remove the pin.
59 Attach a lifting strap from an overhead crane to
50 Remove the number 3 outer arm (index #7) the number 3 inner arm (index #23). Raise the
from the machine. arm to a vertical position.
Crushing hazard. The number 3 60 Remove the retaining fasteners from the
outer arm (index #7) may become number 3 pivot pin at the steer end of the
unbalanced and fall if not properly machine (index #10).
supported when removed from the
machine. 61 Use a soft metal drift to remove the number 3
pivot pin (index #10) from the steer end of the
51 Attach a lifting strap from an overhead crane to machine. Remove the number 3 inner arm
the lug of the rod end of the upper lift cylinder. (index #23) from the machine.
52 Raise the lift cylinder to a vertical position. Crushing hazard. The number 3
inner arm (index #23) may
53 Remove the pin retaining fasteners from the lift
become unbalanced and fall if not
cylinder barrel-end pivot pin (index #22).
properly supported when the pivot
Remove the lift cylinder from the machine.
pin is removed.
Crushing hazard. The lift cylinder
62 Remove the cables from the number 2A and 2B
will fall if not properly supported
cable bridges and lay them off to the side.
when the pivot pin is removed.
Component damage hazard.
Component damage hazard. Be
Cables can be damaged if they
careful not to damage the valve or
are kinked or pinched.
fittings on the cylinder while
removing it from the machine.

4 - 68 GS-30 • GS-32 • GS-46 Part No. 97385


March 2007 Section 4 • Repair Procedures

REV C SCISSOR COMPONENTS

63 Disconnect the number 2A and 2B cable 72 Remove the number 2 outer arm (index #26)
bridges from the scissor linkset and remove from the machine.
both cable bridges from the machine.
Crushing hazard. The number 2
64 Attach a lifting strap from an overhead crane to outer arm (index #26) may
the number 2 outer arm at the ground control become unbalanced and fall if not
side (index #26). properly supported when removed
from the machine.
65 Remove the retaining fasteners from the
number 2 center pivot pin (index #11) at the 73 Attach a lifting strap from an overhead crane to
ground control side. the number 2 inner arm (index #25). Raise the
arm to a vertical position.
66 Place a rod through the number 2 center pivot
pin at the ground control side (index #11) and 74 Remove the retaining fasteners from the
twist to remove the pin. number 2 pivot pin at the steer end of the
machine (index #12).
67 Remove the retaining fasteners from the
number 2 pivot pin (index #27) at the non-steer 75 Use a soft metal drift to remove the number 2
end. pivot pin (index #12) from the steer end of the
machine. Remove the number 2 inner arm
68 Use a soft metal drift to remove the number 2
(index #25) from the machine.
pivot pin (index #27) from the non-steer end of
the machine. Remove the number 2 outer arm Crushing hazard. The number 2
at the ground control side (index #26) from the inner arm (index #25) may
machine. become unbalanced and fall if not
properly supported when the pivot
Crushing hazard. The number 2
pin is removed.
outer arm at the ground control
side (index #26) may become 76 Attach a lifting strap from an overhead crane to
unbalanced and fall if not properly the number 1 inner arm (index #14).
supported when the pivot pin is
77 Raise the number 1 inner arm (index #14)
removed.
approximately 2 feet / 60 cm.
69 Attach a lifting strap from an overhead crane to
78 Place a 4 x 4 x 48 inch / 10 cm x 10 cm x 1.2 m
the number 2 outer arm at the battery side
long block across both sides of the chassis
(index #26).
under the number 1 center pivot pin
70 Remove the retaining fasteners from the (index #13).
number 2 center pivot pin (index #11) at the
79 Lower the scissor arms onto the block that was
battery side.
placed across the chassis.
71 Place a rod through the number 2 center pivot
Bodily injury hazard. Keep hands
pin at the battery side (index #11) and twist to
clear of moving parts when
remove the pin.
lowering the scissor arms.
Crushing hazard. The number 2
80 Attach a lifting strap from an overhead crane to
outer arm (index #26) may
the lug of the rod end of the lower lift cylinder.
become unbalanced and fall if not
properly supported when the pivot
pin is removed.

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 69


Section 4 • Repair Procedures March 2007

SCISSOR COMPONENTS REV C

81 Tag, disconnect and plug the hydraulic hose on 88 Disconnect the number 1 cable bridge from the
the lower lift cylinder. Cap the fittings on the number 1 outer arm (index #29) and remove
cylinder. the cable bridge from the machine.
Bodily injury hazard. Spraying 89 Attach a lifting strap from an overhead crane to
hydraulic oil can penetrate and the number 1 inner arm (index #14).
burn skin. Loosen hydraulic
90 Raise the arm slightly and remove the block.
connections very slowly to allow
the oil pressure to dissipate 91 Lower the arm to the stowed position.
gradually. Do not allow oil to squirt
or spray. Bodily injury hazard. Keep hands
clear of moving parts when
82 Tag and disconnect the wire harness from the lowering the scissor arms.
solenoid valve on the cylinder.
92 Secure the ends of the scissor arms together at
83 Tag and disconnect the wires and manual the steer end of the machine with a strap or
lowering cable from the solenoid valve on the other suitable device.
cylinder.
93 Secure the ends of the scissor arms together at
84 Models with platform overload option: Tag the non-steer end of the machine with a strap or
and disconnect the wire harness from the other suitable device.
platform overload switch.
94 Remove the retaining fasteners securing the
85 Raise the lift cylinder to a vertical position. chassis mount bracket to the chassis.
86 Remove the pin retaining fasteners from the lift 95 Remove the linkset from the machine
cylinder barrel-end pivot pin (index #28). Use a
soft metal drift to remove the pin. Remove the Bodily injury hazard. The number
lift cylinder from the machine. 1 inner and outer arms (index #14
and #29) may become unbalanced
Crushing hazard. The lift cylinder and fall if not properly supported
will fall if not properly supported when removed from the machine.
when the pivot pin is removed.
Component damage hazard. Be
Component damage hazard. Be sure not to damage the limit switch
careful not to damage the valve or or level sensor box components
fittings on the cylinder while when the number 1 inner and
removing it from the machine. outer arms (index #14 and 29) is
removed from the machine.
87 Remove the cables from the number 1 cable
bridge and lay them off to the side.
Component damage hazard.
Cables can be damaged if they
are kinked or pinched.

4 - 70 GS-30 • GS-32 • GS-46 Part No. 97385


March 2007 Section 4 • Repair Procedures

REV C SCISSOR COMPONENTS

How to Replace the Scissor Arm 10 Remove the old wear pad.
Wear Pads 11 Install the new wear pad.

1 Remove the platform. See 2-1, How to Remove 12 Rotate the scissor assembly towards the other
the Platform. side of the machine until the other scissor arm
wear pad is accessible. Do not allow both wear
2 Support and secure the entry ladder to an pads to slide out of the drive chassis.
appropriate lifting device.
Crushing hazard. The scissor
3 Remove the fasteners from the entry ladder and assembly will fall if both wear pads
remove the entry ladder from the machine. are allowed to slide out of the drive
Crushing hazard. The entry ladder chassis.
may become unbalanced and fall if Component damage hazard. Be
not properly supported and careful not to damage the level
secured to the lifting device. sensor or limit switch while moving
4 Secure the ends of the scissor arms together at the scissor assembly.
the steer end of the machine with a strap or 13 Remove the old wear pad.
other suitable device.
14 Install the new wear pad.
5 Secure the ends of the scissor arms together at
the non-steer end of the machine with a strap or 15 Slide the scissor assembly back into the drive
other suitable device. chassis.

6 Remove the retaining fasteners securing the 16 Lower the scissor assembly into position and
chassis mount bracket to the chassis at the install the chassis mount bracket onto the
steer end of the machine. chassis. Securely install and tighten the
fasteners. Do not over tighten.
7 Attach a lifting strap from an overhead crane to
the scissor arm assembly. Component damage hazard. Be
careful not to damage the level
8 Raise the scissor arm assembly at the steer sensor or limit switch while moving
end with the overhead crane until the chassis the scissor assembly.
mount bracket will clear the level sensor.
9 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 is accessible. Do not allow both
wear pads to slide out of the drive chassis.
Component damage hazard. Be
careful not to damage the level
sensor or limit switch while moving
the scissor assembly.

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 71


Section 4 • Repair Procedures March 2007

SCISSOR COMPONENTS REV C

3-6
Lift Cylinder
g
How to Remove the Lift Cylinder
Bodily injury hazard. This
a
procedure requires specific repair
skills, lifting equipment and a N
suitable workshop. Attempting this f Y7

procedure without these skills and


tools could result in death or O
serious injury and significant
b
component damage. Dealer
service is strongly recommended. e
c
When removing a hose assembly or fitting, the d
fitting and/or hose end must be torqued to
specification during installation. Refer to Section 2, a lift cylinder
Hydraulic Hose and Fitting Torque Specifications. b orifice (schematic item O)
c connector fitting
GS-1530, GS-1532, GS-1930 and GS-1932: d hydraulic hose
e manual lowering cable
1 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. f solenoid valve (schematic item N)
g cable mount bracket
2 Lift the safety arm, move it to the center of the
scissor arm and rotate down to a vertical 6 Loosen the adjustment nuts on the solenoid
position. valve and disconnect the manual lowering cable
from the valve.
3 Lower the platform onto the safety arm.
Note: During assembly, the manual platform
Crushing hazard. Keep hands lowering cable needs to be properly adjusted.
clear of the safety arm when See 4-1, How to Adjust the Manual Platform
lowering the platform. Lowering Cable.
4 Tag and disconnect the wiring from the solenoid 7 Remove the fasteners securing the manual
valve coil at the barrel end of the lift cylinder. lowering cable mount bracket to the cylinder.
5 Models with platform overload option: Tag Remove the bracket from the cylinder.
and disconnect the wiring from the platform 8 Tag, disconnect and plug the hydraulic hoses
overload switch. on the lift cylinder. Cap the fittings on the
cylinder.
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.

4 - 72 GS-30 • GS-32 • GS-46 Part No. 97385


March 2007 Section 4 • Repair Procedures

REV C SCISSOR COMPONENTS

9 Attach a lifting strap from an overhead crane to GS-2032, GS-2632, GS-2046 and GS-2646:
the rod end of the lift cylinder for support.
1 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
10 Remove the retaining fasteners from the lift
cylinder rod-end pivot pin. Use a soft metal drift 2 Lift the safety arm, move it to the center of the
to remove the pin. scissor arm and rotate down to a vertical
position.
Crushing hazard. The lift cylinder
will fall if not properly supported. 3 Lower the platform onto the safety arm.

11 Lower the cylinder onto the number 2 inner arm. Crushing hazard. Keep hands
clear of the safety arm when
12 Attach a lifting strap from an overhead crane or lowering the platform.
similar lifting device to the barrel end of the lift
cylinder for support. 4 Tag and disconnect the wiring from the solenoid
valve coil at the barrel end of the lift cylinder.
13 Remove the retaining fasteners from the lift
cylinder barrel-end pivot pin. Use a soft metal
drift to remove the pin.
Crushing hazard. The lift cylinder g
will fall if not properly supported
when the pin is removed.
14 Support and secure the lift cylinder to an a
appropriate lifting device.
N
15 Remove the lift cylinder through the scissor f Y7

arms at the steer end of the machine.


O
Crushing hazard. The lift cylinder
may become unbalanced and fall if b
not properly supported and e
secured to the lifting device. c

Component damage hazard. Be d


careful not to damage the valve or
fittings on the cylinder while a lift cylinder
removing it from the machine. b orifice (schematic item O)
c connector fitting
d hydraulic hose
Torque specification e manual lowering cable
f solenoid valve (schematic item N)
Solenoid valve, 2 position 2 way N.C. 20 ft-lbs g cable mount bracket
(schematic item N) 27 Nm
5 Models with platform overload option: Tag
Coil nut 5 ft-lbs
and disconnect the wiring from the platform
7 Nm
overload switch.

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 73


Section 4 • Repair Procedures March 2007

SCISSOR COMPONENTS REV C

6 Loosen the adjustment nuts on the solenoid 12 Attach a lifting strap from an overhead crane or
valve and disconnect the manual lowering cable similar lifting device to the barrel end of the lift
from the valve. cylinder for support.
Note: During assembly, the manual platform 13 Remove the retaining fasteners from the lift
lowering cable needs to be properly adjusted. cylinder barrel-end pivot pin. Use a soft metal
See 4-1, How to Adjust the Manual Platform drift to remove the pin.
Lowering Cable.
Crushing hazard. The lift cylinder
7 Remove the fasteners securing the manual will fall if not properly supported
lowering cable mount bracket to the cylinder. when the pin is removed.
Remove the bracket from the cylinder. 14 Support and secure the lift cylinder to an
8 Tag, disconnect and plug the hydraulic hoses appropriate lifting device.
on the lift cylinder. Cap the fittings on the 15 Remove the lift cylinder through the scissor
cylinder. arms at the steer end of the machine.
Bodily injury hazard. Spraying Crushing hazard. The lift cylinder
hydraulic oil can penetrate and may become unbalanced and fall if
burn skin. Loosen hydraulic not properly supported and
connections very slowly to allow secured to the lifting device.
the oil pressure to dissipate
gradually. Do not allow oil to squirt Component damage hazard. Be
or spray. careful not to damage the valve or
fittings on the cylinder while
9 Attach a lifting strap from an overhead crane to removing it from the machine.
the rod end of the lift cylinder for support.
10 Remove the retaining fasteners from the lift Torque specification
cylinder rod-end pivot pin. Use a soft metal drift Solenoid valve, 2 position 2 way N.C. 20 ft-lbs
to remove the pin. (schematic item N) 27 Nm
Crushing hazard. The lift cylinder Coil nut 5 ft-lbs
will fall if not properly supported. 7 Nm
11 Lower the cylinder onto the number 1 inner arm
cylinder plate.
Bodily injury hazard. Keep hands
clear of moving parts when
lowering the cylinder.

4 - 74 GS-30 • GS-32 • GS-46 Part No. 97385


March 2007 Section 4 • Repair Procedures

REV C SCISSOR COMPONENTS

GS-3232 and GS-3246: 5 Models with platform overload option: Tag


and disconnect the wiring from the platform
1 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. overload switch.
2 Lift the safety arm, move it to the center of the 6 Loosen the adjustment nuts on the solenoid
scissor arm and rotate down to a vertical valve and disconnect the manual lowering cable
position. from the valve.
3 Lower the platform onto the safety arm. Note: During assembly, the manual platform
Crushing hazard. Keep hands lowering cable needs to be properly adjusted.
clear of the safety arm when See 4-1, How to Adjust the Manual Platform
lowering the platform. Lowering Cable.

4 Tag and disconnect the wiring from the solenoid 7 Remove the fasteners securing the manual
valve coil at the barrel end of the lift cylinder. lowering cable mount bracket to the cylinder.
Remove the bracket from the cylinder.
Skip to step 9 if removing the upper cylinder.
8 Tag, disconnect and plug the hydraulic hoses
on the lift cylinder. Cap the fittings on the
cylinder.
g Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
a connections very slowly to allow
the oil pressure to dissipate
N gradually. Do not allow oil to squirt
f Y7
or spray.

O 9 Attach a lifting strap from an overhead crane to


the rod end of the lift cylinder for support.
b
10 Remove the retaining fasteners from the lift
e
c cylinder rod-end pivot pin. Use a soft metal drift
to remove the pin.
d
Crushing hazard. The lift cylinder
Lower Lift Cylinder will fall if not properly supported.
a lift cylinder 11 Lower the cylinder to a horizontal position.
b orifice fitting (schematic item O)
c connector fitting Bodily injury hazard. Keep hands
d hydraulic hose
clear of moving parts when
e manual lowering cable
f solenoid valve (schematic item N) lowering the cylinder.
g cable mount bracket

Note: At the lower lift cylinder, install the orifice


fitting with the small opening of the orifice fitting
closest to the supply hose.

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 75


Section 4 • Repair Procedures March 2007

SCISSOR COMPONENTS REV C

Q Q
g f
a

O
b
a
c
N N
f Y9
d e Y9

O
b

Upper Lift Cylinder c


(before serial GS4607-83692)
d
a manifold plug
b orifice fitting (schematic item O) Upper Lift Cylinder
c lift cylinder (after serial GS4607-83691)
d connector fitting
e hydraulic hose a lift cylinder
f solenoid valve (schematic item N) b orifice fitting (schematic item O)
g relief valve (schematic item Q) c connector fitting
d hydraulic hose
Note: Before serial number GS4607-83692 at the e solenoid valve (schematic item N)
upper lift cylinder, install the orifice fitting with the f relief valve (schematic item Q)
large opening of the orifice fitting closest to the
manifold plug. Note: After serial number GS4607-83691 and from
GS4609-101, at the upper lift cylinder, install the
12 Attach a lifting strap from an overhead crane or orifice fitting with the small opening of the orifice
similar lifting device to the barrel end of the lift fitting closest to the supply hose.
cylinder for support.
Crushing hazard. The lift cylinder
13 Remove the retaining fasteners from the lift may become unbalanced and fall if
cylinder barrel-end pivot pin. Use a soft metal not properly supported and
drift to remove the pin. secured to the lifting device.
Crushing hazard. The lift cylinder Component damage hazard. Be
will fall if not properly supported careful not to damage the valve or
when the pin is removed. fittings on the cylinder while
removing it from the machine.
14 Support and secure the lift cylinder to an
appropriate lifting device.
Torque specification
15 Remove the lift cylinder through the scissor
Solenoid valve, 2 position 2 way N.C. 20 ft-lbs
arms at the steer end of the machine. (schematic item N) 27 Nm

Relief Valve 20 ft-lbs


(schematic item Q) 27 Nm

Coil nut 5 ft-lbs


7 Nm

4 - 76 GS-30 • GS-32 • GS-46 Part No. 97385


March 2007 Section 4 • Repair Procedures

REV C SCISSOR COMPONENTS

3-7 6 Using a suitable lifting device, place a test


weight, corresponding to the maximum load as
Platform Overload System indicated on the capacity indicator decal, in the
center of the platform floor. Secure the weight
How to Calibrate the Platform to the platform. Refer to the chart below.
Overload System (if equipped) GS-1532 484 kg
Perform this procedure after confirming that the GS-1932 435 kg
maximum height limit switch and the limit switch
bracket are not damaged and are functioning GS-2032 693 kg
correctly.
GS-2632 479 kg
1 Fully charge the batteries and check the
GS-3232 498 kg
hydraulic fluid level.
GS-2046 985 kg
Note: The hydraulic fluid level must be between the
FULL and ADD marks on the hydraulic tank. GS-2646 798 kg
2 Apply a thin layer of dry film lubricant to the GS-3246 649 kg
area of the chassis where the scissor arm wear
pads make contact.
7 Apply a piece of tape onto the side of the
3 Chock both sides of the wheels at the steer end
platform at a point which corresponds to the
of the machine.
maximum load position of the capacity indicator
4 Turn the key switch to ground control and pull decal on the side of the platform.
out the red Emergency Stop button to the on
8 Raise the platform until the position indicator
position at both the ground and platform
corresponds to the maximum load position of
controls.
the capacity indicator decal on the platform.
5 GS-1532 and GS-1932: Raise the platform Release the toggle switch.
approximately 1.5 m.
Tip-over hazard. Raising the
platform with maximum load above
the maximum load position, as
shown on the capacity indicator
decal on the side of the platform,
could result in the machine tipping
over, resulting in death or serious
injury. Do not raise the platform
above the maximum load position
of the capacity indicator decal on
the side of the platform.
Note: To perform this step, the lift relief valve will
need to be adjusted.

9 Lift the safety arm, move it to the center of the


scissor arm and rotate down to a vertical
position.

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 77


Section 4 • Repair Procedures March 2007

SCISSOR COMPONENTS REV C

10 Models with round pressure switch: Remove 15 Using a suitable lifting device, place a test
the retaining ring securing the cover to the weight in the center of the platform floor.
pressure switch and remove the cover. Using a Secure the weight to the platform. Refer to the
flat blade, turn the slotted switch adjustment chart below.
screw of the platform overload pressure switch
into the hydraulic line in 90° increments until the GS-1532 272 kg
overload alarm does not sound.
GS-1932 227 kg
Models with box-shaped pressure switch:
Remove the fasteners securing the cover to the GS-2032 363 kg
pressure switch and remove the cover. Using a
wrench, turn the nut of the platform overload GS-2632 227 kg
pressure switch into the hydraulic line in 90° GS-3232 227 kg
increments until the overload alarm does not
sound. GS-2046 544 kg

Note: To allow the platform overload system to GS-2646 454 kg


reset, the red Emergency Stop button must be
GS-3246 317 kg
cycled after each quarter turn of the nut or slotted
switch adjustment screw.

Note: Turning the nut or slotted switch adjustment 16 Raise the platform to 25 cm less than full height.
screw into the hydraulic line will deactivate the 17 Lift the safety arm, move it to the center of the
alarm; turning the nut or slotted switch adjustment scissor arm and rotate down to a vertical
screw out of the hydraulic line will activate the position.
alarm.
18 Raise the platform in 5 cm increments until the
11 Slowly turn the nut or adjustment screw of the overload alarm sounds. Adjust the up limit
platform overload pressure switch out of the switch until it actuates just before this point was
hydraulic line just until the overload alarm reached.
sounds.
19 Install the cover onto the platform overload
Note: To allow for the platform overload system pressure switch and install and tighten the
delay, wait 3 seconds between each quarter turn of cover retaining fastener(s). Do not over tighten.
the nut or adjustment screw.
20 Apply Sentry Seal to the fastener(s) securing
12 Turn the nut or adjustment screw one quarter the cover onto the platform overload pressure
turn into the hydraulic line. switch.
13 Return the safety arm to the stowed position. 21 Return the safety arm to the stowed position.
14 Using the manual lowering knob, lower the 22 Using the machine controls, lower the platform
platform to the stowed position and remove all to the stowed position and remove all test
test weight from the platform. weight from the platform.
23 Calibrate the lift relief valve. See 6-6, How to
Adjust the Platform Lift Relief Valve.

4 - 78 GS-30 • GS-32 • GS-46 Part No. 97385


March 2007 Section 4 • Repair Procedures

REV D
Ground Controls
4-1 Skip to step 8 if the measurement is correct.
Manual Platform Lowering Cable 6 To adjust, loosen the upper lock nut on the
cable mounting bracket at the cylinder. Turn the
The manual platform lowering cable lowers the lower lock nut clockwise to decrease the
platform in the event of a main power failure. The distance or counterclockwise to increase the
manual platform lowering cable is attached to the distance. Tighten the upper lock nut.
barrel end of the lift cylinder and is activated next
to the ground controls. a

How to Adjust the Manual b


Platform Lowering Cable
1 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. c
2 Lift the safety arm, move it to the center of the
scissor arm and rotate down to a vertical d
position.
3 Lower the platform onto the safety arm. e
Crushing hazard. Keep hands
clear of the safety arm when
lowering the platform. f

4 Pull the handle of the manual platform lowering


cable out until considerable resistance is felt.
Y7 N g
Release the handle.
5 Measure the distance between the base of the
handle and cable mounting nut. a manual lowering cable sheath
b upper lock nut
Result: The measurement should be no greater c cable mounting bracket
than 1/8 inch / 3 mm. d lower lock nut
e cable mounting nut
f end of the lowering cable
g manual lowering valve
(hydraulic schematic item N)

7 Repeat this procedure beginning with step 4.


8 Raise the platform and rotate the safety arm to
the stowed position.
9 Pull the manual lowering handle at the ground
controls 2 to 3 times to ensure it is functioning
correctly.

Platform manual lowering cable specification

Gap, lowering handle to mounting nut 0 to 1/8 inch


0 to 3 mm

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 79


Section 4 • Repair Procedures March 2007

GROUND CONTROLS REV D

4-2 5 Lift the safety arm, move it to the center of the


scissor arm and rotate down to a vertical
Level Sensors position.

The Electronic Control Module (ECM) is 6 Lower the platform onto the safety arm.
programmed to deactivate the lift and drive Crushing hazard. Keep hands
functions and activate an alarm when a signal is clear of the safety arm when
received from the level sensor. lowering the platform.
The tilt alarm sounds when the incline of the If you are not installing a new level sensor,
chassis exceeds 1.5° to the side and 3° to the front proceed to step 15.
or rear.
7 Turn the key switch to the off position and push
How to Install and Calibrate the in the red Emergency Stop button to the off
position at the ground controls.
1.5° Level Sensor
8 Tag and disconnect the level sensor wire
Tip-over hazard. Failure to install harness from the chassis wire harness.
or calibrate the level sensor as
instructed will compromise Note: The wire harness connection is located next
machine stability and cause the to the level sensor, on top of the chassis at the
machine to tip over, resulting in steer end of the machine.
death or serious injury. Do not
install or calibrate the level sensor 9 Remove the level sensor retaining fasteners.
other than specified in this Remove the level sensor from the machine.
procedure. 10 Tag and disconnect the level sensor wires from
1 Move the machine to an area that has a firm, the level sensor connector plug.
level surface and is free of obstructions. 11 Securely install the wires of the new level
2 Remove the platform controls from the platform. sensor into the level sensor connector plug.

3 Turn the key switch to platform control and pull


out the red Emergency Stop button to the on
position at both the ground and platform
controls.
4 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.

4 - 80 GS-30 • GS-32 • GS-46 Part No. 97385


March 2007 Section 4 • Repair Procedures

REV D GROUND CONTROLS

12 Place the new level sensor onto the level Steer end
sensor mount bracket with the "X" on the level
sensor base closest to the long side of the level a
sensor mount and the "Y" on the level sensor
base closest to the short side of the level
f b
sensor mount. Y
X

Tip-over hazard. The level sensor e


c
must be installed with the "X" on
the level sensor base closest to
the long side of the tilt level sensor
box and the "Y" on the level d
sensor base closest to the short
side of the tilt level sensor box.
Failure to install the tilt level
sensor as instructed could result in
the machine tipping over, causing
death or serious injury.
13 Install the level sensor retaining fasteners
through the level sensor and springs, and into
the mount bracket. Tighten the fasteners and
measure the distance between the level sensor
and the level sensor mount bracket.
Result: The measurement should be Non-steer end
approximately 3/8 inch / 10 mm.
a limit switch
14 Connect the chassis wire harness to the level b level sensor mount bracket
sensor wire harness. c level sensor S7
d alarm H5
15 Turn the key switch to the ground control and e level sensor retaining fastener
f scissor chassis
pull out the red Emergency Stop button to the
on position at the ground controls. 17 Raise the platform slightly.
16 Adjust the level sensor retaining fasteners until 18 Return the safety arm to the stowed position.
the bubble in the top of the level sensor is
centered in the circles. 19 Lower the platform to the stowed position.

Result: The tilt sensor alarm should not sound. 20 Center a lifting jack under the drive chassis at
the ground controls side of the machine.
21 Raise the machine approximately
2 inches / 5 cm.

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 81


Section 4 • Repair Procedures March 2007

GROUND CONTROLS REV D

22 GS-1530 and GS-1930: Place a 0.64 x 6 x 6 25 Lower the platform to the stowed position.
inch / 16.2 mm x 15 cm x 15 cm thick steel
26 Raise the machine approximately
block under both wheels at the ground controls
2 inches / 5 cm.
side of the machine.
27 Remove the blocks from under both wheels.
GS-1532 and GS-1932: Place a 0.68 x 6 x 6
inch / 17.2 mm x 15 cm x 15 cm thick steel 28 Lower the machine and remove the jack.
block under both wheels at the ground controls
side of the machine. 29 Center a lifting jack under the drive chassis at
the battery pack side of the machine.
GS-2032, GS-2632 and GS-3232: Place a
0.66 x 6 x 6 inch / 16.8 mm x 15 cm x 15 cm 30 Raise the machine approximately
thick steel block under both wheels at the 2 inches / 5 cm.
ground controls side of the machine. 31 GS-1530 and GS-1930: Place a 0.77 x 6 x 6
GS-2046, GS-2646 and GS-3246: Place a 1 x 6 inch / 19.6 mm x 15 cm x 15 cm thick steel
x 6 inch / 25.4 mm x 15 cm x 15 cm thick steel block under both wheels at the battery pack
block under both wheels at the ground controls side of the machine.
side of the machine. GS-1532 and GS-1932: Place a 0.83 x 6 x 6
23 Lower the machine onto the blocks. inch / 21.1 mm x 15 cm x 15 cm thick steel
block under both wheels at the battery pack
24 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. side of the machine.
Result: The level sensor alarm should not GS-2032, GS-2632 and GS-3232: Place a
sound. 0.8 x 6 x 6 inch / 20.3 mm x 15 cm x 15 cm
thick steel block under both wheels at the
Result: The level sensor alarm does sound and
battery pack side of the machine.
fault code LL appears in the diagnostic display.
Adjust the level sensor retaining fasteners just GS-2046, GS-2646 and GS-3246: Place a
until the level sensor alarm does not sound. 1.22 x 6 x 6 inch / 31 mm x 15 cm x 15 cm thick
steel block under both wheels at the battery
pack side of the machine.

4 - 82 GS-30 • GS-32 • GS-46 Part No. 97385


March 2007 Section 4 • Repair Procedures

REV D GROUND CONTROLS

32 Lower the machine onto the blocks.


33 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
Result: The platform should stop, an alarm
should sound and fault code LL appears in the
diagnostic display.
Result: The platform does not stop or the level
sensor alarm does not sound. Adjust the level
sensor until the alarm just begins to sound OR
the down limit switch may need to be adjusted.
34 Lift the safety arm, move it to the center of the
scissor arm and rotate down to a vertical
position.
35 Lower the scissor arms onto the safety arm.
Crushing hazard. Keep hands
clear of the safety arm when
lowering the platform.
36 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
37 Return the safety arm to the stowed position.
38 Lower the platform to the stowed position.
39 Raise the machine approximately
2 inches / 5 cm.
40 Remove the blocks from under both wheels.
41 Lower the machine and remove the jack.

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 83


Section 4 • Repair Procedures March 2007

GROUND CONTROLS REV D

How to Install the Outrigger 6 Place the new outrigger level sensor onto the
outrigger level sensor base with the flat side of
Level Sensor the outrigger level sensor closest to the battery
Tip-over hazard. Failure to install side access door. Refer to Illustration 1.
the outrigger level sensor as
instructed will compromise
machine stability and cause the
machine to tip over, resulting in
death or serious injury. Do not
install the outrigger level sensor
other than specified in this
procedure.
1 Move the machine to an area that has a firm,
level surface and is free of obstructions.
2 Turn the key switch to the off position and push
in the red Emergency Stop button to the off
position at both the ground and platform
controls.
Illustration 1
3 Open the access door at the battery side of the
machine. 7 Secure the outrigger level sensor onto the base
with the retaining fasteners removed in step 5.
4 Tag and disconnect the outrigger level sensor
wire harness from the outrigger level sensor. 8 Adjust the outrigger level sensor retaining
fasteners until the bubble in the top of the level
5 Remove the outrigger level sensor retaining
sensor is centered in the circles.
fasteners and remove the outrigger level sensor
from the machine. 9 Connect the outrigger level sensor wire harness
to the new outrigger level sensor.
10 Close the access door at the battery side of the
machine.
11 Calibrate the new outrigger level sensor. Refer
to Section 1-4, How to Calibrate the Outrigger
Level Sensor.

4 - 84 GS-30 • GS-32 • GS-46 Part No. 97385


March 2007 Section 4 • Repair Procedures

GROUND CONTROLS

This page intentionally left blank.

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 85


Section 4 • Repair Procedures April 2008

Hydraulic Pump REV B

5-1 4 Activate the platform up function from the


ground controls.
Function Pump
Result: If the pressure gauge reads
The hydraulic pump is attached to the motor which 3200 psi / 221 bar, immediately stop. The pump
makes up the hydraulic power unit. is good.
Result: If pressure fails to reach
How to Test the Hydraulic Pump 3200 psi / 221 bar, the pump is bad and will
When removing a hose assembly or fitting, the need to be serviced or replaced.
fitting and/or hose end must be torqued to Component damage hazard.
specification during installation. There is no relief valve in the
Refer to Section 2, Hydraulic Hose and Fitting hydraulic pump and the pump can
Torque Specifications. be damaged if the pressure is
allowed to exceed
1 Tag, disconnect and plug the high pressure
3200 psi / 221 bar. When testing
hydraulic hose from the hydraulic pump.
the pump, activate the pump in
Bodily injury hazard. Spraying one second intervals until
hydraulic oil can penetrate and 3200 psi / 221 bar is confirmed.
burn skin. Loosen hydraulic Do not over-pressurize the pump.
connections very slowly to allow
5 Remove the pressure gauge and reconnect the
the oil pressure to dissipate
hydraulic hose. Torque to specification.
gradually. Do not allow oil to squirt
or spray. Bodily injury hazard. Spraying
hydraulic oil can penetrate and
2 Connect a 0 to 5000 psi / 0 to 350 bar pressure
burn skin. Loosen hydraulic
gauge to the high pressure port on the pump.
connections very slowly to allow
3 Turn the key switch to ground control and pull the oil pressure to dissipate
out the red Emergency Stop button to the on gradually. Do not allow oil to squirt
position at both the ground and platform or spray.
controls.

4 - 86 GS-30 • GS-32 • GS-46 Part No. 97385


April 2008 Section 4 • Repair Procedures

REV B HYDRAULIC PUMP

How to Remove the 6 Tag, disconnect and plug the high pressure
hose at the pump. Cap the fitting on the pump.
Hydraulic Pump
Bodily injury hazard. Spraying
When removing a hose assembly or fitting, the hydraulic oil can penetrate and
O-ring on the fitting and/or hose end must be burn skin. Loosen hydraulic
replaced and then torqued to specification during connections very slowly to allow
installation. the oil pressure to dissipate
Refer to Section Two, Hydraulic Hose and Fitting gradually. Do not allow oil to squirt
Torque Specifications. or spray.
1 Disconnect the battery pack from the machine. 7 Remove the hydraulic power unit from the
machine.
Electrocution/burn hazard. Contact
with electrically charged circuits 8 Remove the pump mounting bolts. Carefully
could result in death or serious remove the pump.
injury. Remove all rings, watches
and other jewelry. Tip-over hazard. After replacing
the hydraulic pump, it is critical to
2 Tag and disconnect the hydraulic power unit return the function speed settings
cables at the motor controller. to original factory specifications.
Failure to restore the machine to
3 Disconnect the filter head from the filter head
original factory specifications
mounting bracket. Rotate the filter out and away
could cause the machine to tip
from the hydraulic power unit.
over resulting in death or serious
4 Remove the hydraulic power unit retaining injury.
fasteners.
5 Tag, disconnect and plug the hydraulic hard line
from the pump. Cap the fitting on the pump.

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 87


Section 4 • Repair Procedures February 2009

Manifolds REV F

6-1
Function Manifold Components -
GS-1530, GS-1532, GS-1930 and GS-1932
The function manifold is mounted under the machine, between the module trays.
Index Schematic
No. Description Item Function Torque
— Coil nut (item F) .................................................................................................................... 4-5 ft-lbs / 5-7 Nm
— Coil nut (items E and H) ....................................................................................................... 5-7 ft-lbs / 7-9 Nm
1 Diagnostic nipple ....................................... A ......................... Testing
2 Check disc ................................................. B ......................... Steer circuit ............................ 18 ft-lbs / 24 Nm
3 Relief valve,
1800 to 3700 psi / 124 to 255 bar ............. C ......................... Lift relief .................................. 20 ft-lbs / 27 Nm
4 Check valve, 10 psi / 0.7 bar ..................... D ......................... Drive circuit ............................. 20 ft-lbs / 27 Nm
5 Solenoid valve, 3 position 4 way ............... E ......................... Drive forward/reverse ............. 25 ft-lbs / 34 Nm
6 Solenoid valve, 3 position 4 way ............... F ......................... Steer left/right ......................... 25 ft-lbs / 34 Nm
7 Flow regulator and relief valve,
0.75 gpm / 2.8 L/min,
1500 psi / 103 bar ...................................... G ......................... Steer circuit ............................ 26 ft-lbs / 35 Nm
8 Solenoid valve, 2 position 4 way ............... H ......................... Platform up ............................. 25 ft-lbs / 34 Nm
9 Relief valve,
3700 psi / 255 bar maximum ..................... I .......................... System relief ........................... 20 ft-lbs / 27 Nm

How to Install a Valve Cartridge


1 Dip the cartridge in clean oil to lube the O-rings.
2 Screw the cartridge in by hand until the top
O-ring is met, then torque to specification.
3 If required, install the valve coil(s) onto the
valve stem. Install the coil nut onto the valve
stem and torque to specification.

4 - 88 GS-30 • GS-32 • GS-46 Part No. 97385


February 2009 Section 4 • Repair Procedures

REV F MANIFOLDS

1 2

I
9

C
3
Y8
H
8
Y4

G Y3
7
D
4
F INSIDE
6 COIL
OUTSIDE
COIL

E
5

Before serial number GS3005A-76492: drive reverse coil Y5


Before serial number GS3005B-76085: drive reverse coil Y5
After serial number GS3005A-76491: drive forward coil Y6
After serial number GS3005B-76084: drive forward coil Y6

Note: 'alpha' callouts refer


Before serial number GS3005A-76492: drive forward coil Y6 to corresponding notes on
Before serial number GS3005B-76085: drive forward coil Y6 the hydraulic schematic
After serial number GS3005A-76491: drive reverse coil Y5
After serial number GS3005B-76084: drive reverse coil Y5
Note: 'alpha-numeric' callouts
refer to corresponding notes
on the electrical schematic

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 89


Section 4 • Repair Procedures February 2009

MANIFOLDS REV F

6-2
Function Manifold Components -
GS-2032, GS-2632, GS-3232, GS-2046, GS-2646 and GS-3246
The function manifold is mounted behind an inspection door on the ground control side of the machine.
Index Schematic
No. Description Item Function Torque
— Coil nut (item AC) ................................................................................................................. 4-5 ft-lbs / 5-7 Nm
— Coil nut (items AE, AG and AI) ............................................................................................. 5-7 ft-lbs / 7-9 Nm
1 Diagnostic nipple ....................................... AA ...................... Testing
2 Relief valve,
3700 psi / 255 bar maximum ..................... AB ...................... System relief ........................... 20 ft-lbs / 27 Nm
3 Solenoid valve, 3 position 4 way ............... AC ...................... Steer left/right ......................... 25 ft-lbs / 34 Nm
4 Check disc ................................................. AD ...................... Steer circuit ............................ 18 ft-lbs / 24 Nm
5 Solenoid valve, 2 position 4 way ............... AE ...................... Drive speed select circuit ....... 25 ft-lbs / 34 Nm
6 Relief valve,
Before serial number GS3206-80132
and GS4606-79028 130 psi / 9 bar
After serial number GS3206-80131
and GS4606-79027 50 psi / 3.4 bar .......... AF ....................... Brake release ......................... 20 ft-lbs / 27 Nm
7 Solenoid valve, 3 position 5 way ............... AG ...................... Drive forward/reverse ............. 25 ft-lbs / 34 Nm
8 Flow regulator and relief valve,
0.75 gpm / 2.8 L/min,
1500 psi / 103 bar ...................................... AH ...................... Steer circuit ............................ 26 ft-lbs / 35 Nm
9 Solenoid valve, 2 position 4 way ............... AI ........................ Platform up ............................. 25 ft-lbs / 34 Nm
10 Relief valve,
1800 to 3700 psi / 124 to 255 bar ............. AJ ....................... Lift relief .................................. 20 ft-lbs / 27 Nm

How to Install a Valve Cartridge


1 Dip the cartridge in clean oil to lube the O-rings.
2 Screw the cartridge in by hand until the top
O-ring is met, then torque to specification.
3 If required, install the valve coil(s) onto the
valve stem. Install the coil nut onto the valve
stem and torque to specification.

4 - 90 GS-30 • GS-32 • GS-46 Part No. 97385


February 2009 Section 4 • Repair Procedures

REV F MANIFOLDS

1 2 3 4 5

Note: 'alpha' callouts refer


to corresponding notes on
the hydraulic schematic

AD
Note: 'alpha-numeric' callouts
refer to corresponding notes
AB AC on the electrical schematic

AE
AA

Y4

Y3
INSIDE Y1
COIL
OUTSIDE
COIL

Y8

AJ AI AH AG
AF
6

Inside Coil (closest to manifold)


Before serial number GS3206-80132: drive forward coil Y6
Before serial number GS4606-79028: drive forward coil Y6
After serial number GS3206-80131: drive reverse coil Y5
After serial number GS4606-79027: drive reverse coil Y5

Outside Coil (furthest from manifold)


Before serial number GS3206-80132: drive reverse coil Y5
Before serial number GS4606-79028: drive reverse coil Y5
After serial number GS3206-80131: drive forward coil Y6
After serial number GS4606-79027: drive forward coil Y6

10 9 8 7

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 91


Section 4 • Repair Procedures February 2009

MANIFOLDS REV F

6-3
Outrigger Function Manifold Components -
GS-3232
The outrigger function manifold is mounted behind an inspection door on the battery side of the machine.
Index Schematic
No. Description Item Function Torque
— Coil nut (item BA) ................................................................................................................. 4-5 ft-lbs / 5-7 Nm
1 Solenoid valve, 3 position 4 way ............... BA ...................... Outrigger extend/retract ......... 25 ft-lbs / 34 Nm
2 Relief valve,
3500 psi / 241 bar maximum ..................... BB ...................... Outrigger circuit ...................... 20 ft-lbs / 27 Nm

INSIDE
COIL
OUTSIDE Y39
COIL
BB Y40
2

Note: 'alpha-numeric' callouts


refer to corresponding notes
on the electrical schematic

BA
1

How to Install a Valve Cartridge


1 Dip the cartridge in clean oil to lube the O-rings.
2 Screw the cartridge in by hand until the top
O-ring is met, then torque to specification.
3 If required, install the valve coil(s) onto the
Note: 'alpha' callouts refer
valve stem. Install the coil nut onto the valve to corresponding notes on
stem and torque to specification. the hydraulic schematic

4 - 92 GS-30 • GS-32 • GS-46 Part No. 97385


February 2009 Section 4 • Repair Procedures

REV F MANIFOLDS

6-4
Outrigger Cylinder Manifold Components -
GS-3232
The front outrigger cylinders are located behind the inspection doors at the battery side and at the ground
control side of the machine. The rear outrigger cylinders are located inside the outrigger enclosures at the
rear of the machine.
Index Schematic
No. Description Item Function Torque
— Coil nut (item CA, CB, CC, CD) ............................................................................................ 4-5 ft-lbs / 5-7 Nm
1 Solenoid valve, 2 position 2 way ............... CA, CB, CC, CD . Outrigger extend/retract ......... 25 ft-lbs / 34 Nm
2 Orifice - plug,
0.037 inch / 0.94 mm ................................. CE ...................... Outrigger retract
3 Check valve, pilot operated ....................... CF ....................... Retract flow control ............. 20 ft-lbs / 27.1 Nm
4 Pressure Transducer ................................. CG ...................... Outrigger autolevel .............. 16 ft-lbs / 21.7 Nm

CF CF 4
3 3

CG
4
CG

nd
CE
Ex
te 2 te
nd
CE Ex

Re
trac
t

FRONT Re
tr ac
t

REAR
OUTRIGGERS OUTRIGGERS

CA and CB Y35 CC and CD Y33


1 Y36 1 Y34

How to Install a Valve Cartridge


Note: 'alpha-numeric' callouts
1 Dip the cartridge in clean oil to lube the O-rings. refer to corresponding notes
on the electrical schematic
2 Screw the cartridge in by hand until the top
O-ring is met, then torque to specification.
3 If required, install the valve coil(s) onto the Note: 'alpha' callouts refer
to corresponding notes on
valve stem. Install the coil nut onto the valve the hydraulic schematic
stem and torque to specification.

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 93


Section 4 • Repair Procedures February 2009

MANIFOLDS REV F

6-5
Check Valve Manifold Components -
GS-1530, GS-1532, GS-1930 and GS-1932
The check valve manifold is mounted on the function manifold.
Index Schematic
No. Description Item Function Torque
1 Check valve, 200 psi / 13.8 bar ................. S ......................... Drive circuit ............................. 20 ft-lbs / 27 Nm

Note: 'alpha' callouts refer


to corresponding notes on
the hydraulic schematic

How to Install a Valve Cartridge


1 Dip the cartridge in clean oil to lube the O-rings.
2 Screw the cartridge in by hand until the top
O-ring is met, then torque to specification.
3 If required, install the valve coil(s) onto the
valve stem. Install the coil nut onto the valve
stem and torque to specification.

4 - 94 GS-30 • GS-32 • GS-46 Part No. 97385


February 2009 Section 4 • Repair Procedures

REV F MANIFOLDS

6-6 6 Press and hold the function enable switch.


Valve Adjustments - 7 Move and hold the joystick fully in either
direction while observing the pressure reading
Function Manifold on the pressure gauge. Note the pressure.
Refer to Section 2, Specifications.
How to Adjust the
8 Turn the machine off. Hold the system relief
System Relief Valve valve with a wrench and remove the cap
(schematic item I or AB).
Perform this test from the ground with the platform
controls. Do not stand in the platform. 9 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
Be sure that the hydraulic oil level is at the FULL
decrease the pressure.
mark on the hydraulic tank.
Tip-over hazard. Failure to adjust
1 Locate the system relief valve on the function the relief valves to specification
manifold (schematic item I or AB). could result in the machine tipping
2 Connect a 0 to 5000 psi / 0 to 350 bar over, causing death or serious
pressure gauge to the test port on the function injury. Do not adjust the relief
manifold (schematic item A or AA). valve pressures higher than
specifications.
3 Chock both sides of the wheels at the steer end
of the machine. 10 Install the relief valve cap.

4 Remove the platform controls from the platform. 11 Repeat steps 5 through 7 to confirm the relief
valve pressure.
5 Turn the key switch to platform control and pull
out the red Emergency Stop button to the on a b
position at both the ground and platform
controls.

GS-32 and GS-46

a test port
b system relief valve
c steer relief valve
d lift relief valve

GS-1530/32 and GS-1930/32

a test port
b system relief valve

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 95


Section 4 • Repair Procedures February 2009

MANIFOLDS REV F

How to Adjust the 7 Move and hold the joystick fully in either
direction while observing the pressure reading
Platform Lift Relief Valve on the pressure gauge. Note the pressure.
Perform this test from the ground with the platform Refer to Section 2, Specifications.
controls. Do not stand in the platform. 8 Turn the machine off. Hold the system relief
valve with a wrench and remove the cap
Be sure that the hydraulic oil level is at the FULL
(hydraulic schematic item I or AB).
mark on the hydraulic tank.
9 Adjust the internal hex socket. Turn it clockwise
1 Locate the system relief valve on the function to increase the pressure or counterclockwise to
manifold (item I). decrease the pressure.
2 Connect a 0 to 5000 psi / 0 to 350 bar Tip-over hazard. Failure to adjust
pressure gauge to the test port on the function the relief valves to specification
manifold (schematic item A or AA). could result in the machine tipping
3 Chock both sides of the wheels at the steer end over, causing death or serious
of the machine. injury. Do not adjust the relief
valve pressures higher than
4 Remove the platform controls from the platform. specifications.
5 Turn the key switch to platform control and pull 10 Install the relief valve cap.
out the red Emergency Stop button to the on
position at both the ground and platform 11 Repeat steps 4 through 7 to confirm the relief
controls. valve pressure.

6 Press and hold the function enable switch. 12 Place maximum rated load into the platform.
Secure the load to the platform. Refer to
a Section 2, Specifications.
a b

b
c

c
GS-1530/32 and GS-1930/32
GS-32 and GS-46
a test port
a test port
b system relief valve
b system relief valve
c lift relief valve
c steer relief valve
d lift relief valve

4 - 96 GS-30 • GS-32 • GS-46 Part No. 97385


February 2009 Section 4 • Repair Procedures

REV F MANIFOLDS

13 Turn the key switch to ground control and pull


out the red Emergency Stop button to the on
position at both the ground and platform
controls.
14 Hold the lift relief valve with a wrench and
remove the cap (schematic item C or AJ).
15 While activating the platform up function, adjust
the internal hex socket clockwise, just until the
platform fully raises.
16 Fully lower the platform.
17 Add an additional 50 pounds / 22.7 kg to the
platform. Secure the additional weight.
18 Attempt to raise the platform.
Result: The power unit should not be able to lift
the platform.
Result: If the power unit lifts the platform, adjust
the internal hex socket counterclockwise until
the platform will not raise.
19 Install the relief valve cap.
20 Remove the weight from the platform.
21 Bleed the hydraulic system by raising the
platform to full height. If the pump cavitates or
the platform fails to reach full height, add
hydraulic oil until the pump is functioning
correctly. Do not overfill the hydraulic tank.
Component damage hazard. Do
not continue to operate the
machine if the hydraulic pump is
cavitating.

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 97


Section 4 • Repair Procedures February 2009

MANIFOLDS REV F

How to Adjust the Steer Relief 5 Activate the function enable switch and press
and hold the steer thumb rocker switch to the
Valve right. Allow the wheels to completely turn to the
Perform this test from the ground with the platform right. Continue holding the switch while
controls. Do not stand in the platform. observing the pressure reading on the pressure
gauge. Note the pressure. Refer to Section 2,
Be sure that the hydraulic oil level is at the FULL Specifications.
mark on the hydraulic tank.
6 Press and hold the steer thumb rocker switch to
1 Locate the steer relief valve on the function the left. Allow the wheels to completely turn to
manifold (schematic item G or AH). the left. Continue holding the switch while
observing the pressure reading on the pressure
2 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge.
gauge to the test port (schematic item A or AA)
on the function manifold. 7 Turn the machine off. Hold the steer relief valve
with a wrench and remove the cap (schematic
3 Remove the platform controls from the platform. item G or AH).
4 Turn the key switch to platform control and pull 8 Adjust the internal hex socket. Turn it clockwise
out the red Emergency Stop button to the on to increase the pressure or counterclockwise to
position at both the ground and platform decrease the pressure.
controls.
Component damage hazard.
a Do not adjust the relief valve
pressures higher than
specifications.
9 Install the relief valve cap.
10 Repeat steps 5 through 6 to confirm the relief
valve pressure.
a b

GS-1530/32 and GS-1930/32


d
a test port
b steer relief valve

GS-32 and GS-46

a test port
b system relief valve
c steer relief valve
d lift relief valve

4 - 98 GS-30 • GS-32 • GS-46 Part No. 97385


February 2009 Section 4 • Repair Procedures

REV F MANIFOLDS

6-7 Valve Coil Resistance


Valve Coils Specification
Note: The following coil resistance specifications
How to Test a Coil are at an ambient temperature of 68°F / 20°C. As
A properly functioning coil provides an valve coil resistance is sensitive to changes in air
electromagnetic force which operates the solenoid temperature, the coil resistance will typically
valve. Critical to normal operation is continuity increase or decrease by 4% for each 18°F / -7.7°C
within the coil. Zero resistance or infinite that your air temperature increases or decreases
resistance indicates the coil has failed. from 68°F / 20°C.

Since coil resistance is sensitive to temperature, Valve Coil Resistance Specifications


resistance values outside specification can
Description Specification
produce erratic operation. When coil resistance
decreases below specification, amperage Solenoid valve, 3 position 4 way 27.2Ω
increases. As resistance rises above specification, 20V DC with diode (schematic items F and AC)
voltage increases.
Solenoid valve, 3 position 4 way 19Ω
While valves may operate when coil resistance is 20V DC with diode (schematic item E)
outside specification, maintaining coils within
Solenoid valve, 2 position 4 way 19Ω
specification will help ensure proper valve function
20V DC with diode (schematic item H and AI)
over a wide range of operating temperatures.
Solenoid valve, 2 position 2 way N.C. 25Ω
Electrocution/burn hazard. Contact 20V DC with diode (schematic item N)
with electrically charged circuits
could result in death or serious Solenoid valve, 2 position 4 way 19Ω
injury. Remove all rings, watches 20V DC with diode (schematic items AE)
and other jewelry.
Solenoid valve, 3 position 5 way 19Ω
Note: If the machine has been in operation, allow 20V DC with diode (schematic item AG)
the coil to cool at least 3 hours before performing
Solenoid valve, 2 position 2 way 27.2Ω
this test. 20V DC with diode (schematic item CA, CB, CC
and CD)
1 Tag and disconnect the wiring from the coil to
be tested. Solenoid valve, 3 position 4 way 19Ω
20V DC with diode (schematic item BA)
2 Test the coil resistance using a multimeter set
to resistance (Ω). Refer to the Valve Coil
Resistance Specification table.
Result: If the resistance is not within the
adjusted specification, plus or minus 10%,
replace the coil.

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 99


Section 4 • Repair Procedures February 2009

MANIFOLDS REV F

How to Test a Coil Diode


Genie incorporates spike suppressing diodes in all COIL
a
of its coils. Properly functioning coil diodes protect d
MULTI
METER
the electrical circuit by suppressing voltage spikes.
Voltage spikes naturally occur within a function
circuit following the interruption of electrical current c -
to a coil. Faulty diodes can fail to protect the

+
b
electrical system, resulting in a tripped circuit 10 W 9V
breaker or component damage. RESISTOR BATTERY

Electrocution/burn hazard. Contact c


b

+
with electrically charged circuits
-
could result in death or serious
injury. Remove all rings, watches a multimeter
and other jewelry. b 9V DC battery
c 10Ω resistor
1 Test the coil for resistance. See 6-7 How to d coil
Test a Coil.
Note: Dotted lines in illustration indicate a reversed
2 Connect a 10Ω resistor to the negative terminal connection as specified in step 6
of a known good 9V DC battery. Connect the
other end of the resistor to a terminal on the 5 Momentarily connect the positive lead from the
coil. multimeter to the positive terminal on the 9V
battery. Note and record the current reading.
Note: The battery should read 9V DC or more
when measured across the terminals. 6 At the battery or coil terminals, reverse the
connections. Note and record the current
Ω
Resistor, 10Ω reading.
Genie part number 27287 Result: Both current readings are greater than
0 mA and are different by a minimum of 20%.
The coil is good.
3 Set a multimeter to read DC amperage.
Result: If one or both of the current readings are
Note: The multimeter, when set to read DC 0 mA, or if the two current readings do not differ
amperage, should be capable of reading up to by a minimum of 20%, the coil and/or its
800 mA. internal diode are faulty and the coil should be
4 Connect the negative lead to the other terminal replaced.
on the coil.
Note: If testing a single-terminal coil, connect the
negative lead to the internal metallic ring at either
end of the coil.

4 - 100 GS-30 • GS-32 • GS-46 Part No. 97385


April 2008 Section 4 • Repair Procedures

REV B
Hydraulic Tank
7-1 2 Remove the drain plug from the hydraulic tank
and allow all of the oil from the tank to drain into
Hydraulic Tank a suitable container. Refer to Section 2,
Specifications.
The primary functions of the hydraulic tank are to
cool and deaerate the hydraulic fluid during Bodily injury hazard. Spraying
operation. It utilizes internal suction strainers for hydraulic oil can penetrate and
the pump supply lines and has an external return burn skin. Loosen hydraulic
line filter. connections very slowly to allow
the oil pressure to dissipate
How to Remove the gradually. Do not allow oil to squirt
or spray.
Hydraulic Tank
3 Tag and disconnect the hydraulic tank return
Component damage hazard. The hard line from the filter. Remove the hard line
work area and surfaces where this from the machine. Cap the fitting on the filter
procedure will be performed must head.
be clean and free of debris that
could get into the hydraulic 4 Tag and disconnect the hydraulic tank hard line
system. from the pump. Remove the hard line from the
machine. Cap the fitting on the pump.
When removing a hose assembly or fitting, the
fitting and/or hose end must be torqued to 5 Remove the hydraulic tank retaining fasteners
specification during installation. and remove the hydraulic tank from the
Refer to Section 2, Hydraulic Hose and Fitting machine.
Torque Specifications.
Torque specifications
Perform this procedure with the platform in the
Hydraulic tank retaining fasteners, dry 35 in-lbs
stowed position.
4 Nm
1 Disconnect the battery pack from the machine. Hydraulic tank retaining fasteners, lubricated 26 in-lbs
Electrocution/burn hazard. Contact 2.9 Nm
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 101


Section 4 • Repair Procedures November 2008

Steer Axle Components REV B

8-1 7 Tag, disconnect and plug the hydraulic hoses


on the drive motor. Cap the fittings on the drive
Yoke and Drive Motor motor.
Bodily injury hazard. Spraying
How to Remove the Yoke hydraulic oil can penetrate and
and Drive Motor Assembly burn skin. Loosen hydraulic
connections very slowly to allow
When removing a hose assembly or fitting, the
the oil pressure to dissipate
fitting and/or hose end must be torqued to
gradually. Do not allow oil to squirt
specification during installation. Refer to Section 2,
or spray.
Hydraulic Hose and Fitting Torque Specifications.
Component damage hazard.
1 Block the non-steer wheels. Hoses can be damaged if they are
2 Remove the cotter pin from the wheel castle kinked or pinched.
nut. 8 Support and secure the yoke assembly to an
Note: Always replace the cotter pin with a new one appropriate lifting device.
when removing the castle nut. 9 Remove the retaining fastener from the steer
3 Loosen the wheel castle nut. Do not remove it. link at the yoke assembly.

4 Center a lifting jack under the drive chassis at Note: While removing the retaining fasteners, take
the steer end of the machine. note of the quantity and location of the spacers
when disconnecting the steer link from the yoke
5 Raise the machine approximately assembly.
6 inches / 15 cm. Place blocks under the
chassis for support. 10 Remove the retaining fastener from the top of
the yoke pivot shaft.
Crushing hazard. The chassis
could fall if not properly supported. Note: The pivot shaft retaining fastener is located
above the main deck.
6 Remove the wheel castle nut. Remove the
wheel. 11 Lower the yoke assembly out of the chassis.
Bodily injury hazard. The yoke/
motor assembly may fall if not
properly supported when it is
removed from the chassis.

4 - 102 GS-30 • GS-32 • GS-46 Part No. 97385


November 2008 Section 4 • Repair Procedures

REV B STEER AXLE COMPONENTS

How to Remove a Drive Motor 8-2


1 Block the non-steer wheels. Steer Cylinder
2 Remove the cotter pin from the wheel castle nut
of the motor to be removed.
How to Remove the
Note: Always replace the cotter pin with a new one
Steer Cylinder
when removing the castle nut. When removing a hose assembly or fitting, the
O-ring on the fitting and/or hose end must be
3 Loosen the wheel castle nut. Do not remove it.
replaced and then torqued to specification during
4 Center a lifting jack under the drive chassis at installation.
the steer end of the machine. Refer to Section Two, Hydraulic Hose and Fitting
Torque Specifications.
5 Raise the machine approximately
2 inches / 5 cm. Place blocks under the chassis 1 Block the non-steer wheels.
for support.
2 Remove the pin retaining fasteners from the
Crushing hazard. The chassis rod-end pivot pin. Remove the pivot pin.
could fall if not properly supported.
Note: While removing the pin retaining fasteners,
6 Remove the wheel castle nut. Remove the take note of the quantity and location of the
wheel. spacers when removing the pivot pin.
7 Tag, disconnect and plug the hydraulic hoses 3 Remove the pin retaining fasteners from the
on the drive motor. Cap the fittings on the drive barrel-end pivot pin. Remove the pin.
motor.
Note: While removing the pin retaining fasteners,
Bodily injury hazard. Spraying take note of the quantity and location of the
hydraulic oil can penetrate and spacers when removing the pin.
burn skin. Loosen hydraulic
connections very slowly to 4 Remove the steer cylinder from the machine.
allow the oil pressure to 5 Tag, disconnect and plug the hydraulic hoses
dissipate gradually. Do not from the steer cylinder. Cap the fittings on the
allow oil to squirt or spray. cylinder.
Component damage hazard. Bodily injury hazard. Spraying
Hoses can be damaged if they are hydraulic oil can penetrate and
kinked or pinched. burn skin. Loosen hydraulic
8 Remove the drive motor mounting fasteners. connections very slowly to allow
Remove the motor. the oil pressure to dissipate
gradually. Do not allow oil to
Torque specifications squirt or spray.

Drive motor mounting fasteners, dry 75 ft-lbs Component damage hazard.


101.7 Nm Hoses can be damaged if they are
kinked or pinched.
Drive motor mounting fasteners, lubricated 56 ft-lbs
76.3 Nm

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 103


Section 4 • Repair Procedures November 2008

STEER AXLE COMPONENTS REV B

8-3 6 Remove the bellcrank from the machine.


Steer Bellcrank Note: While removing the bellcrank from the
machine, take note of the quantity and location of
the spacers between the bellcrank and the steer
How to Remove the Steer links.
Bellcrank
Note: Before re-installing the steer bellcrank onto
1 Remove the steer cylinder. See 8-2, How to the machine, apply a small amount of Loctite onto
Remove the Steer Cylinder. the threads of the fasteners. Torque the fasteners
to 31 ft-lbs / 42 Nm.
2 Remove the retaining fasteners from the steer
links at each end of the bellcrank.
Note: While removing the retaining fasteners, take
note of the quantity and location of the spacers
between the bellcrank and the steer links.
3 Center a lifting jack under the drive chassis at
the steer end.
4 Raise the machine approximately
14 inches / 36 cm. Place blocks under the
chassis for support.
Crushing hazard. The chassis
could fall if not properly supported.
5 Turn the yokes to the side so the bellcrank can
be removed.

4 - 104 GS-30 • GS-32 • GS-46 Part No. 97385


March 2007 Section 4 • Repair Procedures

REV A
Non-steer Axle Components
9-1 9 Tag, disconnect and plug the hydraulic hose
from the brake. Cap the fitting on the brake.
Drive Brake
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
How to Remove a Drive Brake burn skin. Loosen hydraulic
When removing a hose assembly or fitting, the connections very slowly to allow
fitting and/or hose end must be torqued to the oil pressure to dissipate
specification during installation. gradually. Do not allow oil to squirt
Refer to Section 2, Hydraulic Hose and Fitting or spray.
Torque Specifications. 10 Place a lifting jack under the brake for support.
1 Support and secure the entry ladder to an 11 Remove the fasteners that attach the brake to
appropriate lifting device. the drive chassis. Remove the brake.
2 Remove the entry ladder mounting fasteners. Crushing hazard. The brake will
Remove the entry ladder from the machine. fall if not properly supported when
Crushing hazard. The entry ladder the mounting fasteners are
may become unbalanced and fall if removed.
it is not properly supported and
Torque specifications
secured to the lifting device.
3 Block the steer wheels. Brake mounting fasteners, dry 75 ft-lbs
102 Nm
4 Remove the cotter pin from the wheel castle
Brake mounting fasteners, lubricated 56 ft-lbs
nut.
76 Nm
Note: Always replace the cotter pin with a new one
when removing the castle nut.
5 Loosen the wheel castle nut. Do not remove it.
6 Center a lifting jack under the drive chassis at
the non-steer end.
7 Raise the machine approximately
2 inches / 5 cm. Place blocks under the chassis
for support.
Crushing hazard. The chassis
could fall if not properly supported.
8 Remove the wheel castle nut. Remove the
wheel.

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 105


Section 4 • Repair Procedures March 2007

Brake Release Hand Pump Components REV A

10-1
Brake Release Hand Pump Components
The brake release hand pump manifold is mounted behind the entry ladder.
Index Schematic
No. Description Item Function Torque
1 Hand pump ....................................... L ............... Manual brake release .............................. 30 ft-lbs / 41 Nm
2 Needle valve ..................................... M ............... Manual brake release enable .............. 45-50 in-lbs / 5 Nm

2
M

Note: 'alpha' callouts refer


to corresponding notes on
the hydraulic schematic

4 - 106 GS-30 • GS-32 • GS-46 Part No. 97385


March 2007 Section 4 • Repair Procedures

REV A
Outrigger Components
11-1 7 Support and secure the outrigger cylinder to a
suitable lifting device.
Outrigger Cylinder
8 Remove the outrigger cylinder mounting
fasteners.
How to Remove an Outrigger
Cylinder 9 Remove the outrigger cylinder from the
machine.
Perform this procedure with the platform in the
Crushing hazard. The outrigger
stowed position and the outriggers fully retracted.
cylinder may become unbalanced
and fall if not properly supported
When removing a hose assembly or fitting, the when it is removed from the
O-ring on the fitting and/or hose end must be machine.
replaced and then torqued to specification during Note: After installing a new cylinder or pressure
installation. Refer to Section 2, Hydraulic Hose and transducer, the pressure transducers on the
Fitting Torque Specifications. machine must be calibrated. Refer to Section 1-4,
Steer End: How to Calibrate the Outrigger Pressure
Transducers.
1 Chock the wheels at the non-steer end of the
CF
machine. e

2 With a suitable floor jack, lift the steer end of the CG


a
machine to a height that will allow the outrigger
cylinder to be removed.
3 Open the access door at the battery side and
(or) at the hydraulic tank side of the machine. Ex
te
nd

4 Tag and disconnect the wire harness from the d


outrigger cylinder solenoid valve and the
t
pressure transducer. Re
trac
CE
b
5 Tag and disconnect the pressure transducer
from the outrigger cylinder. Plug the fitting on
the cylinder.
6 Tag, disconnect and plug the hydraulic hoses
from the outrigger cylinder. Cap the fittings on
the cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and CA and CB Y35
c
burn skin. Loosen hydraulic Y36
connections very slowly to allow
Steer End Outrigger
the oil pressure to dissipate
gradually. Do not allow oil to squirt a pressure transducer
or spray. b orifice
c valve coil
d outrigger cylinder
e check valve

Part No. 97385 GS-30 • GS-32 • GS-46 4 - 107


Section 4 • Repair Procedures March 2007

OUTRIGGER COMPONENTS REV A

Non-steer End: e
CF

1 Chock the wheels at the steer end of the


machine. CE
a

2 With a suitable floor jack, lift the non-steer end


of the machine to a height that will allow the
outrigger cylinder to be removed. CG
b
nd
te
Ex

3 Remove the fasteners securing the cover to the d


rear outrigger enclosure. Set the fasteners to
the side and remove the cover. tra
ct
Re

4 Tag and disconnect the wire harness from the


outrigger cylinder solenoid valve and the
pressure transducer.
5 Tag and disconnect the pressure transducer
from the outrigger cylinder. Plug the fitting on
the cylinder.
6 Tag, disconnect and plug the hydraulic hoses
from the outrigger cylinder. Cap the fittings on
CC and CD Y33
the cylinder. c
Y34
Bodily injury hazard. Spraying Non-steer End Outrigger
hydraulic oil can penetrate and
burn skin. Loosen hydraulic a orifice
b pressure transducer
connections very slowly to allow c valve coil
the oil pressure to dissipate d outrigger cylinder
gradually. Do not allow oil to squirt e check valve
or spray.
7 Support and secure the outrigger cylinder to a
suitable lifting device.
8 Remove the outrigger cylinder mounting
fasteners.
9 Remove the outrigger cylinder from the
machine.
Crushing hazard. The outrigger
cylinder may become unbalanced
and fall if not properly supported
when it is removed from the
machine.
Note: After installing a new cylinder or pressure
transducer, the pressure transducers on the
machine must be calibrated. Refer to Section 1-4,
How to Calibrate the Outrigger Pressure
Transducers.

4 - 108 GS-30 • GS-32 • GS-46 Part No. 97385


March 2007 Section 5 • Fault Codes

Fault Codes
Before Troubleshooting:
Read, understand and obey the safety rules
and operating instructions in the appropriate
operator's manual on your machine.
Be sure that all necessary tools and test
equipment are available and ready for use.
Observe and Obey:
Read each appropriate fault code thoroughly.
Troubleshooting and repair procedures shall be Attempting short cuts may produce hazardous
completed by a person trained and qualified on conditions.
the repair of this machine.
Be aware of the following hazards and follow
Immediately tag and remove from service a generally accepted safe workshop practices.
damaged or malfunctioning machine.
Crushing hazard. When testing
Repair any machine damage or malfunction or replacing any hydraulic
before operating the machine. component, always support
the structure and secure it
Unless otherwise specified, perform each from movement.
repair procedure with the machine in the
following configuration: Electrocution/burn hazard. Contact
· Machine parked on a firm, level surface with electrically charged circuits
could result in death or serious
· Platform in the stowed position injury. Remove all rings, watches
· Key switch in the off position with the key and other jewelry.
removed
Bodily injury hazard. Spraying
· The red Emergency Stop button in the off hydraulic oil can penetrate and
position at both ground and platform controls burn skin. Loosen hydraulic
· Wheels chocked connections very slowly to allow
the oil pressure to dissipate
· All external AC power supply disconnected gradually. Do not allow oil to
from the machine squirt or spray.

Part No. 97385 GS-30 • GS-32 • GS-46 5-1


Section 5 • Fault Codes March 2007

FAULT CODES

About This Section LED Diagnostic Readout


When a malfunction is discovered, the fault code
charts in this section will help a service
professional pinpoint the cause of the problem.
To use this section, basic hand tools and certain
pieces of test equipment are required —
voltmeter, ohmmeter, pressure gauges.

General Repair Process

The diagnostic readout displays numerical codes


that provide information about the machine
Malfunction Identify Troubleshoot operating status and about malfunctions. The dot
discovered symptoms to the right of the numbers remain on when a
fault code is displayed.
problem
still exists The codes listed in the Fault Code Chart
describe malfunctions and can aid in
Return to Perform
troubleshooting the machine by pinpointing the
Inspect
service and test repair area or component affected.
problem
solved

5-2 GS-30 • GS-32 • GS-46 Part No. 97385


March 2007 Section 5 • Fault Codes

REV C
Fault Code Chart

Fault Code Problem Possible Causes Solution


01 Internal ECM error. EPROM not programmed. Replace ECM.

Malfunctioning control cable Troubleshoot control cable


ECM/Platform
02 communication error.
OR malfunctioning platform
controls.
OR troubleshoot platform
controls.
Undefined platform DIP DIP switch settings
03 switch settings. incorrect.
Correct DIP switch settings.

Chassis up/down toggle Malfunctioning up/down Troubleshoot up/down


12 closed at start up. switch. switch.
Malfunctioning pothole
Troubleshoot pothole switch
18 Pothole guard failure. switch OR obstruction in
OR remove obstruction.
pothole guard linkage.
Malfunctioning limit switch
Troubleshoot limit switch
19 Limit switch failure. OR wire disconnected from
limit switch.
OR inspect wire connection.

Platform left turn switch Malfunctioning steer left Troubleshoot steer left
42 fault. microswitch. microswitch.
Platform right turn switch Malfunctioning steer right Troubleshoot steer right
43 fault. microswitch. microswitch.
Platform drive enable Malfunctioning drive enable Troubleshoot drive enable
46 switch fault. switch. switch.
Joystick potentiometer not
47 Platform joystick fault.
centered.
Verify potentiometer setting.

Malfunctioning coil OR wire Troubleshoot coil OR


52 Forward coil fault.
disconnected from coil. inspect wire connection.
Malfunctioning coil OR wire Troubleshoot coil OR
53 Reverse coil fault.
disconnected from coil. inspect wire connection.
Up coil fault. (Not used on Malfunctioning coil OR wire Troubleshoot coil OR
54 GS-3232) disconnected from coil. inspect wire connection.
Malfunctioning coil OR wire Troubleshoot coil OR
55 Down coil fault.
disconnected from coil. inspect wire connection.
Malfunctioning coil OR wire Troubleshoot coil OR
56 Steer right coil fault.
disconnected from coil. inspect wire connection.
Malfunctioning coil OR wire Troubleshoot coil OR
57 Steer left coil fault.
disconnected from coil. inspect wire connection.
Malfunctioning coil OR wire Troubleshoot coil OR
58 Brake coil fault.
disconnected from coil. inspect wire connection.
DIP switch settings are Troubleshoot and correct
59 Series/parallel coil fault.
incorrect. DIP switch settings.

68 Low battery voltage. Batteries discharged. Charge batteries.

Tilt of chassis exceeds level


LL Off level fault.
sensor setting
Reduce chassis angle.

Too much weight in


OL Overload cutout fault.
platform
Remove weight.

Part No. 97385 GS-30 • GS-32 • GS-46 5-3


Section 5 • Fault Codes November 2007

FAULT CODES REV B

Outrigger Control Pad


The outrigger control pad displays solid red or
blinking red lights, as well as a audible alarm
that provide information about the outrigger
operating status and about malfunctions.

The codes listed in the Outrigger Fault Code


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

f c

e d

Outrigger Control Pad

a lift enable
b lift error
c right front outrigger
d right rear outrigger
e left rear outrigger
f left front outrigger

5-4 GS-30 • GS-32 • GS-46 Part No. 97385


November 2007 Section 5 • Fault Codes

REV B
Outrigger Fault Code Chart
Fault Code Problem Possible Causes Solution
Lift error light Up coil fault. Malfunctioning coil OR Troubleshoot coil OR
blinks red 2 wire disconnected from inspect wire connection.
times. coil.
Left front Left front outrigger Malfunctioning coil OR Troubleshoot coil OR
outrigger light coil fault. wire disconnected from inspect wire connection.
blinks red 2 coil.
times.
Right front Right front Malfunctioning coil OR Troubleshoot coil OR
outrigger light outrigger coil fault. wire disconnected from inspect wire connection.
blinks red 2 coil.
times.
Right rear Right rear Malfunctioning coil OR Troubleshoot coil OR
outrigger light outrigger coil fault. wire disconnected from inspect wire connection.
blinks red 2 coil.
times.
Left rear Left rear outrigger Malfunctioning coil OR Troubleshoot coil OR
outrigger light coil fault. wire disconnected from inspect wire connection.
blinks red 2 coil.
times.
Left front Left front outrigger Ground short OR wire Inspect wire connection.
outrigger light pressure disconnected from
blinks red 3 transducer fault. pressure transducer.
times.
Right front Right front Ground short OR wire Inspect wire connection.
outrigger light outrigger pressure disconnected from
blinks red 3 transducer fault. pressure transducer.
times.
Right rear Right rear Ground short OR wire Inspect wire connection.
outrigger light outrigger pressure disconnected from
blinks red 3 transducer fault. pressure transducer.
times.
Left rear Left rear outrigger Ground short OR wire Inspect wire connection.
outrigger light pressure disconnected from
blinks red 3 transducer fault. pressure transducer.
times.
Left front Left front outrigger Short to power. Troubleshoot the harness to
outrigger light pressure the pressure transducer OR
blinks red 4 transducer fault. replace the harness.
times.
Right front Right front Short to power. Troubleshoot the harness to
outrigger light outrigger pressure the pressure transducer OR
blinks red 4 transducer fault. replace the harness.
times.

Outrigger fault code chart cotinued on next page.

Part No. 97385 GS-30 • GS-32 • GS-46 5-5


Section 5 • Fault Codes November 2007

OUTRIGGER FAULT CODES cont. REV B

Fault Code Problem Possible Causes Solution


Right rear outrigger light Right rear Short to power. Troubleshoot the
blinks red 4 times. outrigger harness to the
pressure pressure transducer
transducer OR replace the
fault. harness.
Left rear outrigger light Left rear Short to power. Troubleshoot the
blinks red 4 times. outrigger harness to the
pressure pressure transducer
transducer OR replace the
fault. harness.
Outrigger lights blink red, Outrigger level Ground short OR wire Inspect wire
alternating front to rear. sensor fault. disconnected from level connection.
sensor.
Outrigger lights blink red, Outrigger level Short to power. Troubleshoot the
alternating left to right. sensor fault. harness to the
outrigger sensor OR
replace the harness.
Outrigger lights blink red Extend coil Malfunctioning coil OR Troubleshoot coil OR
in a clockwise sequence. fault. wire disconnected from inspect wire
coil. connection.
Outrigger lights blink red Retract coil Malfunctioning coil OR Troubleshoot coil OR
in a counter clockwise fault. wire disconnected from inspect wire
sequence. coil. connection.
All lights turn red on initial No calibration Outrigger level sensor Calibrate the outrigger
power up and the alarm data. and pressure level sensor and
sounds. transducers not pressure transducers.
calibrated.
During operation, all lights Motor controller Motor controller throttle Troubleshoot the
turn red and all functions fault. short. harness to the motor
cut out. controller OR replace
the harness.
After auto-leveling the Outrigger off Machine is out of level Relocate the machine
machine, all lights turn level fault. OR all outriggers are not OR redeploy the
red and the alarm in contact with the outriggers.
sounds. ground.
All lights turn red and the Outrigger level Outrigger level sensor Troubleshoot outrigger
alarm sounds. (Only while sensor fault. installed incorrectly OR level sensor.
calibrating the outrigger the machine in not on
level sensor.) level ground.
All lights turn red and the Outrigger Pressure transducer Make sure the
alarm sounds. (Only while pressure installed incorrectly, in pressure transducers
calibrating the outrigger transducer improper position, or are wired correctly and
pressure transducers.) fault. faulty. functioning properly.
Individual OR light turns Outrigger has Slope too steep to level Retract outriggers and
solid red and the alarm reached End of machine. repeat auto level
sounds. (While auto Stroke. (EOS) procedure.
leveling.)

5-6 GS-30 • GS-32 • GS-46 Part No. 97385


March 2007 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/burn hazard.


Contact with electrically charged
Troubleshooting and repair procedures shall be circuits could result in death or
completed by a person trained and qualified on serious injury. Remove all rings,
the repair of this machine. watches and 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
gradually. Do not allow oil to squirt
Read, understand and obey the safety rules
or spray.
and operating instructions in the appropriate
operator's manual on your machine. General Repair Process
Be sure that all necessary tools and test
equipment are available and ready for use.
Malfunction Identify Troubleshoot
discovered symptoms

problem
still exists

Return to Inspect Perform


service problem and test repair
solved

Part No. 97385 GS-30 • GS-32 • GS-46 6-1


Section 6 • Schematics March 2007

Electrical Component Legend


REV C

ELECTRICAL COMPONENT LEGEND ELECTRICAL COMPONENT LEGEND cont.


Item Description Item Description
B5 Battery P Power switch
BN Button P1 = Emergency Stop button at ground controls
BN5 = Horn P2 = Emergency Stop button at platform controls
BN6 = High torque PS2 Platform overload pressure switch (option)
BN8 = Drive select PT Pressure transducer
BN9 = Lift select PT1 = Left front outrigger (GS-3232)
BN105 = Outrigger extend (GS-3232) PT2 = Right front outrigger (GS-3232)
BN106 = Outrigger function enable (GS-3232) PT3 = Right rear outrigger (GS-3232)
BN107 = Outrigger retract (GS-3232) PT4 = Left rear outrigger (GS-3232)
C5 Capacitor, 4700 uF QD Quick disconnect
CB2 Circuit breaker, 7A QD1 = Battery quick disconnect
CR Control relay QD3 = Control cable to ground
CR5 = Horn relay (with H2 option) QD4 = Control cable to platform
CR27A = Overload (motor controller) (option) QD20 = Cable to outrigger control pad (GS-3232)
CR27B = Overload (load sense) (option) R Resistor
CR27C = Overload (down coil) (option) R24 = 25 ohm
CR27D = Overload (down delay) (option) SW Switch
CR48 = Power relay to U5 (e-stop)
SW5 = Function enable
D7 Voltage regulator (Platform controls circuit board) SW6 = Steer left/right
F6 Fuse, 275A S Sensor
FB Flashing beacons S7 = Tilt level sensor
G Gauge S8 = 2 axis tilt level sensor (GS-3232)
G6 = Hour meter TS66 Platform up/down toggle switch
G8 = Diagnostic Display U Electronic component
GND Ground U3 = Platform controls printed circuit board
H Horn or alarm U5 = Electronic control module
H1 = Horn U6 = Motor controller
H2 = Automotive-style horn (option) U9 = Battery charger
H5 = Multifunction alarm U13 = Voltage inverter (option)
H8 = Multifunction alarm outrigger control pad (GS-3232) U27 = 47 mH inductor, noise suppression
JC1 Joystick controller U36 = Outrigger control printed circuit board (GS-3232)
KS1 Key switch U39 = Outrigger control CPU (GS-3232)
L LED or light U40 = Outrigger control power supply chip (GS-3232)
L16 = Lift U41 = Outrigger control transmit/receive chip (GS-3232)
L17 = Drive U42 = Outrigger electronic control module (GS-3232)
L21 = High torque Y Valve coil
L30 = Work light (option) Y1 = Parallel (GS-2032, GS-2632 and all GS-46)
L51 = LF outrigger (GS-3232) Y3 = Steer right
L52 = RF outrigger (GS-3232) Y4 = Steer left
L53 = LR outrigger (GS-3232) Y5 = Drive reverse
L54 = RR outrigger (GS-3232) Y6 = Drive forward
L69 = Lift enable (outrigger control pad) (GS-3232) Y7 = Platform down
L70 = Lift error (outrigger control pad) (GS-3232) Y8 = Platform up
LS Limit switch Y9 = Platform down (GS-3246)
LS5 = Platform up (option) Y33 = Left rear outrigger (GS-3232)
LS5A = Up Limit Switch (GS-3232) Y34 = Right rear outrigger (GS-3232)
LS5B = Up Limit Switch (GS-3232) Y35 = Left front outrigger (GS-3232)
LS6 = Platform down Y36 = Right front outrigger (GS-3232)
LS7 = Pothole Y39 = Outrigger retract (GS-3232)
LS8 = Pothole Y40 = Outrigger extend (GS-3232)
M5 Hydraulic power unit
NC Normally closed
NCHO Normally closed held open
NOHC Normally open held closed

6-2 GS-30 • GS-32 • GS-46 Part No. 97385


March 2007 Section 6 • Schematics

Wire Color Legend


REV B

WIRE COLOR LEGEND


Color Description
BK Black
BL Blue
BL/BK Blue/Black
BL/WH Blue/White
BN Brown
GN Green
GN/BK Green/Black
GN/WH Green/White
GY Gray
OR Orange
OR/BK Orange/Black
OR/WH Orange/White
PP Purple
RD Red
RD/BK Red/Black
RD/WH Red/White
WH White
WH/BK White/Black

Part No. 97385 GS-30 • GS-32 • GS-46 6-3


Section 6 • Schematics April 2008

ECM Pin-out Legend


REV D

ECM PIN-OUT LEGEND


Item Description
A1 Flashing beacon FB (output)
A2 Ground from platform controls (input)
(W hite wire at platform controls)
A3 Plug
C 1 12
A4 Driv er power (input)
A5 Level sensor power S7 (output ) B 1 12
A6 Platform up coil Y8 (output)
A7 Driv e revers e coil Y5 (output) A 1 12
A8 Motor controller U6, terminal 1
A9 Motor controller U6, terminal 3
A 10 Overload sens or PS2 (input)
A 11 Key switch to platform control (input)
A 12 Platform down TS66 (input)

B1 Platform data link (high) (input)


(Blue wire at platform controls)
B2 Plug
B3 ECM ground (output)
B4 Plug
B5 Plug
B6 Platform down coil Y7 (output)
B7 Steer left coil Y4 (output)
B8 Automotive-style horn H2 (option) (output)
B9 Multi-function alarm H5 (output)
B 10 Pothole limit switch (input)
B 11 Driv e enable power/up limit switch (input)
B 12 Platform up TS66 (input)

C1 Platform data link (low) (input)


(O range wire at platform controls)
C2 Power from platform controls to ECM (input)
(Red wire at platform c ontrols)
C3 Plug
C4 Plug
C5 Not used
C6 Driv e forward coil Y6 (output)
C7 Steer right c oil Y3 (output)
C8 Parallel coil Y1
(not available on GS-1530/32 and GS-1930/32)
C9 Work light L30 (option)
C10 Not used
C11 Level sensor s ignal S7 (input)
C12 Down limit s witc h LS66 (input)

6-4 GS-30 • GS-32 • GS-46 Part No. 97385


March 2007 Section 6 • Schematics

Outrigger ECM Pin-out Legend


REV A

OUTRIGGER ECM PIN-OUT LEGEND


Item Description
A1 24V C
A2 24V CC
A3 Right rear outrigger pressure transducer signal
C 1 12 (input)
A4 Right front outrigger pressure transducer signal
B 1 12 (input)
A5 Left rear outrigger pressure transducer signal
A 1 12 (input)
A6 Left front outrigger pressure transducer signal
(input)
A7 2 axis tilt level sensor - pitch S8 (input)
A8 2 axis tilt level sensor - roll S8 (input)
A9 Outrigger data link (high) (input)
A10 Outrigger data link (lo) (input)
A11 Power for platform controller (output)
A12 Ground for platform controller (output)

B1 Outrigger ECM ground (input)


B2 Plug
B3 Plug
B4 Motor controller throttle (output)
B5 Motor controller enable (input)
B6 Height limit signal (input)
B7 Down limit switch LS66 (input)
B8 Key switch KS1 (input)
B9 Up signal from Gen 5 ECM U5 (input)
B10 Drive reverse Y5 (input)
B11 Drive forward Y6 (input)
B12 24V A

C1 24V B
C2 Plug
C3 Outrigger retract Y39 (output)
C4 Outrigger extend Y40 (output)
C5 Left front outrigger Y35 (output)
C6 Right front outrigger Y36 (output)
C7 Left rear outrigger Y33 (output)
C8 Right rear outrigger Y34 (output)
C9 Motor controller enable (output)
C10 Outrigger transducer, 2 axis tilt level sensor S8
and up limit switch LS5A power (output)
C11 Platform up Y8 (output)
C12 Drive enable

Part No. 97385 GS-30 • GS-32 • GS-46 6-5


Section 6 • Schematics February 2009

Wiring Diagram
Ground Controls and Level Sensor Harness REV B

WH
GROUND CONTROLS
MOTOR CONTROLLER B
TERMINAL B+
RD 1 2 CB2 KS1
7A CIRCUIT KEY SWITCH 3 WH 1
BREAKER
B1

4 2
MOTOR CONTROLLER WH
TERMINAL 1 +
RD
6-PIN CONNECTOR
G6
WH/BK HOUR METER
PIN 1 (J7) -

RD
ECM PIN B12 (J1) 1 (UP)
WH TS66
2 PLATFORM UP/DOWN
BL TOGGLE SWITCH
ECM PIN A12 (J1) 3 (DOWN)
CR48
RD
TERMINAL 30
OR
ECM PIN A1(J1)
P1
1 2 EMERGENCY STOP
WH
NC

LEVEL SENSOR HARNESS


(ANSI AND CSA MODELS)
H5
MULTI-FUNCTION
LS6 ALARM
DOWN LIMIT SWITCH
S7
LEVEL SENSOR
(SHOWN IN STOWED POSITION)
- 1 BL
ECM PIN B9

2
+ OR/BK
CR48 TERMINAL 87

13 14 WH 3 BK
CR48 TERMINAL 87
NOHC
BK 4 RD/BK
ECM PIN C12
RD BK WH
5 GN
ECM PIN C11
6 BN
GROUND
7 RD
ECM PIN A5
8
NOT USED

LEVEL SENSOR HARNESS


(CE MODELS AND
ANSI/CSA MODELS WITH PLATFORM OVERLOAD)
H5
MULTI-FUNCTION
LS6 ALARM
DOWN LIMIT SWITCH
S7
LEVEL SENSOR
(SHOWN IN STOWED POSITION)
- 1 BL
ECM PIN B9

2
+ OR/BK
CR48 TERMINAL 87

13 14 WH 3 BK
CR48 TERMINAL 87
NOHC
21 22
RD BK WH
NCHO
BK 4 RD/BK
ECM PIN C12
5 GN
ECM PIN C11
6 BN
GROUND
7 RD
ECM PIN A5
8
NOT USED
WH
CR27D TERMINALS
85, 87 AND 87A
BK
ECM PIN B6

6-6 GS-30 • GS-32 • GS-46 Part No. 97385


March 2007 Section 6 • Schematics

Wiring Diagram
REV B Platform Control Box and Outrigger Control Pad

PLATFORM
CONTROLS
(GEN 5)
RD
BK

JC1
JOYSTICK
H1 CONTROLLER
ALARM
TO COIL CORD
BK RD GY BK

WH

RD

BL

OR
RD
1 4.
WH/BL

NC 1
WH

OR
RD

GY
BN

BK

PP
BL
YL

P2
2 5.

EMERGENCY
STOP

TO COIL CORD
WH
GN
RD
BK

L69
LIFT ENABLE

L70
U36 LIFT ERROR
OUTRIGGER
PLATFORM CONTROL
CIRCUIT BOARD

OUTRIGGER L51 L52


CONTROL PAD LF OUTRIGGER RF OUTRIGGER

GS-3232

L53 L54
LR OUTRIGGER RR OUTRIGGER

BN107 BN106 BN105


OUTRIGGER FUNCTION OUTRIGGER
RETRACT ENABLE EXTEND

Part No. 97385 GS-30 • GS-32 • GS-46 6-7


Section 6 • Schematics March 2007

Limit Switch Legend


REV C

a b b a d
GS-2032
GS-2632
GS-3232
GS-2046
GS-2646
GS-3246
GS-1530
GS-1532
GS-1930
GS-1932

ALL MODELS
c

Limit Switch Legend

a maximum height limit switch LS5 (CE models)


b down limit switch LS6
c pothole switches LS7, LS8
d 22 ft / 6.7 m maximum drive height when outriggers are not deployed LS5A (GS-3232)

6-8 GS-30 • GS-32 • GS-46 Part No. 97385


March 2007 Section 6 • Schematics

Electrical Symbols Legend


REV B

N.C.
T2 B+
N.O.

A2 3
MOTOR CONTR. ENABLE

Pressure switch, B- 1
LEVEL SENSOR
CIRCUIT BOARD

normally open
S7
Motor controller LEVEL
N.C. N.O. N.C.H.O. N.O.H.C. SENSOR

D1 Level sensor
M5
Limit switch
Wire with description
A1

Motor

Button or switch U9 Solenoid valve

Circuits crossing no
connection

Battery charger
Toggle switch Solenoid valve with diode
Diode -
+

6V DC Battery
Emergency stop button
Capacitor
Circuits connection
CB2

WH B 1 OR
Circuit breaker
2
Connector KS1
KEY PLATFORM
SWITCH CONTROL
30 86

B1 4
87A 87 85

3
Control relay
GROUND
CONTROL

Hour meter Key switch


Fuse

JC1
HALL JOYSTICK
GENERATOR CONTROLLER

Horn or alarm SW6


Light or STEER LEFT/ RIGHT

flashing beacon
RIGHT
LEFT

SW5
FUNCTION
ENABLE

Joystick
Inductor, LED
noise suppression

Part No. 97385 GS-30 • GS-32 • GS-46 6-9


Section 6 • Schematics April 2008

Electrical Schematic
ANSI, CSA and Australia Models REV E
GS-1530/1532/1930/1932 (from serial number GS3005A-76000 to GS3006A-83067)
GS-1530/1532/1930/1932 (from serial number GS3005B-76000 to GS3006B-79659)

6 - 10 GS-30 • GS-32 • GS-46 Part No. 97385


April 2008 Section 6 • Schematics

Electrical Schematic
REV E ANSI, CSA and Australia Models
GS-1530/1532/1930/1932 (from serial number GS3005A-76000 to GS3006A-83067)
GS-1530/1532/1930/1932 (from serial number GS3005B-76000 to GS3006B-79659)
- NOTE -
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF QD4
RD RD 4 4
WH WH 3 3
BL 1 1
30 4 86
CR48
POWER BK 2 2
RELAY TO U5
87 85 OR 5 5
(E-STOP)

N.O.H.C.

LS6
DOWN
LIMIT
SWITCH

RD

WH
N.O.

LEVEL
SENSOR
CIRCUIT
BOARD
ECM POWER

UP LIMIT SWITCH

DWN LIMIT

OVERLOAD POWER

DRIVER POWER

DATA LINK (HIGH)


DATA LINK (LOW)
GND FROM JOYSTICK

LVL SNSR - WHT

LVL SNSR - RED


S7
LEVEL
SENSOR

BK
OR/BK

RD/BK

BL/BK

WH

OR

GN

RD
BK
BK

BL

C2 B11 C12 A10 A4 A2 B1 C1 C11 A5


IN IN IN IN IN IN IN IN IN OUT

U5
ELECTRONIC CONTROL MODULE

OUT OUT OUT OUT OUT OUT OUT


C8 C7 B7 A7 C6 B6 A6
BL

WH/BK

WH
GN/BK

GN/BK
RD/BK

BL/BK

Y1 Y3 Y4 Y5 Y6 Y9 Y7 Y8
PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM
RIGHT LEFT REVERSE FORWARD DOWN DOWN UP
(GS-3246)

GND

ES0141H

Part No. 97385 GS-30 • GS-32 • GS-46 6 - 11


Section 6 • Schematics April 2008

Electrical Schematic
ANSI, CSA and Australia Models REV E
GS-1530/1532/1930/1932 (from serial number GS3005A-76000 to GS3006A-83067)
GS-1530/1532/1930/1932 (from serial number GS3005B-76000 to GS3006B-79659)

P2
EMERGENCY
QD3 STOP
BK
4 4 BK POWER TO PLATFORM
RD
3 3 RD POWER TO GROUND

1 1 WH GROUND PIO3
PIO2
2 2 BL DATA LINK (HIGH) PIO4

5 5 OR DATA LINK (LOW) PIO5


24V DC

U3 D7 5V DC

PLATFORM CONTROLS VOLTAGE


PRINTED CIRCUIT BOARD REGULATOR

BN HALL EFFECT JC1


GENERATOR JOYSTICK
GY CONTROLLER

GN
WH
BL

SW5 SW6
PP FUNCTION ENABLE STEER
LEFT/ RIGHT
OR
LEFT

RIGHT

PIN9
BK
PIN8
RD
PIN10

BK
PLATFORM CONTROLS
MEMBRANE DECAL
POUT1 LIFT LED L16
POUT2 DRIVE LED L17
POUT3 HIGH TORQUE LED L21

G8
POUT4 DIAGNOSTIC
DISPLAY

PIN1 HIGH TORQUE BN6

PIN2 HORN BN5

PIN3 DRIVE ENABLE BN8

PIN4 LIFT ENABLE BN9

RD
POUT11 +

BK
H1
ALARM
PLATFORM
PIN11 - CONTROLLER

ES0141H

6 - 12 GS-30 • GS-32 • GS-46 Part No. 97385


April 2008 Section 6 • Schematics

This page intentionally left blank.

Part No. 97385 GS-30 • GS-32 • GS-46 6 - 13


Section 6 • Schematics April 2008

Electrical Schematic
ANSI, CSA and Australia Models REV C
GS-1530/1532/1930/1932 (from serial number GS3006A-83068 to GS3007A-87490)
GS-1530/1532/1930/1932 (from serial number GS3006B-79660 to GS3007B-82543)

6 - 14 GS-30 • GS-32 • GS-46 Part No. 97385


April 2008 Section 6 • Schematics

Electrical Schematic
REV C ANSI, CSA and Australia Models
GS-1530/1532/1930/1932 (from serial number GS3006A-83068 to GS3007A-87490)
GS-1530/1532/1930/1932 (from serial number GS3006B-79660 to GS3007B-82543)
- NOTE -
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF QD4
RD RD 4 4
WH WH 3 3
BL 1 1
30 4 86
CR48
POWER BK 2 2
RELAY TO U5
87 85 OR 5 5
(E-STOP)

N.O.H.C.

LS6
DOWN
LIMIT
SWITCH

RD

WH
N.O.

LEVEL
SENSOR
CIRCUIT
BOARD
ECM POWER

UP LIMIT SWITCH

DWN LIMIT

OVERLOAD POWER

DRIVER POWER

DATA LINK (HIGH)


DATA LINK (LOW)
GND FROM JOYSTICK

LVL SNSR - WHT

LVL SNSR - RED


S7
LEVEL
SENSOR

BK
OR/BK

RD/BK

BL/BK

WH

OR

GN

RD
BK
BK

BL

C2 B11 C12 A10 A4 A2 B1 C1 C11 A5


IN IN IN IN IN IN IN IN IN OUT

U5
ELECTRONIC CONTROL MODULE

OUT OUT OUT OUT OUT OUT OUT


C8 C7 B7 A7 C6 B6 A6
BL

WH/BK

WH
GN/BK

GN/BK
RD/BK

BL/BK

Y1 Y3 Y4 Y5 Y6 Y9 Y7 Y8
PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM
RIGHT LEFT REVERSE FORWARD DOWN DOWN UP
(GS-3246)

GND

ES0141K

Part No. 97385 GS-30 • GS-32 • GS-46 6 - 15


Section 6 • Schematics April 2008

Electrical Schematic
ANSI, CSA and Australia Models REV C
GS-1530/1532/1930/1932 (from serial number GS3006A-83068 to GS3007A-87490)
GS-1530/1532/1930/1932 (from serial number GS3006B-79660 to GS3007B-82543)

P2
EMERGENCY
QD3 STOP
BK
4 4 BK POWER TO PLATFORM
RD
3 3 RD POWER TO GROUND

1 1 WH GROUND PIO3
PIO2
2 2 BL DATA LINK (HIGH) PIO4

5 5 OR DATA LINK (LOW) PIO5


24V DC

U3 D7 5V DC

PLATFORM CONTROLS VOLTAGE


PRINTED CIRCUIT BOARD REGULATOR

BN HALL EFFECT JC1


GENERATOR JOYSTICK
GY CONTROLLER

GN
WH
BL

SW5 SW6
PP FUNCTION ENABLE STEER
LEFT/ RIGHT
OR
LEFT

RIGHT

PIN9
BK
PIN8
RD
PIN10

BK
PLATFORM CONTROLS
MEMBRANE DECAL
POUT1 LIFT LED L16
POUT2 DRIVE LED L17
POUT3 HIGH TORQUE LED L21

G8
POUT4 DIAGNOSTIC
DISPLAY

PIN1 HIGH TORQUE BN6

PIN2 HORN BN5

PIN3 DRIVE ENABLE BN8

PIN4 LIFT ENABLE BN9

RD
POUT11 +

BK
H1
ALARM
PLATFORM
PIN11 - CONTROLLER

ES0141K

6 - 16 GS-30 • GS-32 • GS-46 Part No. 97385


April 2008 Section 6 • Schematics

This page intentionally left blank.

Part No. 97385 GS-30 • GS-32 • GS-46 6 - 17


Section 6 • Schematics April 2008

Electrical Schematic
ANSI, CSA and Australia Models REV B
GS-1530/1532/1930/1932 (from serial number GS3007A-87491 to GS3007A-89537)
GS-1530/1532/1930/1932 (from serial number GS3007B-82544 to GS3007B-84599)

6 - 18 GS-30 • GS-32 • GS-46 Part No. 97385


April 2008 Section 6 • Schematics

Electrical Schematic
REV B ANSI, CSA and Australia Models
GS-1530/1532/1930/1932 (from serial number GS3007A-87491 to GS3007A-89537)
GS-1530/1532/1930/1932 (from serial number GS3007B-82544 to GS3007B-84599)
- NOTE -
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF QD4
RD RD 4 4
WH WH 3 3
BL 1 1
30 4 86
CR48
POWER BK 2 2
RELAY TO U5
87 85 OR 5 5
(E-STOP)

N.O.H.C.

LS6
DOWN
LIMIT
SWITCH

RD

WH
N.O.

LEVEL
SENSOR
CIRCUIT
BOARD
DRIVER POWER

UP LIMIT SWITCH

DWN LIMIT

OVERLOAD POWER

ECM POWER

DATA LINK (HIGH)


DATA LINK (LOW)
GND FROM JOYSTICK

LVL SNSR - WHT

LVL SNSR - RED


S7
LEVEL
SENSOR

BK
OR/BK

RD/BK

BL/BK

WH

OR

GN

RD
BK
BK

BL

A4 B11 C12 A10 C2 A2 B1 C1 C11 A5


IN IN IN IN IN IN IN IN IN OUT

U5
ELECTRONIC CONTROL MODULE

OUT OUT OUT OUT OUT OUT OUT


C8 C7 B7 A7 C6 B6 A6
BL

WH/BK

WH
GN/BK

GN/BK
RD/BK

BL/BK

Y1 Y3 Y4 Y5 Y6 Y9 Y7 Y8
PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM
RIGHT LEFT REVERSE FORWARD DOWN DOWN UP
(GS-3246)

GND

ES0141M

Part No. 97385 GS-30 • GS-32 • GS-46 6 - 19


Section 6 • Schematics April 2008

Electrical Schematic
ANSI, CSA and Australia Models REV B
GS-1530/1532/1930/1932 (from serial number GS3007A-87491 to GS3007A-89537)
GS-1530/1532/1930/1932 (from serial number GS3007B-82544 to GS3007B-84599)

P2
EMERGENCY
QD3 STOP
BK
4 4 BK POWER TO PLATFORM
RD
3 3 RD POWER TO GROUND

1 1 WH GROUND PIO3
PIO2
2 2 BL DATA LINK (HIGH) PIO4

5 5 OR DATA LINK (LOW) PIO5


24V DC

U3 D7 5V DC

PLATFORM CONTROLS VOLTAGE


PRINTED CIRCUIT BOARD REGULATOR

BN HALL EFFECT JC1


GENERATOR JOYSTICK
GY CONTROLLER

GN
WH
BL

SW5 SW6
PP FUNCTION ENABLE STEER
LEFT/ RIGHT
OR
LEFT

RIGHT

PIN9
BK
PIN8
RD
PIN10

BK
PLATFORM CONTROLS
MEMBRANE DECAL
POUT1 LIFT LED L16
POUT2 DRIVE LED L17
POUT3 HIGH TORQUE LED L21

G8
POUT4 DIAGNOSTIC
DISPLAY

PIN1 HIGH TORQUE BN6

PIN2 HORN BN5

PIN3 DRIVE ENABLE BN8

PIN4 LIFT ENABLE BN9

RD
POUT11 +

BK
H1
ALARM
PLATFORM
PIN11 - CONTROLLER

ES0141M

6 - 20 GS-30 • GS-32 • GS-46 Part No. 97385


April 2008 Section 6 • Schematics

This page intentionally left blank.

Part No. 97385 GS-30 • GS-32 • GS-46 6 - 21


Section 6 • Schematics April 2008

Electrical Schematic
ANSI, CSA and Australia Models REV C
GS-1530/1532/1930/1932 (after serial number GS3007A-89537)
GS-1530/1532/1930/1932 (after serial number GS3007B-84599)

6 - 22 GS-30 • GS-32 • GS-46 Part No. 97385


April 2008 Section 6 • Schematics

Electrical Schematic
REV C ANSI, CSA and Australia Models
GS-1530/1532/1930/1932 (after serial number GS3007A-89537)
GS-1530/1532/1930/1932 (after serial number GS3007B-84599)
QD4
GS-3232 ONLY

RD RD 4 4
WH WH 3 3
BL 1 1
BK 2 2

OR 5 5

30 86 GN MC THROTTLE
4
CR48 BK MC ENABLE (IN)
POWER BK 24V
87 85 RELAY TO U5 OR KS1
(E-STOP)
OR/BK DRIVE ENABLE
GS-3232 ONLY
GROUND
BK MC ENABLE (OUT)
RD/BK DOWN LIM
N.O.H.C.

BN GROUND

LS6
DOWN
LIMIT
SWITCH

UP IN
FORWARD
REVERSE
UP COIL
RD

WH
N.O.

BL/BK
WH
WH/BK
BL/BK
LEVEL
SENSOR
UP LIMIT SWITCH (GS-3232 ONLY)

CIRCUIT
BOARD
OVERLOAD POWER

DATA LINK (HIGH)


DATA LINK (LOW)
ECM POWER
GND FROM JOYSTICK

LVL SNSR - WHT


DWN LIMIT

LVL SNSR - RED


S7
LEVEL
DRIVER POWER

UP LIMIT SWITCH

SENSOR

BK
OR/BK

RD/BK

BL/BK

WH

OR

GN

RD
BK
BK

BL

A4 B11 C12 A10 C2 A2 B1 C1 C11 A5


IN IN IN IN IN IN IN IN IN OUT

NOT CONNECTED
ON GS-3232
NOT CONNECTED
U5 ON GS-3232
ELECTRONIC CONTROL MODULE

OUT OUT OUT OUT OUT OUT OUT


C8 C7 B7 A7 C6 B6 A6
GS-3232
ONLY
GN/BK
BL

WH/BK

WH
GN/BK

RD/BK

BL/BK

GS-3232 ONLY

Y1 Y3 Y4 Y5 Y6 Y9 Y7 Y8
PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM
RIGHT LEFT REVERSE FORWARD DOWN DOWN UP
(GS-3246)

GND

ES0141P

Part No. 97385 GS-30 • GS-32 • GS-46 6 - 23


Section 6 • Schematics April 2008

Electrical Schematic
ANSI, CSA and Australia Models REV C
GS-1530/1532/1930/1932 (after serial number GS3007A-89537)
GS-1530/1532/1930/1932 (after serial number GS3007B-84599)

GS-3232 ONLY +
L70
MC THROTTLE BN105 LIFT ERROR L69
MC ENABLE (IN) H8 LIFT ENABLE
24V
EXTEND - ALARM
KS1 BN107
DRIVE ENABLE U39
GN
25 OHMS RETRACT
GROUND BK CPU
10 WATT BN106
R24 L51 L52
MC ENABLE (OUT) AUTOLEVEL
FL OUTRIGGER FR OUTRIGGER
DOWN LIM OUTRIGGER
BK

UP IN CONTROL
U36 PRINTED
OR

FORWARD
OR/BK

CIRCUIT
RD/BK

REVERSE
BOARD
L53 L54
BL/BK

UP COIL
U41
U40
WH

TX / RX RL OUTRIGGER RR OUTRIGGER
WH/BK

POWER CHIP
BL/BK

SUPPLY
CHIP

1 4 3 2
BN

WH
QD20 GN
BK RD
BL

S8
2 AXIS
TILT LEVEL
MC ENABLE SENSOR

MC THROTTLE

GROUND TO PLAT

POWER TO PLAT

DATA (LOW)

DATA (HIGH)

GROUND
KEYSWITCH

MC ENABLE
DRIVE ENABLE

SWITCH POWER

POWER
PITCH
LS5A

ROLL
N.C.
UP
DOWN LIM

LIMIT
SWITCH

WH
BL
OR
BN
PT1 LS5B
RD/BK

N.C.
UP COIL

REVERSE

FORWARD

UP IN

(LF) UP
LIMIT
SWITCH
RD/BK

PT2
WH/BK

OR/BK
RD/BK

(RF)
BL/BK

BL/BK
WH

WH
OR

GN

GN
RD
BK

BK

BK

BL

PT3 C11 B10 B11 B9 B7 C1 A1 B6 C12 B8 C9 B5 B4 A12 A11 A10 A9


(RR) OUT IN IN IN IN IN IN IN OUT IN OUT IN OUT OUT OUT IN IN
LF XDCR RD A6 IN
RF XDCR OR A4 IN

PT4 RR XDCR GN A3 IN U42 IN A7 BL

(LR) LR XDCR BL A5 IN OUTRIGGER ELECTRONIC CONTROL MODULE IN A8 OR


POWER XDCR WHT C10 OUT
IN IN IN OUT OUT OUT OUT OUT OUT OUT
B1 A2 B12 C2 C3 C4 C5 C6 C7 C8
BN

BK

BK

GN/BK

GN

RD/WH

OR/WH

BL/WH

GN/WH
REGEN COIL (N/A ON 3232)
24V MAIN
GND

Y35 Y36 Y33 Y34


Y39 Y40 LEFT RIGHT LEFT RIGHT
RETRACT EXTEND FRONT FRONT REAR REAR

BK

GND BN

ES0141P

6 - 24 GS-30 • GS-32 • GS-46 Part No. 97385


April 2008 Section 6 • Schematics

Electrical Schematic
REV C ANSI, CSA and Australia Models
GS-1530/1532/1930/1932 (after serial number GS3007A-89537)
GS-1530/1532/1930/1932 (after serial number GS3007B-84599)
P2
EMERGENCY
QD3 STOP
BK
4 4 BK POWER TO PLATFORM
RD
- NOTE -
3 3 RD POWER TO GROUND
MACHINE SHOWN IN THE STOWED
1 1 WH GROUND PIO3
PIO2 POSITION WITH THE POWER OFF
2 2 BL DATA LINK (HIGH) PIO4

5 5 OR DATA LINK (LOW) PIO5


24V DC

U3 D7 5V DC

PLATFORM CONTROLS VOLTAGE


PRINTED CIRCUIT BOARD REGULATOR

BN HALL EFFECT JC1


GENERATOR JOYSTICK
GY CONTROLLER

GN
WH
BL

SW5 SW6
PP FUNCTION ENABLE STEER
LEFT/ RIGHT
OR
LEFT

RIGHT

PIN9
BK
PIN8
RD
PIN10

BK
PLATFORM CONTROLS
MEMBRANE DECAL
POUT1 LIFT LED L16
POUT2 DRIVE LED L17
POUT3 HIGH TORQUE LED L21

G8
POUT4 DIAGNOSTIC
DISPLAY

PIN1 HIGH TORQUE BN6

PIN2 HORN BN5

PIN3 DRIVE ENABLE BN8

PIN4 LIFT ENABLE BN9

RD
POUT11 +

BK
H1
ALARM
PLATFORM
PIN11 - CONTROLLER

ES0141P

Part No. 97385 GS-30 • GS-32 • GS-46 6 - 25


Section 6 • Schematics April 2008

Electrical Schematic
ANSI, CSA and Australia Models REV E
GS-2032/2632 (from serial number GS3205-75407 to GS3206-79991)
GS-2046/2646/3246 (from serial number GS4605-75438 to GS4606-78915)

6 - 26 GS-30 • GS-32 • GS-46 Part No. 97385


April 2008 Section 6 • Schematics

Electrical Schematic
REV E ANSI, CSA and Australia Models
GS-2032/2632 (from serial number GS3205-75407 to GS3206-79991)
GS-2046/2646/3246 (from serial number GS4605-75438 to GS4606-78915)
- NOTE -
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF QD4
RD RD 4 4
WH WH 3 3
BL 1 1
30 4 86
CR48
POWER BK 2 2
RELAY TO U5
87 85 OR 5 5
(E-STOP)

N.O.H.C.

LS6
DOWN
LIMIT
SWITCH

RD

WH
N.O.

LEVEL
SENSOR
CIRCUIT
BOARD
ECM POWER

UP LIMIT SWITCH

DWN LIMIT

OVERLOAD POWER

DRIVER POWER

DATA LINK (HIGH)


DATA LINK (LOW)
GND FROM JOYSTICK

LVL SNSR - WHT

LVL SNSR - RED


S7
LEVEL
SENSOR

BK
OR/BK

RD/BK

BL/BK

WH

OR

GN

RD
BK
BK

BL

C2 B11 C12 A10 A4 A2 B1 C1 C11 A5


IN IN IN IN IN IN IN IN IN OUT

U5
ELECTRONIC CONTROL MODULE

OUT OUT OUT OUT OUT OUT OUT


C8 C7 B7 A7 C6 B6 A6
BL

WH/BK

WH
GN/BK

GN/BK
RD/BK

BL/BK

Y1 Y3 Y4 Y5 Y6 Y9 Y7 Y8
PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM
RIGHT LEFT REVERSE FORWARD DOWN DOWN UP
(GS-3246)

GND

ES0141H

Part No. 97385 GS-30 • GS-32 • GS-46 6 - 27


Section 6 • Schematics April 2008

Electrical Schematic
ANSI, CSA and Australia Models REV E
GS-2032/2632 (from serial number GS3205-75407 to GS3206-79991)
GS-2046/2646/3246 (from serial number GS4605-75438 to GS4606-78915)

P2
EMERGENCY
QD3 STOP
BK
4 4 BK POWER TO PLATFORM
RD
3 3 RD POWER TO GROUND

1 1 WH GROUND PIO3
PIO2
2 2 BL DATA LINK (HIGH) PIO4

5 5 OR DATA LINK (LOW) PIO5


24V DC

U3 D7 5V DC

PLATFORM CONTROLS VOLTAGE


PRINTED CIRCUIT BOARD REGULATOR

BN HALL EFFECT JC1


GENERATOR JOYSTICK
GY CONTROLLER

GN
WH
BL

SW5 SW6
PP FUNCTION ENABLE STEER
LEFT/ RIGHT
OR
LEFT

RIGHT

PIN9
BK
PIN8
RD
PIN10

BK
PLATFORM CONTROLS
MEMBRANE DECAL
POUT1 LIFT LED L16
POUT2 DRIVE LED L17
POUT3 HIGH TORQUE LED L21

G8
POUT4 DIAGNOSTIC
DISPLAY

PIN1 HIGH TORQUE BN6

PIN2 HORN BN5

PIN3 DRIVE ENABLE BN8

PIN4 LIFT ENABLE BN9

RD
POUT11 +

BK
H1
ALARM
PLATFORM
PIN11 - CONTROLLER

ES0141H

6 - 28 GS-30 • GS-32 • GS-46 Part No. 97385


April 2008 Section 6 • Schematics

This page intentionally left blank.

Part No. 97385 GS-30 • GS-32 • GS-46 6 - 29


Section 6 • Schematics April 2008

Electrical Schematic
ANSI, CSA and Australia Models REV C
GS-2032/2632 (from serial number GS3206-79992 to GS3207-83650)
GS-2046/2646/3246 (from serial number GS4606-78916 to GS4607-82535)

6 - 30 GS-30 • GS-32 • GS-46 Part No. 97385


April 2008 Section 6 • Schematics

Electrical Schematic
REV C ANSI, CSA and Australia Models
GS-2032/2632 (from serial number GS3206-79992 to GS3207-83650)
GS-2046/2646/3246 (from serial number GS4606-78916 to GS4607-82535)
- NOTE -
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF QD4
RD RD 4 4
WH WH 3 3
BL 1 1
30 4 86
CR48
POWER BK 2 2
RELAY TO U5
87 85 OR 5 5
(E-STOP)

N.O.H.C.

LS6
DOWN
LIMIT
SWITCH

RD

WH
N.O.

LEVEL
SENSOR
CIRCUIT
BOARD
ECM POWER

UP LIMIT SWITCH

DWN LIMIT

OVERLOAD POWER

DRIVER POWER

DATA LINK (HIGH)


DATA LINK (LOW)
GND FROM JOYSTICK

LVL SNSR - WHT

LVL SNSR - RED


S7
LEVEL
SENSOR

BK
OR/BK

RD/BK

BL/BK

WH

OR

GN

RD
BK
BK

BL

C2 B11 C12 A10 A4 A2 B1 C1 C11 A5


IN IN IN IN IN IN IN IN IN OUT

U5
ELECTRONIC CONTROL MODULE

OUT OUT OUT OUT OUT OUT OUT


C8 C7 B7 A7 C6 B6 A6
BL

WH/BK

WH
GN/BK

GN/BK
RD/BK

BL/BK

Y1 Y3 Y4 Y5 Y6 Y9 Y7 Y8
PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM
RIGHT LEFT REVERSE FORWARD DOWN DOWN UP
(GS-3246)

GND

ES0141K

Part No. 97385 GS-30 • GS-32 • GS-46 6 - 31


Section 6 • Schematics April 2008

Electrical Schematic
ANSI, CSA and Australia Models REV C
GS-2032/2632 (from serial number GS3206-79992 to GS3207-83650)
GS-2046/2646/3246 (from serial number GS4606-78916 to GS4607-82535)

P2
EMERGENCY
QD3 STOP
BK
4 4 BK POWER TO PLATFORM
RD
3 3 RD POWER TO GROUND

1 1 WH GROUND PIO3
PIO2
2 2 BL DATA LINK (HIGH) PIO4

5 5 OR DATA LINK (LOW) PIO5


24V DC

U3 D7 5V DC

PLATFORM CONTROLS VOLTAGE


PRINTED CIRCUIT BOARD REGULATOR

BN HALL EFFECT JC1


GENERATOR JOYSTICK
GY CONTROLLER

GN
WH
BL

SW5 SW6
PP FUNCTION ENABLE STEER
LEFT/ RIGHT
OR
LEFT

RIGHT

PIN9
BK
PIN8
RD
PIN10

BK
PLATFORM CONTROLS
MEMBRANE DECAL
POUT1 LIFT LED L16
POUT2 DRIVE LED L17
POUT3 HIGH TORQUE LED L21

G8
POUT4 DIAGNOSTIC
DISPLAY

PIN1 HIGH TORQUE BN6

PIN2 HORN BN5

PIN3 DRIVE ENABLE BN8

PIN4 LIFT ENABLE BN9

RD
POUT11 +

BK
H1
ALARM
PLATFORM
PIN11 - CONTROLLER

ES0141K

6 - 32 GS-30 • GS-32 • GS-46 Part No. 97385


April 2008 Section 6 • Schematics

This page intentionally left blank.

Part No. 97385 GS-30 • GS-32 • GS-46 6 - 33


Section 6 • Schematics April 2008

Electrical Schematic
ANSI, CSA and Australia Models REV B
GS-2032/2632 (from serial number GS3207-83651 to GS3207-84866)
GS-2046/2646/3246 (from serial number GS4607-82536 to GS4607-84839)

6 - 34 GS-30 • GS-32 • GS-46 Part No. 97385


April 2008 Section 6 • Schematics

Electrical Schematic
REV B ANSI, CSA and Australia Models
GS-2032/2632 (from serial number GS3207-83651 to GS3207-84866)
GS-2046/2646/3246 (from serial number GS4607-82536 to GS4607-84839)
- NOTE -
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF QD4
RD RD 4 4
WH WH 3 3
BL 1 1
30 4 86
CR48
POWER BK 2 2
RELAY TO U5
87 85 OR 5 5
(E-STOP)

N.O.H.C.

LS6
DOWN
LIMIT
SWITCH

RD

WH
N.O.

LEVEL
SENSOR
CIRCUIT
BOARD
DRIVER POWER

UP LIMIT SWITCH

DWN LIMIT

OVERLOAD POWER

ECM POWER

DATA LINK (HIGH)


DATA LINK (LOW)
GND FROM JOYSTICK

LVL SNSR - WHT

LVL SNSR - RED


S7
LEVEL
SENSOR

BK
OR/BK

RD/BK

BL/BK

WH