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GS™-2032
GS™-2632 For detailed maintenance
GS™-2646
GS™-3246
GS™-4047
Part No. 1272217GT
Rev C
January 2019
Service and Repair Manual January 2019
Introduction
Intr oducti on Intr oducti on
Introduction
Revision History
Revision Date Section Procedure / Page / Description
A 3/2016 Initial Release
A1 5/2016 Repair Procedures 2-3, 2-4, 9-11
Diagnostics H067 fault
A2 5/2016 Repair Procedure 2-6
Diagnostics Type CXXX and UXXX fault codes
A3 9/2016 Introduction Serial Number Legend
Specifications Add drive speed stowed parameters
B 4/2017 Repair Procedure 11-1
Diagnostics Battery charger and fault codes
B1 12/2017 Schematics GS46, GS47 AS/CE
C 1/2019 All Sections Added GS-1330m
Reference Examples:
Section – Repair Procedure, 4-2 Electronic Version
Click on any content or procedure in the Table of Contents to view
Section – Fault Codes, All charts the update.
Section – Schematics, Legends and schematics
Introduction
Revision History(continued)
Revision Date Section Procedure / Page / Description
Reference Examples:
Section – Repair Procedure, 4-2 Electronic Version
Click on any content or procedure in the Table of Contents to view
Section – Fault Codes, All charts the update.
Section – Schematics, Legends and schematics
Introduction
Safety Rules
Section 1 Safety R ules
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.
Safety Rules
Read each procedure thoroughly. This Be sure to keep sparks, flames and
manual and the decals on the machine, lighted tobacco away from flammable and
use signal words to identify the following: combustible materials like battery gases
and engine fuels. Always have an
Safety alert symbol—used to alert approved fire extinguisher within easy
personnel to potential personal reach.
injury hazards. Obey all safety
messages that follow this symbol Be sure that all tools and working areas
to avoid possible injury or death. are properly maintained and ready for
use. Keep work surfaces clean and free of
Indicates a imminently hazardous debris that could get into machine
situation which, if not avoided, will components and cause damage.
result in death or serious injury.
Be sure any forklift, overhead crane or
Indicates a potentially hazardous other lifting or supporting device is fully
situation which, if not avoided, capable of supporting and stabilizing the
could result in death or serious weight to be lifted. Use only chains or
injury. straps that are in good condition and of
ample capacity.
Indicates a potentially hazardous
situation which, if not avoided, Be sure that fasteners intended for one
may cause minor or moderate time use (i.e., cotter pins and self-locking
injury. nuts) are not reused. These components
may fail if they are used a second time.
Indicates a potentially hazardous
situation which, if not avoided, Be sure to properly dispose of old oil or
may result in property damage. other fluids. Use an approved container.
Please be environmentally safe.
Be sure to wear protective eye wear and
other protective clothing if the situation Be sure that your workshop or work area
warrants it. is properly ventilated and well lit.
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.
Table of Contents
Table of Contents
Table of Contents
Manifolds .............................................................................................................57
5-1 Function Manifold Components – GS-1330m ................................................57
5-2 Function Manifold Components – GS-1530, GS-1532,
GS-1930 and GS-1932 .................................................................................58
5-3 Function Manifold Components – GS-2032, GS-2632,
GS-3232, GS-2046, GS-2646 and GS-3246 ................................................60
5-4 Function Manifold Components – GS-4047 ...................................................62
5-5 Check Valve Manifold Components – GS-1530, GS-1532,
GS-1930 and GS-1932 .................................................................................64
5-6 Lift Pressure Selector Manifold Components – GS-4047 ..............................65
5-7 Outrigger Function Manifold Components – GS-3232 ...................................66
5-8 Outrigger Cylinder Manifold Components – GS-3232 ...................................67
5-9 Valve Adjustments – Function Manifold .........................................................68
5-10 Valve Coils ...................................................................................................74
Table of Contents
Table of Contents
Table of Contents
Table of Contents
Table of Contents
Table of Contents
Specifications
Section 2 Specific ati ons
Specifications
Specifications
Specifications
Specifications
Specifications
Specifications
Specifications
Specifications
Petro-Canada Environ MV 46
Fluid Properties UCON Hydrolube HP-5046 Fluid
ISO Grade 46 Properties
Viscosity index 154 ISO Grade 46
Kinematic Viscosity Viscosity index 192
cSt @ 200°F / 100°C 8.0
Kinematic Viscosity
cSt @ 104°F / 40°C 44.4
cSt @ 149°F / 65°C 22
Flash point 482°F / 250°C cSt @ 104°F / 40°C 46
Pour point -49°F / -45°C cSt @ 0°F / -18°C 1300
Specifications
Displacement per revolution 0.094 cu in Steer relief valve pressure 1600 psi
1.54 cc 110 bar
Flow rate @1500 psi / 103 bar 1.3 gpm Function manifold – GS-4047
4.9 L/min System relief valve pressure, 3500 psi
Hydraulic tank return filter 10 micron with maximum 241 bar
25 psi / 1.7 bar Platform relief valve pressure 3000 psi
bypass 206 bar
Function pump – GS-1530, GS1532, GS-1930 and Steer relief valve pressure 1500 psi
GS-1932 103 bar
Type Gear Outrigger manifold
Displacement per revolution 0.244 cu in Relief valve pressure, maximum 3500 psi
4 cc 241 bar
Flow rate @ 2500 psi / 172 bar 3 gpm Check valve manifold -
11.3 L/min GS-1530, GS-1532, GS-1930. GS-1932
Hydraulic tank return filter 10 micron with Check valve pressure, maximum 200 psi
25 psi / 1.7 bar 13.8 bar
bypass
Lift pressure selector manifold - GS-4047
Function pump – GS-2032, GS-2632, GS-3232,
Platform relief valve pressure, 2000 psi
GS-2046, GS-2646, GS-3246 and GS-4047
maximum 138 bar
Type Gear
Displacement per revolution 0.355 cu in Manifold Component
5.5 cc Specifications
Flow rate @ 2500 psi / 172 bar 4 gpm
15 L/min Plug torque
Hydraulic tank return filter 10 micron with SAE No. 2 50 in-lbs / 6 Nm
25 psi / 1.7 bar SAE No. 4 13 ft-lbs / 18 Nm
bypass
SAE No. 6 18 ft-lbs / 24 Nm
Function manifold – All models except GS-1330m
and GS-4047 SAE No. 8 50 ft-lbs / 68 Nm
Specifications
Specifications
1 jam nut
JIC 37° Fittings
(swivel nut or hose connection)
SAE Dash Size Thread Size Flats
SAE O-ring Boss Port
-4 7/16-20 2
(tube fitting - installed into Steel)
-6 9/16-18 1 1/2
SAE Dash Size Torque
-8 3/4-16 1 1/2
-4 ORFS / 37° (Adj) 15 ft-lbs / 20,3 Nm
-10 7/8-14 1 1/2 ORFS (Non-adj) 26 ft-lbs / 35,3 Nm
-12 1 1/16-12 1 1/4 37° (Non-adj) 22 ft-lbs / 30 Nm
Specifications
Torque Procedure
JIC 37° fittings
Seal-Lok™ fittings 1 Align the tube flare (hex nut) against the nose
of the fitting body (body hex fitting) and tighten
1 Replace the O-ring. The O-ring must be
the hex nut to the body hex fitting to hand tight,
replaced anytime the seal has been broken.
approximately 30 in-lbs / 3.4 Nm.
The O-ring cannot be re-used if the fitting or
hose end has been tightened beyond finger 2 Using a permanent ink marker, make a
tight. reference mark on one the flats of the hex nut
and continue the mark onto the body of the
Note: The O-ring in Parker Seal Lok™ fittings and
hex fitting. Refer to Illustration 1.
hose end are custom-size O-rings. They are not
standard size O-rings. They are available in the
O-ring field service kit (Genie part number 49612).
2 Lubricate the O-ring before installation.
3 Be sure the O-ring face seal is seated and
retained properly.
4 Position the tube and nut squarely on the face
seal end of the fitting, and tighten the nut
finger tight.
Illustration 1
5 Tighten the nut or fitting to the appropriate
torque. Refer to the appropriate torque chart in 1 hex nut
this section. 2 reference mark
3 body hex fitting
6 Operate all machine functions and inspect the
hose, fittings and related components to
confirm there are no leaks.
Specifications
Illustration 2
1 body hex fitting
2 reference mark
3 second mark
Repair Procedures
Machine Configuration:
Section 3 Repair Pr oc edures
Repair Procedures
Platform Controls
Platform Controls
Operational Indicator Codes Note: The Ld Operation Indicator Code will appear
when the outriggers are not fully retracted, the
These codes are generated by the electrical machine is not auto leveled, an outrigger has lost
system to indicate machine operating status. contact with the ground or either level sensor
During normal operation, a code will appear in the detects the machine is no longer level. When any
platform controls LED readout if a condition such of the above scenarios occur, the lift function is
as off-level, overload cutout, chassis mode disabled.
operation or pothole guard stuck occurs.
The lift function will also be disabled while
If the platform controls LED readout displays an extending or retracting the outriggers and during
operational indicator code such as LL, the fault the outrigger auto level procedure. While
condition must be repaired or removed before performing the above operations, the Ld Operation
resuming machine operation. Push in and pull out Indicator Code will appear.
the red Emergency Stop button to reset the
system. Note: A code and a description of a code can also
be viewed at the ground controls LCD display.
Code Condition
LL Off-level
OL Platform Overload (CE and Australia)
CH Chassis Mode Operation
PHS Pothole Guard Stuck
nd No Drive (option)
Ld Lifting Disabled (GS-3232 only)
BR Brake Release by manual (GS-1330m only)
Platform Controls
5 Remove the ties securing the wire harness. 9 Carefully remove the platform controls circuit
6 Disconnect the red and black wires from the board fasteners.
alarm. 10 Carefully remove the platform controls circuit
7 Carefully remove the alarm from the platform board from the platform control box.
control box. 11 Remove the transparent caps from the
platform controls circuit board and save.
Circuit board fastener torque specifications
Hand tighten until screws seat < 5 in-lbs
< 0.6 Nm
Note: Before installing a circuit board, place the
transparent caps removed in step 11, over the
circuit board buttons.
Note: After installing the circuit board, check for
proper button operation. Excessive torque of the
circuit board fasteners will cause the buttons to
bind. Moderate torque of the circuit board fasteners
will not allow the buttons to engage.
Platform Controls
1-2 1-3
Joystick Platform Controls Alarm
Platform Controls
Ground Controls
Ground Controls
Result: The display at the ground controls will a ground control LCD display
show the machine model and hour meter b ground control scroll down button
information. After 3 seconds, the machine
model will not show on the display. See
example below.
Ground Controls
Ground Controls
Ground Controls
5 Locate the diagnostic port on the side of the 8 Launch a web browser such as Internet
GCON. Remove one of the fasteners securing Explorer ®, Chrome ® or Firefox ® on your PC
the cover and set aside. Loosen the other or laptop. Type the IP address from step 7 into
fastener. Do not remove it. the web browser address bar and press enter.
Result: The following screen will be displayed.
6 Connect one end of a CAT5 Ethernet cable Note: Verify it is the correct flash file.
into the diagnostic port. Connect the other end 10 Select the Load Flash File button to verify the
into a PC or laptop. file is a .gff file.
Result: The ground controls LCD display will Result: The following screen will be displayed.
show the following:
Ground Controls
11 Select the Reprogram Device(s) button to 15 Perform a function test. Refer to the
start the ECM software update. Operator's Manual on your machine.
Result: The following screen will be displayed 16 Return the machine to service.
after the software update is complete.
Machine Application Mode
Note: Do not turn off power while the ECM is being
reprogrammed. 1 Open the GCON compartment.
Note: Some models will require opening the ground
control box to access the GCON.
2 Turn the key switch to ground controls or
platform controls and pull out the red
Emergency Stop button to the on position at
both ground and platform controls.
3 Locate the diagnostic port on the side of the
GCON. Remove one of the fasteners securing
the cover and set aside. Loosen the other
fastener. Do not remove it.
Ground Controls
5 Read and record the IP address. 8 Select the Software tab at the header bar.
Note: The display wil only show the Result: The following screen will be displayed.
IP address for 3 seconds. Press the
scroll up button to display the IP
address for another 3 seconds.
Ground Controls
11 Select the Load Flash File button to verify the 15 Secure the diagnostic port cover using the
file is a .gff file. retaining fasteners removed in step 5. Do not
over tighten.
Result: The following screen will be displayed.
Note: Machines equipped with AGM batteries will
need to select the AGM battery type using the
GCON set parameters screen. Refer to the
Machine Setup procedure in the Service and
Repair manual that is appropriate for your machine.
12 Select the Reprogram Device(s) button to Perform drive speed test. Refer
start the ECM software update. to the Maintenance Manual that
is appropriate for your machine.
Result: The following screen will be displayed
after the software update is complete. 16 Perform a function test. Refer to the
Note: Do not turn off power while the ECM is being Operator's Manual on your machine.
reprogrammed. 17 Return the machine to service.
Ground Controls
Ground Controls
5 Read and record the IP address. 9 Enter the following username and password
then select OK.
Note: The display wil only show the
IP address for 3 seconds. Press the Username: smart.link
scroll up button to display the IP Password: SL1000
address for another 3 seconds. Note: The username and password are case
sensitive.
6 On a PC, laptop or mobile device, set up a Result: The following screen will be displayed.
wireless network for the portable router.
Note: Refer to the Operating System's procedure
for connecting to a wireless network.
7 After establishing a new wireless network,
select the appropriate network your portable
wireless router.
Note: Refer to the Operating System's procedure
for connecting to a wireless network.
8 Launch a web browser such as Internet 10 After using the Smart Link Service Tool web
Explorer ®, Chrome ® or Firefox ® on your site, push in the red Emergency Stop button
PC, laptop or mobile device. Type the IP and disconnect the CAT5 cable from the
address from step 5 into the web browser GCON.
address bar and press enter. 11 Secure the diagnostic port cover using the
Result: The following screen will be displayed. retaining fasteners removed in step 3. Do not
over tighten.
Note: Machines equipped with AGM batteries will
need to select the AGM battery type using the
GCON set parameters screen. Refer to the
Machine Setup procedure in the Service and
Repair manual that is appropriate for your machine.
Ground Controls
Ground Controls
3 Pull out the red Emergency Stop button to the 6 Press the Enter button.
on position at the ground controls.
Result: The ground controls LCD display will
Result: The ground controls LCD display will show an alternating message every
show the following: 1.5 seconds.
Ground Controls
2-6
Level Sensors
The Electronic Control Module (ECM) is
programmed to deactivate the lift and drive
functions and activate an alarm when a signal is
received from the level sensor.
GS-1330m
The tilt alarm sounds when the incline of the
chassis exceeds 1.5° to the side and 2.5° to the
front or rear.
Use the illustrations to verify which type of level
sensor is installed and perform the procedure that
is appropriate for your machine.
Procedure 3
1 X axis
2 Y axis
Procedure 1
Ground Controls
How to Install and Calibrate the 6 Lower the platform onto the safety arm.
Level Sensor - Procedure 1 Crushing hazard. Keep hands
clear of the safety arm when
lowering the platform.
Ground Controls
12 Place the new level sensor onto the level 13 Install the level sensor retaining fasteners
sensor mount bracket with the "X" on the level through the level sensor and springs, and into
sensor base closest to the long side of the the mount bracket. Tighten the fasteners and
level sensor mount, and the "Y" on the level measure the distance between the level
sensor base closest to the short side of the sensor and the level sensor mount bracket.
level sensor mount.
Result: The measurement should be
Tip-over hazard. Failure to install approximately 0.375 inch / 10 mm.
the level sensor as instructed, 14 Connect the chassis wire harness to the level
could result in the machine sensor wire harness.
tipping over, causing death or
serious injury. 15 Turn the key switch to the ground control and
pull out the red Emergency Stop button to the
Steer End on position at the ground controls.
16 Adjust the level sensor retaining fasteners
until the bubble at the top of the level sensor is
centered in the circles.
Result: The tilt sensor alarm should not sound.
17 Raise the platform slightly.
18 Return the safety arm to the stowed position.
19 Lower the platform to the stowed position.
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. Place blocks under the chassis for
support.
Non-steer End
1 limit switch
2 level sensor mount bracket
3 level sensor S7
4 scissor chassis
5 alarm H5
Ground Controls
22 GS-1530 and GS-1930: Place a 0.64 x 6 x 29 Center a lifting jack under the drive chassis at
6 inch / 16.2 mm x 15 cm x 15 cm thick steel the battery pack side of the machine.
block under both wheels at the ground
30 Raise the machine approximately 2 inches /
controls side of the machine.
5 cm. Place blocks under the chassis for
GS-1532 and GS-1932: Place a 0.68 x 6 x support.
6 inch / 17.2 mm x 15 cm x 15 cm thick steel
31 GS-1530 and GS-1930: Place a 0.77 x 6 x
block under both wheels at the ground
6 inch / 19.6 mm x 15 cm x 15 cm thick steel
controls side of the machine.
block under both wheels at the battery pack
GS-2032, GS-2632 and GS-3232: Place a side of the machine.
0.66 x 6 x 6 inch / 16.8 mm x 15 cm x 15 cm
GS-1532 and GS-1932: Place a 0.83 x 6 x
thick steel block under both wheels at the
6 inch / 21.1 mm x 15 cm x 15 cm thick steel
ground controls side of the machine.
block under both wheels at the battery pack
GS-2046, GS-2646, GS-3246 and GS-4047: side of the machine.
Place a 1 x 6 x 6 inch / 25.4 mm x 15 cm x
GS-2032, GS-2632 and GS-3232: Place a
15 cm thick steel block under both wheels at
0.8 x 6 x 6 inch / 20.3 mm x 15 cm x 15 cm
the ground controls side of the machine.
thick steel block under both wheels at the
23 Lower the machine onto the blocks. battery pack side of the machine.
24 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. GS-2046, GS-2646, GS-3246 and GS-4047:
Place a 1.22 x 6 x 6 inch / 31 mm x 15 cm x
Result: The level sensor alarm should not
15 cm thick steel block under both wheels at
sound.
the battery pack side of the machine.
Result: The level sensor alarm does sound
32 Lower the machine onto the blocks.
and fault code LL appears in the diagnostic
display. Adjust the level sensor retaining 33 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
fasteners just until the level sensor alarm does
Result: The platform should stop, an alarm
not sound.
should sound and fault code LL appears in the
25 Lower the platform to the stowed position. diagnostic display.
26 Raise the machine approximately 2 inches / Result: The platform does not stop or the level
5 cm. Place blocks under the chassis for sensor alarm does not sound. Adjust the level
support. sensor until the alarm just begins to sound OR
the down limit switch may need to be adjusted.
27 Remove the blocks from under both wheels.
34 Lower the platform to the stowed position.
28 Lower the machine and remove the jack.
35 Raise the machine approximately 2 inches /
5 cm.
36 Remove the blocks from under both wheels.
37 Lower the machine and remove the jack.
Ground Controls
How to Install and Calibrate the 3 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
Level Sensor - Procedure 2 4 Lift the safety arm, move it to the center of the
scissor arm and rotate down to a vertical
position.
5 Lower the platform onto the safety arm.
Crushing hazard. Keep hands
clear of the safety arm when
lowering the platform.
Ground Controls
10 Place the new level sensor on to the level 11 Install the level sensor retaining fasteners
sensor bracket with the "Y" on the level sensor through the level sensor and into the mount
closest to the ground controls of the machine bracket.
and the "X" on the level sensor closest to the
12 Connect the chassis wire harness to the level
steer end of the machine.
sensor.
Tip-over hazard. Failure to install 13 Turn the key switch to ground control and pull
the level sensor as instructed, out the red Emergency Stop button to the on
could result in the machine position at both ground and platform controls.
tipping over, causing death or
serious injury. Result: GCON will display a ‘C051:
SYSTEMFAULT, TILT:NoCal fault.
Steer End 14 Push in the red Emergency Stop button to the
off position at the ground controls.
15 Press and hold the ground control scroll up
and scroll down buttons.
Non-steer End
1 limit switch
2 level sensor mount bracket
3 level sensor S7
4 scissor chassis
5 alarm H5
Ground Controls
16 Pull out the red Emergency Stop button to the 22 Press and hold the Enter button to start
on position at the ground controls. calibration.
Result: The ground controls LCD display will Result: An audible alarm will sound when
show the following: calibration is complete.
Note: The machine will not calibrate if it is on a
slope of one degree or greater.
Note: If the level sensor has been replaced,
continue with step 23. If the level sensor was not
replaced skip to step 26.
17 Release the Scroll Up and Scroll Down
buttons after the ground controller powers up.
18 Use the Scroll Up or Scroll Down buttons to
scroll to Select Option.
Ground Controls
28 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. 34 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
Result: No audible alarm is heard. Result: No audible alarm is heard.
Result: The platform stops, an audible alarm is Result: The platform stops, an audible alarm is
heard and Fault LL is displayed. Repeat this heard and Fault LL is displayed. Repeat this
procedure starting at step 15 on a firm level procedure starting at step 15 on a firm level
surface. surface.
29 Lower the platform to the stowed position. 35 Lower the platform to the stowed position.
30 Continue driving the machine up the ramp until 36 Continue driving the machine up the ramp until
it is just over 2.5°. it is just over 2.5°.
31 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. 37 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
Result: The platform should stop, an alarm Result: The platform should stop, an alarm
should sound and fault code LL appears in the should sound and fault code LL appears in the
diagnostic display. diagnostic display.
Result: The platform does not stop or the level Result: The platform does not stop or the level
sensor alarm does not sound. Repeat this sensor alarm does not sound. Repeat this
procedure starting at step 15 on a firm level procedure starting at step 15 on a firm level
surface. surface.
32 Lower the platform to the stowed position. 38 Lower the platform to the stowed position.
33 Drive the non-steer end of the machine up a 39 Place a digital level on the steer end of the
ramp until it is just under 3°. drive chassis. Zero out the digital level.
40 Drive the ground control side of the machine
onto a ramp until it is just under 1.5°.
Ground Controls
41 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. 47 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
Result: No audible alarm is heard. Result: No audible alarm is heard.
Result: The platform stops, an audible alarm is Result: The platform stops, an audible alarm is
heard and Fault LL is displayed. Repeat this heard and Fault LL is displayed. Repeat this
procedure starting at step 15 on a firm level procedure starting at step 15 on a firm level
surface. surface.
42 Lower the platform to the stowed position. 48 Lower the platform to the stowed position.
43 Continue driving the machine onto the ramp 49 Continue driving the machine onto the ramp
until it is just over 1.5°. until it is just over 1.5°.
44 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. 50 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
Result: The platform should stop, an alarm Result: The platform should stop, an alarm
should sound and fault code LL appears in the should sound and fault code LL appears in the
diagnostic display. diagnostic display.
Result: The platform does not stop or the level Result: The platform does not stop or the level
sensor alarm does not sound. Repeat this sensor alarm does not sound. Repeat this
procedure starting at step 15 on a firm level procedure starting at step 15 on a firm level
surface. surface.
45 Lower the platform to the stowed position. 51 Lower the platform to the stowed position.
46 Drive the battery compartment side of the
machine onto a ramp until it is just under 1.5°.
Ground Controls
How to Install and Calibrate the 5 Lower the platform onto the safety arm.
Level Sensor - Procedure 3 Crushing hazard. Keep hands
clear of the safety arm when
lowering the platform.
Ground Controls
10 Place the new level sensor on to the level 11 Install the level sensor retaining fasteners
sensor bracket with the "Y" on the level sensor through the level sensor and into the mount
away from the ground controls of the machine bracket.
and the "X" on the level sensor closest to the
12 Connect the chassis wire harness to the level
steer end of the machine.
sensor.
Tip-over hazard. Failure to install 13 Turn the key switch to ground control and pull
the level sensor as instructed, out the red Emergency Stop button to the on
could result in the machine position at both ground and platform controls.
tipping over, causing death or
serious injury. Result: GCON will display a ‘C051:
SYSTEMFAULT, TILT:NoCal fault.
Steer End 14 Push in the red Emergency Stop button to the
off position at the ground controls.
15 Press and hold the ground control scroll up
and scroll down buttons.
Non-steer End
1 limit switch
2 level sensor mount bracket
3 level sensor S7
4 scissor chassis
5 alarm H5
Ground Controls
16 Pull out the red Emergency Stop button to the 22 Press and hold the Enter button to start
on position at the ground controls. calibration.
Result: The ground controls LCD display will Result: An audible alarm will sound when
show the following: calibration is complete.
Note: The machine will not calibrate if it is on a
slope of one degree or greater.
Note: If the level sensor has been replaced,
continue with step 23. If the level sensor was not
replaced skip to step 26.
17 Release the Scroll Up and Scroll Down
buttons after the ground controller powers up.
18 Use the Scroll Up or Scroll Down buttons to
scroll to Select Option.
Ground Controls
28 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. 34 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
Result: No audible alarm is heard. Result: No audible alarm is heard.
Result: The platform stops, an audible alarm is Result: The platform stops, an audible alarm is
heard and Fault LL is displayed. Repeat this heard and Fault LL is displayed. Repeat this
procedure starting at step 15 on a firm level procedure starting at step 15 on a firm level
surface. surface.
29 Lower the platform to the stowed position. 35 Lower the platform to the stowed position.
30 GS-1330m: Drive the steer end of the 36 GS-1330m: Drive the steer end of the
machine up a ramp until it is just under 2.5°. machine up a ramp until it is just under 2.5°.
All other models: Drive the steer end of the All other models: Drive the steer end of the
machine up a ramp until it is just under 3°. machine up a ramp until it is just under 3°.
31 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. 37 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
Result: The platform should stop, an alarm Result: The platform should stop, an alarm
should sound and fault code LL appears in the should sound and fault code LL appears in the
diagnostic display. diagnostic display.
Result: The platform does not stop or the level Result: The platform does not stop or the level
sensor alarm does not sound. Repeat this sensor alarm does not sound. Repeat this
procedure starting at step 15 on a firm level procedure starting at step 15 on a firm level
surface. surface.
32 Lower the platform to the stowed position. 38 Lower the platform to the stowed position.
33 GS-1330m: Drive the steer end of the 39 Place a digital level on the steer end of the
machine up a ramp until it is just under 2.5°. drive chassis. Zero out the digital level.
All other models: Drive the steer end of the 40 Drive the ground control side of the machine
machine up a ramp until it is just under 3°. onto a ramp until it is just under 1.5°.
Ground Controls
41 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. 47 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
Result: No audible alarm is heard. Result: No audible alarm is heard.
Result: The platform stops, an audible alarm is Result: The platform stops, an audible alarm is
heard and Fault LL is displayed. Repeat this heard and Fault LL is displayed. Repeat this
procedure starting at step 15 on a firm level procedure starting at step 15 on a firm level
surface. surface.
42 Lower the platform to the stowed position. 48 Lower the platform to the stowed position.
43 Continue driving the machine onto the ramp 49 Continue driving the machine onto the ramp
until it is just over 1.5°. until it is just over 1.5°.
44 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. 50 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
Result: The platform should stop, an alarm Result: The platform should stop, an alarm
should sound and fault code LL appears in the should sound and fault code LL appears in the
diagnostic display. diagnostic display.
Result: The platform does not stop or the level Result: The platform does not stop or the level
sensor alarm does not sound. Repeat this sensor alarm does not sound. Repeat this
procedure starting at step 15 on a firm level procedure starting at step 15 on a firm level
surface. surface.
45 Lower the platform to the stowed position. 51 Lower the platform to the stowed position.
46 Drive the battery compartment side of the
machine onto a ramp until it is just under 1.5°.
Ground Controls
Outrigger Level Sensor - GS-3232 6 Place the new outrigger level sensor onto the
outrigger level sensor base with the flat side of
Models the outrigger level sensor closest to the
(from serial number GS3211A to GS3215A-141898) battery side access door. Refer to the
(from serial number GS3212C-10000) illustration below.
Tip-over hazard. Failure to install
the 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
level sensor other than specified
in this procedure.
Ground Controls
Ground Controls
Ground Controls
(GS-3232 - facility code C) 14 Continue holding the Enter button after the
(GS-3232 - facility code A, to GS3215A-141898)
outriggers retract. The outriggers will now
extend and the system will gather and save
1 Move the machine to an area that has a firm, data to calibrate the outriggers.
level surface and is free of obstructions. Use
digital level to confirm. 15 Continue holding the Enter button after the
outriggers extend. The outriggers will now
2 Turn the key switch to ground controls. retract while the outrigger system gathers and
3 At the ground controls, press and hold the saves data.
Menu Up and Menu Down buttons. Result: The alarms at the ground and platform
4 While pressing both buttons down, pull out the controls should sound for 1 second. The
red Emergency Stop Button. outrigger system is calibrated.
5 Release the Menu Up and Menu Down Note: After installing a new outrigger level sensor,
buttons after the ground controller powers up. the new outrigger level sensor must be calibrated
following this procedure.
6 Use the Menu Up or Menu Down buttons to
scroll to Machine Options.
7 Press the Enter button to select Machine
Options.
Hydraulic Tank
4 Remove the tank/pump/manifold assembly
3-1 fasteners and remove the assembly from the
Hydraulic Tank machine.
The primary functions of the hydraulic tank are to 5 Remove the hydraulic tank retaining fasteners
cool and deaerate the hydraulic fluid during and remove the hydraulic tank from the pump
operation. It utilizes internal suction strainers for assembly.
the pump supply lines and has an external return Bodily injury hazard. Spraying
line filter. hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
How to Remove the Hydraulic the oil pressure to dissipate
Tank gradually. Do not allow oil to
squirt or spray.
Component damage hazard.
The work area and surfaces 6 Remove the hydraulic tank cap and drain the
where this procedure will be tank into a suitable container.
performed must be clean and
free of debris that could get into 7 Remove the hydraulic tank retaining fasteners
the hydraulic system. and remove the hydraulic tank from the
pump/manifold assembly.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose Torque specifications GS-1330m
end must be replaced. All connections must be Hydraulic retaining fasteners, dry 26 in-lbs
torqued to specification during installation. Refer to 2.9 Nm
Specifications, Hydraulic Hose and Fitting Torque Hydraulic retaining fasteners, lubricated 18 in-lbs
Specifications. 2 Nm
GS-1330m
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,
watches and other jewelry.
Hydraulic Tank
Hydraulic Pump
Hydraulic Pump
5 Remove the hydraulic power unit mounting
How to R emove the Hydr aulic Pump
How to Remove the Hydraulic bolts, then remove the hydraulic power unit
Pump from the machine.
Note: When removing a hose assembly or fitting, 6 Tag and remove the hydraulic tank mounting
the O-ring (if equipped) on the fitting and/or hose bolts and clamps, then remove the hydraulic
end must be replaced. All connections must be tank from the machine.
torqued to specification during installation. Refer to
7 Disconnect the pump inlet line and remove the
Specifications, Hydraulic Hose and Fitting Torque
Specifications. pump mounting bolts. Cap the fittings on the
pump, manifolds and hydraulic tank.
GS-1330m 8 Carefully remove the pump.
1 Disconnect the battery pack from the machine.
All other Models
Electrocution/burn hazard. 1 Disconnect the battery pack from the machine.
Contact with electrically charged
circuits could result in death or Electrocution/burn hazard.
serious injury. Remove all rings, Contact with electrically charged
watches and other jewelry. circuits could result in death or
serious injury. Remove all rings,
2 Refer to Repair Procedure 3-1, How to watches and other jewelry.
Remove the Hydraulic Tank.
2 Tag and disconnect the hydraulic power unit
3 Disconnect the filter head from the filter head
cables at the motor controller.
monting bracket. Rotate the filter out and away
from the hydraulic power unit. 3 Disconnect the filter head from the filter head
4 Tag, disconnect and plug the hoses from the mounting bracket. Rotate the filter out and
power unit. Cap the fittings on the poer unit. away from the hydraulic power unit.
4 Remove the hydraulic power unit retaining
fasteners.
Hydraulic Pump
5 Tag, disconnect and plug the hydraulic tank
hard line from the pump. Cap the fitting on the
pump.
6 Tag, disconnect and plug the high pressure
hose from the pump. Cap the fitting on the
pump.
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.
Manifolds
5-1
Function Manifold Components –
GS-1330m
The function manifold is mounted on the hydaulic pump.
Manifolds
5-2
Function Manifold Components –
GS-1530, GS-1532, GS-1930 and GS-1932
The function manifold is mounted under the machine, between the module trays.
Manifolds
Manifolds
5-3
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, at the ground control side of the machine.
Manifolds
Manifolds
5-4
Function Manifold Components – GS-4047
The function manifold is mounted behind an inspection door, at the ground control side of the machine.
Manifolds
Manifolds
5-5
Check Valve Manifold Components –
GS-1530, GS-1532, GS-1930 and GS-1932
The check valve manifold is mounted on the function manifold.
Manifolds
5-6
Lift Pressure Selector Manifold Components – GS-4047
The lift pressure selector manifold is mounted behind an inspection door, at the ground control side of the
machine.
Manifolds
5-7
Outrigger Function Manifold Components – GS-3232
The outrigger function manifold is mounted behind an inspection door, at the battery side of the machine.
Manifolds
5-8
Outrigger Cylinder Manifold Components – GS-3232
The outrigger function manifold is mounted behind an inspection door, at the battery side of the machine.
Manifolds
5-9
Valve Adjustments -
Function Manifold
Note: Perform this test from the ground with the
platform controls. Do not stand in the platform.
Note: Verify the hydraulic oil level is at the FULL
mark on the hydraulic tank.
GS-1330m
1 test port
2 system relief valve
3 steer relief valve
Manifolds
3 Adjust the internal hex socket. Turn it How to Adjust the Platform Lift
clockwise to increase the pressure or
counterclockwise to decrease the pressure.
Relief Valve
Note: Perform this test from the ground with the
Tip-over hazard. Failure to adjust
platform controls. Do not stand in the platform.
the relief valves to specification
could result in the machine Note: Verify the hydraulic oil level is at the FULL
tipping over, causing death or mark on the hydraulic tank.
serious injury. Do not adjust the
relief valve pressures higher 1 Locate the system relief valve on the function
than specifications. manifold (schematic item I, AB or DB).
2 Connect a 0 to 5000 psi / 0 to 350 bar
4 Install the relief valve cap. pressure gauge to the test port on the function
5 Repeat steps 5 and 6 to confirm the relief manifold (schematic item A, AA or DA).
valve pressure. 3 Chock both sides of the wheels at the steer
end of the machine.
4 Remove the platform controls from the
platform.
5 Turn the key switch to platform controls and
pull out the red Emergency Stop button to the
on position at both ground and platform
controls.
Manifolds
6 Move and hold the joystick fully in either 12 Turn the key switch to ground control and pull
direction while observing the pressure reading out the red Emergency Stop button to the on
on the pressure gauge. Note the pressure. position at both ground and platform controls.
Refer to Specifications, Hydraulic Component
13 Hold the lift relief valve with a wrench and
Specifications.
remove the cap (schematic item C, AJ or DJ).
7 Turn the machine off. Hold the system relief
14 While activating the platform up function,
valve with a wrench and remove the cap
adjust the internal hex socket clockwise, just
(schematic item I, AB or DB).
until the platform fully rises.
8 Adjust the internal hex socket. Turn it
15 Fully lower the platform to the stowed position.
clockwise to increase the pressure or
counterclockwise to decrease the pressure. 16 Add an additional 50 pounds / 22.7 kg to the
platform. Secure the additional weight.
Tip-over hazard. Failure to adjust
the relief valves to specification 17 Attempt to raise the platform.
could result in the machine Result: The power unit should not be able to
tipping over, causing death or
lift platform.
serious injury. Do not adjust the
relief valve pressures higher Result: If the power unit lifts the platform,
than specifications. adjust the internal hex nut socket
counterclockwise until the platform will not
9 Install the relief valve cap. rise.
10 Repeat steps 5 and 6 to confirm the relief 18 Install the relief valve cap.
valve pressure.
19 Remove the weight from the platform.
11 Place maximum rated load into the platform.
20 Bleed the hydraulic system by raising the
Secure the load to the platform. Refer to
platform to full height. If the pump cavitates or
Specifications, Machine Specifications.
the platform fails to reach full height, add
hydraulic oil until the pump is functioning
correctly. Do not overfill the hydraulic tank.
Manifolds
1 test port
2 system relief valve
3 steer relief valve
4 lift relief valve
Manifolds
8 Adjust the internal hex socket. Turn it How to Adjust the Steer Relief
clockwise to increase the pressure or
counterclockwise to decrease the pressure.
Valve
Note: Perform this test from the ground with the
Tip-over hazard. Failure to adjust
platform controls. Do not stand in the platform.
the relief valves to specification
could result in the machine Note: Verify the hydraulic oil level is at the FULL
tipping over, causing death or mark on the hydraulic tank.
serious injury. Do not adjust the
relief valve pressures higher 1 Locate the steer relief valve on the function
than specifications. manifold (item 3).
2 Connect a 0 to 5000 psi / 0 to 350 bar
9 Install the relief valve cap. pressure gauge to the test port on the function
10 Fully lower the platform to the stowed position. manifold (illustrations item 1).
11 Using a suitable lifting device, add and secure 3 Remove the platform controls from the
an additional 150 lbs / 68 kg to the platform platform.
deck. 4 Turn the key switch to platform controls and
12 Raise the platform. pull out the red Emergency Stop button to the
on position at both ground and platform
Result: The platform does not rise. Proceed to controls.
step 13.
Result: The platform rises. Perform steps
7 through 10 to decrease the pressure in small
increments until the platform does not rise.
13 Fully lower the platform to the stowed position.
14 Using a suitable lifting device, remove the
weight from the platform.
GS-1330m
1 test port
2 system relief valve
3 steer relief valve
Manifolds
Manifolds
Manifolds
Note: If testing a single terminal coil, connect the
How to Test a Coil Diode negative lead to the internal metallic ring at either
Genie incorporates spike suppressing diodes in all end of the coil.
of its coils. Properly functioning coil diodes protect
the electrical circuit by suppressing voltage spikes.
Voltage spikes naturally occur within a function
circuit following the interruption of electrical current
to a coil. Faulty diodes can fail to protect the
electrical system, resulting in a tripped circuit
breaker or component damage.
Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.
All Models except GS-1330m 9 Remove the retaining fastener from the steer
link at the yoke assembly.
1 Block the non-steer tires.
Note: While removing the retaining fasteners, take
2 Remove the cotter pin from the wheel castle note of the quantity and location of the spacers
nut. when disconnecting the steer link from the yoke
Note: Always replace the cotter pin with a new one assembly.
when removing the castle nut. 10 Remove the retaining fastener from the top of
3 Loosen the wheel castle nut. Do not remove it. the yoke pivot shaft.
4 Center a lifting jack under the drive chassis at Note: The pivot shaft retaining fastener is located
the steer end of the machine. above the main deck.
5 Raise the machine approximately 6 inches / 11 Lower the yoke assembly out of the chassis.
15 cm. Place blocks under the chassis for
Bodily injury hazard. The
support.
yoke/motor assembly may fall if
6 Remove the wheel castle nut. Remove the not properly supported when it is
wheel. removed from the chassis.
GS-1330m
1 Refer to Repair Procedure, How to Remove a
Drive Motor.
Note: Always replace the cotter pin with a new one Drive motor mounting fasteners, dry 75 ft-lbs
101.7 Nm
when removing the castle nut.
Drive motor mounting fasteners, 56 ft-lbs
4 Loosen the wheel castle nut. Do not remove it. lubricated 76.3 Nm
5 Raise the machine approximately 2 inches / Torque specifications
5 cm. Place blocks under the chassis for GS-1330m
support. Drive motor mounting fasteners, dry 43 ft-lbs
58.3 Nm
Crushing hazard. The chassis
will fall if not properly supported. Drive motor mounting fasteners, 32 ft-lbs
lubricated 43.4 Nm
6 Remove the wheel castle nut. Remove the
wheel.
7 All Models except GS-1330m: Tag,
disconnect and plug the hydraulic hoses on
the drive motor. Cap the fittings on the drive
motor.
6-3 6-4
Steer Cylinder Steer Bellcrank
6 Center a lifting jack under the drive chassis at Brake mounting fasteners, lubricated 56 ft-lbs
76 Nm
the non-steer end of the machine.
8-1
Brake Release Hand Pump Components- All models except GS-1330m
The brake release hand pump manifold is mounted behind the entry ladder.
Scissor Components
Scissor Components
How to Disassemble the Scissor 5 At the ground controls, turn the key switch to
the off position and push in the red Emergency
Assembly Stop button to the off position.
Bodily injury hazard. The 6 Disconnect the battery pack from the machine.
procedures in this section
require specific repair skills, Electrocution/burn hazard.
lifting equipment and a suitable Contact with electrically charged
workshop. Attempting this circuits could result in death or
procedure without these skills serious injury. Remove all rings,
and tools could result in death or watches and other jewelry.
serious injury and significant
component damage. Dealer 7 Remove the fasteners securing the large
service is required. platform height sensor cover to the large
platform height sensor bracket. (index #11)
Note: When removing a hose assembly or fitting, 8 Remove the platform height sensor cover.
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be 9 Tag and disconnect the platform height sensor
torqued to specification during installation. Refer to from the platform height sensor harness.
Specifications, Hydraulic Hose and Fitting Torque
10 Remove the fastener securing the platform
Specifications.
height sensor assembly to the number 1 inner
Note: Machines equipped with a Platform Height arm.
Sensor, begin the Scissor Disassembly procedure 11 Remove the platform height sensor assembly
at step 1. Machines without a Platform Height from the number 1 pivot pin.
Sensor, begin the Scissor Disassembly procedure
at step 24. 12 Remove the plastic nut securing the squeeze
connector to the large platform height sensor
1 Turn the key switch to ground controls and pull bracket.
out the red Emergency Stop button to the on
position at both ground and platform controls. 13 Remove the squeeze connector from the large
platform height sensor bracket.
2 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
14 Remove the fasteners securing the large
3 Lift the safety arm, move it to the center of the platform height sensor bracket to the number
scissor arm and rotate down to a vertical 1 inner arm pivot bracket.
position.
Scissor Components
15 Remove the large platform height sensor 23 Fully lower the platform to the stowed position.
bracket from the number 1 inner arm pivot
bracket.
16 Install the fasteners removed in 14 to the
number 1 inner arm pivot bracket and chassis.
Tip-over hazard. Failure
to install the fasteners securing
the number 1 inner arm pivot
bracket to the chassis, could
result in the machine tipping
over, causing death or serious
injury.
Scissor Components
27 Attach a lifting strap from an overhead crane 35 Use a soft metal drift to remove the number
to the number 4 outer arm (index #13). 4 pivot pin (index #3) at the steer end.
28 Remove the external snap rings and retaining Remove the number 4 inner arm (index #12)
fasteners from the number 4 center pivot pins from the machine.
(index #2).
Crushing hazard. The number
29 Use a soft metal drift to remove the number 4 inner arm may become
4 center pivot pins (index #2). unbalanced and fall if not
properly supported when
30 Remove the retaining fasteners from the
removed from the machine.
number 4 pivot pin (index #14) at the
non-steer end of the machine. 36 Remove the cables from the number 3 cable
31 Use a soft metal drift to remove the number bridge and number 3 inner arm and lay them
4 pivot pin (index #14) from the non-steer end off to the side.
of the machine. Remove the number 4 outer
arm (index #13) from the machine. Component damage hazard.
Cables can be damaged if they
Crushing hazard. The number are kinked or pinched.
4 outer arm may become
unbalanced and fall if not 37 Remove the number 3 cable from the
properly supported when machine.
removed from the machine. 38 Attach a lifting strap from an overhead crane
to the number 3 outer arm (index #4) at the
32 Remove the number 4 cable bridge mounting ground controls side.
fasteners and remove the cable bridge from
the machine. 39 Remove the external snap rings and retaining
fasteners from the number 3 center pivot pin
33 Attach a lifting strap from an overhead crane (index #4).
to the number 4 inner arm (index #12).
40 Use a soft metal drift to remove the number
34 Remove the retaining fasteners from the 3 center pivot pin (index #4) at the ground
number 4 pivot pin (index #3). control side.
Scissor Components
41 Use a soft metal drift to tap the number 3 pivot 46 Remove the pin retaining fasteners from the
pin (index #17) halfway out at the non-steer lift cylinder rod-end pivot pin (index #5). Use a
end of the machine. Remove the number soft metal drift to remove the pin.
3 outer arm (index #16) at the ground controls
side from the machine. Bodily injury hazard. The
cylinder may fall when the
Bodily injury hazard. The number rod-end pivot pin is removed if
3 outer arm at the ground not properly supported.
controls side may become
unbalanced and fall if not 47 Lower the cylinder onto the number 1 inner
properly supported when arm (index #9).
removed from the machine.
Component damage hazard.
42 Attach a lifting strap from an overhead crane Cables can be damaged if they
to the number 3 outer arm (index #16) at the are kinked or pinched.
battery pack side.
48 Attach a lifting strap from an overhead crane
43 Use a soft metal drift to tap the number 3 pivot to the number 3 inner arm (index #15).
pin (index #17) in the other direction. Remove
the number 3 outer arm (index #16) from the 49 Remove the retaining fasteners from the
battery pack side of the machine. number 3 pivot pin (index #6) at the steer end.
50 Use a soft metal drift to remove the number
Bodily injury hazard. The number
3 pivot pin (index #6). Remove the number
3 outer arm at the battery pack
3 inner arm (index #15) from the machine.
side may become unbalanced
and fall if not properly supported Bodily injury hazard. The number
when removed from the 3 inner arm may become
machine. unbalanced and fall if not
properly supported when
44 Remove the number 3 pivot pin (index #17) removed from the machine.
from the non-steer end of the machine.
45 Attach a lifting strap from an overhead crane 51 Remove the cables from the number 2 cable
to the lug on the rod end of the lift cylinder for bridge and lay them off to the side.
support. Do not apply any lifting pressure. 52 Remove the external snap rings and retaining
fasteners from the number 2 center pivot pin
(index #7) at the ground controls side.
Scissor Components
53 Remove the number 2 cable bridge mounting 61 Use a soft metal drift to tap the number 2 pivot
fasteners and remove the cable bridge from pin (index #20) in the other direction at the
the machine. non-steer end. Remove the number 2 outer
arm (index #19) from the battery pack side of
54 Attach a lifting strap from an overhead crane
the machine.
to the number 2 outer arm (index #19) at the
ground controls side. Bodily injury hazard. The number
55 Use a soft metal drift to remove the number 2 outer arm at the battery pack
2 center pivot pin (index #7) at the ground side may become unbalanced
controls side. and fall if not properly supported
when removed from the
56 Remove the retaining fasteners from the machine.
number 2 pivot pin (index #20) at the
non-steer end of the machine. 62 Remove the number 2 pivot pin (index #20)
from the non-steer end of the machine.
57 Use a soft metal drift to tap the number 2 pivot
pin (index #20) halfway out at the non-steer 63 Attach a lifting strap from an overhead crane
end of the machine. Remove the number to the number 2 inner arm (index #18).
2 outer arm (index #19) from the ground
controls side of the machine. 64 Remove the retaining fasteners from the
number 2 pivot pin (index #8) at the steer end
Bodily injury hazard. The number of the machine.
2 outer arm at the ground 65 Use a soft metal drift to remove the number
controls side may become
2 pivot pin (index #8). Remove the number
unbalanced and fall if not
2 inner arm (index #18) from the machine.
properly supported when
removed from the machine. Bodily injury hazard. The number
2 inner arm may become
58 Attach a lifting strap from an overhead crane unbalanced and fall if not
to the number 2 outer arm (index #19) at the properly supported when
battery pack side. removed from the machine.
59 Remove the external snap rings and retaining
fasteners from the number 2 center pivot pin 66 Remove the safety arm from the number
(index #7) at the battery pack side. 2 inner arm (index #18) that was just removed.
60 Use a soft metal drift to remove the number 67 Attach a lifting strap from an overhead crane
2 center pivot pin (index #7) at the battery to the number 1 inner arm (index #10).
pack side.
Bodily injury hazard. The number
2 outer arm at the battery pack
side may become unbalanced
and fall if not properly supported
when removed from the
machine.
Scissor Components
68 Raise the number 1 inner arm (index #10) 74 Remove the pin retaining fasteners from the
approximately 2 feet / 60 cm and install the lift cylinder barrel-end pin (index #21). Use a
safety arm between the number 1 inner arm soft metal drift to remove the pin. Remove the
(index #10) and the number 1 outer arm (index lift cylinder from the machine.
#22) at the non-steer end of the machine.
Lower the scissor arms onto the safety arm. Crushing hazard. The lift cylinder
will become unbalanced and fall
Bodily injury hazard. Keep hands if not properly supported and
clear of moving parts when secured to the lifting device.
lowering the scissor arms onto
the safety arm. Component damage hazard. Be
careful not to damage the valve
69 Attach a lifting strap from an overhead crane or fittings on the cylinder while
to the lug on the rod end of the lift cylinder removing it from the machine.
(index #5). Raise the lift cylinder
approximately 3 ft / 1 m. 75 Place a 4 x 4 x 48 inch / 10 cm x 10 cm x
1.2 m long block across both sides of the
70 Tag, disconnect and plug the hydraulic hoses chassis under the number 1 center pivot pin
on the lift cylinder. Cap the fittings on the (index #11).
cylinder.
76 Attach a lifting strap from an overhead crane
Bodily injury hazard. Spraying to the number 1 inner arm (index #10) at the
hydraulic oil can penetrate and non-steer end. Raise the number 1 inner arm
burn skin. Loosen hydraulic and remove the safety arm. Lower the number
connections very slowly to allow 1 inner arm (index #10) onto the block that
the oil pressure to dissipate was placed across the chassis.
gradually. Do not allow oil to
squirt or spray. Bodily injury hazard. Keep hands
clear of moving parts when
71 Tag and disconnect the wires and manual lowering the scissor arms.
lowering cable from the solenoid valve on the
cylinder. 77 Remove the cables from the number 1 cable
bridge and lay them off to the side.
72 Models with platform overload option: Tag
and disconnect the wire harness from the Component damage hazard.
platform overload pressure transducer. Cables can be damaged if they
are kinked or pinched.
Note: After replacing the scissor assembly, the
platform overload system must be calibrated.
78 Support and secure the entry ladder to an
Refer to Repair Procedure, How to Calibrate the
appropriate lifting device.
Platform Overload System (if equipped).
73 Raise the lift cylinder to a vertical position.
Scissor Components
79 Remove the fasteners from the entry ladder 86 Remove the upper fasteners securing the
and remove the entry ladder from the number 1 inner arm pivot bracket to the end of
machine. the chassis. Loosen the lower fasteners.
Crushing hazard. The entry 87 Remove the number 1 inner arm (index #10)
ladder will fall if not properly from the machine.
supported and secured to the
Bodily injury hazard. The number
lifting device.
1 inner arm may become
80 Attach a lifting strap from an overhead crane unbalanced and fall if not
properly supported when
to the number 1 outer arm (index #22). Do not
apply any lifting pressure. removed from the machine.
81 Remove the external snap rings and retaining Component damage hazard. Be
fasteners from the number 1 center pivot pins sure not to damage the limit
(index #11). switch or level sensor
components when the number
82 Remove the number 1 cable bridge from the 1 inner arm is removed from the
machine. machine.
83 Use a soft metal drift to remove the number
1 center pivot pins (index #9).
Bodily injury hazard. The number
1 outer arm may become
unbalanced and fall if not
properly supported when the pin
is removed.
Scissor Components
Scissor Components
How to Disassemble the Scissor 5 At the ground controls, turn the key switch to
the off position and push in the red Emergency
Assembly Stop button to the off position.
Bodily injury hazard. The 6 Disconnect the battery pack from the machine.
procedures in this section
require specific repair skills, Electrocution/burn hazard.
lifting equipment and a suitable Contact with electrically charged
workshop. Attempting this circuits could result in death or
procedure without these skills serious injury. Remove all rings,
and tools could result in death or watches and other jewelry.
serious injury and significant
component damage. Dealer 7 Remove the fasteners securing the large
service is required. platform height sensor cover to the large
platform height sensor bracket.
Note: When removing a hose assembly or fitting, 8 Remove the platform height sensor cover.
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be 9 Tag and disconnect the platform height sensor
torqued to specification during installation. Refer to from the platform height sensor harness.
Specifications, Hydraulic Hose and Fitting Torque
10 Remove the fastener securing the platform
Specifications.
height sensor assembly to the number 1 inner
Note: Machines equipped with a Platform Height arm.
Sensor, begin the Scissor Disassembly procedure 11 Remove the platform height sensor assembly
at step 1. Machines without a Platform Height from the number 1 pivot pin.
Sensor, begin the Scissor Disassembly procedure
at step 24. 12 Remove the plastic nut securing the squeeze
connector to the large platform height sensor
1 Turn the key switch to ground controls and pull bracket.
out the red Emergency Stop button to the on
position at both ground and platform controls. 13 Remove the squeeze connector from the large
platform height sensor bracket.
2 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
14 Remove the fasteners securing the large
3 Lift the safety arm, move it to the center of the platform height sensor bracket to the number
scissor arm and rotate down to a vertical 1 inner arm pivot bracket.
position.
15 Remove the large platform height sensor
bracket from the number 1 inner arm pivot
bracket.
Scissor Components
16 Install the fasteners removed in 14 to the 24 Remove the platform. Refer to Repair
number 1 inner arm pivot bracket and chassis. Procedure, How to Remove the Platform.
17 Connect the battery pack to the machine. 25 Remove the cables from the number 3 outer
arm (index #11) at the ground controls side.
18 Turn the key switch to ground controls.
19 Press and hold the ground control scroll up Component damage hazard.
and scroll down buttons. Cables can be damaged if they
are kinked or pinched.
20 Pull out the red Emergency Stop button to the
on position at the ground controls. 26 Remove the cables from the number 3 cable
bridge and lay them off to the side.
21 Using the ground control menu buttons,
navigate to Service Override Mode. Select Component damage hazard.
Service Override Mode. Cables can be damaged if they
Note: The machine must be in Service Override are kinked or pinched.
Mode to raise the platform. While in Service
Override Mode, only the GCON will operate with 27 Attach a lifting strap from an overhead crane
limited functionality. The platform will raise a to the number 3 outer arm (index #11).
predetermined amount of time and stop. 28 Remove the external snap rings and retaining
fasteners from the number 3 center pivot pins
22 Raise the platform and rotate the safety arm to
(index #2).
the stowed position.
29 Use a soft metal drift to remove the number
23 Fully lower the platform to the stowed position.
3 center pivot pins (index #2).
30 Remove the retaining fasteners from the
number 3 pivot pin (index #12) at the
non-steer end of the machine.
31 Use a soft metal drift to remove the number
3 pivot pin (index #12) from the non-steer end
of the machine. Remove the number 3 outer
arm (index #11) from the machine.
Crushing hazard. The number
3 outer arm may become
unbalanced and fall if not
properly supported when
removed from the machine.
Scissor Components
34 Remove the pin retaining fasteners from the 42 Attach a lifting strap from an overhead crane
lift cylinder rod-end pivot pin (index #3). Use a to the number 2 outer arm (index #14) at the
soft metal drift to remove the pin. ground controls side.
Bodily injury hazard. The 43 Use a soft metal drift to remove the number
cylinder may fall when the 2 center pivot pin (index #5) at the ground
rod-end pivot pin is removed if controls side.
not properly supported. 44 Remove the retaining fasteners from the
number 2 pivot pin (index #15) at the
35 Lower the cylinder onto the number 1 inner non-steer end of the machine.
arm (index #8).
45 Use a soft metal drift to tap the number 2 pivot
Component damage hazard. pin (index #15) halfway out at the non-steer
Cables can be damaged if they end of the machine. Remove the number
are kinked or pinched. 2 outer arm (index #14) from the ground
controls side of the machine.
36 Attach a lifting strap from an overhead crane
to the number 3 inner arm (index #10). Bodily injury hazard. The number
2 outer arm at the ground
37 Remove the retaining fasteners from the
controls side may become
number 3 pivot pin (index #4) at the steer end.
unbalanced and fall if not
38 Use a soft metal drift to remove the number properly supported when
3 pivot pin (index #4). Remove the number removed from the machine.
3 inner arm (index #10) from the machine.
46 Attach a lifting strap from an overhead crane
Bodily injury hazard. The number to the number 2 outer arm (index #14) at the
3 inner arm may become battery pack side.
unbalanced and fall if not
properly supported when 47 Remove the external snap rings and retaining
removed from the machine. fasteners from the number 2 center pivot pin
(index #5) at the battery pack side.
39 Remove the cables from the number 2 cable 48 Use a soft metal drift to remove the number
bridge and lay them off to the side. 2 center pivot pin (index #5) at the battery
Component damage hazard. pack side.
Cables can be damaged if they Bodily injury hazard. The number
are kinked or pinched. 2 outer arm at the battery pack
side may become unbalanced
40 Remove the external snap rings and retaining and fall if not properly supported
fasteners from the number 2 center pivot pin when removed from the
(index #5) at the ground controls side. machine.
41 Remove the number 2 cable bridge mounting
fasteners and remove the cable bridge from
the machine.
Scissor Components
49 Use a soft metal drift to tap the number 2 pivot 56 Attach a lifting strap from an overhead crane
pin (index #15) in the other direction at the to the lug on the rod end of the lift cylinder
non-steer end. Remove the number 2 outer (index #3). Raise the lift cylinder
arm (index #14) from the battery pack side of approximately 3 ft / 1 m.
the machine.
57 Tag, disconnect and plug the hydraulic hoses
Bodily injury hazard. The number on the lift cylinder. Cap the fittings on the
2 outer arm at the battery pack cylinder.
side may become unbalanced
Bodily injury hazard. Spraying
and fall if not properly supported
hydraulic oil can penetrate and
when removed from the
burn skin. Loosen hydraulic
machine.
connections very slowly to allow
the oil pressure to dissipate
50 Attach a lifting strap from an overhead crane
gradually. Do not allow oil to
to the number 2 inner arm (index #13).
squirt or spray.
51 Remove the retaining fasteners from the
number 2 pivot pin (index #6) at the steer end 58 Tag and disconnect the wires and manual
of the machine. lowering cable from the solenoid valve on the
cylinder.
52 Use a soft metal drift to remove the number
2 pivot pin (index #6). Remove the number 59 Models with platform overload option: Tag
2 inner arm (index #13) from the machine. and disconnect the wire harness from the
platform overload pressure transducer.
Bodily injury hazard. The number
2 inner arm may become Note: After replacing the scissor assembly, the
unbalanced and fall if not platform overload system must be calibrated.
properly supported when Refer to Repair Procedure, How to Calibrate the
removed from the machine. Platform Overload System (if equipped).
53 Remove the safety arm from the number 60 Raise the lift cylinder to a vertical position.
2 inner arm (index #13) that was just removed. 61 Remove the pin retaining fasteners from the
54 Attach a lifting strap from an overhead crane lift cylinder barrel-end pin (index #16). Use a
to the number 1 inner arm (index #8). soft metal drift to remove the pin. Remove the
lift cylinder from the machine.
55 Raise the number 1 inner arm (index #8)
approximately 2 feet / 60 cm and install the Crushing hazard. The lift cylinder
safety arm between the number 1 inner arm will become unbalanced and fall
(index #8) and the number 1 outer arm (index if not properly supported and
#17). Lower the scissor arms onto the safety secured to the lifting device.
arm.
Component damage hazard. Be
Bodily injury hazard. Keep hands careful not to damage the valve
clear of moving parts when or fittings on the cylinder while
lowering the scissor arms onto removing it from the machine.
the safety arm.
Scissor Components
Scissor Components
Scissor Components
How to Disassemble the Scissor 5 At the ground controls, turn the key switch to
the off position and push in the red Emergency
Assembly Stop button to the off position.
Bodily injury hazard. The 6 Disconnect the battery pack from the machine.
procedures in this section
require specific repair skills, Electrocution/burn hazard.
lifting equipment and a suitable Contact with electrically charged
workshop. Attempting this circuits could result in death or
procedure without these skills serious injury. Remove all rings,
and tools could result in death or watches and other jewelry.
serious injury and significant
component damage. Dealer 7 Remove the fasteners securing the large
service is required. platform height sensor cover to the large
platform height sensor bracket.
Note: When removing a hose assembly or fitting, 8 Remove the platform height sensor cover.
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be 9 Tag and disconnect the platform height sensor
torqued to specification during installation. Refer to from the platform height sensor harness.
Specifications, Hydraulic Hose and Fitting Torque
10 Remove the fastener securing the platform
Specifications.
height sensor assembly to the number 1 inner
Note: Machines equipped with a Platform Height arm.
Sensor, begin the Scissor Disassembly procedure 11 Remove the platform height sensor assembly
at step 1. Machines without a Platform Height from the number 1 pivot pin.
Sensor, begin the Scissor Disassembly procedure
at step 24. 12 Remove the plastic nut securing the squeeze
connector to the large platform height sensor
1 Turn the key switch to ground controls and pull bracket.
out the red Emergency Stop button to the on
position at both ground and platform controls. 13 Remove the squeeze connector from the large
platform height sensor bracket.
2 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
14 Remove the fasteners securing the large
3 Lift the safety arm, move it to the center of the platform height sensor bracket to the number
scissor arm and rotate down to a vertical 1 inner arm pivot bracket.
position.
Scissor Components
15 Remove the large platform height sensor 23 Fully lower the platform to the stowed position.
bracket from the number 1 inner arm pivot
bracket.
16 Install the fasteners removed in 14 to the
number 1 inner arm pivot bracket and chassis.
Tip-over hazard. Failure
to install the fasteners securing
the number 1 inner arm pivot
bracket to the chassis, could
result in the machine tipping
over, causing death or serious
injury.
Scissor Components
26 Remove the cables from the number 4 cable 35 Use a soft metal drift to remove the number
bridge and lay them off to the side. 4 pivot pin (index #3) at the steer end.
Component damage hazard. Remove the number 4 inner arm (index #12)
Cables can be damaged if they from the machine.
are kinked or pinched. Crushing hazard. The number
4 inner arm may become
27 Attach a lifting strap from an overhead crane unbalanced and fall if not
to the number 4 outer arm (index #13). properly supported when
28 Remove the external snap rings and retaining removed from the machine.
fasteners from the number 4 center pivot pins
(index #2). 36 Remove the cables from the number 3 cable
bridge and lay them off to the side.
29 Use a soft metal drift to remove the number
4 center pivot pins (index #2). Component damage hazard.
Cables can be damaged if they
30 Remove the retaining fasteners from the
are kinked or pinched.
number 4 pivot pin (index #14) at the
non-steer end of the machine. 37 Remove the number 3 cable bridge mounting
31 Use a soft metal drift to remove the number fasteners and remove the cable bridge from
4 pivot pin (index #14) from the non-steer end the machine.
of the machine. Remove the number 4 outer 38 Attach a lifting strap from an overhead crane
arm (index #13) from the machine. to the number 3 outer arm (index #4) at the
Crushing hazard. The number ground controls side.
4 outer arm may become 39 Remove the external snap rings and retaining
unbalanced and fall if not fasteners from the number 3 center pivot pins
properly supported when (index #4).
removed from the machine.
40 Use a soft metal drift to remove the number
32 Remove the number 4 cable bridge mounting 3 center pivot pin (index #4) at the ground
fasteners and remove the cable bridge from control side.
the machine. 41 Remove the retaining fasteners from the
33 Attach a lifting strap from an overhead crane number 3 pivot pin (index #17) at the
to the number 4 inner arm (index #12). non-steer end of the machine.
34 Remove the retaining fasteners from the
number 4 pivot pin (index #3).
Scissor Components
42 Use a soft metal drift to tap the number 3 pivot 48 Remove the pin retaining fasteners from the
pin (index #17) halfway out at the non-steer lift cylinder rod-end pivot pin (index #5). Use a
end of the machine. Remove the number soft metal drift to remove the pin.
3 outer arm (index #16) at the ground controls
side from the machine. Bodily injury hazard. The
cylinder may fall when the
Bodily injury hazard. The number rod-end pivot pin is removed if
3 outer arm at the ground not properly supported.
controls side may become
unbalanced and fall if not 49 Lower the cylinder onto the number 1 inner
properly supported when arm (index #9).
removed from the machine.
Component damage hazard.
43 Attach a lifting strap from an overhead crane Cables can be damaged if they
to the number 3 outer arm (index #16) at the are kinked or pinched.
battery pack side.
50 Attach a lifting strap from an overhead crane
44 Use a soft metal drift to remove the number to the number 3 inner arm (index #15).
3 center pivot pin (index #4) at the battery
pack side of the machine. 51 Remove the retaining fasteners from the
number 3 pivot pin (index #6) at the steer end.
45 Use a soft metal drift to tap the number 3 pivot
pin (index #17) in the other direction. Remove 52 Use a soft metal drift to remove the number
the number 3 outer arm (index #16) from the 3 pivot pin (index #6). Remove the number
battery pack side of the machine. 3 inner arm (index #15) from the machine.
Bodily injury hazard. The number Bodily injury hazard. The number
3 outer arm at the battery pack 3 inner arm may become
side may become unbalanced unbalanced and fall if not
and fall if not properly supported properly supported when
when removed from the removed from the machine.
machine.
53 Remove the cables from the number 2 cable
46 Remove the number 3 pivot pin (index #17) bridge and lay them off to the side.
from the non-steer end of the machine. Component damage hazard.
47 Attach a lifting strap from an overhead crane Cables can be damaged if they
to the lug on the rod end of the lift cylinder for are kinked or pinched.
support. Do not apply any lifting pressure.
54 Remove the external snap rings and retaining
fasteners from the number 2 center pivot pin
(index #7) at the ground controls side.
Scissor Components
55 Remove the number 2 cable bridge mounting 63 Use a soft metal drift to tap the number 2 pivot
fasteners and remove the cable bridge from pin (index #20) in the other direction at the
the machine. non-steer end. Remove the number 2 outer
arm (index #19) from the battery pack side of
56 Attach a lifting strap from an overhead crane
the machine.
to the number 2 outer arm (index #19) at the
ground controls side. Bodily injury hazard. The number
57 Use a soft metal drift to remove the number 2 outer arm at the battery pack
2 center pivot pin (index #7) at the ground side may become unbalanced
controls side. and fall if not properly supported
when removed from the
58 Remove the retaining fasteners from the machine.
number 2 pivot pin (index #20) at the
non-steer end of the machine. 64 Remove the number 3 pivot pin (index #17)
from the non-steer end of the machine.
59 Use a soft metal drift to tap the number 2 pivot
pin (index #20) halfway out at the non-steer 65 Attach a lifting strap from an overhead crane
end of the machine. Remove the number to the number 2 inner arm (index #18).
2 outer arm (index #19) from the ground
controls side of the machine. 66 Remove the retaining fasteners from the
number 2 pivot pin (index #8) at the steer end
Bodily injury hazard. The number of the machine.
2 outer arm at the ground 67 Use a soft metal drift to remove the number
controls side may become
2 pivot pin (index #8). Remove the number
unbalanced and fall if not
2 inner arm (index #18) from the machine.
properly supported when
removed from the machine. Bodily injury hazard. The number
2 inner arm may become
60 Attach a lifting strap from an overhead crane unbalanced and fall if not
to the number 2 outer arm (index #19) at the properly supported when
battery pack side. removed from the machine.
61 Remove the external snap rings and retaining
fasteners from the number 2 center pivot pin 68 Remove the safety arm from the number
(index #7) at the battery pack side. 2 inner arm (index #18) that was just removed.
62 Use a soft metal drift to remove the number 69 Attach a lifting strap from an overhead crane
2 center pivot pin (index #7) at the battery to the number 1 inner arm (index #10).
pack side.
Bodily injury hazard. The number
2 outer arm at the battery pack
side may become unbalanced
and fall if not properly supported
when removed from the
machine.
Scissor Components
70 Raise the number 1 inner arm (index #10) 76 Remove the pin retaining fasteners from the
approximately 2 feet / 60 cm and install the lift cylinder barrel-end pin (index #21). Use a
safety arm between the number 1 inner arm soft metal drift to remove the pin. Remove the
(index #10) and the number 1 outer arm (index lift cylinder from the machine.
#22) at the non-steer end of the machine.
Lower the scissor arms onto the safety arm. Crushing hazard. The lift cylinder
will become unbalanced and fall
Bodily injury hazard. Keep hands if not properly supported and
clear of moving parts when secured to the lifting device.
lowering the scissor arms onto
the safety arm. Component damage hazard. Be
careful not to damage the valve
71 Attach a lifting strap from an overhead crane or fittings on the cylinder while
to the lug on the rod end of the lift cylinder removing it from the machine.
(index #5). Raise the lift cylinder
approximately 3 ft / 1 m. 77 Place a 4 x 4 x 48 inch / 10 cm x 10 cm x
1.2 m long block across both sides of the
72 Tag, disconnect and plug the hydraulic hoses chassis under the number 1 center pivot pin
on the lift cylinder. Cap the fittings on the (index #11).
cylinder.
78 Attach a lifting strap from an overhead crane
Bodily injury hazard. Spraying to the number 1 inner arm (index #10) at the
hydraulic oil can penetrate and non-steer end. Raise the number 1 inner arm
burn skin. Loosen hydraulic and remove the safety arm. Lower the number
connections very slowly to allow 1 inner arm (index #10) onto the block that
the oil pressure to dissipate was placed across the chassis.
gradually. Do not allow oil to
squirt or spray. Bodily injury hazard. Keep hands
clear of moving parts when
73 Tag and disconnect the wires and manual lowering the scissor arms.
lowering cable from the solenoid valve on the
cylinder. 79 Remove the cables from the number 1 cable
bridge and lay them off to the side.
74 Models with platform overload option: Tag
and disconnect the wire harness from the Component damage hazard.
platform overload pressure transducer. Cables can be damaged if they
are kinked or pinched.
Note: After replacing the scissor assembly, the
platform overload system must be calibrated.
80 Support and secure the entry ladder to an
Refer to Repair Procedure, How to Calibrate the
appropriate lifting device.
Platform Overload System (if equipped).
75 Raise the lift cylinder to a vertical position.
Scissor Components
81 Remove the fasteners from the entry ladder 88 Remove the upper fasteners securing the
and remove the entry ladder from the number 1 inner arm pivot bracket to the end of
machine. the chassis. Loosen the lower fasteners.
Crushing hazard. The entry 89 Remove the number 1 inner arm (index #10)
ladder will fall if not properly from the machine.
supported and secured to the
Bodily injury hazard. The number
lifting device.
1 inner arm may become
82 Attach a lifting strap from an overhead crane unbalanced and fall if not
properly supported when
to the number 1 outer arm (index #22). Do not
apply any lifting pressure. removed from the machine.
83 Remove the external snap rings and retaining Component damage hazard. Be
fasteners from the number 1 center pivot pins sure not to damage the limit
(index #11). switch or level sensor
components when the number
84 Remove the number 1 cable bridge from the 1 inner arm is removed from the
machine. machine.
85 Use a soft metal drift to remove the number
1 center pivot pins (index #9).
Bodily injury hazard. The number
1 outer arm may become
unbalanced and fall if not
properly supported when the pin
is removed.
Scissor Components
Scissor Components
How to Disassemble the Scissor 5 At the ground controls, turn the key switch to
the off position and push in the red Emergency
Assembly, GS-2032 and GS-2046 Stop button to the off position.
Bodily injury hazard. The 6 Disconnect the battery pack from the machine.
procedures in this section
require specific repair skills, Electrocution/burn hazard.
lifting equipment and a suitable Contact with electrically charged
workshop. Attempting this circuits could result in death or
procedure without these skills serious injury. Remove all rings,
and tools could result in death or watches and other jewelry.
serious injury and significant
component damage. Dealer 7 Remove the fasteners securing the large
service is required. platform height sensor cover to the large
platform height sensor bracket.
Note: When removing a hose assembly or fitting, 8 Remove the platform height sensor cover.
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be 9 Tag and disconnect the platform height sensor
torqued to specification during installation. Refer to from the platform height sensor harness.
Specifications, Hydraulic Hose and Fitting Torque
10 Remove the fastener securing the platform
Specifications.
height sensor assembly to the number 1 inner
Note: Machines equipped with a Platform Height arm.
Sensor, begin the Scissor Disassembly procedure 11 Remove the platform height sensor assembly
at step 1. Machines without a Platform Height from the number 1 pivot pin.
Sensor, begin the Scissor Disassembly procedure
at step 24. 12 Remove the plastic nut securing the squeeze
connector to the large platform height sensor
1 Turn the key switch to ground controls and pull bracket.
out the red Emergency Stop button to the on
position at both ground and platform controls. 13 Remove the squeeze connector from the large
platform height sensor bracket.
2 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
14 Remove the fasteners securing the large
3 Lift the safety arm, move it to the center of the platform height sensor bracket to the number
scissor arm and rotate down to a vertical 1 inner arm pivot bracket.
position.
15 Remove the large platform height sensor
bracket from the number 1 inner arm pivot
bracket.
Scissor Components
16 Install the fasteners removed in 14 to the 23 Fully lower the platform to the stowed position.
number 1 inner arm pivot bracket and chassis.
Tip-over hazard. Failure
to install the fasteners securing
the number 1 inner arm pivot
bracket to the chassis, could
result in the machine tipping
over, causing death or serious
injury.
Scissor Components
27 Remove the cables from the number 3 cable 36 Attach a lifting strap from an overhead crane
bridge and lay them off to the side. to the number 3 outer arm at the battery side
(index #11).
Component damage hazard.
Cables can be damaged if they 37 Remove the retaining fasteners from the
are kinked or pinched. number 3 center pivot pin (index #2) at the
battery side.
28 Disconnect the number 3 cable bridge from 38 Place a rod through the number 3 center pivot
the number 3 outer arm (index #11) and pin at the battery side (index #2) and twist to
remove the cable bridge from the machine. remove the pin.
29 Remove the retaining fasteners from the 39 Remove the number 3 outer arm (index #11)
number 4 pivot pin (index #1). from the machine.
30 Use a soft metal drift to remove the number
4 pivot pin (index #1). Remove the platform Crushing hazard. The number
mount bracket from the machine. 3 outer arm (index #11) may
become unbalanced and fall if
31 Attach a lifting strap from an overhead crane not properly supported when
to the number 3 outer arm at the ground removed from the machine.
control side (index #11).
40 Attach a lifting strap from an overhead crane
32 Remove the retaining fasteners from the
to the lug of the rod end of the lift cylinder.
number 3 center pivot pin (index #2) at the
ground control side. 41 Remove the retaining fasteners from the lift
cylinder rod end pivot pin (index #3).
33 Place a rod through the number 3 center pivot
pin at the ground control side (index #2) and 42 Use a soft metal drift to remove the lift cylinder
twist to remove the pin. rod end pivot pin (index #3) from the machine.
34 Remove the retaining fasteners from the Crushing hazard. The lift cylinder
number 3 pivot pin (index #12) at the will fall if not properly supported
non-steer end. when the pivot pin is removed.
35 Use a soft metal drift to remove the number
3 pivot pin (index #12) from the non-steer end 43 Place a 4 x 4 x 10 inch / 10 x 10 x 25 cm block
of the machine. Remove the number 3 outer onto the number 1 inner arm cylinder plate
arm at the ground control side (index #11) (index #8).
from the machine. 44 Lower the cylinder onto the block.
Crushing hazard. The number Bodily injury hazard. Keep hands
3 outer arm at the ground control clear of moving parts when
side (index #11) may become lowering the cylinder.
unbalanced and fall if not
properly supported when 45 Attach a lifting strap from an overhead crane
removed from the machine. to the number 3 inner arm (index #10). Raise
the arm to a vertical position.
Scissor Components
46 Remove the retaining fasteners from the 54 Use a soft metal drift to remove the number
number 3 pivot pin at the steer end of the 2 pivot pin (index #15) from the non-steer end
machine (index #4). of the machine. Remove the number 2 outer
arm at the ground control side (index #14)
47 Use a soft metal drift to remove the number
from the machine.
3 pivot pin (index #4) from the steer end of the
machine. Remove the number 3 inner arm The number 2 outer arm at the
(index #10) from the machine. ground control side (index #14)
may become unbalanced and fall
Crushing hazard. The number
if not properly supported when
3 inner arm (index #10) may
the pivot pin is removed.
become unbalanced and fall if
not properly supported when the 55 Attach a lifting strap from an overhead crane
pivot pin is removed.
to the number 2 outer arm at the battery side
(index #14).
48 Remove the cables from the number 2A and
2B cable bridges and lay them off to the side. 56 Remove the retaining fasteners from the
number 2 center pivot pin (index #5) at the
Component damage hazard. battery side.
Cables can be damaged if they
are kinked or pinched. 57 Place a rod through the number 2 center pivot
pin at the battery side (index #5) and twist to
49 Disconnect the number 2A and 2B cable remove the pin.
bridges from the scissor linkset and remove
both cable bridges from the machine. Crushing hazard. The number
2 outer arm (index #14) may
50 Attach a lifting strap from an overhead crane become unbalanced and fall if
to the number 2 outer arm at the ground not properly supported when the
control side (index #14). pivot pin is removed.
51 Remove the retaining fasteners from the
58 Remove the number 2 outer arm (index #14)
number 2 center pivot pin (index #5) at the
from the machine.
ground control side.
52 Place a rod through the number 2 center pivot Crushing hazard. The number
pin at the ground control side (index #5) and 2 outer arm (index #14) may
twist to remove the pin. become unbalanced and fall if
not properly supported when
53 Remove the retaining fasteners from the removed from the machine.
number 2 pivot pin (index #15) at the
non-steer end. 59 Attach a lifting strap from an overhead crane
to the number 2 inner arm (index #13). Raise
the arm to a vertical position.
Scissor Components
60 Remove the retaining fasteners from the 67 Tag, disconnect and plug the hydraulic hose
number 2 pivot pin at the steer end of the on the lower lift cylinder. Cap the fittings on the
machine (index #6). cylinder.
61 Use a soft metal drift to remove the number Bodily injury hazard. Spraying
2 pivot pin (index #6) from the steer end of the hydraulic oil can penetrate and
machine. Remove the number 2 inner arm burn skin. Loosen hydraulic
(index #13) from the machine. connections very slowly to allow
the oil pressure to dissipate
Crushing hazard. The number
gradually. Do not allow oil to
2 inner arm (index #13) may
squirt or spray.
become unbalanced and fall if
not properly supported when the 68 Tag and disconnect the wire harness from the
pivot pin is removed.
solenoid valve on the cylinder.
62 Attach a lifting strap from an overhead crane 69 Tag and disconnect the wires and manual
to the number 1 inner arm (index #8). lowering cable from the solenoid valve on the
cylinder.
63 Raise the number 1 inner arm (index #8)
approximately 2 feet / 60 cm. 70 Models with platform overload option: Tag
and disconnect the wire harness from the
64 Place a 4 x 4 x 48 inch / 10 cm x 10 cm x
platform overload pressure transducer.
1.2 m long block across both sides of the
chassis under the number 1 center pivot pin Note: After replacing the scissor assembly, the
(index #7). platform overload system must be calibrated.
Refer to Repair Procedure, How to Calibrate the
65 Lower the scissor arms onto the block that
Platform Overload System (if equipped).
was placed across the chassis.
71 Raise the lift cylinder to a vertical position.
Bodily injury hazard. Keep hands
clear of moving parts when 72 Remove the pin retaining fasteners from the
lowering the scissor arms. lift cylinder barrel-end pin (index #16). Use a
soft metal drift to remove the pin. Remove the
66 Attach a lifting strap from an overhead crane lift cylinder from the machine.
to the lug of the rod end of the lower lift
cylinder. Crushing hazard. The lift cylinder
will fall if not properly supported
when the pivot pin is removed.
Scissor Components
Scissor Components
Scissor Components
How to Disassemble the Scissor 5 At the ground controls, turn the key switch to
the off position and push in the red Emergency
Assembly Stop button to the off position.
Bodily injury hazard. The 6 Disconnect the battery pack from the machine.
procedures in this section
require specific repair skills, Electrocution/burn hazard.
lifting equipment and a suitable Contact with electrically charged
workshop. Attempting this circuits could result in death or
procedure without these skills serious injury. Remove all rings,
and tools could result in death or watches and other jewelry.
serious injury and significant
component damage. Dealer 7 Remove the fasteners securing the large
service is required. platform height sensor cover to the large
platform height sensor bracket.
Note: When removing a hose assembly or fitting, 8 Remove the platform height sensor cover.
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be 9 Tag and disconnect the platform height sensor
torqued to specification during installation. Refer to from the platform height sensor harness.
Specifications, Hydraulic Hose and Fitting Torque
10 Remove the fastener securing the platform
Specifications.
height sensor assembly to the number 1 inner
Note: Machines equipped with a Platform Height arm.
Sensor, begin the Scissor Disassembly procedure 11 Remove the platform height sensor assembly
at step 1. Machines without a Platform Height from the number 1 pivot pin.
Sensor, begin the Scissor Disassembly procedure
at step 24. 12 Remove the plastic nut securing the squeeze
connector to the large platform height sensor
1 Turn the key switch to ground controls and pull bracket.
out the red Emergency Stop button to the on
position at both ground and platform controls. 13 Remove the squeeze connector from the large
platform height sensor bracket.
2 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
14 Remove the fasteners securing the large
3 Lift the safety arm, move it to the center of the platform height sensor bracket to the number
scissor arm and rotate down to a vertical 1 inner arm pivot bracket.
position.
15 Remove the large platform height sensor
bracket from the number 1 inner arm pivot
bracket.
Scissor Components
16 Install the fasteners removed in 14 to the 23 Fully lower the platform to the stowed position.
number 1 inner arm pivot bracket and chassis.
Tip-over hazard. Failure
to install the fasteners securing
the number 1 inner arm pivot
bracket to the chassis, could
result in the machine tipping
over, causing death or serious
injury.
Scissor Components
24 Remove the platform. Refer to Repair 34 Remove the retaining fasteners from the
Procedure, How to Remove the Platform. number 4 pivot pin (index #15) at the
non-steer end.
25 Support and secure the entry ladder to an
appropriate lifting device. 35 Use a soft metal drift to remove the number
4 pivot pin (index #14) from the non-steer end
26 Remove the fasteners from the entry ladder
of the machine. Remove the number 4 outer
and remove the entry ladder from the
arm at the ground control side (index #13)
machine.
from the machine.
Crushing hazard. The entry
Crushing hazard. The number
ladder will fall if not properly
4 outer arm at the ground control
supported and secured to the
side (index #13) may become
lifting device.
unbalanced and fall if not
properly supported when
27 Remove the cables from the number 4 cable
removed from the machine.
bridge and lay them off to the side.
Component damage hazard. 36 Attach a lifting strap from an overhead crane
Cables can be damaged if they to the number 4 outer arm at the battery side
are kinked or pinched. (index #13).
37 Remove the retaining fasteners from the
28 Disconnect the number 4 cable bridge from number 4 center pivot pin (index #2) at the
the number 4 outer arm (index #13) and battery side.
remove the cable bridge from the machine.
38 Place a rod through the number 4 center pivot
29 Remove the retaining fasteners from the pin at the battery side (index #2) and twist to
number 5 pivot pin (index #1). remove the pin.
30 Use a soft metal drift to remove the number 39 Remove the number 4 outer arm (index #13)
5 pivot pin (index #1). Remove the platform from the machine.
mount bracket from the machine.
Crushing hazard. The number
31 Attach a lifting strap from an overhead crane
4 outer arm (index #13) may
to the number 4 outer arm at the ground
become unbalanced and fall if
control side (index #13).
not properly supported when
32 Remove the retaining fasteners from the removed from the machine.
number 4 center pivot pin (index #2) at the
ground control side. 40 Attach a lifting strap from an overhead crane
to the number 4 inner arm (index #12). Raise
33 Place a rod through the number 4 center pivot
the arm to a vertical position.
pin at the ground control side (index #2) and
twist to remove the pin.
Scissor Components
41 Remove the retaining fasteners from the 49 Use a soft metal drift to remove the number
number 4 pivot pin at the steer end of the 3 pivot pin (index #17) from the non-steer end
machine (index #3). of the machine. Remove the number 3 outer
arm at the ground control side (index #16)
42 Use a soft metal drift to remove the number
from the machine.
4 pivot pin (index #3) from the steer end of the
machine. Remove the number 4 inner arm Crushing hazard. The number
(index #12) from the machine. 3 outer arm at the ground control
side (index #16) may become
Crushing hazard. The number
unbalanced and fall if not
4 inner arm (index #12) may
properly supported when
become unbalanced and fall if
removed from the machine.
not properly supported when
removed from the machine.
50 Attach a lifting strap from an overhead crane
to the number 3 outer arm at the battery side
43 Remove the cables from the number 3A and
(index #16).
3B cable bridge and lay them off to the side.
51 Remove the retaining fasteners from the
Component damage hazard. number 3 center pivot pin (index #4) at the
Cables can be damaged if they battery side.
are kinked or pinched.
52 Place a rod through the number 3 center pivot
44 Disconnect the number 3A and 3B cable pin at the battery side (index #4) and twist to
bridges from the scissor linkset and remove remove the pin.
both cable bridges from the machine. 53 Remove the number 3 outer arm (index #16)
45 Attach a lifting strap from an overhead crane from the machine.
to the number 3 outer arm at the ground
control side (index #16). Crushing hazard. The number
3 outer arm (index #16) may
46 Remove the retaining fasteners from the become unbalanced and fall if
number 3 center pivot pin (index #4) at the not properly supported when
ground control side. removed from the machine.
47 Place a rod through the number 3 center pivot
54 Attach a lifting strap from an overhead crane
pin at the ground control side (index #4) and
to the lug of the rod end of the lift cylinder.
twist to remove the pin.
55 Remove the retaining fasteners from the lift
48 Remove the retaining fasteners from the
cylinder rod end pivot pin (index #5).
number 3 pivot pin (index #17) at the
non-steer end.
Scissor Components
56 Use a soft metal drift to remove the lift cylinder 63 Disconnect the number 2A and 2B cable
rod end pivot pin (index #5) from the machine. bridges from the scissor linkset and remove
both cable bridges from the machine.
Crushing hazard. The lift cylinder
64 Attach a lifting strap from an overhead crane
will fall if not properly supported
to the number 2 outer arm at the ground
when the pivot pin is removed.
control side (index #19).
57 Place a 4 x 4 x 10 inch / 10 x 10 x 25 cm block 65 Remove the retaining fasteners from the
onto the number 1 inner arm cylinder plate number 2 center pivot pin (index #7) at the
(index #10). ground control side.
58 Lower the cylinder onto the block. 66 Place a rod through the number 2 center pivot
pin at the ground control side (index #7) and
Bodily injury hazard. Keep hands twist to remove the pin.
clear of moving parts when
lowering the cylinder. 67 Remove the retaining fasteners from the
number 2 pivot pin (index #20) at the
59 Attach a lifting strap from an overhead crane non-steer end.
to the number 3 inner arm (index #15). Raise
68 Use a soft metal drift to remove the number
the arm to a vertical position.
2 pivot pin (index #20) from the non-steer end
60 Remove the retaining fasteners from the of the machine. Remove the number 2 outer
number 3 pivot pin at the steer end of the arm at the ground control side (index #19)
machine (index #6). from the machine.
61 61 Use a soft metal drift to remove the The number 2 outer arm at the
number 3 pivot pin (index #6) from the steer ground control side (index #19)
end of the machine. Remove the number may become unbalanced and fall
3 inner arm (index #15) from the machine. if not properly supported when
the pivot pin is removed.
Crushing hazard. The number
3 inner arm (index #15) may 69 Attach a lifting strap from an overhead crane
become unbalanced and fall if to the number 2 outer arm at the battery side
not properly supported when the (index #19).
pivot pin is removed.
70 Remove the retaining fasteners from the
62 Remove the cables from the number 2A and number 2 center pivot pin (index #7) at the
2B cable bridge and lay them off to the side. battery side.
Scissor Components
Scissor Components
85 Raise the lift cylinder to a vertical position. 93 Secure the ends of the scissor arms together
at the non-steer end of the machine with a
86 Remove the pin retaining fasteners from the
strap or other suitable device.
lift cylinder barrel-end pin (index #21). Use a
soft metal drift to remove the pin. Remove the 94 Remove the retaining fasteners securing the
lift cylinder from the machine. chassis mount bracket to the chassis.
Crushing hazard. The lift cylinder 95 Remove the linkset from the machine
will fall if not properly supported
Bodily injury hazard. The number
when the pivot pin is removed.
1 inner and outer arms (index
Component damage hazard. Be #10 and #22) may become
careful not to damage the valve unbalanced and fall if not
or fittings on the cylinder while properly supported when
removing it from the machine. removed from the machine.
87 Remove the cables from the number 1 cable Component damage hazard. Be
sure not to damage the limit
bridge and lay them off to the side.
switch or level sensor
Component damage hazard. components when the number
Cables can be damaged if they 1 inner and outer arms (index
are kinked or pinched. #10 and #22) are removed from
the machine.
88 Disconnect the number 1 cable bridge from
the number 1 outer arm (index #22) and
remove the cable bridge from the machine.
89 Attach a lifting strap from an overhead crane
to the number 1 inner arm (index #10).
90 Raise the arm slightly and remove the block.
91 Lower the arm to the stowed position.
Bodily injury hazard. Keep hands
clear of moving parts when
lowering the scissor arms.
Scissor Components
Scissor Components
Bodily injury hazard. The 5 At the ground controls, turn the key switch to
procedures in this section the off position and push in the red Emergency
require specific repair skills, Stop button to the off position.
lifting equipment and a suitable
workshop. Attempting this 6 Disconnect the battery pack from the machine.
procedure without these skills Electrocution/burn hazard.
and tools could result in death or Contact with electrically charged
serious injury and significant circuits could result in death or
component damage. Dealer serious injury. Remove all rings,
service is required. watches and other jewelry.
Note: When removing a hose assembly or fitting, 7 Remove the fasteners securing the large
the O-ring (if equipped) on the fitting and/or hose platform height sensor cover to the large
end must be replaced. All connections must be platform height sensor bracket.
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque 8 Remove the platform height sensor cover.
Specifications.
9 Tag and disconnect the platform height sensor
Note: Machines equipped with a Platform Height from the platform height sensor harness.
Sensor, begin the Scissor Disassembly procedure 10 Remove the fastener securing the platform
at step 1. Machines without a Platform Height height sensor assembly to the number 1 inner
Sensor, begin the Scissor Disassembly procedure arm.
at step 24.
11 Remove the platform height sensor assembly
1 Turn the key switch to ground controls and pull from the number 1 pivot pin.
out the red Emergency Stop button to the on
position at both ground and platform controls. 12 Remove the plastic nut securing the squeeze
connector to the large platform height sensor
2 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. bracket.
Scissor Components
13 Remove the squeeze connector from the large 22 Raise the platform and rotate the safety arm to
platform height sensor bracket. the stowed position.
14 Remove the fasteners securing the large 23 Fully lower the platform to the stowed position.
platform height sensor bracket to the number
1 inner arm pivot bracket.
15 Remove the large platform height sensor
bracket from the number 1 inner arm pivot
bracket.
16 Install the fasteners removed in 14 to the
number 1 inner arm pivot bracket and chassis.
Tip-over hazard. Failure
to install the fasteners securing
the number 1 inner arm pivot
bracket to the chassis, could
result in the machine tipping
over, causing death or serious
injury.
Scissor Components
24 Remove the platform. Refer to Repair 35 Use a soft metal drift to remove the number
Procedure, How to Remove the Platform. 5 pivot pin (index #18) from the non-steer end
of the machine. Remove the number 5 outer
25 Support and secure the entry ladder to an
arm at the ground control side (index #17)
appropriate lifting device.
from the machine.
26 Remove the fasteners from the entry ladder
and remove the entry ladder from the Crushing hazard. The number
machine. 5 outer arm at the ground control
side (index #17) may become
Crushing hazard. The entry unbalanced and fall if not
ladder will fall if not properly properly supported when
supported and secured to the removed from the machine.
lifting device.
36 Attach a lifting strap from an overhead crane
27 Remove the cables from the number 5 cable to the number 5 outer arm at the battery side
bridge and lay them off to the side. (index #17).
28 Disconnect the number 4 cable bridge from 37 Remove the retaining fasteners from the
the number 5 outer arm (index #17) and number 5 center pivot pin (index #2) at the
remove the cable bridge from the machine. battery side.
29 Remove the retaining fasteners from the 38 Place a rod through the number 5 center pivot
number 6 pivot pin (index #1). pin at the battery side (index #2) and twist to
remove the pin.
30 Use a soft metal drift to remove the number
6 pivot pin (index #1). Remove the platform 39 Remove the number 5 outer arm (index #17)
mount bracket from the machine. from the machine.
31 Attach a lifting strap from an overhead crane Crushing hazard. The number
to the number 5 outer arm at the ground 5 outer arm (index #17) may
control side (index #17). become unbalanced and fall if
32 Remove the retaining fasteners from the not properly supported when
number 5 center pivot pin (index #2) at the removed from the machine.
ground control side.
40 Attach a lifting strap from an overhead crane
33 Place a rod through the number 5 center pivot to the number 5 inner arm (index #16). Raise
pin at the ground control side (index #2) and the arm to a vertical position.
twist to remove the pin.
41 Remove the retaining fasteners from the
34 Remove the retaining fasteners from the number 5 pivot pin at the steer end of the
number 5 pivot pin (index #18) at the machine (index #4).
non-steer end.
Scissor Components
42 Use a soft metal drift to remove the number 49 Use a soft metal drift to remove the upper lift
5 pivot pin (index #18) from the steer end of cylinder rod end pivot pin (index #3) from the
the machine. Remove the number 5 inner arm machine.
(index #16) from the machine.
Crushing hazard. The lift cylinder
Crushing hazard. The number will fall if not properly supported
5 inner arm (index #16) may when the pivot pin is removed.
become unbalanced and fall if
not properly supported when 50 Lower the cylinder onto the linkset.
removed from the machine.
51 Attach a lifting strap from an overhead crane
to the number 4 outer arm at the ground
43 Tag, disconnect and plug the hydraulic hose
control side (index #20).
on the upper lift cylinder. Cap the fittings on
the cylinder. 52 Remove the retaining fasteners from the
number 4 center pivot pin (index #5) at the
Bodily injury hazard. Spraying ground control side.
hydraulic oil can penetrate and
burn skin. Loosen hydraulic 53 Place a rod through the number 4 center pivot
connections very slowly to allow pin at the ground control side (index #5) and
the oil pressure to dissipate twist to remove the pin.
gradually. Do not allow oil to 54 Remove the retaining fasteners from the
squirt or spray. number 4 pivot pin (index #21) at the
non-steer end.
44 Tag and disconnect the wire harness from the
solenoid valve on the cylinder. 55 Use a soft metal drift to remove the number
4 pivot pin (index #21) from the non-steer end
45 Remove the cables from the number 4A and
of the machine. Remove the number 4 outer
4B cable bridges and lay them off to the side.
arm at the ground control side (index #20)
Component damage hazard. from the machine.
Cables can be damaged if they
Crushing hazard. The number
are kinked or pinched.
4 outer arm at the ground control
side (index #20) may become
46 Disconnect the number 4A and 4B cable
unbalanced and fall if not
bridges from the scissor linkset and remove
properly supported when
both cable bridges from the machine.
removed from the machine.
47 Attach a lifting strap from an overhead crane
to the lug of the rod end of the upper lift 56 Attach a lifting strap from an overhead crane
cylinder. to the number 4 outer arm at the battery side
(index #20).
48 Remove the retaining fasteners from the
upper lift cylinder rod end pivot pin (index #3). 57 Remove the retaining fasteners from the
number 4 center pivot pin (index #5) at the
battery side.
Scissor Components
58 Place a rod through the number 4 center pivot 66 Remove the retaining fasteners from the
pin at the battery side (index #5) and twist to number 3 center pivot pin (index #8) at the
remove the pin. ground control side.
59 Remove the number 4 outer arm (index #20) 67 Place a rod through the number 3 center pivot
from the machine. pin at the ground control side (index #8) and
twist to remove the pin.
Crushing hazard. The number
4 outer arm (index #20) may 68 Remove the retaining fasteners from the
become unbalanced and fall if number 3 pivot pin (index #24) at the
not properly supported when non-steer end.
removed from the machine. 69 Use a soft metal drift to remove the number
3 pivot pin (index #24) from the non-steer end
60 Attach a lifting strap from an overhead crane of the machine. Remove the number 3 outer
to the number 4 inner arm (index #19). Raise arm at the ground control side (index #7) from
the arm to a vertical position. the machine.
61 Remove the retaining fasteners from the
number 4 pivot pin at the steer end of the Crushing hazard. The number
3 outer arm at the ground control
machine (index #6).
side (index #7) may become
62 Use a soft metal drift to remove the number unbalanced and fall if not
4 pivot pin (index #6) from the steer end of the properly supported when
machine. Remove the number 4 inner arm removed from the machine.
(index #19) from the machine.
70 Attach a lifting strap from an overhead crane
Crushing hazard. The number to the number 3 outer arm at the battery side
4 inner arm (index #19) may (index #7).
become unbalanced and fall if
not properly supported when 71 Remove the retaining fasteners from the
removed from the machine. number 3 center pivot pin (index #8) at the
battery side.
63 Remove the cables from the number 3A and 72 Place a rod through the number 3 center pivot
3B cable bridges and lay them off to the side. pin at the battery side (index #8) and twist to
Component damage hazard. remove the pin.
Cables can be damaged if they 73 Remove the number 3 outer arm (index #7)
are kinked or pinched. from the machine.
64 Disconnect the number 3A and 3B cable Crushing hazard. The number
bridges from the scissor linkset and remove 3 outer arm (index #7) may
both cable bridges from the machine. become unbalanced and fall if
not properly supported when
65 Attach a lifting strap from an overhead crane
removed from the machine.
to the number 3 outer arm at the ground
control side (index #7).
Scissor Components
74 Attach a lifting strap from an overhead crane 83 Remove the retaining fasteners from the
to the lug of the rod end of the upper lift number 3 pivot pin at the steer end of the
cylinder. machine (index #10).
75 Raise the lift cylinder to a vertical position. 84 Use a soft metal drift to remove the number
76 Remove the pin retaining fasteners from the 3 pivot pin (index #10) from the steer end of
lift cylinder barrel-end pivot pin (index #22). the machine. Remove the number 3 inner arm
Remove the lift cylinder from the machine. (index #23) from the machine.
78 Remove the retaining fasteners from the lower 86 Disconnect the number 2A and 2B cable
lift cylinder rod end pivot pin (index #9). bridges from the scissor linkset and remove
both cable bridges from the machine.
79 Use a soft metal drift to remove the lower lift
cylinder rod end pivot pin (index #9) from the 87 Attach a lifting strap from an overhead crane
machine. to the number 2 outer arm at the ground
control side (index #26).
Crushing hazard. The lift cylinder
will fall if not properly supported 88 Remove the retaining fasteners from the
when the pivot pin is removed. number 2 center pivot pin (index #11) at the
ground control side.
80 Place a 4 x 4 x 10 inch / 10 x 10 x 25 cm block
89 Place a rod through the number 2 center pivot
onto the number 1 inner arm cylinder plate
pin at the ground control side (index #11) and
(index #14).
twist to remove the pin.
81 Lower the cylinder onto the block.
90 Remove the retaining fasteners from the
Bodily injury hazard. Keep hands number 2 pivot pin (index #27) at the
clear of moving parts when non-steer end.
lowering the cylinder.
Scissor Components
91 Use a soft metal drift to remove the number 97 Remove the retaining fasteners from the
2 pivot pin (index #27) from the non-steer end number 2 pivot pin at the steer end of the
of the machine. Remove the number 2 outer machine (index #12).
arm at the ground control side (index #26)
98 Use a soft metal drift to remove the number
from the machine.
2 pivot pin (index #12) from the steer end of
The number 2 outer arm at the the machine. Remove the number 2 inner arm
ground control side (index #26) (index #25) from the machine.
may become unbalanced and fall
Crushing hazard. The number
if not properly supported when
2 inner arm (index #25) may
the pivot pin is removed.
become unbalanced and fall if
92 Attach a lifting strap from an overhead crane not properly supported when the
pivot pin is removed.
to the number 2 outer arm at the battery side
(index #26).
99 Attach a lifting strap from an overhead crane
93 Remove the retaining fasteners from the to the number 1 inner arm (index #14).
number 2 center pivot pin (index #11) at the
100 Raise the number 1 inner arm (index #14)
battery side.
approximately 2 feet / 60 cm.
94 Place a rod through the number 2 center pivot
101 Place a 4 x 4 x 48 inch / 10 cm x 10 cm x
pin at the battery side (index #11) and twist to
1.2 m long block across both sides of the
remove the pin.
chassis under the number 1 center pivot pin
Crushing hazard. The number (index #13).
2 outer arm (index #26) may 102 Lower the scissor arms onto the block that
become unbalanced and fall if was placed across the chassis.
not properly supported when the
pivot pin is removed. Bodily injury hazard. Keep hands
clear of moving parts when
95 Remove the number 2 outer arm (index #26) lowering the scissor arms.
from the machine.
103 Attach a lifting strap from an overhead crane
Crushing hazard. The number to the lug of the rod end of the lower lift
2 outer arm (index #26) may cylinder.
become unbalanced and fall if
not properly supported when 104 Tag, disconnect and plug the hydraulic hose
removed from the machine. on the lower lift cylinder. Cap the fittings on the
cylinder.
96 Attach a lifting strap from an overhead crane
to the number 2 inner arm (index #25). Raise Bodily injury hazard. Spraying
the arm to a vertical position. 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.
Scissor Components
105 Tag and disconnect the wire harness from the 113 Lower the arm to the stowed position.
solenoid valve on the cylinder.
Bodily injury hazard. Keep hands
106 Models with platform overload option: Tag
clear of moving parts when
and disconnect the wire harness from the
lowering the scissor arms.
platform overload pressure transducer.
Note: After replacing the scissor assembly, the 114 Secure the ends of the scissor arms together
platform overload system must be calibrated. at the steer end of the machine with a strap or
Refer to Repair Procedure, How to Calibrate the other suitable device.
Platform Overload System (if equipped).
115 Secure the ends of the scissor arms together
107 Raise the lift cylinder to a vertical position. at the non-steer end of the machine with a
strap or other suitable device.
108 Remove the pin retaining fasteners from the
lift cylinder barrel-end pin (index #28). Use a 116 Remove the retaining fasteners securing the
soft metal drift to remove the pin. Remove the chassis mount bracket to the chassis.
lift cylinder from the machine. 117 Remove the linkset from the machine.
Crushing hazard. The lift cylinder Bodily injury hazard. The number
will fall if not properly supported 1 inner and outer arms (index
when the pivot pin is removed. #14 and #29) may become
unbalanced and fall if not
Component damage hazard. Be properly supported when
careful not to damage the valve removed from the machine.
or fittings on the cylinder while
removing it from the machine. Component damage hazard. Be
sure not to damage the limit
109 Remove the cables from the number 1 cable switch or level sensor
bridge and lay them off to the side. components when the number
Component damage hazard. 1 inner and outer arms (index
Cables can be damaged if they #14 and #29) are removed from
are kinked or pinched. the machine.
Scissor Components
Scissor Components
Bodily injury hazard. This 5 At the ground controls, turn the key switch to
procedure requires specific repair the off position and push in the red Emergency
skills, lifting equipment and a Stop button to the off position.
suitable workshop. Attempting
this procedure without these skills 6 Disconnect the battery pack from the machine.
and tools could result in death or Electrocution/burn hazard.
serious injury and significant Contact with electrically charged
component damage. Dealer circuits could result in death or
service is strongly recommended. serious injury. Remove all rings,
watches and other jewelry.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose 7 Remove the fasteners securing the large
end must be replaced. All connections must be platform height sensor cover to the large
torqued to specification during installation. Refer to platform height sensor bracket.
Specifications, Hydraulic Hose and Fitting Torque
Specifications. 8 Remove the platform height sensor cover.
Note: Machines equipped with a Platform Height 9 Tag and disconnect the platform height sensor
Sensor, begin the Scissor Disassembly procedure from the platform height sensor harness.
at step 1. Machines without a Platform Height 10 Remove the fastener securing the platform
Sensor, begin the Scissor Disassembly procedure height sensor assembly to the number 1 inner
at step 24. arm.
1 Turn the key switch to ground controls and pull 11 Remove the platform height sensor assembly
out the red Emergency Stop button to the on from the number 1 pivot pin.
position at both ground and platform controls.
12 Remove the plastic nut securing the squeeze
2 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. connector to the large platform height sensor
bracket.
Scissor Components
13 Remove the squeeze connector from the large 23 Fully lower the platform to the stowed position.
platform height sensor bracket.
14 Remove the fasteners securing the large
platform height sensor bracket to the number
1 inner arm pivot bracket.
15 Remove the large platform height sensor
bracket from the number 1 inner arm pivot
bracket.
16 Install the fasteners removed in 14 to the
number 1 inner arm pivot bracket and chassis.
Tip-over hazard. Failure
to install the fasteners securing
the number 1 inner arm pivot
bracket to the chassis, could
result in the machine tipping
over, causing death or serious
injury.
Scissor Components
24 Remove the platform. Refer to Repair 35 Place a rod through the number 6 center pivot
Procedure, How to Remove the Platform. pin at the battery side (index #2) and twist to
remove the pin.
25 Remove the cables from cable bridges a, b, c,
d and e. 36 Remove the number 6 outer arm (index #19)
from the machine.
26 Remove the retaining fasteners from the
number 7 pivot pin (index #1). Crushing hazard. The number
27 Use a soft metal drift to remove the number 6 outer arm (index #19) may
7 pivot pin (index #1). Remove the platform become unbalanced and fall if
mount bracket from the machine. not properly supported when
removed from the machine.
28 Attach a lifting strap from an overhead crane
to the number 6 outer arm at the ground 37 Attach a lifting strap from an overhead crane
control side (index #19). to the number 6 inner arm (index #18). Raise
the arm to a vertical position.
29 Remove the retaining fasteners from the
number 6 center pivot pin (index #2) at the 38 Remove the retaining fasteners from the
ground control side. number 6 pivot pin at the steer end of the
machine (index #3).
30 Place a rod through the number 6 center pivot
pin at the ground control side (index #2) and 39 Use a soft metal drift to remove the number
twist to remove the pin. 6 pivot pin (index #3) from the steer end of the
machine. Remove the number 6 inner arm
31 Remove the retaining fasteners from the
(index #18) from the machine.
number 6 pivot pin (index #20) at the
non-steer end. Crushing hazard. The number
32 Use a soft metal drift to remove the number 5 inner arm (index #16) may
6 pivot pin (index #20) from the non-steer end become unbalanced and fall if
of the machine. Remove the number 6 outer not properly supported when
arm at the ground control side (index #19) removed from the machine.
from the machine.
40 Tag, disconnect and plug the hydraulic hose
Crushing hazard. The number on the upper lift cylinder. Cap the fittings on
6 outer arm at the ground control the cylinder.
side (index #19) may become
unbalanced and fall if not Bodily injury hazard. Spraying
properly supported when hydraulic oil can penetrate and
removed from the machine. burn skin. Loosen hydraulic
connections very slowly to allow
33 Attach a lifting strap from an overhead crane the oil pressure to dissipate
to the number 6 outer arm at the battery side gradually. Do not allow oil to
(index #19). squirt or spray.
34 Remove the retaining fasteners from the 41 Attach a lifting strap from an overhead crane
number 6 center pivot pin (index #2) at the to the number 5 outer arm at the ground
battery side. control side (index #22).
Scissor Components
42 Remove the retaining fasteners from the 49 Attach a lifting strap from an overhead crane
number 5 center pivot pin (index #4) at the to the lug of the rod end of the upper lift
ground control side. cylinder.
43 Place a rod through the number 5 center pivot 50 Remove the retaining fasteners from the
pin at the ground control side (index #4) and upper lift cylinder rod end pivot pin (index #5).
twist to remove the pin. 51 Use a soft metal drift to remove the upper lift
44 Remove the retaining fasteners from the cylinder rod end pivot pin (index #5) from the
number 5 pivot pin (index #23) at the machine.
non-steer end. Crushing hazard. The lift cylinder
45 Use a soft metal drift to remove the number will fall if not properly supported
5 pivot pin (index #23) from the non-steer end when the pivot pin is removed.
of the machine. Remove the number 5 outer
arm at the ground control side (index #22) 52 Lower the cylinder onto the linkset.
from the machine. 53 Attach a lifting strap from an overhead crane
Crushing hazard. The number to the number 4 outer arm at the ground
5 outer arm at the ground control control side (index #25).
side (index #22) may become 54 Remove the retaining fasteners from the
unbalanced and fall if not number 4 center pivot pin (index #7) at the
properly supported when ground control side.
removed from the machine.
55 Place a rod through the number 4 center pivot
46 Attach a lifting strap from an overhead crane pin at the ground control side (index #7) and
to the number 5 outer arm at the battery side twist to remove the pin.
(index #22). 56 Remove the retaining fasteners from the
47 Remove the number 5 outer arm (index #22) number 4 pivot pin (index #26) at the
from the machine. non-steer end.
57 Use a soft metal drift to remove the number
Crushing hazard. The number
4 pivot pin (index #26) from the non-steer end
5 outer arm at the battery side
of the machine. Remove the number 4 outer
(index #22) may become
arm at the ground control side (index #25)
unbalanced and fall if not
from the machine.
properly supported when
removed from the machine. Crushing hazard. The number
4 outer arm at the ground control
48 Tag and disconnect the wire harness from the side (index #25) may become
solenoid valve on the cylinder. unbalanced and fall if not
Component damage hazard. properly supported when
Cables can be damaged if they removed from the machine.
are kinked or pinched.
58 Attach a lifting strap from an overhead crane
to the number 4 outer arm at the battery side
(index #25).
Scissor Components
59 Remove the retaining fasteners from the 67 Remove the retaining fasteners from the
number 4 center pivot pin (index #7) at the number 3 center pivot pin (index #10) at the
battery side. ground control side.
60 Place a rod through the number 4 center pivot 68 Place a rod through the number 3 center pivot
pin at the battery side (index #7) and twist to pin at the ground control side (index #10) and
remove the pin. twist to remove the pin.
61 Remove the number 4 outer arm (index #25) 69 Remove the retaining fasteners from the
from the machine. number 3 pivot pin (index #29) at the
non-steer end.
Crushing hazard. The number
4 outer arm (index #25) may 70 Use a soft metal drift to remove the number
become unbalanced and fall if 3 pivot pin (index #29) from the non-steer end
not properly supported when of the machine. Remove the number 3 outer
removed from the machine. arm at the ground control side (index #9) from
the machine.
62 Attach a lifting strap from an overhead crane
to the number 4 inner arm (index #24). Raise Crushing hazard. The number
the arm to a vertical position. 3 outer arm at the ground control
side (index #9) may become
63 Remove the retaining fasteners from the unbalanced and fall if not
number 4 pivot pin at the steer end of the properly supported when
machine (index #8). removed from the machine.
64 Use a soft metal drift to remove the number
71 Attach a lifting strap from an overhead crane
4 pivot pin (index #8) from the steer end of the
to the number 3 outer arm at the battery side
machine. Remove the number 4 inner arm
(index #9).
(index #24) from the machine.
72 Remove the number 3 outer arm (index #9)
Crushing hazard. The number from the machine.
4 inner arm (index #24) may
become unbalanced and fall if Crushing hazard. The number
not properly supported when 3 outer arm (index #9) may
removed from the machine. become unbalanced and fall if
not properly supported when
65 Remove the cables from cable bridges f,h,i,j,k removed from the machine.
and l.
73 Attach a lifting strap from an overhead crane
Component damage hazard. to the number 3 inner arm (index #28). Raise
Cables can be damaged if they the number 3 inner arm and place a 4 x 4 x
are kinked or pinched. 48 inch / 10 cm x 10 cm x 1.2 m block across
the link stack to gain access to the barrel end
66 Attach a lifting strap from an overhead crane pivot pin (index 27).
to the number 3 outer arm at the ground
control side (index #9).
Scissor Components
74 Attach a lifting strap from an overhead crane 83 Lower the cylinder onto the block.
to the lug of the rod end of the upper lift
cylinder. Bodily injury hazard. Keep hands
clear of moving parts when
75 Raise the lift cylinder to a vertical position. lowering the cylinder.
Crushing hazard. The lift cylinder 84 Attach a lifting strap from an overhead crane
will fall if not properly supported
to the number 3 inner arm (index #28). Raise
when the pivot pin is removed. the arm to a vertical position.
Component damage hazard. Be 85 Remove the retaining fasteners from the
careful not to damage the valve number 3 pivot pin at the steer end of the
or fittings on the cylinder while machine (index #12).
removing it from the machine.
86 Use a soft metal drift to remove the number
76 Use a soft metal drift to remove the upper lift 3 pivot pin (index #12) from the steer end of
cylinder barrel end pivot pin (index #27) from the machine. Remove the number 3 inner arm
the machine. (index #28) from the machine.
77 Attach a lifting strap from an overhead crane Crushing hazard. The number
to the number 3 inner arm (index #28). Raise 3 inner arm (index #28) may
the number 3 inner arm and remove the 4 x become unbalanced and fall if
4 x 48 inch / 10 cm x 10 cm x 1.2 m block from not properly supported when the
the link stack. pivot pin is removed.
78 Lower the number 3 inner arm (index #28) and 87 Attach a lifting strap from an overhead crane
remove the lifting strap. to the number 2 outer arm at the ground
79 Attach a lifting strap from an overhead crane control side (index #31).
to the lug of the rod end of the lower lift 88 Remove the retaining fasteners from the
cylinder. number 2 center pivot pin (index #13) at the
80 Remove the retaining fasteners from the lower ground control side.
lift cylinder rod end pivot pin (index 11). 89 Place a rod through the number 2 center pivot
81 Use a soft metal drift to remove the lower lift pin at the ground control side (index #13) and
cylinder rod end pivot pin (index 11) from the twist to remove the pin.
machine. 90 Remove the retaining fasteners from the
number 2 pivot pin (index #32) at the
Crushing hazard. The lift cylinder
will fall if not properly supported non-steer end.
when the pivot pin is removed.
Scissor Components
91 Use a soft metal drift to remove the number 97 Remove the retaining fasteners from the
2 pivot pin (index #32) from the non-steer end number 2 pivot pin at the steer end of the
of the machine. Remove the number 2 outer machine (index #14).
arm at the ground control side (index #31)
98 Use a soft metal drift to remove the number
from the machine.
2 pivot pin (index #14) from the steer end of
Crushing hazard. The number the machine. Remove the number 2 inner arm
2 outer arm at the ground control (index #30) from the machine.
side (index #31) may become
Crushing hazard. The number
unbalanced and fall if not
2 inner arm (index #30) may
properly supported when the
become unbalanced and fall if
pivot pin is removed.
not properly supported when the
pivot pin is removed.
92 Attach a lifting strap from an overhead crane
to the number 2 outer arm at the battery side
99 Attach a lifting strap from an overhead crane
(index #31).
to the number 1 inner arm (index #16).
93 Remove the retaining fasteners from the
100 Raise the number 1 inner arm (index #16)
number 2 center pivot pin (index #13) at the
approximately 2 feet / 60 cm.
battery side.
101 Place a 4 x 4 x 48 inch / 10 cm x 10 cm x
94 Place a rod through the number 2 center pivot
1.2 m long block across both sides of the
pin at the battery side (index #13) and twist to
chassis under the number 1 center pivot pin
remove the pin.
(index #15).
Crushing hazard. The number 102 Lower the scissor arms onto the block that
2 outer arm (index #31) may was placed across the chassis.
become unbalanced and fall if
not properly supported when the Bodily injury hazard. Keep hands
pivot pin is removed. clear of moving parts when
lowering the scissor arms.
95 Remove the number 2 outer arm (index #31)
from the machine. 103 Attach a lifting strap from an overhead crane
to the lug of the rod end of the lower lift
Crushing hazard. The number cylinder.
2 outer arm (index #31) may
become unbalanced and fall if 104 Tag, disconnect and plug the hydraulic hose
not properly supported when on the lower lift cylinder. Cap the fittings on the
removed from the machine. cylinder.
96 Attach a lifting strap from an overhead crane Bodily injury hazard. Spraying
to the number 2 inner arm (index #30). Raise hydraulic oil can penetrate and
the arm to a vertical position. burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
Scissor Components
105 Tag and disconnect the wire harness from the 113 Attach a lifting strap from an overhead crane
solenoid valve on the cylinder. to the number 1 inner arm (index #16).
106 Tag and disconnect the wires and manual 114 Raise the arm slightly and remove the block.
lowering cable from the solenoid valve on the
cylinder. 115 Lower the arm to the stowed position.
107 Models with platform overload option: Tag Bodily injury hazard. Keep hands
and disconnect the wire harness from the clear of moving parts when
platform overload pressure transducer. lowering the scissor arms.
Note: After replacing the scissor assembly, the
116 Secure the ends of the scissor arms together
platform overload system must be calibrated.
at the steer end of the machine with a strap or
Refer to Repair Procedure 9-10, How to Calibrate
other suitable device.
the Platform Overload System (if equipped).
117 Secure the ends of the scissor arms together
108 Raise the lift cylinder to a vertical position. at the non-steer end of the machine with a
109 Remove the pin retaining fasteners from the strap or other suitable device.
lift cylinder barrel-end pivot pin (index #28). 118 Remove the retaining fasteners securing the
Use a soft metal drift to remove the pin. chassis mount bracket to the chassis.
Remove the lift cylinder from the machine.
119 Remove the linkset from the machine.
Crushing hazard. The lift cylinder
will fall if not properly supported Bodily injury hazard. The number
when the pivot pin is removed. 1 inner and outer arms (index
#16 and #34) may become
Component damage hazard. Be unbalanced and fall if not
careful not to damage the valve properly supported when
or fittings on the cylinder while removed from the machine.
removing it from the machine.
Component damage hazard. Be
110 Remove the cables from the number 1 cable sure not to damage the limit
bridge and lay them off to the side. switch or level sensor
components when the number
Component damage hazard. 1 inner and outer arms (index
Cables can be damaged if they #16 and 34) are removed from
are kinked or pinched. the machine.
Scissor Components
Scissor Components
21 Using the ground control menu buttons, 31 Raise the scissor arm assembly at the steer
navigate to Service Override Mode. Select end with the overhead crane until the chassis
Service Override Mode. mount bracket will clear the level sensor.
Note: The machine must be in Service Override 32 Remove the scissor assembly from the
Mode to raise the platform. While in Service machine just enough to access both wear
Override Mode, only the GCON will operate with pads.
limited functionality. The platform will raise a
predetermined amount of time and stop. Crushing hazard. The scissor
assembly will fall if not properly
22 Raise the platform and return the safety arm to supported when removed from
the stowed position. the drive chassis.
23 Fully lower the platform to the stowed position. Component damage hazard. Be
24 Remove the platform. Refer to Repair careful not to damage the level
Procedure, How to Remove the Platform. sensor or limit switch while
moving the scissor assembly.
25 Support and secure the entry ladder to an
appropriate lifting device. 33 Remove both old wear pads.
26 Remove the fasteners from the entry ladder 34 Install two new wear pads.
and remove the entry ladder from the
machine. 35 Slide the scissor assembly back into the drive
chassis.
Crushing hazard. The entry
ladder will fall if not properly 36 Lower the scissor assembly into position and
supported and secured to the install the chassis mount bracket onto the
lifting device. chassis. Securely install and tighten the
fasteners. Do not over tighten.
27 Secure the ends of the scissor arms together Component damage hazard. Be
at the steer end of the machine with a strap or careful not to damage the level
other suitable device. sensor or limit switch while
28 Secure the ends of the scissor arms together moving the scissor assembly.
at the non-steer end of the machine with a
strap or other suitable device.
29 Remove the retaining fasteners securing the
chassis mount bracket to the chassis at the
steer end of the machine.
30 Attach a lifting strap from an overhead crane
to the scissor arm assembly.
Scissor Components
Scissor Components
15 Remove the platform height sensor from the 18 Remove the fasteners securing the large
small angle sensor bracket. platform height bracket to the number 1 inner
arm pivot bracket.
16 Remove the plastic nut securing the squeeze
connector to the large platform height sensor 19 Remove the large platform height sensor
bracket. bracket from the number 1 inner arm pivot
bracket.
17 Remove the squeeze connector from the large
platform height sensor bracket. Tip-over hazard. Failure to install
the fasteners securing the large
platform height sensor bracket
and number 1 inner arm pivot
bracket to the chassis, could
result in the machine tipping
over, causing death or serious
injury.
Steer End
1 number 1 inner arm
2 fastener (platform height sensor assembly)
3 number 1 pivot pin
4 lever arm retaining screw
5 squeeze connector
6 lever arm
7 platform height sensor harness connection
8 platform height sensor
9 fastener (large platform height sensor
bracket)
10 fastener (platform height sensor)
11 platform height sensor assembly
Scissor Components
Scissor Components
6 At the ground controls, turn the key switch to 13 Attach a lifting strap from an overhead crane
the off position and push in the red Emergency to the rod end of the lift cylinder for support.
Stop button to the off position. 14 Remove the fasteners from the lift cylinder
7 Disconnect the battery pack from the machine. rod-end pivot pin. Use a soft metal drift to
remove the pin.
Electrocution/burn hazard.
Contact with electrically charged Crushing hazard. The lift cylinder
circuits could result in death or will fall if not properly supported
serious injury. Remove all rings, when the pivot pin is removed.
watches and other jewelry.
15 Lower the cylinder onto the number 2 inner
8 Tag and disconnect the wiring from the arm.
solenoid valve coil at the barrel end of the lift 16 Attach a lifting strap from an overhead crane
cylinder. or similar lifting device to the barrel end of the
9 If equipped, tag and disconnect the three-pin lift cylinder for support.
connector from the pressure transducer 17 Remove the fasteners from the lift cylinder
harness. To remove the pressure transducer barrel-end pivot pin. Use a soft metal drift to
refer to Repair Procedure, How to Remove the remove the pin.
Pressure Transducer (if equipped).
Crushing hazard. The lift cylinder
10 Loosen the adjustment nuts on the solenoid will fall if not properly supported
valve and disconnect the manual lowering when the pivot pin is removed.
cable from the valve.
Note: During assembly, the manual platform 18 Support and secure the lift cylinder to an
lowering cable needs to be properly adjusted. appropriate lifting device.
Refer to Repair Procedure, How to Adjust the 19 Remove the lift cylinder through the scissor
Manual Platform Lowering Cable. arms at the steer end of the machine.
11 Remove the fasteners securing the manual Crushing hazard. The lift cylinder
lowering cable mount bracket to the cylinder. will become unbalanced and fall
Remove the bracket from the cylinder. if not properly supported and
12 Tag, disconnect and plug the hydraulic hoses secured to the lifting device.
on the lift cylinder. Cap the fittings on the
cylinder. Component damage hazard. Be
careful not to damage the valve
Bodily injury hazard. Spraying or fittings on the cylinder while
hydraulic oil can penetrate and removing it from the machine.
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
Scissor Components
20 Install new cylinder, fittings, hoses and GS-2032, GS-2632, GS-2046 and GS-2646
pressure transducer (if equipped).
Bodily injury hazard. The
Torque specifications procedures in this section
require specific repair skills,
Solenoid valve, 2 position 2 way, 20 ft-lbs
27 Nm lifting equipment and a suitable
N.C.
workshop. Attempting this
(schematic item N)
procedure without these skills
Coil nut 5 ft-lbs and tools could result in death or
7 Nm serious injury and significant
component damage. Dealer
Pressure transducer(if equipped) 27 ft-lbs
service is required.
(schematic item R) 37 Nm
Note: When removing a hose assembly or fitting,
21 Remove the lifting device supporting the link the O-ring (if equipped) on the fitting and/or hose
stack at the steer end of the machine. end must be replaced. All connections must be
22 Connect the battery pack to the machine. torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
23 Turn the key switch to ground control. Specifications.
Models without a pressure transducer Note: Models without a pressure transducer follow
continue at step 27. steps 1 through 23, 27 and 28.
Models with a pressure transducer Models equipped with a pressure transducer follow
continue at step 24. steps 1 through 28.
24 Press and hold the ground control scroll up 1 Turn the key switch to ground controls and pull
and scroll down buttons. out the red Emergency Stop button to the on
position at both ground and platform controls.
25 Pull out the red Emergency Stop button to the
on position at the ground controls. 2 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
26 Using the ground control menu buttons,
navigate to Service Override Mode. Select
Service Override Mode.
Note: The machine must be in Service Override
Mode to raise the platform. While in Service
Override Mode, only the GCON will operate with
limited functionality. The platform will raise a
predetermined amount of time and stop.
27 Raise the platform and rotate the safety arm to
the stowed position.
28 Fully lower the platform to the stowed position.
Note: Models with a pressure transducer, calibrate
the Platform Overload System. Refer to Repair
Procedure, How to Calibrate the Platform Overload
System (if equipped).
Scissor Components
3 Lift the safety arm, move it to the center of the 6 At the ground controls, turn the key switch to
scissor arm and rotate down to a vertical the off position and push in the red Emergency
position. Stop button to the off position.
7 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,
watches and other jewelry.
Scissor Components
13 Attach a lifting strap from an overhead crane 20 Install new cylinder, fittings, hoses and
to the rod end of the lift cylinder for support. pressure transducer (if equipped).
14 Remove the fasteners from the lift cylinder
Torque specifications
rod-end pivot pin. Use a soft metal drift to
remove the pin. Solenoid valve, 2 position 2 way, 20 ft-lbs
N.C. 27 Nm
Crushing hazard. The lift cylinder (schematic item N)
will fall if not properly supported
when the pivot pin is removed. Coil nut 5 ft-lbs
7 Nm
15 Lower the cylinder onto the number 1 inner Pressure transducer(if equipped) 27 ft-lbs
arm cylinder plate. (schematic item R) 37 Nm
16 Attach a lifting strap from an overhead crane
or similar lifting device to the barrel end of the 21 Remove the lifting device supporting the link
lift cylinder for support. stack at the steer end of the machine.
17 Remove the fasteners from the lift cylinder 22 Connect the battery pack to the machine.
barrel-end pivot pin. Use a soft metal drift to 23 Turn the key switch to ground control.
remove the pin.
Models without a pressure transducer
Crushing hazard. The lift cylinder continue at step 27.
will fall if not properly supported
when the pivot pin is removed. Models with a pressure transducer
continue at step 24.
18 Support and secure the lift cylinder to an 24 Press and hold the ground control scroll up
appropriate lifting device. and scroll down buttons.
19 Remove the lift cylinder through the scissor 25 Pull out the red Emergency Stop button to the
arms at the steer end of the machine. on position at the ground controls.
Crushing hazard. The lift cylinder 26 Using the ground control menu buttons,
will become unbalanced and fall navigate to Service Override Mode. Select
if not properly supported and Service Override Mode.
secured to the lifting device.
Note: The machine must be in Service Override
Component damage hazard. Be Mode to raise the platform. While in Service
careful not to damage the valve Override Mode, only the GCON will operate with
or fittings on the cylinder while limited functionality. The platform will raise a
removing it from the machine. predetermined amount of time and stop.
27 Raise the platform and rotate the safety arm to
the stowed position.
28 Fully lower the platform to the stowed position.
Note: Models with a pressure transducer, calibrate
the Platform Overload System. Refer to Repair
Procedure, How to Calibrate the Platform Overload
System (if equipped).
Scissor Components
GS-3232 and GS-3246 3 Lift the safety arm, move it to the center of the
scissor arm and rotate down to a vertical
Bodily injury hazard. The
position.
procedures in this section
require specific repair skills,
lifting equipment and a suitable
workshop. Attempting this
procedure without these skills
and tools could result in death or
serious injury and significant
component damage. Dealer
service is required.
Scissor Components
4 Lower the platform onto the safety arm. 10 Loosen the adjustment nuts on the solenoid
valve and disconnect the manual lowering
Crushing hazard. Keep hands cable from the valve.
clear of the safety arm when
lowering the platform. Note: During assembly, the manual platform
lowering cable needs to be properly adjusted.
5 Using a suitable lifting device, support the link Refer to Repair Procedure, How to Adjust the
stack at the steer end of the machine. Manual Platform Lowering Cable.
6 At the ground controls, turn the key switch to 11 Remove the fasteners securing the manual
the off position and push in the red Emergency lowering cable mount bracket to the cylinder.
Stop button to the off position. Remove the bracket from the cylinder.
7 Disconnect the battery pack from the machine. 12 Tag, disconnect and plug the hydraulic hoses
on the lift cylinder. Cap the fittings on the
Electrocution/burn hazard. cylinder.
Contact with electrically charged
circuits could result in death or Bodily injury hazard. Spraying
serious injury. Remove all rings, hydraulic oil can penetrate and
watches and other jewelry. burn skin. Loosen hydraulic
connections very slowly to allow
Note: At the lower lift cylinder, install the orifice the oil pressure to dissipate
fitting with the small opening of the orifice fitting gradually. Do not allow oil to
closest to the supply hose. squirt or spray.
8 Tag and disconnect the wiring from the
13 Attach a lifting strap from an overhead crane
solenoid valve coil at the barrel end of the lift
or similar lifting device to the barrel end of the
cylinder.
lift cylinder for support.
Skip to step 13 if removing the upper 14 Remove the fasteners from the lift cylinder
cylinder. rod-end pivot pin. Use a soft metal drift to
remove the pin.
9 If equipped, tag and disconnect the three-pin
connector from the pressure transducer Crushing hazard. The lift cylinder
harness. To remove the pressure transducer will fall if not properly supported
refer to Repair Procedure, How to Remove the when the pivot pin is removed.
Pressure Transducer (if equipped).
15 Lower the cylinder onto the number 1 inner
arm cylinder plate.
Scissor Components
16 Attach a lifting strap from an overhead crane 20 Install new cylinder, fittings, hoses and
or similar lifting device to the barrel end of the pressure transducer (if equipped).
lift cylinder for support.
17 Remove the fasteners from the lift cylinder
barrel-end pivot pin. Use a soft metal drift to
remove the pin.
Crushing hazard. The lift cylinder
will fall if not properly supported
when the pivot pin is removed.
Torque specifications
Solenoid valve, 2 position 2 way, 20 ft-lbs
N.C. 27 Nm
(schematic item N)
Scissor Components
Note: The machine must be in Service Override 1 Turn the key switch to ground controls and pull
Mode to raise the platform. While in Service out the red Emergency Stop button to the on
Override Mode, only the GCON will operate with position at both ground and platform controls.
limited functionality. The platform will raise a 2 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
predetermined amount of time and stop.
27 Raise the platform and rotate the safety arm to
the stowed position.
28 Fully lower the platform to the stowed position.
Note: Models with a pressure transducer, calibrate
the Platform Overload System. Refer to Repair
Procedure, How to Calibrate the Platform Overload
System (if equipped).
Scissor Components
3 Lift the safety arm, move it to the center of the 4 Lower the platform onto the safety arm.
scissor arm and rotate down to a vertical
position. Crushing hazard. Keep hands
clear of the safety arm when
lowering the platform.
Scissor Components
12 Tag, disconnect and plug the hydraulic hoses 19 Remove the lift cylinder through the scissor
on the lift cylinder. Cap the fittings on the arms at the steer end of the machine.
cylinder.
Crushing hazard. The lift cylinder
Bodily injury hazard. Spraying will become unbalanced and fall
hydraulic oil can penetrate and if not properly supported and
burn skin. Loosen hydraulic secured to the lifting device.
connections very slowly to allow
the oil pressure to dissipate Component damage hazard. Be
gradually. Do not allow oil to careful not to damage the valve
squirt or spray. or fittings on the cylinder while
removing it from the machine.
13 Attach a lifting strap from an overhead crane
or similar lifting device to the barrel end of the 20 Install new cylinder, fittings, hoses and
lift cylinder for support. pressure transducer (if equipped).
14 Remove the fasteners from the lift cylinder
rod-end pivot pin. Use a soft metal drift to
remove the pin.
Crushing hazard. The lift cylinder
will fall if not properly supported
when the pivot pin is removed.
Scissor Components
Scissor Components
Torque specifications
Pressure transducer(if equipped) 27 ft-lbs
(schematic item R) 37 Nm
Scissor Components
Personnel are not allowed in the platform while Note: If a new Ground Controller is installed on a
calibrating the platform overload system. machine, the Full Load Calibration procedure is
required to maintain rated load platform capacity.
Perform this procedure in an environment that If a No Load Calibration is performed, machine
allows the platform to be fully raised. Models rated lifting performance will be significantly reduced.
for indoor use only, should be calibrated inside a
facility with enough ceiling height to fully raise the Note: Ambient temperature must be above 32°F /
platform. If the facility height is not suitable to fully 0°C before calibrating the Platform Overload
raise the platform, then an indoor only rated model System.
may be calibrated outdoors if wind speeds are less Note: To calibrate the platform overload system,
then 28 mph / 12.5 m/s. Only use flat weights while follow the menu structure indicated on the ground
calibrating indoor only rated machines, outdoors. control LCD display.
Perform this procedure after confirming that the
platform height sensor is not damaged and
functions correctly.
Scissor Components
Full Load Calibration: Part 1 8 Release the Menu Up and Menu Down
1 Fully charge the batteries and check the buttons after the ground controller powers up.
hydraulic fluid level. 9 Use the Menu Up or Menu Down buttons to
Note: The hydraulic fluid level must be between the scroll to, Select Option. Press the Enter
FULL and ADD marks on the hydraulic tank. button.
10 Use the Menu Up or Menu Down buttons to
2 Apply a thin layer of dry film lubricant to the
scroll to Platform Overload.
area of the chassis and platform, where the
scissor arm wear pads make contact. 11 Press the Enter button to select Platform
Overload.
3 Chock both sides of the wheels at the steer
end of the machine. 12 Use the Menu Up or Menu Down buttons to
scroll to Platform Overload Calibrate.
4 Using a suitable lifting device, place a test
weight corresponding to the machine 13 Press the Enter button to select Platform
maximum load, in the center of the platform Overload Calibrate.
deck. Secure the weight to the platform. Refer
14 Confirm the Platform Overload Calibrate
to the chart below.
selection by pressing the Enter button again.
GS-1330m 500 lbs / 227 kg 15 Use the Menu Up or Menu Down buttons to
GS-1530 and GS-1532 600 lbs / 272 kg select Full Load calibration.
GS-1930 and GS-1932 500 lbs / 227 kg 16 Press the Enter button to select Full Load
GS-2032 800 lbs / 363 kg calibration.
GS-2632 500 lbs / 227 kg 17 Press the Enter button to confirm rated load is
GS-3232 500 lbs / 227 kg in the platform.
Note: In the event of frequent nuisance trips 18 At the ground controls, press and hold the
occurring after calibrating a GS-3232 machine, it is Function Enable and Platform Up buttons until
recommended to recalibrate the machine, full load the platform reaches maximum height.
and no load, with 250 kg of weight in the platform.
19 All Models except GS-4047: When the
GS-2046 1200 lbs / 544 kg platform reaches maximum height, press the
GS-2646 1000 lbs / 454 kg
ground controls Enter button. Allow the ground
controls to gather data. GS-4047 only: Press
GS-3246 700 lbs / 317 kg and hold the Menu Enter button to determine
GS-4047 770 lbs / 350 kg the maximum height. The machine will lower
5 Turn the key switch to ground control. for 1.2 seconds and then raise in 1.2 second
durations, until maximum height is reached.
6 At the ground controls, press and hold the When the platform reaches the maximum
Menu Up and Menu Down buttons. height, a message will appear on the LCD
screen to release the Menu Enter button.
7 While pressing both buttons down, pull out the
red Emergency Stop Button. Note: If at any point the Menu Enter button is
released before the message appears on the LCD
screen, the calibration procedure will restart at step
18.
Scissor Components
20 When prompted, press and hold the Function 23 When prompted, press and hold the Function
Enable and Platform Down buttons. The Enable and Platform Down buttons until the
platform will lower, then automatically stop at a platform is fully stowed. When the platform
predetermined point to gather data. Allow the reaches the stowed position, press the enter
ground controls to gather data. button.
21 Continue pressing the Function Enable and Note: If the Function Enable or Platform Down
Platform Down buttons throughout the buttons are released while the machine is
lowering and data gathering sequence. The collecting data, the GCON LCD will prompt the
machine will stop to gather data and lower user to raise the platform for 5 seconds before
several times before the machine reaches the prompting to lower the platform to the stowed
stowed position. When the platform reaches position again.
the stowed position, press the enter button.
Note: If the machine is switched to PCON mode to
Note: Software revision H or prior, and drive the machine to an area for weight removal,
GS-3032, GS-2646 and GS-4047 models, step 3 and steps 5 through 14 will have to be
continue to step 24. repeated before Full Load Calibration: Part 2 is
performed. Additionally, the CO25 fault will appear.
Note: All other models with software revision J This is expected and the data collected in Full Load
or higher, continue with step 22. Calibration: Part 1 has not been lost.
22 When prompted, press and hold the Function 24 Using a suitable lifting device, remove the test
Enable and Platform Up buttons until the weight from the platform deck.
platform reaches full height. When the
platform reaches full height, press the enter 25 After the weight is removed from the platform
button. deck, press the Enter button to confirm the
weight has been removed.
Note: If the Function Enable or Platform Up buttons
are released while the machine is collecting data,
the GCON LCD will prompt the user to lower the
platform for 5 seconds before prompting to raise
the platform to full height again.
Scissor Components
Scissor Components
Scissor Components
Scissor Components
3 Pull out the red Emergency Stop button at the 7 Press and hold the scroll down button for
ground controls. 5 seconds.
Result: The ground control LCD display will Result: The ground control LCD display will
show the following. show the following.
5 Press the enter button. 9 Press the buttons in the following sequence:
(down)(down)(up)(enter).
Result: The ground control LCD display will
show the following. Note: After each key press an asterisk (*) will
appear on the second line of the LCD display.
Result: The ground control LCD display will
show the following.
Platform Components
Platform Components
Battery Charger
11-1
Battery Charger
The charger contains selectable charging profiles
stored in its internal memory to charge batteries.
These profiles are specific to each battery type.
The charging profile must be programmed to match
the specific battery type on the machine.
Battery Charger
Sel ecti ng a Charge Profil e
Selecting a Charge Profile 5 Press and hold the charge profile selection
button until the error indicator and charging
Electrocution/burn hazard. indicator lights turn off and the AC status
Contact with electrically charged indicator light turns on to confirm selection and
circuits could result in death or exit charge profile mode. Release the button.
serious injury. Remove all rings,
watches and other jewelry. Note: Charge profile mode will time out and exit if
there is 15 seconds of inactivity, the charge profile
1 At the ground controls, turn the key switch to number has been displayed three times or the AC
the off position and push in the red Emergency power source had been disconnected.
Stop button to the off position. 6 Press and release the charge profile selection
2 Open the battery compartment. button to confirm the correct charge profile has
been selected.
3 Press and hold the charge profile selection
button and plug the battery charger into an AC
power source. Continue to hold the button until
the amber error indicator is on and the green
charging indicator light is flashing. Release the
button.
4 Press and release the charge profile selection
button to navigate to the charge profile
appropriate for your machine and battery type.
Refer to the chart below.
Profile Description
P001 Scissor, GR, GRC, QS (does not include
GS-4047) - Flooded lead acid batteries -
Temperature compensated *
P003 Scissor, GR, GRC, QS (does not include
GS-4047) - Flooded lead acid batteries -
Not temperature compensated **
P007 GS-4047 - Flooded lead acid batteries - Not
temperature compensated **
P043 All Scissors, GR, GRC, QS - AGM batteries
- Temperature compensated *
* Temperature compensated: Battery temperature
sensor has been installed on the machine.
** Not temperature compensated: Battery
temperature sensor has not been installed on the
machine.
Diagnostics
Section 4 Diagnostics
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
Observe and Obey: equipment are available and ready for use.
Troubleshooting and repair procedures shall Read each appropriate fault code thoroughly.
be completed by a person trained and qualified Attempting short cuts may produce hazardous
on the repair of this machine conditions.
Immediately tag and remove from service a Be aware of the following hazards and follow
damaged or malfunctioning machine. generally accepted safe workshop practices.
Repair any machine damage or malfunction Crushing hazard. When testing
before operating the machine. or replacing any hydraulic
Unless otherwise specified, perform each component, always support
repair procedure with the machine in the the structure and secure it
following configuration: from movement
• The red Emergency Stop button in the off Bodily injury hazard. Spraying
position at both ground and platform controls hydraulic oil can penetrate and
burn skin. Loosen hydraulic
• Wheels chocked
connections very slowly to allow
• All external AC power supply disconnected the oil pressure to dissipate
from the machine gradually. Do not allow oil to
squirt or spray.
Diagnostics
Diagnostics
Diagnostics
GCON I/O Map without Load Sense (all models except GS-3232)
GCON Pin Number Circuit Function I/O Type Wire Gauge and Color
J1 Connector – Gray
J1-01 ECM Power Power Input 14 RD
J1-02 PCON, E-Stop Power Power Output 18 RD
J1-03 PCON, E-Stop Return Power Input 18 WH
J1-04 Link to PCON — CANH Data Bus 18GR
J1-05 Link to PCON — CANL Data Bus 18 OR
J1-06 PCON — Ground Ground Output 18 BR
J1-07 GCON — Ground Ground Input 14 BR
J1-08 Key Switch — PCON Mode Digital Input 18 BK
J1-09 Key Switch — GCON Mode Digital Input 18 WH
J1-10 GCON — Emergency Mode Digital Input 18 WH/BK
J1-11 No Circuit N/A N/A
J1-12 Driver Power Power Input 14 RD
J-2 Connector – Black
J2-01 Platform Up Coil Digital Output 18 OR
J2-02 Platform Down Coil Digital Output 18 OR/BK
J2-03 Steer Left Coil Digital Output 18 BL/BK
J2-04 Steer Right Coil Digital Output 18 BL
J2-05 Parallel Coil (GS-32 & GS-46) Digital Output 18 RD/WH
J2-06 Drive Forward Coil Digital Output 18 WH
J2-07 No Circuit N/A N/A
J2-08 Motor Controller Enable Digital Output 18 GR/WH
J2-09 No Circuit N/A N/A
J2-10 Drive Reverse Coil Digital Output 18 WH/BK
J2-11 Motor Controller Throttle Analog Output 18 GR
J2-12 No Circuit N/A N/A
J-3 Connector – Green
J3-01 No Circuit N/A N/A
J3-02 GCON — Alarm Digital Output 18 BL
J3-03 Switch/Sensor Power Digital Output 14 RD
J3-04 Automotive Horn Digital Output 18 WH
J3-05 Pothole Limit Switch Digital Input 18 OR/RD
J3-06 Ground Ground Input 18 BR
J3-07 Down Limit Switch Digital Input 18 OR
J3-08 Level Sensor Digital Input 18 RD/BK
J3-09 Ground Ground Input 18 BK
J3-10 Ground Ground Input 18 BK
J3-11 No Circuit N/A N/A
J3-12 Load Sense — Ground Ground Input 18 BK
Diagnostics
GCON I/O Map with Load Sense (all model except GS-3232)
GCON Pin Number Circuit Function I/O Type Wire Gauge and Color
J1 Connector – Gray
J1-01 ECM Power Power Input 14 RD
J1-02 PCON, E-Stop Power Power Output 18 RD
J1-03 PCON, E-Stop Return Power Input 18 WH
J1-04 Link to PCON — CANH Data Bus 18GR
J1-05 Link to PCON — CANL Data Bus 18 OR
J1-06 PCON — Ground Ground Output 18 BR
J1-07 GCON — Ground Ground Input 14 BR
J1-08 Key Switch — PCON Mode Digital Input 18 BK
J1-09 Key Switch — GCON Mode Digital Input 18 WH
J1-10 GCON — Emergency Mode Digital Input 18 WH/BK
J1-11 No Circuit N/A N/A
J1-12 Driver Power Power Input 14 RD
J-2 Connector – Black
J2-01 Platform Up Coil Digital Output 18 OR
J2-02 Platform Down Coil Digital Output 18 OR/BK
J2-03 Steer Left Coil Digital Output 18 BL/BK
J2-04 Steer Right Coil Digital Output 18 BL
J2-05 Parallel Coil (GS-32, GS-46 & GS-47) Digital Output 18 RD/WH
J2-06 Drive Forward Coil Digital Output 18 WH
J2-07 Ground (GS-4047) Ground Input 18 BR
J2-08 Motor Controller Enable Digital Output 18 GR/WH
J2-09 Lift Pressure Selector (GS-4047) N/A N/A
J2-10 Drive Reverse Coil Digital Output 18 WH/BK
J2-11 Motor Controller Throttle Analog Output 18 GR
J2-12 No Circuit N/A N/A
J-3 Connector – Green
J3-01 No Circuit N/A N/A
J3-02 GCON — Alarm Digital Output 18 BL
J3-03 Switch/Sensor Power Digital Output 14 RD
J3-04 Automotive Horn Digital Output 18 WH
J3-05 Pothole Limit Switch Digital Input 18 OR/RD
J3-06 Ground Ground Input 18 BR
J3-07 Down Limit Switch Digital Input 18 OR
J3-08 Level Sensor Digital Input 18 RD/BK
J3-09 Platform Overload Pressure Transducer Ground Input 18 BL/WH
J3-10 Platform Height Sensor Ground Input 18 OR/WH
J3-11 No Circuit N/A N/A
J3-12 Load Sense — Ground Ground Input 18 BK
Diagnostics
GCON I/O Map without Load Sense (GS-3232 only)
GCON Pin Number Circuit Function I/O Type Wire Gauge and Color
J1 Connector – Gray
J1-01 ECM Power Power Input 14 RD
J1-02 PCON, E-Stop Power Power Output 18 RD
J1-03 PCON, E-Stop Return Power Input 18 WH
J1-04 Link to PCON — CANH Data Bus 18GR
J1-05 Link to PCON — CANL Data Bus 18 OR
J1-06 PCON — Ground Ground Output 18 BR
J1-07 GCON — Ground Ground Input 14 BR
J1-08 Key Switch — PCON Mode Digital Input 18 BK
J1-09 Key Switch — GCON Mode Digital Input 18 WH
J1-10 GCON — Emergency Mode Digital Input 18 WH/BK
J1-11 No Circuit N/A N/A
J1-12 Driver Power Power Input 14 RD
J-2 Connector – Black
J2-01 Platform Up Coil Digital Output 18 OR
J2-02 Platform Down Coil Digital Output 18 OR/BK
J2-03 Steer Left Coil Digital Output 18 BL/BK
J2-04 Steer Right Coil Digital Output 18 BL
J2-05 Parallel Coil (GS-32 & GS-46) Digital Output 18 RD/WH
J2-06 Drive Forward Coil Digital Output 18 WH
J2-07 No Circuit N/A N/A
J2-08 Motor Controller Enable Digital Output 18 GR/WH
J2-09 No Circuit N/A N/A
J2-10 Drive Reverse Coil Digital Output 18 WH/BK
J2-11 Motor Controller Throttle Analog Output 18 GR
J2-12 No Circuit N/A N/A
Diagnostics
Diagnostics
GCON I/O Map with Load Sense (GS-3232 only)
GCON Pin Number Circuit Function I/O Type Wire Gauge and Color
J1 Connector – Gray
J1-01 ECM Power Power Input 14 RD
J1-02 PCON, E-Stop Power Power Output 18 RD
J1-03 PCON, E-Stop Return Power Input 18 WH
J1-04 Link to PCON — CANH Data Bus 18GR
J1-05 Link to PCON — CANL Data Bus 18 OR
J1-06 PCON — Ground Ground Output 18 BR
J1-07 GCON — Ground Ground Input 14 BR
J1-08 Key Switch — PCON Mode Digital Input 18 BK
J1-09 Key Switch — GCON Mode Digital Input 18 WH
J1-10 GCON — Emergency Mode Digital Input 18 WH/BK
J1-11 No Circuit N/A N/A
J1-12 Driver Power Power Input 14 RD
J-2 Connector – Black
J2-01 Platform Up Coil Digital Output 18 OR
J2-02 Platform Down Coil Digital Output 18 OR/BK
J2-03 Steer Left Coil Digital Output 18 BL/BK
J2-04 Steer Right Coil Digital Output 18 BL
J2-05 Parallel Coil (GS-32, GS-46 & GS-47) Digital Output 18 RD/WH
J2-06 Drive Forward Coil Digital Output 18 WH
J2-07 Ground (GS-4047) Ground Input 18 BR
J2-08 Motor Controller Enable Digital Output 18 GR/WH
J2-09 Lift Pressure Selector (GS-4047) N/A N/A
J2-10 Drive Reverse Coil Digital Output 18 WH/BK
J2-11 Motor Controller Throttle Analog Output 18 GR
J2-12 No Circuit N/A N/A
Diagnostics
Diagnostics
Operational Indicator Codes Note: The CHrg code indicates the charger is
connected to an AC power source and functionality
(OIC) is limited. To clear the code, disconnect the
These codes are generated by the electrical charger from the AC power source.
system to indicate machine operating status.
Note: The LoHt code indicates the platform has
During normal operation a code will appear in the
reached the maximum working height or a
platform controls LED readout if a condition such
maximum working height has been activated by the
as off-level, overload cutout, chassis mode
operator.
operation or pothole guards stuck occurs.These
codes are not indicators of a device malfunction in Note: The FLHt code indicates the operator has
the electrical system. deactivated the maximum working height LoHt
code.
Code Condition
LL Off-Level Note: The ObS code indicates the contact alarm
has been actuated by an obstruction. Move the
OL Platform Overload (CE and Australia) machine away from the obstruction to clear the
CH Chassis Mode Operation code.
PHS Pothole Guard Stuck
Note: The BR operation indicator code will appear
nd No Drive (option) when the drive brake was release by manual.
Ld Lifting Disabled (GS-3232 only) When the code appears, drive and lift functions are
CHrg Charger Interlock (option) disabled.
LoHt Lift Height Limited (CE / AS models)
FLHt Limited Lift Height Cleared
ObS Obstruction (option)
BR Brake release by manual (GS-1330m only)
Note: The Ld Operation Indicator Code will appear
when the outriggers are not fully retracted, the
machine is not auto leveled, an outrigger has lost
contact with the ground or either level sensor
detects the machine is no longer level. When any
of the above scenarios occur, the lift function is
disabled.
The lift function will also be disabled while
extending or retracting the outriggers and during
the outrigger auto level procedure. While
performing the above operations, the Ld Operation
Indicator Code will appear.
Diagnostics
Diagnostic Chart
No
1 Check the faulted device for a short or open circuit. Good Replace faulted device.
Good
No
Check short or open circuit of the harness or
2 Good Repair or replace harness an/or connector.
connector between Ground Controls and faulted device.
Good
No
3 Check GCON Electronic Control Module (ECM). Good Replace ECM.
Wiring Diagram
The wiring diagram shown below illustrates how fault type "HXXX" and "PXXX" devices are typically wired.
The signal of these types of devices originates at the Ground Controls and terminates at system ground.
GCON
Electronic Control Module
(ECM) Signal Wire Signal Side Device Return Side Return Wire
In order to successfully troubleshoot "HXXX" or "PXXX" type faults, the entire faulted out circuit must be
investigated.
2 Check the harness between the ground controls and the faulted device
1 Disconnect the GCON ECM connectors, J1, J2 and J3.
2 Disconnect the faulted device connector.
3 Check the continuity between the GCON ECM connector
and the signal side of the faulted device.
Result: Resistance should be close to 0 Ω
4 Check the continuity between the return side of faulted
device and system ground.
Result: Resistance should be close to 0 Ω
5 Check resistance between return side and signal side of
the harness plug of faulted device.
Result: Resistance should be 1M Ω or higher.
OK Go to step 3 No Good Replace or repair harness
Note: An error code C053 will be displayed if an updated PCON is installed on a machine that has not had
the GCON updated. The GCOn must be updated, or the original PCON must be installed back on the
machine.
Battery Charger
Battery Charger
The charger continuously monitors internal and external conditions. Fault and Error codes are generated
by the charger to indicate that an internal or external malfunction has been detected in the electrical system.
The types of Diagnostic Trouble Codes that may occur are explained below.
Type "F" codes – Indicate an internal fault condition has occurred and caused charging to stop.
Type "E" codes - Indicate an external fault condition has occurred and caused charging to stop.
Type "P" code - Indicates charger programming mode is active. This will occur when the charger profile is
being configured.
Type "USB" code - Indicates the USB interface is active, and the USB should not be removed. This will
occur when the charger firmware is being updated.
Battery Charger
Battery Charger
Char ger Error C odes
Battery Charger
Battery Charger
Battery Charger
Schematics
Electrical Schematics
Electrocution/burn hazard.
Contact with electrically charged
Observe and Obey: circuits could result in death or
serious injury. Remove all rings,
Troubleshooting and repair procedures shall watches and other jewelry.
be completed by a person trained and qualified
on the repair of this machine
Hydraulic Schematics
Immediately tag and remove from service a
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
Read, understand and obey the safety rules squirt or spray.
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.
Wire with description or color Limit Switch Motor controller Key switch
Circuits crossing no connection Emergency Stop button Motor Solenoid valve with diode
Fixed displacement Shuttle valve Solenoid operated 3 position Solenoid operated 3 position 4 way
pump 4 way directional valve directional valve
Schematics
Hydraulic Schematics
Hydraulic Schematics
Hydraulic Schematics
Hydraulic Schematics
Hydraulic Schematics
Hydraulic Schematics
Hydraulic Schematics
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