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Service and Repair Manual

Serial Number Range

GS™-1330m refer to Introduction


for serial number ranges
This manual includes:
Repair procedures

GS™-1530/32 Fault Codes


Electrical and

GS™-1930/32 Hydraulic Schematics

GS™-2032
GS™-2632 For detailed maintenance

GS™-3232 procedures, refer to the


appropriate Maintenance

GS™-2046 Manual for your machine.

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

Serial Number Range


Compliance Use the following chart to identify the specific serial
number for models included in this manual.
Machine Classification
Models Serial number
Group A/Type 3 as defined by ISO 16368
GS-1330m from SN GS30MD-101

Machine Design Life GS-1530 / GS-1532 from SN GS3010A-110000


GS-1930 / GS-1932 from SN GS3011C-10000 to
Unrestricted with proper operation, inspection and
GS3016C-23999
scheduled maintenance. from SN GS3014D-101 to
GS3016D-607
from SN GS3016P-151487 to
Contact Us: GS3016P-160599
from GS30C-24000
Internet: www.genielift.com from GS30D-6080
E-mail: awp.techpub@terex.com from GS30P-160600
GS-2032/2632/3232 from SN GS3211A-110000
Find a Manual for this Model from SN GS3212C-10000 to
GS3216C-17299
Go to http://www.genielift.com from SN GS3216P-142676 to
GS3216P-148699
Use the links to locate Service Manuals,
from GS32C-17300
Maintenance Manuals, Service and Repair
from GS32P-148700
Manuals, Parts Manuals and Operator's Manuals.
GS-2046/2646/3246 from SN GS4612A-110000
from SN GS4612C-10000 to
GS4616C-18099
from SN GS4614D-101 to
GS4616D-5029
from SN GS4616P-138362 to
GS4616P-141799
from GS46C-18100
from GS46D-5030
from GS46P-141800
GS-4047 from SN GS4712C-101 to
GS4716C-4499
from SN GS4714D-101 to
GS4716D-3959
from GS4716P-101 to
Copyright © 2016 by Terex Corporation
GS4716P-999
1272215GT Rev C, January 2019 from GS47C-4500
First Edition, Third Printing from GS47D-3960
Genie is a registered trademark of Terex South Dakota, Inc. in from GS47P-1000
the U.S.A. and many other countries.
“GS” is a trademark of Terex South Dakota, Inc.

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January 2019 Service and Repair Manual

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

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 iii


Service and Repair Manual January 2019

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

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January 2019 Service and Repair Manual

Introduction

Serial Number Legend


To August 31, 2016

1 Model 1 Sequence number


2 Model year 2 Serial label (located on chassis)
3 Facility code 3 Serial number (stamped on chassis)
From September 1, 2016

1 Model 1 Serial label (located on chassis)


2 Facility code 2 Serial number (stamped on chassis)
3 Sequence number

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 v


Service and Repair Manual January 2019

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.

Do Not Perform Maintenance


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

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Safety Rules

Personal Safety Workplace Safety


Any person working on or around a machine must Any person working on or around a machine must
be aware of all known safety hazards. Personal be aware of all known safety hazards. Personal
safety and the continued safe operation of the safety and the continued safe operation of the
machine should be your top priority. machine should be your top priority.

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.

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January 2019

Table of Contents

Introduction Introduction ........................................................................................................... ii


Find a Manual for this Model .................................................................................. ii
Serial Number Range ............................................................................................. ii
Revision History ..................................................................................................... iii
Serial Number Legend ............................................................................................ v

Section 1 Safety Rules .........................................................................................................vi


General Safety Rules ............................................................................................ vi

Section 2 Specifications ....................................................................................................... 1


Machine Specifications ........................................................................................... 1
Performance Specifications (models without proportional lift function) ..................3
Performance Specifications (models with proportional lift) ....................................5
Hydraulic Oil Specifications .................................................................................... 7
Hydraulic Component Specifications ....................................................................10
Manifold Component Specifications .....................................................................10
Hydraulic Hose and Fitting Torque Specifications................................................12
Torque Procedure .................................................................................................13

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Table of Contents

Section 3 Repair Procedures ............................................................................................. 15


Introduction ........................................................................................................... 15

Platform Controls ............................................................................................... 17


1-1 Circuit Board................................................................................................... 19
1-2 Joystick........................................................................................................... 20
1-3 Platfrom Controls Alarm ................................................................................. 20
1-4 Platform Emergency Stop Button ................................................................... 21

Ground Controls ................................................................................................. 22


2-1 Software Revision Level................................................................................. 23
2-2 Machine Setup ............................................................................................... 24
2-3 Loading or Updating Machine Software ......................................................... 25
2-4 Using a Wi-Fi Router to Connect to the SmartLink Web Service Tool .......... 30
2-5 Service Override Mode .................................................................................. 32
2-6 Level Sensors ................................................................................................ 34
2-7 Manual Platform Lowering Cable ................................................................... 49
2-8 Outrigger Calibration ...................................................................................... 51

Hydraulic Tank .................................................................................................... 52


3-1 Hydraulic Tank ............................................................................................... 52

Hydraulic Pump .................................................................................................. 54


4-1 Hydraulic Pump .............................................................................................. 54
How to Remove the Hydraulic Pump .............................................................. 55

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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

Steer Axle Components .....................................................................................76


6-1 Yoke Assembly ...............................................................................................76
6-2 Drive Motors ...................................................................................................77
6-3 Steer Cylinder .................................................................................................78
6-4 Steer Bellcrank ...............................................................................................78

Non-Steer Axle Components .............................................................................80


7-1 Drive Brake .....................................................................................................80

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Brake Release Hand Pump Components ......................................................... 81


8-1 Brake Release Hand Pump Components ...................................................... 81

Scissor Components ......................................................................................... 82


9-1 Scissor Assembly, GS-1330m ....................................................................... 83
9-2 Scissor Assembly, GS-1530 and GS-1532 .................................................... 91
9-3 Scissor Assembly, GS-1930 and GS-1932 .................................................... 97
9-4 Scissor Assembly, GS-2032 and GS-2046 .................................................. 105
9-5 Scissor Assembly, GS-2632 and GS-2646 .................................................. 112
9-6 Scissor Assembly, GS-3232 and GS-3246 .................................................. 120
9-7 Scissor Assembly, GS-4047 ........................................................................ 129
9-8 Scissor Arm Wear Pads ............................................................................... 137
9-9 Platform Height Sensor ................................................................................ 139
9-10 Lift Cylinder ................................................................................................ 141
9-11 Pressure Transducer .................................................................................. 152
9-12 Platform Overload System ......................................................................... 154
9-13 Platform Overload Recovery ...................................................................... 159

Platform Components ...................................................................................... 161


10-1 Platform ...................................................................................................... 161
10-2 Platform Extension Deck ............................................................................ 162

Battery Charger ................................................................................................ 163


11-1 Battery Charger .......................................................................................... 163
Selecting a Charge Profile ............................................................................ 164

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Table of Contents

Section 4 Diagnostics .......................................................................................................166


Introduction .........................................................................................................166
GCON I/O Map without Load Sense (all machines except GS-3232)................169
GCON I/O Map with Load Sense (all machines except GS-3232).....................170
GCON I/O Map without Load Sense GS-3232 only) ..........................................171
GCON I/O Map with Load Sense (GS-3232 only) ..............................................173
Operation Indicator Codes (OIC) ........................................................................175
Diagnostic Trouble Codes (DTC) .......................................................................176
Troubleshooting "HXXX" and "PXXX" Faults .....................................................177
Fault Inspection Procedure.................................................................................178
Type "HXXX" Faults ...........................................................................................180
Type "PXXX" Faults ............................................................................................184
Type "PXXX" Faults ............................................................................................185
Type "UXXX" Faults ...........................................................................................186
Type "FXXX" Faults ............................................................................................189
Type "CXXX" Faults ...........................................................................................192
Battery Charger ..................................................................................................194
Charger Fault Codes .....................................................................................195
Charger Error Codes .....................................................................................196

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Table of Contents

Section 5 Schematics........................................................................................................ 200


Introduction ......................................................................................................... 200
Electrical Component and Wire Color Legends ................................................. 201
Wiring Diagram Ground and Platform Controls .................................................. 203
Limit Switch Legend ........................................................................................... 204
Electrical Symbol Legend ................................................................................... 205
Hydraulic Symbols Legend ................................................................................. 206

Hydraulic Schematics ...................................................................................... 207


Hydraulic Component Reference Legend .......................................................... 207
Hydraulic Component Abbreviation Legend ....................................................... 209
Hydraulic Schematic, GS-1330m (from serial number GS30MD-101) .............. 210
Hydraulic Schematic, GS-1530, 1532, 1930, 1932 (from serial number
GS3010A-110000, GS3011C-10000, GS3014D-101,
GS3016P-142281) ...................................................................................... 211
Hydraulic Schematic, GS-2032, 2632, 3232, 2046, 2646, 3246
(from serial number GS3211A-110000 to GS3214A-119070,
GS3212C-10000 to GS3214C-11873, GS4612A-110000 to
GS4614A-117177, GS4614C-10000 to GS4614C-12073) ........................ 212
Hydraulic Schematic, GS-2032, 2632, 3232, 2046, 2646, 3246
(from serial number GS3214A-119071, GS3214C-11874,
GS4614A-117178, GS4614C-12074, GS4614D-101) ............................... 213
Hydraulic Schematic, GS-3232 (from serial number GS3211A-110000,
GS3212C-10000, GS3216P-142677) ........................................................ 214
Hydraulic Schematic, GS-4047 (from serial number GS4712C-101 to
GS4714C-1459) ......................................................................................... 215
Hydraulic Schematic, GS-4047 (from serial number GS4714C-1460,
GS4714D-101, GS4716P-101)................................................................... 216

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Table of Contents

Electrical Schematics – ANSI / CSA Models ..................................................217


Electrical Schematic GS-1330m, ANSI / CSA
(from serial number GS30MD-101) ............................................................218
Electrical Schematic GS-1530 / GS-1930, ANSI / CSA (from serial number
GS3010A-110000 to GS3011A-110827) ....................................................220
Electrical Schematic, GS-1530 / GS-1930, ANSI / CSA (from serial number
GS3011A-110828 to GS3014A-136972,
GS3014D-101 to GS3015D-1113) .............................................................224
Electrical Schematic, GS-1530 / GS-1930 (from serial number
GS3014A-136973, GS3015D-1114 to GS3016D-5426,
GS3016P-142281 to GS3016P-158208) ....................................................228
Electrical Schematic, GS-1530/1930, ANSI/CSA (from serial number
GS3016D-5427, GS3016P-158209) ...........................................................232
Electrical Schematic, GS-3232, ANSI / CSA (from serial number
GS3211A-110000 to GS3214A-135714) ....................................................234
Electrical Schematic, GS-3232, ANSI / CSA (from serial number
GS3214A-135715 to GS3215A-141898) ....................................................238
Electrical Schematic, GS-3232, ANSI / CSA (from serial number
GS3215A-141899, GS3216P-142677 to GS3216P-146462) .....................242
Electrical Schematic, GS-3232, ANSI / CSA (from serial number
GS3216P-146463) ......................................................................................246
Electrical Schematic, GS-2032, 2632, 2046, 2646, ANSI / CSA
(from serial number GS3211A-110000 to GS3214A-135714,
GS4612A-110000 to GS4614A-135366,
GS4613D-101 to GS4615D-1303) .............................................................250
Electrical Schematic, GS-2032, 2632, 2046, 2646, ANSI/CSA
(from serial number GS3214A-1135715 to GS3215A-141898,
GS4614A-135367 to GS4615A-137959, GS4615D-1304).........................254
Electrical Schematic, GS-2032, 2632, 2046, 2646, ANSI / CSA
(from serial number GS3215A-141899, GS3216P-142676 to
GS3216P-146462, GS4615A-137960, GS4615D-1305 to
GS4616D-4432, GS4616P-138362 to GS4616P-139710) .........................258

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Table of Contents

Electrical Schematic, GS-2032, 2632, 2046, 2646, ANSI / CSA


(from serial number GS3216P-146463, GS4616D-4433,
GS4616P-139711) ...................................................................................... 262
Electrical Schematic, GS-3246 / GS-4047, ANSI / CSA (from serial number
GS4612A-110000 to GS4614A-135366, GS4614D-101 to
GS4615D-1303, GS4714D-101 to GS4715D-749) .................................... 264
Electrical Schematic, GS-3246 / GS-4047, ANSI / CSA (from serial number
GS4614A-135367 to GS4615A-137959, GS4615D-1304 to
GS4616D-4432, GS4616P-138362 to GS4616P-139710,
GS4715D-750 to GS4716D-3101) ............................................................. 268
Electrical Schematic, GS-3246, GS4047 ANSI / CSA (from serial number
GS4616D-4433, GS4616P-139711, GS4716D-3102, GS4716P-101) ...... 272

Electrical Schematics – CE and Australia Models ........................................ 273


Electrical Schematic GS-1330m, AS / CE
(from serial number GS30MD-101) ............................................................ 274
Electrical Schematic GS-1530, 1532, 1930, 1932, (from serial number
GS3010A-110000 to GS3011A-110827) AS / CE ...................................... 276
Electrical Schematic, GS-1530/32_GS-1930/32 (from serial number
GS3011A-110828 to GS3014A-136972, GS3011C-10000 to
GS3015C-18038, GS3014D-101 to GS3015D-1113) ................................ 280
Electrical Schematic, GS-1530, 1532, 1930, 1932, AS/CE
(from serial number GS3014A-136973, GS3015C-18039,
GS3015D-1114 to GS3016D-5426,
GS3016P-142281 to GS3016P-158208) .................................................... 284
Electrical Schematic, GS-1530, 1532, 1930, 1932, AS/CE
(from serial numbers GS3015D-5427, GS3016P-158209) ........................ 288
Electrical Schematic, GS-3232, AS / CE (from serial number
GS3211A-110000 to GS3214A-135714,
GS3212C-10000 to GS3215C-14503) ....................................................... 290
Electrical Schematic, GS-3232, AS / CE (from serial number
GS3214A-135715 to GS3215A-141898, GS3215C-14504) ...................... 294
Electrical Schematic, GS-3232, AS / CE (from serial number
GS3215A-141899, GS3216P-142676 to GS3216P-146462) ..................... 298

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Table of Contents

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


GS3216P-146463) ......................................................................................302
Electrical Schematic, GS-2032, 2632, 2046, 2646, AS / CE
(from serial number GS3211A-110000 to GS3214A-135714,
GS3212C-10000 to GS3215C-14377, GS4612A-110000 to
GS4614A-135366, GS4612C-10000 to GS4615C-14503,
GS4613D-101 to GS4615D-1303) .............................................................306
Electrical Schematic, GS-2032, 2632, 2046, 2646, AS/CE
(from serial number GS3214A-1135715 to GS3215A-141898,
GS3215C-14378, GS4614A-135367 to GS4615A-137959,
GS4615C-14504, GS4615D-1304) ............................................................311
Electrical Schematic, GS-2032, 2632, 2046, 2646, AS / CE
(from serial number GS3215A-141899, GS3216P-142676 to
GS3216P-146462, GS4615A-137960, GS4616P-138362 to
GS4616P-139710) ......................................................................................315
Electrical Schematic, GS-2032, 2632, 2046, 2646, AS / CE
(from serial number GS3216P-146463, GS4616P-139711) ......................319
Electrical Schematic, GS-3246, AS / CE (from serial number
GS4612A-110000 to GS4614A-135366, GS4612C-10000 to
GS4615C-14503, GS4614D-101 to GS4615D-1303) ................................321
Electrical Schematic, GS-3246, AS / CE (from serial number
GS4614A-135367 to GS4615A-137959, GS4615C-14504,
GS4615D-1304) ..........................................................................................325
Electrical Schematic, GS-3246, AS / CE (from serial number
GS4615A-137960, GS4616P-138362, GS4616P to
GS4616P-139710) ......................................................................................329
Electrical Schematic, GS-3246, AS / CE (from serial number
GS4616D-4433, GS4616P-139711) ...........................................................333
Electrical Schematic, GS-4047, AS / CE (from serial number
GS4712C-101 to GS4715C-2130, GS4714D-101 to GS4715D-749) ........335
Electrical Schematic, GS-4047, AS / CE (from serial number
GS4715C-2131, GS4715D-750 to GS4716D-3101) ..................................339
Electrical Schematic, GS-4047, AS / CE (from serial number
GS4716D-3102) ..........................................................................................343

Electrical Schematic – Foot Switch (option) All Models ..............................344


Foot Switch (option) All Models ..........................................................................345

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Specifications
Section 2 Specific ati ons

Machine Specifications Batteries, Maintenance-free (option)


All models except GS-1330m, GS-4047
Batteries, Standard Voltage 6V DC
All models except GS-1330m, GS-4047
Group GC2
Voltage 6V DC
Type 6V-AGM
Group GC2
Quantity 4
Type T-105
Battery capacity, maximum 200AH
Quantity 4
Reserve capacity @ 25A rate 380 minutes
Battery capacity, maximum C20 = 225AH
Weight, each 62 lbs
Reserve capacity @ 25A rate 447 minutes 28 kg
Weight, each 62 lbs Batteries, Optional, GS-1330m
28 kg
Voltage 12V DC
Batteries, Standard, GS-1330m
Group 24
Voltage 12V DC
Type DC85-12
Group 24
Quantity 2
Type 24TMX
Battery capacity, maximum 85AH
Quantity 2
Reserve capacity @ 25A rate 145 minutes
Battery capacity, maximum 85AH
Weight, each 57 lbs
Reserve capacity @ 25A rate 140 minutes 26 kg
Weight, each 46 lbs Platform Overload Pressure Transducer
21 kg (if equipped) All models except GS-3232, GS-4047
Batteries, Standard, GS-4047 Input voltage 8 to 30 VDC
Voltage 12V DC Signal voltage 1 to 5 V
Group GC2 Platform Overload Pressure Transducer
Type T-1275 (if equipped) GS-3232, GS-4047
Quantity 4 Input voltage 8 to 30 VDC
Battery capacity, maximum C20 = 150AH Signal voltage 0.25 to 6.25 V
Reserve capacity @ 25A rate 280 minutes Angle Sensor (if equipped)
Weight, each 82 lbs Input voltage 8 to 30 VDC
37 kg
Signal voltage 3 to 4 V, PMW output
Outrigger Pressure Transducer, GS-3232 only
Input voltage 8 to 30 VDC
Signal voltage 1 to 5 V

For operational specifications, refer to the


Operator's Manual.

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 1


Service and Repair Manual January 2019

Specifications

Fluid capacities Tires and wheels


Hydraulic tank 3.4 gallons GS-1330m
All models except GS-1330m, GS-4047 12.9 liters
Tire size (solid rubber) 10 x 3 in
Hydraulic tank GS-4047 5.9 gallons 25.4 x 7.6 cm
22.4 liters Tire contact area 6.5 sq in
Hydraulic tank GS-1330m 1.06 gallons 42 cm2
4 liters Castle nut torque, dry 200 ft-lbs
Hydraulic system (including tank) 3.8 gallons 271.2 Nm
GS-1530, GS-1532, GS-1930, GS-1932 14.2 liters Castle nut torque, lubricated 150 ft-lbs
Hydraulic system (including tank) 4.5 gallons 203.4 Nm
GS-2032, GS-2632, GS-2046, GS-2646 17 liters GS-1530, GS-1532, GS-1930, GS-1932
Hydraulic system (including tank) 5.5 gallons Tire size (solid rubber) 12 x 4.5 in
GS-3232, GS-3246 20.8 liters 30.5 x 11.4 cm
Hydraulic system (including tank) 7.5 gallons Tire contact area 9 sq in
GS-4047 28.4 liters 58 cm2
Hydraulic system (including tank) 1.49 gallons Castle nut torque, dry 300 ft-lbs
GS-1330m 5.64 liters 406.7 Nm
Castle nut torque, lubricated 225 ft-lbs
305 Nm
GS-2032, GS-2632, GS-3232, GS-2046, GS-2646,
GS-3246, GS-4047
Tire size (solid rubber) 15 x 5 in
38.1 x 12.7 cm
Tire contact area 15 sq in
96.7 cm2
Castle nut torque, dry 300 ft-lbs
406.7 Nm
Castle nut torque, lubricated 225 ft-lbs
305 Nm

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Specifications

Performance Specifications GS-4047

(models without proportional lift) Platform stowed, fast 2.0 mph


40 ft / 13.6 sec
Drive speed, maximum 3.2 km/h
12.2 m / 13.6 sec
GS-1530, GS-1532, GS-1930, GS-1932
Platform raised 0.5 mph
Platform stowed, fast 2.5 mph 40 ft / 55 sec
40 ft / 10.9 sec 0.8 km/h
4 km/h 12.2 m / 55 sec
12.2 m / 10.9 sec
Braking distance, maximum
Platform raised 0.5 mph
40 ft / 55 sec High range on paved surface 1 - 3 ft
0.8 km/h 0.3 - 0.9 m
12.2 m / 55 sec Gradeability
GS-2032, GS-2632, GS-3232, GS-2046, GS-2646, GS-1930, GS-1932, 25%
GS-3246 GS-2632,GS-3232, GS-3246 and
Platform stowed, fast 2.2 mph GS-4047
to serial number: 40 ft / 12.4 sec GS-1530, GS-1532, GS-2032, 30%
GS3216P-145830 3.5 km/h GS-2046 and GS-2646
GS4616P-139575 12.2 m / 12.4 sec
Airborne noise emissions
Platform stowed, fast 2.0 mph
Sound pressure level at ground < 70 dBA
from serial number: 40 ft / 12.4 sec
workstation
GS3216P-145831 3.2 km/h
GS4616P-139576 12.2 m / 12.4 sec Sound pressure level at platform < 70 dBA
workstation
Platform raised 0.5 mph
40 ft / 55 sec
0.8 km/h
12.2 m / 55 sec

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Service and Repair Manual January 2019

Specifications

Performance Specifications GS-4047


(without proportional lift), continued Platform up (fast mode) 71 to 76 seconds
Platform up (slow mode) 83 to 87 seconds
Function speed, maximum from platform controls Platform down 41 to 46 seconds
(with 1 person in platform)
Rated work load at full height, maximum
GS-1530 and GS-1532
GS-1530 and GS-1532 600 lbs
Platform up (fast mode) 15 to 17 seconds 272 kg
Platform up (slow mode) 30 to 32 seconds
Platform down 28 to 30 seconds GS-1930, GS-1932, 500 lbs
GS-2632 and GS-3232 227 kg
GS-1930 and GS-1932
GS-2032 800 lbs
Platform up (fast mode) 15 to 17 seconds 363 kg
Platform up (slow mode) 30 to 32 seconds
Platform down 28 to 30 seconds GS-2046 1200 lbs
544 kg
GS-2032 and GS-2632
GS-2646 1000 lbs
Platform up (fast mode) 28 to 32 seconds 454 kg
Platform up (slow mode) 58 to 62 seconds
Platform down 32 to 36 seconds GS-3246 700 lbs
317 kg
GS-2046 and GS-2646
GS-4047 770 lbs
Platform up (fast mode) 28 to 32 seconds (CE and AS models) 350 kg
Platform up (slow mode) 58 to 62 seconds
Platform down 32 to 36 seconds GS-4047 550 lbs
(ANSI and CSA models) 250 kg
GS-3232 and GS-3246
GS-3232 Outrigger leveling capacity, maximum
Platform up (fast mode) 55 to 59 seconds
Platform up (slow mode) 108 to 112 seconds Side to side 5°
Platform down 33 to 37 seconds Front to rear 3°

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January 2019 Service and Repair Manual

Specifications

Performance Specifications GS-4047

(models with proportional lift) Platform stowed 2.0 mph


40 ft / 13.6 sec
Drive speed, maximum 3.2 km/h
12.2 m / 13.6 sec
GS-1330m, GS-1530, GS-1532, GS-1930, GS-1932
Platform raised 0.5 mph
Platform stowed 2.5 mph 40 ft / 55 sec
40 ft / 10.9 sec 0.8 km/h
4 km/h 12.2 m / 55 sec
12.2 m / 10.9 sec
Braking distance, maximum
Platform raised 0.5 mph
40 ft / 55 sec High range on paved surface 1 - 3 ft
0.8 km/h 0.3 - 0.9 m
12.2 m / 55 sec Gradeability
GS-2032, GS-2632, GS-3232, GS-2046, GS-2646, GS-1330m, GS-1930, GS-1932, 25%
GS-3246 GS-2632,GS-3232, GS-3246 and
Platform stowed 2.2 mph GS-4047
to serial number: 40 ft / 12.4 sec GS-1530, GS-1532, GS-2032, 30%
GS3216P-145830 3.5 km/h GS-2046 and GS-2646
GS4616P-139575 12.2 m / 12.4 sec
Airborne noise emissions
Platform stowed 2.0 mph
Sound pressure level at ground < 70 dBA
from serial number: 40 ft / 12.4 sec
workstation
GS3216P-145831 3.2 km/h
GS4616P-139576 12.2 m / 12.4 sec Sound pressure level at platform < 70 dBA
workstation
Platform raised 0.5 mph
40 ft / 55 sec
0.8 km/h
12.2 m / 55 sec

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Service and Repair Manual January 2019

Specifications

Performance Specifications Rated work load at full height, maximum


(with proportional lift), continued GS-1330m 500 lbs
227 kg
Function speed, maximum from platform controls
(with 1 person in platform) GS-1530 and GS-1532 600 lbs
272 kg
GS-1330m
GS-1930, GS-1932, 500 lbs
Platform up 19 to 22 seconds GS-2632 and GS-3232 227 kg
Platform down 20 to 24 seconds
GS-1930PAR 400 lbs
GS-1530 and GS-1532 181 kg
Platform up 15 to 17 seconds GS-2032 800 lbs
Platform down 18 to 25 seconds 363 kg
GS-1930, 1930PAR and GS-1932 GS-2046 1200 lbs
Platform up 15 to 17 seconds 544 kg
Platform down 18 to 25 seconds GS-2646 1000 lbs
GS-2032 and GS-2632 454 kg
Platform up 28 to 32 seconds GS-3246 700 lbs
Platform down 24 to 28 seconds 317 kg

GS-2046 and GS-2646 GS-4047 770 lbs


(CE and AS models) 350 kg
Platform up 28 to 32 seconds
Platform down 28 to 32 seconds GS-4047 550lbs
(ANSI and CSA models) 250 kg
GS-3232 and GS-3246
GS-3232 Outrigger leveling capacity, maximum
Platform up 55 to 59 seconds
Platform down 28 to 32 seconds Side to side 5°
Front to rear 3°
GS-4047
Platform up 71 to 76 seconds
Platform down 41 to 46 seconds

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January 2019 Service and Repair Manual

Specifications

Hydraulic Oil Specifications Do not top off with incompatible


hydraulic fluids. Hydraulic fluids
Hydraulic Fluid Specifications may be incompatible due to the
Genie specifications require hydraulic oils which are differences in base additive
designed to give maximum protection to hydraulic chemistry. When incompatible
systems, have the ability to perform over a wide fluids are mixed, insoluble
temperature range, and the viscosity index should materials may form and deposit
exceed 140. They should provide excellent antiwear, in the hydraulic system,
oxidation prevention, corrosion inhibition, seal plugging hydraulic lines, filters,
conditioning, and foam and aeration suppression control valves and may result in
properties. component damage.
Cleanliness level, ISO 15/13
minimum Note: Do not operate the machine when the
Water content, 250 ppm ambient air temperature is consistently above
maximum 120°F / 49°C.
Recommended Hydraulic Fluid
Hydraulic oil type Chevron Rando HD Premium Hydraulic Fluid Temperature
Viscosity grade 32 Range
Viscosity index 200
Optional Hydraulic Fluids
Mineral based Shell Tellus S2 V 32
Shell Tellus S2 V 46
Shell Tellus S4 VX 32 Shell
Shell Donax TG (Dexron III)
Chevron 5606A
Biodegradable Petro Canada Environ MV 46
Fire resistant UCON Hydrolube HP-5046
Note: Genie specifications require additional
equipment and special installation instructions for Ambient air temperature
the approved optional fluids. Consult Genie
Product Support before use. 1 Chevron hydraulic oil 5606A
2 Petro-Canada Environ MV 46
Optional fluids may not have 3 UCON Hydrolube HP-5046D
the same hydraulic lifespan and 4 Chevron Rando HD premium oil MV
may result in component
damage.

Note: Extended machine operation can cause the


hydraulic fluid temperature to increase beyond it's
maximum allowable range. If the hydraulic fluid
temperature consistently exceeds 200°F / 90°C an
optional oil cooler may be required.

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Service and Repair Manual January 2019

Specifications

Chevron Rando HD Premium Oil Chevron 5606A Hydraulic Oil


MV Fluid Properties Fluid Properties
ISO Grade 32 ISO Grade 15
Viscosity index 200 Viscosity index 300
Kinematic Viscosity Kinematic Viscosity
cSt @ 200°F / 100°C 7.5 cSt @ 200°F / 100°C 5.5
cSt @ 104°F / 40°C 33.5 cSt @ 104°F / 40°C 15.0
cSt @ -40°F / -40°C 510
Brookfield Viscosity
cP @ -4°F / -20°C 1040 Flash point 180°F / 82°C
cP @ -22°F / -30°C 3310
Pour point -81°F / -63°C
Flash point 375°F / 190°C
Maximum continuous operating 124°F / 51°C
Pour point -58°F / -50°C temperature
Maximum continuous operating 171°F / 77°C Note: Use of Chevron 5606A hydraulic fluid, or
temperature equivalent, is required when ambient temperatures
Note: A hydraulic oil heating system is are consistently below 0°F / -17°C unless an oil
recommended when the ambient temperature is heating system is used.
consistently below 0°F / -18°C.
Continued use of Chevron
Note: Do not operate the machine when the 5606A hydraulic fluid, or
ambient temperature is below -20°F / -29°C with equivalent, when ambient
Rando HD Premium MV. temperatures are consistently
above 32°F / 0°C may result in
component damage

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January 2019 Service and Repair Manual

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

Maximum continuous operating 180°F / 82°C Flash point None


temperature Pour point -81°F / -63°C
Maximum continuous operating 189°F / 87°C
temperature
Shell Tellus S4 VX Fluid
Properties
ISO Grade 32
Viscosity index 300
Kinematic Viscosity
cSt @ 200°F / 100°C 9
cSt @ 104°F / 40°C 33.8
Brookfield Viscosity
cSt @ -4°F / -20°C 481
cSt @ -13°F / -25°C 702.4
cSt @ -40°F / -40°C 2624
Flash point >100
Pour point -76°F / -60°C
Maximum continuous operating 103°F / 75°C
temperature

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 9


Service and Repair Manual January 2019

Specifications

Hydraulic Component Function manifold - GS-1330m


Specifications System relief valve pressure, 2250 psi
maximum 155 bar
Function pump - GS-1330m Platform relief valve pressure 2250 psi
Type Gear 155 bar

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

System relief valve pressure, 3700 psi SAE No. 10 55 ft-lbs / 75 Nm


maximum 255 bar SAE No. 12 75 ft-lbs / 102 Nm
Lift relief valve pressure 1800 to 3700 psi
142 to 241 bar
Steer relief valve pressure 1500 psi
103 bar

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January 2019 Service and Repair Manual

Specifications

Valve coil resistance


Note: The following coil resistance specifications are at
an ambient temperature of 68°F / 20°C. As valve coil
resistance is sensitive to change in air temperature, the
coil resistance will typically increase or decrease by 4%
of each 18°F / -7.7°C that your air temperature
increases or decreases from 68°F / 20°C.
Description Specification
Solenoid valve, 3 position 4 way, 27.2Ω
20V DC with diode
(schematic items F, AC or DC)
Solenoid valve, 3 position 4 way, 19Ω
20V DC with diode
(schematic item E)
Solenoid valve, 2 position 4 way, 19Ω
20V DC with diode
(schematic items H, AI or DI)
Solenoid valve, 2 position 2 way, 25Ω
N.C. 20V DC with diode
(schematic item N)
Solenoid valve, 2 position 4 way, 19Ω
20V DC with diode
(schematic item AE or DE)
Solenoid valve, 3 position 5 way, 19Ω
20V DC with diode
(schematic item AG or DG)
Solenoid valve, 2 position 2 way, 27.2Ω
20V DC with diode
(schematic items CA, CB, CC and
CD)
Solenoid valve, 3 position 4 way, 19Ω
20V DC with diode
(schematic item BA)
Solenoid valve, 2 position 2 way, 23.9Ω
20V DC with diode
(schematic item DN)
Solenoid valve, 3 position 4 way 33.75Ω
24V DC with diode
(schematic item EA)
Solenoid valve, 2 position 4 way 33.75Ω
24V DC with diode
(schematic item EC)

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 11


Service and Repair Manual January 2019

Specifications

Hydraulic Hose and Fitting


Torque Specifications SAE O-ring Boss Port
(tube fitting - installed into Aluminum)
Your machine is equipped with Parker Seal-Lok™
(all types)
ORFS or 37° JIC fittings and hose ends. Genie
specifications require that fittings and hose ends be SAE Dash Size Torque
torqued to specification when they are removed -4 14 ft-lbs / 19 Nm
and installed or when new hoses or fittings are -6 23 ft-lbs / 31,2 Nm
installed.
-8 36 ft-lbs / 54,2 Nm
-10 62 ft-lbs / 84 Nm
Seal-Lok™ Fittings -12 84 ft-lbs / 114 Nm
(hose end - ORFS)
-16 125 ft-lbs / 169,5 Nm
SAE Dash Size Torque
-20 151 ft-lbs / 204,7 Nm
-4 18 ft-lbs / 25 Nm
-24 184 ft-lbs / 249,5 Nm
-6 30 ft-lbs / 41 Nm
-8 40 ft-lbs / 55 Nm
-10 60 ft-lbs / 81 Nm
-12 85 ft-lbs / 115 Nm
-16 110 ft-lbs / 150 Nm
-20 150 ft-lbs / 205 Nm
-24 230 ft-lbs / 315 Nm
Adjustable Fitting Non-adjustable fitting

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

-16 1 5/16-12 1 -6 ORFS (Adj / Non-adj) 35 ft-lbs / 47,5 Nm


37° (Adj / Non-adj) 29 ft-lbs / 39,3 Nm
-20 1 5/8-12 1
-8 ORFS (Adj / Non-adj) 60 ft-lbs / 81,3 Nm
-24 1 7/8-12 1 37° (Adj / Non-adj) 52 ft-lbs / 70,5 Nm
-10 ORFS (Adj / Non-adj) 100 ft-lbs / 135,6 Nm
37° (Adj / Non-adj) 85 ft-lbs / 115,3 Nm
-12 (All types) 135 ft-lbs / 183 Nm
-16 (All types) 200 ft-lbs / 271,2 Nm
-20 (All types) 250 ft-lbs / 339 Nm
-24 (All types) 305 ft-lbs / 413,5 Nm

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January 2019 Service and Repair Manual

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.

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Service and Repair Manual January 2019

Specifications

3 Working clockwise on the body hex fitting,


make a second mark with a permanent ink
marker to indicate the proper tightening
position. Refer to Illustration 2.
Note: Use the JIC 37° Fitting table in this section to
determine the correct number of flats, for the
proper tightening position.
Note: The marks indicate the correct tightening
positions have been determined. Use the second
mark on the body hex fitting to properly tighten the
joint after it has been loosened.

Illustration 2
1 body hex fitting
2 reference mark
3 second mark

4 Tighten the hex nut until the mark on the hex


nut is aligned with the second mark on the
body hex fitting.
5 Operate all machine functions and inspect the
hose, fittings and related components to
confirm there are no leaks.

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January 2019 Service and Repair Manual

Repair Procedures

Machine Configuration:
Section 3 Repair Pr oc edures

 Unless otherwise specified, perform each


repair procedure with the machine in the
following configuration:
• Machine parked on a firm, level surface
• Key switch in the off position with the key
Observe and Obey: removed
 Repair procedures shall be completed by a • The red Emergency Stop button in the off
person trained and qualified on the repair of position at both the ground and platform
this machine. controls
 Immediately tag and remove from service a • Wheels chocked
damaged or malfunctioning machine.
• All external AC power supply disconnected
 Repair any machine damage or malfunction from the machine
before operating the machine.
• Platform in the stowed position

Before Repairs Start:


 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 parts are
available and ready for use.
 Use only Genie approved replacement parts.
 Read each procedure completely and adhere
to the instructions. Attempting shortcuts may
produce hazardous conditions.

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 15


Service and Repair Manual January 2019

Repair Procedures

About This Section


Symbols Legend
Most of the procedures in this section should only
be performed by trained service professional in a Safety alert symbol—used to alert
suitably equipped workshop. Select the appropriate personnel to potential personal
repair procedure after troubleshooting the problem. injury hazards. Obey all safety
messages that follow this symbol
Perform disassembly procedures to the point to avoid possible injury or death.
where repairs can be completed. Then to
re-assemble, perform the disassembly steps in Indicates a imminently hazardous
reverse order. situation which, if not avoided, will
result in death or serious injury.

Indicates a potentially hazardous


situation which, if not avoided,
could result in death or serious
injury.

Indicates a potentially hazardous


situation which, if not avoided,
may cause minor or moderate
injury.

Indicates a potentially hazardous


situation which, if not avoided,
may result in property damage.

Indicates that a specific result is expected


after performing a series of steps.
Indicates that an incorrect result has occurred
after performing a series of steps.

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January 2019 Service and Repair Manual

Platform Controls

The platform controls are used to operate the


machine from the platform.
Activating a function button sends a signal to the
Electronic Control Module (ECM). When the ECM
is in the function mode, the platform controls are
used to operate the various machine functions.
The platform controls consist of an Emergency
Stop button, electronic circuit board, proportional
control handle, drive/steer enable switch, alarm,
function buttons and LED display.
For further information or assistance, contact
Genie Product Support.

a red Emergency Stop button P2


b platform controls circuit board U3
c proportional control handle and drive/steer
enable switch JC9
d alarm H1

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 17


Service and Repair Manual January 2019

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.

Platform Controls LED Readout

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)

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Platform Controls

1-1 8 Carefully disconnect all wire harness


connectors from the platform controls circuit
Circuit Board board.
Electrocution/burn hazard.
How to Remove the Platform Contact with electrically charged
Controls Circuit Board circuits could result in death or
serious injury. Remove all rings,
1 Push in the red Emergency Stop button to the watches and other jewelry.
off position at both the ground and platform
controls. Component damage hazard.
2 Disconnect the platform controls from the Electrostatic discharge (ESD)
control cable at the platform. can damage printed circuit board
components. Maintain firm
3 Remove the fasteners securing the platform contact with a metal part of the
control box to the platform control bracket. machine that is grounded at all
4 Remove the fasteners securing the bottom times when handling printed
cover to the platform control box. Open the circuit boards OR use a
control box. grounded wrist strap.

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.

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 19


Service and Repair Manual January 2019

Platform Controls

1-2 1-3
Joystick Platform Controls Alarm

How to Remove the Joystick How to Remove the Platform


1 Push in the red Emergency Stop button to the Controls Alarm
off position at both the ground and platform
1 Push in the red Emergency Stop button to the
controls.
off position at both the ground and platform
2 Disconnect the platform controls from the controls.
control cable at the platform.
2 Disconnect the platform controls from the
3 Remove the fasteners securing the platform control cable at the platform.
control box to the platform control bracket.
3 Remove the fasteners securing the platform
4 Remove the fasteners securing the bottom control box to the platform control bracket.
cover to the platform control box. Open the
4 Remove the fasteners securing the bottom
control box.
cover to the platform control box. Open the
5 Remove the ties securing the joystick wire control box.
harness. 5 Disconnect the red and black wires from the
6 Carefully disconnect the joystick wire harness alarm.
from the platform controls circuit board.
Electrocution/burn hazard.
Electrocution/burn hazard. Contact with electrically charged
Contact with electrically charged circuits could result in death or
circuits could result in death or serious injury. Remove all rings,
serious injury. Remove all rings, watches and other jewelry.
watches and other jewelry.
Component damage hazard.
Component damage hazard. Electrostatic discharge (ESD)
Electrostatic discharge (ESD) can damage printed circuit board
can damage printed circuit board components. Maintain firm
components. Maintain firm contact with a metal part of the
contact with a metal part of the machine that is grounded at all
machine that is grounded at all times when handling printed
times when handling printed circuit boards OR use a
circuit boards OR use a grounded wrist strap.
grounded wrist strap.
6 Carefully remove the alarm from the platform
7 Carefully remove the joystick fasteners. control box.
8 Carefully remove the joystick from the platform
control box.
Torque specifications
Joystick fasteners 9 in-lbs
1 Nm

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Platform Controls

1-4 5 Disconnect the white wires from the


Emergency Stop base.
Platform Emergency Stop Button
Electrocution/burn hazard.
Contact with electrically charged
How to Remove the Platform circuits could result in death or
Controls Emergency Stop Button serious injury. Remove all rings,
watches and other jewelry.
1 Push in the red Emergency Stop button to the
off position at both the ground and platform Component damage hazard.
controls. Electrostatic discharge (ESD)
2 Disconnect the platform controls from the can damage printed circuit board
control cable at the platform. components. Maintain firm
contact with a metal part of the
3 Remove the fasteners securing the platform machine that is grounded at all
control box to the platform control bracket. times when handling printed
4 Remove the fasteners securing the bottom circuit boards OR use a
cover to the platform control box. Open the grounded wrist strap.
control box.
6 Carefully remove the Emergency Stop base
from the Emergency Stop button.
7 Carefully remove the retaining ring from the
Emergency Stop button.
8 Carefully remove the Emergency Stop button
from the platform control box.

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The ground controls, used to operate the machine


from the ground, can also be used to tune the
performance of the machine.
The ground controls consist of an Electronic
Control Module (ECM), emergency stop button,
key switch and circuit breaker.
Activating the function enable button and the up or
down at the same time, sends a signal to the
(ECM). This allows the platform to be raised or
lowered at the ground controls.
Note: Steer and drive functions are not available at
the ground controls.
When the ECM is in the set up mode, the ground
controls are used to adjust the function speed
parameters, machine models, or machine options.
1 machine setup escape button
For further information or assistance, contact
2 machine setup scroll up button
Genie Product Support.
3 LCD readout
4 machine setup scroll down button
5 machine setup enter button
6 Key switch KS1
7 red Emergency Stop P1
8 circuit breaker CB2
9 Diagnostic port (if equipped)
10 platform down button
11 lift function enable button
12 platform up button

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2-1 2 Press the ground control scroll down button.


Software Revision Level Result: The ground control LCD display will
indicate the software revision and hour meter
information. After 5 seconds, the ground
How to Determine the Revision controls LCD display will display machine
Level model and hour meter information again. See
example below.
The machine software revision level is displayed at
the ground controls LCD display. 3 Push in the red Emergency Stop button to the
off position at both the ground and platform
1 Turn the key switch to the ground controls or controls and turn the key switch to the off
platform controls position. Pull out the red position.
Emergency Stop button to the on position at
both ground and platform controls.
Result: The display at the platform controls will
show "CH". See example below.

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.

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2-2 2 Press and hold the ground control scroll up


and scroll down buttons.
Machine Setup

How to Setup the Machine from


Ground Controls
The ground controls can be used to setup the
machine parameters from the ground. Features
that can be adjusted from the ground controls
include machine Model, Options and Speed setup.
This menu can only be entered from ground
controls with the key switch in the ground controls
position.
Ground Control Menu Buttons
Tip-over hazard. Do not adjust
function speeds higher than 1 scroll down button
specified in this procedure. 2 enter button
Setting the function speeds 3 scroll up button
greater than specifications could 4 escape button
cause the machine to tip over 5 LCD display
resulting in death or serious
injury. 3 Pull out the red Emergency Stop button to the
on position at the ground controls.
Tip-over hazard. This procedure Result: The ground controls LCD display will
must only be performed by a show the following:
trained service professional.
Attempting this procedure
without the necessary skills
could result in death or serious
injury.

Note: Select a test area that is firm, level and free


of obstructions. 4 Use the ground control menu buttons to select
machine Model, Options and Speed Setup
1 Turn the key switch to ground controls. parameters. Follow the menu structure
indicated on the ground control LCD display.

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2-3 Bootloader Mode


Loading or Updating Machine 1 Open the GCON compartment.
Software Note: Some models will require opening the ground
control box to access the GCON.
Note: Before updating the machine software, open
a web browser and navigate to the following 2 Turn the key switch to the ground controls
location for the Genie Machine Software Download position and pull out the red Emergency Stop
portal, http://firmware.genielift.com. Perform a button to the on position at the platform
search by applying the appropriate filters and controls.
download the machine software.
3 At the ground controls, press and hold the
Note: There are two procedures available to update Enter and Escape buttons.
the machine software. These are Bootloader
Mode and Machine Application Mode.

Bootloader Mode: The Bootloader mode is only


available with the key switch in the GCON position.
It allows the user to update or reinstall the machine
software by directing the system into the
Bootloader.
Choose this mode if the GCON ECM is not
opertaing correctly.

Machine Application Mode: The machine


Application mode is available with the key switch in a LCD display
the GCON or PCON position. This mode of b enter button
machine software update requires the user to enter c escape button
the Machine Service Tool.
4 Pull out the red Emergency Stop button to the
Choose this mode if the machine is operating on position at the ground controls.
correctly and you are updating the machine
software. Result: The ground controls LCD display will
show the following:

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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.

9 Select the Choose File button and navigate to


a diagnostic port the downloaded Genie Flash file (.gff).

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:

7 Read and record the IP address.

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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.

12 Select the Run Application button to exit the


software update mode.
13 Push in the red Emergency Stop button and
disconnect the CAT5 cable from the GCON.
14 Secure the diagnostic port cover using the
retaining fasteners removed in step 5. 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.
a diagnostic port
Tip over hazard. Updating the
SmartLink software may have 4 Connect one end of a CAT5 Ethernet cable
impacted the machines default into the diagnostic port. Connect the other end
drive speeds. Tipping over the into a PC or laptop.
machine will result in death or
serious injury. Result: The ground controls LCD display will
show the following:
Perform drive speed test. Refer
to the Maintenance Manual that
is appropriate for your machine.

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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.

6 Launch a web browser such as Internet


Explorer ®, Chrome ® or Firefox ® on your PC
or laptop. Type the IP address from step 5 into
the web browser address bar and press enter.
Result: The following screen will be displayed.

9 Select the Update Machine Software button.


Result: The following screen will be displayed.
7 Enter the following username and password
then select OK.
Username: smart.link
Password: SL1000
Note: The username and password are case
sensitive.
Result: The following screen will be displayed.

10 Select the Choose File button and navigate to


the downloaded Genie Flash file (.gff).
Note: Verify it is the correct flash file.

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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.

Tip over hazard. Updating the


SmartLink software may have
impacted the machines default
drive speeds. Tipping over the
machine will result in death or
serious injury.

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.

13 Select the Run Application button to exit the


software update mode.
14 Push in the red Emergency Stop button and
disconnect the CAT5 cable from the GCON.

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2-4 3 Locate the diagnostic port on the side of the


GCON. Remove one of the fasteners securing
Using a Wi-Fi Router to Connect the cover and set aside. Loosen the other
to the SmartLink Web Service fastener. Do not remove it.
Tool
Note: Before using a portable wireless router to
connect to the Smart Link Service Tool web site,
the router must be configured to the type of
connection desired. Refer to the portable wireless
router users manual for set-up and configuration
instructions.
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 a diagnostic port
both ground and platform controls.
4 Connect one end of a CAT5 Ethernet cable
Result: The display at the platform controls will into the diagnostic port. Connect the other end
show "CH". See example below. into the ethernet port of the portable wireless
router.
Result: The ground controls LCD display will
show the following:

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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.

Tip over hazard. Updating the


SmartLink software may have
impacted the machines default
drive speeds. Tipping over the
machine will result in death or
serious injury.
Perform drive speed test. Refer
to the Maintenance Manual that
is appropriate for your machine.

12 Perform a function test. Refer to the


Operator's Manual on your machine.

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2-5 Note: Perform this operation on a firm, level


surface and if equipped, with the outriggers auto
Service Override Mode leveled or fully retracted.
The Electronic Control Module (ECM) is Tip-over hazard. Operating the
programmed with a Service Override mode. machine on a surface that is not
Service Override mode is only indented for certain level while in Service Override
circumstances and is not part of the normal mode will result in death or
machine operation. Service Override mode should serious injury. Follow proper
only be accessed by trained personal to repair operating procedures and safety
faults and/ or a malfunctioning machine. precautions. Do not use Service
Note: Service Override mode can only be entered Override mode if you are not
at the ground controls and is intended to allow the trained and familiar with the
platform to be raised or lowered. Once the platform operation of the machine.
has reached the maximum allowable height, the
system will exit Service Override mode. Repeat this 1 Turn the key switch to the ground controls
procedure to lower the platform. position and pull out the red Emergency Stop
button to the on position at the platform
Note: When in Service Override mode, an audible controls.
alarm will sound. 2 Press and hold the ground control scroll up
Note: Before entering Service Override mode, fault and scroll down buttons.
codes or the malfunction affecting the operation of
the machine should be fully understood to ensure
Service Override mode is required.

Ground Control Menu Buttons


a scroll down button
b enter button
c scroll up button
d escape button
e LCD display

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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.

4 Release the Scroll Up and Scroll Down


buttons after the ground controller powers up.
5 At the ground controls, use the Scroll Down
button to scroll to SVC Override.
Result: The ground controls LCD display will
show the following:

7 Press the Enter button.


Result: The ground controls LCD display will
show the following:

8 Press the Enter button.


Result: The ground controls LCD display will
show the following:

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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.

All models except GS-1330m


The tilt alarm sounds when the incline of the Procedure 2
chassis exceeds 1.5° to the side and 3° to the front
or rear.

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

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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.

7 Turn the key switch to the off position and


push in the red Emergency Stop button to the
off position at the ground controls.
8 Tag and disconnect the level sensor wire
harness from the chassis wire harness.
Note: The wire harness connection is located next
to the level sensor, on top of the chassis at the
Procedure 1 steer end of the machine.
1 X axis 9 Remove the level sensor retaining fasteners
2 Y axis and remove the level sensor from the
machine.
Tip-over hazard. Failure to install
or calibrate the level sensor as 10 Tag and disconnect the level sensor wires
instructed will compromise from the level sensor connector plug.
machine stability and cause the
11 Securely install the wires of the new level
machine to tip over, resulting in
sensor into the level sensor connector plug.
death or serious injury. Do not
install or calibrate the level
sensor other than specified in
this procedure.

Note: If you are not installing a new level sensor,


proceed to step 15.
1 Move the machine to an area that has a firm,
level surface and is free of obstructions.
Note: The surface must be 0° +/- 0.5°.
2 Remove the platform controls from the
platform.
3 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.
4 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
5 Lift the safety arm, move it to the center of the
scissor arm and rotate down to a vertical
position.

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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

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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.

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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.

6 Turn the key switch to the off position and


push in the red Emergency Stop button to the
off position at the ground controls.
Procedure 2
7 Tag and disconnect the level sensor wire
1 X axis harness from the chassis wire harness.
2 Y axis
Note: The wire harness connection is located on
Tip-over hazard. Failure to install the level sensor, on top of the chassis at the steer
the level sensor as instructed will end of the machine.
compromise machine stability
and cause the machine to tip 8 Remove the level sensor retaining fasteners
over, resulting in death or and remove the level sensor from the
serious injury. Do not install the machine.
level sensor other than specified 9 Securely install the wires of the new level
in this procedure. sensor into the level sensor connector plug.
Note: If you are not installing a new level sensor,
proceed to step 14.
1 Move the machine to an area that has a firm,
level surface and is free of obstructions.
Note: Use a digital level to verify the surface is
level.
2 Turn the key switch to ground control and pull
out the red Emergency Stop button to the on
position at both ground and platform controls.

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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.

Ground Control Menu Buttons


1 scroll down button
2 enter button
3 scroll up button
4 escape button
5 LCD display

Non-steer End
1 limit switch
2 level sensor mount bracket
3 level sensor S7
4 scissor chassis
5 alarm H5

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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.

19 Press the Enter button.


23 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
20 Use the Scroll Up or Scroll Down buttons to
scroll to Tilt Sensor. 24 Return the safety arm to the stowed position.
25 Lower the platform to the stowed position.
26 Place a digital level on the ground control side
of the drive chassis. Zero out the digital level.
27 Drive the steer end of the machine up a ramp
until it is just under 3°.
21 Press the Enter button.

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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°.

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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°.

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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.

6 Turn the key switch to the off position and


push in the red Emergency Stop button to the
off position at the ground controls.
7 Tag and disconnect the level sensor wire
harness from the chassis wire harness.
Note: The wire harness connection is located on
the level sensor, on top of the chassis at the steer
Procedure 3 end of the machine.
1 X axis 8 Remove the level sensor retaining fasteners
2 Y axis and remove the level sensor from the
machine.
Tip-over hazard. Failure to install
the level sensor as instructed will 9 Securely install the wires of the new level
compromise machine stability sensor into the level sensor connector plug.
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.

Note: If you are not installing a new level sensor,


proceed to step 14.
1 Move the machine to an area that has a firm,
level surface and is free of obstructions.
Note: Use a digital level to verify the surface is
level.
2 Turn the key switch to ground control and pull
out the red Emergency Stop button to the on
position at both ground and platform controls.
3 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
4 Lift the safety arm, move it to the center of the
scissor arm and rotate down to a vertical
position.

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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.

Ground Control Menu Buttons


1 scroll down button
2 enter button
3 scroll up button
4 escape button
5 LCD display

Non-steer End
1 limit switch
2 level sensor mount bracket
3 level sensor S7
4 scissor chassis
5 alarm H5

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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.

19 Press the Enter button.


23 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
20 Use the Scroll Up or Scroll Down buttons to
scroll to Tilt Sensor. 24 Return the safety arm to the stowed position.
25 Lower the platform to the stowed position.
26 Place a digital level on the ground control side
of the drive chassis. Zero out the digital level.
27 GS-1330m: Drive the steer end of the
machine up a ramp until it is just under 2.5°.
21 Press the Enter button.
All other models: Drive the steer end of the
machine up a ramp until it is just under 3°

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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°.

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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°.

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Service and Repair Manual January 2019

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.

1 Move the machine to an area that has a firm,


level surface and is free of obstructions.
2 Turn the key switch to the off position and
push in the red Emergency Stop button to the
off position at both the ground and platform
controls.
3 Open the access door at the battery side of 1 outrigger level sensor (GS-3232)
the machine.
7 Secure the outrigger level sensor onto the
4 Tag and disconnect the outrigger level sensor
base with the retaining fasteners removed in
wire harness from the outrigger level sensor.
step 5.
5 Remove the outrigger level sensor retaining
8 Adjust the outrigger level sensor retaining
fasteners and remove the outrigger level
fasteners until the bubble at the top of the level
sensor from the machine.
sensor is centered in the circles.
9 Connect the outrigger level sensor wire
harness to the new outrigger level sensor.
10 Close the access door at the battery side of
the machine.
11 Calibrate the outrigger level sensor. Refer to
Repair Procedure, How to Calibrate the
Outrigger System.

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Ground Controls

2-7 5 Measure the distance between the base of the


handle and cable mounting nut.
Manual Platform Lowering Cable
Result: The measurement should be no
The manual platform lowering cable lowers the greater than 0.125 inch / 3 mm.
platform in the event of a main power failure. The
manual platform lowering cable is attached to the Note: Proceed to step 8 if measurement is correct.
barrel end of the lift cylinder and is activated next to
the ground controls.

How to Adjust the Manual


Platform Lowering Cable
1 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
2 Lift the safety arm, move it to the center of the
scissor arm and rotate down to a vertical
position.
3 Lower the platform onto the safety arm.
Crushing hazard. Keep hands Platform manual lowering cable specification
clear of the safety arm when Gap, lowering handle to mounting 0 to 0.125 inch
lowering the platform. nut 0 to 3 mm

4 Pull the handle of the manual platform


lowering cable out until considerable
resistance is felt. Release the handle.

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Service and Repair Manual January 2019

Ground Controls

Skip to step 8 if the measurement is


correct.
6 To adjust, loosen the upper lock nut on the
cable mounting bracket at the cylinder. Turn
the lower lock nut clockwise to decrease the
distance or counterclockwise to increase the
distance. Tighten the upper lock nut.

1 manual lowering cable sheath


2 upper lock nut
3 cable mounting bracket
4 lower lock nut
5 cable mounting nut
6 end of lowering cable
7 manual lowering valve (hydraulic
schematic item N)

7 Repeat this procedure beginning with step 4.


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

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Ground Controls

2-8 8 Use the Menu Up or Menu Down buttons to


scroll to Outriggers.
Outrigger Calibration
9 Press the Enter button to select Outriggers.
The Electronic Control Module (ECM) is
programmed to deactivate the drive and steer 10 Use the Menu Up or Menu Down buttons to
functions while the outriggers are deployed and scroll to Calibrate Outriggers.
activate an alarm when a signal is received from 11 Press the Enter button to select Calibrate
the outrigger level sensor, indicating the outriggers Outriggers.
are not deployed or the machine is out of level.
12 Press and hold the Enter button while the
The ECM is also used to calibrate the outrigger system gathers data to calibrate the outrigger
level sensor to achieve a levelness of 0° +/- 0.5° level sensor.
front to back and side to side, while the outriggers
are deployed. Crushing hazard. Keep body
parts away from outriggers
For further information or assistance, contact during outrigger movement.
Genie Product Support.
13 Continue holding the Enter button after the
outrigger level sensor is calibrated. The
How to Calibrate the Outrigger outriggers will retract while the outrigger
System system gathers and saves data.

(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.

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Service and Repair Manual January 2019

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

Perform this procedure with the platform in the


stowed position.

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.

2 Tag and disconnect the hydraulic lines from


the function manifold. Cap the fittings.
3 Tag and disconnect the electrical wires from
the function manifold.

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Hydraulic Tank

GS-1530 / 32, GS-1930 / 32, GS-2032,


GS-3232, GS-2046, GS-2626, GS-3246,
GS-4047
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.

2 Tag and disconnect the hydraulic tank return


hard line from the filter. Remove the hard line
from the machine. Cap the fitting on the filter
head.
3 Tag and disconnect the hydraulic tank hard
line from the pump. Remove the hard line from
the machine. Cap the fitting on the pump.
4 Remove the hydraulic tank retaining fasteners
and remove the hydraulic tank from the
machine.
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.

5 Remove the hydraulic tank cap and drain the


tank into a suitable container.
Torque specifications All models except GS-1330m
Hydraulic retaining fasteners, dry 35 in-lbs
4 Nm
Hydraulic tank retaining fasteners, 26 in-lbs
lubricated 2.9 Nm

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Service and Repair Manual January 2019

Hydraulic Pump

4-1 4 Activate the platform up function from the


ground controls.
Function Pump
Result: GS-1330m- If the pressure gauge
The hydraulic pump is attached to the motor which reads 2250 psi / 155 bar, immediately stop.
makes up the hydraulic power unit. The pump is good.
Result: All other models- If the pressure
How to Test the Hydraulic Pump gauge reads 3200 psi / 221 bar, immediately
stop. The pump is good
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose Result: GS-1330m- If the pressure gauge fails
end must be replaced. All connections must be to reach 2250 psi / 155 bar, the pump is bad
torqued to specification during installation. Refer to and will need to be serviced or replaced.
Specifications, Hydraulic Hose and Fitting Torque Result: All other models- If the pressure
Specifications. gauge fails to reach 3200 psi / 221 bar, the
pump is bad and will need to be serviced or
Component damage hazard. replaced.
The work area and surfaces
where this procedure will be Component damage hazard.
performed must be clean and There is no relief valve in the
free of debris that could get into hydraulic pump and the pump
the hydraulic system. can be damaged if the pressure
is allowed to exceed
1 Tag, disconnect and plug the high pressure 3200 psi / 221 bar. When testing
hydraulic hose from the hydraulic pump. the pump, activate the pump in
2 Connect a 0 to 5000 psi / 0 to 350 bar one second intervals until
pressure gauge to the high pressure port on 3200 psi / 221 bar is confirmed.
the pump. Do not over-pressurize the
pump.
3 Turn the key switch to ground control and pull
out the red Emergency Stop button to the on 5 Remove the pressure gauge and reconnect
position at both ground and platform controls. the hydraulic hose. Torque to specifications.

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January 2019 Service and Repair Manual

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.

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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.

7 Remove the hydraulic power unit from the


machine.
8 Remove the pump mounting bolts. Carefully
remove the pump.
Tip-over hazard. After replacing
the hydraulic pump, it is critical to
return the function speed
settings to original factory
specifications. Failure to restore
the machine to original factory
specifications could cause the
machine to tip over resulting in
death or serious injury.

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Manifolds

5-1
Function Manifold Components –
GS-1330m
The function manifold is mounted on the hydaulic pump.

Index No. Description Schematic Item Function Torque


1 Solenoid valve, 2 position 4 way EC Platform up 20 ft-lbs / 27 Nm
2 Diagnostic port EF Test port
3 Check valve EE Drive circuit 25 ft-lbs / 34 Nm
4 Relief valve, 2250 psi / 155 bar ED System relief 22 ft-lbs / 30 Nm
5 Solenoid valve, 3 position 4 way EA Steer left/right 20 ft-lbs / 27 Nm
6 Relief valve, 1600 psi / 110 bar EB Steer relief 22 ft-lbs / 30 Nm
Coil nut EA, EC 4-5 ft-lbs / 5-7 Nm

Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic.

How to Install a Valve Cartridge


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

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Service and Repair Manual January 2019

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.

Index No. Description Schematic Item Function Torque


— Coil nut (item F) — — 4-5 ft-lbs / 5-7 Nm
— Coil nut (items E and H) — — 5-7 ft-lbs / 7-9 Nm
1 Diagnostic port A Test port —
2 Check disc B Steer circuit 18 ft-lbs / 24 Nm
Relief valve, 1800 to 3700 psi / 124 to
3 C Lift relief 20 ft-lbs / 27 Nm
255 bar
4 Check valve, 10 psi / 0.7 bar D Drive circuit 20 ft-lbs / 27 Nm
Drive
5 Solenoid valve, 3 position 4 way E 25 ft-lbs / 34 Nm
forward/reverse
6 Solenoid valve, 3 position 4 way F Steer left/right 25 ft-lbs / 34 Nm
7 Flow regulator and relief valve, G Steer circuit 26 ft-lbs / 35 Nm
0.75 gpm / 2.8 L/min
1500 psi / 130 bar
8 Solenoid valve, 2 position 4 way H Platform up 25 ft-lbs / 34 Nm
9 Relief valve, 3700 psi / 255 bar maximum I System relief 20 ft-lbs / 27 Nm

How to Install a Valve Cartridge


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

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Manifolds

Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic.


Note: 'alpha-numeric' callouts refer to corresponding notes on the electrical schematic.

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Service and Repair Manual January 2019

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.

Index No. Description Schematic Item Function Torque


— Coil nut (item AC) — — 4-5 ft-lbs / 5-7 Nm
— Coil nut (items AE, AG and AI) — — 5-7 ft-lbs / 7-9 Nm
1 Diagnostic port AA Test port —
2 Relief valve, 3700 psi / 255 bar maximum AB System relief 20 ft-lbs / 27 Nm
3 Solenoid valve, 3 position 4 way AC Steer left/right 25 ft-lbs / 34 Nm
Check valve, (GS-3232 and GS-3246
4 AK Lift circuit 23 ft-lbs / 31 Nm
with load sense installed)
5 Check disc AD Steer circuit 18 ft-lbs / 24 Nm
6 Solenoid valve, 2 position 4 way AE Drive speed select 25 ft-lbs / 34 Nm
circuit
7 Relief valve, 50 psi / 3.4 bar AF Brake release 20 ft-lbs / 27 Nm
Drive
8 Solenoid valve, 3 position 5 way AG 25 ft-lbs / 34 Nm
forward/reverse
9 Flow regulator and relief valve, AH Steer circuit 26 ft-lbs / 35 Nm
0.75 gpm / 2.8 L/min,
1500 psi / 103 bar
10 Solenoid valve, 2 position 4 way AI Platform up 25 ft-lbs / 34 Nm
Relief valve, 1800 to 3700 psi / 124 to
11 AJ Lift relief 20 ft-lbs / 27 Nm
255 bar

How to Install a Valve Cartridge


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

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Manifolds

Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic.


Note: 'alpha-numeric' callouts refer to corresponding notes on the electrical schematic.

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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.

Index No. Description Schematic Item Function Torque


— Coil nut (item DC) — — 4-5 ft-lbs / 5-7 Nm
— Coil nut (items DE, DG and DI) — — 5-7 ft-lbs / 7-9 Nm
1 Diagnostic port DA Test port —
Relief valve, 3500 psi / 241 bar
2 DB System relief 20 ft-lbs / 27 Nm
maximum
3 Solenoid valve, 3 position 4 way DC Steer left/right 25 ft-lbs / 34 Nm
4 Check disc DD Steer circuit 18 ft-lbs / 24 Nm
5 Solenoid valve, 2 position 4 way DE Drive speed select 25 ft-lbs / 34 Nm
circuit
6 Relief valve, 50 psi / 3.4 bar DF Brake release 20 ft-lbs / 27 Nm
Drive
7 Solenoid valve, 3 position 5 way DG 25 ft-lbs / 34 Nm
forward/reverse
8 Flow regulator and relief valve, DH Steer circuit 26 ft-lbs / 35 Nm
0.75 gpm / 2.8 L/min,
1500 psi / 103 bar
9 Solenoid valve, 2 position 4 way DI Platform up 25 ft-lbs / 34 Nm
10 Relief valve, 3000 psi / 207 bar DJ Lift relief 20 ft-lbs / 27 Nm

How to Install a Valve Cartridge


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

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Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic.


Note: 'alpha-numeric' callouts refer to corresponding notes on the electrical schematic.

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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.

Index No. Description Schematic Item Function Torque


1 Check valve, 200 psi / 13.8 bar S Drive circuit 20 ft-lbs / 27 Nm

Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic.

How to Install a Valve Cartridge


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

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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.

Index No. Description Schematic Item Function Torque


— Coil nut (item DN) — — 4-5 ft-lbs / 5-7 Nm
— Plug — — 13 ft-lbs / 18 Nm
Lift pressure selector valve, 200 psi /
1 DM Lift relief 20 ft-lbs / 27 Nm
138 bar
2 Solenoid valve, 2 position 2 way DN Lift circuit 20 ft-lbs / 27 Nm

Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic.


Note: 'alpha-numeric' callouts refer to corresponding notes on the electrical schematic.

How to Install a Valve Cartridge


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

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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.

Index No. Description Schematic Item Function Torque


— Coil nut (item BA) — — 4-5 ft-lbs / 5-7 Nm
Outriggers extend /
1 Solenoid valve, 3 position 4 way BA 25 ft-lbs / 34 Nm
retract
Relief valve, 3500 psi / 241 bar
2 BB Outrigger circuit 20 ft-lbs / 27 Nm
maximum

Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic.


Note: 'alpha-numeric' callouts refer to corresponding notes on the electrical schematic.

How to Install a Valve Cartridge


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

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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.

Index No. Description Schematic Item Function Torque


— Coil nut (item CA, CB. CC, CD) — — 4-5 ft-lbs / 5-7 Nm
Outriggers extend /
1 Solenoid valve, 2 position 2 way CA, CB, CC, CD 25 ft-lbs / 34 Nm
retract
2 Orifice Plug, 0.037 inch / 0.94 mm CE Outrigger retract —
3 Check Valve, pilot operated CF Retract flow control 20 ft-lbs / 27.1 Nm
4 Pressure transducer CG Outrigger auto level 16 ft-lbs / 21.7 Nm

Front Outriggers Rear Outriggers


Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic.
Note: 'alpha-numeric' callouts refer to corresponding notes on the electrical schematic.

How to Install a Valve Cartridge


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

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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.

How to Adjust the System Relief


Valve
1 Locate the system relief valve on the function
manifold (item 2).
2 Connect a 0 to 5000 psi / 0 to 350 bar
GS-1530/32 and GS-1930/32
pressure gauge to the test port on the function
manifold (item 1). 1 test port
2 system relief valve
3 Chock both sides of the wheels at the steer
end of the machine. 1 Move and hold the joystick fully in either
4 Remove the platform controls from the direction while observing the pressure reading
platform. on the pressure gauge. Note the pressure.
Refer to Specifications, Hydraulic Component
5 Turn the key switch to platform controls and Specifications.
pull out the red Emergency Stop button to the
on position at both ground and platform 2 Turn the machine off. Hold the system relief
controls. valve with a wrench and remove the cap
(schematic item 2).

GS-1330m
1 test port
2 system relief valve
3 steer relief valve

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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.

GS-32, GS-46 and GS-47


1 test port
2 system relief valve
3 steer relief valve
4 lift relief valve

GS-1530/32 and GS-1930/32


1 test port
2 system relief valve
3 lift relief valve

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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.

GS-32, GS-46 and GS-47


1 test port
2 system relief valve
3 steer relief valve
4 lift relief valve

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How to Adjust the 3 Using a suitable lifting device, place and


secure the maximum rated load in the center
Lift Pressure Selector Valve of the platform deck.
(GS-4047 only)
Maximum load
Note: The System Relief Valve and Platform Lift
CE and AS models 770 lbs
Relief Valve must be adjusted before making an 350 kg
adjustment to the Lift Pressure Selector Valve.
Refer to Repair Procedures, How to Adjust the ANSI and CSA models 550 lbs
250 kg
System Relief Valve and How to Adjust the
Platform Lift Relief Valve. 4 Remove the platform controls from the
platform.
Note: Perform this test from the ground with the
platform controls. Do not stand in the platform. 5 Turn the key switch to platform controls and
pull out the red Emergency Stop button to the
Note: Verify the hydraulic oil level is at the FULL on position at both ground and platform
mark on the hydraulic tank. controls.
1 Locate the pressure selector relief valve on 6 Press and hold the lift function enable button
the pressure selector manifold (schematic and the press the platform up button to raise
item DM). the platform 4 ft / 1.2 m above the stowed
position.
2 Connect a 0 to 5000 psi / 0 to 350 bar
pressure gauge to the test port on the function Result: The platform does not rise. Perform
manifold (schematic item DA). steps 7 through 10 to increase the pressure in
small increments until the platform rises. Then
proceed to step 12.
Result: The platform rises. Perform steps
7 through 10 to decrease the pressure in small
increments until the platform does not rise.
Then follow steps 7 through 10 again to
increase the pressure in small increments until
the platform is able to rise.
7 Turn the machine off. Hold the lift pressure
selector valve with a wrench and remove the
cap (schematic item DM).

1 test port
2 system relief valve
3 steer relief valve
4 lift relief valve

1 lift pressure selector valve


2 solenoid valve

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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

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5 Activate the function enable switch and press


and hold the steer thumb rocker switch to the
right. Allow the wheels to completely turn to
the right. Continue holding the switch while
observing the pressure reading on the
pressure gauge. Note the pressure. Refer to
Specifications, Hydraulic Component
Specifications..
6 Press and hold the steer thumb rocker switch
to the left. Allow the wheels to completely turn
to the left. Continue holding the switch while
observing the pressure reading on the
pressure gauge.
7 Turn the machine off. Hold the steer relief
valve with a wrench and remove the cap
(schematic item 3).
GS-1530/32 and GS-1930/32
8 Adjust the internal hex socket. Turn it
4 test port clockwise to increase the pressure or
5 steer relief valve counterclockwise to decrease the pressure.
Component damage hazard. Do
not adjust the relief valve
pressures higher than
specifications.

9 Install the relief valve cap.

10 Repeat steps 5 and 6 to confirm the relief


valve pressure.

GS-32, GS-46 and GS-47


6 test port
7 system relief valve
8 steer relief valve
9 lift relief valve

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 73


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Manifolds

5-10 Valve Coil Resistance


Valve Coils Specifications
Note: The following coil resistance specifications
How to Test a Coil are at an ambient temperature of 68°F / 20°C. As
valve coil resistance is sensitive to changes in air
A properly functioning coil provides an temperature, the coil resistance will typically
electromagnetic force which operates the solenoid increase or decrease by 4% for each 18°F / -7.7°C
valve. Critical to normal operation is continuity that your air temperature increases or decreases
within the coil. Zero resistance or infinite resistance from 68°F / 20°C.
indicates the coil has failed.
Description Specification
Since coil resistance is sensitive to temperature,
resistance values outside specification can Solenoid valve, 3 position 4 way, 27.2Ω
produce erratic operation. When coil resistance 20V DC with diode (schematic item F,
decreases below specification, amperage AC or DC)
increases. As resistance rises above specification, Solenoid valve, 3 position 4 way, 19Ω
voltage increases. 20V DC with diode (schematic item E)
While valves may operate when coil resistance is Solenoid valve, 2 position 4 way, 19Ω
outside specification, maintaining coils within 20V DC with diode (schematic item H, AI
specification will help ensure proper valve function or DI)
over a wide range of operating temperatures. Solenoid valve, 2 position 2 way, 25Ω
N.C. 20V DC with diode (schematic item
Electrocution/burn hazard. N)
Contact with electrically charged Solenoid valve, 2 position 4 way, 19Ω
circuits could result in death or 20V DC with diode (schematic item AE or
serious injury. Remove all rings, DE)
watches and other jewelry. Solenoid valve, 3 position 5 way, 19Ω
20V DC with diode (schematic item AG or
Note: If the machine has been in operation, allow DG)
the coil to cool at least 3 hours before performing
Solenoid valve, 2 position 2 way, 27.2Ω
this test.
20V DC with diode (schematic item CA,
1 Tag and disconnect the wiring from the coil to CB, CC and CD
be tested. Solenoid valve, 3 position 4 way, 19Ω
20V DC with diode (schematic item BA)
2 Test the coil resistance using a multimeter set
Proportional solenoid valve, 2 position 23.9Ω
to resistance (W). Refer to the Valve Coil
2 way,
Resistance Specification table. 20V DC with diode (schematic item DN)
Result: If the resistance is not within the Solenoid valve, 3 position 4 way 33.75Ω
adjusted specification, plus or minus 10%, 24V DC with diode (schematic item EA)
replace the coil. Solenoid valve, 2 position 4 way 33.75Ω
24V DC with diode (schematic item EC

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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.

1 Test the coil resistance. Refer to Repair


Procedure, How to Test a Coil.
1 multimeter
2 Connect a 10Ω resistor to the negative 2 9V DC battery
terminal of a known good 9V DC battery. 3 10Ω resistor
Connect the other end of the resistor to a 4 coil
terminal on the coil.
Note: Dotted lines in illustration indicate a reversed
Note: The battery should read 9V DC or more when connection as specified in step 6.
measured across the terminals.
5 Momentarily connect the positive lead from
Resistor, 10Ω the multimeter to the positive terminal on the
Genie part number 27287 9V battery. Note and record the reading.
3 Set a multimeter to read DC amperage. 6 At the battery or coil terminals, reverse the
connections. Note and record the current
Note: The multimeter, when set to read DC
reading.
amperage, should be capable of reading up to
800 mA. Result: Both current readings are greater than
0 mA and are different by a minimum of 20%.
4 Connect the negative lead to the other The coil is good.
terminal on the coil.
Result: if one or both current readings are
greater than 0 mA, or if the two current
readings do not differ by a minimum of 20%,
the coil and/or its internal diode are faulty and
the coil should be replaced.

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Steer Axle Components

6-1 7 Tag, disconnect and plug the hydraulic hoses


on the drive motor. Cap the fittings on the
Yoke and Drive Motor drive motor.
Bodily injury hazard. Spraying
How to Remove the Yoke and hydraulic oil can penetrate and
Drive Motor burn skin. Loosen hydraulic
connections very slowly to allow
Note: When removing a hose assembly or fitting, the oil pressure to dissipate
the O-ring (if equipped) on the fitting and/or hose gradually. Do not allow oil to
end must be replaced. All connections must be squirt or spray.
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque 8 Support and secure the yoke assembly to an
Specifications. appropriate lifting device.

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.

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Steer Axle Components


8 GS-1330m: Tag and disconnect the wiring
6-2 from the drive motor.
Drive Motors
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
How to Remove a Drive Motor burn skin. Loosen hydraulic
Note: When removing a hose assembly or fitting, connections very slowly to allow
the O-ring (if equipped) on the fitting and/or hose the oil pressure to dissipate
end must be replaced. All connections must be gradually. Do not allow oil to
torqued to specification during installation. Refer to squirt or spray.
Specifications, Hydraulic Hose and Fitting Torque
Specifications. Component damage hazard.
Hoses can be damaged if they
1 All Models except GS-1330m: Block the are kinked or pinched.
non-steer tires.
2 GS-1330m: Block the steer wheels. 9 Remove the drive motor mounting fasteners.
Remove the motor.
3 Remove the cotter pin from the wheel castle
nut of the motor to be removed. Torque specifications All models except GS-1330m

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.

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Steer Axle Components

6-3 6-4
Steer Cylinder Steer Bellcrank

How to Remove the Steer How to Remove the Steer


Cylinder Bellcrank
Note: When removing a hose assembly or fitting, 1 Remove the steer cylinder. Refer to Repair
the O-ring (if equipped) on the fitting and/or hose Procedure, How to Remove the Steer
end must be replaced. All connections must be Cylinder.
torqued to specification during installation. Refer to
2 Remove the retaining fasteners from the steer
Specifications, Hydraulic Hose and Fitting Torque
links at each end of the bellcrank.
Specifications.
Note: While removing the retaining fasteners, take
1 Block the non-steer tires. note of the quantity and location of the spacers
2 Remove the pin retaining fasteners from the between the bellcrank and the steer links.
rod-end pivot pin. Remove the pivot pin.
3 Center a lifting jack under the drive chassis at
Note: While removing the pin retaining fasteners, the steer end of the machine.
take note of the quantity and location of the
4 Raise the machine approximately 14 inches /
spacers when removing the pivot pin.
36 cm. Place blocks under the chassis for
3 Remove the pin retaining fasteners from the support.
barrel-end pivot pin. Remove the pin.
Crushing hazard. The chassis
Note: While removing the pin retaining fasteners, will fall if not properly supported.
take note of the quantity and location of the
spacers when removing the pivot pin. 5 Turn the yokes to the side so the bellcrank can
be removed.
4 Remove the steer cylinder from the machine.
5 Tag, disconnect and plug the hydraulic hoses
from the steer cylinder. Cap the fittings on the
cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.

Component damage hazard.


Hoses can be damaged if they
are kinked or pinched.

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Steer Axle Components

6 Remove the bellcrank from the machine.

1 apply removable thread lock to fastener


threads

Note: While removing the bellcrank from the


machine, take note of the quantity and location of
the spacers between the bellcrank and the steer
links.
Note: Before re-installing the steer bellcrank onto
the machine, apply a small amount of removable
thread lock onto the threads of the fasteners.
Torque the fasteners to 31 ft-lbs / 42 Nm.

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Non-Steer Axle Components

7-1 7 Raise the machine approximately 2 inches /


5 cm. Place blocks under the chassis for
Drive Brake - All models except support.
GS-1330m
Crushing hazard. The chassis
will fall if not properly supported.
How to Remove the Drive Brake
8 Remove the wheel castle nut. Remove the
Note: When removing a hose assembly or fitting, wheel.
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be 9 Tag, disconnect and plug the hydraulic hose
torqued to specification during installation. Refer to from the brake. Cap the fitting on the brake.
Specifications, Hydraulic Hose and Fitting Torque Bodily injury hazard. Spraying
Specifications. hydraulic oil can penetrate and
1 Support and secure the entry ladder to an burn skin. Loosen hydraulic
appropriate lifting device. connections very slowly to allow
the oil pressure to dissipate
2 Remove the entry ladder mounting fasteners. gradually. Do not allow oil to
Remove the entry ladder from the machine. squirt or spray.
Crushing hazard. The entry 10 Place a lifting jack under the brake for support.
ladder will fall if not properly
supported and secured to the 11 Remove the fasteners that attach the brake to
lifting device. the drive chassis. Remove the brake.

3 Block the steer wheels. Crushing hazard. The brake will


fall if not properly supported
4 Remove the cotter pin from the wheel castle when the mounting fasteners are
nut. removed.
Note: Always replace the cotter pin with a new one
Torque specifications
when removing the castle nut.
Brake mounting fasteners, dry 75 ft-lbs
5 Loosen the wheel castle nut. Do not remove it. 102 Nm

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.

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Brake Release Hand Pump Components

8-1
Brake Release Hand Pump Components- All models except GS-1330m
The brake release hand pump manifold is mounted behind the entry ladder.

Index No. Description Schematic Item Function Torque


1 Hand pump L Manual brake release 30 ft-lbs / 41 Nm
2 Needle valve M Manual brake release enable 45-50 in-lbs / 5 Nm

Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic.

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 81


Service and Repair Manual January 2019

Scissor Components

Steer End Non-steer End


1 - Number 5 pivot pin 12 - Number 4 inner arm
2 - Number 4 center pivot pin (Qty. 2) 13 - Number 4 outer arm
3 - Number 4 pivot pin (steer end) 14 - Number 4 pivot pin (non-steer end)
4 - Number 3 center pivot pin (Qty. 2) 15 - Number 3 inner arm
5 - Lower lift cylinder rod-end pivot pin 16 - Number 3 outer arm
6 - Number 3 pivot pin (steer end) 17 - Number 3 pivot pin (non-steer end)
7 - Number 2 center pivot pin (Qty. 2) 18 - Number 2 inner arm
8 - Number 2 pivot pin (steer end) 19 - Number 2 outer arm
9 - Number 1 center pivot pin (Qty. 2) 20 - Number 2 pivot pin (non-steer end)
10 - Number 1 inner arm 21 - Lower lift cylinder barrel-end pivot pin
11 - Number 1 pivot pin 22 - Number 1 outer arm
11 - platform height sensor

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Scissor Components

9-1 4 Lower the platform onto the safety arm.


Scissor Assembly, Crushing hazard. Keep hands
GS-1330m clear of the safety arm when
lowering the platform.

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.

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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.

17 Connect the battery pack to the machine.


18 Turn the key switch to ground controls.
19 Press and hold the ground control scroll up
and scroll down buttons.
20 Pull out the red Emergency Stop button to the
on position at the ground controls.
21 Using the ground control menu buttons,
navigate to Service Override Mode. Select Cable bridge and platform height sensor
Service Override Mode.
1 cable bridge 4
Note: The machine must be in Service Override 2 cable bridge 3
Mode to raise the platform. While in Service
3 cable bridge 2
Override Mode, only the GCON will operate with
4 platform height sensor
limited functionality. The platform will raise a
predetermined amount of time and stop. 24 Remove the platform. Refer to Repair
22 Raise the platform and rotate the safety arm to Procedure, How to Remove the Platform.
the stowed position. 25 Remove the cables from the number 4 outer
arm (index #13) at the ground controls side.
Component damage hazard.
Cables can be damaged if they
are kinked or pinched.

26 Remove the cables from the number 4 cable


bridge and lay them off to the side.
Component damage hazard.
Cables can be damaged if they
are kinked or pinched.

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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.

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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.

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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.

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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.

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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.

84 Slide the number 1 outer arm (index #22) to


the non-steer end and remove it from the
machine.
Bodily injury hazard. The number
1 outer arm may become
unbalanced and fall if not
properly supported when
removed from the machine.

85 Attach the strap from an overhead crane to the


number 1 inner arm (index #10). Do not lift it.

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Steer End Non-steer End


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

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9-2 4 Lower the platform onto the safety arm.


Scissor Assembly, Crushing hazard. Keep hands
GS-1530 and GS-1532 clear of the safety arm when
lowering the platform.

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.

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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.

32 Remove the number 3 cable bridge mounting


fasteners and remove the cable bridge from
the machine.
Cable bridge and platform height sensor 33 Attach a lifting strap from an overhead crane
to the lug on the rod end of the lift cylinder for
1 cable bridge 3
support. Do not apply any lifting pressure.
2 cable bridge 2
3 cable bridge 1
4 platform height sensor

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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.

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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.

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62 Place a 4 x 4 x 48 inch / 10 cm x 10 cm x 70 Use a soft metal drift to remove the number


1.2 m long block across both sides of the 1 center pivot pins (index #7).
chassis under the number 1 center pivot pin
(index #7). Bodily injury hazard. The number
1 outer arm may become
63 Attach a lifting strap from an overhead crane unbalanced and fall if not
to the number 1 inner arm (index #8) at the properly supported when the pin
non-steer end. Raise the number 1 inner arm is removed.
and remove the safety arm. Lower the number
1 inner arm (index #8) onto the block that was 71 Slide the number 1 outer arm (index #17) to
placed across the chassis. the non-steer end and remove it from the
machine.
Bodily injury hazard. Keep hands
clear of moving parts when Bodily injury hazard. The number
lowering the scissor arms. 1 outer arm may become
unbalanced and fall if not
64 Remove the cables from the number 1 cable properly supported when
bridge and lay them off to the side. removed from the machine.
Component damage hazard. 72 Attach the strap from an overhead crane to the
Cables can be damaged if they
number 1 inner arm (index #8). Do not lift it.
are kinked or pinched.
73 Remove the upper fasteners securing the
65 Support and secure the entry ladder to an number 1 inner arm pivot bracket to the end of
appropriate lifting device. the chassis. Loosen the lower fasteners.
66 Remove the fasteners from the entry ladder 74 Remove the number 1 inner arm (index #8)
and remove the entry ladder from the from the machine.
machine.
Bodily injury hazard. The number
Crushing hazard. The entry 1 inner arm may become
ladder will fall if not properly unbalanced and fall if not
supported and secured to the properly supported when
lifting device. removed from the machine.

67 Attach a lifting strap from an overhead crane Component damage hazard. Be


to the number 1 outer arm (index #17). Do not sure not to damage the limit
apply any lifting pressure. switch or level sensor
components when the number
68 Remove the external snap rings and retaining 1 inner arm is removed from the
fasteners from the number 1 center pivot pins machine.
(index #7).
69 Remove the number 1 cable bridge from the
machine.

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Steer End Non-steer End


1 - Number 5 pivot pin 12 - Number 4 inner arm
2 - Number 4 center pivot pin (Qty. 2) 13 - Number 4 outer arm
3 - Number 4 pivot pin (steer end) 14 - Number 4 pivot pin (non-steer end)
4 - Number 3 center pivot pin (Qty. 2) 15 - Number 3 inner arm
5 - Lower lift cylinder rod-end pivot pin 16 - Number 3 outer arm
6 - Number 3 pivot pin (steer end) 17 - Number 3 pivot pin (non-steer end)
7 - Number 2 center pivot pin (Qty. 2) 18 - Number 2 inner arm
8 - Number 2 pivot pin (steer end) 19 - Number 2 outer arm
9 - Number 1 center pivot pin (Qty. 2) 20 - Number 2 pivot pin (non-steer end)
10 - Number 1 inner arm 21 - Lower lift cylinder barrel-end pivot pin
11 - Number 1 pivot pin 22 - Number 1 outer arm

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9-3 4 Lower the platform onto the safety arm.


Scissor Assembly, Crushing hazard. Keep hands
GS-1930 and GS-1932 clear of the safety arm when
lowering the platform.

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.

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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.

17 Connect the battery pack to the machine.


18 Turn the key switch to ground controls.
19 Press and hold the ground control scroll up
and scroll down buttons.
20 Pull out the red Emergency Stop button to the
on position at the ground controls.
21 Using the ground control menu buttons,
Cable bridge and platform height sensor
navigate to Service Override Mode. Select
Service Override Mode. 1 cable bridge 4
2 cable bridge 3
Note: The machine must be in Service Override
3 cable bridge 2
Mode to raise the platform. While in Service
Override Mode, only the GCON will operate with 4 cable bridge 1
limited functionality. The platform will raise a 5 platform height sensor
predetermined amount of time and stop.
24 Remove the platform. Refer to Repair
22 Raise the platform and rotate the safety arm to Procedure, How to Remove the Platform.
the stowed position. 25 Remove the cables from the number 4 outer
arm (index #13) at the ground controls side.
Component damage hazard.
Cables can be damaged if they
are kinked or pinched.

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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).

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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.

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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.

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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.

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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.

86 Slide the number 1 outer arm (index #22) to


the non-steer end and remove it from the
machine.
Bodily injury hazard. The number
1 outer arm may become
unbalanced and fall if not
properly supported when
removed from the machine.

87 Attach the strap from an overhead crane to the


number 1 inner arm (index #10). Do not lift it.

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Steer End Non-steer End


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

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9-4 4 Lower the platform onto the safety arm.


Scissor Assembly, Crushing hazard. Keep hands
GS-2032 and GS-2046 clear of the safety arm when
lowering the platform.

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.

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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.

17 Connect the battery pack to the machine.


18 Turn the key switch to ground controls.
19 Press and hold the ground control scroll up
and scroll down buttons.
20 Pull out the red Emergency Stop button to the
on position at the ground controls.
21 Using the ground control menu buttons, Cable bridge and platform height sensor
navigate to Service Override Mode. Select
1 cable bridge 3
Service Override Mode.
2 cable bridge 2A
Note: The machine must be in Service Override 3 cable bridge 2B
Mode to raise the platform. While in Service 4 cable bridge 1
Override Mode, only the GCON will operate with 5 platform height sensor
limited functionality. The platform will raise a
predetermined amount of time and stop. 24 Remove the platform. Refer to Repair
Procedure, How to Remove the Platform.
22 Raise the platform and rotate the safety arm to
the stowed position. 25 Support and secure the entry ladder to an
appropriate lifting device.
26 Remove the fasteners from the entry ladder
and remove the entry ladder from the
machine.
Crushing hazard. The entry
ladder will fall if not properly
supported and secured to the
lifting device.

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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.

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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.

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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.

Component damage hazard. Be


careful not to damage the valve
or fittings on the cylinder while
removing it from the machine.

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73 Remove the cables from the number 1 cable


bridge and lay them off to the side.
Component damage hazard.
Cables can be damaged if they
are kinked or pinched.

74 Disconnect the number 1 cable bridge from


the number 1 outer arm (index #17) and
remove the cable bridge from the machine.
75 Attach a lifting strap from an overhead crane
to the number 1 inner arm (index #8).
76 Raise the arm slightly and remove the block.
77 Lower the arm to the stowed position.
Bodily injury hazard. Keep hands
clear of moving parts when
lowering the scissor arms.

78 Secure the ends of the scissor arms together


at the steer end of the machine with a strap or
other suitable device.
79 Secure the ends of the scissor arms together
at the non-steer end of the machine with a
strap or other suitable device.
80 Remove the retaining fasteners securing the
chassis mount bracket to the chassis.
81 Remove the linkset from the machine
Bodily injury hazard. The number
1 inner and outer arms (index
#8 and #17) may become
unbalanced and fall if not
properly supported when
removed from the machine.

Component damage hazard. Be


sure not to damage the limit
switch or level sensor
components when the number
1 inner and outer arms (index
#8 and #17) are removed from
the machine.

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Steer End Non-steer End


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

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9-5 4 Lower the platform onto the safety arm.


Scissor Assembly, Crushing hazard. Keep hands
GS-2632 and GS-2646 clear of the safety arm when
lowering the platform.

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.

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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.

17 Connect the battery pack to the machine.


18 Turn the key switch to ground controls.
19 Press and hold the ground control scroll up
and scroll down buttons.
20 Pull out the red Emergency Stop button to the
on position at the ground controls.
21 Using the ground control menu buttons,
navigate to Service Override Mode. Select
Service Override Mode.
Note: The machine must be in Service Override
Cable bridge and platform height sensor
Mode to raise the platform. While in Service
Override Mode, only the GCON will operate with 1 cable bridge 4
limited functionality. The platform will raise a 2 cable bridge 3A
predetermined amount of time and stop. 3 cable bridge 3B
4 cable bridge 2A
22 Raise the platform and rotate the safety arm to
5 cable bridge 2B
the stowed position.
6 cable bridge 1
7 platform height sensor

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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.

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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.

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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.

Component damage hazard.


Cables can be damaged if they
are kinked or pinched.

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71 Place a rod through the number 2 center pivot 78 Place a 4 x 4 x 48 inch / 10 cm x 10 cm x


pin at the battery side (index #7) and twist to 1.2 m long block across both sides of the
remove the pin. chassis under the number 1 center pivot pin
(index #9).
Crushing hazard. The number
2 outer arm (index #19) may 79 Lower the scissor arms onto the block that
become unbalanced and fall if was placed across the chassis.
not properly supported when the
Bodily injury hazard. Keep hands
pivot pin is removed.
clear of moving parts when
lowering the scissor arms.
72 Remove the number 2 outer arm (index #19)
from the machine.
80 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 #19) may cylinder.
become unbalanced and fall if 81 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.
73 Attach a lifting strap from an overhead crane Bodily injury hazard. Spraying
to the number 2 inner arm (index #18). Raise hydraulic oil can penetrate and
the arm to a vertical position. burn skin. Loosen hydraulic
connections very slowly to allow
74 Remove the retaining fasteners from the
number 2 pivot pin at the steer end of the the oil pressure to dissipate
gradually. Do not allow oil to
machine (index #8).
squirt or spray.
75 Use a soft metal drift to remove the number
2 pivot pin (index #8) from the steer end of the 82 Tag and disconnect the wire harness from the
machine. Remove the number 2 inner arm solenoid valve on the cylinder.
(index #18) from the machine.
83 Tag and disconnect the wires and manual
Crushing hazard. The number lowering cable from the solenoid valve on the
2 inner arm (index #18) may cylinder.
become unbalanced and fall if 84 Models with platform overload option: Tag
not properly supported when the and disconnect the wire harness from the
pivot pin is removed. platform overload pressure transducer.
76 Attach a lifting strap from an overhead crane Note: After replacing the scissor assembly, the
to the number 1 inner arm (index #10). platform overload system must be calibrated.
Refer to Repair Procedure, How to Calibrate the
77 Raise the number 1 inner arm (index #10) Platform Overload System (if equipped).
approximately 2 feet / 60 cm.

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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.

92 Secure the ends of the scissor arms together


at the steer end of the machine with a strap or
other suitable device.

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Steer End Non-steer End


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

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9-6 3 Lift the safety arm, move it to the center of the


scissor arm and rotate down to a vertical
Scissor Assembly, position.
GS-3232 and GS-3246 4 Lower the platform onto the safety arm.
Crushing hazard. Keep hands
How to Disassemble the Scissor clear of the safety arm when
Assembly lowering the platform.

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.

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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.

17 Connect the battery pack to the machine.


18 Turn the key switch to ground controls.
19 Press and hold the ground control scroll up
and scroll down buttons.
20 Pull out the red Emergency Stop button to the
on position at the ground controls.
21 Using the ground control menu buttons,
navigate to Service Override Mode. Select Cable bridge and platform height sensor
Service Override Mode.
1 cable bridge 5
Note: The machine must be in Service Override 2 cable bridge 4A
Mode to raise the platform. While in Service 3 cable bridge 4B
Override Mode, only the GCON will operate with 4 cable bridge 3A
limited functionality. The platform will raise a 5 cable bridge 3B
predetermined amount of time and stop.
6 cable bridge 2A
7 cable bridge 2B
8 cable bridge 1
9 platform height sensor

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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.

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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.

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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).

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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.

Crushing hazard. The lift cylinder Crushing hazard. The number


will fall if not properly supported 3 inner arm (index #23) may
when the pivot pin is removed. become unbalanced and fall if
not properly supported when the
Component damage hazard. Be pivot pin is removed.
careful not to damage the valve
or fittings on the cylinder while 85 Remove the cables from the number 2A and
removing it from the machine. 2B cable bridges and lay them off to the side.

77 Attach a lifting strap from an overhead crane Component damage hazard.


to the lug of the rod end of the lower lift Cables can be damaged if they
cylinder. are kinked or pinched.

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.

82 Attach a lifting strap from an overhead crane


to the number 3 inner arm (index #23). Raise
the arm to a vertical position.

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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.

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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.

110 Disconnect the number 1 cable bridge from


the number 1 outer arm (index #29) and
remove the cable bridge from the machine.
111 Attach a lifting strap from an overhead crane
to the number 1 inner arm (index #14).
112 Raise the arm slightly and remove the block.

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Steer End Non-steer End


1 - Number 7 pivot pin 13 - Number 2 center pivot pin (Qty. 2) 25 - Number 4 outer arm
2 - Number 6 center pivot pin (Qty. 2) 14 - Number 2 pivot pin (steer end) 26 - Number 4 pivot pin (non-steer end)
3 - Number 6 pivot pin (steer end) 15 - Number 1 center pivot pin (Qty. 2) 27 - Upper lift cylinder barrel-end pivot pin
4 - Number 5 center pivot pin 16 - Number 1 inner arm 28 - Number 3 inner arm
17 - Number 1 pivot pin (steer end) (Qty.
5 - Upper lift cylinder rod-end pivot pin 29 - Number 3 pivot pin (non-steer end)
2)
6 - Number 5 pivot pin (steer end) 18 - Number 6 inner arm 30 - Number 2 inner arm
7 - Number 4 center pivot pin (Qty. 2) 19 - Number 6 outer arm 31 - Number 2 inner arm
8 - Number 4 pivot pin (steer end) 20 - Number 6 pivot pin (non-steer end) 32 - Number 2 pivot pin (non-steer end)
9 - Number 3 outer arm 21 - Number 5 inner arm 33 - Lower lift cylinder barrel-end pivot pin
10 - Number 3 center pivot pin (Qty. 2) 22 - Number 5 outer arm 34 - Number 1 outer arm
11 - Lower lift cylinder rod-end pivot pin 23 - Number 5 pivot pin (non-steer end)
12 - Number 3 pivot pin (steer end) 24 - Number 4 inner arm

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9-7 3 Lift the safety arm, move it to the center of the


scissor arm and rotate down to a vertical
Scissor Assembly, position.
GS-4047 4 Lower the platform onto the safety arm.
Crushing hazard. Keep hands
How to Disassemble the Scissor clear of the safety arm when
Assembly lowering the platform.

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.

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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.

17 Connect the battery pack to the machine.


18 Turn the key switch to ground controls.
19 Press and hold the ground control scroll up
and scroll down buttons.
20 Pull out the red Emergency Stop button to the
on position at the ground controls.
21 Using the ground control menu buttons,
navigate to Service Override Mode. Select
Service Override Mode.
Cable bridge and platform height sensor
Note: The machine must be in Service Override
Mode to raise the platform. While in Service 1 cable bridge 6
Override Mode, only the GCON will operate with 2 cable bridge 5B
limited functionality. The platform will raise a 3 cable bridge 5A
predetermined amount of time and stop. 4 cable bridge 4B
5 cable bridge 4A
22 Raise the platform and rotate the safety arm to
6 cable bridge 1A
the stowed position.
7 platform height sensor
8 cable bridge 1B
9 cable bridge 2A
10 cable bridge 2B
11 cable bridge 2C
12 cable bridge 2D

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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).

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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).

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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).

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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.

82 Place a 4 x 4 x 10 inch / 10 x 10 x 25 cm block


onto the number 1 inner arm cylinder plate
(index #16).

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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.

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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.

111 Remove the cables from the number 1 cable


bridge and lay them off to the side.
112 Disconnect the number 1 cable bridge from
the number 1 outer arm (index #34) and
remove the cable bridge from the machine.

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9-8 10 Remove the fastener securing the platform


height sensor assembly to the number 1 inner
Scissor Arm Wear Pads arm.
11 Remove the platform height sensor assembly
How to Replace the Scissor Arm from the number 1 pivot pin.
Wear Pads 12 Remove the plastic nut securing the squeeze
Note: Machines equipped with a Platform Height connector to the large platform height sensor
Sensor, begin at step 1. Machines without a bracket.
Platform Height Sensor, begin at step 24. 13 Remove the squeeze connector from the large
platform height sensor bracket.
1 Turn the key switch to ground control and pull
out the red Emergency Stop button to the on 14 Remove the fasteners securing the large
position at both the ground and platform platform height sensor bracket to the number
controls. 1 inner arm pivot bracket.
2 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. 15 Remove the large platform height sensor
bracket from the number 1 inner arm pivot
3 Lift the safety arm, move it to the center of the bracket.
scissor arm and rotate down to a vertical
position. 16 Install the fasteners removed in 14 to the
number 1 inner arm pivot bracket and chassis.
4 Lower the platform onto the safety arm.
Tip-over hazard. Failure
Crushing hazard. Keep hands to install the fasteners securing
clear of the safety arm when the number 1 inner arm pivot
lowering the platform. bracket to the chassis, could
result in the machine tipping
5 At the ground control, turn the key switch to
over, causing death or serious
the off position and push in the red Emergency
injury.
Stop button to the off position.
6 Disconnect the battery pack from the machine. 17 Connect the battery pack to the machine.

Electrocution/burn hazard. 18 Turn the key switch to the ground control


Contact with electrically charged position.
circuits could result in death or 19 Press and hold the ground control scroll up
serious injury. Remove all rings, and scroll down buttons.
watches and other jewelry.
20 Pull out the red Emergency Stop button to the
7 Remove the fasteners securing the platform on position at the ground controls.
height sensor cover to the large platform
height sensor bracket.
8 Remove the platform height sensor cover.
9 Tag and disconnect the platform height sensor
from the platform height sensor harness.

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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.

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9-9 7 Remove the platform height sensor cover.


Platform Height Sensor

How to Disassemble the Platform


Height Sensor Assembly
(if equipped)
Note: When a Platform Height Sensor Assembly is
removed or replaced, the platform overload system
must be calibrated. Refer to Repair Procedure,
How to Calibrate the Platform Overload System (if
equipped) and follow the no load calibration
procedure.
1 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. Steer End
2 Lift the safety arm, move it to the center of the 1 fasteners (platform height sensor cover)
scissor arm and rotate down to a vertical 2 platform height sensor cover
position.
3 Lower the platform onto the safety arm. 8 Tag and disconnect the platform height sensor
from the platform height sensor harness.
Crushing hazard. Keep hands
9 Remove the fastener securing the platform
clear of the safety arm when
height sensor assembly to the number 1 inner
lowering the platform.
arm.
4 Turn the key switch to the off position. 10 Remove the platform height sensor assembly
from the number 1 pivot pin.
5 Disconnect the battery pack from the machine.
11 Remove the set screw securing the lever arm
Electrocution/burn hazard. to the platform height sensor.
Contact with electrically charged
circuits could result in death or 12 Remove the lever arm from the platform height
serious injury. Remove all rings, sensor assembly.
watches and other jewelry. 13 Working with the platform height sensor
assembly, remove the Deustch connector
6 Remove the fasteners securing the large
from the plastic clip.
platform height sensor cover to the large
platform height sensor bracket. 14 Remove the fasteners securing the platform
height sensor to the small platform height
sensor bracket.

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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

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9-10 3 Lift the safety arm, move it to the center of the


scissor arm and rotate down to a vertical
Lift Cylinders position.

How to Remove the Lift Cylinder


Bodily injury hazard. The
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.

Note: When removing a hose assembly or fitting,


the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Specifications.

GS-1330m, GS-1530, GS-1532,


GS-1930 and GS-1932: 1 lift cylinder
2 orifice(schematic item O) GS-1530,
Note: Models without a pressure transducer follow GS-1532, GS-1930, GS-1932
steps 1 through 23, 27 and 28. 3 connector fitting
Models equipped with a pressure transducer follow 4 hydraulic hose
steps 1 through 28.
5 pressure transducer(schematic item R)(if
1 Turn the key switch to ground controls and pull equipped)
out the red Emergency Stop button to the on 6 manual lowering cable
position at both ground and platform controls. 7 solenoid valve(schematic item N)
8 cable mount bracket
2 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
9 orifice(schematic item O) GS-1330m

4 Lower the platform onto the safety arm.


Crushing hazard. Keep hands
clear of the safety arm when
lowering the platform.

5 Using a suitable lifting device, support the link


stack at the steer end of the machine.

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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.

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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).

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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.

8 Tag and disconnect the wiring from the


solenoid valve coil at the barrel end of the lift
cylinder.
9 If equipped, tag and disconnect the three-pin
connector from the pressure transducer
harness. To remove the pressure transducer
refer to Repair Procedure, How to Remove the
Pressure Transducer (if equipped).
10 Loosen the adjustment nuts on the solenoid
valve and disconnect the manual lowering
cable from the valve.
Note: During assembly, the manual platform
1 lift cylinder
lowering cable needs to be properly adjusted.
Refer to Repair Procedure, How to Adjust the
2 orifice(schematic item O)
Manual Platform Lowering Cable.
3 connector fitting
4 hydraulic hose 11 Remove the fasteners securing the manual
5 pressure transducer(schematic item R)(if lowering cable mount bracket to the cylinder.
equipped) Remove the bracket from the cylinder.
6 manual lowering cable
12 Tag, disconnect and plug the hydraulic hoses
7 solenoid valve(schematic item N)
on the lift cylinder. Cap the fittings on the
8 cable mount bracket cylinder.
4 Lower the platform onto the safety arm. Bodily injury hazard. Spraying
hydraulic oil can penetrate and
Crushing hazard. Keep hands
burn skin. Loosen hydraulic
clear of the safety arm when
connections very slowly to allow
lowering the platform.
the oil pressure to dissipate
5 Using a suitable lifting device, support the link gradually. Do not allow oil to
squirt or spray.
stack at the steer end of the machine.

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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).

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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.

Note: When removing a hose assembly or fitting,


the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Specifications.
Note: Models without a pressure transducer follow
steps 1 through 21, 25 and 26.
Models equipped with a pressure transducer follow
steps 1 through 26.
1 Turn the key switch to ground controls and pull
out the red Emergency Stop button to the on Lower Lift Cylinder
position at both ground and platform controls.
1 lift cylinder
2 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. 2 orifice(schematic item O)
3 connector fitting
4 hydraulic hose
5 pressure transducer(schematic item R)(if
equipped)
6 manual lowering cable
7 solenoid valve(schematic item N)
8 cable mount bracket

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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.

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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.

18 Support and secure the lift cylinder to an


appropriate lifting device.
19 Remove the lift cylinder through the scissor
arms at the steer end of the machine.
Crushing hazard. The lift cylinder
will become unbalanced and fall
if not properly supported and
secured to the lifting device. Upper Lift Cylinder
1 lift cylinder
Component damage hazard. Be
2 connector fitting
careful not to damage the valve
or fittings on the cylinder while 3 hydraulic hose
removing it from the machine. 4 solenoid valve (schematic item N)
5 orifice (schematic item O)
6 relief valve (schematic item Q)

Note: At the upper lift cylinder, install the orifice


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

Torque specifications
Solenoid valve, 2 position 2 way, 20 ft-lbs
N.C. 27 Nm
(schematic item N)

Relief valve 20 ft-lbs


(schematic item Q) 27 Nm

Coil nut 5 ft-lbs


7 Nm

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21 Remove the lifting device supporting the link GS-4047


stack at the steer end of the machine.
Bodily injury hazard. The
22 Connect the battery pack to the machine. procedures in this section
require specific repair skills,
23 Turn the key switch to ground control.
lifting equipment and a suitable
Models without a pressure transducer workshop. Attempting this
continue at step 27. procedure without these skills
and tools could result in death or
Models with a pressure transducer serious injury and significant
continue at step 24. component damage. Dealer
24 Press and hold the ground control scroll up service is required.
and scroll down buttons.
Note: When removing a hose assembly or fitting,
25 Pull out the red Emergency Stop button to the the O-ring (if equipped) on the fitting and/or hose
on position at the ground controls. end must be replaced. All connections must be
26 Using the ground control menu buttons, torqued to specification during installation. Refer to
navigate to Service Override Mode. Select Specifications, Hydraulic Hose and Fitting Torque
Service Override Mode. Specifications.

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).

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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.

5 Using a suitable lifting device, support the link


stack at the steer end of the machine.
6 At the ground controls, turn the key switch to
the off position and push in the red Emergency
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.

8 Tag and disconnect the wiring from the


solenoid valve coil at the barrel end of the lift
cylinder.

Skip to step 13 if removing the upper


cylinder.
9 If equipped, tag and disconnect the three-pin
1 relief valve(schematic item Q) connector from the pressure transducer
2 lift cylinder
harness. To remove the pressure transducer
refer to Repair Procedure, How to Remove the
3 connector fitting
Pressure Transducer (if equipped).
4 hydraulic hose
5 pressure transducer(schematic item R)(if 10 Loosen the adjustment nuts on the solenoid
equipped) valve and disconnect the manual lowering
6 manual lowering cable cable from the valve.
7 solenoid valve(schematic item DO) Note: During assembly, the manual platform
8 cable mount bracket lowering cable needs to be properly adjusted.
Refer to Repair Procedure, How to Adjust the
Manual Platform Lowering Cable.
11 Remove the fasteners securing the manual
lowering cable mount bracket to the cylinder.
Remove the bracket from the cylinder.

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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.

15 Lower the cylinder onto the number 1 inner


arm cylinder plate.
16 Attach a lifting strap from an overhead crane
or similar lifting device to the barrel end of the
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.

18 Support and secure the lift cylinder to an Upper Lift Cylinder


appropriate lifting device. 1 relief valve(schematic item Q)
2 lift cylinder
3 connector fitting
4 hydraulic hose
5 check valve(schematic item DK)

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Torque specifications 9-11


Solenoid valve, 2 position 2 way, 20 ft-lbs
27 Nm
Pressure Transducer
N.C.
(schematic item N)
How to Remove the Pressure
Relief valve 20 ft-lbs
(schematic item Q) 27 Nm Transducer
(if equipped)
Coil nut 5 ft-lbs
7 Nm Note: Calibrating the platform overload system is
Pressure transducer(if equipped) 27 ft-lbs not required if the pressure transducer is the only
(schematic item R) 37 Nm component replaced on the machine lift structure.
In the event of frequent nuisance trips occurring
Check valve 20 ft-lbs after a pressure transducer is replaced, a no load
(schematic item DK) 27 Nm calibration is recommended. Refer to Repair
Procedure, How to Calibrate the Platform Overload
21 Remove the lifting device supporting the link System (if equipped)
stack at the steer end of the machine. 1 Turn the key switch to ground controls and pull
22 Connect the battery pack to the machine. out the red Emergency Stop button to the on
position at both ground and platform controls.
23 Turn the key switch to ground controls.
2 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
24 Press and hold the ground control scroll up
and scroll down buttons. 3 Lift the safety arm, move it to the center of the
scissor arm and rotate down to a vertical
25 Pull out the red Emergency Stop button to the position.
on position at the ground controls.
4 Lower the platform onto the safety arm.
26 Using the ground control menu buttons,
navigate to Service Override Mode. Select 5 At the ground controls, turn the key switch to
Service Override Mode. the off position and push in the red Emergency
Stop button to the off position.
Note: The machine must be in Service Override
Mode to raise the platform. While in Service 6 Disconnect the battery pack from the machine.
Override Mode, only the GCON will operate with
Electrocution/burn hazard.
limited functionality. The platform will raise a
Contact with electrically charged
predetermined amount of time and stop.
circuits could result in death or
27 Raise the platform and rotate the safety arm to serious injury. Remove all rings,
the stowed position. watches and other jewelry.
28 Fully lower the platform to the stowed position. 7 Pull the manual lowering cable and hold for
Note: Models with a pressure transducer, calibrate 3 seconds.
the Platform Overload System. Refer to Repair 8 Tag and disconnect the three-pin connector
Procedure, How to Calibrate the Platform Overload from the pressure transducer harness.
System (if equipped).

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9 Slowly loosen the pressure transducer from


the lift cylinder and remove. Discard the
pressure transducer.
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.

10 Connect the battery pack to the machine.


11 Turn the key switch to ground controls.
12 Press and hold the ground control scroll up
and scroll down buttons.
13 Pull out the red Emergency Stop button to the
on position at the ground controls.
14 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.
15 Raise the platform and rotate the safety arm to
the stowed position.
16 Fully lower the platform to the stowed position.
Note: After replacing the pressure transducer,
calibrating the platform overload system is not
required. If the machine begins to nuisance trip
frequently, a no load calibration is recommended.
Refer to Repair Procedure, How to Calibrate the
Platform Overload System (if equipped).

Torque specifications
Pressure transducer(if equipped) 27 ft-lbs
(schematic item R) 37 Nm

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9-12 There are two options to the platform overload


calibration procedure in this section, Full Load
Platform Overload System (if Calibration and No Load Calibration. Full Load
equipped) Calibration has two steps requiring calibration with
and without rated load in the platform. No Load
Calibration does not require rated load in the
How to Calibrate the Platform platform.
Overload System Note: No Load Calibration can be completed stand
Perform this procedure with the machine in the alone to fulfill the C-2 overload calibration
stowed position and on a firm, level surface that is requirements, if the machine has completed the
free of obstructions. Full Load Calibration procedure.

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.

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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.

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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.

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30 When prompted, press and hold the Function


Full Load Calibration: Part 2 Enable and Platform Up buttons until the
26 At the ground controls, press and hold the platform reaches full height. When the
platform reaches full height, press the enter
Function Enable and Platform Up buttons until
the platform reaches maximum height. button.
Note: If the Function Enable or Platform Up buttons
27 All Models except GS-4047: When the
are released while the machine is collecting data,
platform reaches maximum height, press the
the GCON LCD will prompt the user to lower the
Enter button. Allow the ground controls to
platform for 5 seconds before prompting to raise
gather data. GS-4047 only: Press and hold
the platform to full height again.
the Menu Enter button to determine the
maximum height. The machine will lower for 31 When prompted, press and hold the Function
1.2 seconds and then raise in 1.2 second Enable and Platform Down buttons until the
durations, until maximum height is reached. platform is fully stowed. When the platform
When the platform reaches the maximum reaches the stowed position, press the enter
height, a message will appear on the LCD button.
screen to release the Menu Enter button.
Note: If the Function Enable or Platform Down
Note: If at any point the Menu Enter button is buttons are released while the machine is
released before the message appears on the LCD collecting data, the GCON LCD will prompt the
screen, the calibration procedure will restart at step user to raise the platform for 5 seconds before
26. prompting to lower the platform to the stowed
position again.
28 When prompted, press and hold the Function
Enable and Platform Down buttons to lower 32 When prompted, push the red Emergency
the platform. The platform will move down, Stop button in to complete the Platform
then automatically stop at a predetermined Overload Calibration procedure.
point to gather data. Allow the ground controls
to gather data.
29 Continue pressing the Function Enable and
Platform Down buttons throughout the
lowering and data gathering sequence. The
machine will stop to gather data and lower
several times before the machine reaches the
stowed position. When the platform reaches
the stowed position, press the Enter button.
Note: Software revision H or prior, and
GS-2032, GS-2646 and GS-4047 models,
continue to step 32.

Note: All other models with software revision J


or higher, continue with step 30.

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No Load Calibration 15 Press the Enter button to confirm no load is in


1 Fully charge the batteries and check the the platform.
hydraulic fluid level. 16 At the ground controls, press and hold the
Note: The hydraulic fluid level must be between the Function Enable and Platform Up buttons until
FULL and ADD marks on the hydraulic tank. the platform reaches maximum height.
17 All Models except GS-4047: When the
2 Apply a thin layer of dry film lubricant to the
platform reaches maximum height, press the
area of the chassis where the scissor arm
ground controls Enter button. Allow the ground
wear pads make contact.
controls to gather data. GS-4047 only: Press
3 Chock both sides of the wheels at the steer and hold the Menu Enter button to determine
end of the machine. the maximum height. The machine will lower
for 1.2 seconds and then raise in 1.2 second
4 Turn the key switch to ground control.
durations, until maximum height is reached.
5 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. If at
6 While pressing both buttons down, pull out the any point the Menu Enter button is released
red Emergency Stop Button. before the message appears on the LCD
7 Release the Menu Up and Menu Down screen, the calibration procedure will restart at
buttons after the ground controller powers up. step 16.
8 At the ground controls, use the Menu Up 18 When prompted, press and hold the Function
or Menu Down buttons to scroll to Platform Enable and Platform Down buttons to lower
Overload. the platform. The platform will move down,
then automatically stop at a predetermined
9 Press the Enter button to select the Platform point to gather data. Allow the ground controls
Overload. to gather data.
10 Use the Menu Up or Menu Down buttons to 19 Continue pressing the Function Enable and
scroll to Platform Overload Calibrate. Platform Down buttons throughout the
11 Press the Enter button to select Platform lowering and data gathering sequence. The
Overload Calibrate. machine will stop to gather data and lower
several times before the machine reaches the
12 Confirm the Platform Overload Calibrate stowed position. When the platform reaches
selection by pressing the Enter button again. the stowed position, press the Enter button.
13 Use the Menu Up or Menu Down buttons to Note: Software revision H or prior, and
select No Load calibration. GS-2032, GS-2646 and GS-4047 models,
14 Press the Enter button to select No Load continue to step 22.
calibration.
Note: All other models with software revision J
or higher, continue with step 20.

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20 When prompted, press and hold the Function 9-13


Enable and Platform Up buttons until the
platform reaches full height. When the
Platform Overload Recovery
platform reaches full height, press the enter Message
button.
If the ground controls LCD screen displays OL:
Note: If the Function Enable or Platform Up buttons
PLATFORM OVERLOADED, the emergency
are released while the machine is collecting data,
lowering system has been used while the platform
the GCON LCD will prompt the user to lower the
was overloaded.
platform for 5 seconds before prompting to raise
the platform to full height again.
21 When prompted, press and hold the Function
How to Clear the Platform
Enable and Platform Down buttons until the Overload Recovery Message
platform is fully stowed. When the platform
Note: This message shall be cleared by a person
reaches the stowed position, press the enter
trained and qualified on the troubleshooting and
button.
repair of this machine.
Note: If the Function Enable or Platform Down
buttons are released while the machine is Note: Use the following chart to identify the
collecting data, the GCON LCD will prompt the description of each LCD screen control button used
user to raise the platform for 5 seconds before in this procedure.
prompting to lower the platform to the stowed
position again.
22 When prompted, push the red Emergency
Stop button in to complete the No Load
Calibration procedure.
Escape Scroll up Scroll down Enter

1 Turn the key switch to the ground controls


position and pull out the red Emergency Stop
button to the on position at the platform
controls.
2 Press and hold the ground control scroll up
and scroll down buttons.

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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.

4 Press the scroll down button. 8 Press the enter button.


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.

6 Press the enter button.


Result: The ground control LCD display will
show the following.
Note: After 3 seconds the LCD display will return to
SELECT OPTION PLAT. OVERLOAD.
10 Push in the red Emergency stop button.

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Platform Components

10-1 9 Support the platform with a forklift at the


non-steer end. Do not apply any lifting
Platform pressure.
10 Attach a strap from the lanyard anchorage
How to Remove the Platform point on the platform railings to the carriage on
the forklift to help support the platform.
Perform this procedure with the platform extension
fully retracted and locked in position. 11 GS-1330m, GS-1530/32 and GS-1930/32:
Lift the steer end of the platform slightly to
1 Raise the platform to approximately 3 ft / 1 m. clear the platform mount and slide the platform
2 Remove the retaining fasteners securing the towards the non-steer end of the machine until
platform to the platform mount at the steer end the platform slide blocks at the non-steer end
of the machine. of the machine are visible through the access
holes in the bottom of the platform.
3 Lower the platform to the stowed position.
All other models: Lift the steer end of the
4 Disconnect the battery pack from the machine. platform slightly to clear the platform mount
and slide the platform towards the steer end of
Electrocution/burn hazard.
the machine until the platform slide blocks at
Contact with electrically charged
the non-steer end of the machine are visible
circuits could result in death or
through the access holes in the bottom of the
serious injury. Remove all rings,
platform.
watches and other jewelry.
Crushing hazard. The platform
5 Disconnect the platform controls from the will fall if not properly supported.
control cable at the platform.
6 Remove the cover from the AC outlet. Tag and 12 Carefully lift the platform off of the machine
disconnect the wiring from the outlet. and place it on a structure capable of
supporting it.
Electrocution/burn hazard.
Note: Take notice of the wear pad position before
Contact with electrically charged
the platform is removed. Correct wear pad position
circuits could result in death or
is essential for proper platform functionality.
serious injury. Remove all rings,
watches and other jewelry.

7 Disconnect the wiring from the platform and


pull the wiring free of the platform.
8 Models with air line to platform option:
Disconnect the air line from the platform. Pull
the air line free of the platform.

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Platform Components

10-2 7 Remove the platform roller wheels from the


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

1 roller bracket assembly


2 assembly retaining fastener
3 platform roller bolt

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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.

Remote charger status indicators


1 Error / Fault indicator
2 Error / Fault
3 Charge complete
4 Charging, high state of charge
5 Charging, low state of charge

Charger status indicators


1 Error / Fault indicator
2 AC status indicator
3 Charging status
4 USB port
5 Charging indicator
6 Charger display
7 Charge profile selection button

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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.

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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

• Machine parked on a firm, level surface Electrocution/burn hazard.


Contact with electrically charged
• Platform in the stowed position circuits could result in death or
• Key switch in the off position with the key serious injury. Remove all rings,
removed watches and other jewelry.

• 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.

About This Section


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

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Diagnostics

Definitions GCON LCD Diagnostic Readout


GSDS – Genie SmartLink™ Diagnostic System
ECM – Electronic Control Module
GCON – Ground Controls
PCON – Platform Controls
The diagnostic readout displays alpha numeric
OIC – Operational Indicator Codes codes that provide information about the machine
operating status and about malfunctions.
DTC – Diagnostic Trouble Codes
The codes listed in the Diagnostic Trouble Code
Charts describe malfunctions and can aid in
troubleshooting the machine by pinpointing the
area or component affected.
Models are listed below each code to assist in the
troubleshooting codes for a specific model.

Genie® SmartLink™ Diagnostic


System
This machine is equipped with the Genie
SmartLink™ Diagnostic System (GSDS). The
GSDS indicates a machine malfunction has
happened by displaying Operational Indicator
Codes (OIC) and Diagnostic Trouble Codes (DTC).
These codes are displayed at the Platform Controls
and the Ground Controls. The Ground Controls will
display a brief description of the code at the LCD
display as well. Refer to the GCON I/O Maps,
Operational Indicator Codes (OIC) and Diagnostic
Trouble Codes (DTC) in this section, to assist in
troubleshooting faults.

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Diagnostics

GCON ECM Connector Layout

Rear of Ground Controls ECM (models without


outriggers)

Rear of Ground Controls ECM (models with outriggers)

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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

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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

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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

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Diagnostics

GCON I/O Map without Load Sense (GS-3232 only) continued


GCON Pin Number Circuit Function I/O Type Wire Gauge and Color
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 GR
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
J-4 Connector – Brown
J4-01 Left Front Pressure Transducer Analog Input 18 WH
J4-02 Right Front Pressure Transducer Analog Input 18 OR
J4-03 Left Rear Pressure Transducer Analog Input 18 BL
J4-04 Right Rear Pressure Transducer Analog Input 18 GR
J4-05 Lever Sensor — X Axis Analog Input 18 OR
J4-06 Lever Sensor — Y Axis Analog Input 18 BR
J4-07 Left Front Outrigger Coil Digital Output 18 RD/WH
J4-08 Right Front Outrigger Coil Digital Output 18 OR/WH
J4-09 Left Rear Outrigger Coil Digital Output 18 BL/WH
J4-10 Right Rear Outrigger Coil Digital Output 18 GR/WH
J4-11 Outrigger Extend Coil Digital Output 18 GR
J4-12 Outrigger Retract Coil Digital Output 18 GR/BK

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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

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Service and Repair Manual January 2019

Diagnostics

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


GCON Pin Number Circuit Function I/O Type Wire Gauge and Color
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 GR
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
J-4 Connector – Brown
J4-01 Left Front Pressure Transducer Analog Input 18 WH
J4-02 Right Front Pressure Transducer Analog Input 18 OR
J4-03 Left Rear Pressure Transducer Analog Input 18 BL
J4-04 Right Rear Pressure Transducer Analog Input 18 GR
J4-05 Lever Sensor — X Axis Analog Input 18 OR
J4-06 Lever Sensor — Y Axis Analog Input 18 BR
J4-07 Left Front Outrigger Coil Digital Output 18 RD/WH
J4-08 Right Front Outrigger Coil Digital Output 18 OR/WH
J4-09 Left Rear Outrigger Coil Digital Output 18 BL/WH
J4-10 Right Rear Outrigger Coil Digital Output 18 GR/WH
J4-11 Outrigger Extend Coil Digital Output 18 GR
J4-12 Outrigger Retract Coil Digital Output 18 GR/BK

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January 2019 Service and Repair Manual

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.

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 175


Service and Repair Manual January 2019

Diagnostics

Diagnostic Trouble Codes (DTC)


These codes are generated by the system to
indicate that a device or circuit malfunction has
been detected in the electrical system.
The types of Diagnostic Trouble Codes that may
occur are explained below.
Type "HXXX" – Indicate a malfunction associated
with devices that control hydraulic functions in the
electrical system. The "HXXX" faults are divided
into short circuit battery negative, short circuit to
battery positive, open circuit and generic shorts.
Examples of these devices are solenoid controlled
hydraulic valves and motor controller.
Type "PXXX" – Indicate a malfunction associated
with power type devices in the electrical system.
The "PXXX" faults are divided into short circuit to
battery negative, short circuit to battery positive,
open circuit and generic shorts. Examples of these
devices are horns, sensor power and alarms.
Type "UXXX" – Indicate a malfunction associated
with user interface devices in the electrical system.
The "UXXX" faults are divided into short circuit to
battery negative, short circuit to battery positive,
open circuit and generic shorts. Examples of these
devices are GCON up and down switches and
PCON drive joystick.
Type "FXXX" – Indicate a malfunction associated
with machine feedback devices in the electrical
system. The "FXXX" faults are divided into short
circuit to battery negative, short circuit to battery
positive, open circuit and generic shorts. Examples
of these devices are limit switches, height sensors
and pressure transducers.
Type "CXXX" – Indicate a malfunction associated
with controls devices in the electrical system.
Examples of these devices are platform controls
and ground controls ECM.

176 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Troubleshooting "HXXX" and "PXXX" Faults

Troubleshooting "HXXX" and "PXXX" Faults


The procedure below illustrates typical steps for diagnosing and fixing faults of type "HXXX" and "PXXX".

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.

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 177


Service and Repair Manual January 2019

Fault Inspection Procedure

Fault Inspection Procedure


1 Check the device associated with the faulted circuit
1 Disconnect the faulted device connector.
2 Using a multi-meter, measure resistance between the two
terminals of the faulted device.
3 Resistance should be as follows.
Device Typical Resistance
Solenoid Valve, Drive 27.2 Ω
Solenoid Valve, Steer 19 Ω
Solenoid Valve, Platform Up 25 Ω
Solenoid Valve, Platform Down 6.25 Ω
GCON and PCON Alarm >1M Ω
Automotive Horn 1.0 Ω
Motor Controller – Enable 5.7k Ω
Motor Controller – Throttle 5.7k Ω
Contactor Coil 47 Ω
OK Go to step 2 No Good Replace faulted device

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

178 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Fault Inspection Procedure

3 Check the GCON ECM

1 Disconnect the GCON ECM connectors, J1, J2 and J3.


2 For short to B- type faults, measure resistance between
pins J1-7 (ground) and the GCON pin associated with the
fault code. Refer to the GCON I/O Map in this section to
identify the faulted out circuit pin.
3 Short to ground resistance should be greater than 5k Ω.
4 For short to B+ type faults, measure resistance between
pins J1-12 (driver power) and the GCON pin associated
with the fault code. Refer to the GCON I/O Map in this
section to identify the faulted out circuit pin.
5 Short to power resistance should be greater than 50k Ω.

No Good Replace GCON ECM

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Service and Repair Manual January 2019

Type "HXXX" Faults

Type "HXXX" Faults


DTC Message on
Description Possible Causes Failure Mode
Number GCON LCD
H001:
GS30, • Short circuit in platform up #1 harness.
H001:COILFAULT Short circuit of the platform up #1 circuit to Platform up function
GS32, • Platform up #1 coil short circuit.
PLAT UP1:BAT- battery negative. inhibited.
GS46 & • GCON ECM.
GS47
H002:
GS30, • Short circuit in platform up #1 harness.
H002:COILFAULT Platform up function
GS32, Open circuit in the platform up #1 circuit. • Platform up #1 coil open circuit.
PLAT UP1:OPEN inhibited.
GS46 & • GCON ECM.
GS47
H003:
GS30, • Short circuit in platform up #1 harness. All functions inhibited
H003:COILFAULT Short circuit of the platform up #1 circuit to
GS32, • Platform up #1 coil short circuit. except platform
PLAT UP1:BAT+ battery positive.
GS46 & • GCON ECM. down.
GS47
H009:
GS30, • Short circuit in platform down #1 harness.
H009:COILFAULT Short circuit of the platform down #1 circuit to All functions
GS32, • Platform down #1 coil short circuit.
PLAT DOWN1:BAT+ battery positive. inhibited.
GS46 & • GCON ECM.
GS47
H013:
GS30, • Short circuit in drive forward #1 harness.
H013:COILFAULT Short circuit of the drive forward #1 circuit to Drive forward
GS32, • Drive forward #1 coil short circuit.
DRIVE FWD1:BAT- battery negative. function inhibited.
GS46 & • GCON ECM.
GS47
H014:
GS30, • Open circuit in drive forward #1 harness.
H014:COILFAULT Drive forward
GS32, Open circuit in the drive forward #1 circuit. • Drive forward #1 coil open circuit.
DRIVE FWD1:OPEN function inhibited.
GS46 & • GCON ECM.
GS47
H015:
GS30, • Short circuit in drive forward #1 harness. All functions inhibited
H015:COILFAULT Short circuit of the drive forward #1 circuit to
GS32, • Drive forward #1 coil short circuit. except platform
DRIVE FWD1:BAT+ battery positive.
GS46 & • GCON ECM. down.
GS47
H019:
GS30, • Short circuit in drive reverse #1 harness.
H019:COILFAULT Short circuit of the drive reverse #1 circuit to Drive reverse
GS32, • Drive reverse #1 coil short circuit.
DRIVE REV1:BAT- battery negative. function inhibited.
GS46 & • GCON ECM.
GS47
H020:
GS30, • Open circuit in drive reverse #1 harness.
H020:COILFAULT Drive reverse
GS32, Open circuit in the drive reverse #1 circuit. • Drive reverse #1 coil open circuit.
DRIVE REV1:OPEN function inhibited.
GS46 & • GCON ECM.
GS47
H021:
GS30, • Short circuit in drive reverse #1 harness. All functions inhibited
H021:COILFAULT Short circuit of the drive reverse #1 circuit to
GS32, • Drive reverse #1 coil short circuit. except platform
DRIVE REV1:BAT+ battery positive.
GS46 & • GCON ECM. down.
GS47
H027:
GS30, • Short circuit in steer right harness. All functions inhibited
H027:COILFAULT Short circuit of the steer right circuit to battery
GS32, • Steer right coil short circuit. except platform
DRIVE STEER RIGHT:BAT+ positive.
GS46 & • GCON ECM. down.
GS47
H030:
GS30, • Short circuit in steer left harness. All functions inhibited
H030:COILFAULT Short circuit of the steer left circuit to battery
GS32, • Steer left coil short circuit. except platform
DRIVE STEER LEFT:BAT+ positive.
GS46 & • GCON ECM. down.
GS47
H033:
Hi/Lo speed coil
GS30, • Short circuit in Hi/Lo speed coil harness.
H033:COILFAULT Short circuit of the hi/lo speed coil to battery disabled. Machine
GS32, • Hi/Lo speed coil short circuit.
HI/LO SPEED:BAT+ positive. will operate in low
GS46 & • GCON ECM.
speed mode.
GS47

180 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Type "HXXX" Faults

Type "HXXX" Faults, continued


DTC Message on
Description Possible Causes Failure Mode
Number GCON LCD
• Short circuit in brake release enable harness All functions inhibited
HO43 H043:COILFAULT Short circuit of the brake circuit to battery
•Brake release relay short circuit except platform
GS-1330m BRAKE REL:BAT- negative.
• GCON ECM. down.
• Short circuit in brake release enable harness All functions inhibited
HO45 H045:COILFAULT Short circuit of the brake circuit to battery
• Brake release relay short circuit except platform
GS-1330m BRAKE REL:BAT+ positive.
• GCON ECM. down.
• Short circuit in outrigger extend coil harness. Only outrigger
H049: H049:COILFAULT Short circuit of the outrigger extend coil to
• Outrigger extend coil short circuit. extend function
GS-3232 O/R EXTEND:BAT- battery negative.
• GCON ECM. disabled.
• Short circuit in outrigger extend coil harness. Only outrigger
H050: H050:COILFAULT Open circuit in the outrigger extend coil
• Outrigger extend coil open circuit. extend function
GS-3232 O/R EXTEND:OPEN circuit.
• GCON ECM. disabled.
• Short circuit in outrigger extend coil harness. All functions inhibited
H051: H051:COILFAULT Short circuit of the outrigger extend coil to
• Outrigger extend coil short circuit. except platform
GS-3232 O/R EXTEND:BAT+ battery positive.
• GCON ECM. down.
• Short circuit in outrigger retract coil harness. Only outrigger
H052: H052:COILFAULT Short circuit of the outrigger retract coil to
• Outrigger retract coil short circuit. retract function
GS-3232 O/R RETRACT:BAT- battery negative.
• GCON ECM. disabled.
• Short circuit in outrigger retract coil harness. Only outrigger
H053: H053:COILFAULT Open circuit in the outrigger retract coil
• Outrigger retract coil open circuit. retract function
GS-3232 O/R RETRACT:OPEN circuit.
• GCON ECM. disabled.
• Short circuit in outrigger retract coil harness. All functions inhibited
H054: H054:COILFAULT Short circuit of the outrigger retract coil to
• Outrigger retract coil short circuit. except platform
GS-3232 O/R RETRACT:BAT+ battery positive.
• GCON ECM. down.
• Short circuit in left front outrigger coil harness. All functions inhibited
H057: H057:COILFAULT Short circuit of the left front outrigger coil to
• Left front outrigger coil short circuit. except platform
GS-3232 LF RIGGER:BAT+ battery positive.
• GCON ECM. down.
• Short circuit in left rear outrigger coil harness. All functions inhibited
H060: H060:COILFAULT Short circuit of the left rear outrigger coil to
• Left rear outrigger coil short circuit. except platform
GS-3232 LR RIGGER:BAT+ battery positive.
• GCON ECM. down.
• Short circuit in right front outrigger coil harness. All functions inhibited
H063: H063:COILFAULT Short circuit of the right front outrigger coil to
• Right front outrigger coil short circuit. except platform
GS-3232 RF RIGGER:BAT+ battery positive.
• GCON ECM. down.
• Short circuit in right rear outrigger coil harness. All functions inhibited
H066: H066:COILFAULT Short circuit of the right rear outrigger coil to
• Right rear outrigger coil short circuit. except platform
GS-3232 RR RIGGER:BAT+ battery positive.
• GCON ECM. down.
H067:
• Short circuit in motor controller enable wire.
GS30, All functions inhibited
H067:FAULT Short circuit of the motor controller circuit to • Motor Controller.
GS32, except platform
MC ENABLE:BAT- battery negative. • Contactor coil shorted to battery negative.
GS46 & down.
• GCON ECM.
GS47
H069:
• Short circuit in motor controller enable wire.
GS30, All functions inhibited
H069:FAULT Short circuit of the motor controller circuit to • Motor Controller.
GS32, except platform
MC ENABLE:BAT+ battery positive. • Contactor Coil.
GS46 & down.
• GCON ECM.
GS47
H070:
GS30, • Short circuit in motor controller throttle wire. All functions inhibited
H070:FAULT Short circuit of the motor controller throttle
GS32, • Motor Controller. except platform
MC THROTTLE:BAT- circuit to battery negative.
GS46 & • GCON ECM. down.
GS47

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 181


Service and Repair Manual January 2019

Type "HXXX" Faults

Type "HXXX" Faults, continued


DTC Message on
Description Possible Causes Failure Mode
Number GCON LCD
H072:
GS30, • Short circuit in motor controller throttle wire.
H072:FAULT Short circuit of the motor controller throttle All functions inhibited
GS32, • Motor Controller.
MC THROTTLE:BAT+ circuit to battery positive. except platform down.
GS46 & • GCON ECM.
GS47
• Short or open circuit in left front outrigger
H074: H074:COILFAULT Short circuit of the left front outrigger circuit to harness. Left front outrigger
GS-3232 LF RIGGER battery positive/negative or open circuit. • Left front outrigger coil short or open circuit. function inhibited.
• GCON ECM.
• Short or open circuit in left rear outrigger
H075: H075:COILFAULT Short circuit of the left rear outrigger circuit to harness. Left rear outrigger
GS-3232 LR RIGGER battery positive/negative or open circuit. • Left rear outrigger coil short or open circuit. function inhibited.
• GCON ECM.
• Short or open circuit in right front outrigger
H076: H076:COILFAULT Short circuit of the right front outrigger circuit harness. Right front outrigger
GS-3232 RF RIGGER to battery positive/negative or open circuit. • Right front outrigger coil short or open circuit. function inhibited.
• GCON ECM.
• Short or open circuit in right rear outrigger
H077: H077:COILFAULT Short circuit of the right rear outrigger circuit harness. Right rear outrigger
GS-3232 RR RIGGER to battery positive/negative or open circuit. • Right rear outrigger coil short or open circuit. function inhibited.
• GCON ECM.
H078:
• Short or open circuit in platform down
GS30,
H078:COILFAULT Short circuit of the platform down #1 circuit to #1 harness. Platform down function
GS32,
PLAT DOWN1 battery positive/negative or open circuit. • Platform down #1 coil short or open circuit. inhibited.
GS46 &
• GCON ECM.
GS47
Hi/Lo speed coil
disabled. Machine will
operate in high speed
H079:
• Short circuit in HI/LO speed harness. mode if open circuit or
GS32, H079:COILFAULT Short circuit of the HI/LO speed circuit to
• HI/LO speed coil short or open circuit. short with battery
GS46 & HI/LO SPEED battery positive/negative or open circuit.
• GCON ECM. negative. Machine will
GS47
operate in low speed
mode if short with
battery positive.
H080:
GS30, • Short or open circuit in steer left harness.
H080:COILFAULT Short circuit of the steer left circuit to battery Steer left function
GS32, • Steer left coil short or open circuit.
STEER LEFT negative or open circuit. inhibited.
GS46 & • GCON ECM.
GS47
H081:
GS30, • Short or open circuit in steer right harness.
H081:COILFAULT Short circuit of the steer right circuit to battery Steer right function
GS32, • Steer right coil short or open circuit.
STEER RIGHT negative or open circuit. inhibited.
GS46 & • GCON ECM.
GS47
All functions
• Short circuit in relief valve harness.
H102: H102:COILFAULT Short circuit of the relief valve circuit to inhibited except
• Relief valve coil short circuit.
GS-4047 RELIEF VALVE:BAT+ battery positive. platform down while
• GCON ECM.
above limit switch.
All functions
• Short circuit in relief valve harness.
H103: H103:COILFAULT Short circuit of the relief valve circuit to inhibited except
• Relief valve coil short circuit.
GS-4047 RELIEF VALVE:BAT- battery negative. platform down while
• GCON ECM.
above limit switch.
All functions
• Open circuit in relief valve harness.
H104: H104:COILFAULT inhibited except
Relief valve circuit open. • Relief valve coil open circuit.
GS-4047 RELIEF VALVE:OPEN platform down while
• GCON ECM.
above limit switch.

182 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Type "HXXX" Faults

Type "HXXX" Faults, continued


DTC Message on
Description Possible Causes Failure Mode
Number GCON LCD
• Short circuit in PED harness.
H106: H106:COILFAULT Short circuit of the platform extend circuit to
• PED extend valve coil short circuit. All functions inhibited.
GS-2646AV DECK EXTEND:BAT- battery negative.
• GCON ECM.
• Open circuit in PED harness.
H107: H107:COILFAULT
Open circuit in the platform extend circuit. • PED extend valve coil open circuit. All functions inhibited.
GS-2646AV DECK EXTEND:OPEN
• GCON ECM.
• Short circuit in PED harness.
H108: H108:COILFAULT Short circuit of the platform extend circuit to
• PED extend valve coil short circuit. All functions inhibited.
GS-2646AV DECK EXTEND:BAT+ battery positive.
• GCON ECM.
• Short circuit in PED harness.
H109: H109:COILFAULT Short circuit of the platform retract circuit to
• PED retract valve coil short circuit. All functions inhibited.
GS-2646AV DECK RETRACT:BAT- battery negative.
• GCON ECM.
• Open circuit in PED harness.
H110: H110:COILFAULT
Open circuit in the platform retract circuit. • PED retract valve coil open circuit. All functions inhibited.
GS-2646AV DECK RETRACT:OPEN
• GCON ECM.
• Short circuit in PED harness.
H111: H111:COILFAULT Short circuit of the platform retract circuit to
• PED retract valve coil short circuit. All functions inhibited.
GS-2646AV DECK RETRACT:BAT+ battery positive.
• GCON ECM.
• Short circuit in PED harness.
H114: H114:COILFAULT Short circuit of the platform enable circuit to
• PED enable valve coil short circuit. All functions inhibited.
GS-2646AV DECK ENABLE:BAT+ battery positive.
• GCON ECM.
H115: H115:COILFAULT • Short circuit in PED harness.
Short circuit of the platform enable circuit. All functions inhibited.
GS-2646AV DECK ENABLE • GCON ECM.

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Type "PXXX" Faults

Type "PXXX" Faults


DTC Message on
Description Possible Causes Failure Mode
Number GCON LCD
P001:
• Short circuit in switched power #1, down limit
GS30,
P001:PWR FAULT Short circuit of the switched power #1 switch, pothole limit switch, digital tilt switch All functions
GS32,
SW PWR1:BAT- circuit to battery negative. harness. inhibited.
GS46 &
• GCON ECM.
GS47
P003:
• Short circuit in switched power #1, down limit
GS30,
P003:PWR FAULT Short circuit of the switched power #1 switch, pothole limit switch, digital tilt switch All functions
GS32,
SW PWR1:BAT+ circuit to battery positive. harness. inhibited.
GS46 &
• GCON ECM.
GS47
P004:
GS30, • Short circuit in automotive horn harness.
P004:DEVICEFAULT Short circuit of the automotive horn circuit to Automotive horn
GS32, • Automotive horn short circuit.
HORN:BAT- battery negative. inhibited.
GS46 & • GCON ECM.
GS47
P005:
GS30, • Open circuit in automotive horn harness.
P005:DEVICEFAULT Automotive horn
GS32, Open circuit of the automotive horn circuit. • Automotive horn open circuit.
HORN:OPEN inhibited.
GS46 & • GCON ECM.
GS47
P006:
GS30, • Short circuit in automotive horn harness.
P006:DEVICEFAULT Short circuit of the automotive horn circuit to Automotive horn
GS32, • Automotive horn short circuit.
HORN:BAT+ battery positive. inhibited.
GS46 & • GCON ECM.
GS47
P007:
GS30, • Short circuit in GCON alarm harness.
P007:DEVICEFAULT Short circuit of the GCON alarm circuit to GCON alram
GS32, • GCON alarm short circuit.
GCON ALARM:BAT- battery negative. inhibited.
GS46 & • GCON ECM.
GS47
P009:
GS30, • Short circuit in GCON alarm harness.
P009:DEVICEFAULT Short circuit of the GCON alarm circuit to GCON alram
GS32, • GCON alarm short circuit.
GCON ALARM:BAT+ battery positive. inhibited.
GS46 & • GCON ECM.
GS47
P013:
GS30,
P013:PWR FAULT Short circuit of the PCON power return circuit • Short circuit in PCON power return harness. All functions
GS32,
PCON PWRET:BAT- to battery negative. • GCON ECM. inhibited.
GS46 &
GS47
P015:
GS30,
P015:PWR FAULT Short circuit of the PCON power return circuit • Short circuit in PCON power return harness. All functions
GS32,
PCON PWRET:BAT+ to battery positive. • GCON ECM. inhibited.
GS46 &
GS47
P018:
GS30,
018:PWR FAULT Short circuit of the PCON power circuit to • Short circuit in PCON power harness. All functions
GS32,
PCON POWER:BAT- battery negative. • GCON ECM. inhibited.
GS46 &
GS47
P019:
GS30,
018:PWR FAULT Short circuit of the PCON power circuit to • Short circuit in PCON power harness. All functions
GS32,
PCON POWER:BAT+ battery positive. • GCON ECM. inhibited.
GS46 &
GS47

184 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


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Type "PXXX" Faults

Type "PXXX" Faults


DTC Message on
Description Possible Causes Failure Mode
Number GCON LCD
• Pump voltage to low.
P023: P023:PUMP MOTOR All functions
Pump motor voltage out of range • Pump voltage to high.
GS1330m VOLTAGE NOT OK inhibited.
• DCON ECM.
• Open or short circuit in pump motor P-cable.
P025: P025:PUMP MOTOR Open or short circuit of the P- circuit from the All functions
• Faulty pump.
GS1330m CURRENT FEEDBK+ right rear drive controller to the pump motor. inhibited.
• DCON ECM.
Open or short circuit of the U or W circuit from • Open circuit in right rear drive motor U or W cable.
P026: P026:MOTOR RIGHT REAR All functions
the right rear drive controller to the right rear • Drive motor.
GS1330m VOLTAGE NOT OK inhibited.
drive motor. • DCON ECM.
• Short circuit in main contactor harness.
P028: P028:CONTACTOR All functions
Main contactor stuck in the closed position. • Faulty contactor.
GS1330m STUCK CLOSED inhibited.
• DCON ECM.
• Open circuit in main contactor harness.
P029: P029:CONTACTOR All functions
Main contactor stuck in the open position. • Faulty contactor.
GS1330m DOES NOT CLOSE inhibited.
• DCON ECM.
• Open or short circuit in main contactor harness.
P030: Short circuit of the main contactor coil to All functions
P030:COIL FAULT • Faulty contactor.
GS1330m battery negative or open circuit. inhibited.
• DCON ECM.
• Open or short circuit in voltage sensor circuits
• Low batteries.
P037: PO37: BATTERY All functions
Battery voltage is out of range at startup. • Faulty battery.
GS1330m OUT OF RANGE inhibited.
• Battery charger connected to AC power source.
• DCON ECM.
• Open or short circuit in brake relay harness.
P039: P039: DEVICE FAULT Open or short circuit of the brake relay • Brake relay contact stuck closed. All functions
GS1330m BRAKE PWR RELAY contact or coil. • Faulty brake relay. inhibited.
• GCON ECM.
• Open or short circuit in brake relay harness.
P040 P040: COIL FAULT Open or short circuit of the brake relay • Faulty brake relay. All functions
GS1330m BRAKE PWR OPEN contact or coil to battery negative. • Left or right DCON ECM. inhibited.
• GCON ECM.

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 185


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Type "UXXX" Faults

Type "UXXX" Faults


DTC Message on Description Possible Causes Failure Mode
Number GCON LCD
U001:
GS30, • Short circuit of the GCON main function enable
U001:SWITCHFAULT Short circuit of the GCON main function All GCON functions
GS32, switch.
GCON MAIN FTN EN enable switch at system startup. inhibited.
GS46 & • GCON ECM.
GS47
U002:
GS30, All GCON functions
U002:SWITCHFAULT Short circuit of the GCON up directional • Short circuit of the GCON up directional switch.
GS32, inhibited except
GCON PLAT UP switch at system startup. • GCON ECM.
GS46 & platform down.
GS47
U003:
GS30, All GCON functions
U003:SWITCHFAULT Short circuit of the GCON down directional • Short circuit of the GCON down directional switch.
GS32, inhibited except
GCON PLAT DOWN switch at system startup. • GCON ECM.
GS46 & platform up.
GS47
U004:
GS30,
U004:SWITCHFAULT Short circuit of the GCON LCD scroll up • Short circuit of the GCON LCD scroll up switch. All GCON LCD menu
GS32,
GCON LCD UP switch at system startup. • GCON ECM. functions inhibited.
GS46 &
GS47
U005:
GS30,
U005:SWITCHFAULT Short circuit of the GCON LCD scroll down • Short circuit of the GCON LCD scroll down switch. All GCON LCD menu
GS32,
GCON LCD DOWN switch at system startup. • GCON ECM. functions inhibited.
GS46 &
GS47
U006:
GS30,
U006:SWITCHFAULT Short circuit of the GCON LCD enter switch • Short circuit of the GCON LCD enter switch. All GCON LCD menu
GS32,
GCON LCD ENTER at system startup. • GCON ECM. functions inhibited.
GS46 &
GS47
U007:
GS30,
U007:SWITCHFAULT Short circuit of the GCON LCD escape switch • Short circuit of the GCON LCD escape switch. All GCON LCD menu
GS32,
GCON LCD ESCAPE at system startup. • GCON ECM. functions inhibited.
GS46 &
GS47
U014:
GS30, All PCON drive and
U014:SWITCHFAULT Short circuit of the PCON drive enable switch • Short circuit of the PCON drive enable switch.
GS32, steer functions
PCON DRIVE EN at system startup. • GCON ECM.
GS46 & inhibited.
GS47
U015:
GS30, All PCON drive and
U015:SWITCHFAULT Short circuit of the PCON steer left switch at • Short circuit of the PCON steer left switch.
GS32, steer functions
PCON STEER LEFT system startup. • GCON ECM.
GS46 & inhibited.
GS47
U016:
GS30, All PCON drive and
U016:SWITCHFAULT Short circuit of the PCON steer right switch at • Short circuit of the PCON steer right switch.
GS32, steer functions
PCON STEER RIGHT system startup. • GCON ECM.
GS46 & inhibited.
GS47
U017:
GS30,
U017:SWITCHFAULT Short circuit of the PCON horn switch at • Short circuit of the PCON horn switch. PCON horn switch
GS32,
PCON HORN system startup. • GCON ECM. function inhibited.
GS46 &
GS47
U018:
GS30, The machine is
U018:SWITCHFAULT Short circuit of the PCON low drive speed • Short circuit of the PCON low drive speed switch.
GS32, limited to low drive
PCON LO DRIV SPD switch at system startup. • GCON ECM.
GS46 & speed.
GS47
U019:
GS30, PCON platform up
U019:SWITCHFAULT Short circuit of the PCON low lift speed • Short circuit of the PCON low lift speed switch.
GS32, and down functions
PCON LO LIFT SPD switch at system startup. • GCON ECM.
GS46 & inhibited.
GS47

186 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Type "UXXX" Faults

Type "UXXX" Faults, continued


DTC Message on
Description Possible Causes Failure Mode
Number GCON LCD
U020:
GS30, PCON platform up
U020:SWITCHFAULT Short circuit of the PCON high lift speed • Short circuit of the PCON hi lift speed switch.
GS32, and down functions
PCON HI LIFT SPD switch at system startup. • GCON ECM.
GS46 & inhibited.
GS47
U021:
GS30,
U021:SWITCHFAULT Short circuit of the PCON up directional • Short circuit of the PCON up directional switch. PCON platform up
GS32,
PCON UP switch at system startup. • GCON ECM. function inhibited.
GS46 &
GS47
U022:
GS30, • Short circuit of the PCON down directional PCON platform
U022:SWITCHFAULT Short circuit of the PCON down directional
GS32, switch. down functions
PCON DOWN switch at system startup.
GS46 & • GCON ECM. inhibited.
GS47
• Short circuit of the PCON outrigger enable
U023: U023:SWITCHFAULT Short circuit of the PCON outrigger enable All outrigger
switch.
GS-3232 PCON O/R ENABLE switch at system startup. functions inhibited.
• GCON ECM.
U033:
• PCON drive joystick is not in neutral position at
GS30, PCON drive joystick signal is outside All PCON drive and
U033:JSTICKFAULT startup.
GS32, acceptable calibration range at system steer functions
OUT OF CAL RANGE • PCON joystick.
GS46 & startup. inhibited.
• GCON ECM.
GS47
U034:
• Short circuit of the PCON drive joystick signal
GS30, All PCON drive and
U034:JSTICKFAULT Short circuit of the PCON drive joystick circuit.
GS32, steer functions
OUT OF RANGE:HI signal to battery positive at system startup. • PCON joystick.
GS46 & inhibited.
• GCON ECM.
GS47
U035:
• Short circuit of the PCON drive joystick signal
GS30, All PCON drive and
U035:JSTICKFAULT Short circuit of the PCON drive joystick circuit.
GS32, steer functions
OUT OF RANGE:LO signal to battery negative at system startup. • PCON joystick.
GS46 & inhibited.
• GCON ECM.
GS47
U036:
GS30,
U036:SWITCHFAULT Mis-wiring or short circuit of GCON key • GCON key switch. All functions
GS32,
GCON + PCON:ON switch. • GCON ECM. inhibited.
GS46 &
GS47
U037:
GS30, • Short circuit in the foot switch harness.
U037:SWITCHFAULT All functions
GS32, Foot switch pressed at machine startup. • Foot switch.
FOOTSW PRESSED inhibited.
GS46 & • GCON ECM.
GS47
U038:
GS30, • Short circuit in the foot switch harness.
U038:SWITCHFAULT Mis-wiring or short circuit of foot switch to All functions
GS32, • Foot switch.
FOOTSWITCH:BAT+ battery positive. inhibited.
GS46 & • GCON ECM.
GS47
U039:
GS30, • Short circuit in the foot switch harness.
U039:SWITCHFAULT Mis-wiring, open or short circuit of foot All functions
GS32, • Foot switch.
FOOTSW:OPEN/BAT- switch to battery negative. inhibited.
GS46 & • GCON ECM.
GS47
U040:
GS30,
• Short circuit in the foot switch harness.
GS32, U040:SWITCHFAULT PCON deck switch pressed at machine All functions
• Foot switch.
GS46 & FOOTSW:TIMEOUT startup. inhibited.
• GCON ECM.
GS47
(GS-3232 excluded)

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 187


Service and Repair Manual January 2019

Type "UXXX" Faults

Type "UXXX" Faults, continued


DTC Message on
Description Possible Causes Failure Mode
Number GCON LCD
U041:
• GCON deck enable switch stuck closed.
GS30,
U041:SWITCHFAULT GCON deck enable switch stuck closed, or • GCON deck enable switch depressed at system All functions
GS32,
GCON DECK ENABLE depressed at system startup. startup. inhibited.
GS46 &
• GCON ECM.
GS47
U042:
• PCON drive mode switch stuck closed.
GS30,
U042:SWITCHFAULT PCON drive mode switch stuck closed, or • PCON drive mode switch depressed at system Drive functions
GS32,
PCON DRIVE MODE depressed at system startup. startup. inhibited.
GS46 &
• PCON ECM.
GS47
• PCON outrigger mode switch stuck closed.
Outrigger
U043: U043:SWITCHFAULT PCON outrigger mode switch stuck closed, or • PCON outrigger mode switch depressed at system
extend/retract
GS-3232 PCON OR MODE depressed at system startup. startup.
functions inhibited.
• PCON ECM.
U045:
• PCON function enable switch stuck closed.
GS30,
U045:SWITCHFAULT PCON function enable switch stuck closed, or • PCON function enable switch depressed at system All drive and steer
GS32,
PCON FUNCTION EN depressed at system startup. startup. functions inhibited.
GS46 &
• PCON ECM.
GS47
U046:
• PCON lift mode switch stuck closed.
GS30, All functions
U046:SWITCHFAULT PCON Lift mode switch stuck closed, or • PCON lift mode switch depressed at system
GS32, operate except
PCON LIFT MODE depressed at system startup. startup.
GS46 & platform up/down.
• PCON ECM.
GS47

188 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Type "FXXX" Faults

Type "FXXX" Faults


DTC Message on
Description Possible Causes Failure Mode
Number GCON LCD
• Short circuit of the up limit switch circuit.
F001: F001:SWITCHFAULT Short circuit of the up limit #1 switch at Platform up function
• Up limit #1 switch short circuit.
GS-3232 UP LIMIT1:BAT+ system startup. inhibited.
• GCON ECM.
F003:
GS30, • Short circuit of the down limit switch circuit.
F003:SWITCHFAULT Short circuit of the down limit #1 switch at All functions inhibited
GS32, • Down limit #1 switch short circuit.
DOWN LIMIT1:BAT+ system startup. except platform down.
GS46 & • GCON ECM.
GS47
All functions inhibited
except platform down
F005:
as long as machine is
GS30, • Short circuit of the pothole switch circuit.
F005:SWITCHFAULT Short circuit of the pothole limit #1 switch at in the elevated
GS32, • Pothole limit #1 switch short circuit.
POTHOLE:BAT+ system startup. position. If machine is
GS46 & • GCON ECM.
in stowed position, all
GS47
functionality is
resumed.
All functions inhibited
except platform down
F007:
• Short circuit of the chassis digital tilt switch as long as machine is
GS30,
F007:SWITCHFAULT Short circuit of the chassis digital tilt switch at circuit. in the elevated
GS32,
CHASSISTILT:BAT+ system startup. • Chassis digital tilt switch short circuit. position. If machine is
GS46 &
• GCON ECM. in stowed position, all
GS47
functionality is
resumed.
F008:
GS30, • Short circuit in the transducer circuit.
F008:SENSORFAULT Short circuit of the Platform Overload
GS32, • Faulty pressure transducer. All functions inhibited.
OVLD XDUCER:BAT+ Transducer circuit to battery positive.
GS46 & • GCON ECM.
GS47
F009:
GS30, • Short circuit in the transducer circuit.
F009:SENSORFAULT Short circuit of the Platform Overload
GS32, • Faulty pressure transducer. All functions inhibited.
OVLD XDUCER:BAT- Transducer circuit to battery negative.
GS46 & • GCON ECM.
GS47
All functions inhibited
except platform down
F010:
as long as machine is
GS30, • Short circuit in the platform height circuit.
F010:SENSORFAULT Short circuit of the Platform Height Sensor in the elevated
GS32, • Faulty platform height sensor.
PLAT HEIGHT:BAT+ circuit to battery positive. position. If machine is
GS46 & • GCON ECM.
in stowed position, all
GS47
functionality is
resumed.
All functions inhibited
except platform down
F011:
as long as machine is
GS30, • Short circuit in the platform height circuit.
F011:SENSORFAULT Short circuit of the Platform Height Sensor in the elevated
GS32, • Faulty platform height sensor.
PLAT HEIGHT:BAT- circuit to battery negative. position. If machine is
GS46 & • GCON ECM.
in stowed position, all
GS47
functionality is
resumed.

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 189


Service and Repair Manual January 2019

Type "FXXX" Faults

Type "FXXX" Faults, continued


DTC Message on
Description Possible Causes Failure Mode
Number GCON LCD
• Short circuit in the level pitch sensor circuit.
F012: F012:SENSORFAULT Short circuit of the Level Pitch Sensor circuit
• Faulty level sensor. All functions inhibited.
GS-3232 LEVEL PITCH:BAT+ to battery positive.
• GCON ECM.
• Short circuit in the level pitch sensor circuit.
F013: F013:SENSORFAULT Short circuit of the Level Pitch Sensor circuit
• Faulty level sensor. All functions inhibited.
GS-3232 LEVEL PITCH:BAT- to battery negative.
• GCON ECM.
• Short circuit in the level roll sensor circuit.
F014: F014:SENSORFAULT Short circuit of the Level Roll Sensor circuit to
• Faulty level sensor. All functions inhibited.
GS-3232 LEVEL ROLL:BAT+ battery positive.
• GCON ECM.
• Short circuit in the level roll sensor circuit.
F015: F015:SENSORFAULT Short circuit of the Level Roll Sensor circuit to
• Faulty level sensor. All functions inhibited.
GS-3232 LEVEL ROLL:BAT- battery negative.
• GCON ECM.
Left front outrigger
• Short circuit in the left front outrigger sensor
inhibited if outrigger
F016: F016:SENSORFAULT Short circuit of the Left Front Outrigger circuit.
extend is activated.
GS-3232 LF RIGGER:BAT+ Sensor circuit to battery positive. • Faulty pressure transducer.
Outrigger can still be
• GCON ECM.
retracted.
Left front outrigger
• Short circuit in the left front outrigger sensor
inhibited if outrigger
F017: F017:SENSORFAULT Short circuit of the Left Front Outrigger circuit.
extend is activated.
GS-3232 LF RIGGER:BAT- Sensor circuit to battery negative. • Faulty pressure transducer.
Outrigger can still be
• GCON ECM.
retracted.
Right front outrigger
• Short circuit in the right front outrigger sensor
inhibited if outrigger
F018: F018:SENSORFAULT Short circuit of the Right Front Outrigger circuit.
extend is activated.
GS-3232 RF RIGGER:BAT+ Sensor circuit to battery positive. • Faulty pressure transducer.
Outrigger can still be
• GCON ECM.
retracted.
Right front outrigger
• Short circuit in the right front outrigger sensor
inhibited if outrigger
F019: F019:SENSORFAULT Short circuit of the Right Front Outrigger circuit.
extend is activated.
GS-3232 RF RIGGER:BAT- Sensor circuit to battery negative. • Faulty pressure transducer.
Outrigger can still be
• GCON ECM.
retracted.
Left rear outrigger
• Short circuit in the left rear outrigger sensor
inhibited if outrigger
F020: F020:SENSORFAULT Short circuit of the Left Rear Outrigger circuit.
extend is activated.
GS-3232 LR RIGGER:BAT+ Sensor circuit to battery positive. • Faulty pressure transducer.
Outrigger can still be
• GCON ECM.
retracted.
Left rear outrigger
• Short circuit in the left rear outrigger sensor
inhibited if outrigger
F021: F021:SENSORFAULT Short circuit of the Left Rear Outrigger circuit.
extend is activated.
GS-3232 LR RIGGER:BAT- Sensor circuit to battery negative. • Faulty pressure transducer.
Outrigger can still be
• GCON ECM.
retracted.
Right rear outrigger
• Short circuit in the right rear outrigger sensor
inhibited if outrigger
F022: F022:SENSORFAULT Short circuit of the Right Rear Outrigger circuit.
extend is activated.
GS-3232 RR RIGGER:BAT+ Sensor circuit to battery positive. • Faulty pressure transducer.
Outrigger can still be
• GCON ECM.
retracted.

190 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Type "FXXX" Faults

Type "FXXX" Faults, continued


DTC Message on
Description Possible Causes Failure Mode
Number GCON LCD
Right rear outrigger
• Short circuit in the right rear outrigger sensor
inhibited if outrigger
F023: F023:SENSORFAULT Short circuit of the Right Rear Outrigger circuit.
extend is activated.
GS-3232 RR RIGGER:BAT- Sensor circuit to battery negative. • Faulty pressure transducer.
Outrigger can still be
• GCON ECM.
retracted.
F034:
GS30, • Height sensor needs calibration for stowed
F034:SENSORFAULT Height Sensor settings are not calibrated
GS32, height and maximum height settings. All functions inhibited.
OVLD:PLAT HEIGHT correctly.
GS46 & • GCON or PCON ECM.
GS47
F035:
GS30, • Height sensor not calibrated for stowed height
F035:SENSORFAULT Height Sensor setting is lower than calibrated
GS32, correctly. All functions inhibited.
OVLD RANGE:LOW stowed height.
GS46 & • GCON or PCON ECM.
GS47
F036:
GS30, • Height sensor not calibrated for maximum height
F036:SENSORFAULT Height Sensor setting is higher than
GS32, correctly. All functions inhibited.
OVLD RANGE:HI calibrated maximum height.
GS46 & • GCON or PCON ECM.
GS47
• Faulty extension deck limit switch.
F072: F072:SENSORFAULT
Function Cutout sensor B+ fault. • Faulty gate proximity switch. All functions inhibited.
GS-2646AV FUNCTION CUT B+
• GCON ECM.
F073: F073:SENSORFAULT • Short circuit in deck sensor input circuit.
Power Deck sensor B+ fault. All functions inhibited.
GS-2646AV DECK SENSOR B+ • GCON ECM.
F129:
GS30,
UTS mismatch fault. Two accelerometers
GS32, F129:TILT SENSOR FAULT • Faulty UTS. All functions inhibited.
inside UTS mismatch.(universal tilt sensor)
GS46 &
GS47

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 191


Service and Repair Manual January 2019

Type "CXXX" Faults

Type "CXXX" Faults


DTC Message on Description
Possible Causes Failure Mode
Number GCON LCD
C001:
GS30,
C001:GCON ECM • Incorrect software file. All functions
GS32, GCON ECM CRC check error.
FAULT TYPE 1 • GCON ECM internal failure. inhibited.
GS46 &
GS47
C004:
GS30,
C004:GCON ECM • Short circuit in the master switch circuit. All functions
GS32, GCON ECM master switch error.
FAULT TYPE 4 • GCON ECM. inhibited.
GS46 &
GS47
C005:
GS30,
C005:GCOM ECM • Short circuit in the safety switch circuit. All functions
GS32, GCON ECM safety switch error.
FAULT TYPE 5 • GCON ECM. inhibited.
GS46 &
GS47
C006:
GS30,
C006:GCON ECM • Input conditioning circuit failure. All functions
GS32, GCON input redundancy error.
FAULT TYPE 6 • GCON ECM. inhibited.
GS46 &
GS47
C007:
GS30, • Incorrectly programmed device.
C007:GCON ECM GCON ECM inter-processor communication All functions
GS32, • Error in loading software on device.
FAULT TYPE 7 error. inhibited.
GS46 & • GCON ECM.
GS47
C009:
GS30;
C009:GCON ECM FAULT All functions
GS32' GCON fault type 9. • Contact Genie support.
FAULT TYPE 9 inhibited.
GS46 &
GS47
C010:
GS30, • Incorrectly programmed device.
C010:SECONDARY GCON secondary processor not All functions
GS32, • Error in loading software on device.
NOT PROGRAMMED programmed. inhibited.
GS46 & • GCON ECM.
GS47
C021:
GS30, • PCON disconnected.
C021:PCON NOT All functions
GS32, PCON not detected error. • CAN communication failure.
DETECTED inhibited.
GS46 & • GCON or PCON ECM.
GS47
C023:
GS30,
C023:MACHINE Discrepancy between model detected and • Incorrect machine model programmed. All functions
GS32,
MODEL FAULT model programmed. • GCON or PCON ECM. inhibited.
GS46 &
GS47
C025:
GS30,
C025:SYSTEMFAULT • Platform overload system not calibrated. All functions
GS32, Platform overload system not calibrated.
PLAT OVLD:NOCAL • GCON or PCON ECM. inhibited.
GS46 &
GS47

192 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Type "CXXX" Faults

Type "CXXX" Faults


DTC Message on Description
Possible Causes Failure Mode
Number GCON LCD
All functions inhibited
except for down
function and up
function.
C028:
Platform can be
GS30,
C028:SERVICE • Machine programmed for use in service override elevated only once
GS32, Machine is in service override mode.
OVERRIDE MODE ON mode. with the maximum
GS46 &
elevate time of XX
GS47
seconds.
Elevate time XX
depends on machine
model.
All functions operate.
C029: C029:SYSTEMFAULT • Outrigger not calibrated.
Outrigger not calibrated. Will not lift above the
GS-3232 O/R SENSOR:NOCAL • GCON ECM.
down limit switch.
C053:
GS30,
C053:PCON-GCOM Software revisions do not match between the • Short circuit in the safety switch circuit. All functions
GS32,
SOFTWARE MISMATCH PCON and GCON. • GCON ECM. inhibited.
GS46 &
GS47
Performance
C055
C055 DCON ECM Fault Type 01 Hardware failur of drive controller DCON ECM reduced or all
functions inhibited.
• Drive input active at system startup
Performance
C056 Setup initialization failure of the drive • Faulty drive joystick
C056 DCON ECM Fault Type 02 reduced or all
controller at system startup • Incorrect software D14
functions inhibited.
• DCON ECM
• Battery charger connected
C058 All functions
C058 DCON ECM Fault Type 04 Drive controller voltage out of range • Batteries too low
inhibited.
• DCON ECM
C059 • Open on B+ or B- to the drive contoller All functions
C059 DCON ECM Fault Type 05 Capacitor charge failure of the drive controller
• DCON ECM inhibited.
• Open circuit of the motor controller harness
Open circuit of the key switch circuit or
C061 • Open circuit to the B+ and/or B- All functions
C061 DCON ECM Fault Type 07 battery positive / negative of the drive
• Key switch relay power not closed inhibited.
controller
• DCON or GCON ECM
C063 Communication error of the CAN circuit • Open circuit of the motor controller harness All functions
C063 DCON ECM Fault Type 09
between the GCON and the motor controller • DCON or GCON ECM inhibited.
C064 Output error of the thermal sensor circuit of All functions
C064 DCON ECM Fault Type 10 DCON ECM
the motor controller inhibited.

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.

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 193


Service and Repair Manual January 2019

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.

Solid red - Internal fault condition. Type "F" fault code.

Flashing amber - External fault condition. Type "E" error code.

Flashing green - USB interface is active.

Solid green - Firmware update is complete. Remove USB from charger.


Codes are displayed as F, E or P and followed by three numbers and a period (example: E-0-0-4). The
charger can display multiple codes.
If the batteries are changed from one type to another, (example: flooded lead acid to AGM), the charger
profile must be programmed. Refer to Repair Procedure, Programming the Charger Profile.

194 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Battery Charger

Charger status indicators

Remote charger status indicators


1 Error / Fault indicator
2 Charger display
3 Error / Fault
Char ger Fault C odes

Charger Fault Codes


Fault Code Description Possible Causes Solution
DC-DC failure: LLC excessive leakage
F-0-0-1
fault.
F-0-0-2 PFC failure: PFC excessive leakage fault. Disconnect AC input and battery
pack for 30 seconds.
F-0-0-3 PFC taken too long to boost. Internal charger fault.
If fault does not clear, contact
F-0-0-4 Charger unable to calibrate current offset. Genie Product Support.
Output relay voltage too high when
F-0-0-5
closed.

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 195


Service and Repair Manual January 2019

Battery Charger
Char ger Error C odes

Charger Error Codes


Error Code Description Condition Possible Causes
E-0-0-1 High battery voltage Battery voltage too high to charge. Check battery voltage and cable
connections.
Self clearing when condition has
been corrected.
E-0-0-2 Low battery voltage detected prior to Battery voltage too low to charge. Check battery voltage and cable
starting charge cycle connections.
Check battery condition.
Self clearing when condition has
been corrected.
E-0-0-3 Charge timeout Charge timeout caused by battery Charge output reduced due to
pack not reaching required voltage high temperature. Charge at
within safe time limit. lower temperature.
Check battery condition.
Replace damaged battery.
Check battery connections.
Battery pack deep discharge.
Disconnect battery pack for
30 seconds to clear fault when
condition has been corrected.
E-0-0-4 Defective battery Battery pack could not be trickle Check battery condition.
charged up to the minimum voltage. Replace damaged battery.
Check battery connections.
Disconnect battery pack for
30 seconds to clear fault when
condition has been corrected.
E-0-0-7 Amp hour limit exceeded Safety limit exceeded. Check battery condition.
Replace damaged battery.
Check battery connections.
Battery pack deep discharge.
High parasitic loads on battery
pack while charging.
Disconnect parasitic loads.
Disconnect battery pack for
30 seconds to clear fault when
condition has been corrected.

196 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Battery Charger

Charger Error Codes


Error Code Description Condition Possible Causes
E-0-0-8 Battery temperature out of range Battery temperature sensor. Check temperature sensor and
electrical connections.
Rest charger. Disconnect AC
power for 30 seconds.
Self clearing when condition has
been corrected.
E-0-1-1 Charger disabled by external command Battery pack not being charged.. Power outage.
AC power disconnected before
charging complete.
E-0-1-2 Reverse polarity Battery connected incorrectly. Check battery connections.
Self clearing when condition has
been corrected.
E-0-1-3 Battery does not take current Battery voltage is detected, but Incorrect profile for battery type.
charger is unable to charge the Installed from a different machine
battery pack.. with different battery type.
Disconnect battery pack for
30 seconds to clear fault when
condition has been corrected.
E-0-1-6 Software update failed Software update failed. Confirm USB Flash Drive is
formatted with correct software.
If software update continues to
fail, contact Genie Product
support.
E-0-1-7 USB error USB not connected correctly. Remove and re-insert USB Flash
Drive.
Disconnect AC input and battery
pack for 30 seconds.
E-0-1-8 Slot CRC error Software update failed. Confirm USB Flash Drive is
formatted with correct software.
If software update continues to
fail, contact Genie Product
support.
E-0-1-9 Hardware does not support software Charger hardware does not support Confirm USB Flash Drive is
software version being programmed. formatted with correct software.
If software update continues to
fail, contact Genie Product
support.
E-0-2-0 No algorithm selected Charger profile not programmed. Program the charger for the
proper battery profile.

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Service and Repair Manual January 2019

Battery Charger

Charger Error Codes


Error Code Description Condition Possible Causes
E-0-2-1 High battery voltage detected while Battery voltage too high as Check battery voltage and cable
charging detected by charger profile. connections.
Confirm charger profile is
programmed for correct battery
type.
Self clearing when condition has
been corrected.
E-0-2-2 Low battery voltage detected while Battery voltage too low as detected Check battery voltage and cable
charging by charger profile. connections.
Confirm charger profile is
programmed for correct battery
type.
Self clearing when condition has
been corrected.
E-0-2-3 High AC voltage AC voltage greater than 270 VAC. Connect to a stable AC source
between 85 - 270 VAC / 45 - 65 Hz.
Self clearing when condition has
been corrected.
E-0-2-4 Failure to initialize Charger failed to turn on correctly. Disconnect AC input and battery
pack for 30 seconds.
Contact Genie Product Support.
E-0-2-5 Low AC voltage oscillation AC voltage unstable. Connect to a stable AC source
between 85 - 270 VAC / 45 - 65 Hz.
Using an undersized generator.
Self clearing when condition has
been corrected.
E-0-2-6 Script failure Software update failed. Confirm USB Flash Drive is
formatted with correct software.
If software update continues to fail,
contact Genie Product support.
E-0-2-7 USB over current fault USB over current protection has Remove and re-insert USB Flash
been tripped. Drive.
Use different USB Flash drive.
E-0-2-8 Charge profile incompatibility Selected charger profile is not Update charger software.
compatible with charger software. Confirm charger profile is
programmed for correctly.
Updating current firmware and
error occurs, contact Genie
Product Support.

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Battery Charger

Charger Error Codes


Error Code Description Condition Possible Causes
E-0-2-9 CAN Bus error CAN Bus network error. Check CAN Bus connections.
CAN modules not functioning
correctly.
Termination resistance is ~60 ohms.
E-0-3-0 COMM battery module error CAN Bus battery module error. CAN Buss battery module not
functioning correctly.
E-0-3-1 Vref for ADC measurements triggered Internal charger error. Disconnect AC input and battery
alarm pack for 30 seconds.
Contact Genie Product Support.
E-0-3-2 CAN Bus heartbeat error CAN Bus heartbeat error. CAN Bus devices not functioning
correctly.
E-0-3-6 Battery temperature sensor charge profile Battery temperature sensor is Check battery temperature sensor
required by charger profile but is connections.
not installed. Check charger profile and confirm
battery temperature sensor is
installed.
E-0-3-8 CAN Open Error CAN Open reprogramming failed. Download CAN Open software.
Reprogram charger using USB
Flash Drive.

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Service and Repair Manual January 2019

Schematics

About This Section


Section 5 Schem atics

There are two groups of schematics in this section.

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.

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Electrical Component and Wire Color Legends

ELECTRICAL COMPONENT LEGEND ELECTRICAL COMPONENT LEGEND cont.


Item Description Item Description
B5 Batteries C Connector
B5 = Battery Pack 24V DC, 4 each @ 6V DC (all C37 = Left Rear Outrigger Pressure Transducer
machines except GS-4047) (GS-3232)
B10 = Battery Pack 24 V DC Wired in Parallel, C38 = Right Rear Outrigger Pressure Transducer
4 each @ 12 V DC (GS-4047) (GS-3232)
C Connector C39 = Outrigger Sensor Power (GS-3232)
C40 = Up Limit Switch (GS-3232)
C1 = Anderson Connector C41 = Platform Control Bus
C2 = PCON Cable Connector C43 = Key Switch, Platform Mode
C3 = PCON Coil Cord Connector C44 = Key Switch, Emergency Stop
C4 = Power Control (J1) C45 = Automotive Style Horn +
C5 = Sensors & Switches (J3) C46 = Emergency Stop
C6 = Function Manifold (J2) C47 = GCON Alarm +
C7 = Sensor Power Bus C48 = Circuit Breaker, MTR V+
C8 = Sensor Ground Bus C49 = Emergency Stop, ECM Driver V+
C9 = Pot Hole Limit Switch C50 = Circuit Breaker, ECM Driver V+
C10 = Down Limit Switch C51 = Key Switch, Ground Mode
C11 = Level Sensor C52 = GCON Alarm -
C12 = Function Manifold Ground Bus C53 = Automotive Style Horn -
C13 = Drive Reverse Coil C70 = Platform Down Coil + (GS-3232 &
C14 = Drive Forward Coil GS-3246)
C15 = Steer Right Coil C71 = Platform Down Coil - (GS-3232 & GS-3246)
C16 = Steer Left Coil C84 = Lift Pressure Selector Coil (GS-4047)
C17 = Platform Up Coil
C18 = Platform Down Coil CB2 Circuit Breaker, 7A
C19 = Load Sense Cable E Enclosure
C20 = Platform Height Cable
C21 = Load Sense Ground Cable EN1 = Platform Control Box
C22 = Parallel Coil EN4 = AC Outlet Box
C23 = Platform Height Sensor
C24 = Platform Overload Transducer FB Flashing Beacon (option)
C25 = Outrigger (J4) (GS-3232) FS1 Foot Switch (option)
C26 = Outrigger Retract Coil (GS-3232)
C27 = Outrigger Extend Coil (GS-3232) GND Ground Stud
C28 = Right Rear Outrigger Coil (GS-3232) H Horn or Alarm
C29 = Left Rear Outrigger Coil (GS-3232)
C30 = Right Front Outrigger Coil (GS-3232) H1 = Horn or Alarm
C31 = Left Front Outrigger Coil (GS-3232) H2 = Automotive Style Horn (option)
C32 = Outrigger Manifold Ground Bus (GS-332) H5 = Multifunction Alarm
C33 = Outrigger Sensor Power Bus (GS-3232) J Connector Plug
C34 = Outrigger Level Sensor Ground Bus
(GS-3232) J1 = Power Control (U5)
C35 = Left Front Outrigger Pressure Transducer J2 = Function Manifold (U5)
(GS-3232) J3 = Sensors & Switches (U5)
C36 = Right Front Outrigger Pressure Transducer J4 = Outriggers (U5) GS-3232)
(GS-3232) J5 = PCON Coil Cord to Platform Controls PC
Board
J6 = PCON Emergency Stop & Alarm to Platform
Controls PC Board
J7 = Joystick to Platform Controls PC Board

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 201


Service and Repair Manual January 2019

Electrical Component and Wire Color Legends

ELECTRICAL COMPONENT LEGEND cont. WIRE COLOR LEGEND


Item Description Color Description
JC9 Joystick Controller BK Black
K1 Contactor, Motor Controller Power, N.O.H.C. BK/RD Black/Red
KS1 Key Switch
BL Blue
LS Limit Switch
BL/BK Blue/Black
LS1 = Maximum Drive Height (GS-3232)
LS6 = Platform Down BL/OR Blue/Orange
LS7 = Pothole BL/WH Blue/White
LS8 = Pothole
LS10 = Maximum Drive Height (GS-3232) BR Brown
M5 Hydraulic Power Unit GR Green
N.C. Normally Closed GR/BK Green/Black
N.C.H.O Normally Closed Held Open GR/WH Green/White
N.O.H.C. Normally Open Held Closed
GR/YL Green/Yellow
P Power Switch
LB Light Blue
P1 = Emergency Stop Button at Ground Controls
P2 = Emergency Stop Button at Platform Controls OR Orange
PT Pressure Transducer OR/BK Orange/Black
PT1 = Left Front Outrigger (GS-3232) OR/RD Orange/Red
PT2 = Right Front Outrigger (GS-3232)
PT3 = Left Rear Outrigger (GS-3232)
OR/WH Orange/White
PT4 = Right Rear Outrigger (GS-3232) RD Red
PT15 = Platform Overload (option)
RD/BK Red/Black
R30 Resistor, 20 Ohm, 10W
RD/WH Red/White
S Sensor
S7 = Level Sensor
WH White
S8 = Outrigger Level Sensor (GS-3232) WH/BK White/Black
S14 = Platform Height Sensor
YL Yellow
U Electronic Component
U3 = PCON Printed Circuit Board
U5 = Electronic Control Module
U6 = Motor Controller
U9 = Battery Charger
U13 = Voltage Inverter (option)
Y Valve Coil
Y1 = Parallel (GS-32, GS-46 & GS47 models)
Y2 = Lift Pressure Selector (GS-4047)
Y3 = Steer Right
Y4 = Steer Left
Y5 = Drive Reverse
Y6 = Drive Forward
Y7 = Platform Down
Y8 = Platform Up
Y9 = Platform Down GS-3232 & GS-3246)
Y33 = Left Rear Outrigger (GS-3232)
Y34 = Right Rear Outrigger (GS-3232)
Y35 = Left Front Outrigger (GS-3232)
Y36 = Right Front Outrigger (GS-3232)
Y39 = Outrigger Retract (GS-3232)
Y40 = Outrigger Extend (GS-3232)

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January 2019 Service and Repair Manual

Wiring Diagram Ground and Platform Controls

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 203


Service and Repair Manual January 2019

Limit Switch Legend

Limit Switch Legend


a down limit switch LS6
b pothole limit switches LS7, LS8
c 22ft / 6.7 m maximum drive height when outriggers are not deployed (LS1, LS10 GS-3232)

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January 2019 Service and Repair Manual

Electrical Symbol Legend

Wire with description or color Limit Switch Motor controller Key switch

Circuits crossing no connection Emergency Stop button Motor Solenoid valve with diode

Diode Circuit breaker Battery charger Level sensor

Circuit connection Fuse 6V or 12V DC battery Deutsch connector

Resistor Contactor Horn or alarm Flashing beacon

Platform height sensor Pressure transducer

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 205


Service and Repair Manual January 2019

Hydraulic Symbols Legend

Hydraulic cylinder Variable speed motor Pressure transducer Solenoid operated


2 position 4 way
directional valve

Relief valve Bi-directional motor Solenoid operated Solenoid operated


2 position 2 way 2 position 4 way
blocking valve directional valve
normally open

Priority flow regulator Brake Solenoid operated Proportional solenoid operated


2 position 2 way valve 2 position 2 way directional valve
normally closed normally closed

Accumulator Check valve Solenoid operated Solenoid operated


2 position 2 way 3 position 5 way
directional valve directional valve
normally closed

Fixed displacement Shuttle valve Solenoid operated 3 position Solenoid operated 3 position 4 way
pump 4 way directional valve directional valve

Filter Orifice with size

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January 2019 Service and Repair Manual

Schematics

Hydraulic Component Reference Legend

Function manifold Function manifold Function manifold


GS-2032, GS-2632, GS-3232, GS-2046, GS-1530, GS-1532, GS-1330m
GS-2646 and GS-3246 GS-1930 and GS-1932

Function manifold Lift Pressure Selector Brake Release Manifold


GS-4047 Manifold All models except GS-1330m
GS-4047

Outrigger manifold Front Outrigger Cylinder Rear Outrigger Cylinder


GS-3232 GS-3232 GS-3232

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This page intentionally left blank.

208 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Hydraulic Component Abbreviation Legend

Item Description Item Description


A Test port BA 3 position, 4 way directional valve – outrigger cylinder
extend/retract
B Check valve, steer circuit
BB Relief valve, outrigger circuit
C Relief valve, lift
CA Right front outrigger extend/retract
D Check valve, drive circuit
CB Left front outrigger extend/retract
E Drive forward/reverse
CC Right rear outrigger extend/retract
F Steer left/right
CD Left rear outrigger extend/retract
G Flow regulator/relief valve
CE Orifice plug – outrigger retract
H Platform up
CF Check valve, pilot operated
I Relief valve, system
CG Pressure transducer
L Hand pump, manual brake release
DA Test port
M Needle valve, manual brake release
DB Relief valve, system
N Platform lowering valve
DC Steer left/right
O Orifice, platform down circuit
DD Check valve steer circuit
P Accumulator
DE Drive speed
Q Relief valve, platform down
DF Relief valve, brake release
R Pressure transducer, platform overload (CE only)
DG Drive forward/reverse
S Check valve, drive circuit
DH Flow regulator/relief valve
AA Test Port
DI Platform up
AB Relief valve, system
DJ Relief valve, lift
AC Steer left/right
DK Check valve, upper cylinder
AD Check dics, steer circuit
DL Check valve, lower cylinder
AE Drive speed
DM Relief valve, lift
AF Relief valve, brake circuit
DN Lift circuit
AG Drive forward/reverse
DO Platform lowering valve
AH Flow regulator/relive valve
EA Steer lift/right
AI Platform up
EB Relief valve steer
AJ Relief valve, lift
EC Platform up
AK Check valve, lift (GS-3232 and GS-3246 equipped with
load sense only) ED Relief valve system
EE Test port

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Service and Repair Manual January 2019

Hydraulic Schematics

Hydraulic Schematic, GS-1330m


(from serial number GS30MD-101)

210 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Hydraulic Schematics

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


(from serial number GS3010A-110000, GS3011C-10000, GS3014D-101, GS3016P-142281)

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 211


Service and Repair Manual January 2019

Hydraulic Schematics

Hydraulic Schematic, GS-2032 / 2632 / 3232 (from serial number GS3211A-110000 to


GS3214A-119070, GS3212C-10000 to GS3214C-11873)
GS-2046 / 2646 / 3246 (from serial number GS4612A-110000 to GS4614A-117177,
GS4614C-10000 to GS4614C-12073)

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January 2019 Service and Repair Manual

Hydraulic Schematics

Hydraulic Schematic, GS-2032 / 2632 / 3232


(from serial number GS3214A-119071, GS3214C-11874)
GS-2046 / 2646 / 3246
(from serial number GS4614A-117178, GS4614C-12074, GS4614D-101)

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 213


Service and Repair Manual January 2019

Hydraulic Schematics

Hydraulic Schematic, GS-3232


(from serial number GS3211A-110000, GS3212C-10000, GS3216P-142677)

214 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Hydraulic Schematics

Hydraulic Schematic, GS-4047


(from serial number GS4712C-101 to GS4714C-1459)

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 215


Service and Repair Manual January 2019

Hydraulic Schematics

Hydraulic Schematic, GS-4047


(from serial number GS4714C-1460, GS4714D-101, GS4716P-101)

216 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Electrical Schematic, GS-1330m, ANSI / CSA


(from serial number GS30MD-101)

217
Service and Repair Manual January 2019

Electrical Schematic, GS-1330m, ANSI / CSA


(from serial number GS30MD-101)

218 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Electrical Schematic, GS-1530 / GS-1930, ANSI / CSA


(from serial number GS3010A-110000 to GS3011A-110827)

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 219


Service and Repair Manual January 2019

Electrical Schematic, GS-1530 / GS-1930, ANSI / CSA


(from serial number GS3010A-110000 to GS3011A-110827)

220 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Electrical Schematic, GS-1530 / GS-1930, ANSI / CSA


(from serial number GS3010A-110000 to GS3011A-110827)

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 221


Service and Repair Manual January 2019

Electrical Schematic, GS-1530 / GS-1930, ANSI / CSA


(from serial number GS3010A-110000 to GS3011A-110827)

222
January 2019 Service and Repair Manual

Electrical Schematic, GS-1530 / GS-1930, ANSI / CSA


(from serial numbers GS3011A-110828 to GS3014A-136972, GS3014D-101 to GS3015D-1113)

223
Service and Repair Manual January 2019

Electrical Schematic, GS-1530 / GS-1930, ANSI / CSA


(from serial numbers GS3011A-110828 to GS3014A-136972, GS3014D-101 to GS3015D-1113)

224 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Electrical Schematic, GS-1530 / GS-1930, ANSI / CSA


(from serial numbers GS3011A-110828 to GS3014A-136972, GS3014D-101 to GS3015D-1113)

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 225


Service and Repair Manual January 2019

Electrical Schematic, GS-1530 / GS-1930, ANSI / CSA


(from serial numbers GS3011A-110828 to GS3014A-136972, GS3014D-101 to GS3015D-1113)

226
January 2019 Service and Repair Manual

Electrical Schematic, GS-1530 / GS-1930, ANSI / CSA


(from serial numbers GS3014A-136973, GS3015D-1114 to GS3016D-5426,
GS3016P-142281 to GS3016P-158208)

227
Service and Repair Manual January 2019

Electrical Schematic, GS-1530 / GS-1930, ANSI / CSA


(from serial numbers GS3014A-136973, GS3015D-1114 to GS3016D-5426,
GS3016P-142281 to GS3016P-158208)

228 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Electrical Schematic, GS-1530 / GS-1930, ANSI / CSA


(from serial numbers GS3014A-136973, GS3015D-1114 to GS3016D-5426,
GS3016P-142281 to GS3016P-158208)

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 229


Service and Repair Manual January 2019

Electrical Schematic, GS-1530 / GS-1930, ANSI / CSA


(from serial numbers GS3014A-136973, GS3015D-1114 to GS3016D-5426,
GS3016P-142281 to GS3016P-158208)

230
January 2019 Service and Repair Manual

Electrical Schematic, GS-1530, GS-1930 ANSI / CSA


(from serial numbers GS3016D-5427, GS301P-158209)

231
Service and Repair Manual January 2019

Electrical Schematic, GS-1530 / GS-1930, ANSI / CSA


(from serial numbers GS3016D-5427, GS3016P-158209)

232 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Electrical Schematic, GS-3232, ANSI / CSA


(from serial number GS3211A-110000 to GS3214A-135714)

233
Service and Repair Manual January 2019

Electrical Schematic, GS-3232, ANSI / CSA


(from serial number GS3211A-110000 to GS3214A-135714)

234 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Electrical Schematic, GS-3232, ANSI / CSA


(from serial number GS3211A-110000 to GS3214A-135714)

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 235


Service and Repair Manual January 2019

Electrical Schematic, GS-3232, ANSI / CSA


(from serial number GS3211A-110000 to GS3214A-135714)

236
January 2019 Service and Repair Manual

Electrical Schematic, GS-3232, ANSI / CSA


(from serial number GS3214A-135715 to GS3215A-141898)

237
Service and Repair Manual January 2019

Electrical Schematic, GS-3232, ANSI / CSA


(from serial number GS3214A-135715 to GS3215A-141898)

238 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Electrical Schematic, GS-3232, ANSI / CSA


(from serial number GS3214A-135715 to GS3215A-141898)

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 239


Service and Repair Manual January 2019

Electrical Schematic, GS-3232, ANSI / CSA


(from serial number GS3214A-135715 to GS3215A-141898)

240
January 2019 Service and Repair Manual

Electrical Schematic, GS-3232, ANSI / CSA


(from serial numbers GS3215A-141899, GS3216P-142677 to GS3216P-146462)

241
Service and Repair Manual January 2019

Electrical Schematic, GS-3232, ANSI / CSA


(from serial numbers GS3215A-141899, GS3216P-142677 to GS3216P-146462)

242 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Electrical Schematic, GS-3232, ANSI / CSA


(from serial numbers GS3215A-141899, GS3216P-142677 to GS3216P-146462)

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 243


Service and Repair Manual January 2019

Electrical Schematic, GS-3232, ANSI / CSA


(from serial numbers GS3215A-141899, GS3216P-142677 to GS3216P-146462)

244
January 2019 Service and Repair Manual

Electrical Schematic, GS-3232, ANSI / CSA


(from serial number GS3216P-146463)

245
Service and Repair Manual January 2019

Electrical Schematic, GS-3232, ANSI / CSA


(from serial numbers GS3216P-146463)

246 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Electrical Schematic, GS-3232, ANSI / CSA


(from serial number GS3216P-146463)

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 247


Service and Repair Manual January 2019

Electrical Schematic, GS-3232, ANSI / CSA


(from serial number GS3216P-146463)

248
January 2019 Service and Repair Manual

Electrical Schematic, GS-2032, 2632, 2046, 2646, ANSI / CSA


(from serial numbers GS3211A-110000 to GS3214A-135714,
GS4612A-110000 to GS4614A-135366, GS4613D-101 to GS4615D-1303)

249
Service and Repair Manual January 2019

Electrical Schematic, GS-2032, 2632, 2046, 2646, ANSI / CSA


(from serial numbers GS3211A-110000 to GS3214A-135714,
GS4612A-110000 to GS4614A-135366, GS4613D-101 to GS4615D-1303)

250 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Electrical Schematic, GS-2032, 2632, 2046, 2646, ANSI / CSA


(from serial numbers GS3211-110000 to GS3214A-135714,
GS4612A-110000 to GS4614A-135366, GS4613D-101 to GS4615D-1303)

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 251


Service and Repair Manual January 2019

Electrical Schematic, GS-2032, 2632, 2046, 2646, ANSI / CSA


(from serial numbers GS3211A-110000 to GS3214A-135714,
GS4612A-110000 to GS4614A-135366, GS4613D-101 to GS4615D-1303)

252
January 2019 Service and Repair Manual

Electrical Schematic, GS-2032, 2632, 2046, 2646, ANSI / CSA


(from serial numbers GS3214A-135715 to GS3215A-141898,
GS4614A-135367 to GS4615A-137959, GS4615D-1304)

253
Service and Repair Manual January 2019

Electrical Schematic, GS-2032, GS-2632, 2046, 2646, ANSI / CSA


(from serial numbers GS3214A-135715 to GS3215A-141898,
GS4614A-135367 to GS4615A-137959, GS4615D-1304)

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January 2019 Service and Repair Manual

Electrical Schematic, GS-2032, 2632, 2046, 2646, ANSI / CSA


(from serial numbers GS3214A-1135715 to GS3215A-1141898,
GS4614A-135367 to GS4615A-137959, GS4615D-1304)

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 255


Service and Repair Manual January 2019

Electrical Schematic, GS-2032, 2632, 2046, 2646, ANSI / CSA


(from serial numbers GS3214A-135715 to GS3215A-141898,
GS4614A-135367 to GS4615A-137959, GS4615D-1304)

256
January 2019 Service and Repair Manual

Electrical Schematic, GS-2032, 2632, 2046, 2646, ANSI / CSA


(from serial numbers GS3215A-141899, GS3216P-142676 to GS3216P-146462,
GS4615A-137960, GS4615D-1305 to GS4616D-4432, GS4616P-138362 to GS4616P-139710)

257
Service and Repair Manual January 2019

Electrical Schematic, GS-2032, 2632, 2046, 2646, ANSI / CSA


(from serial numbers GS3215A-141899, GS3216P-142676 to GS3216P-146462,
GS4615A-137960, GS4615D-1305 to GS4616D-4432, GS4616P-138362 to GS4616P-139710)

258 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Electrical Schematic, GS-2032, 2632, 2046, 2646, ANSI / CSA


(from serial numbers GS3215A-141899, GS3216P-142676 to GS3216P-146462,
GS4615A-137960, GS4615D-1305 to GS4616D-4432, GS4616P-138362 to GS4616P-139710)

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 259


Service and Repair Manual January 2019

Electrical Schematic, GS-2032, 2632, 2046, 2646, ANSI / CSA


(from serial numbers GS3215A-14189, GS3216P-142676 to GS3216P-146462,
GS4615A-137960, GS4615D-1305 to GS4616D-4432, GS4616P-138362 to GS4616P-139710)

260
January 2019 Service and Repair Manual

Electrical Schematic, GS-2032, 2632, 2046, 2646, ANSI / CSA


(from serial numbers, GS3216P-146463, GS4616D-4433, GS4616P-139711)

261
Service and Repair Manual January 2019

Electrical Schematic, GS-2032, 2632, 2046, 2646, ANSI / CSA


(from serial numbers GS3216P-146463, GS4616D-4433, GS4616P-139711)

262 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Electrical Schematic, GS-3246 / GS-4047, ANSI / CSA


(from serial numbers GS4612A-110000 to GS4614A-135366, GS4614D-101 to GS4615D-1303,
GS4714D-101 to GS4715D-749)

263
Service and Repair Manual January 2019

Electrical Schematic, GS-3246 / GS-4047, ANSI / CSA


(from serial numbers GS4612A-110000 to GS4614A-135366, GS4614D-101 to GS4615D-1303,
GS4714D-101 to GS4715D-749)

264 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Electrical Schematic, GS-3246 / GS-4047, ANSI / CSA


(from serial numbers GS4621A-110000 to GS4614A-135366, GS4614D-101 to GS4615D-1303,
GS4714D-101 to GS4715D-749)

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 265


Service and Repair Manual January 2019

Electrical Schematic, GS-3246 / GS-4047, ANSI / CSA


(from serial numbers GS4612A-110000 to GS4614A-135366, GS4614D-101 to GS4615D-1303,
GS4714D-101 to GS4715D-749)

266
January 2019 Service and Repair Manual

Electrical Schematic, GS-3246 / GS-4047, ANSI / CSA


(from serial numbers GS4614A-135367 to GS4615A-137959, GS4615D-1304 to GS4616D-4432,
GS4616P-138362 to GS4616P-139710, GS4715D-750 to GS4716D-3101)

267
Service and Repair Manual January 2019

Electrical Schematic, GS-3246 / GS-4047, ANSI / CSA


(from serial numbers GS4614A-135367 to GS4615A-137959, GS4615D-1304 to GS4616D-4432,
GS4616P-138362 to GS4616P-139710, GS4715D-750 to GS4716D-3101)

268 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Electrical Schematic, GS-3246 / GS-4047, ANSI / CSA


(from serial numbers GS4614A-135367 to GS4615A-137959, GS4615D-1304 to GS4616D-4432,
GS4616P-138362 to GS4616P-139710, GS4715D-750 to GS4716D-3101)

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 269


Service and Repair Manual January 2019

Electrical Schematic, GS-3246 / GS-4047, ANSI / CSA


(from serial numbers GS4614A-135367 to GS4615A-137959, GS4615D-1304 to GS4616D-4432,
GS4616P-138362 to GS4616P-139710, GS4715D-750 to GS4716D-3101)

270
January 2019 Service and Repair Manual

Electrical Schematic, GS-3246, GS-4047 ANSI / CSA


(from serial numbers GS4616D-4433, GS4616P-139711, GS4716D-3102, GS4716P-101)

271
Service and Repair Manual January 2019

Electrical Schematic, GS-3246, GS-4047 ANSI / CSA


(from serial numbers GS4616D-4433, GS4616P-139711, GS4716D-3102, GS4716P-101)

272 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Electrical Schematic, GS-1330m, AS/CE


(from serial number GS30MD-101)

273
Service and Repair Manual January 2019

Electrical Schematic, GS-1330m, AS/CE


(from serial number GS30MD-101)

274 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Electrical Schematic, GS-1530, 1532, 1930, 1932, AS / CE


(from serial number GS3010A-110000 to GS3011A-110827)

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 275


Service and Repair Manual January 2019

Electrical Schematic, GS-1530, 1532, 1930, 1932, AS / CE


(from serial number GS3010A-110000 to GS3011A-110827)

276 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Electrical Schematic, GS-1530, 1532, 1930, 1932, AS / CE


(from serial number GS3010A-110000 to GS3011A-110827)

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 277


Service and Repair Manual January 2019

Electrical Schematic, GS-1530, 1532, 1930, 1932, AS / CE


(from serial number GS3010A-110000 to GS3011A-110827)

278
January 2019 Service and Repair Manual

Electrical Schematic, GS-1530, 1530, 1930, 1932, AS / CE


(from serial numbers GS3011A-110828 to GS3014A-136972,
GS3011C-10000 to GS3015C-18038, GS3014D-101 to GS3015D-1113)

279
Service and Repair Manual January 2019

Electrical Schematic, GS-1530, 1532, 1930, 1932, AS / CE


(from serial numbers GS3011A-110828 to GS3014A-136972,
GS3011C-10000 to GS3015C-18038, GS3014D-101 to GS3015D-1113)

280 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Electrical Schematic, GS-1530, 1532, 1930, 1932, AS / CE


(from serial numbers GS3011A-110828 to GS3014A-136972,
GS3011C-10000 to GS3015C-18038, GS3014D-101 to GS3015D-1113)

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 281


Service and Repair Manual January 2019

Electrical Schematic, GS-1530, 1532, 1930, 1932, AS / CE


(from serial numbers GS3011A-110828 to GS3014A-136972,
GS3011C-10000 to GS3015C-18038, GS3014D-101 to GS3015D-1113)

282
January 2019 Service and Repair Manual

Electrical Schematic, GS-1530, 1532, 1930, 1932, AS / CE


(from serial numbers GS3014A-136973, GS3015C-18039, GS3015D-1114 to GS3016D-5426,
GS3016P-142281 to GS3016P-158208)

283
Service and Repair Manual January 2019

Electrical Schematic, GS-1530, 1532, 1930, 1932, AS / CE


(from serial numbers GS3014A-136973, GS3015C-18039, GS3015D-1114 to GS3016D-5426,
GS3016P-142281 to GS3016P-158208)

284 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Electrical Schematic, GS-1530, 1532, 1930, 1932, AS / CE


(from serial numbers GS3014A-136973, GS3015C-18039, GS3015D-1114 to GS3016D-5426,
GS3016P-142281 to GS3016P-158208)

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 285


Service and Repair Manual January 2019

Electrical Schematic, GS-1530, 1532, 1930, 1932, AS / CE


(from serial numbers GS3014A-136973, GS3015C-18039, GS3015D-1114 to GS3016D-5426,
GS3016P-142281 to GS3016P-158208)

286
January 2019 Service and Repair Manual

Electrical Schematic, GS-1530, 1532, 1930 1932, AS / CE


(from serial number GS3016D-5427, GS3016P-158209)

287
Service and Repair Manual January 2019

Electrical Schematic, GS-1530, 1532, 1930, 1932, AS / CE


(from serial numbers GS3016D-5427, GS3016P-158209)

288 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Electrical Schematic, GS-3232, AS / CE


(from serial number GS3211A-110000 to GS3214A-135714,
GS3212C-10000 to GS3215C-14503)

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 289


Service and Repair Manual January 2019

Electrical Schematic, GS-3232, AS / CE


(from serial number GS3211A-110000 to GS3214A-135714,
GS3212C-10000 to GS3215C-14503)

290 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Electrical Schematic, GS-3232, AS / CE


(from serial number GS3211A-110000 to GS3214A-135714,
GS3212C-10000 to GS3215C-14503)

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 291


Service and Repair Manual January 2019

Electrical Schematic, GS-3232, AS / CE


(from serial number GS3211A-110000 to GS3214A-135714,
GS3212C-10000 to GS3215C-14503)

292
January 2019 Service and Repair Manual

Electrical Schematic, GS-3232, AS / CE


(from serial number GS3214A-135715 to GS3215A-141898, GS3215C-14504)

293
Service and Repair Manual January 2019

Electrical Schematic, GS-3232, AS / CE


(from serial number GS3214A-135715 to GS3215A-141898, GS3215C-14504)

294 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Electrical Schematic, GS-3232, AS / CE


(from serial number GS3214A-135715 to GS3215A-141898, GS3215C-14504)

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 295


Service and Repair Manual January 2019

Electrical Schematic, GS-3232, AS / CE


(from serial number GS3214A-135715 to GS3215A-141898, GS32115C-14504)

296
January 2019 Service and Repair Manual

Electrical Schematic, GS-3232, AS / CE


(from serial numbers GS3215A-141899, GS3216P-142676 to GS3216P-146462)

297
Service and Repair Manual January 2019

Electrical Schematic, GS-3232, AS / CE


(from serial number GS3215A-141899, GS3216P-142676 to GS3216P-146462)

298 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Electrical Schematic, GS-3232, AS / CE


(from serial numbers GS3215A-141899, GS3216P-142676 to GS3216P-146462)

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 299


Service and Repair Manual January 2019

Electrical Schematic, GS-3232, AS / CE


(from serial numbers GS3215A-141899, GS3216P-142676 to GS3216P-146462)

300
January 2019 Service and Repair Manual

Electrical Schematic, GS-3232, AS / CE


(from serial number GS3216P-146463)

301
Service and Repair Manual January 2019

Electrical Schematic, GS-3232, AS / CE


(from serial number GS3216P-146463)

302 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Electrical Schematic, GS-3232, AS / CE


(from serial number GS3216P-146463)

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 303


Service and Repair Manual January 2019

Electrical Schematic, GS-3232, AS / CE


(from serial number GS3216P-143463)

304
January 2019 Service and Repair Manual

Electrical Schematic, GS-2032, 2632, 2046, 2646, AS / CE


(from serial number GS3211A-110000 to GS3214A-135715, GS3212C-10000 to GS3215C-14377,
GS4612A-110000 to GS4614A-135366, GS4612C-10000 to GS4615C-14503,
GS4613D-101 to GS4615D-1303)

305
Service and Repair Manual January 2019

Electrical Schematic, GS-2032, 2632, 2046, 2646, AS / CE


(from serial number GS3211A-110000 to GS3214A-1135714, GS3212C-10000 to GS3215C-14377,
GS4612A-110000 to GS4614A-135366, GS4612C-10000 to GS4615C-14503,
GS4613D-101 to GS4615D-1303)

306 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Electrical Schematic, GS-2032, 2632, 2046, 2646, AS / CE


(from serial number GS3211A-110000 to GS3214A-135714, GS3212C-10000 to GS3215C-14377,
GS4612A-110000 to GS4614A-135366, GS4612C-10000 to GS4615C-14503,
GS4613D-101 to GS4615D-1303)

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 307


Service and Repair Manual January 2019

308 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Electrical Schematic, GS-2032, 2632, 2046, 2646, AS / CE


(from serial number GS3211A-110000 to GS3214A-1135714, GS3215C-10000 to GS3215C-14377,
GS4612A-110000 to GS4614A-135366, GS4612C-10000 to GS4615C-14503,
GS4613D-101 to GS4615D-1303)

309
Service and Repair Manual January 2019

Electrical Schematic, GS-2032, 2632, 2046, 2646, AS / CE


(from serial numbers GS3214A-135715 to GS3215A-141898, GS3215C-14378,
GS4614A-135367 to GS4615A-137959, GS46C-14504, GS4615D-1304)

310
January 2019 Service and Repair Manual

Electrical Schematic, GS-2032, 2632, 2046, 2646, AS / CE


(from serial numbers GS3214A-135715 to GS3215A-141898, GS3215C-14378,
GS4614A-135367 to GS4615A-137959, GS4615C-14504, GS4615D-1304)

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 311


Service and Repair Manual January 2019

Electrical Schematic, GS-2032, 2632, 2046, 2646, AS / CE


(from serial numbers GS3214A-1135715 to GS3215A-1141898, GS3215C-14378,
GS4614A-135367 to GS4615A-137959, GS4615C-14504, GS4615D-1304)

312 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Electrical Schematic, GS-2032, 2632, 2046, 2646, AS / CE


(from serial numbers GS3214A-135715 to GS3215A-141898, GS3215C-14378,
GS4614A-135367 to GS4615A-137959, GS4615C-14504, GS4615D-1304)

313
Service and Repair Manual January 2019

Electrical Schematic, GS-2032, 2632, 2046, 2646, AS / CE


(from serial numbers GS3215A-141899, GS3216P-142676 to GS3216P-146462,
GS4615A-137960, GS4616P-138362 to GS4616P-139710)

314
January 2019 Service and Repair Manual

Electrical Schematic, GS-2032, 2632, 2046, 2646, AS / CE


(from serial numbers GS3215A-141899, GS3216P-142676 to GS3216P-146462,
GS4615A-137960, GS4616P-138362 to GS4616P-139710)

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 315


Service and Repair Manual January 2019

Electrical Schematic, GS-2032, 2632, 2046, 2646, AS / CE


(from serial numbers GS3215A-141899, GS3216P-142676 to GS3216P-146462,
GS4615A-137960, GS4616P-138362 to GS4616P-139710)

316 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Electrical Schematic, GS-2032, 2632, 2046, 2646, AS / CE


(from serial numbers GS3215A-141899, GS3216P-142676 to GS3216P-146462,
GS4615A-137960, GS4616P-138362 to GS4616P-139710)

317
Service and Repair Manual January 2019

Electrical Schematic, GS-2032, 2632, 2046, 2646, AS / CE


(from serial numbers GS3216P-146463, GS4616P-139711)

318
January 2019 Service and Repair Manual

Electrical Schematic, GS-2032, 2632, 2046, 2646, AS / CE


(from serial numbers GS3216P-146463, GS4616P-139711)

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 319


Service and Repair Manual January 2019

Electrical Schematic, GS-3246, AS / CE


(from serial numbers GS4612A-110000 to GS4614A-135366,
GS4612C-10000 to GS4615C-14503, GS4614D-101 to GS4615D-1303)

320
January 2019 Service and Repair Manual

Electrical Schematic, GS-3246, AS / CE


(from serial numbers GS4612A-110000 to GS4614A-135366,
GS4612C-10000 to GS4615C-14503, GS4614D-101 to GS4615D-1303)

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 321


Service and Repair Manual January 2019

Electrical Schematic, GS-3246, AS / CE


(from serial numbers GS4621A-110000 to GS4614A-135366,
GS4612C-10000 to GS4615C-14503, GS4614D-101 to GS4615D-1303)

322 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Electrical Schematic, GS-3246, AS / CE


(from serial numbers GS4612A-110000 to GS4614A-135366,
GS4612C-10000 to GS4615C-14503, GS4614D-101 to GS4615D-1303)

323
Service and Repair Manual January 2019

Electrical Schematic, GS-3246, AS / CE


(from serial numbers GS4614A-135367 to GS4615A-137959,
GS4615C-14504, GS4615D-1304 to GS4616D-4432)

324
January 2019 Service and Repair Manual

Electrical Schematic, GS-3246, AS / CE


(from serial numbers GS4614A-135367 to GS4615A-137959,
GS4615C-14504, GS4615D-1304 to GS4616D-4432)

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 325


Service and Repair Manual January 2019

Electrical Schematic, GS-3246, AS / CE


(from serial numbers GS4614A-135367 to GS4615A-137959,
GS4615C-14504, GS4615D-1304 to GS4616D-4432)

326 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Electrical Schematic, GS-3246, AS / CE


(from serial numbers GS4614A-135368 to GS4615A-137959,
GS4615C-14504, GS4615D-1304 to GS4616D-4432)

327
Service and Repair Manual January 2019

Electrical Schematic, GS-3246, AS / CE


(from serial number GS4615A-137960, GS4616P-138362 to GS4616P-139710)

328
January 2019 Service and Repair Manual

Electrical Schematic, GS-3246, AS / CE


(from serial number GS4615A-137960, GS4616P-138362 to GS4616P-139710)

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 329


Service and Repair Manual January 2019

Electrical Schematic, GS-3246, AS / CE


(from serial number GS4615A-137960, GS4616P-138362 to GS4616P-139710)

330 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Electrical Schematic, GS-3246, AS / CE


(from serial number GS4615A-137960, GS4616P-138362 to GS4616P-139710)

331
Service and Repair Manual January 2019

Electrical Schematic, GS-3246, AS / CE


(from serial number GS4616D-4433, GS4616P-139711)

332
January 2019 Service and Repair Manual

Electrical Schematic, GS-3246, AS / CE


(from serial number GS4616D-4433, GS4616P-139711)

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 333


Service and Repair Manual January 2019

Electrical Schematic, GS-4047, AS / CE


(from serial numbers GS4712C-101 to GS4715C-2130,
GS4714D-101 to GS4715D-749)

334 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Electrical Schematic, GS-4047, AS / CE


(from serial numbers GS4712C-101 to GS4715C-2130,
GS4714D-101 to GS4715D-749)

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 335


Service and Repair Manual January 2019

Electrical Schematic, GS-4047, AS / CE


(from serial numbers GS4712C-101 to GS4715C-2130,
GS4714D-101 to GS4715D-749)

336 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Electrical Schematic, GS-4047, AS / CE


(from serial numbers GS4712C-101 to GS4715C-2130,
GS4714D-101 to GS4715D-749)

337
Service and Repair Manual January 2019

Electrical Schematic, GS-4047, AS / CE


(from serial number GS4715C-2131, GS4715D-750 to GS4716D-3101)

338
January 2019 Service and Repair Manual

Electrical Schematic, GS-4047, AS / CE


(from serial number GS4715C-2131, GS4715D-750 to GS4716D-3101)

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 339


Service and Repair Manual January 2019

Electrical Schematic, GS-4047, AS / CE


(from serial number GS4715C-2131, GS4715D-750 to GS4716D-3101)

340 GS™-30 • GS™-32 • GS™-46 • GS™-47 Part No. 1272217GT


January 2019 Service and Repair Manual

Electrical Schematic, GS-4047, AS / CE


(from serial numbers GS4715C-2131, GS4715D-750 to GS4716D-3101)

341
Service and Repair Manual January 2019

Electrical Schematic, GS-4047, AS / CE


(from serial number GS4716D-3102)

342
January 2019 Service and Repair Manual

Electrical Schematic, GS-4047, AS / CE


(from serial number GS4716D-3102)

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 343


Service and Repair Manual January 2019

Electrical Schematic • Foot Switch (option) All Models

344
January 2019 Service and Repair Manual

Electrical Schematic • Foot Switch (option) All Models

GS™- 30 • GS™- 32 • GS™- 46 • GS™- 47 Part No. 1272217GT Servic e and R epair M anual January 2019

Part No. 1272217GT GS™-30 • GS™-32 • GS™-46 • GS™-47 345

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