Page 1 Service Manual Serial Number Range GS -1530/32 from GS3005A-76000 to GS3011A-109999 from GS3005B-76000 GS -1930/32 to GS3009B-98941 from GS3008C-101 to GS3011C-9999 GS -2032 from GS3205-75407 to GS3209-94602 from GS3209A-94603 GS -2632 to GS3212A-109999 from GS3205B-76000 to GS3209B-98941 GS -3232 from GS3208C-101 to GS3212C-9999 GS -2046 from GS4605-75438...
Page 2: Introduction
Genie has endeavored to deliver the highest Genie GS-2046, GS-2646 and GS-3246 degree of accuracy possible. However, continuous Service Manual, First Edition improvement of our products is a Genie policy. (before serial number 17408) ....... 48339 Therefore, product specifications Genie GS-2046, GS-2646 and GS-3246 are subject to change without notice.
Page 3: Serial Number Legend
February 2012 INTRODUCTION Serial Number Legend Part No. 97385 GS-30 • GS-32 • GS-46...
Page 4 February 2012 This page intentionally left blank. GS-30 • GS-32 • GS-46...
Page 5: Safety Rules
February 2012 Section 1 • Safety Rules Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the appropriate Operator's Manual on your machine will result in death or serious injury. Many of the hazards identified in the operator’s manual are also safety hazards when maintenance and repair procedures are performed.
Page 6 Section 1 • Safety Rules February 2012 SAFETY RULES Personal Safety Workplace Safety Any person working on or around a machine must Be sure to keep sparks, flames and be aware of all known safety hazards. Personal lighted tobacco away from flammable and safety and the continued safe operation of the combustible materials like battery gases machine should be your top priority.
Page 7: Table Of Contents
February 2012 Table of Contents Introduction Important Information ..................ii Serial Number Information ................. ii Serial Number Legend ..................iii Section 1 Safety Rules General Safety Rules ..................v Section 2 Specifications Machine Specifications ................2 - 1 Performance Specifications ................. 2 - 2 Hydraulic Specifications ................
Page 8 February 2012 TABLE OF CONTENTS Section 3 Scheduled Maintenance Procedures, continued Checklist B Procedures B-1 Inspect the Batteries ................3 - 9 B-2 Inspect the Electrical Wiring ............. 3 - 12 B-3 Inspect the Electrical Contactor ............3 - 13 B-4 Inspect the Tires, Wheels and Castle Nut Torque ......
Page 9 Platform ................... 4 - 34 Platform Extension ................4 - 35 Scissor Components Scissor Assembly, GS-1530 and GS-1532 ........4 - 36 Scissor Assembly, GS-1930 and GS-1932 ........4 - 42 Scissor Assembly, GS-2032 and GS-2046 ........4 - 50 Scissor Assembly, GS-2632 and GS-2646 ........
Page 10 Section 4 Repair Procedures, continued Manifolds Function Manifold Components - GS-1530, GS-1532, GS-1930 and GS-1932 ........4 - 88 Function Manifold Components - GS-2032, GS-2632, GS-3232, GS-2046, GS-2646 and GS-3246 ..4 - 90 Outrigger Function Manifold Components - GS-3232 ..................4 - 92 Outrigger Cylinder Manifold Components - GS-3232 ..................
Page 11 Limit Switch Legend ..................6 - 8 Electrical Symbols Legend ................6 - 9 Electrical Schematics - ANSI, CSA and Australia Models GS-1530/1532/1930/1932 (from serial number GS3005A-76000 to GS3006A-83067) (from serial number GS3005B-76000 to GS3006B-79659) ......6 - 10 GS-1530/1532/1930/1932 (from serial number GS3006A-83068 to GS3007A-87490) (from serial number GS3006B-79660 to GS3007B-82543) ......
Page 12 (from serial number GS3211A-97904 to GS3212A-109999) GS-2046/2646/3246 (from serial number GS4611A-97983 to GS4612A-109999) ...... 6 - 50 Electrical Schematics - CE Models GS-1530/1532/1930/1932 (from serial number GS3005A-76000 to GS3005A-76388) (from serial number GS3005B-76000 to GS3005B-76030) ......6 - 54 GS-1530/1532/1930/1932 (from serial number GS3005A-76389 to GS3005A-79394) (from serial number GS3005B-76031 to GS3005B-76920) ......
Page 13 February 2012 TABLE OF CONTENTS Section 6 Schematics, continued GS-1530/1532/1930/1932 (from serial number GS3010A-99456 to GS3011A-109999) (from serial number GS3010C-2190 to GS3011C-5059) ......6 - 78 GS-1530/1532/1930/1932 (from serial number GS3012C-5060 to GS3012C-5311) ......6 - 82 GS-2032/2632 (from serial number GS3205-75407 to GS3205-77290) GS-2046/2646/3246 (from serial number GS4605-75438 to GS4605-76734) ......
Page 14 February 2012 TABLE OF CONTENTS Hydraulic Schematics Component Reference and Hydraulic Symbols Legend ......6 - 114 GS-1530/1532/1930/1932 (from serial number GS3005A-76000 to 76491) (from serial number GS3005B-76000 to 76084) ........6 - 116 GS-1530/1532/1930/1932 (after serial number GS3005A-76491) (after serial number GS3005B-76084) (from serial number GS3008C-101) ............
Page 15: G Machine Specifications
February 2009 Section 2 • Specifications Specifications REV G Machine Specifications Tires and wheels GS-1530, GS-1532, GS-1930, GS-1932 Batteries, Standard Tire size (solid rubber) 12 x 4.5 in Voltage 6V DC 30.5 x 11.4 cm Group Tire contact area 9 sq in...
Page 16: Performance Specifications
REV G Performance Specifications Function speed, maximum from platform controls (with 1 person in platform) Drive speed, maximum GS-1530 and GS-1532 GS-1530, GS-1532, GS-1930 and GS-1932 Platform up 15 to 17 seconds Platform down 16 to 18 seconds Platform stowed, fast 2.5 mph...
Page 17: Hydraulic Specifications
25 psi / 1.7 bar bypass Chevron Rando HD oil is fully compatible and Function manifold mixable with Shell Donax TG (Dexron III) oils. Genie specifications require hydraulic oils which are System relief valve pressure, maximum 3700 psi designed to give maximum protection to hydraulic...
Page 18: Manifold Component Specifications
Solenoid valve, 3 position 4 way 19Ω 20V DC with diode (schematic item BA) Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. 2 - 4 GS-30 • GS-32 • GS-46 Part No. 97385...
Page 19: Hydraulic Hose And Fitting Torque Specifications
Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with JIC 37° flared fittings and hose ends. Genie specifications require that fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed.
Page 20 Section 2 • Specifications February 2009 SPECIFICATIONS REV G 3 Working clockwise on the body hex fitting, make Torque Procedure a second mark with a permanent ink marker to JIC 37° fittings indicate the proper tightening position. Refer to Figure 2. 1 Align the tube flare (hex nut) against the nose of Note: Use the JIC 37°...
Page 21 February 2009 Section 2 • Specifications REV G SPECIFICATIONS SAE FASTENER TORQUE CHART • This chart is to be used as a guide only unless noted elsewhere in this manual • A574 High Strength Grade 5 Grade 8 SIZE THREAD Black Oxide Bolts LUBED LUBED...
Page 22 Section 2 • Specifications February 2009 This page intentionally left blank. 2 - 8 GS-30 • GS-32 • GS-46 Part No. 97385...
Page 23 Indicates a potentially hazardous situation which, if not avoided, Use only Genie approved replacement parts. may result in property damage. Machines that have been out of service for a Indicates that a specific result is expected after period longer than 3 months must complete the performing a series of steps.
Page 24: Pre-Delivery Preparation Report
Section 3 • Scheduled Maintenance Procedures April 2008 SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend Pre-delivery Preparation Report Note: The following symbols have been used in The pre-delivery preparation report contains this manual to help communicate the intent of the checklists for each type of scheduled inspection. instructions.
Page 25 Grantham, Lincolnshire Watertown, SD 57201-6150 NG31- 6BH England (605) 882-4000 (44) 1476-584333 Copyright © 2011 Terex Corporation. Genie® is a registered trademark of Terex South Dakota, Inc. 133192 Rev D Part No. 97385 GS-30 • GS-32 • GS-46 3 - 3...
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Page 27: Maintenance Inspection Report
February 2012 Section 3 • Scheduled Maintenance Procedures Maintenance Inspection Report Model Checklist A - Rev C Y N R Checklist B - Rev K Y N R A-1 Inspect the manuals B-1 Batteries Serial number and decals B-2 Electrical wiring A-2 Pre-operation B-3 Electrical contactor Date...
Page 28: Checklist A Procedures
They also Note: Contact your authorized Genie distributor or provide users with operation and maintenance Genie if replacement manuals or decals are information. An illegible decal will fail to alert needed.
Page 29: Perform Pre-Operation Inspection
March 2007 Section 3 • Scheduled Maintenance Procedures REV C CHECKLIST A PROCEDURES Perform Pre-operation Inspection Perform Function Tests Completing a Pre-operation Inspection is essential Completing the function tests is essential to safe to safe machine operation. The Pre-operation machine operation. Function tests are designed to Inspection is a visual inspection performed by the discover any malfunctions before the machine is operator prior to each work shift.
Page 30: Perform 30 Day Service
Perform 30 Day Service Grease the Steer Yokes The 30 day maintenance procedure is a one time Genie specifications require that this procedure be procedure to be performed after the first 30 days or performed every 100 hours of operation.
Page 31: Checklist B Procedures
6 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer. Note the results. Genie requires that this procedure be performed 7 Check the ambient air temperature and adjust every 250 hours or quarterly, whichever comes the specific gravity reading for each cell as first.
Page 32 Section 3 • Scheduled Maintenance Procedures February 2012 CHECKLIST B PROCEDURES REV K 10 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows: • Add 0.004 to the reading of each cell for every 10°...
Page 33 50 feet / 15 m. Note: If you have any further questions regarding the battery charger operation, please contact the Genie Service Department. Part No. 97385 GS-30 • GS-32 • GS-46 3 - 11...
Page 34: Inspect The Electrical Wiring
5 Raise the platform approximately 8 feet / 2.4 m from the ground. Genie requires that this procedure be performed 6 Rotate the safety arm away from the machine every 250 hours or quarterly, whichever comes and let it hang down.
Page 35: Inspect The Electrical Contactor
CHECKLIST B PROCEDURES Inspect the Electrical Contactor Inspect the Tires and Wheels (including castle nut torque) Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes Genie requires that this procedure be performed first. every 250 hours or quarterly, whichever comes first.
Page 36: Test The Emergency Stop
CHECKLIST B PROCEDURES REV K Test the Emergency Stop Test the Key Switch Genie requires that this procedure be performed Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes every 250 hours or quarterly, whichever comes first.
Page 37: Test The Automotive-Style Horn (If Equipped)
REV K CHECKLIST B PROCEDURES Test the Automotive-style Horn (if equipped) Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first. The horn is activated at the platform controls and sounds at the ground as a warning to ground personnel.
Page 38: Test The Drive Brakes
4 Press the drive function select button. Refer to Illustration 1. Illustration 1 drive function select button BN8 GS-1530 • GS-1532 • GS-1930 • GS-1932 5 Choose a point on the machine; i.e., contact Illustration 2 patch of a tire, as a visual reference for use when crossing the test line.
Page 39 Note: For reassembly, it will be helpful to leave the wire harness attached to the valve coils. 16 Connect the battery pack to the machine. For GS-1530, GS-1532, GS-1930 and GS-1932 17 Replace the brakes and repeat this procedure (all models) proceed to step 11.
Page 40 Repeat this procedure beginning with step 1. This indicates the machine is equipped with 28 Contact the Genie Service Parts Department a dynamic brake valve. Proceed to step 23. and order kit part number 105458.
Page 41: Test The Drive Speed - Stowed Position
Begin timing when your reference point on the machine crosses the start line. Genie requires that this procedure be performed 7 Continue at full speed and note the time when every 250 hours or quarterly, whichever comes your reference point on the machine passes first.
Page 42: Test The Drive Speed - Raised Position
6 Press the drive function select button. 7 Choose a point on the machine; i.e., contact Genie requires that this procedure be performed patch of a tire, as a visual reference for use every 250 hours or quarterly, whichever comes when crossing the start and finish lines.
Page 43: Test The Slow Drive Speed
6 Bring the machine to top drive speed before reaching the start line. Begin timing when your reference point on the machine crosses the Genie requires that this procedure be performed start line. every 250 hours or quarterly, whichever comes 7 Continue at full speed and note the time when first.
Page 44: Perform Hydraulic Oil Analysis
B-13 Perform Hydraulic Oil Analysis Inspect the Hydraulic Tank Cap Venting System Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes Genie requires that this procedure be performed first. quarterly or every 250 hours, whichever comes first.
Page 45: Check The Module Tray Latch Components
REV K CHECKLIST B PROCEDURES B-14 Check the Module Tray Latch Components Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first. Maintaining the module tray latch components in good condition is essential to good performance and service life.
Page 46: Inspect The Voltage Inverter (If Equipped)
10 minutes. If the left fault LED (REV_POL) is illuminated, Genie requires that this procedure be performed the inverter is connected to batteries with the every 250 hours or quarterly, whichever comes incorrect polarity.
Page 47: Test The Down Limit Switch And The Pothole Limit Switches
February 2012 Section 3 • Scheduled Maintenance Procedures REV K CHECKLIST B PROCEDURES 7 GS-1530/32 and GS-1930/32: Follow the B-16 platform control cable down the scissor stack to Test the Down Limit Switch and the alarm bracket on the chassis deck. Tag and...
Page 48 Section 3 • Scheduled Maintenance Procedures February 2012 CHECKLIST B PROCEDURES REV K 13 Press the drive function select button. Attempt 19 Turn the key switch to the off position. to drive the machine. 20 Disconnect the platform controls from the ECM Result: The diagnostic display will show code cable.
Page 49 February 2012 Section 3 • Scheduled Maintenance Procedures REV K CHECKLIST B PROCEDURES Pothole Limit Switches 32 Press the lift function select button. Attempt to raise the platform approximately 8 feet / 2.4 m. 27 Move the machine onto a grade which exceeds Result: The pothole guard contacts the block the rating of the level sensor.
Page 50: Test The Up Limit Switch (If Equipped) And The Outrigger Limit Switches (If Equipped)
Result: The platform stops raising. The machine Genie requires that this procedure be performed is functioning properly. every 250 hours or quarterly, whichever comes first.
Page 51: Checklist C Procedures
(if equipped) over lift relief which would cause the pressure switch to falsely indicate an overload condition. Genie specifications require that this procedure be performed every 500 hours or six months, whichever comes first OR when the machine fails to lift the maximum rated load.
Page 52 Section 3 • Scheduled Maintenance Procedures March 2007 CHECKLIST C PROCEDURES REV C 1 Locate the lift valve coil on the function 5 Fully raise the platform. Release the toggle manifold. switch. Result: The alarm should sound. Result: The alarm does not sound. Calibrate the platform overload system.
Page 53: Replace The Hydraulic Tank Breather Cap - Models With Optional Hydraulic Oil
CHECKLIST C PROCEDURES Replace the Hydraulic Tank Breather Cap - Models with Optional Hydraulic Oil Genie requires that this procedure be performed every 500 hours or semi-annually, whichever comes first. The hydraulic tank is a vented-type tank. The breather cap has an internal air filter that can become clogged or, over time, can deteriorate.
Page 54: Checklist D Procedures
Checklist D Procedures REV E Check the Scissor Arm Wear Pads Genie requires that this procedure be performed every 1000 hours or annually, whichever comes first. Maintaining the condition of the scissor arm wearpads is essential to safe machine operation.
Page 55 June 2009 Section 3 • Scheduled Maintenance Procedures REV E CHECKLIST D PROCEDURES 2 From serial numbers GS3003A-60000 to GS3006A-85006 and from GS3005B-76000 to GS3006B-80468: Measure the distance between the number one outer arm cross tube and the chassis deck at the battery pack side of the non-steer end of the machine.
Page 56 Section 3 • Scheduled Maintenance Procedures June 2009 CHECKLIST D PROCEDURES REV E GS-2032, GS-2632, GS-3232, GS-2046, GS-2646 and GS-3246: 1 Measure the distance between the number one outer arm cross tube and the fork lift tube at the ground controls side of the non-steer end of the machine.
Page 57: Replace The Hydraulic Tank Return Filter Element
6 Activate and hold the platform up toggle switch. 7 Inspect the filter and related components to be sure that there are no leaks. Genie requires that this procedure be performed every 1000 hours or annually, whichever comes 8 Clean up any oil that may have spilled.
Page 58: Checklist E Procedure
4 Tag and disconnect the hydraulic pump inlet hard line and remove the hard line from the Genie requires that this procedure be performed tank. Cap the fitting on the pump. every 2000 hours or every two years, whichever 5 Remove the hydraulic tank retaining fasteners comes first.
Page 59 April 2008 Section 3 • Scheduled Maintenance Procedures REV C CHECKLIST E PROCEDURE 10 Install the hydraulic pump inlet hard line into the tank. Install the fitting onto the pump and torque to specification. Refer to Section 2, Specifications . 11 Install the hydraulic pump return hard line into the tank.
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Page 61 Indicates a potentially hazardous available and ready for use. situation which, if not avoided, could result in death or serious Use only Genie approved replacement parts. injury. Read each procedure completely and adhere to Indicates a potentially hazardous the instructions. Attempting shortcuts may situation which, if not avoided, produce hazardous conditions.
Page 62: Platform Controls
LEDs and a diagnostic display. Electrocution/burn hazard. Contact with electrically charged circuits For further information or assistance, consult the could result in death or serious Genie Service Department. injury. Remove all rings, watches and other jewelry. Component damage hazard. Electrostatic discharge (ESD) can...
Page 63 LEDs. Electrocution/burn hazard. Contact with electrically charged circuits For further information or assistance, consult the could result in death or serious Genie Service Department. injury. Remove all rings, watches and other jewelry. Component damage hazard. Electrostatic discharge (ESD) can...
Page 64: Controller Adjustments
The function speeds are determined by the percentage of total controller output. For further information or assistance, consult the Genie Service Department. Tip-over hazard. Do not adjust the lift and/or drive speed higher than joystick controller JC1 lift function select button BN9 specified in this procedure.
Page 65 October 2009 Section 4 • Repair Procedures REV J PLATFORM CONTROLS How to Adjust the Lift Speed Tip-over hazard. Do not adjust the lift and/or drive speed higher than specified in this procedure. Setting the function speeds greater than specifications could cause the machine to tip over resulting in death or serious injury.
Page 66 Section 4 • Repair Procedures October 2009 PLATFORM CONTROLS REV J How to Adjust the Stowed Drive Speed Tip-over hazard. Do not adjust the lift and/or drive speed higher than specified in this procedure. Setting the function speeds greater than specifications could cause the machine to tip over resulting in death or serious injury.
Page 67 October 2009 Section 4 • Repair Procedures REV J PLATFORM CONTROLS How to Adjust the Raised Drive Speed Tip-over hazard. Do not adjust the lift and/or drive speed higher than specified in this procedure. Setting the function speeds greater than specifications could cause the machine to tip over resulting in death or serious injury.
Page 68 Section 4 • Repair Procedures October 2009 PLATFORM CONTROLS REV J How to Adjust the Slow or High Torque Drive Speed Tip-over hazard. Do not adjust the lift and/or drive speed higher than specified in this procedure. Setting the function speeds greater than specifications could cause the machine to tip over resulting in death or serious injury.
Page 69: Software Configuration
REV J PLATFORM CONTROLS Software Configuration The Electronic Control Module (ECM) contains programming for all configurations of the Genie GS-30, GS-32 and GS-46. The machine can be adjusted to a different configuration using the buttons at the platform controls. How to Determine the...
Page 70 Section 4 • Repair Procedures October 2009 PLATFORM CONTROLS REV J How to Change the Software Configuration 1 Pull out the red Emergency Stop button to the on position at the ground controls. 2 Push in the red Emergency Stop button to the off position at the platform controls.
Page 71 GS-1530 • GS-1532 • GS-1930 • GS-1932 (ECMs with software revisins A0 to A4) GS-1530 • GS-1532 • GS-1930 • GS-1932 (ECMs with software revisions A5 and higher)
Page 72 Section 4 • Repair Procedures October 2009 PLATFORM CONTROLS REV J Machine Configuration Code Chart Machine Configuration Code Chart (before serial numbers (after serial numbers GS3207-85152 and GS4607-84771) GS3207-85153 and GS4607-84772) (from serial numbers GS3208C-101 and A mark in the four right columns indicates that the GS4609C-101) machine configuration code, in the left column, includes this feature.
Page 73 October 2009 Section 4 • Repair Procedures REV J PLATFORM CONTROLS How to Activate the How to Determine the Battery Battery Drain Alarm Option Voltage 1 Pull out the red Emergency Stop button to the The diagnostic display on the platform controls is on position at the ground controls.
Page 74: Outrigger Ecm
The right front outrigger and left rear For further information or assistance, consult the outrigger lights remain green. Genie Service Department. Result: All lights turn red on the outrigger How to Calibrate the Outrigger control pad and the alarm sounds continuously.
Page 75 October 2009 Section 4 • Repair Procedures REV J PLATFORM CONTROLS How to Calibrate the Outrigger Pressure Transducers Note: For best performance, calibrate the pressure transducers when the ambient temperature is 32°F / 0°C, or above. 1 Move the machine to a firm level surface that is free of obstructions.
Page 76 Section 4 • Repair Procedures October 2009 PLATFORM CONTROLS REV J 8 Press and hold the function enable and How to Activate the outrigger extend buttons until the outriggers Outrigger Motion Alarm Option are fully extended. Continue to hold the outrigger extend button and release the function 1 Turn the key switch to platform control.
Page 77: Outrigger Controls Software Update
Prior to updating the outrigger controls system, the software programmer, hardware and firmware must be acquired through the Genie Service Department. Note: Perform this procedure with the machine on a firm, level surface.
Page 78 Section 4 • Repair Procedures October 2009 PLATFORM CONTROLS REV J 6 Remove the top enclosure of the control pad 8 Using a set of pliers, grasp the connector of the and set to the side. Refer to Illustration 2. coil cord and slowly pull the coil cord away from the printed circuit board.
Page 79 October 2009 Section 4 • Repair Procedures REV J PLATFORM CONTROLS How to Remove and Disassemble the Outrigger ECM 10 At the battery pack side of the machine, open the access door to the ECM. Refer to Illustration 4. Illustration 4 outrigger ECM 11 Tag and disconnect the wire harness from the Outrigger ECM.
Page 80 (Genie part number 125132) and the updated board. Refer to Illustration 6. Hex files for the outrigger ECM (Genie part number 125131) must be installed on a PC or laptop. 16 Plug the USB end of the PSoC MiniProg cable into a PC or laptop.
Page 81 October 2009 Section 4 • Repair Procedures REV J PLATFORM CONTROLS 19 Select "MINIProg1/048E47470618" from the Result: All the boxes in the lower right corner of "Port" drop down menu. the "PSoC Programmer" window should have a green background and show as being "Connected."...
Page 82 Section 4 • Repair Procedures October 2009 PLATFORM CONTROLS REV J 20 Click the "File Load" button. All Green Backgrounds Not Powered Idle Connected 4 - 22 GS-30 • GS-32 • GS-46 Part No. 97385...
Page 83 October 2009 Section 4 • Repair Procedures REV J PLATFORM CONTROLS 21 Browse the folder containing the appropriate Note: To ensure the correct file is selected for .hex file, select the file and click "Open." either the ECM or control pad update, refer to the decals located in Illustrations 2 and 5.
Page 84 Section 4 • Repair Procedures October 2009 PLATFORM CONTROLS REV J 22 With the background of all boxes in the lower right corner of the PSoc Programmer window green in color, locate the "Device Family" drop down menu and select "29x66." All Green Backgrounds Not Powered...
Page 85 Note: The ECM printed circuit board will be labeled Note: The control pad printed circuit board will be with Genie part number 105368 and will serve as labeled with Genie part number 105370 and will the identifier when for selecting "29x66" from the serve as the identifier when for selecting "29x66"...
Page 86 Section 4 • Repair Procedures October 2009 PLATFORM CONTROLS REV J 23 At the "Device" drop-down menu select CY8C29666 if the outrigger ECM firmware is being updated OR select CY8C29466 if the outrigger control pad firmware is being updated. All Green Backgrounds Not Powered Pass...
Page 87 October 2009 Section 4 • Repair Procedures REV J PLATFORM CONTROLS 24 At "Programming Mode", select the "Reset" bullet. All Green Backgrounds Not Powered Pass Idle Connected Part No. 97385 GS-30 • GS-32 • GS-46 4 - 27...
Page 88 Section 4 • Repair Procedures October 2009 PLATFORM CONTROLS REV J 25 Click the "Toggle Device Power" button. 26 Click the "Program" button to update the firmware of either the ECM or the control pad. Result: A portion of the lower right hand corner in the "PSoC Programmer"...
Page 89 October 2009 Section 4 • Repair Procedures REV J PLATFORM CONTROLS 27 Click the "Toggle Device Power" button to 28 Carefully disconnect the "MiniProg" cable from power down the printed circuit board. the printed circuit board. Result: All the boxes in the lower right hand Component damage hazard.
Page 90 Section 4 • Repair Procedures October 2009 PLATFORM CONTROLS REV J How to Assemble and Install the 33 Install the control pad onto the control pad bracket and secure using the fasteners Outrigger Control Pad removed in step 4. Do not over tighten the fasteners.
Page 91 October 2009 Section 4 • Repair Procedures REV J PLATFORM CONTROLS How to Assemble and Install the Outrigger ECM 35 Insert the ECM printed circuit board into the ECM enclosure. Refer to Illustration 5. Component damage hazard. Electrostatic discharge (ESD) can damage printed circuit board components.
Page 92 43 Perform the function tests. Refer to the Operator's Manual on your machine. 44 Return the machine to service. If you have any further questions regarding these instructions or need assistance, please contact the Genie Service Department, 1-800-536-1800 Ext. 8710 Illustration 9 ECM assembly ECM bracket 38 Connect the ECM harness to the ECM.
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Page 94: Platform Components
1 Raise the platform to approximately 3 ft / 1 m. forklift to help support the platform. 2 Remove the retaining fasteners securing the 11 GS-1530/32 and GS-1930/32: Lift the steer end platform to the platform mount at the steer end of the platform slightly to clear the platform of the machine.
Page 95: Platform Extension
April 2008 Section 4 • Repair Procedures REV B PLATFORM COMPONENTS 7 Remove the platform roller wheels from the machine. Platform Extension 8 Carefully slide the platform extension out from the platform and place it on a structure capable How to Remove the of supporting it.
Page 96: Scissor Components
Section 4 • Repair Procedures March 2007 Scissor Components REV C GS-1530 GS-1532 Steer End Non-steer End 1 Number 4 pivot pin 10 Number 3 inner arm 2 Number 3 center pivot pin (2 pins) 11 Number 3 outer arm...
Page 97: Scissor Assembly, Gs-1530 And Gs-1532
March 2007 Section 4 • Repair Procedures REV C SCISSOR COMPONENTS Scissor Assembly, GS-1530 and GS-1532 How to Disassemble the Scissor Assembly, GS-1530 and GS-1532 Bodily injury hazard. The procedures in this section require specific repair skills, lifting GS-1530 equipment and a suitable GS-1532 workshop.
Page 98 Section 4 • Repair Procedures March 2007 SCISSOR COMPONENTS REV C 10 Remove the external snap rings and retaining 20 Remove the pin retaining fasteners from the lift fasteners from the number 3 center pivot pin at cylinder rod-end pivot pin (index #3). Use a soft the battery pack side of the machine (index#2).
Page 99 March 2007 Section 4 • Repair Procedures REV C SCISSOR COMPONENTS 30 Remove the retaining fasteners from the 38 Use a soft metal drift to remove the number 2 number 2 pivot pin (index #15) at the non-steer pivot pin (index #6). Remove the number 2 end of the machine.
Page 100 Section 4 • Repair Procedures March 2007 SCISSOR COMPONENTS REV C 46 Raise the lift cylinder to a vertical position. 53 Attach a lifting strap from an overhead crane to the number 1 outer arm (index #17). Do not 47 Remove the pin retaining fasteners from the lift apply any lifting pressure.
Page 101 March 2007 Section 4 • Repair Procedures REV C SCISSOR COMPONENTS How to Replace the Scissor Arm 9 Remove the scissor assembly from the machine just enough to access both wear pads. Wear Pads Crushing hazard. The scissor 1 Remove the platform. See 2-1, How to Remove assembly will fall if not properly the Platform.
Page 102 Section 4 • Repair Procedures March 2007 SCISSOR COMPONENTS REV C GS-1930 GS-1932 Steer End Non-steer End 1 Number 5 pivot pin 12 Number 4 inner arm 2 Number 4 center pivot pin (2 pins) 13 Number 4 outer arm 3 Number 4 pivot pin (steer end) 14 Number 4 pivot pin (non-steer end) 4 Number 3 center pivot pin (2 pins)
Page 103: Scissor Assembly, Gs-1930 And Gs-1932
March 2007 Section 4 • Repair Procedures REV C SCISSOR COMPONENTS Scissor Assembly, GS-1930 and GS-1932 How to Disassemble the Scissor Assembly, GS-1930 and GS-1932 Bodily injury hazard. The procedures in this section require specific repair skills, lifting equipment and a suitable workshop.
Page 104 Section 4 • Repair Procedures March 2007 SCISSOR COMPONENTS REV C 8 Use a soft metal drift to remove the number 4 16 Remove the retaining fasteners from the pivot pin (index #14) from the non-steer end of number 4 pivot pin (index #14) at the non-steer the machine.
Page 105 March 2007 Section 4 • Repair Procedures REV C SCISSOR COMPONENTS 24 Attach a lifting strap from an overhead crane to 33 Attach a lifting strap from an overhead crane to the number 3 outer arm (index #4) at the the lug on the rod end of the lift cylinder for ground controls side.
Page 106 Section 4 • Repair Procedures March 2007 SCISSOR COMPONENTS REV C 41 Remove the number 2 cable bridge mounting 49 Use a soft metal drift to tap the number 2 pivot fasteners and remove the cable bridge from the pin at the non-steer end (index #20) in the other machine.
Page 107 March 2007 Section 4 • Repair Procedures REV C SCISSOR COMPONENTS 57 Attach a lifting strap from an overhead crane to 64 Attach a lifting strap from an overhead crane to the lug on the rod end of the lift cylinder the number 1 inner arm (index #10) at the non- (index #5).
Page 108 Section 4 • Repair Procedures March 2007 REV C 72 Slide the number 1 outer arm (index #22) to the How to Replace the Scissor Arm non-steer end and remove it from the machine. Wear Pads Bodily injury hazard. The number 1 Remove the platform.
Page 109 March 2007 Section 4 • Repair Procedures REV C 9 Remove the scissor assembly from the machine just enough to access both wear pads. Crushing hazard. The scissor assembly will fall if not properly supported when removed from the drive chassis. Component damage hazard.
Page 110 Section 4 • Repair Procedures March 2007 SCISSOR COMPONENTS REV C GS-2032 GS-2046 Steer end Non-steer end 1 Number 4 pivot pin 10 Number 3 inner arm 2 Number 3 center pivot pin (2 pins 11 Number 3 outer arm 3 Lift cylinder rod-end pivot pin 12 Number 3 pivot pin (non-steer end) 4 Number 3 pivot pin (steer end)
Page 111: Scissor Assembly, Gs-2032 And Gs-2046
March 2007 Section 4 • Repair Procedures REV C SCISSOR COMPONENTS Scissor Assembly, GS-2032 and GS-2046 How to Disassemble the Scissor Assembly, GS-2032 and GS-2046 Bodily injury hazard. The procedures in this section require specific repair skills, lifting GS-2032 equipment and a suitable GS-2046 workshop.
Page 112 Section 4 • Repair Procedures March 2007 SCISSOR COMPONENTS REV C 12 Use a soft metal drift to remove the number 3 21 Lower the cylinder onto the block. pivot pin (index #12) from the non-steer end of Bodily injury hazard. Keep hands the machine.
Page 113 March 2007 Section 4 • Repair Procedures REV C SCISSOR COMPONENTS 30 Remove the retaining fasteners from the 37 Remove the retaining fasteners from the number 2 pivot pin (index #15) at the non-steer number 2 pivot pin at the steer end of the end.
Page 114 Section 4 • Repair Procedures March 2007 SCISSOR COMPONENTS REV C 46 Tag and disconnect the wires and manual 54 Lower the arm to the stowed position. lowering cable from the solenoid valve on the Bodily injury hazard. Keep hands cylinder.
Page 115 March 2007 Section 4 • Repair Procedures REV C SCISSOR COMPONENTS How to Replace the Scissor Arm 9 Move the scissor assembly towards the non-steer end of the machine slightly and to Wear Pads one side of the machine until one of the scissor arm wear pads is accessible.
Page 116 Section 4 • Repair Procedures March 2007 SCISSOR COMPONENTS REV C GS-2632 GS-2646 Steer end Non-steer end 1 Number 5 pivot pin 12 Number 4 inner arm 2 Number 4 center pivot pin (2 pins) 13 Number 4 outer arm 3 Number 4 pivot pin (steer end) 14 Number 4 pivot pin (non-steer end) 4 Number 3 center pivot pin (2 pins)
Page 117: Scissor Assembly, Gs-2632 And Gs-2646
March 2007 Section 4 • Repair Procedures REV C SCISSOR COMPONENTS Scissor Assembly, GS-2632 and GS-2646 How to Disassemble the Scissor Assembly, GS-2632 and GS-2646 Bodily injury hazard. The procedures in this section require specific repair skills, lifting equipment and a suitable workshop.
Page 118 Section 4 • Repair Procedures March 2007 SCISSOR COMPONENTS REV C 7 Use a soft metal drift to remove the number 5 15 Place a rod through the number 4 center pivot pivot pin (index #1). Remove the platform pin at the battery side (index #2) and twist to mount bracket from the machine.
Page 119 March 2007 Section 4 • Repair Procedures REV C SCISSOR COMPONENTS 22 Attach a lifting strap from an overhead crane to 30 Remove the number 3 outer arm (index #16) the number 3 outer arm at the ground control from the machine. side (index #16).
Page 120 Section 4 • Repair Procedures March 2007 SCISSOR COMPONENTS REV C 38 Use a soft metal drift to remove the number 3 45 Use a soft metal drift to remove the number 2 pivot pin (index #6) from the steer end of the pivot pin (index #20) from the non-steer end of machine.
Page 121 March 2007 Section 4 • Repair Procedures REV C SCISSOR COMPONENTS 50 Attach a lifting strap from an overhead crane to 58 Tag, disconnect and plug the hydraulic hose on the number 2 inner arm (index #18). Raise the the lower lift cylinder. Cap the fittings on the arm to a vertical position.
Page 122 Section 4 • Repair Procedures March 2007 SCISSOR COMPONENTS REV C 64 Remove the cables from the number 1 cable How to Replace the Scissor Arm bridge and lay them off to the side. Wear Pads Component damage hazard. 1 Remove the platform. See 2-1, How to Remove Cables can be damaged if they the Platform.
Page 123 March 2007 Section 4 • Repair Procedures REV C SCISSOR COMPONENTS 10 Remove the old wear pad. 11 Install the new wear pad. 12 Rotate the scissor assembly towards the other side of the machine until the other scissor arm wear pad is accessible.
Page 124 Section 4 • Repair Procedures March 2007 SCISSOR COMPONENTS REV C GS-3232 GS-3246 Steer end Non-steer end 1 Number 6 pivot pin 16 Number 5 inner arm 2 Number 5 center pivot pin (2 pins) 17 Number 5 outer arm 3 Upper lift cylinder rod-end pivot pin 18 Number 5 pivot pin (non-steer end) 4 Number 5 pivot pin (steer end)
Page 125: Scissor Assembly, Gs-3232 And Gs-3246
March 2007 Section 4 • Repair Procedures REV C SCISSOR COMPONENTS Scissor Assembly, GS-3232 and GS-3246 How to Disassemble the Scissor Assembly, GS-3232 and GS-3246 Bodily injury hazard. The procedures in this section require specific repair skills, lifting equipment and a suitable workshop.
Page 126 Section 4 • Repair Procedures March 2007 SCISSOR COMPONENTS REV C 9 Remove the retaining fasteners from the 18 Remove the retaining fasteners from the number 5 center pivot pin (index #2) at the number 5 pivot pin at the steer end of the ground control side.
Page 127 March 2007 Section 4 • Repair Procedures REV C SCISSOR COMPONENTS 26 Use a soft metal drift to remove the upper lift 36 Remove the number 4 outer arm (index #20) cylinder rod end pivot pin (index #3) from the from the machine.
Page 128 Section 4 • Repair Procedures March 2007 SCISSOR COMPONENTS REV C 46 Use a soft metal drift to remove the number 3 54 Attach a lifting strap from an overhead crane to pivot pin (index #24) from the non-steer end of the lug of the rod end of the lower lift cylinder.
Page 129 March 2007 Section 4 • Repair Procedures REV C SCISSOR COMPONENTS 63 Disconnect the number 2A and 2B cable 72 Remove the number 2 outer arm (index #26) bridges from the scissor linkset and remove from the machine. both cable bridges from the machine. Crushing hazard.
Page 130 Section 4 • Repair Procedures March 2007 SCISSOR COMPONENTS REV C 81 Tag, disconnect and plug the hydraulic hose on 88 Disconnect the number 1 cable bridge from the the lower lift cylinder. Cap the fittings on the number 1 outer arm (index #29) and remove cylinder.
Page 131 March 2007 Section 4 • Repair Procedures REV C SCISSOR COMPONENTS How to Replace the Scissor Arm 10 Remove the old wear pad. Wear Pads 11 Install the new wear pad. 12 Rotate the scissor assembly towards the other 1 Remove the platform. See 2-1, How to Remove side of the machine until the other scissor arm the Platform.
Page 132: Lift Cylinder
Hydraulic Hose and Fitting Torque Specifications. orifice (schematic item O) connector fitting GS-1530, GS-1532, GS-1930 and GS-1932: hydraulic hose manual lowering cable solenoid valve (schematic item N) 1 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
Page 133 March 2007 Section 4 • Repair Procedures REV C SCISSOR COMPONENTS 9 Attach a lifting strap from an overhead crane to GS-2032, GS-2632, GS-2046 and GS-2646: the rod end of the lift cylinder for support. 1 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. 10 Remove the retaining fasteners from the lift 2 Lift the safety arm, move it to the center of the cylinder rod-end pivot pin.
Page 134 Section 4 • Repair Procedures March 2007 SCISSOR COMPONENTS REV C 6 Loosen the adjustment nuts on the solenoid 12 Attach a lifting strap from an overhead crane or valve and disconnect the manual lowering cable similar lifting device to the barrel end of the lift from the valve.
Page 135 March 2007 Section 4 • Repair Procedures REV C SCISSOR COMPONENTS GS-3232 and GS-3246: 5 Models with platform overload option: Tag and disconnect the wiring from the platform 1 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. overload switch.
Page 136 Section 4 • Repair Procedures March 2007 SCISSOR COMPONENTS REV C Upper Lift Cylinder (before serial GS4607-83692) manifold plug orifice fitting (schematic item O) Upper Lift Cylinder lift cylinder (after serial GS4607-83691) connector fitting hydraulic hose lift cylinder solenoid valve (schematic item N) orifice fitting (schematic item O) relief valve (schematic item Q) connector fitting...
Page 137: Platform Overload System
March 2007 Section 4 • Repair Procedures REV C SCISSOR COMPONENTS 6 Using a suitable lifting device, place a test weight, corresponding to the maximum load as Platform Overload System indicated on the capacity indicator decal, in the center of the platform floor. Secure the weight How to Calibrate the Platform to the platform.
Page 138 Section 4 • Repair Procedures March 2007 SCISSOR COMPONENTS REV C 10 Models with round pressure switch: Remove 15 Using a suitable lifting device, place a test the retaining ring securing the cover to the weight in the center of the platform floor. pressure switch and remove the cover.
Page 139: Ground Controls
March 2007 Section 4 • Repair Procedures Ground Controls REV D Skip to step 8 if the measurement is correct. Manual Platform Lowering Cable 6 To adjust, loosen the upper lock nut on the cable mounting bracket at the cylinder. Turn the lower lock nut clockwise to decrease the The manual platform lowering cable lowers the distance or counterclockwise to increase the...
Page 140: Level Sensors
Section 4 • Repair Procedures March 2007 GROUND CONTROLS REV D 5 Lift the safety arm, move it to the center of the scissor arm and rotate down to a vertical Level Sensors position. 6 Lower the platform onto the safety arm. The Electronic Control Module (ECM) is programmed to deactivate the lift and drive Crushing hazard.
Page 141 March 2007 Section 4 • Repair Procedures REV D GROUND CONTROLS 12 Place the new level sensor onto the level Steer end sensor mount bracket with the "X" on the level sensor base closest to the long side of the level sensor mount and the "Y"...
Page 142 March 2007 GROUND CONTROLS REV D 22 GS-1530 and GS-1930: Place a 0.64 x 6 x 6 25 Lower the platform to the stowed position. inch / 16.2 mm x 15 cm x 15 cm thick steel 26 Raise the machine approximately block under both wheels at the ground controls 2 inches / 5 cm.
Page 143 March 2007 Section 4 • Repair Procedures REV D GROUND CONTROLS 32 Lower the machine onto the blocks. 33 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. Result: The platform should stop, an alarm should sound and fault code appears in the diagnostic display.
Page 144 Section 4 • Repair Procedures March 2007 GROUND CONTROLS REV D How to Install the Outrigger 6 Place the new outrigger level sensor onto the outrigger level sensor base with the flat side of Level Sensor the outrigger level sensor closest to the battery side access door.
Page 145 March 2007 Section 4 • Repair Procedures GROUND CONTROLS This page intentionally left blank. Part No. 97385 GS-30 • GS-32 • GS-46 4 - 85...
Page 146: Hydraulic Pump
Section 4 • Repair Procedures April 2008 Hydraulic Pump REV B 4 Activate the platform up function from the ground controls. Function Pump Result: If the pressure gauge reads 3200 psi / 221 bar, immediately stop. The pump The hydraulic pump is attached to the motor which is good.
Page 147 April 2008 Section 4 • Repair Procedures REV B HYDRAULIC PUMP How to Remove the 6 Tag, disconnect and plug the high pressure hose at the pump. Cap the fitting on the pump. Hydraulic Pump Bodily injury hazard. Spraying When removing a hose assembly or fitting, the hydraulic oil can penetrate and O-ring on the fitting and/or hose end must be burn skin.
Page 148: Function Manifold Components - Gs-1530, Gs-1532, Gs-1930 And Gs-1932
Section 4 • Repair Procedures February 2009 Manifolds REV F Function Manifold Components - GS-1530, GS-1532, GS-1930 and GS-1932 The function manifold is mounted under the machine, between the module trays. Index Schematic Description Item Function Torque — Coil nut (item F) ........................4-5 ft-lbs / 5-7 Nm —...
Page 149 February 2009 Section 4 • Repair Procedures REV F MANIFOLDS INSIDE COIL OUTSIDE COIL Before serial number GS3005A-76492: drive reverse coil Y5 Before serial number GS3005B-76085: drive reverse coil Y5 After serial number GS3005A-76491: drive forward coil Y6 After serial number GS3005B-76084: drive forward coil Y6 Note: 'alpha' callouts refer Before serial number GS3005A-76492: drive forward coil Y6 to corresponding notes on...
Page 150: Function Manifold Components - Gs-2032, Gs-2632, Gs-3232, Gs-2046, Gs-2646 And Gs-3246
Section 4 • Repair Procedures February 2009 MANIFOLDS REV F Function Manifold Components - GS-2032, GS-2632, GS-3232, GS-2046, GS-2646 and GS-3246 The function manifold is mounted behind an inspection door on the ground control side of the machine. Index Schematic Description Item Function...
Page 151 February 2009 Section 4 • Repair Procedures REV F MANIFOLDS Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic Note: 'alpha-numeric' callouts refer to corresponding notes on the electrical schematic INSIDE COIL OUTSIDE COIL Inside Coil (closest to manifold) Before serial number GS3206-80132: drive forward coil Y6 Before serial number GS4606-79028: drive forward coil Y6...
Page 152: Outrigger Function Manifold Components - Gs-3232
Section 4 • Repair Procedures February 2009 MANIFOLDS REV F Outrigger Function Manifold Components - GS-3232 The outrigger function manifold is mounted behind an inspection door on the battery side of the machine. Index Schematic Description Item Function Torque — Coil nut (item BA) .........................
Page 153: Outrigger Cylinder Manifold Components - Gs-3232
February 2009 Section 4 • Repair Procedures REV F MANIFOLDS Outrigger Cylinder Manifold Components - GS-3232 The front outrigger cylinders are located behind the inspection doors at the battery side and at the ground control side of the machine. The rear outrigger cylinders are located inside the outrigger enclosures at the rear of the machine.
Page 154: Check Valve Manifold Components - Gs-1530, Gs-1532, Gs-1930 And Gs-1932
Section 4 • Repair Procedures February 2009 MANIFOLDS REV F Check Valve Manifold Components - GS-1530, GS-1532, GS-1930 and GS-1932 The check valve manifold is mounted on the function manifold. Index Schematic Description Item Function Torque Check valve, 200 psi / 13.8 bar ....S ......Drive circuit ......20 ft-lbs / 27 Nm...
Page 155: Valve Adjustments - Function Manifold
GS-32 and GS-46 test port system relief valve steer relief valve lift relief valve GS-1530/32 and GS-1930/32 test port system relief valve Part No. 97385 GS-30 • GS-32 • GS-46 4 - 95...
Page 156 12 Place maximum rated load into the platform. 6 Press and hold the function enable switch. Secure the load to the platform. Refer to Section 2, Specifications . GS-1530/32 and GS-1930/32 GS-32 and GS-46 test port test port system relief valve...
Page 157 February 2009 Section 4 • Repair Procedures REV F MANIFOLDS 13 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls. 14 Hold the lift relief valve with a wrench and remove the cap (schematic item C or AJ).
Page 158 Do not adjust the relief valve pressures higher than specifications. 9 Install the relief valve cap. 10 Repeat steps 5 through 6 to confirm the relief valve pressure. GS-1530/32 and GS-1930/32 test port steer relief valve GS-32 and GS-46 test port system relief valve...
Page 159: Valve Coils
February 2009 Section 4 • Repair Procedures REV F MANIFOLDS Valve Coil Resistance Valve Coils Specification Note: The following coil resistance specifications How to Test a Coil are at an ambient temperature of 68°F / 20°C. As 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...
Page 160 Section 4 • Repair Procedures February 2009 MANIFOLDS REV F How to Test a Coil Diode Genie incorporates spike suppressing diodes in all COIL of its coils. Properly functioning coil diodes protect MULTI METER the electrical circuit by suppressing voltage spikes.
Page 161: Hydraulic Tank
April 2008 Section 4 • Repair Procedures Hydraulic Tank REV B 2 Remove the drain plug from the hydraulic tank and allow all of the oil from the tank to drain into Hydraulic Tank a suitable container. Refer to Section 2, Specifications .
Page 162: Steer Axle Components
Section 4 • Repair Procedures November 2008 Steer Axle Components REV B 7 Tag, disconnect and plug the hydraulic hoses on the drive motor. Cap the fittings on the drive Yoke and Drive Motor motor. Bodily injury hazard. Spraying How to Remove the Yoke hydraulic oil can penetrate and and Drive Motor Assembly burn skin.
Page 163: Steer Cylinder
November 2008 Section 4 • Repair Procedures REV B STEER AXLE COMPONENTS How to Remove a Drive Motor Steer Cylinder 1 Block the non-steer wheels. 2 Remove the cotter pin from the wheel castle nut How to Remove the of the motor to be removed. Steer Cylinder Note: Always replace the cotter pin with a new one when removing the castle nut.
Page 164: Steer Bellcrank
Section 4 • Repair Procedures November 2008 STEER AXLE COMPONENTS REV B 6 Remove the bellcrank from the machine. Steer Bellcrank Note: While removing the bellcrank from the machine, take note of the quantity and location of the spacers between the bellcrank and the steer How to Remove the Steer links.
Page 165: Non-Steer Axle Components
March 2007 Section 4 • Repair Procedures Non-steer Axle Components REV A 9 Tag, disconnect and plug the hydraulic hose from the brake. Cap the fitting on the brake. Drive Brake Bodily injury hazard. Spraying hydraulic oil can penetrate and How to Remove a Drive Brake burn skin.
Page 166: Brake Release Hand Pump Components
Section 4 • Repair Procedures March 2007 Brake Release Hand Pump Components REV A 10-1 Brake Release Hand Pump Components The brake release hand pump manifold is mounted behind the entry ladder. Index Schematic Description Item Function Torque Hand pump ........L ....Manual brake release ......30 ft-lbs / 41 Nm Needle valve ........
Page 167: Outrigger Components
March 2007 Section 4 • Repair Procedures Outrigger Components REV A 11-1 7 Support and secure the outrigger cylinder to a suitable lifting device. Outrigger Cylinder 8 Remove the outrigger cylinder mounting fasteners. How to Remove an Outrigger 9 Remove the outrigger cylinder from the Cylinder machine.
Page 168 Section 4 • Repair Procedures March 2007 OUTRIGGER COMPONENTS REV A Non-steer End: 1 Chock the wheels at the steer end of the machine. 2 With a suitable floor jack, lift the non-steer end of the machine to a height that will allow the outrigger cylinder to be removed.
Page 169 March 2007 Section 5 • Fault Codes Fault Codes Before Troubleshooting: Read, understand and obey the safety rules and operating instructions in the appropriate operator's manual on your machine. Be sure that all necessary tools and test equipment are available and ready for use. Observe and Obey: Read each appropriate fault code thoroughly.
Page 170 Section 5 • Fault Codes February 2012 FAULT CODES About This Section Fault Code Note When a malfunction is discovered, the fault code If the machine will not drive or lift, but the readout charts in this section will help a service is powered and no fault code is displayed, the professional pinpoint the cause of the problem.
Page 171: Fault Code Chart
March 2007 Section 5 • Fault Codes Fault Code Chart REV C Fault Code Problem Possible Causes Solution Internal ECM error. EPROM not programmed. Replace ECM. Malfunctioning control cable Troubleshoot control cable ECM/Platform OR malfunctioning platform OR troubleshoot platform communication error. controls.
Page 172 Section 5 • Fault Codes November 2007 FAULT CODES REV B Outrigger Control Pad The outrigger control pad displays solid red or blinking red lights, as well as a audible alarm that provide information about the outrigger operating status and about malfunctions. The codes listed in the Outrigger Fault Code Chart describe malfunctions and can aid in troubleshooting the machine by pinpointing the...
Page 173: Outrigger Fault Code Chart
Section 5 • Fault Codes November 2007 Outrigger Fault Code Chart REV B Fault Code Problem Possible Causes Solution Lift error light Up coil fault. Malfunctioning coil OR Troubleshoot coil OR blinks red 2 wire disconnected from inspect wire connection. times.
Page 174 Section 5 • Fault Codes November 2007 OUTRIGGER FAULT CODES cont. REV B Fault Code Problem Possible Causes Solution Right rear outrigger light Right rear Short to power. Troubleshoot the blinks red 4 times. outrigger harness to the pressure pressure transducer transducer OR replace the fault.
Page 175: Hydraulic Schematics
March 2007 Section 6 • Schematics Schematics About This Section There are two groups of schematics in this section. An illustration legend precedes each group of drawings. Electrical Schematics Observe and Obey: Electrocution/burn hazard. Contact with electrically charged Troubleshooting and repair procedures shall be circuits could result in death or completed by a person trained and qualified on serious injury.
Page 176: Electrical Component Legend
Section 6 • Schematics March 2007 Electrical Component Legend REV C ELECTRICAL COMPONENT LEGEND ELECTRICAL COMPONENT LEGEND cont. Item Description Item Description Battery Power switch Button P1 = Emergency Stop button at ground controls P2 = Emergency Stop button at platform controls BN5 = Horn BN6 = High torque Platform overload pressure switch (option)
Page 177: Wire Color Legend
March 2007 Section 6 • Schematics Wire Color Legend REV B WIRE COLOR LEGEND Color Description Black Blue BL/BK Blue/Black BL/WH Blue/White Brown Green GN/BK Green/Black GN/WH Green/White Gray Orange OR/BK Orange/Black OR/WH Orange/White Purple RD/BK Red/Black RD/WH Red/White White WH/BK White/Black Part No.
Page 178: Ecm Pin-Out Legend
Not used Driv e forward coil Y6 (output) Steer right c oil Y3 (output) Parallel coil Y1 (not available on GS-1530/32 and GS-1930/32) Work light L30 (option) Not used Level sensor s ignal S7 (input) Down limit s witc h LS66 (input) 6 - 4 GS-30 •...
Page 179: Outrigger Ecm Pin-Out Legend
March 2007 Section 6 • Schematics Outrigger ECM Pin-out Legend REV A OUTRIGGER ECM PIN-OUT LEGEND Item Description 24V C 24V CC Right rear outrigger pressure transducer signal (input) Right front outrigger pressure transducer signal (input) Left rear outrigger pressure transducer signal (input) Left front outrigger pressure transducer signal (input)
Page 180 Section 6 • Schematics February 2009 Wiring Diagram Ground Controls and Level Sensor Harness REV B GROUND CONTROLS MOTOR CONTROLLER TERMINAL B+ KEY SWITCH 7A CIRCUIT BREAKER MOTOR CONTROLLER TERMINAL 1 6-PIN CONNECTOR WH/BK HOUR METER PIN 1 (J7) (UP) ECM PIN B12 (J1) TS66 PLATFORM UP/DOWN...
Page 181 March 2007 Section 6 • Schematics Wiring Diagram REV B Platform Control Box and Outrigger Control Pad PLATFORM CONTROLS (GEN 5) JOYSTICK CONTROLLER ALARM TO COIL CORD EMERGENCY STOP TO COIL CORD LIFT ENABLE LIFT ERROR OUTRIGGER PLATFORM CONTROL CIRCUIT BOARD OUTRIGGER CONTROL PAD OUTRIGGER...
Page 182: Limit Switch Legend
March 2007 Limit Switch Legend REV C GS-2032 GS-2632 GS-3232 GS-2046 GS-2646 GS-3246 GS-1530 GS-1532 GS-1930 GS-1932 ALL MODELS Limit Switch Legend maximum height limit switch LS5 (CE models) down limit switch LS6 pothole switches LS7, LS8 22 ft / 6.7 m maximum drive height when outriggers are not deployed LS5A (GS-3232) 6 - 8 GS-30 •...
Page 183: Electrical Symbols Legend
February 2012 Section 6 • Schematics Electrical Symbols Legend REV C Pressure switch, normally open Motor controller Level sensor Limit switch Wire with description Motor Button or switch Solenoid valve Circuits crossing no connection Toggle switch Diode Battery charger Solenoid valve with diode Emergency stop button Circuits connection 6V DC Battery...
Page 184 Section 6 • Schematics April 2008 Electrical Schematic ANSI, CSA and Australia Models REV E GS-1530/1532/1930/1932 (from serial number GS3005A-76000 to GS3006A-83067) GS-1530/1532/1930/1932 (from serial number GS3005B-76000 to GS3006B-79659) 6 - 10 GS-30 • GS-32 • GS-46 Part No. 97385...
Page 185 Section 6 • Schematics Electrical Schematic ANSI, CSA and Australia Models REV E GS-1530/1532/1930/1932 (from serial number GS3005A-76000 to GS3006A-83067) GS-1530/1532/1930/1932 (from serial number GS3005B-76000 to GS3006B-79659) - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF...
Page 186 Section 6 • Schematics April 2008 Electrical Schematic ANSI, CSA and Australia Models REV E GS-1530/1532/1930/1932 (from serial number GS3005A-76000 to GS3006A-83067) GS-1530/1532/1930/1932 (from serial number GS3005B-76000 to GS3006B-79659) EMERGENCY STOP POWER TO PLATFORM POWER TO GROUND GROUND PIO3 PIO2...
Page 187 April 2008 Section 6 • Schematics This page intentionally left blank. Part No. 97385 GS-30 • GS-32 • GS-46 6 - 13...
Page 188 Section 6 • Schematics April 2008 Electrical Schematic ANSI, CSA and Australia Models REV C GS-1530/1532/1930/1932 (from serial number GS3006A-83068 to GS3007A-87490) GS-1530/1532/1930/1932 (from serial number GS3006B-79660 to GS3007B-82543) 6 - 14 GS-30 • GS-32 • GS-46 Part No. 97385...
Page 189 Section 6 • Schematics Electrical Schematic ANSI, CSA and Australia Models REV C GS-1530/1532/1930/1932 (from serial number GS3006A-83068 to GS3007A-87490) GS-1530/1532/1930/1932 (from serial number GS3006B-79660 to GS3007B-82543) - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF...
Page 190 Section 6 • Schematics April 2008 Electrical Schematic ANSI, CSA and Australia Models REV C GS-1530/1532/1930/1932 (from serial number GS3006A-83068 to GS3007A-87490) GS-1530/1532/1930/1932 (from serial number GS3006B-79660 to GS3007B-82543) EMERGENCY STOP POWER TO PLATFORM POWER TO GROUND GROUND PIO3 PIO2...
Page 191 April 2008 Section 6 • Schematics This page intentionally left blank. Part No. 97385 GS-30 • GS-32 • GS-46 6 - 17...
Page 192 Section 6 • Schematics April 2008 Electrical Schematic ANSI, CSA and Australia Models REV B GS-1530/1532/1930/1932 (from serial number GS3007A-87491 to GS3007A-89537) GS-1530/1532/1930/1932 (from serial number GS3007B-82544 to GS3007B-84599) 6 - 18 GS-30 • GS-32 • GS-46 Part No. 97385...
Page 193 Section 6 • Schematics Electrical Schematic ANSI, CSA and Australia Models REV B GS-1530/1532/1930/1932 (from serial number GS3007A-87491 to GS3007A-89537) GS-1530/1532/1930/1932 (from serial number GS3007B-82544 to GS3007B-84599) - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF...
Page 194 Section 6 • Schematics April 2008 Electrical Schematic ANSI, CSA and Australia Models REV B GS-1530/1532/1930/1932 (from serial number GS3007A-87491 to GS3007A-89537) GS-1530/1532/1930/1932 (from serial number GS3007B-82544 to GS3007B-84599) EMERGENCY STOP POWER TO PLATFORM POWER TO GROUND GROUND PIO3 PIO2...
Page 195 April 2008 Section 6 • Schematics This page intentionally left blank. Part No. 97385 GS-30 • GS-32 • GS-46 6 - 21...
Page 196 Section 6 • Schematics February 2012 Electrical Schematic ANSI, CSA and Australia Models REV D GS-1530/1532/1930/1932 (from serial number GS3007A-89538 to GS3010A-99455) GS-1530/1532/1930/1932 (from serial number GS3007B-84600 to GS3009B-98941) 6 - 22 GS-30 • GS-32 • GS-46 Part No. 97385...
Page 197 February 2012 Section 6 • Schematics Electrical Schematic ANSI, CSA and Australia Models REV D GS-1530/1532/1930/1932 (from serial number GS3007A-89538 to GS3010A-99455) GS-1530/1532/1930/1932 (from serial number GS3007B-84600 to GS3009B-98941) MC THROTTLE CR48 MC ENABLE (IN) POWER RELAY TO U5 (E-STOP)
Page 198 Section 6 • Schematics February 2012 Electrical Schematic ANSI, CSA and Australia Models REV D GS-1530/1532/1930/1932 (from serial number GS3007A-89538 to GS3010A-99455) GS-1530/1532/1930/1932 (from serial number GS3007B-84600 to GS3009B-98941) GS-3232 ONLY BN105 MC THROTTLE LIFT ERROR (IN) MC ENABLE LIFT ENABLE...
Page 199 February 2012 Section 6 • Schematics Electrical Schematic ANSI, CSA and Australia Models REV D GS-1530/1532/1930/1932 (from serial number GS3007A-89538 to GS3010A-99455) GS-1530/1532/1930/1932 (from serial number GS3007B-84600 to GS3009B-98941) EMERGENCY STOP - NOTE - POWER TO PLATFORM MACHINE SHOWN IN THE STOWED...
Page 200 Section 6 • Schematics February 2012 Electrical Schematic ANSI, CSA and Australia Models REV A GS-1530/1532/1930/1932 (from serial number GS3010A-99456 to GS3011A-109999) 6 - 26 GS-30 • GS-32 • GS-46 Part No. 97385...
Page 201 February 2012 Section 6 • Schematics Electrical Schematic ANSI, CSA and Australia Models REV A GS-1530/1532/1930/1932 (from serial number GS3010A-99456 to GS3011A-109999) Part No. 97385 GS-30 • GS-32 • GS-46 6 - 27...
Page 202 Section 6 • Schematics February 2012 Electrical Schematic ANSI, CSA and Australia Models REV A GS-1530/1532/1930/1932 (from serial number GS3010A-99456 to GS3011A-109999) 6 - 28 GS-30 • GS-32 • GS-46 Part No. 97385...
Page 203 February 2012 Section 6 • Schematics Electrical Schematic ANSI, CSA and Australia Models REV A GS-1530/1532/1930/1932 (from serial number GS3010A-99456 to GS3011A-109999) Part No. 97385 GS-30 • GS-32 • GS-46 6 - 29...
Page 204 Section 6 • Schematics April 2008 Electrical Schematic ANSI, CSA and Australia Models REV E GS-2032/2632 (from serial number GS3205-75407 to GS3206-79991) GS-2046/2646/3246 (from serial number GS4605-75438 to GS4606-78915) 6 - 30 GS-30 • GS-32 • GS-46 Part No. 97385...
Page 205 April 2008 Section 6 • Schematics Electrical Schematic ANSI, CSA and Australia Models REV E GS-2032/2632 (from serial number GS3205-75407 to GS3206-79991) GS-2046/2646/3246 (from serial number GS4605-75438 to GS4606-78915) - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF CR48 POWER RELAY TO U5...
Page 206 Section 6 • Schematics April 2008 Electrical Schematic ANSI, CSA and Australia Models REV E GS-2032/2632 (from serial number GS3205-75407 to GS3206-79991) GS-2046/2646/3246 (from serial number GS4605-75438 to GS4606-78915) EMERGENCY STOP POWER TO PLATFORM POWER TO GROUND GROUND PIO3 PIO2 DATA LINK (HIGH) PIO4 DATA LINK (LOW)
Page 207 April 2008 Section 6 • Schematics This page intentionally left blank. Part No. 97385 GS-30 • GS-32 • GS-46 6 - 33...
Page 208 Section 6 • Schematics April 2008 Electrical Schematic ANSI, CSA and Australia Models REV C GS-2032/2632 (from serial number GS3206-79992 to GS3207-83650) GS-2046/2646/3246 (from serial number GS4606-78916 to GS4607-82535) 6 - 34 GS-30 • GS-32 • GS-46 Part No. 97385...
Page 209 April 2008 Section 6 • Schematics Electrical Schematic ANSI, CSA and Australia Models REV C GS-2032/2632 (from serial number GS3206-79992 to GS3207-83650) GS-2046/2646/3246 (from serial number GS4606-78916 to GS4607-82535) - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF CR48 POWER RELAY TO U5...
Page 210 Section 6 • Schematics April 2008 Electrical Schematic ANSI, CSA and Australia Models REV C GS-2032/2632 (from serial number GS3206-79992 to GS3207-83650) GS-2046/2646/3246 (from serial number GS4606-78916 to GS4607-82535) EMERGENCY STOP POWER TO PLATFORM POWER TO GROUND GROUND PIO3 PIO2 DATA LINK (HIGH) PIO4 DATA LINK (LOW)
Page 211 April 2008 Section 6 • Schematics This page intentionally left blank. Part No. 97385 GS-30 • GS-32 • GS-46 6 - 37...
Page 212 Section 6 • Schematics April 2008 Electrical Schematic ANSI, CSA and Australia Models REV B GS-2032/2632 (from serial number GS3207-83651 to GS3207-84866) GS-2046/2646/3246 (from serial number GS4607-82536 to GS4607-84839) 6 - 38 GS-30 • GS-32 • GS-46 Part No. 97385...
Page 213 April 2008 Section 6 • Schematics Electrical Schematic ANSI, CSA and Australia Models REV B GS-2032/2632 (from serial number GS3207-83651 to GS3207-84866) GS-2046/2646/3246 (from serial number GS4607-82536 to GS4607-84839) - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF CR48 POWER RELAY TO U5...
Page 214 Section 6 • Schematics April 2008 Electrical Schematic ANSI, CSA and Australia Models REV B GS-2032/2632 (from serial number GS3207-83651 to GS3207-84866) GS-2046/2646/3246 (from serial number GS4607-82536 to GS4607-84839) EMERGENCY STOP POWER TO PLATFORM POWER TO GROUND GROUND PIO3 PIO2 DATA LINK (HIGH) PIO4 DATA LINK (LOW)
Page 215 April 2008 Section 6 • Schematics This page intentionally left blank. Part No. 97385 GS-30 • GS-32 • GS-46 6 - 41...
Page 216 Section 6 • Schematics February 2012 Electrical Schematic ANSI, CSA and Australia Models REV D GS-2032/2632/3232 (from serial number GS3207A-84867 to GS3210A-94974) GS-2046/2646/3246 (from serial number GS4607A-84840 to GS4610A-95454) 6 - 42 GS-30 • GS-32 • GS-46 Part No. 97385...
Page 217 February 2012 Section 6 • Schematics Electrical Schematic ANSI, CSA and Australia Models REV D GS-2032/2632/3232 (from serial number GS3207A-84867 to GS3210A-94974) GS-2046/2646/3246 (from serial number GS4607A-84840 to GS4610A-95454) MC THROTTLE CR48 MC ENABLE (IN) POWER RELAY TO U5 (E-STOP) DRIVE ENABLE OR/BK GS-3232 ONLY...
Page 218 Section 6 • Schematics February 2012 Electrical Schematic ANSI, CSA and Australia Models REV D GS-2032/2632/3232 (from serial number GS3207A-84867 to GS3210A-94974) GS-2046/2646/3246 (from serial number GS4607A-84840 to GS4610A-95454) GS-3232 ONLY BN105 MC THROTTLE LIFT ERROR (IN) MC ENABLE LIFT ENABLE EXTEND ALARM BN107...
Page 219 February 2012 Section 6 • Schematics Electrical Schematic ANSI, CSA and Australia Models REV D GS-2032/2632/3232 (from serial number GS3207A-84867 to GS3210A-94974) GS-2046/2646/3246 (from serial number GS4607A-84840 to GS4610A-95454) EMERGENCY STOP - NOTE - POWER TO PLATFORM MACHINE SHOWN IN THE STOWED POWER TO GROUND POSITION WITH THE POWER OFF GROUND...
Page 220 Section 6 • Schematics February 2012 Electrical Schematic ANSI, CSA and Australia Models REV A GS-2032/2632/3232 (from serial number GS3210A-94975 to GS3211A-97903) GS-2046/2646/3246 (from serial number GS4610A-95455 to GS4611A-97982) 6 - 46 GS-30 • GS-32 • GS-46 Part No. 97385...
Page 221 February 2012 Section 6 • Schematics Electrical Schematic ANSI, CSA and Australia Models REV A GS-2032/2632/3232 (from serial number GS3210A-94975 to GS3211A-97903) GS-2046/2646/3246 (from serial number GS4610A-95455 to GS4611A-97982) Part No. 97385 GS-30 • GS-32 • GS-46 6 - 47...
Page 222 Section 6 • Schematics February 2012 Electrical Schematic ANSI, CSA and Australia Models REV A GS-2032/2632/3232 (from serial number GS3210A-94975 to GS3211A-97903) GS-2046/2646/3246 (from serial number GS4610A-95455 to GS4611A-97982) 6 - 48 GS-30 • GS-32 • GS-46 Part No. 97385...
Page 223 February 2012 Section 6 • Schematics Electrical Schematic ANSI, CSA and Australia Models REV A GS-2032/2632/3232 (from serial number GS3210A-94975 to GS3211A-97903) GS-2046/2646/3246 (from serial number GS4610A-95455 to GS4611A-97982) Part No. 97385 GS-30 • GS-32 • GS-46 6 - 49...
Page 224 Section 6 • Schematics February 2012 Electrical Schematic ANSI, CSA and Australia Models REV A GS-2032/2632/3232 (from serial number GS3211A-97904 to GS3212A-109999) GS-2046/2646/3246 (from serial number GS4611A-97983 to GS4612A-109999) 6 - 50 GS-30 • GS-32 • GS-46 Part No. 97385...
Page 225 February 2012 Section 6 • Schematics Electrical Schematic ANSI, CSA and Australia Models REV A GS-2032/2632/3232 (from serial number GS3211A-97904 to GS3212A-109999) GS-2046/2646/3246 (from serial number GS4611A-97983 to GS4612A-109999) Part No. 97385 GS-30 • GS-32 • GS-46 6 - 51...
Page 226 Section 6 • Schematics February 2012 Electrical Schematic ANSI, CSA and Australia Models REV A GS-2032/2632/3232 (from serial number GS3211A-97904 to GS3212A-109999) GS-2046/2646/3246 (from serial number GS4611A-97983 to GS4612A-109999) 6 - 52 GS-30 • GS-32 • GS-46 Part No. 97385...
Page 227 February 2012 Section 6 • Schematics Electrical Schematic ANSI, CSA and Australia Models REV A GS-2032/2632/3232 (from serial number GS3211A-97904 to GS3212A-109999) GS-2046/2646/3246 (from serial number GS4611A-97983 to GS4612A-109999) Part No. 97385 GS-30 • GS-32 • GS-46 6 - 53...
Page 228 Section 6 • Schematics April 2008 Electrical Schematic CE Models REV E GS-1530/1532/1930/1932 (from serial number GS3005A-76000 to GS3005A-76388) GS-1530/1532/1930/1932 (from serial number GS3005B-76000 to GS3005B-76030) 6 - 54 GS-30 • GS-32 • GS-46 Part No. 97385...
Page 229 April 2008 Section 6 • Schematics Electrical Schematic CE Models REV E GS-1530/1532/1930/1932 (from serial number GS3005A-76000 to GS3005A-76388) GS-1530/1532/1930/1932 (from serial number GS3005B-76000 to GS3005B-76030) - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF CR48...
Page 230 Section 6 • Schematics April 2008 Electrical Schematic CE Models REV E GS-1530/1532/1930/1932 (from serial number GS3005A-76000 to GS3005A-76388) GS-1530/1532/1930/1932 (from serial number GS3005B-76000 to GS3005B-76030) EMERGENCY STOP POWER TO PLATFORM POWER TO GROUND GROUND PIO3 PIO2 DATA LINK (HIGH)
Page 231 April 2008 Section 6 • Schematics This page intentionally left blank. Part No. 97385 GS-30 • GS-32 • GS-46 6 - 57...
Page 232 Section 6 • Schematics April 2008 Electrical Schematic CE Models REV E GS-1530/1532/1930/1932 (from serial number GS3005A-76389 to GS3005A-79394) GS-1530/1532/1930/1932 (from serial number GS3005B-76031 to GS3005B-76920) 6 - 58 GS-30 • GS-32 • GS-46 Part No. 97385...
Page 233 April 2008 Section 6 • Schematics Electrical Schematic CE Models REV E GS-1530/1532/1930/1932 (from serial number GS3005A-76389 to GS3005A-79394) GS-1530/1532/1930/1932 (from serial number GS3005B-76031 to GS3005B-76920) - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF CR48...
Page 234 Section 6 • Schematics April 2008 Electrical Schematic CE Models REV E GS-1530/1532/1930/1932 (from serial number GS3005A-76389 to GS3005A-79394) GS-1530/1532/1930/1932 (from serial number GS3005B-76031 to GS3005B-76920) EMERGENCY STOP POWER TO PLATFORM POWER TO GROUND GROUND PIO3 PIO2 DATA LINK (HIGH)
Page 235 April 2008 Section 6 • Schematics This page intentionally left blank. Part No. 97385 GS-30 • GS-32 • GS-46 6 - 61...
Page 236 Section 6 • Schematics April 2008 Electrical Schematic CE Models REV D GS-1530/1532/1930/1932 (from serial number GS3005A-79395 to GS3006A-83067) GS-1530/1532/1930/1932 (from serial number GS3005B-76921 to GS3006B-79659) 6 - 62 GS-30 • GS-32 • GS-46 Part No. 97385...
Page 237 April 2008 Section 6 • Schematics Electrical Schematic CE Models REV D GS-1530/1532/1930/1932 (from serial number GS3005A-79395 to GS3006A-83067) GS-1530/1532/1930/1932 (from serial number GS3005B-76921 to GS3006B-79659) - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF CR28...
Page 238 Section 6 • Schematics April 2008 Electrical Schematic CE Models REV D GS-1530/1532/1930/1932 (from serial number GS3005A-79395 to GS3006A-83067) GS-1530/1532/1930/1932 (from serial number GS3005B-76921 to GS3006B-79659) EMERGENCY STOP POWER TO PLATFORM POWER TO GROUND GROUND PIO3 PIO2 DATA LINK (HIGH)
Page 239 April 2008 Section 6 • Schematics This page intentionally left blank. Part No. 97385 GS-30 • GS-32 • GS-46 6 - 65...
Page 240 Section 6 • Schematics April 2008 Electrical Schematic CE Models REV C GS-1530/1532/1930/1932 (from serial number GS3006A-83068 to GS3007A-87490) GS-1530/1532/1930/1932 (from serial number GS3006B-79660 to GS3007B-82543) 6 - 66 GS-30 • GS-32 • GS-46 Part No. 97385...
Page 241 April 2008 Section 6 • Schematics Electrical Schematic CE Models REV C GS-1530/1532/1930/1932 (from serial number GS3006A-83068 to GS3007A-87490) GS-1530/1532/1930/1932 (from serial number GS3006B-79660 to GS3007B-82543) - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF CR28...
Page 242 Section 6 • Schematics April 2008 Electrical Schematic CE Models REV C GS-1530/1532/1930/1932 (from serial number GS3006A-83068 to GS3007A-87490) GS-1530/1532/1930/1932 (from serial number GS3006B-79660 to GS3007B-82543) EMERGENCY STOP POWER TO PLATFORM POWER TO GROUND GROUND PIO3 PIO2 DATA LINK (HIGH)
Page 243 April 2008 Section 6 • Schematics This page intentionally left blank. Part No. 97385 GS-30 • GS-32 • GS-46 6 - 69...
Page 244 Section 6 • Schematics April 2008 Electrical Schematic CE Models REV B GS-1530/1532/1930/1932 (from serial number GS3007A-87491 to GS3007A-89537) GS-1530/1532/1930/1932 (from serial number GS3007B-82544 to GS3007B-84599) 6 - 70 GS-30 • GS-32 • GS-46 Part No. 97385...
Page 245 April 2008 Section 6 • Schematics Electrical Schematic CE Models REV B GS-1530/1532/1930/1932 (from serial number GS3007A-87491 to GS3007A-89537) GS-1530/1532/1930/1932 (from serial number GS3007B-82544 to GS3007B-84599) - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF CR28...
Page 246 Section 6 • Schematics April 2008 Electrical Schematic CE Models REV B GS-1530/1532/1930/1932 (from serial number GS3007A-87491 to GS3007A-89537) GS-1530/1532/1930/1932 (from serial number GS3007B-82544 to GS3007B-84599) EMERGENCY STOP POWER TO PLATFORM POWER TO GROUND GROUND PIO3 PIO2 DATA LINK (HIGH)
Page 247 April 2008 Section 6 • Schematics This page intentionally left blank. Part No. 97385 GS-30 • GS-32 • GS-46 6 - 73...
Page 248 Section 6 • Schematics February 2012 Electrical Schematic CE Models REV G GS-1530/32 & 1930/32 (from serial number GS3007A-89538 to GS3010A-99455 and GS3007B-84600 to GS3009B-98941 and GS3008C-101 to GS3010C-2189) 6 - 74 GS-30 • GS-32 • GS-46 Part No. 97385...
Page 249 February 2012 Section 6 • Schematics Electrical Schematic CE Models REV G GS-1530/32 & 1930/32 (from serial number GS3007A-89538 to GS3010A-99455 and GS3007B-84600 to GS3009B-98941 and GS3008C-101 to GS3010C-2189) MC THROTTLE CR48 MC ENABLE (IN) POWER RELAY TO U5 (E-STOP)
Page 250 Section 6 • Schematics February 2012 Electrical Schematic CE Models REV G GS-1530/32 & 1930/32 (from serial number GS3007A-89538 to GS3010A-99455 and GS3007B-84600 to GS3009B-98941 and GS3008C-101 to GS3010C-2189) GS-3232 ONLY BN107 MC THROTTLE LIFT ENABLE (IN) MC ENABLE RETRACT...
Page 251 February 2012 Section 6 • Schematics Electrical Schematic CE Models REV G GS-1530/32 & 1930/32 (from serial number GS3007A-89538 to GS3010A-99455 and GS3007B-84600 to GS3009B-98941 and EMERGENCY STOP - NOTE - POWER TO PLATFORM MACHINE SHOWN IN THE STOWED POWER TO GROUND...
Page 252 Section 6 • Schematics February 2012 Electrical Schematic CE Models REV A GS-1530/32 & 1930/32 (from serial number GS3010A-99456 to GS3011A-109999) GS-1530/32 & 1930/32 (from serial number GS3010C-2190 to GS3011C-5059) 6 - 78 GS-30 • GS-32 • GS-46 Part No. 97385...
Page 253 February 2012 Section 6 • Schematics Electrical Schematic CE Models REV A GS-1530/32 & 1930/32 (from serial number GS3010A-99456 to GS3011A-109999) GS-1530/32 & 1930/32 (from serial number GS3010C-2190 to GS3011C-5059) Part No. 97385 GS-30 • GS-32 • GS-46 6 - 79...
Page 254 Section 6 • Schematics February 2012 Electrical Schematic CE Models REV A GS-1530/32 & 1930/32 (from serial number GS3010A-99456 to GS3011A-109999) GS-1530/32 & 1930/32 (from serial number GS3010C-2190 to GS3011C-5059) 6 - 80 GS-30 • GS-32 • GS-46 Part No. 97385...
Page 255 February 2012 Section 6 • Schematics Electrical Schematic CE Models REV A GS-1530/32 & 1930/32 (from serial number GS3010A-99456 to GS3011A-109999) GS-1530/32 & 1930/32 (from serial number GS3010C-2190 to GS3011C-5059) Part No. 97385 GS-30 • GS-32 • GS-46 6 - 81...
Page 256 Section 6 • Schematics February 2012 Electrical Schematic CE Models REV A GS-1530/32 & 1930/32 (from serial number GS3012C-5060 to GS3012C-5311) 6 - 82 GS-30 • GS-32 • GS-46 Part No. 97385...
Page 257 February 2012 Section 6 • Schematics Electrical Schematic CE Models REV A GS-1530/32 & 1930/32 (from serial number GS3012C-5060 to GS3012C-5311) Part No. 97385 GS-30 • GS-32 • GS-46 6 - 83...
Page 258 Section 6 • Schematics February 2012 Electrical Schematic CE Models REV A GS-1530/32 & 1930/32 (from serial number GS3012C-5060 to GS3012C-5311) 6 - 84 GS-30 • GS-32 • GS-46 Part No. 97385...
Page 259 February 2012 Section 6 • Schematics Electrical Schematic CE Models REV A GS-1530/32 & 1930/32 (from serial number GS3012C-5060 to GS3012C-5311) Part No. 97385 GS-30 • GS-32 • GS-46 6 - 85...
Page 260 Section 6 • Schematics April 2008 Electrical Schematic CE Models REV E GS-2032/2632 (from serial number GS3205-75407 to GS3205-77290) GS-2046/2646/3246 (from serial number GS4605-75438 to GS4605-76734) 6 - 86 GS-30 • GS-32 • GS-46 Part No. 97385...
Page 261 April 2008 Section 6 • Schematics Electrical Schematic CE Models REV E GS-2032/2632 (from serial number GS3205-75407 to GS3205-77290) GS-2046/2646/3246 (from serial number GS4605-75438 to GS4605-76734) - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF CR48 POWER RELAY TO U5 (E-STOP)
Page 262 Section 6 • Schematics April 2008 Electrical Schematic CE Models REV E GS-2032/2632 (from serial number GS3205-75407 to GS3205-77290) GS-2046/2646/3246 (from serial number GS4605-75438 to GS4605-76734) EMERGENCY STOP POWER TO PLATFORM POWER TO GROUND GROUND PIO3 PIO2 DATA LINK (HIGH) PIO4 DATA LINK (LOW) PIO5...
Page 263 April 2008 Section 6 • Schematics This page intentionally left blank. Part No. 97385 GS-30 • GS-32 • GS-46 6 - 89...
Page 264 Section 6 • Schematics April 2008 Electrical Schematic CE Models REV D GS-2032/2632 (from serial number GS3205-77291 to GS3206-79991) GS-2046/2646/3246 (from serial number GS4605-76735 to GS4606-78915) 6 - 90 GS-30 • GS-32 • GS-46 Part No. 97385...
Page 265 April 2008 Section 6 • Schematics Electrical Schematic CE Models REV D GS-2032/2632 (from serial number GS3205-77291 to GS3206-79991) GS-2046/2646/3246 (from serial number GS4605-76735 to GS4606-78915) - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF CR28 CR48 CUT OUT POWER...
Page 266 Section 6 • Schematics April 2008 Electrical Schematic CE Models REV D GS-2032/2632 (from serial number GS3205-77291 to GS3206-79991) GS-2046/2646/3246 (from serial number GS4605-76735 to GS4606-78915) EMERGENCY STOP POWER TO PLATFORM POWER TO GROUND GROUND PIO3 PIO2 DATA LINK (HIGH) PIO4 DATA LINK (LOW) PIO5...
Page 267 April 2008 Section 6 • Schematics This page intentionally left blank. Part No. 97385 GS-30 • GS-32 • GS-46 6 - 93...
Page 268 Section 6 • Schematics April 2008 Electrical Schematic CE Models REV C GS-2032/2632 (from serial number GS3206-79992 to GS3207-83650) GS-2046/2646/3246 (from serial number GS4606-78916 to GS4607-82535) 6 - 94 GS-30 • GS-32 • GS-46 Part No. 97385...
Page 269 April 2008 Section 6 • Schematics Electrical Schematic CE Models REV C GS-2032/2632 (from serial number GS3206-79992 to GS3207-83650) GS-2046/2646/3246 (from serial number GS4606-78916 to GS4607-82535) - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF CR28 CR48 CUT OUT POWER...
Page 270 Section 6 • Schematics April 2008 Electrical Schematic CE Models REV C GS-2032/2632 (from serial number GS3206-79992 to GS3207-83650) GS-2046/2646/3246 (from serial number GS4606-78916 to GS4607-82535) EMERGENCY STOP POWER TO PLATFORM POWER TO GROUND GROUND PIO3 PIO2 DATA LINK (HIGH) PIO4 DATA LINK (LOW) PIO5...
Page 271 April 2008 Section 6 • Schematics This page intentionally left blank. Part No. 97385 GS-30 • GS-32 • GS-46 6 - 97...
Page 272 Section 6 • Schematics April 2008 Electrical Schematic CE Models REV B GS-2032/2632 (from serial number GS3207-83651 to GS3207-84866) GS-2046/2646/3246 (from serial number GS4607-82536 to GS4607-84839) 6 - 98 GS-30 • GS-32 • GS-46 Part No. 97385...
Page 273 April 2008 Section 6 • Schematics Electrical Schematic CE Models REV B GS-2032/2632 (from serial number GS3207-83651 to GS3207-84866) GS-2046/2646/3246 (from serial number GS4607-82536 to GS4607-84839) - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF CR28 CR48 CUT OUT POWER...
Page 274 Section 6 • Schematics April 2008 Electrical Schematic CE Models REV B GS-2032/2632 (from serial number GS3207-83651 to GS3207-84866) GS-2046/2646/3246 (from serial number GS4607-82536 to GS4607-84839) EMERGENCY STOP POWER TO PLATFORM POWER TO GROUND GROUND PIO3 PIO2 DATA LINK (HIGH) PIO4 DATA LINK (LOW) PIO5...
Page 275 April 2008 Section 6 • Schematics This page intentionally left blank. Part No. 97385 GS-30 • GS-32 • GS-46 6 - 101...
Page 276 Section 6 • Schematics February 2012 Electrical Schematic - CE Models CE Models REV G GS-2032/2632/3232 (from serial numberGS3207-84867 to GS3210A-94974 and GS3208C-101 to GS3210C-378) GS-2046/2646/3246 (from serial number GS4607-84840 to GS4610A-95454 and GS4609C-101 to GS4610C-118) 6 - 102 GS-30 • GS-32 • GS-46 Part No.
Page 277 February 2012 Section 6 • Schematics Electrical Schematic CE Models REV G GS-2032/2632/3232 (from serial numberGS3207-84867 to GS3210A-94974 and GS3208C-101 to GS3210C-378) GS-2046/2646/3246 (from serial number GS4607-84840 to GS4610A-95454 and GS4609C-101 to GS4610C-118) MC THROTTLE CR48 MC ENABLE (IN) POWER RELAY TO U5 (E-STOP) OR/BK...
Page 278 Section 6 • Schematics February 2012 Electrical Schematic - CE Models CE Models REV G GS-2032/2632/3232 (from serial numberGS3207-84867 to GS3210A-94974 and GS3208C-101 to GS3210C-378) GS-2046/2646/3246 (from serial number GS4607-84840 to GS4610A-95454 and GS4609C-101 to GS4610C-118) GS-3232 ONLY BN107 MC THROTTLE LIFT ENABLE (IN) MC ENABLE...
Page 279 February 2012 Section 6 • Schematics Electrical Schematic CE Models REV G GS-2032/2632/3232 (from serial numberGS3207-84867 to GS3210A-94974 and GS3208C-101 to GS3210C-378) GS-2046/2646/3246 (from serial number GS4607-84840 to GS4610A-95454 and GS4609C-101 to GS4610C-118) EMERGENCY STOP - NOTE - POWER TO PLATFORM MACHINE SHOWN IN THE STOWED POWER TO GROUND POSITION WITH THE POWER OFF...
Page 280 Section 6 • Schematics February 2012 Electrical Schematic - CE Models CE Models REV A GS-2032/2632/3232 (from serial number GS3210A-94975 to GS3211A-97903 and GS3210C-379 to GS3212C-1386) GS-2046/2646/3246 (from serial number GS4610A-95455 to GS4611A-97982 and GS4610C-119 to GS4612C-1385) 6 - 106 GS-30 •...
Page 281 February 2012 Section 6 • Schematics Electrical Schematic CE Models REV A GS-2032/2632/3232 (from serial number GS3210A-94975 to GS3211A-97903 and GS3210C-379 to GS3212C-1386) GS-2046/2646/3246 (from serial number GS4610A-95455 to GS4611A-97982 and GS4610C-119 to GS4612C-1385) Part No. 97385 GS-30 • GS-32 • GS-46 6 - 107...
Page 282 Section 6 • Schematics February 2012 Electrical Schematic - CE Models CE Models REV A GS-2032/2632/3232 (from serial number GS3210A-94975 to GS3211A-97903 and GS3210C-379 to GS3212C-1386) GS-2046/2646/3246 (from serial number GS4610A-95455 to GS4611A-97982 and GS4610C-119 to GS4612C-1385) 6 - 108 GS-30 •...
Page 283 February 2012 Section 6 • Schematics Electrical Schematic CE Models REV A GS-2032/2632/3232 (from serial number GS3210A-94975 to GS3211A-97903 and GS3210C-379 to GS3212C-1386) GS-2046/2646/3246 (from serial number GS4610A-95455 to GS4611A-97982 and GS4610C-119 to GS4612C-1385) Part No. 97385 GS-30 • GS-32 • GS-46 6 - 109...
Page 284 Section 6 • Schematics February 2012 Electrical Schematic - CE Models CE Models REV A GS-2032/2632/3232 (from serial number GS3211A-97904 to GS3212A-109999 and GS3212C-1387 to GS3212C-9999) GS-2046/2646/3246 (from serial number GS4611A-97983 to GS4612A-109999 and GS4612C-1386 to GS4612C-9999) 6 - 110 GS-30 •...
Page 285 February 2012 Section 6 • Schematics Electrical Schematic CE Models REV A GS-2032/2632/3232 (from serial number GS3211A-97904 to GS3212A-109999 and GS3212C-1387 to GS3212C-9999) GS-2046/2646/3246 (from serial number GS4611A-97983 to GS4612A-109999 and GS4612C-1386 to GS4612C-9999) Part No. 97385 GS-30 • GS-32 • GS-46 6 - 111...
Page 286 Section 6 • Schematics February 2012 Electrical Schematic - CE Models CE Models REV A GS-2032/2632/3232 (from serial number GS3211A-97904 to GS3212A-109999 and GS3212C-1387 to GS3212C-9999) GS-2046/2646/3246 (from serial number GS4611A-97983 to GS4612A-109999 and GS4612C-1386 to GS4612C-9999) 6 - 112 GS-30 •...
Page 287 February 2012 Section 6 • Schematics Electrical Schematic CE Models REV A GS-2032/2632/3232 (from serial number GS3211A-97904 to GS3212A-109999 and GS3212C-1387 to GS3212C-9999) GS-2046/2646/3246 (from serial number GS4611A-97983 to GS4612A-109999 and GS4612C-1386 to GS4612C-9999) Part No. 97385 GS-30 • GS-32 • GS-46 6 - 113...
Page 288: Component Reference And Hydraulic Symbols Legend
Section 6 • Schematics March 2007 Component Reference and Hydraulic Symbols Legend REV B Hydraulic cylinder Variable speed motor Brake Pilot operated check valve with needle valve Shuttle valve Fixed displacement Relief valve pump Solenoid operated 3 position 4 way directional valve Solenoid operated Bi-directional motor...
Page 289 March 2007 Section 6 • Schematics Component Reference and Hydraulic Symbols Legend REV B Function manifold, GS-1530, GS-1532, Function manifold, GS-1930 and GS-1932 GS-2032, GS-2632, GS-3232 GS-2046, GS-2646 and GS-3246 Outrigger manifold, Brake release manifold, GS-3232 all models CA and CB...
Page 290 Section 6 • Schematics March 2007 Hydraulic Schematic GS-1530/1532/1930/1932 (from serial number GS3005A-76000 to GS3005A-76491) REV B GS-1530/1532/1930/1932 (from serial number GS3005B-76000 to GS3005B-76084) LEFT RIGHT LIFT CYLINDER (ALL MODELS) BRAKE RELEASE BRAKE PRESSURE 370 to 450 psi 26 to 31 bar...
Page 291 June 2009 Section 6 • Schematics Hydraulic Schematic GS-1530/1532/1930/1932 (after serial number GS3005A-76491) REV D GS-1530/1532/1930/1932 (after serial number GS3005B-76084) GS-1530/1532/1930/1932 (from serial number GS3008C-101) LEFT RIGHT LIFT CYLINDER (ALL MODELS) BRAKE RELEASE BRAKE PRESSURE 370 to 450 psi 26 to 31 bar...
Page 292: (From Serial Number Gs3205-75407 To Gs3206-80131) Gs-2046/2646/3246 (From Serial Number Gs4605-75438 To Gs4606-79027)
Section 6 • Schematics March 2007 Hydraulic Schematic GS-2032/2632 (from serial number GS3205-75407 to GS3206-80131) REV D GS-2046/2646/3246 (from serial number GS4605-75438 to GS4606-79027) LEFT RIGHT LIFT CYLINDER PLATFORM (ALL MODELS) OVERLOAD BRAKE RELEASE BRAKE (CE MODELS) PRESSURE 370 to 450 psi 26 to 31 bar MANUAL RELEASE...
Page 293 March 2007 Section 6 • Schematics Hydraulic Schematic GS-2032/2632 (from serial number GS3206-80132 to GS3207-84866) REV A GS- 2046/2646/3246 (from serial number GS4606-79028 to GS4607-84839) LEFT RIGHT LIFT CYLINDER PLATFORM (ALL MODELS) OVERLOAD BRAKE RELEASE BRAKE (CE MODELS) PRESSURE 370 to 450 psi 26 to 31 bar MANUAL RELEASE...
Page 294: (From Serial Number Gs3206-80132 To Gs3207-84866) Gs-2046/2646/3246 (Form Serial Number Gs4606-79028 To Gs4607-84839)
Section 6 • Schematics June 2009 Hydraulic Schematic REV D GS-2032/2632/3232 (after serial number GS3207-84866 and from GS3208C-101) GS-2046/2646/3246 (after serial number GS4607-84839 and from GS4609C-101) LEFT RIGHT LIFT CYLINDER PLATFORM (ALL MODELS) OVERLOAD BRAKE RELEASE BRAKE (CE MODELS) PRESSURE 370 to 450 psi 26 to 31 bar MANUAL...
Page 295: (From Serial Number Gs3208C-101)
June 2009 Section 6 • Schematics Hydraulic Schematic GS-3232 (from serial number GS3207-84867) REV D (from serial number GS3208C-101) LF OUTRIGGER RF OUTRIGGER CYLINDER CYLINDER EXTEND EXTEND 0.037 in 0.037 in 0.94 mm 0.94 mm 0.035 in 0.035 in 0.9 mm 0.9 mm RETRACT RETRACT...
Page 296 Section 6 • Schematics March 2007 6 - 122 GS-30 • GS-32 • GS-46 Part No. 97385...
Page 297 Genie North America Phone 425.881.1800 Toll Free USA and Canada 800.536.1800 425.883.3475 Genie Australia Pty Ltd. Phone + 61 7 3375 1660 Fax + 61 7 3375 1002 Genie China Genie Scandinavia Phone + 86 21 53852570 Phone + 46 31 575100...

This manual is also suitable for:

Gs-1532 Gs-2032 Gs-2632 Gs-1930 Gs-3232 Gs-2646 ... Show all

Genie GS-1530 Service Manual

Introduction

Safety Rules

Checklist a Procedures

Checklist B Procedures

Checklist C Procedures

Checklist D Procedures

Checklist E Procedure

Platform Controls

Platform Components

Scissor Components

Ground Controls

Hydraulic Pump

Hydraulic Tank

Steer Axle Components

Non-Steer Axle Components

Brake Release Hand Pump Components

Outrigger Components

Quick Links

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Summary of Contents for Genie GS-1530

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Table of Contents