Genie GC-1530 Service Manual
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Genie GC-1530 Service Manual

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  • Page 2: Introduction

    Genie GS-2046, GS-2646 and GS-3246 Service Manual degree of accuracy possible. However, continuous (from serial number 17408 to 59999) ....... 72972 improvement of our products is a Genie policy. Genie GS-2046, GS-2646 and GS-3246 Service Manual (from serial number 60000 to 75437) ....... 96316 Therefore, product specifications are subject to change without notice.

  • Page 3: Revision History

    June 2012 Revision History Revision Date Section Procedure / Schematic Page / Description 4/2011 New release 1/2012 2 - Spec. Machine, Performance, Hydraulic 3 - Maint. Inspection report, B-1, B-3, B-17, C-1, D-1 4 - Repair 4-2, 4-12, 4-13, 4-14, 4-20, 4-22, 4-25, 4-26, 4-27, 4-28, 4-29, 4-30, 4-32, 4-33, 4-60, 4-68, 4-78, 4-90, 4-103, 4-105, 4-108, 4-111, 4-115, 4-119, 4-120 5 - Diagnos.

  • Page 4: June 2012

    June 2012 REVISION HISTORY, CONTINUED Revision Date Section Procedure / Schematic Page / Description REFERENCE EXAMPLES: Electronic Version Section 3_Maintenance, B-3. Section 4_Repair Procedure, 4-2. Click on any procedure or page number Section 5_Diagnostic Codes, All charts. highlighted in blue to view the update. Section 6_Schematics, Legends diagrams and schematics.

  • Page 5: Serial Number Legend

    June 2012 INTRODUCTION Serial Number Legend Part No. 228901 GS-30 • GS-32 • GS-46 • GS-47...

  • Page 6: Safety Rules

    Section 1 • Safety Rules June 2012 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 7: June 2012

    June 2012 Section 1 • Safety Rules 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 8: Table Of Contents

    June 2012 Table of Contents Introduction Important Information ..................ii Serial Number Information ................. ii Revision History ....................iii Serial Number Legend ..................v Section 1 Safety Rules General Safety Rules ..................vi Section 2 Specifications Machine Specifications ................2 - 1 Performance Specifications .................
  • Page 9 June 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 10 June 2012 TABLE OF CONTENTS Section 4 Repair Procedures Introduction ....................4 - 1 Platform Controls Circuit Boards ..................4 - 3 Joystick ....................4 - 4 Platform Controls Alarm ..............4 - 4 Platform Emergency Stop Button ............4 - 5 Ground Controls Software Revision Level ..............
  • Page 11 June 2012 TABLE OF CONTENTS Section 4 Repair Procedures, continued Steer Axle Components Yoke and Drive Motor ..............4 - 35 Steer Cylinder .................. 4 - 36 Steer Bellcrank ................. 4 - 37 Non-steer Axle Components Drive Brake ..................4 - 38 Brake Release Hand Pump Components Brake Release Hand Pump Components .........
  • Page 12 June 2012 TABLE OF CONTENTS Section 5 Diagnostics Introduction ....................5 - 1 GCON I/O Map without Load Sense - (all machines except GS-3232) ..5 - 4 GCON I/O Map with Load Sense (all machines except GS-3232) ....5 - 5 GCON I/O Map without Load Sense - (GS-3232 only) .........
  • Page 13 June 2012 TABLE OF CONTENTS Section 6 Schematics Introduction ....................6 - 1 Electrical Component and Wire Color Legend ..........6 - 2 Wiring Diagram - Ground and Platform Controls .......... 6 - 4 Limit Switch Legend ..................6 - 5 Electrical Symbols Legend ................
  • Page 14 June 2012 TABLE OF CONTENTS Section 6 Schematics, continued Electrical Schematics - CE and Australia Models GS-1530/1532/1930/1932 (from serial number GS3010A-110000 to GS3011A-110827) ....6 - 32 GS-1530/1532/1930/1932 (from serial number GS3011A-110828) (from serial number GS3011C-10000) ............6 - 36 GS-2032 and GS-2632 (from serial number GS3211A-110000) (from serial number GS3212C-10000) ............

  • Page 15: June 2012

    June 2012 TABLE OF CONTENTS Section 6 Schematics, continued Hydraulic Schematics Component Reference and Hydraulic Symbols Legend ......6 - 59 GS-1530/1532/1930/1932 (from serial number GS3010A-110000) (from serial number GS3011C-10000) ............6 - 61 GS-2032, GS-2632 and GS-3232 (from serial number GS3211A-110000) (from serial number GS3212C-10000) GS-2046, GS-2646 and GS-3246 (from serial number GS4611A-110000)

  • Page 16: Gs-30 • Gs-32 • Gs-46 • Gs-47 Part

    June 2012 This page intentionally left blank. GS-30 • GS-32 • GS-46 • GS-47 Part No. 228901...

  • Page 17: Specifications

    January 2012 Section 2 • Specifications Specifications Machine Specifications Platform Overload Pressure Transducer, if equipped All models except GS-3232 and GS-4047 Batteries, Standard Input voltage 8 to 30 VDC All models except GS-4047 Signal voltage 1 to 5 V Voltage 6V DC Platform Overload Pressure Transducer, if equipped GS-3232 and GS-4047...
  • Page 18 406.7 Nm Castle nut torque, lubricated 225 ft-lbs 305 Nm Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. 2 - 2 GS-30 • GS-32 • GS-46 • GS-47 Part No. 228901...

  • Page 19: Performance Specifications

    40 ft / 55 sec 0.8 km/h Continuous improvement of our products is a 12.2 m / 55 sec Genie policy. Product specifications are subject to change without notice. Part No. 228901 GS-30 • GS-32 • GS-46 • GS-47 2 - 3...

  • Page 20: Gs-2032 And

    Platform up (fast mode) 55 to 59 seconds Continuous improvement of our products is a Platform up (slow mode) 108 to 112 seconds Genie policy. Product specifications are Platform down 38 to 42 seconds subject to change without notice. GS-4047...

  • Page 21: Hydraulic Specifications

    Chevron Rando HD oil is fully compatible and mixable with Shell Donax TG (Dexron III) oils. Note: Genie specifications require additional Genie specifications require hydraulic oils which are equipment and special installation instructions for designed to give maximum protection to hydraulic the approved optional fluids.

  • Page 22: Manifold Component Specifications

    Steer relief valve pressure 1500 psi 103 bar Continuous improvement of our products is a Function manifold - GS-4047 Genie policy. Product specifications are System relief valve pressure, maximum 3500 psi subject to change without notice. 241 bar Platform relief valve pressure...
  • Page 23 Solenoid valve, 2 position 2 way 23.9Ω 20V DC with diode (schematic item DO) Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. Part No. 228901 GS-30 • GS-32 • GS-46 • GS-47...

  • Page 24: 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 25 January 2012 Section 2 • Specifications SPECIFICATIONS 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 26 Section 2 • Specifications January 2012 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 LUBED...

  • Page 27: Scheduled Maintenance Procedures

    Use only Genie approved replacement parts. Indicates a potentially hazardous Machines that have been out of service for a situation which, if not avoided, period longer than 3 months must complete the may result in property damage.

  • Page 28: Pre-Delivery Preparation Report

    Section 3 • Scheduled Maintenance Procedures January 2012 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 29 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. 228901 GS-30 • GS-32 • GS-46 • GS-47...
  • Page 30 Section 3 • Scheduled Maintenance Procedures January 2012 This page intentionally left blank. 3 - 4 GS-30 • GS-32 • GS-46 • GS-47 Part No. 228901...

  • Page 31: Maintenance Inspection Report

    January 2012 Section 3 • Scheduled Maintenance Procedures Maintenance Inspection Report Model Checklist A Y N R Checklist B 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 inspection B-4 Tires and wheels...

  • Page 32: 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 33: Perform Pre-Operation Inspection

    January 2012 Section 3 • Scheduled Maintenance Procedures 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 34: 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 35: 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 36 Section 3 • Scheduled Maintenance Procedures January 2012 CHECKLIST B PROCEDURES 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° / 5.5° C above 80° F / 26.7° C. •...
  • Page 37 50 feet / 15 m. Note: If you have any further questions regarding the battery charger operation, please contact the Genie Service Department. Part No. 228901 GS-30 • GS-32 • GS-46 • GS-47 3 - 11...

  • Page 38: 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 39: 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 40: Test The Emergency Stop

    Emergency Stop button to the on Test the Emergency Stop position at both the ground and platform controls. Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes 4 Push down the red Emergency Stop button at first.

  • Page 41: Test The Key Switch

    CHECKLIST B PROCEDURES Test the Key Switch Test the Automotive-style Horn (if equipped) 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 42: Test The Drive Brakes

    Section 3 • Scheduled Maintenance Procedures January 2012 CHECKLIST B PROCEDURES Test the Drive Brakes Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper brake action is essential to safe machine operation. The drive brake function should operate smoothly, free of hesitation, jerking and unusual noise.
  • Page 43 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES Test the Drive Speed - Platform Stowed, Fast Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper drive functions are essential to safe machine operation. The drive function should respond quickly and smoothly to operator control.

  • Page 44: Test The Slow Drive Speed

    CHECKLIST B PROCEDURES B-10 Test the Drive Speed - Platform Raised Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper drive functions are essential to safe machine operation. The drive function should respond quickly and smoothly to operator control.
  • Page 45 CHECKLIST B PROCEDURES B-11 Test the Drive Speed - Platform Stowed, Slow Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper drive functions are essential to safe machine operation. The drive function should respond quickly and smoothly to operator control.

  • Page 46: 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 47: Check The Module Tray Latch Components

    Section 3 • Scheduled Maintenance Procedures 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 48: 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 49: Test The Down Limit Switch, Level Sensor

    Do not activate the switch contacts. 10 Turn the key switch to platform control. 11 Raise the platform and return the safety arm to Genie requires that this procedure be performed the stowed position. every 250 hours or quarterly, whichever comes first.
  • Page 50 Section 3 • Scheduled Maintenance Procedures January 2012 CHECKLIST B PROCEDURES 13 Press and hold the drive/steer function enable 16 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. switch on the control handle. Attempt to drive 17 Lift the safety arm, move it to the center of the and steer the machine.
  • Page 51 January 2012 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES Level Sensor 30 Standing on the up-hill side of the machine, press and hold the drive/steer function enable 27 Move the machine onto a grade which exceeds switch on the control handle. Attempt to drive the rating of the level sensor.
  • Page 52 Section 3 • Scheduled Maintenance Procedures January 2012 CHECKLIST B PROCEDURES Pothole Limit Switches 35 Press and hold the drive/steer function enable switch on the control handle. Attempt to drive 32 Place a wooden block approximately and steer the machine. 2 inches / 5 cm tall under the right pothole Result: The ground controls LCD displays guard.

  • Page 53: Test The Up Limit Switch (If Equipped) And The Maximum Drive Height Limit Switches (If Equipped)

    Genie requires that this procedure be performed Result: The platform stops raising. The machine every 250 hours or quarterly, whichever comes is functioning properly.

  • Page 54: Checklist C Procedures

    C of the pressure transducer cable rubber boot. Refer to the illustration below. Genie specifications require that this procedure be 8 Using the negative post of a multimeter probe, performed every 500 hours or six months,...
  • Page 55 June 2012 Section 3 • Scheduled Maintenance Procedures CHECKLIST C PROCEDURES GS-3232 and GS-4047 16 Turn the key switch to ground control and pull out the red Emergency Stop button to the on Result: The voltage reading of the pressure position.

  • Page 56: Calibrate The Platform Overload System (If Equipped)

    The overload pressure transducer and the platform Genie specifications require that this procedure be height sensor provide the ECM with necessary performed every 500 hours or six months, information to determine the load in the platform.

  • Page 57: 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 58: Checklist D Procedures

    January 2012 Checklist D Procedures 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 59 January 2012 Section 3 • Scheduled Maintenance Procedures CHECKLIST D PROCEDURES GS-2032, GS-2632, GS-3232, GS-2046, GS-2646, GS-3246 and GS-4047: 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 60: 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 61: 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 62 Section 3 • Scheduled Maintenance Procedures January 2012 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.
  • Page 63 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 64: Platform Controls

    Push in and pull out For further information or assistance, consult the the red Emergency Stop button to reset the Genie Service Department. system. Platform Controls LED Readout Code Condition...

  • Page 65: Circuit Boards

    January 2012 Section 4 • Repair Procedures PLATFORM CONTROLS 9 Carefully remove the platform controls circuit board fasteners. Circuit Board 10 Carefully remove the platform controls circuit board from the platform control box. How to Remove the Platform 11 Remove the transparent caps from the platform Controls Circuit Board controls circuit board and save.

  • Page 66: Joystick

    Section 4 • Repair Procedures January 2012 PLATFORM CONTROLS Joystick Platform Controls Alarm How to Remove the Joystick How to Remove the Platform Controls Alarm 1 Push in the red Emergency Stop button to the off position at both the ground and platform 1 Push in the red Emergency Stop button to the controls.

  • Page 67: Platform Emergency Stop Button

    January 2012 Section 4 • Repair Procedures PLATFORM CONTROLS 6 Carefully remove the Emergency Stop base from the Emergency Stop button. Platform Emergency Stop Button 7 Carefully remove the retaining ring from the Emergency Stop button. How to Remove the Platform 8 Carefully remove the Emergency Stop button Controls Emergency Stop Button from the platform control box.

  • Page 68: Ground Controls

    For further information or assistance, consult the LCD readout Genie Service Department. machine setup, scroll down button machine setup, enter button key switch KS1 red Emergency Stop P1...

  • Page 69: Software Revision Level

    January 2012 Section 4 • Repair Procedures GROUND CONTROLS 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 controls LCD display will display machine Software Revision Level...

  • Page 70: Machine Setup

    Section 4 • Repair Procedures January 2012 GROUND CONTROLS 1 Turn the key switch to the ground controls position and pull out the red Emergency Stop Machine Setup button to the on position at the platform controls. How to Setup the Machine from 2 Press and hold the ground control scroll up and Ground Controls scroll down buttons.

  • Page 71: Manual Platform Lowering Cable

    January 2012 Section 4 • Repair Procedures GROUND CONTROLS 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 72: Level Sensors

    Section 4 • Repair Procedures January 2012 GROUND CONTROLS If you are not installing a new level sensor, proceed to step 15. Level Sensors 7 Turn the key switch to the off position and push in the red Emergency Stop button to the off The Electronic Control Module (ECM) is position at the ground controls.
  • Page 73 January 2012 Section 4 • Repair Procedures GROUND CONTROLS 13 Install the level sensor retaining fasteners Steer end through the level sensor and springs, and into the mount bracket. Tighten the fasteners and measure the distance between the level sensor and the level sensor mount bracket.

  • Page 74: Gs-2032, Gs-2632 And Gs-3232

    Section 4 • Repair Procedures January 2012 GROUND CONTROLS 22 GS-1530 and GS-1930: Place a 0.64 x 6 x 6 31 GS-1530 and GS-1930: Place a 0.77 x 6 x 6 inch / 16.2 mm x 15 cm x 15 cm thick steel inch / 19.6 mm x 15 cm x 15 cm thick steel block under both wheels at the ground controls block under both wheels at the battery pack...
  • Page 75 January 2012 Section 4 • Repair Procedures GROUND CONTROLS 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 76: Outrigger Calibration

    For further information or assistance, consult the gathers and saves data. Genie Industries Service Department. 14 Continue holding the Enter button after the outriggers retract. The outriggers will now How to Calibrate the Outrigger...

  • Page 77: Hydraulic Tank

    January 2012 Section 4 • Repair Procedures Hydraulic Tank 2 Tag and disconnect the hydraulic tank return hard line from the filter. Remove the hard line Hydraulic Tank from the machine. Cap the fitting on the filter head. The primary functions of the hydraulic tank are to 3 Tag and disconnect the hydraulic tank hard line cool and deaerate the hydraulic fluid during from the pump.

  • Page 78: Hydraulic Pump

    Section 4 • Repair Procedures January 2012 Hydraulic Pump 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 79 January 2012 Section 4 • Repair Procedures 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 80: Function Manifold Components - Gs-1530, Gs-1532, Gs-1930 And Gs-1932

    Section 4 • Repair Procedures January 2012 Manifolds 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 81 January 2012 Section 4 • Repair Procedures MANIFOLDS Part No. 228901 GS-30 • GS-32 • GS-46 • GS-47 4 - 19...

  • Page 82: Function Manifold Components - Gs-2032, Gs-2632, Gs-3232, Gs-2046, Gs-2646 And Gs-3246

    Section 4 • Repair Procedures January 2012 MANIFOLDS 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 Torque —...
  • Page 83 January 2012 Section 4 • Repair Procedures MANIFOLDS Part No. 228901 GS-30 • GS-32 • GS-46 • GS-47 4 - 21...

  • Page 84: Function Manifold Components - Gs-4047

    Section 4 • Repair Procedures January 2012 MANIFOLDS Function Manifold Components - GS-4047 The function manifold is mounted behind an inspection door on the ground control side of the machine. Index Schematic Description Item Function Torque — Coil nut (item DC) ......................... 4-5 ft-lbs / 5-7 Nm —...
  • Page 85 January 2012 Section 4 • Repair Procedures MANIFOLDS Part No. 228901 GS-30 • GS-32 • GS-46 • GS-47 4 - 23...

  • Page 86: Check Valve Manifold Components - Gs-1530, Gs-1532, Gs-1930 And Gs-1932

    Section 4 • Repair Procedures January 2012 MANIFOLDS 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 How to Install a Valve Cartridge 1 Dip the cartridge in clean oil to lube the O-rings.

  • Page 87: Lift Pressure Selector Manifold Components - Gs-4047

    January 2012 Section 4 • Repair Procedures MANIFOLDS Lift Pressure Selector Manifold Components - GS-4047 The check valve manifold is mounted on the function manifold. Index Schematic Description Item Function Torque — Coil nut (item DN) ......................... 4-5 ft-lbs / 5-7 Nm —...

  • Page 88: Outrigger Function Manifold Components - Gs-3232

    Section 4 • Repair Procedures January 2012 MANIFOLDS 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) ......................... 4-5 ft-lbs / 5-7 Nm Solenoid valve, 3 position 4 way ....

  • Page 89: Outrigger Cylinder Manifold Components - Gs-3232

    January 2012 Section 4 • Repair Procedures 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 90: Valve Adjustments - Function Manifold

    Section 4 • Repair Procedures January 2012 MANIFOLDS 6 Move and hold the joystick fully in either direction while observing the pressure reading Valve Adjustments - on the pressure gauge. Note the pressure. Refer to Section 2, Specifications . Function Manifold 7 Turn the machine off.
  • Page 91 January 2012 Section 4 • Repair Procedures MANIFOLDS How to Adjust the 6 Move and hold the joystick fully in either direction while observing the pressure reading Platform Lift Relief Valve on the pressure gauge. Note the pressure. Refer to Section 2, Specifications . Perform this test from the ground with the platform controls.
  • Page 92 Section 4 • Repair Procedures January 2012 MANIFOLDS 12 Turn the key switch to ground control and pull How to Adjust the out the red Emergency Stop button to the on Lift Pressure Selector Valve position at both the ground and platform (GS-4047 only) controls.
  • Page 93 January 2012 Section 4 • Repair Procedures MANIFOLDS 3 Using a suitable lifting device, place and secure 8 Adjust the internal hex socket. Turn it clockwise the maximum rated load in the center of the to increase pressure and counterclockwise to platform deck.
  • Page 94 Section 4 • Repair Procedures January 2012 MANIFOLDS How to Adjust the Steer Relief 5 Activate the function enable switch and press and hold the steer thumb rocker switch to the Valve right. Allow the wheels to completely turn to the right.

  • Page 95: Valve Coils

    January 2012 Section 4 • Repair Procedures 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 96 Section 4 • Repair Procedures January 2012 MANIFOLDS How to Test a Coil Diode Genie incorporates spike suppressing diodes in all 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.

  • Page 97: Steer Axle Components

    January 2012 Section 4 • Repair Procedures Steer Axle Components 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 98: Steer Cylinder

    Section 4 • Repair Procedures January 2012 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 99: Steer Bellcrank

    January 2012 Section 4 • Repair Procedures Steer Bellcrank How to Remove the Steer Bellcrank 1 Remove the steer cylinder. See 6-2, How to Remove the Steer Cylinder. 2 Remove the retaining fasteners from the steer links at each end of the bellcrank. Note: While removing the retaining fasteners, take note of the quantity and location of the spacers between the bellcrank and the steer links.

  • Page 100: Non-Steer Axle Components

    Section 4 • Repair Procedures January 2012 Non-steer Axle Components 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 101: Brake Release Hand Pump Components

    January 2012 Section 4 • Repair Procedures Brake Release Hand Pump Components 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 102: Scissor Components

    Section 4 • Repair Procedures January 2012 Scissor Components Steer End Non-steer End 10 Number 3 inner arm 1 Number 4 pivot pin 11 Number 3 outer arm 2 Number 3 center pivot pin (2 pins) 12 Number 3 pivot pin (non-steer end) 3 Lift cylinder rod-end pivot pin 13 Number 2 inner arm 4 Number 3 pivot pin (steer end)

  • Page 103: Scissor Assembly, Gs-1530 And Gs-1532

    January 2012 Section 4 • Repair Procedures SCISSOR COMPONENTS 4 Lower the platform onto the safety arm. Scissor Assembly, Crushing hazard. Keep hands clear of the safety arm when GS-1530 and GS-1532 lowering the platform. 5 At the ground control, turn the key switch to the How to Disassemble the off position and push in the red Emergency Scissor Assembly,...
  • Page 104 Section 4 • Repair Procedures January 2012 SCISSOR COMPONENTS 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.
  • Page 105 January 2012 Section 4 • Repair Procedures SCISSOR COMPONENTS 27 Attach a lifting strap from an overhead crane to 35 Lower the cylinder onto the number 1 inner arm the number 3 outer arm (index #11). (index #8). 28 Remove the external snap rings and retaining Component damage hazard.
  • Page 106 Section 4 • Repair Procedures January 2012 SCISSOR COMPONENTS 43 Use a soft metal drift to remove the number 2 49 Use a soft metal drift to tap the number 2 pivot center pivot pin (index #5) at the ground pin (index #15) in the other direction at the non- controls side.
  • Page 107 January 2012 Section 4 • Repair Procedures SCISSOR COMPONENTS 55 Raise the number 1 inner arm (index #8) 59 Models with platform overload option: Tag approximately 2 feet / 60 cm and install the and disconnect the wire harness from the safety arm between the number 1 inner arm platform overload pressure transducer.
  • Page 108 Section 4 • Repair Procedures January 2012 SCISSOR COMPONENTS 63 Attach a lifting strap from an overhead crane to 70 Use a soft metal drift to remove the number 1 the number 1 inner arm (index #8) at the non- center pivot pins (index #7).
  • Page 109 January 2012 Section 4 • Repair Procedures SCISSOR COMPONENTS How to Replace the Scissor Arm 7 Remove the fasteners securing the platform height sensor cover to the large platform height Wear Pads sensor bracket. Note: Machines equipped with a Platform Height 8 Remove the platform height sensor cover.
  • Page 110 Section 4 • Repair Procedures January 2012 SCISSOR COMPONENTS 16 Install the fasteners removed in 14 to the 23 Fully lower the platform to the stowed position. number 1 inner arm pivot bracket and chassis. 24 Remove the platform. See 10-1, How to Tip-over hazard.
  • Page 111 January 2012 Section 4 • Repair Procedures SCISSOR COMPONENTS 32 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 112 Section 4 • Repair Procedures January 2012 SCISSOR COMPONENTS Steer End Non-steer End 1 Number 5 pivot pin 12 Number 4 inner arm 2 Number 4 center pivot pin (2 pins) 13 Number 4 outer arm 3 Number 4 pivot pin (steer end) 14 Number 4 pivot pin (non-steer end) 4 Number 3 center pivot pin (2 pins) 15 Number 3 inner arm...

  • Page 113: Scissor Assembly, Gs-1930 And Gs-1932

    January 2012 Section 4 • Repair Procedures SCISSOR COMPONENTS 4 Lower the platform onto the safety arm. Scissor Assembly, Crushing hazard. Keep hands clear of the safety arm when GS-1930 and GS-1932 lowering the platform. 5 At the ground control, turn the key switch to the How to Disassemble the off position and push in the red Emergency Scissor Assembly,...
  • Page 114 Section 4 • Repair Procedures January 2012 SCISSOR COMPONENTS 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.
  • Page 115 January 2012 Section 4 • Repair Procedures SCISSOR COMPONENTS 27 Attach a lifting strap from an overhead crane to 36 Remove the cables from the number 3 cable the number 4 outer arm (index #13). bridge and lay them off to the side. 28 Remove the external snap rings and retaining Component damage hazard.
  • Page 116 Section 4 • Repair Procedures January 2012 SCISSOR COMPONENTS 43 Attach a lifting strap from an overhead crane to 51 Remove the retaining fasteners from the the number 3 outer arm (index #16) at the number 3 pivot pin (index #6) at the steer end. battery pack side.
  • Page 117 January 2012 Section 4 • Repair Procedures SCISSOR COMPONENTS 59 Use a soft metal drift to tap the number 2 pivot 64 Remove the number 3 pivot pin (index #17) pin (index #20) halfway out at the non-steer end from the non-steer end of the machine. of the machine.
  • Page 118 Section 4 • Repair Procedures January 2012 SCISSOR COMPONENTS 72 Tag, disconnect and plug the hydraulic hoses 77 Place a 4 x 4 x 48 inch / 10 cm x 10 cm x 1.2 m on the lift cylinder. Cap the fittings on the long block across both sides of the chassis cylinder.
  • Page 119 January 2012 Section 4 • Repair Procedures SCISSOR COMPONENTS 84 Remove the number 1 cable bridge from the How to Replace the Scissor Arm machine. Wear Pads 85 Use a soft metal drift to remove the number 1 Note: Machines equipped with a Platform Height center pivot pins (index #9).
  • Page 120 Section 4 • Repair Procedures January 2012 SCISSOR COMPONENTS 9 Tag and disconnect the platform height sensor 20 Pull out the red Emergency Stop button to the from the platform height sensor harness. on position at the ground controls. 10 Remove the fastener securing the platform 21 Using the ground control menu buttons, height sensor assembly to the number 1 inner navigate to Service Override Mode.
  • Page 121 January 2012 Section 4 • Repair Procedures SCISSOR COMPONENTS 30 Attach a lifting strap from an overhead crane to the scissor arm assembly. 31 Raise the scissor arm assembly at the steer end with the overhead crane until the chassis mount bracket will clear the level sensor.
  • Page 122 Section 4 • Repair Procedures January 2012 SCISSOR COMPONENTS 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) 13 Number 2 inner arm...

  • Page 123: Scissor Assembly, Gs-2032 And Gs-2046

    January 2012 Section 4 • Repair Procedures SCISSOR COMPONENTS 4 Lower the platform onto the safety arm. Scissor Assembly, Crushing hazard. Keep hands clear of the safety arm when GS-2032 and GS-2046 lowering the platform. 5 At the ground control, turn the key switch to the How to Disassemble the off position and push in the red Emergency Scissor Assembly,...
  • Page 124 Section 4 • Repair Procedures January 2012 SCISSOR COMPONENTS 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.
  • Page 125 January 2012 Section 4 • Repair Procedures SCISSOR COMPONENTS 28 Disconnect the number 3 cable bridge from the 39 Remove the number 3 outer arm (index #11) number 3 outer arm (index #11) and remove from the machine. the cable bridge from the machine. Crushing hazard.
  • Page 126 Section 4 • Repair Procedures January 2012 SCISSOR COMPONENTS 48 Remove the cables from the number 2A and 2B 57 Place a rod through the number 2 center pivot cable bridge and lay them off to the side. pin at the battery side (index #5) and twist to remove the pin.
  • Page 127 January 2012 Section 4 • Repair Procedures SCISSOR COMPONENTS 65 Lower the scissor arms onto the block that was 73 Remove the cables from the number 1 cable placed across the chassis. bridge and lay them off to the side. Bodily injury hazard.
  • Page 128 Section 4 • Repair Procedures January 2012 SCISSOR COMPONENTS How to Replace the Scissor Arm 9 Tag and disconnect the platform height sensor from the platform height sensor harness. Wear Pads 10 Remove the fastener securing the platform Note: Machines equipped with a Platform Height height sensor assembly to the number 1 inner Sensor, begin at step 1.
  • Page 129 January 2012 Section 4 • Repair Procedures SCISSOR COMPONENTS 20 Pull out the red Emergency Stop button to the 30 Attach a lifting strap from an overhead crane to on position at the ground controls. the scissor arm assembly. 21 Using the ground control menu buttons, 31 Raise the scissor arm assembly at the steer navigate to Service Override Mode.
  • Page 130 Section 4 • Repair Procedures January 2012 SCISSOR COMPONENTS 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) 15 Number 3 inner arm...

  • Page 131: Scissor Assembly, Gs-2632 And Gs-2646

    January 2012 Section 4 • Repair Procedures SCISSOR COMPONENTS 4 Lower the platform onto the safety arm. Scissor Assembly, Crushing hazard. Keep hands clear of the safety arm when GS-2632 and GS-2646 lowering the platform. 5 At the ground control, turn the key switch to the How to Disassemble the off position and push in the red Emergency Scissor Assembly,...
  • Page 132 Section 4 • Repair Procedures January 2012 SCISSOR COMPONENTS 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.
  • Page 133 January 2012 Section 4 • Repair Procedures SCISSOR COMPONENTS 28 Disconnect the number 4 cable bridge from the 37 Remove the retaining fasteners from the number 4 outer arm (index #13) and remove number 4 center pivot pin (index #2) at the the cable bridge from the machine.
  • Page 134 Section 4 • Repair Procedures January 2012 SCISSOR COMPONENTS 44 Disconnect the number 3A and 3B cable 52 Place a rod through the number 3 center pivot bridges from the scissor linkset and remove pin at the battery side (index #4) and twist to both cable bridges from the machine.
  • Page 135 January 2012 Section 4 • Repair Procedures SCISSOR COMPONENTS 60 Remove the retaining fasteners from the 68 Use a soft metal drift to remove the number 2 number 3 pivot pin at the steer end of the pivot pin (index #20) from the non-steer end of machine (index #6).
  • Page 136 Section 4 • Repair Procedures January 2012 SCISSOR COMPONENTS 73 Attach a lifting strap from an overhead crane to 81 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 137 January 2012 Section 4 • Repair Procedures SCISSOR COMPONENTS 87 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. Note: Machines equipped with a Platform Height Cables can be damaged if they Sensor, begin at step 1.
  • Page 138 Section 4 • Repair Procedures January 2012 SCISSOR COMPONENTS 9 Tag and disconnect the platform height sensor 20 Pull out the red Emergency Stop button to the from the platform height sensor harness. on position at the ground controls. 10 Remove the fastener securing the platform 21 Using the ground control menu buttons, height sensor assembly to the number 1 inner navigate to Service Override Mode.
  • Page 139 January 2012 Section 4 • Repair Procedures SCISSOR COMPONENTS 30 Attach a lifting strap from an overhead crane to the scissor arm assembly. 31 Raise the scissor arm assembly at the steer end with the overhead crane until the chassis mount bracket will clear the level sensor.
  • Page 140 Section 4 • Repair Procedures January 2012 SCISSOR COMPONENTS 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) 19 Number 4 inner arm...

  • Page 141: Scissor Assembly, Gs-3232 And Gs-3246

    January 2012 Section 4 • Repair Procedures SCISSOR COMPONENTS 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.
  • Page 142 Section 4 • Repair Procedures January 2012 SCISSOR COMPONENTS 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.
  • Page 143 January 2012 Section 4 • Repair Procedures SCISSOR COMPONENTS 26 Remove the fasteners from the entry ladder and 35 Use a soft metal drift to remove the number 5 remove the entry ladder from the machine. pivot pin (index #18) from the non-steer end of the machine.
  • Page 144 Section 4 • Repair Procedures January 2012 SCISSOR COMPONENTS 41 Remove the retaining fasteners from the 47 Attach a lifting strap from an overhead crane to number 5 pivot pin at the steer end of the the lug of the rod end of the upper lift cylinder. machine (index #4).
  • Page 145 January 2012 Section 4 • Repair Procedures SCISSOR COMPONENTS 56 Attach a lifting strap from an overhead crane to 63 Remove the cables from the number 3A and 3B the number 4 outer arm at the battery side cable bridges and lay them off to the side. (index #20).
  • Page 146 Section 4 • Repair Procedures January 2012 SCISSOR COMPONENTS 70 Attach a lifting strap from an overhead crane to 77 Attach a lifting strap from an overhead crane to the number 3 outer arm at the battery side the lug of the rod end of the lower lift cylinder. (index #7).
  • Page 147 January 2012 Section 4 • Repair Procedures SCISSOR COMPONENTS 85 Remove the cables from the number 2A and 2B 92 Attach a lifting strap from an overhead crane to cable bridges and lay them off to the side. the number 2 outer arm at the battery side (index #26).
  • Page 148 Section 4 • Repair Procedures January 2012 SCISSOR COMPONENTS 98 Use a soft metal drift to remove the number 2 105 Tag and disconnect the wire harness from the pivot pin (index #12) from the steer end of the solenoid valve on the cylinder. machine.
  • Page 149 January 2012 Section 4 • Repair Procedures SCISSOR COMPONENTS 113 Lower the arm to the stowed position. How to Replace the Scissor Arm Wear Pads Bodily injury hazard. Keep hands clear of moving parts when Note: Machines equipped with a Platform Height lowering the scissor arms.
  • Page 150 Section 4 • Repair Procedures January 2012 SCISSOR COMPONENTS 9 Tag and disconnect the platform height sensor 19 Press and hold the ground control scroll up and from the platform height sensor harness. scroll down buttons. 10 Remove the fastener securing the platform 20 Pull out the red Emergency Stop button to the height sensor assembly to the number 1 inner on position at the ground controls.
  • Page 151 January 2012 Section 4 • Repair Procedures SCISSOR COMPONENTS 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. 31 Raise the scissor arm assembly at the steer end with the overhead crane until the chassis mount bracket will clear the level sensor.
  • Page 152 Section 4 • Repair Procedures January 2012 SCISSOR COMPONENTS Steer end Non-steer end Number 7 pivot pin 23 Number 5 pivot pin (non-steer end) Number 6 cylinder pivot pin (2 pins) 24 Number 4 inner arm Number 6 pivot pin (steer end) 13 Number 2 center pivot pin (2 pins) 25 Number 4 outer arm Number 5 center pivot pin...

  • Page 153: Scissor Assembly, Gs-4047

    January 2012 Section 4 • Repair Procedures SCISSOR COMPONENTS 4 Lower the platform onto the safety arm. Scissor Assembly, Crushing hazard. Keep hands clear of the safety arm when GS-4047 lowering the platform. 5 At the ground control, turn the key switch to the How to Disassemble the off position and push in the red Emergency Scissor Assembly,...
  • Page 154 Section 4 • Repair Procedures January 2012 SCISSOR COMPONENTS 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.
  • Page 155 January 2012 Section 4 • Repair Procedures SCISSOR COMPONENTS 27 Use a soft metal drift to remove the number 7 36 Remove the number 6 outer arm (index #19) pivot pin (index #1). Remove the platform from the machine. mount bracket from the machine. Crushing hazard.
  • Page 156 Section 4 • Repair Procedures January 2012 SCISSOR COMPONENTS 42 Remove the retaining fasteners from the 49 Attach a lifting strap from an overhead crane to number 5 center pivot pin (index #4) at the the lug of the rod end of the upper lift cylinder. ground control side.
  • Page 157 January 2012 Section 4 • Repair Procedures SCISSOR COMPONENTS 58 Attach a lifting strap from an overhead crane to 66 Attach a lifting strap from an overhead crane to the number 4 outer arm at the battery side the number 3 outer arm at the ground control (index #25).
  • Page 158 Section 4 • Repair Procedures January 2012 SCISSOR COMPONENTS 73 Attach a lifting strap from an overhead crane 82 Place a 4 x 4 x 10 inch / 10 x 10 x 25 cm block to the number 3 inner arm (index #28). onto the number 1 inner arm cylinder plate Raise the number 3 inner arm and place a (index #16).
  • Page 159 January 2012 Section 4 • Repair Procedures SCISSOR COMPONENTS 91 Use a soft metal drift to remove the number 2 97 Remove the retaining fasteners from the pivot pin (index #32) from the non-steer end of number 2 pivot pin at the steer end of the the machine.
  • Page 160 Section 4 • Repair Procedures January 2012 SCISSOR COMPONENTS 105 Tag and disconnect the wire harness from the 112 Disconnect the number 1 cable bridge from solenoid valve on the cylinder. the number 1 outer arm (index #34) and remove the cable bridge from the machine. 106 Tag and disconnect the wires and manual lowering cable from the solenoid valve on the 113 Attach a lifting strap from an overhead crane...
  • Page 161 January 2012 Section 4 • Repair Procedures SCISSOR COMPONENTS How to Replace the Scissor Arm 10 Remove the fastener securing the platform height sensor assembly to the number 1 inner Wear Pads arm. Note: Machines equipped with a Platform Height 11 Remove the platform height sensor assembly Sensor, begin at step 1.
  • Page 162 Section 4 • Repair Procedures January 2012 SCISSOR COMPONENTS 21 Using the ground control menu buttons, 31 Raise the scissor arm assembly at the steer navigate to Service Override Mode. Select end with the overhead crane until the chassis Service Override Mode. mount bracket will clear the level sensor.

  • Page 163: Platform Height Sensor

    January 2012 Section 4 • Repair Procedures SCISSOR COMPONENTS 7 Remove the platform height sensor cover. Platform Height Sensor How to Disassemble the Platform Height Sensor Assembly (if equipped) When a Platform Height Sensor Assembly is removed or replaced, the platform overload system must be calibrated.
  • Page 164 Section 4 • Repair Procedures January 2012 SCISSOR COMPONENTS 14 Remove the fasteners securing the platform 18 Remove the fasteners securing the large height sensor to the small platform height platform height bracket to the number 1 inner sensor bracket. arm pivot bracket.

  • Page 165: Lift Cylinder

    January 2012 Section 4 • Repair Procedures SCISSOR COMPONENTS Lift Cylinder How to Remove the Lift Cylinder Bodily injury hazard. This procedure requires 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.
  • Page 166 Section 4 • Repair Procedures January 2012 SCISSOR COMPONENTS 6 At the ground control, turn the key switch to the 14 Remove the retaining fasteners from the lift off position and push in the red Emergency cylinder rod-end pivot pin. Use a soft metal drift Stop button to the off position.

  • Page 167: Gs-2046 And

    January 2012 Section 4 • Repair Procedures SCISSOR COMPONENTS GS-2032, GS-2632, GS-2046 and GS-2646: Torque specification Bodily injury hazard. This Solenoid valve, 2 position 2 way N.C. 20 ft-lbs procedure requires specific repair (schematic item N) 27 Nm skills, lifting equipment and a Coil nut 5 ft-lbs suitable workshop.
  • Page 168 Section 4 • Repair Procedures January 2012 SCISSOR COMPONENTS 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.
  • Page 169 January 2012 Section 4 • Repair Procedures SCISSOR COMPONENTS 13 Attach a lifting strap from an overhead crane to 20 Install new cylinder, fittings, hoses and pressure the rod end of the lift cylinder for support. transducer (if equipped). 14 Remove the retaining fasteners from the lift Torque specification cylinder rod-end pivot pin.
  • Page 170 Section 4 • Repair Procedures January 2012 SCISSOR COMPONENTS GS-3232 and GS-3246: Bodily injury hazard. This procedure requires 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.
  • Page 171 January 2012 Section 4 • Repair Procedures SCISSOR COMPONENTS 7 Disconnect the battery pack from the machine. 13 Attach a lifting strap from an overhead crane to the rod end of the lift cylinder for support. Electrocution/burn hazard. Contact with electrically charged circuits 14 Remove the retaining fasteners from the lift could result in death or serious cylinder rod-end pivot pin.
  • Page 172 Section 4 • Repair Procedures January 2012 SCISSOR COMPONENTS 20 Install new cylinder, fittings, hoses and pressure 21 Remove the lifting device supporting the link transducer (if equipped). stack at the steer end of the machine. 22 Connect the battery pack to the machine. 23 Turn the key switch to the ground control position.
  • Page 173 January 2012 Section 4 • Repair Procedures SCISSOR COMPONENTS GS-4047: Bodily injury hazard. This procedure requires 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.
  • Page 174 Section 4 • Repair Procedures January 2012 SCISSOR COMPONENTS 7 Disconnect the battery pack from the machine. 13 Attach a lifting strap from an overhead crane to the rod end of the lift cylinder for support. Electrocution/burn hazard. Contact with electrically charged circuits 14 Remove the retaining fasteners from the lift could result in death or serious cylinder rod-end pivot pin.
  • Page 175 January 2012 Section 4 • Repair Procedures SCISSOR COMPONENTS 21 Remove the lifting device supporting the link stack at the steer end of the machine. 22 Connect the battery pack to the machine. 23 Turn the key switch to the ground control position.

  • Page 176: Pressure Transducer

    Section 4 • Repair Procedures January 2012 SCISSOR COMPONENTS 9 Slowly loosen the pressure transducer from the lift cylinder and remove. Discard the pressure Pressure Transducer transducer. Bodily injury hazard. Spraying How to Remove the Pressure hydraulic oil can penetrate and Transducer (if equipped) burn skin.

  • Page 177: Platform Overload System

    January 2012 Section 4 • Repair Procedures SCISSOR COMPONENTS 9-10 Note: To calibrate the platform overload system, follow the menu structure indicated on the ground Platform Overload System control LCD display. Full Load Calibration: Part 1 How to Calibrate the Platform Overload System (if equipped) 1 Fully charge the batteries and check the hydraulic fluid level.
  • Page 178 Section 4 • Repair Procedures January 2012 SCISSOR COMPONENTS 5 Turn the key switch to ground control. 18 At the ground controls, press and hold the Function Enable and Platform Up buttons until 6 At the ground controls, press and hold the the platform reaches maximum height.
  • Page 179 January 2012 Section 4 • Repair Procedures SCISSOR COMPONENTS Full Load Calibration: Part 2 No Load Calibration 24 At the ground controls, press and hold the 1 Fully charge the batteries and check the Function Enable and Platform Up buttons until hydraulic fluid level.
  • Page 180 Section 4 • Repair Procedures January 2012 SCISSOR COMPONENTS 13 Use the Menu Up or Menu Down buttons to select No Load calibration. 14 Press the Enter button to select No Load calibration. 15 Press the Enter button to confirm no load is in the platform.

  • Page 181: Platform Components

    January 2012 Section 4 • Repair Procedures Platform Components 10-1 8 Models with air line to platform option: Disconnect the air line from the platform. Pull Platform the air line free of the platform. 9 Support the platform with a forklift at the How to Remove the Platform non-steer end.

  • Page 182: Platform Extension

    Section 4 • Repair Procedures January 2012 PLATFORM COMPONENTS 10-2 7 Remove the platform roller wheels from the machine. Platform Extension 8 Carefully slide the platform extension out from the platform and place it on a structure capable How to Remove the of supporting it.
  • Page 183 Section 5 • Diagnostics January 2012 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 equipment are available and ready for use. Observe and Obey: Read each appropriate fault code thoroughly.
  • Page 184 DIAGNOSTICS About This Section Definitions When a malfunction is discovered, the fault code GSDS - Genie SmartLink Diagnostic System charts in this section will help a service ECM - Electronic Control Module professional pinpoint the cause of the problem. To use this section, basic hand tools and certain GCON - Ground Controls pieces of test equipment are required —...
  • Page 185 Section 5 • Diagnostics DIAGNOSTICS GCON LCD Diagnostic Readout 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 The diagnostic readout displays alpha numeric...
  • Page 186 Section 5 • Diagnostics January 2012 GCON I/O Map without Load Sense (all models except GS-3232) Rear of Ground Controls ECM 5 - 4 GS-30 • GS-32 • GS-46 • GS-47 Part No. 228901...

  • Page 187: Gcon I/O Map With Load Sense (All Machines Except Gs-3232)

    January 2012 Section 5 • Diagnostics GCON I/O Map with Load Sense (all models except GS-3232) Part No. 228901 GS-30 • GS-32 • GS-46 • GS-47 5 - 5...

  • Page 188: Gcon I/O Map Without Load Sense - (Gs-3232 Only)

    Section 5 • Diagnostics January 2012 GCON I/O Map without Load Sense (GS-3232 only) Rear of Ground Controls ECM 5 - 6 GS-30 • GS-32 • GS-46 • GS-47 Part No. 228901...

  • Page 189: Gcon I/O Map With Load Sense (Gs-3232 Only)

    January 2012 Section 5 • Diagnostics GCON I/O Map with Load Sense (GS-3232 only) Part No. 228901 GS-30 • GS-32 • GS-46 • GS-47 5 - 7...

  • Page 190: Operational Indicator Codes

    Section 5 • Diagnostics January 2012 DIAGNOSTICS Operational Indicator Codes Diagnostic Trouble Codes (DTC) (OIC) These codes are generated by the system to indicate that a device or circuit malfunction has These codes are generated by the electrical been detected in the electrical system. system to indicate machine operating status The types of Diagnostic Trouble Codes that may such as Off-level, Overload Cutout, Chassis...

  • Page 191: Troubleshooting "Hxx" And "Pxxx" Faults

    January 2012 Section 5 • Diagnostics DIAGNOSTICS Troubleshooting "HXXX" and "PXXX" Faults The procedure below illustrates typical steps for diagnosing and fixing faults of type "HXXX and PXXX". Diagnostic Chart No Good Check the fault device for a short or open circuit. Replace faulted device.

  • Page 192: Fault Inspection Procedure

    Section 5 • Diagnostics January 2012 DIAGNOSTICS Fault Inspection Procedure 5 - 10 GS-30 • GS-32 • GS-46 • GS-47 Part No. 228901...
  • Page 193 January 2012 Section 5 • Diagnostics DIAGNOSTICS Part No. 228901 GS-30 • GS-32 • GS-46 • GS-47 5 - 11...

  • Page 194: Type "Hxxx" Faults

    Section 5 • Diagnostics January 2012 Type "HXXX" Faults 5 - 12 GS-30 • GS-32 • GS-46 • GS-47 Part No. 228901...
  • Page 195 January 2012 Section 5 • Diagnostics TYPE "HXXX" FAULTS, CONTINUED Part No. 228901 GS-30 • GS-32 • GS-46 • GS-47 5 - 13...
  • Page 196 Section 5 • Diagnostics January 2012 TYPE "HXXX" FAULTS, CONTINUED 5 - 14 GS-30 • GS-32 • GS-46 • GS-47 Part No. 228901...

  • Page 197: Type "Pxxx" Faults

    January 2012 Section 5 • Diagnostics Type "PXXX" Faults Part No. 228901 GS-30 • GS-32 • GS-46 • GS-47 5 - 15...

  • Page 198: Type "Uxxx" Faults

    Section 5 • Diagnostics January 2012 Type "UXXX" Faults 5 - 16 GS-30 • GS-32 • GS-46 • GS-47 Part No. 228901...
  • Page 199 January 2012 Section 5 • Diagnostics TYPE "UXXX" FAULTS, CONTINUED Part No. 228901 GS-30 • GS-32 • GS-46 • GS-47 5 - 17...

  • Page 200: Type "Fxxx" Faults

    Section 5 • Diagnostics January 2012 Type "FXXX" Faults 5 - 18 GS-30 • GS-32 • GS-46 • GS-47 Part No. 228901...
  • Page 201 January 2012 Section 5 • Diagnostics TYPE "FXXX" FAULTS, CONTINUED Part No. 228901 GS-30 • GS-32 • GS-46 • GS-47 5 - 19...
  • Page 202 Section 5 • Diagnostics January 2012 TYPE "FXXX" FAULTS, CONTINUED 5 - 20 GS-30 • GS-32 • GS-46 • GS-47 Part No. 228901...

  • Page 203: Type "Cxxx" Faults

    January 2012 Section 5 • Diagnostics Type "CXXX" Faults Part No. 228901 GS-30 • GS-32 • GS-46 • GS-47 5 - 21...
  • Page 204 Section 5 • Diagnostics January 2012 TYPE "CXXX" FAULTS, CONTINUED 5 - 22 GS-30 • GS-32 • GS-46 • GS-47 Part No. 228901...

  • Page 205: Hydraulic Schematics

    January 2012 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 circuits Troubleshooting and repair procedures shall be could result in death or serious completed by a person trained and qualified on injury.
  • Page 206 Section 6 • Schematics January 2012 Electrical Component and Wire Color Legends 6 - 2 GS-30 • GS-32 • GS-46 • GS-47 Part No. 228901...
  • Page 207 January 2012 Section 6 • Schematics Electrical Component and Wire Color Legends Part No. 228901 GS-30 • GS-32 • GS-46 • GS-47 6 - 3...
  • Page 208 Section 6 • Schematics January 2012 Wiring Diagram Ground and Platform Controls 6 - 4 GS-30 • GS-32 • GS-46 • GS-47 Part No. 228901...

  • Page 209: Limit Switch Legend

    January 2012 Section 6 • Schematics Limit Switch Legend Limit Switch Legend down limit switch LS6 pothole switches LS7, LS8 22ft / 6.7 m maximum drive height when outriggers are not deployed (LS5A GS-3232) Part No. 228901 GS-30 • GS-32 • GS-46 • GS-47 6 - 5...

  • Page 210: Electrical Symbols Legend

    Section 6 • Schematics January 2012 Electrical Symbols Legend Limit switch Motor controller Key switch Emergency Stop button Wire with description or color Solenoid valve Motor with diode Circuit breaker Circuits crossing no connection Fuse Level sensor Battery charger Diode Horn or alarm Deutsch connector 6V or 12v DC battery...

  • Page 211: From Serial Number

    January 2012 Section 6 • Schematics Electrical Schematic GS-1530/32 and GS-1930/32 • ANSI and CSA Models (from serial number GS3010A-110000 to GS3011A-110827) 6 - 8 6 - 7...
  • Page 212 Section 6 • Schematics January 2012 Electrical Schematic GS-1530/32 and GS-1930/32 • ANSI and CSA Models (from serial number GS3010A-110000 to GS3011A-110827) 6 - 8 GS-30 • GS-32 • GS-46 • GS-47 Part No. 228901...
  • Page 213 January 2012 Section 6 • Schematics Electrical Schematic GS-1530/32 and GS-1930/32 • ANSI and CSA Models (from serial number GS3010A-110000 to GS3011A-110827) Part No. 228901 GS-30 • GS-32 • GS-46 • GS-47 6 - 9...
  • Page 214 January 2012 Section 6 • Schematics Electrical Schematic GS-1530/32 and GS-1930/32 • ANSI and CSA Models (from serial number GS3010A-110000 to GS3011A-110827) 6 - 9 6 - 10...
  • Page 215 January 2012 Section 6 • Schematics Electrical Schematic GS-1530/32 and GS-1930/32 • ANSI and CSA Models (from serial number GS3011A-110828) 6 - 11 6 - 12...
  • Page 216 Section 6 • Schematics January 2012 Electrical Schematic GS-1530/32 and GS-1930/32 • ANSI and CSA Models (from serial number GS3011A-110828) 6 - 12 GS-30 • GS-32 • GS-46 • GS-47 Part No. 228901...
  • Page 217 January 2012 Section 6 • Schematics Electrical Schematic GS-1530/32 and GS-1930/32 • ANSI and CSA Models (from serial number GS3011A-110828) Part No. 228901 GS-30 • GS-32 • GS-46 • GS-47 6 - 13...
  • Page 218 January 2012 Section 6 • Schematics Electrical Schematic GS-1530/32 and GS-1930/32 • ANSI and CSA Models (from serial number GS3011A-110828) 6 - 13 6 - 14...
  • Page 219 January 2012 Section 6 • Schematics Electrical Schematic GS-2032 and GS-2632 • ANSI and CSA Models (from serial number GS3211A-110000) 6 - 15 6 - 16...
  • Page 220 Section 6 • Schematics January 2012 Electrical Schematic GS-2032 and GS-2632 • ANSI and CSA Models (from serial number GS3211A-110000) 6 - 16 GS-30 • GS-32 • GS-46 • GS-47 Part No. 228901...
  • Page 221 January 2012 Section 6 • Schematics Electrical Schematic GS-2032 and GS-2632 • ANSI and CSA Models (from serial number GS3011A-110000) Part No. 228901 GS-30 • GS-32 • GS-46 • GS-47 6 - 17...
  • Page 222 January 2012 Section 6 • Schematics Electrical Schematic GS-2032 and GS-2632 • ANSI and CSA Models (from serial number GS3011A-110000) 6 - 17 6 - 18...
  • Page 223 January 2012 Section 6 • Schematics Electrical Schematic GS-3232 • ANSI and CSA Models (from serial number GS3211A-110000) 6 - 19 6 - 20...
  • Page 224 Section 6 • Schematics January 2012 Electrical Schematic GS-3232 • ANSI and CSA Models (from serial number GS3211A-110000) 6 - 20 GS-30 • GS-32 • GS-46 • GS-47 Part No. 228901...
  • Page 225 January 2012 Section 6 • Schematics Electrical Schematic GS-3232 • ANSI and CSA Models (from serial number GS3211A-110000) Part No. 228901 GS-30 • GS-32 • GS-46 • GS-47 6 - 21...
  • Page 226 January 2012 Section 6 • Schematics Electrical Schematic GS-3232 • ANSI and CSA Models (from serial number GS3211A-110000) 6 - 21 6 - 22...
  • Page 227 January 2012 Section 6 • Schematics Electrical Schematic GS-2046 and GS-2646 • ANSI and CSA Models (from serial number GS4611A-110000) 6 - 23 6 - 24...
  • Page 228 Section 6 • Schematics January 2012 Electrical Schematic GS-2046 and GS-2646 • ANSI and CSA Models (from serial number GS4611A-110000) 6 - 24 GS-30 • GS-32 • GS-46 • GS-47 Part No. 228901...
  • Page 229 January 2012 Section 6 • Schematics Electrical Schematic GS-2046 and GS-2646 • ANSI and CSA Models (from serial number GS4611A-110000) Part No. 228901 GS-30 • GS-32 • GS-46 • GS-47 6 - 25...
  • Page 230 January 2012 Section 6 • Schematics Electrical Schematic GS-2046 and GS-2646 • ANSI and CSA Models (from serial number GS4611A-110000) 6 - 25 6 - 26...
  • Page 231 January 2012 Section 6 • Schematics Electrical Schematic GS-3246 • ANSI and CSA Models (from serial number GS4611A-110000) 6 - 27 6 - 28...
  • Page 232 Section 6 • Schematics January 2012 Electrical Schematic GS-3246 • ANSI and CSA Models (from serial number GS4611A-110000) 6 - 28 GS-30 • GS-32 • GS-46 • GS-47 Part No. 228901...
  • Page 233 January 2012 Section 6 • Schematics Electrical Schematic GS-3246 • ANSI and CSA Models (from serial number GS4611A-110000) Part No. 228901 GS-30 • GS-32 • GS-46 • GS-47 6 - 29...
  • Page 234 January 2012 Section 6 • Schematics Electrical Schematic GS-3246 • ANSI and CSA Models (from serial number GS4611A-110000) 6 - 29 6 - 30...
  • Page 235 January 2012 Section 6 • Schematics Electrical Schematic GS-1530/32 and GS-1930/32 • CE and AUS Models (from serial number GS3010A-110000 to GS3011A-110827) 6 - 31 6 - 32...
  • Page 236 Section 6 • Schematics January 2012 Electrical Schematic GS-1530/32 and GS-1930/32 • CE and AUS Models (from serial number GS3010A-110000 to GS3011A-110827) 6 - 32 GS-30 • GS-32 • GS-46 • GS-47 Part No. 228901...
  • Page 237 January 2012 Section 6 • Schematics Electrical Schematic GS-1530/32 and GS-1930/32 • CE and AUS Models (from serial number GS3010A-110000 to GS3011A-110827) Part No. 228901 GS-30 • GS-32 • GS-46 • GS-47 6 - 33...
  • Page 238 January 2012 Section 6 • Schematics Electrical Schematic GS-1530/32 and GS-1930/32 • CE and AUS Models (from serial number GS3010A-110000 to GS3011A-110827) 6 - 33 6 - 34...
  • Page 239 January 2012 Section 6 • Schematics Electrical Schematic GS-1530/32 and GS-1930/32 • CE and AUS Models (from serial number GS3011A-110828 and serial number GS3011C-10000) 6 - 35 6 - 36...
  • Page 240 Section 6 • Schematics January 2012 Electrical Schematic GS-1530/32 and GS-1930/32 • CE and AUS Models (from serial number GS3011A-110828 and serial number GS3011C-10000) 6 - 36 GS-30 • GS-32 • GS-46 • GS-47 Part No. 228901...
  • Page 241 January 2012 Section 6 • Schematics Electrical Schematic GS-1530/32 and GS-1930/32 • CE and AUS Models (from serial number GS3011A-110828 and serial number GS3011C-10000) Part No. 228901 GS-30 • GS-32 • GS-46 • GS-47 6 - 37...
  • Page 242 January 2012 Section 6 • Schematics Electrical Schematic GS-1530/32 and GS-1930/32 • CE and AUS Models (from serial number GS3011A-110828 and serial number GS3011C-10000) 6 - 37 6 - 38...
  • Page 243 January 2012 Section 6 • Schematics Electrical Schematic GS-2032 and GS-2632 • CE and AUS Models (from serial number GS3211A-110000 and serial number GS-3212C-10000) 6 - 39 6 - 40...
  • Page 244 Section 6 • Schematics January 2012 Electrical Schematic GS-2032 and GS-2632 • CE and AUS Models (from serial number GS3211A-110000 and serial number GS-3212C-10000) 6 - 40 GS-30 • GS-32 • GS-46 • GS-47 Part No. 228901...
  • Page 245 January 2012 Section 6 • Schematics Electrical Schematic GS-2032 and GS-2632 • CE and AUS Models (from serial number GS3211A-110000 and serial number GS3212C-10000) Part No. 228901 GS-30 • GS-32 • GS-46 • GS-47 6 - 41...
  • Page 246 January 2012 Section 6 • Schematics Electrical Schematic GS-2032 and GS-2632 • CE and AUS Models (from serial number GS3211A-110000 and serial number GS3212C-10000) 6 - 41 6 - 42...
  • Page 247 January 2012 Section 6 • Schematics Electrical Schematic GS-3232 • CE and AUS Models (from serial number GS3211A-110000 and serial number GS3212C-10000) 6 - 43 6 - 44...
  • Page 248 Section 6 • Schematics January 2012 Electrical Schematic GS-3232 • CE and AUS Models (from serial number GS3211A-110000 and serial number GS3212C-10000) 6 - 44 GS-30 • GS-32 • GS-46 • GS-47 Part No. 228901...
  • Page 249 January 2012 Section 6 • Schematics Electrical Schematic GS-3232 • CE and AUS Models (from serial number GS3211A-110000 and serial number GS3212C-10000) Part No. 228901 GS-30 • GS-32 • GS-46 • GS-47 6 - 45...
  • Page 250 January 2012 Section 6 • Schematics Electrical Schematic GS-3232 • CE and AUS Models (from serial number GS3211A-110000 and serial number GS3212C-10000) 6 - 45 6 - 46...
  • Page 251 January 2012 Section 6 • Schematics Electrical Schematic GS-2046 and GS-2646 • CE and AUS Models (from serial number GS4611A-110000 and serial number GS-4612C-10000) 6 - 47 6 - 48...
  • Page 252 Section 6 • Schematics January 2012 Electrical Schematic GS-2046 and GS-2646 • CE and AUS Models (from serial number GS4611A-110000 and serial number GS-4612C-10000) 6 - 48 GS-30 • GS-32 • GS-46 • GS-47 Part No. 228901...
  • Page 253 January 2012 Section 6 • Schematics Electrical Schematic GS-2046 and GS-2646 • CE and AUS Models (from serial number GS4611A-110000 and serial number GS4612C-10000) Part No. 228901 GS-30 • GS-32 • GS-46 • GS-47 6 - 49...
  • Page 254 January 2012 Section 6 • Schematics Electrical Schematic GS-2046 and GS-2646 • CE and AUS Models (from serial number GS4611A-110000 and serial number GS4612C-10000) 6 - 49 6 - 50...
  • Page 255 January 2012 Section 6 • Schematics Electrical Schematic GS-3246 • CE and AUS Models (from serial number GS4611A-110000 and serial number GS-4612C-10000) 6 - 51 6 - 52...
  • Page 256 Section 6 • Schematics January 2012 Electrical Schematic GS-3246 • CE and AUS Models (from serial number GS4611A-110000 and serial number GS-4612C-10000) 6 - 52 GS-30 • GS-32 • GS-46 • GS-47 Part No. 228901...
  • Page 257 January 2012 Section 6 • Schematics Electrical Schematic GS-3246 • CE and AUS Models (from serial number GS4611A-110000 and serial number GS4612C-10000) Part No. 228901 GS-30 • GS-32 • GS-46 • GS-47 6 - 53...
  • Page 258 January 2012 Section 6 • Schematics Electrical Schematic GS-3246 • CE and AUS Models (from serial number GS4611A-110000 and serial number GS4612C-10000) 6 - 53 6 - 54...
  • Page 259 January 2012 Section 6 • Schematics Electrical Schematic GS-4047 • CE and AUS Models (from serial number GS-4612C-101) 6 - 55 6 - 56...
  • Page 260 Section 6 • Schematics January 2012 Electrical Schematic GS-4047 • CE and AUS Models (from serial number GS-4612C-101) 6 - 56 GS-30 • GS-32 • GS-46 • GS-47 Part No. 228901...
  • Page 261 January 2012 Section 6 • Schematics Electrical Schematic GS-4047 • CE and AUS Models (from serial number GS4612C-101) Part No. 228901 GS-30 • GS-32 • GS-46 • GS-47 6 - 57...
  • Page 262 January 2012 Section 6 • Schematics Electrical Schematic GS-4047 • CE and AUS Models (from serial number GS4612C-101) This page left blank intentionally 6 - 57 6 - 58...

  • Page 263: Component Reference And Hydraulic Symbols Legend

    January 2012 Section 6 • Schematics Component Reference and Hydraulic Symbols Legend Hydraulic cylinder Variable speed Brake motor Shuttle valve Fixed displacement pump Relief valve Solenoid operated 3 position 4 way directional valve Orifice Bi-directional motor with size Solenoid operated 2 position 4 way Solenoid operated directional valve...

  • Page 264: Gs-2046, Gs-2646 And Gs-3246

    Section 6 • Schematics January 2012 Component Reference and Hydraulic Symbols Legend Function manifold, GS-1530, GS-1532, GS-1930 and GS-1932 Function manifold, GS-2032, GS-2632, GS-3232, GS-2046, GS-2646 and GS- 3246 Lift pressure selector manifold, GS-4047 Function manifold, Brake release manifold, GS-4047 all models Outrigger manifold, GS-3232...
  • Page 265 January 2012 Section 6 • Schematics Hydraulic Schematic GS-1530/1532/1930/1932 (from serial number GS3010A-110000) GS-1530/1532/1930/1932 (from serial number GS3011C-10000) ABBREVIATION LEGEND Item Description Test port Check valve, steer circuit Relief valve, lift Check valve, brake circuit Drive forward/reverse Steer left/right Flow regulator/relief valve Platform up Relief valve, system Hand pump, manual brake release...
  • Page 266 Section 6 • Schematics January 2012 Hydraulic Schematic GS-2032/2632/3232 (from serial number GS3211A-110000 and GS3212C-10000) GS-2046/2646/3246 (from serial number GS4611A-110000 and GS4612C-10000) 6 - 62 GS-30 • GS-32 • GS-46 • GS-47 Part No. 228901...

  • Page 267: (From Serial Number Gs3212C-10000)

    January 2012 Section 6 • Schematics Hydraulic Schematic GS-3232 (from serial number GS3211A-110000) (from serial number GS3212C-10000) Part No. 228901 GS-30 • GS-32 • GS-46 • GS-47 6 - 63...
  • Page 268 Section 6 • Schematics January 2012 Hydraulic Schematic GS-4047 (from serial number GS4712C-101) 6 - 64 GS-30 • GS-32 • GS-46 • GS-47 Part No. 228901...
  • Page 269 Genie North America Phone 425.881.1800 Toll Free USA and Canada 800.536.1800 Fax 425.883.3475 Genie Australia Pty Ltd. Phone +61 7 3375 1660 Fax +61 7 3375 1002 Genie Scandinavia Genie China Phone +46 31 575100 Fax + 46 31 579020...

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