Terex Genie GS-1530 Service Manual
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Terex Genie GS-1530 Service Manual

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Service Manual
GS -1530/32
GS -1930/32
GS -2032
GS -2632
GS -2046
GS -2646
GS -3246
Serial Number Range
from GS3003-60000
to GS3005-75999
from GS3003-60000
to GS3005-75999
from GS3204-60000
to GS3205-75406
from GS3204-60000
to GS3205-75406
from GS4604-60000
to GS4605-75437
from GS4604-60000
to GS4605-75437
from GS4604-60000
to GS4605-75437
Part No. 96316
Rev E5
November 2010

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Summary of Contents for Terex Genie GS-1530

  • Page 1 Service Manual Serial Number Range GS -1530/32 from GS3003-60000 to GS3005-75999 GS -1930/32 from GS3003-60000 to GS3005-75999 GS -2032 from GS3204-60000 to GS3205-75406 GS -2632 from GS3204-60000 to GS3205-75406 GS -2046 from GS4604-60000 to GS4605-75437 GS -2646 from GS4604-60000 to GS4605-75437 GS -3246 from GS4604-60000 to GS4605-75437...

  • Page 2: Introduction

    Manuals for these models: Manual on your machine before attempting any Title Part No. maintenance procedure. Genie GS-1530 and GS-1930 Service Manual, Basic mechanical, hydraulic and electrical First Edition skills are required to perform most procedures. (before serial number 17408) ....... 39528...

  • Page 3: Serial Number Legend

    June 2009 INTRODUCTION Serial Number Legend GS-1930 Model: GS3005-12345 Serial number: 2005 04/12/05 Model year: Manufacture date: ES0141 Electrical schematic number: 2,714 lb / 1,231 kg Machine unladen weight: GS30 05 - 12345 500 lb / 227 kg Rated work load (including occupants): Maximum allowable inclination of the chassis: Model Sequence...
  • Page 4 September 2005 This page intentionally left blank. GS-30 • GS-32 • GS-46 Part No. 96316...

  • Page 5: Safety Rules

    September 2005 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 September 2005 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

    June 2009 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 June 2009 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 - 11 B-3 Inspect the Tires and Wheels (including castle nut torque) ....3 - 12 B-4 Test the Emergency Stop ..............
  • Page 9 June 2009 TABLE OF CONTENTS Section 4 Repair Procedures Introduction ....................4 - 1 Platform Controls Circuit Boards ..................4 - 3 Controller Adjustments ............... 4 - 4 Software Configuration (before serial numbers GS3005-75000, GS3205-75000 and GS4605-75000) ......4 - 9 Software Configuration (after serial numbers GS3005-74999, GS3205-74999 and GS4605-74999) ......
  • Page 10 June 2009 TABLE OF CONTENTS Hydraulic Pump Function Pump ................. 4 - 64 Section 4 Repair Procedures, continued Manifolds Function Manifold Components - GS-1530, GS-1532, GS-1930 and GS-1932 ........4 - 66 Function Manifold Components - GS-2032, GS-2632, GS-2046, GS-2646 and GS-3246 ....4 - 68 Check Valve Manifold Components - GS-1530, GS-1532, GS-1930 and GS-1932 (after serial number GS3004-66986) ..........

  • Page 11: Electrical Schematics

    June 2009 TABLE OF CONTENTS Fault Code Chart ..................5 - 3 Section 6 Schematics Introduction ....................6 - 1 Electrical Component and Wire Color Legends ........... 6 - 2 ECM Pin-out Legend ................... 6 - 3 Wiring Diagram - Ground Controls and Level Sensor Harness ....6 - 4 Wiring Diagram - Platform Control Box ............
  • Page 12 June 2009 TABLE OF CONTENTS Section 6 Schematics, continued Hydraulic Schematics Component Reference and Hydraulic Symbols Legend ......6 - 39 Hydraulic Schematic - GS-1530/1532/1930/1932 (from serial number GS3003-60000 to GS3004-65104) ......6 - 40 Hydraulic Schematic - GS-1530/1532/1930/1932 (from serial number GS3004-65105 to 66986) ........... 6 - 42 Hydraulic Schematic - GS-1530/1532/1930/1932 (from serial number GS3004-66987 to GS3005-75999) ......

  • Page 13: E Machine Specifications

    June 2009 Section 2 • Specifications Specifications REV E 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 58 cm Type T-105...

  • Page 14: Performance Specifications

    Section 2 • Specifications June 2009 SPECIFICATIONS REV E Performance Specifications Function speed, maximum from platform controls (with 1 person in platform) Drive speed, maximum GS-1530, GS-1532 GS-1530, GS-1532, GS-1930, GS-1932 Platform up 15 to 17 seconds Platform down 16 to 18 seconds Platform stowed 2.5 mph 40 ft / 10.7 sec...

  • Page 15: Hydraulic Specifications

    June 2009 Section 2 • Specifications REV E SPECIFICATIONS Hydraulic Specifications Function pump Hydraulic Oil Specifications Type Gear Hydraulic oil type Chevron Rando HD equivalent ISO viscosity grade Multi-viscosity Displacement per revolution 0.244 cu in Viscosity index 4 cc Cleanliness level, minimum 15/13 Flow rate @ 2500 psi / 172 bar 4 gpm...

  • Page 16: Manifold Component Specifications

    Section 2 • Specifications June 2009 SPECIFICATIONS REV E Manifold Component Valve Coil Resistance Specifications Note: The following coil resistance specifications are at an ambient temperature of 68°F / 20°C. As valve coil Plug torque resistance is sensitive to changes in air temperature, the coil resistance will typically increase or decrease by SAE No.

  • Page 17: Hydraulic Hose And Fitting Torque Specifications

    June 2009 Section 2 • Specifications REV E 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 18 Section 2 • Specifications June 2009 SPECIFICATIONS REV E Torque Procedure 3 Working clockwise on the body hex fitting, make a second mark with a permanent ink marker to JIC 37° fittings indicate the proper tightening position. Refer to Figure 2. 1 Align the tube flare (hex nut) against the nose of Note: Use the JIC 37°...
  • Page 19 June 2009 Section 2 • Specifications REV E 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 20 Section 2 • Specifications June 2009 This page intentionally left blank. 2 - 8 GS-30 • GS-32 • GS-46 Part No. 96316...

  • Page 21: Observe And Obey

    October 2008 Section 3 • Scheduled Maintenance Procedures Scheduled Maintenance Procedures About This Section This section contains detailed procedures for each scheduled maintenance inspection. Each procedure includes a description, safety warnings and step-by-step instructions. Observe and Obey: Symbols Legend Safety alert symbol—used to alert Maintenance inspections shall be completed by personnel to potential personal a person trained and qualified on the...

  • Page 22: Pre-Delivery Preparation Report

    Section 3 • Scheduled Maintenance Procedures October 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 23 Pre-Deliver Pre-Deliver y Preparation Pre-Deliver y Preparation y Preparation y Preparation Pre-Deliver Pre-Deliver y Preparation October 2008 Section 3 • Scheduled Maintenance Procedures Fundamentals Instructions It is the responsibility of the dealer to perform the Use the operator’s manual on your machine. Pre-delivery Preparation.
  • Page 24 Section 3 • Scheduled Maintenance Procedures October 2008 This page intentionally left blank. 3 - 4 GS-30 • GS-32 • GS-46 Part No. 96316...

  • Page 25: Maintenance Inspection Report

    June 2009 Section 3 • Scheduled Maintenance Procedures Maintenance Inspection Report Model Checklist A - Rev C Y N R Checklist B - Rev F 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 Tires and wheels Date...

  • Page 26: Checklist A Procedures

    Section 3 • Scheduled Maintenance Procedures October 2008 Checklist A Procedures REV C 3 Open the operator's manual to the decals inspection section. Carefully and thoroughly Inspect the Manuals and Decals inspect all decals on the machine for legibility and damage. Maintaining the operator’s and safety manuals in good condition is essential to safe machine Result: The machine is equipped with all...

  • Page 27: Perform Pre-Operation Inspection

    October 2008 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 28: Perform 30 Day Service

    Section 3 • Scheduled Maintenance Procedures October 2008 CHECKLIST A PROCEDURES REV C Perform 30 Day Service Grease the Steer Yokes The 30 day maintenance procedure is a one time Genie specifications require that procedure to be performed after the first 30 days or this procedure be performed every 40 hours of usage.

  • Page 29: Checklist B Procedures

    June 2009 Section 3 • Scheduled Maintenance Procedures Checklist B Procedures REV F Models without maintenance-free or sealed batteries: Inspect the Batteries 6 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer. Note the results. Genie requires that this procedure be performed 7 Check the ambient air temperature and adjust every 250 hours or quarterly, whichever comes...
  • Page 30 Section 3 • Scheduled Maintenance Procedures June 2009 CHECKLIST B PROCEDURES REV F 11 Check the battery acid level. If needed, All models: replenish with distilled water to inch / 3 mm 13 Check each battery pack and verify that the below the bottom of the battery fill tube.

  • Page 31: Inspect The Electrical Wiring

    June 2009 Section 3 • Scheduled Maintenance Procedures REV F CHECKLIST B PROCEDURES 4 Turn the key switch to ground control and pull out the red Emergency Stop button to the on Inspect the Electrical Wiring position at both the ground and platform controls.

  • Page 32: Inspect The Tires And Wheels (Including Castle Nut Torque)

    Section 3 • Scheduled Maintenance Procedures June 2009 CHECKLIST B PROCEDURES REV F Inspect the Tires and Wheels Test the Emergency Stop (including castle nut torque) Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first.

  • Page 33: Test The Key Switch

    June 2009 Section 3 • Scheduled Maintenance Procedures REV F 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.

  • Page 34: Test The Drive Brakes

    Section 3 • Scheduled Maintenance Procedures June 2009 CHECKLIST B PROCEDURES REV F 6 Bring the machine to top drive speed before reaching the test line. Release the function Test the Drive Brakes enable switch or the joystick when your reference point on the machine crosses the test line.
  • Page 35 June 2009 Section 3 • Scheduled Maintenance Procedures REV F CHECKLIST B PROCEDURES 12 Carefully inspect the hex portion of the valve for an identification stamp. Result: SV10-4727 is stamped on the hex portion of the drive forward/reverse valve. This indicates the machine is equipped with a dynamic brake valve.
  • Page 36 Section 3 • Scheduled Maintenance Procedures June 2009 CHECKLIST B PROCEDURES REV F 21 Remove the drive forward/reverse valve from 25 Install the coil nut onto the valve and tighten. the function manifold. Cap the open port of the Torque to 60 in-lbs 7 Nm. manifold.

  • Page 37: Test The Drive Speed - Stowed Position

    June 2009 Section 3 • Scheduled Maintenance Procedures REV F CHECKLIST B PROCEDURES 5 Choose a point on the machine; i.e., contact patch of a tire, as a visual reference for use Test the Drive Speed - when crossing the start and finish lines. Stowed Position 6 Bring the machine to top drive speed before reaching the start line.

  • Page 38: Test The Drive Speed - Raised Position

    Section 3 • Scheduled Maintenance Procedures June 2009 CHECKLIST B PROCEDURES REV F 4 Press and hold the function enable switch on the joystick. Test the Drive Speed - 5 Raise the platform approximately 4 feet / 1.2 m Raised Position from the ground.

  • Page 39: Perform Hydraulic Oil Analysis

    June 2009 Section 3 • Scheduled Maintenance Procedures REV F CHECKLIST B PROCEDURES B-10 B-11 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.

  • Page 40: Check The Module Tray Latch Components

    Section 3 • Scheduled Maintenance Procedures June 2009 CHECKLIST B PROCEDURES REV F B-12 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 41: Inspect The Voltage Inverter (If Equipped)

    June 2009 Section 3 • Scheduled Maintenance Procedures REV F CHECKLIST B PROCEDURES B-13 3 Connect an appropriate power tool to the inverter. Activate the tool. Inspect the Voltage Inverter Result: The power tool should operate. There (if equipped) may be a brief (0.5 second) delay if the power tool has not been used in the previous 10 minutes.

  • Page 42: Test The Down Limit Switch And The Pothole Limit Switches

    Section 3 • Scheduled Maintenance Procedures June 2009 CHECKLIST B PROCEDURES REV F B-14 7 GS-1530/32 and GS-1930/32: Follow the platform control cable down the scissor stack to Test the Down Limit Switch and the alarm bracket on the chassis deck. Tag and the Pothole Limit Switches disconnect the platform control cable from the ECM cable at the 6-pin Deutsch connector.
  • Page 43 June 2009 Section 3 • Scheduled Maintenance Procedures REV F CHECKLIST B PROCEDURES 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 44 Section 3 • Scheduled Maintenance Procedures June 2009 CHECKLIST B PROCEDURES REV F 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 45: Test The Up Limit Switch (If Equipped)

    June 2009 Section 3 • Scheduled Maintenance Procedures REV F CHECKLIST B PROCEDURES B-15 Test the Up Limit Switch (if equipped) Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first. Maintaining the limit switches is essential to safe operation and good machine performance.

  • Page 46: Test The Platform Overload System (If Equipped)

    Section 3 • Scheduled Maintenance Procedures April 2006 Checklist C Procedures REV C The maximum height limit switch, located in the middle of the drive chassis under the scissor arms, Test the is used to disable the lift valve coil when the Platform Overload System platform is near maximum height.
  • Page 47 April 2006 Section 3 • Scheduled Maintenance Procedures REV C CHECKLIST C PROCEDURES 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 48: Replace The Hydraulic Tank Breather Cap - Models With Optional Hydraulic Oil

    Section 3 • Scheduled Maintenance Procedures April 2006 CHECKLIST C PROCEDURES REV C 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.

  • Page 49: Checklist D Procedures

    June 2006 Section 3 • Scheduled Maintenance Procedures Checklist D Procedures REV C Check the Scissor Arm Wear Pads Genie requires that this procedure be performed every 1000 hours or annually, whichever comes first. Maintaining the scissor arm wear pads in good condition is essential to safe machine operation.
  • Page 50 Section 3 • Scheduled Maintenance Procedures June 2006 CHECKLIST D PROCEDURES REV C GS-2032, GS-2632, 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 51: Replace The Hydraulic Tank Return Filter

    June 2006 Section 3 • Scheduled Maintenance Procedures REV C CHECKLIST D PROCEDURES 5 Turn the key switch to ground control and pull out the red Emergency Stop button to the on Replace the position at both the ground and platform Hydraulic Tank Return Filter controls.

  • Page 52: Checklist E Procedure

    Section 3 • Scheduled Maintenance Procedures September 2005 Checklist E Procedure REV B 3 Tag and disconnect the hydraulic tank return hard line from the hydraulic filter head and Test or Replace the Hydraulic Oil remove the hard line from the tank. Cap the fitting on the filter head.
  • Page 53 September 2005 Section 3 • Scheduled Maintenance Procedures REV B 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 54 Section 3 • Scheduled Maintenance Procedures October 2008 This page intentionally left blank. 3 - 34 GS-30 • GS-32 • GS-46 Part No. 96316...
  • Page 55 October 2008 Section 4 • Repair Procedures Repair Procedures About This Section Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop. Select the appropriate repair procedure after troubleshooting the problem.
  • Page 56 Section 4 • Repair Procedures June 2009 Platform Controls REV D The platform controls, used to operate the machine from the platform or while standing on the ground, can also be used to tune the performance of the machine. EMERGENCY STOP Moving the joystick or activating a button sends a PLATFORM CONTROLS signal to the Electronic Control Module (ECM).

  • Page 57: Circuit Boards

    June 2009 Section 4 • Repair Procedures REV D Circuit Boards How to Remove the Platform Controls Circuit Board 1 Push in the red Emergency Stop button to the off position at both the ground and platform controls. 2 Remove the fasteners securing the platform control box together.

  • Page 58: Controller Adjustments

    Section 4 • Repair Procedures June 2009 PLATFORM CONTROLS REV D 4 Press the lift function select button. Controller Adjustments Stop ® Platform lift speed, stowed drive speed, raised drive speed and high torque drive speed are adjustable to compensate for wear in the hydraulic pump and drive motors.
  • Page 59 June 2009 Section 4 • Repair Procedures REV D PLATFORM CONTROLS How to Adjust the Lift Speed Stop ® 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 60 Section 4 • Repair Procedures June 2009 PLATFORM CONTROLS REV D How to Adjust the Stowed Drive Stop ® 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 61 June 2009 Section 4 • Repair Procedures REV D PLATFORM CONTROLS How to Adjust the Raised Drive Stop ® 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 62 Section 4 • Repair Procedures June 2009 PLATFORM CONTROLS REV D How to Adjust the High Torque Stop ® 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 63: Software Configuration (Before Serial Numbers Gs3005-75000, Gs3205-75000 And Gs4605-75000)

    June 2009 Section 4 • Repair Procedures REV D PLATFORM CONTROLS Machine Option Definitions Software Configuration Motion Beacon: The motion beacon option (before serial numbers GS3005-75000, flashes only when operating a function. GS3205-75000 and GS4605-75000) Motion Alarm: The motion alarm will sound The ECM (Electronic Control Module) contains when operating any function.
  • Page 64 Section 4 • Repair Procedures June 2009 PLATFORM CONTROLS REV D How to Set the DIP Switch Codes EMERGENCY STOP BUTTON Tip-over hazard. Do not adjust the DIP switch settings to other than PLATFORM CONTROLS CIRCUIT BOARD what is specified in this procedure. JOYSTICK CONTROLLER Exceeding specifications could...
  • Page 65 June 2009 Section 4 • Repair Procedures REV D PLATFORM CONTROLS DIP Switch Code Chart A mark in the column indicates that the machine configuration includes this option. Diagnostic Diagnostic Display Switch Display Switch Code Code Code Code • 00000000 10000000 •...

  • Page 66: Software Configuration (After Serial Numbers Gs3005-74999, Gs3205-74999 And Gs4605-74999)

    Section 4 • Repair Procedures June 2009 PLATFORM CONTROLS REV D Software Configuration (after serial numbers GS3005-74999, GS3205-74999 and GS4605-74999) 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.
  • Page 67 June 2009 Section 4 • Repair Procedures REV D PLATFORM CONTROLS 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 68 Section 4 • Repair Procedures June 2009 PLATFORM CONTROLS REV D Machine Configuration Code Chart Machine Configuration Code Chart A mark in the four right columns indicates that the A mark in the four right columns indicates that the machine configuration, at left, includes this option. machine configuration, at left, includes this option.
  • Page 69 June 2009 Section 4 • Repair Procedures REV D 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 70: Platform Components

    Section 4 • Repair Procedures September 2005 Platform Components REV A 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 71: Platform Extension

    September 2005 Section 4 • Repair Procedures REV A 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 72: Scissor Components

    Section 4 • Repair Procedures October 2008 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 outer arm 11 Number 3 outer arm 3 Number 3 center pivot pin (2 pins) 12 Number 3 pivot pin (non-steer end) 4 Lift cylinder rod-end pivot pin 13 Number 2 inner arm...

  • Page 73: Scissor Assembly, Gs-1530 And Gs-1532

    October 2008 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 74 Section 4 • Repair Procedures October 2008 SCISSOR COMPONENTS REV C 9 Remove the number 3 cable bridge mounting 18 Remove the number 2 cable bridge mounting fasteners and remove the cable bridge from the fasteners and remove the cable bridge from the machine.
  • Page 75 October 2008 Section 4 • Repair Procedures REV C SCISSOR COMPONENTS 26 Use a soft metal drift to tap the number 2 pivot 33 Attach a lifting strap from an overhead crane to pin (index #15) in the other direction at the non- the lug on the rod end of the lift cylinder steer end.
  • Page 76 Section 4 • Repair Procedures October 2008 SCISSOR COMPONENTS REV C 40 Attach a lifting strap from an overhead crane to 47 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 77 October 2008 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 78 Section 4 • Repair Procedures October 2008 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 79: Scissor Assembly, Gs-1930 And Gs-1932

    October 2008 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 80 Section 4 • Repair Procedures October 2008 SCISSOR COMPONENTS REV C 6 Use a soft metal drift to remove the number 4 13 Remove the cables from the number 3 cable center pivot pins (index #2). bridge and lay them off to the side. 7 Remove the retaining fasteners from the Component damage hazard.
  • Page 81 October 2008 Section 4 • Repair Procedures REV C SCISSOR COMPONENTS 20 Attach a lifting strap from an overhead crane to 27 Attach a lifting strap from an overhead crane to the number 3 outer arm (index #16) at the the number 3 inner arm (index #15).
  • Page 82 Section 4 • Repair Procedures October 2008 SCISSOR COMPONENTS REV C 36 Use a soft metal drift to tap the number 2 pivot 41 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.
  • Page 83 October 2008 Section 4 • Repair Procedures REV C SCISSOR COMPONENTS 49 Tag, disconnect and plug the hydraulic hoses 55 Attach a lifting strap from an overhead crane to on the lift cylinder. Cap the fittings on the the number 1 inner arm (index #10) at the non- cylinder.
  • Page 84 Section 4 • Repair Procedures October 2008 REV C 62 Use a soft metal drift to remove the number 1 How to Replace the Scissor Arm center pivot pins (index #9). Wear Pads Bodily injury hazard. The number 1 Remove the platform. See 2-1, How to Remove 1 outer arm may become the Platform.
  • Page 85 October 2008 Section 4 • Repair Procedures REV C 9 Remove the scissor assembly from the machine just enough to access both wear pads. Component damage hazard. Be careful not to damage the level sensor or limit switch while moving the scissor assembly.
  • Page 86 Section 4 • Repair Procedures October 2008 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 outer arm 11 Number 3 outer arm 3 Number 3 center pivot pin (2 pins) 12 Number 3 pivot pin (non-steer end) 4 Lift cylinder rod-end pivot pin 13 Number 2 inner arm...

  • Page 87: Scissor Assembly, Gs-2032 And Gs-2046

    October 2008 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 88 Section 4 • Repair Procedures October 2008 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 89 October 2008 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 90 Section 4 • Repair Procedures October 2008 SCISSOR COMPONENTS REV C 46 Tag and disconnect the wires and manual 55 Secure the ends of the scissor arms together at lowering cable from the solenoid valve on the the steer end of the machine with a strap or cylinder.
  • Page 91 October 2008 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 92 Section 4 • Repair Procedures October 2008 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 93: Scissor Assembly, Gs-2632 And Gs-2646

    October 2008 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 94 Section 4 • Repair Procedures October 2008 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 95 October 2008 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 96 Section 4 • Repair Procedures October 2008 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 97 October 2008 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 98 Section 4 • Repair Procedures October 2008 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 99 October 2008 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 100 Section 4 • Repair Procedures October 2008 SCISSOR COMPONENTS REV C 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 101: Scissor Assembly, Gs-3246

    October 2008 Section 4 • Repair Procedures REV C SCISSOR COMPONENTS Scissor Assembly, GS-3246 How to Disassemble the Scissor Assembly, GS-3246 Bodily injury hazard. The procedures in this section require specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant...
  • Page 102 Section 4 • Repair Procedures October 2008 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 103 October 2008 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 104 Section 4 • Repair Procedures October 2008 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 105 October 2008 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 106 Section 4 • Repair Procedures October 2008 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 107 October 2008 Section 4 • Repair Procedures REV C SCISSOR COMPONENTS How to Replace the Scissor Arm 11 Install the new wear pad. Wear Pads 12 Rotate the scissor assembly towards the other side of the machine until the other scissor arm 1 Remove the platform.

  • Page 108: Lift Cylinder

    Section 4 • Repair Procedures October 2008 SCISSOR COMPONENTS REV C Lift Cylinder How to Remove the Lift Cylinder - GS-1530, GS-1532, GS-1930 and GS-1932 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...
  • Page 109 October 2008 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 110 Section 4 • Repair Procedures October 2008 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 111 October 2008 Section 4 • Repair Procedures REV C SCISSOR COMPONENTS GS-3246: 5 Models with platform overload option: Tag and disconnect the wiring from the platform 1 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. overload switch. 2 Lift the safety arm, move it to the center of the 6 Loosen the adjustment nuts on the solenoid scissor arm and rotate down to a vertical...
  • Page 112 Section 4 • Repair Procedures October 2008 SCISSOR COMPONENTS REV C 14 Support and secure the lift cylinder to an appropriate lifting device. 15 Remove the lift cylinder through the scissor arms at the steer end of the machine. Crushing hazard. The lift cylinder may become unbalanced and fall if not properly supported and secured to the lifting device.

  • Page 113: Ground Controls

    October 2008 Section 4 • Repair Procedures Ground Controls REV B 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 114: Control Relays

    Section 4 • Repair Procedures October 2008 GROUND CONTROLS REV B 3 Connect 24V DC and a ground wire to terminals 85 and 86, then test the following terminal Control Relays combinations. Relays used for single function switching are single Test Desired result pole double throw (SPDT) relays.

  • Page 115: Level Sensor

    October 2008 Section 4 • Repair Procedures REV B GROUND CONTROLS 5 Lift the safety arm, move it to the center of the scissor arm and rotate down to a vertical Level Sensor 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 116 Section 4 • Repair Procedures October 2008 GROUND CONTROLS REV B 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 117 October 2008 Section 4 • Repair Procedures REV B 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 118: Hydraulic Pump

    Section 4 • Repair Procedures September 2005 Hydraulic Pump REV A 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 119 September 2005 Section 4 • Repair Procedures REV A 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 Note: When removing a hose assembly or fitting, hydraulic oil can penetrate and the O-ring on the fitting and/or hose end must be burn skin.

  • Page 120: Function Manifold Components - Gs-1530, Gs-1532, Gs-1930 And Gs-1932

    Section 4 • Repair Procedures October 2008 Manifolds REV C 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 (items E, F and H) ......................5 ft-lbs / 7 Nm Diagnostic nipple ........
  • Page 121 October 2008 Section 4 • Repair Procedures REV C MANIFOLDS Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic Note: 'alpha-numeric' callouts refer to corresponding notes on the electrical schematic Part No. 96316 GS-30 • GS-32 • GS-46 4 - 67...

  • Page 122: Function Manifold Components - Gs-2032, Gs-2632, Gs-2046, Gs-2646 And Gs-3246

    Section 4 • Repair Procedures October 2008 MANIFOLDS REV C Function Manifold Components - GS-2032, GS-2632, 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 123 October 2008 Section 4 • Repair Procedures REV C MANIFOLDS Note: 'alpha-numeric' callouts refer to corresponding notes on the electrical schematic Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic Part No. 96316 GS-30 • GS-32 • GS-46 4 - 69...

  • Page 124: Check Valve Manifold Components

    Section 4 • Repair Procedures October 2008 MANIFOLDS REV C Check Valve Manifold Components - GS-1530, GS-1532, GS-1930 and GS-1932 (after serial number GS3004-66986) The check valve manifold is mounted on the function manifold. Index Schematic Description Item Function Torque Check valve, 200 psi / 13.8 bar ....

  • Page 125: Valve Adjustments - Function Manifold

    October 2008 Section 4 • Repair Procedures REV C MANIFOLDS 6 Press and hold the function enable switch. Valve Adjustments - 7 Move and hold the joystick fully in either direction while observing the pressure reading Function Manifold on the pressure gauge. Note the pressure. Refer to Section 2, Specifications .
  • Page 126 Section 4 • Repair Procedures October 2008 MANIFOLDS REV C How to Adjust the 7 Move and hold the joystick fully in either direction while observing the pressure reading Platform Lift Relief Valve on the pressure gauge. Note the pressure. Refer to Section 2, Specifications .
  • Page 127 October 2008 Section 4 • Repair Procedures REV C 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 128 Section 4 • Repair Procedures October 2008 MANIFOLDS REV C 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 129: Valve Coils

    October 2008 Section 4 • Repair Procedures REV C 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 130 Section 4 • Repair Procedures October 2008 MANIFOLDS REV C 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. Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil.

  • Page 131: Hydraulic Tank

    September 2005 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 132: Steer Axle Components

    Section 4 • Repair Procedures June 2009 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 133: Steer Cylinder

    June 2009 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 134: Steer Bellcrank

    Section 4 • Repair Procedures June 2009 STEER AXLE COMPONENTS REV B Note: While removing the bellcrank from the machine, take note of the quantity and location of Steer Bellcrank the spacers between the bellcrank and the steer links. How to Remove the Steer Note: Before re-installing the steer bellcrank onto Bellcrank the machine, apply a small amount of Loctite onto...

  • Page 135: Non-Steer Axle Components

    September 2005 Section 4 • Repair Procedures Non-steer Axle Components REV A 7 Raise the machine approximately 2 inches / 5 cm. Place blocks under the chassis Drive Brake for support. Crushing hazard. The chassis How to Remove a Drive Brake could fall if not properly supported.

  • Page 136: Brake Release Hand Pump Components

    Section 4 • Repair Procedures September 2005 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 Shuttle valve ........J ....Brake release circuit ......45-50 in-lbs / 5 Nm Check valve, pilot operated ....

  • Page 137: Platform Overload Components

    October 2008 Section 4 • Repair Procedures Platform Overload Components REV B 11-1 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.
  • Page 138 Section 4 • Repair Procedures October 2008 REV B 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 October 2008 Section 4 • Repair Procedures REV B TROUBLESHOOTING THE PLATFORM OVERLOAD SYSTEM CONDITION POSSIBLE CAUSE SOLUTION CANNOT LIFT RATED LOAD RELIEF VALVE SETTING INCREASE RELIEF VALVE PRESSURE AT MAX HEIGHT THE PRESSURE SWITCH TURN OFF RED EMERGENCY STOP ALARM CONTINUES TO SOUND AFTER SYSTEM NEEDS TO BE RESET BUTTON, WAIT THREE SECONDS AND TURN...
  • Page 140 Section 4 • Repair Procedures October 2008 This page intentionally left blank. 4 - 86 GS-30 • GS-32 • GS-46 Part No. 96316...

  • Page 141: Fault Codes

    Section 5 • Fault Codes September 2005 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 142: Malfunction Discovered

    Section 5 • Fault Codes September 2005 FAULT CODES About This Section LED Diagnostic Readout When a malfunction is discovered, the fault code charts in this section will help a service professional pinpoint the cause of the problem. To use this section, basic hand tools and certain pieces of test equipment are required—voltmeter, ohmmeter, pressure gauges.

  • Page 143: Fault Code Chart

    Section 5 • Fault Codes September 2005 Fault Code Chart REV A 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 144 Section 5 • Fault Codes September 2005 This page intentionally left blank. 5 - 4 GS-30 • GS-32 • GS-46 Part No. 96316...
  • Page 145 September 2005 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 146: Electrical Component And Wire Color Legends

    Section 6 • Schematics September 2005 Electrical Component and Wire Color Legends REV A WIRE COLOR LEGEND ELECTRICAL COMPONENT LEGEND Item Description Color Description Battery Black Button Blue BN5 = Horn Brown BN6 = High torque Green BN8 = Drive enable Gray BN9 = Lift enable Orange...

  • Page 147: Ecm Pin-Out Legend

    September 2005 Section 6 • Schematics ECM Pin-out Legend REV C ECM PIN-OUT LEGEND Item Description Flashing beacon FB1 (output) Ground from platform controls (input) (White wire at platform controls) Plug Power from platform controls to ECM (input) (Red wire at platform controls) Level sensor power S7 (output) Platform up coil Y8 (output) Drive reverse coil Y5 (output)
  • Page 148 Section 6 • Schematics June 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 149: Wiring Diagram Platform Control Box

    September 2005 Section 6 • Schematics Wiring Diagram REV B Platform Control Box EMERGENCY STOP BUTTON PLATFORM CONTROLS SW25 (GEN 4) PLATFORM CONTROLS CIRCUIT BOARD DIP SWITCH WH/BL JOYSTICK CONTROLLER ALARM TO COIL CORD ASSEMBLY PLATFORM CONTROLS (GEN 5) JOYSTICK CONTROLLER ALARM TO COIL CORD...

  • Page 150: Limit Switch Legend

    Section 6 • Schematics October 2008 Limit Switch Legend REV B Limit Switch Legend maximum height limit switch LS5 (CE models) down limit switch LS6 pothole switches LS7, LS8 6 - 6 GS-30 • GS-32 • GS-46 Part No. 96316...

  • Page 151: Electrical Symbols Legend

    September 2005 Section 6 • Schematics Electrical Symbols Legend REV A N.O. N.O. Pressure switch, LEVEL SENSOR CIRCUIT BOARD normally open Motor controller LEVEL SENSOR N.C. N.C.H.O. Level sensor Limit switch Wire with description Motor Button or switch Solenoid valve Circuits crossing no connection Battery charger...

  • Page 152: (From Serial Number Gs3003-60000 To Gs3005-74999)

    Section 6 • Schematics October 2008 Electrical Schematic ANSI, CSA and Australia Models REV C GS-1530/1532/1930/1932 (from serial number GS3003-60000 to GS3005-74999) 6 - 8 GS-30 • GS-32 • GS-46 Part No. 96316...
  • Page 153 October 2008 Section 6 • Schematics Electrical Schematic ANSI, CSA and Australia Models REV C GS-1530/1532/1930/1932 (from serial number GS3003-60000 to GS3005-74999) - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF CR48 POWER RELAY TO U5 (E-STOP) N.O.H.C.
  • Page 154 Section 6 • Schematics October 2008 Electrical Schematic ANSI, CSA and Australia Models REV C GS-1530/1532/1930/1932 (from serial number GS3003-60000 to GS3005-74999) EMERGENCY STOP POWER TO PLATFORM POWER TO GROUND GROUND PIO3 PIO2 DATA LINK (HIGH) PIO4 DATA LINK (LOW) PIO5 24V DC SW25...
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  • Page 156: (From Serial Number Gs3005-75000 To 75999)

    Section 6 • Schematics September 2005 Electrical Schematic ANSI, CSA and Australia Models REV B GS-1530/1532/1930/1932 (from serial number GS3005-75000 to 75999) EMERGENCY STOP PLATFORM CONTROL SWITCH - NOTE - ALARM MACHINE SHOWN IN THE STOWED POSITION WITH N.C.H.O. GROUND THE POWER OFF CONTROL POTHOLE...
  • Page 157 September 2005 Section 6 • Schematics Electrical Schematic ANSI, CSA and Australia Models REV B GS-1530/1532/1930/1932 (from serial number GS3005-75000 to 75999) - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF CR48 POWER RELAY TO U5 (E-STOP) N.O.H.C.
  • Page 158 Section 6 • Schematics September 2005 Electrical Schematic ANSI, CSA and Australia Models REV B GS-1530/1532/1930/1932 (from serial number GS3005-75000 to 75999) EMERGENCY STOP POWER TO PLATFORM POWER TO GROUND GROUND PIO3 PIO2 DATA LINK (HIGH) PIO4 DATA LINK (LOW) PIO5 24V DC 5V DC...
  • Page 159 September 2005 Section 6 • Schematics This page intentionally left blank. Part No. 96316 GS-30 • GS-32 • GS-46 6 - 15...

  • Page 160: Dgs-2032/2632

    Section 6 • Schematics June 2009 Electrical Schematic ANSI, CSA and Australia Models REV D GS-2032/2632 (from serial number GS3204-60000 to GS3205-74999) GS-2046/2646/3246 (from serial number GS4604-60000 to GS4605-74999) 6 - 16 GS-30 • GS-32 • GS-46 Part No. 96316...
  • Page 161 June 2009 Section 6 • Schematics Electrical Schematic ANSI, CSA and Australia Models REV D GS-2032/2632 (from serial number GS3204-60000 to GS3205-74999) GS-2046/2646/3246 (from serial number GS4604-60000 to GS4605-74999) - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF CR48 POWER RELAY TO U5...
  • Page 162 Section 6 • Schematics June 2009 Electrical Schematic ANSI, CSA and Australia Models REV D GS-2032/2632 (from serial number GS3204-60000 to GS3205-74999) GS-2046/2646/3246 (from serial number GS4604-60000 to GS4605-74999) EMERGENCY STOP POWER TO PLATFORM POWER TO GROUND GROUND PIO3 PIO2 DATA LINK (HIGH) PIO4 DATA LINK (LOW)
  • Page 163 June 2009 Section 6 • Schematics This page intentionally left blank. Part No. 96316 GS-30 • GS-32 • GS-46 6 - 19...

  • Page 164: Gs-2032/2632 (From Serial Number Gs3205-75000 To 75406) Gs-2046/2646/3246 (From Serial Number Gs4605-75000 To 75437)

    Section 6 • Schematics September 2005 Electrical Schematic ANSI, CSA and Australia Models REV B GS-2032/2632 (from serial number GS3205-75000 to 75406) GS-2046/2646/3246 (from serial number GS4605-75000 to 75437) EMERGENCY STOP PLATFORM CONTROL SWITCH - NOTE - ALARM MACHINE SHOWN IN THE STOWED POSITION WITH N.C.H.O.
  • Page 165 September 2005 Section 6 • Schematics Electrical Schematic ANSI, CSA and Australia Models REV B GS-2032/2632 (from serial number GS3205-75000 to 75406) GS-2046/2646/3246 (from serial number GS4605-75000 to 75437) - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF CR48 POWER RELAY TO U5...
  • Page 166 Section 6 • Schematics September 2005 Electrical Schematic ANSI, CSA and Australia Models REV B GS-2032/2632 (from serial number GS3205-75000 to 75406) GS-2046/2646/3246 (from serial number GS4605-75000 to 75437) EMERGENCY STOP POWER TO PLATFORM POWER TO GROUND GROUND PIO3 PIO2 DATA LINK (HIGH) PIO4 DATA LINK (LOW)
  • Page 167 September 2005 Section 6 • Schematics This page intentionally left blank. Part No. 96316 GS-30 • GS-32 • GS-46 6 - 23...

  • Page 168: (From Serial Number Gs3003-60000 To Gs3005-74999)

    Section 6 • Schematics October 2008 Electrical Schematic CE Models REV C GS-1530/1532/1930/1932 (from serial number GS3003-60000 to GS3005-74999) 6 - 24 GS-30 • GS-32 • GS-46 Part No. 96316...
  • Page 169 October 2008 Section 6 • Schematics Electrical Schematic CE Models REV C GS-1530/1532/1930/1932 (from serial number GS3003-60000 to GS3005-74999) - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF CR48 POWER RELAY TO U5 (E-STOP) N.C. PLATFORM N.C.H.O.
  • Page 170 Section 6 • Schematics October 2008 Electrical Schematic CE Models REV C GS-1530/1532/1930/1932 (from serial number GS3003-60000 to GS3005-74999) EMERGENCY STOP POWER TO PLATFORM POWER TO GROUND GROUND PIO3 PIO2 DATA LINK (HIGH) PIO4 DATA LINK (LOW) PIO5 24V DC SW25 5V DC PLATFORM CONTROLS...
  • Page 171 October 2008 Section 6 • Schematics This page intentionally left blank. Part No. 96316 GS-30 • GS-32 • GS-46 6 - 27...

  • Page 172: (From Serial Number Gs3005-75000 To 75999)

    Section 6 • Schematics September 2005 Electrical Schematic CE Models REV B GS-1530/1532/1930/1932 (from serial number GS3005-75000 to 75999) EMERGENCY STOP PLATFORM CONTROL SWITCH - NOTE - ALARM MACHINE SHOWN IN THE STOWED POSITION WITH N.C.H.O. GROUND THE POWER OFF CONTROL POTHOLE TS66...
  • Page 173 September 2005 Section 6 • Schematics Electrical Schematic CE Models REV B GS-1530/1532/1930/1932 (from serial number GS3005-75000 to 75999) - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF CR48 POWER RELAY TO U5 (E-STOP) N.C. PLATFORM N.C.H.O.
  • Page 174 Section 6 • Schematics September 2005 Electrical Schematic CE Models REV B GS-1530/1532/1930/1932 (from serial number GS3005-75000 to 75999) EMERGENCY STOP POWER TO PLATFORM POWER TO GROUND GROUND PIO3 PIO2 DATA LINK (HIGH) PIO4 DATA LINK (LOW) PIO5 24V DC 5V DC PLATFORM CONTROLS VOLTAGE...
  • Page 175 September 2005 Section 6 • Schematics This page intentionally left blank. Part No. 96316 GS-30 • GS-32 • GS-46 6 - 31...

  • Page 176: Dgs-2032/2632

    Section 6 • Schematics June 2009 Electrical Schematic CE Models REV D GS-2032/2632 (from serial number GS3204-60000 to GS3205-74999) GS-2046/2646/3246 (from serial number GS4604-60000 to GS4605-74999) 6 - 32 GS-30 • GS-32 • GS-46 Part No. 96316...
  • Page 177 June 2009 Section 6 • Schematics Electrical Schematic CE Models REV D GS-2032/2632 (from serial number GS3204-60000 to GS3205-74999) GS-2046/2646/3246 (from serial number GS4604-60000 to GS4605-74999) - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF CR48 POWER RELAY TO U5 (E-STOP)
  • Page 178 Section 6 • Schematics June 2009 Electrical Schematic CE Models REV D GS-2032/2632 (from serial number GS3204-60000 to GS3205-74999) GS-2046/2646/3246 (from serial number GS4604-60000 to GS4605-74999) EMERGENCY STOP POWER TO PLATFORM POWER TO GROUND GROUND PIO3 PIO2 DATA LINK (HIGH) PIO4 DATA LINK (LOW) PIO5...
  • Page 179 June 2009 Section 6 • Schematics This page intentionally left blank. Part No. 96316 GS-30 • GS-32 • GS-46 6 - 35...

  • Page 180: Gs-2032/2632 (From Serial Number Gs3205-75000 To 75406) Gs-2046/2646/3246 (From Serial Number Gs4605-75000 To 75437)

    Section 6 • Schematics September 2005 Electrical Schematic CE Models REV B GS-2032/2632 (from serial number GS3205-75000 to 75406) GS-2046/2646/3246 (from serial number GS4605-75000 to 75437) EMERGENCY STOP PLATFORM CONTROL SWITCH - NOTE - ALARM MACHINE SHOWN IN THE STOWED POSITION WITH N.C.H.O.
  • Page 181 September 2005 Section 6 • Schematics Electrical Schematic CE Models REV B GS-2032/2632 (from serial number GS3205-75000 to 75406) GS-2046/2646/3246 (from serial number GS4605-75000 to 75437) - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF CR48 POWER RELAY TO U5 (E-STOP)
  • Page 182 Section 6 • Schematics September 2005 Electrical Schematic CE Models REV B GS-2032/2632 (from serial number GS3205-75000 to 75406) GS-2046/2646/3246 (from serial number GS4605-75000 to 75437) EMERGENCY STOP POWER TO PLATFORM POWER TO GROUND GROUND PIO3 PIO2 DATA LINK (HIGH) PIO4 DATA LINK (LOW) PIO5...
  • Page 183 September 2005 Section 6 • Schematics Component Reference and Hydraulic Symbols Legend REV A 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 184: Hydraulic Schematic Gs-1530/1532/1930/1932 (From Serial Number Gs3003-60000 To Gs3004-65104)

    Section 6 • Schematics September 2005 Hydraulic Schematic GS-1530/1532/1930/1932 REV A (from serial number GS3003-60000 to GS3004-65104) PLATFORM LIFT CYLINDER OVERLOAD (CE MODELS) GS-1530 = 0.046” / 1.17 mm GS-1930 = 0.037” / 0.94 mm The lift cylinder orifice is located underneath the fitting on the lift cylinder.
  • Page 185 September 2005 Section 6 • Schematics Hydraulic Schematic GS-1530/1532/1930/1932 REV A (from serial number GS3003-60000 to GS3004-65104) STEER STEER LEFT RIGHT LEFT RIGHT LEFT RIGHT BRAKE BRAKE DRIVE DRIVE MOTOR MOTOR BRAKE HAND PUMP 1.03 cu. in. 16.9 cc BRAKE MANUAL RELEASE RELEASE...

  • Page 186: Hydraulic Schematic Gs-1530/1532/1930/1932 (From Serial Number Gs3004-65105 To 66986)

    Section 6 • Schematics September 2005 Hydraulic Schematic GS-1530/1532/1930/1932 REV B (from serial number GS3004-65105 to 66986) PLATFORM LIFT CYLINDER OVERLOAD (CE MODELS) GS-1530 = 0.046” / 1.17 mm GS-1930 = 0.037” / 0.94 mm The lift cylinder orifice is located underneath the fitting on the lift cylinder.
  • Page 187 September 2005 Section 6 • Schematics Hydraulic Schematic GS-1530/1532/1930/1932 REV B (from serial number GS3004-65105 to 66986) STEER STEER LEFT RIGHT LEFT RIGHT LEFT RIGHT BRAKE BRAKE DRIVE DRIVE MOTOR MOTOR BRAKE MANUAL RELEASE 1.03 cu. in. 16.9 cc HAND BRAKE PUMP RELEASE...

  • Page 188: Hydraulic Schematic Gs-1530/1532/1930/1932 (From Serial Number Gs3004-66987 To Gs3005-75999)

    Section 6 • Schematics September 2005 Hydraulic Schematic GS-1530/1532/1930/1932 REV A (from serial number GS3004-66987 to GS3005-75999) LIFT CYLINDER PLATFORM OVERLOAD (CE MODELS) GS-1530 = 0.046” / 1.17 mm GS-1930 = 0.037” / 0.94 mm The lift cylinder orifice is located underneath the fitting on the lift cylinder.
  • Page 189 September 2005 Section 6 • Schematics Hydraulic Schematic GS-1530/1532/1930/1932 REV A (from serial number GS3004-66987 to GS3005-75999) STEER STEER LEFT RIGHT LEFT RIGHT LEFT RIGHT BRAKE BRAKE DRIVE DRIVE MOTOR MOTOR BRAKE MANUAL RELEASE 1.03 cu. in. 16.9 cc HAND BRAKE PUMP RELEASE...

  • Page 190: A Hydraulic Schematic - Gs-2032/2632

    Section 6 • Schematics September 2005 Hydraulic Schematic GS-2032/2632 REV A (from serial number GS3204-60000 to GS3205-75406) UPPER LIFT CYLINDER PLATFORM LIFT CYLINDER (GS-3246) OVERLOAD (CE MODELS) The lift cylinder orifice is located underneath the fitting on the lift cylinder. 0.037”...
  • Page 191 September 2005 Section 6 • Schematics Hydraulic Schematic GS-2032/2632 REV A (from serial number GS3204-60000 to GS3205-75406) STEER STEER LEFT RIGHT LEFT RIGHT LEFT RIGHT BRAKE BRAKE DRIVE DRIVE MOTOR MOTOR BRAKE MANUAL RELEASE 1.03 CU. IN. HAND 16.9 cc BRAKE PUMP RELEASE...

  • Page 192: B Hydraulic Schematic - Gs-2046/2646/3246

    Section 6 • Schematics June 2009 Hydraulic Schematic GS-2046/2646/3246 REV B (from serial number GS4604-60000 to GS4604-60878) UPPER LIFT CYLINDER PLATFORM LIFT CYLINDER (GS-3246) OVERLOAD (CE MODELS) The lift cylinder orifice is located underneath the fitting on the lift cylinder. 0.037”...
  • Page 193 June 2009 Section 6 • Schematics Hydraulic Schematic GS-2046/2646/3246 REV B (from serial number GS4604-60000 to GS4604-60878) STEER STEER LEFT RIGHT LEFT RIGHT LEFT RIGHT DRIVE DRIVE BRAKE BRAKE MOTOR MOTOR BRAKE HAND PUMP 1.03 CU. IN. 16.9 cc BRAKE MANUAL RELEASE RELEASE...

  • Page 194: A Hydraulic Schematic - Gs-2046/2646/3246

    Section 6 • Schematics September 2005 Hydraulic Schematic GS-2046/2646/3246 REV A (from serial number GS4604-60879 to GS4605-75437) UPPER LIFT CYLINDER PLATFORM LIFT CYLINDER (GS-3246) OVERLOAD (CE MODELS) The lift cylinder orifice is located underneath the fitting on the lift cylinder. 0.037”...
  • Page 195 September 2005 Section 6 • Schematics Hydraulic Schematic GS-2046/2646/3246 REV A (from serial number GS4604-60879 to GS4605-75437) STEER STEER LEFT RIGHT LEFT RIGHT LEFT RIGHT BRAKE BRAKE DRIVE DRIVE MOTOR MOTOR BRAKE MANUAL RELEASE 1.03 CU. IN. HAND 16.9 cc BRAKE PUMP RELEASE...
  • Page 196 Section 6 • Schematics September 2005 This page intentionally left blank. 6 - 52 GS-30 • GS-32 • GS-46 Part No. 96316...
  • Page 197 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 Phone +86 21 53852570 Fax +86 21 53852569 Genie France...
  • Page 198 Part No. 96316 Rev E5...

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