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Genie gS-1530/32, Service And Repair Manual

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Genie gS-1530/32 Service And Repair Manual Download Page 189

April 2017

 

Service and Repair Manual

 

 

Type "UXXX" Faults

 

 

 

Part No. 1272217

 

GS-30 • GS-32 • GS-46 • GS-47

 

173 

 

 

Type "UXXX" Faults 

DTC

 

Number

 

Message on

 

GCON LCD

 

Description

 

Possible Causes

 

Failure Mode

 

U001:

 

GS30, 

GS32, 

GS46 & 

GS47 

U001:SWITCHFAULT 

GCON MAIN FTN EN 

Short circuit of the GCON main function 

enable switch at system startup. 

• Short circuit of the GCON main function enable 

switch. 

• GCON ECM. 

All GCON functions 

inhibited. 

U002:

 

GS30, 

GS32, 

GS46 & 

GS47 

U002:SWITCHFAULT 

GCON PLAT UP 

Short circuit of the GCON up directional 

switch at system startup. 

• Short circuit of the GCON up directional switch. 

• GCON ECM. 

All GCON functions 

inhibited except 

platform down. 

U003:

 

GS30, 

GS32, 

GS46 & 

GS47 

U003:SWITCHFAULT 

GCON PLAT DOWN 

Short circuit of the GCON down directional 

switch at system startup. 

• Short circuit of the GCON down directional switch. 

• GCON ECM. 

All GCON functions 

inhibited except 

platform up. 

U004:

 

GS30, 

GS32, 

GS46 & 

GS47 

U004:SWITCHFAULT 

GCON LCD UP 

Short circuit of the GCON LCD scroll up 

switch at system startup. 

• Short circuit of the GCON LCD scroll up switch. 

• GCON ECM. 

All GCON LCD menu 

functions inhibited. 

U005:

 

GS30, 

GS32, 

GS46 & 

GS47 

U005:SWITCHFAULT 

GCON LCD DOWN 

Short circuit of the GCON LCD scroll down 

switch at system startup. 

• Short circuit of the GCON LCD scroll down switch. 

• GCON ECM. 

All GCON LCD menu 

functions inhibited. 

U006:

 

GS30, 

GS32, 

GS46 & 

GS47 

U006:SWITCHFAULT 

GCON LCD ENTER 

Short circuit of the GCON LCD enter switch 

at system startup. 

• Short circuit of the GCON LCD enter switch. 

• GCON ECM. 

All GCON LCD menu 

functions inhibited. 

U007:

 

GS30, 

GS32, 

GS46 & 

GS47 

U007:SWITCHFAULT 

GCON LCD ESCAPE 

Short circuit of the GCON LCD escape switch 

at system startup. 

• Short circuit of the GCON LCD escape switch. 

• GCON ECM. 

All GCON LCD menu 

functions inhibited. 

U014:

 

GS30, 

GS32, 

GS46 & 

GS47 

U014:SWITCHFAULT 

PCON DRIVE EN 

Short circuit of the PCON drive enable switch 

at system startup. 

• Short circuit of the PCON drive enable switch. 

• GCON ECM. 

All PCON drive and 

steer functions 

inhibited. 

U015:

 

GS30, 

GS32, 

GS46 & 

GS47 

U015:SWITCHFAULT 

PCON STEER LEFT 

Short circuit of the PCON steer left switch at 

system startup. 

• Short circuit of the PCON steer left switch. 

• GCON ECM. 

All PCON drive and 

steer functions 

inhibited. 

U016:

 

GS30, 

GS32, 

GS46 & 

GS47 

U016:SWITCHFAULT 

PCON STEER RIGHT 

Short circuit of the PCON steer right switch at 

system startup. 

• Short circuit of the PCON steer right switch. 

• GCON ECM. 

All PCON drive and 

steer functions 

inhibited. 

U017:

 

GS30, 

GS32, 

GS46 & 

GS47 

U017:SWITCHFAULT 

PCON HORN 

Short circuit of the PCON horn switch at 

system startup. 

• Short circuit of the PCON horn switch. 

• GCON ECM. 

PCON horn switch 

function inhibited. 

U018:

 

GS30, 

GS32, 

GS46 & 

GS47 

U018:SWITCHFAULT 

PCON LO DRIV SPD 

Short circuit of the PCON low drive speed 

switch at system startup. 

• Short circuit of the PCON low drive speed switch. 

• GCON ECM. 

The machine is 

limited to low drive 

speed. 

U019:

 

GS30, 

GS32, 

GS46 & 

GS47 

U019:SWITCHFAULT 

PCON LO LIFT SPD 

Short circuit of the PCON low lift speed 

switch at system startup. 

• Short circuit of the PCON low lift speed switch. 

• GCON ECM. 

PCON platform up 

and down functions 

inhibited. 

 

Summary of Contents for gS-1530/32

Page 1: ...epair procedures Fault Codes Electrical and Hydraulic Schematics GS 1930 32 GS 2032 GS 2632 GS 3232 For detailed maintenance procedures refer to the appropriate Maintenance Manual for your machine GS 2046 GS 2646 GS 3246 GS 4047 Part No 1272217 Rev B April 2017 ...

Page 2: ...Design Life Unrestricted with proper operation inspection and scheduled maintenance Technical Publications Genie has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in suggestions for improveme...

Page 3: ...GS3016P 160599 from GS30C 24000 from GS30D 6080 from GS30P 160600 GS 2032 2632 3232 from SN GS3211A 110000 from SN GS3212C 10000 to GS3216C 17299 from SN GS3216P 142676 to GS3216P 148699 from GS32C 17300 from GS32P 148700 GS 2046 2646 3246 from SN GS4612A 110000 from SN GS4612C 10000 to GS4616C 18099 from SN GS4614D 101 to GS4616D 5029 from SN GS4616P 138362 to GS4616P 141799 from GS46C 18100 from...

Page 4: ...2016 Repair Procedure 2 6 Diagnostics Type CXXX and UXXX fault codes A3 9 2016 Introduction Serial Number Legend Specifications Add drive speed stowed parameters B 4 2017 Repair Procedure 11 1 Diagnostics Battery charger and fault codes Reference Examples Electronic Version Click on any content or procedure in the Table of Contents to view the update Section Repair Procedure 4 2 Section Fault Code...

Page 5: ...Revision History continued Revision Date Section Procedure Page Description Reference Examples Electronic Version Click on any content or procedure in the Table of Contents to view the update Section Repair Procedure 4 2 Section Fault Codes All charts Section Schematics Legends and schematics ...

Page 6: ...Serial Number Legend To August 31 2016 1 Model 2 Model year 3 Facility code 1 Sequence number 2 Serial label located on chassis 3 Serial number stamped on chassis From September 1 2016 1 Model 2 Facility code 3 Sequence number 1 Serial label located on chassis 2 Serial number stamped on chassis ...

Page 7: ...s injury Many of the hazards identified in the operator s manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless You are trained and qualified to perform maintenance on this machine You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulati...

Page 8: ...tial crushing hazards such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Workplace Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority Be sure to keep sparks flames and lighted tobacco away fro...

Page 9: ...Machine Specifications 1 Performance Specifications models without proportional lift function 3 Performance Specifications models with proportional lift 5 Hydraulic Oil Specifications 7 Hydraulic Component Specifications 10 Manifold Component Specifications 11 Hydraulic Hose and Fitting Torque Specifications 12 Torque Procedure 13 Section 3 Repair Procedures 15 Introduction 15 Platform Controls 17...

Page 10: ...3 How to Remove the Hydraulic Pump 54 Manifolds 56 5 1 Function Manifold Components GS 1530 GS 1532 GS 1930 and GS 1932 56 5 2 Function Manifold Components GS 2032 GS 2632 GS 3232 GS 2046 GS 2646 and GS 3246 58 5 3 Function Manifold Components GS 4047 60 5 4 Check Valve Manifold Components GS 1530 GS 1532 GS 1930 and GS 1932 62 5 5 Lift Pressure Selector Manifold Components GS 4047 63 5 6 Outrigge...

Page 11: ...32 86 9 3 Scissor Assembly GS 2032 and GS 2046 94 9 4 Scissor Assembly GS 2632 and GS 2646 101 9 5 Scissor Assembly GS 3232 and GS 3246 109 9 6 Scissor Assembly GS 4047 118 9 7 Scissor Arm Wear Pads 126 9 8 Platform Height Sensor 128 9 9 Lift Cylinder 130 9 10 Pressure Transducer 141 9 11 Platform Overload System 143 9 12 Platform Overload Recovery 148 Platform Components 150 10 1 Platform 150 10 ...

Page 12: ...xcept GS 3232 159 GCON I O Map without Load Sense GS 3232 only 160 GCON I O Map with Load Sense GS 3232 only 162 Operation Indicator Codes OIC 164 Diagnostic Trouble Codes DTC 164 Troubleshooting HXXX and PXXX Faults 165 Fault Inspection Procedure 166 Type HXXX Faults 168 Type PXXX Faults 172 Type UXXX Faults 173 Type FXXX Faults 176 Type CXXX Faults 179 Battery Charger 181 Charger Fault Codes 182...

Page 13: ...3010A 110000 GS3011C 10000 GS3014D 101 GS3016P 142281 196 Hydraulic Schematic GS 2032 2632 3232 2046 2646 3246 from serial number GS3211A 110000 to GS3214A 119070 GS3212C 10000 to GS3214C 11873 GS4612A 110000 to GS4614A 117177 GS4614C 10000 to GS4614C 12073 197 Hydraulic Schematic GS 2032 2632 3232 2046 2646 3246 from serial number GS3214A 119071 GS3214C 11874 GS4614A 117178 GS4614C 12074 GS4614D ...

Page 14: ...trical Schematic GS 2032 2632 2046 2646 ANSI CSA from serial number GS3211A 110000 to GS3214A 135714 GS4612A 110000 to GS4614A 135366 GS4613D 101 to GS4615D 1303 234 Electrical Schematic GS 2032 2632 2046 2646 ANSI CSA from serial number GS3214A 1135715 to GS3215A 141898 GS4614A 135367 to GS4615A 137959 GS4615D 1304 238 Electrical Schematic GS 2032 2632 2046 2646 ANSI CSA from serial numbers GS321...

Page 15: ...272 Electrical Schematic GS 3232 AS CE from serial number GS3214A 135715 to GS3215A 141898 GS3215C 14504 276 Electrical Schematic GS 3232 AS CE from serial numbers GS3215A 141899 GS3216P 142676 to GS3216P 146462 280 Electrical Schematic GS 3232 CE AS from serial number GS3216P 146463 284 Electrical Schematic GS 2032 2632 2046 2646 AS CE from serial number GS3211A 110000 to GS3214A 135714 GS3212C 1...

Page 16: ...ematic GS 3246 AS CE from serial number GS4615A 137960 GS4616P 138362 GS4616P to GS4616P 139710 310 Electrical Schematic GS 3246 AS CE from serial number GS4616D 4433 GS4616P 139711 314 Electrical Schematic GS 4047 AS CE from serial number GS4712C 101 to GS4715C 2130 GS4714D 101 to GS4715D 749 316 Electrical Schematic GS 4047 AS CE from serial number GS4715C 2131 GS4715D 750 to GS4716D 3101 320 El...

Page 17: ... Batteries Maintenance free option All models except GS 4047 Voltage 6V DC Group GC2 Type 6V AGM Quantity 4 Battery capacity maximum 200AH Reserve capacity 25A rate 380 minutes Weight each 62 lbs 28 kg Platform Overload Pressure Transducer if equipped All models except GS 3232 and GS 4047 Input voltage 8 to 30 VDC Signal voltage 1 to 5 V Platform Overload Pressure Transducer if equipped GS 3232 an...

Page 18: ...7 liters Hydraulic system including tank GS 3232 and GS 3246 5 5 gallons 20 8 liters Hydraulic system including tank GS 4047 7 5 gallons 28 4 liters Tires and wheels GS 1530 GS 1532 GS 1930 GS 1932 Tire size solid rubber 12 x 4 5 in 30 5 x 11 4 cm Tire contact area 9 sq in 58 cm2 Castle nut torque dry 300 ft lbs 406 7 Nm Castle nut torque lubricated 225 ft lbs 305 Nm GS 2032 GS 2632 GS 3232 GS 204...

Page 19: ...t 12 4 sec 3 5 km h 12 2 m 12 4 sec Platform stowed fast from serial number GS3216P 145831 GS4616P 139576 2 0 mph 40 ft 12 4 sec 3 2 km h 12 2 m 12 4 sec Platform raised 0 5 mph 40 ft 55 sec 0 8 km h 12 2 m 55 sec GS 4047 Platform stowed fast 2 0 mph 40 ft 13 6 sec 3 2 km h 12 2 m 13 6 sec Platform raised 0 5 mph 40 ft 55 sec 0 8 km h 12 2 m 55 sec Braking distance maximum High range on paved surf...

Page 20: ... GS 2046 and GS 2646 Platform up fast mode Platform up slow mode Platform down 28 to 32 seconds 58 to 62 seconds 32 to 36 seconds GS 3232 and GS 3246 Platform up fast mode Platform up slow mode Platform down 55 to 59 seconds 108 to 112 seconds 33 to 37 seconds GS 4047 Platform up fast mode Platform up slow mode Platform down 71 to 76 seconds 83 to 87 seconds 41 to 46 seconds Rated work load at ful...

Page 21: ... 12 4 sec 3 5 km h 12 2 m 12 4 sec Platform stowed from serial number GS3216P 145831 GS4616P 139576 2 0 mph 40 ft 12 4 sec 3 2 km h 12 2 m 12 4 sec Platform raised 0 5 mph 40 ft 55 sec 0 8 km h 12 2 m 55 sec GS 4047 Platform stowed 2 0 mph 40 ft 13 6 sec 3 2 km h 12 2 m 13 6 sec Platform raised 0 5 mph 40 ft 55 sec 0 8 km h 12 2 m 55 sec Braking distance maximum High range on paved surface 1 3 ft ...

Page 22: ... and GS 2646 Platform up Platform down 28 to 32 seconds 28 to 32 seconds GS 3232 and GS 3246 Platform up Platform down 55 to 59 seconds 28 to 32 seconds GS 4047 Platform up Platform down 71 to 76 seconds 41 to 46 seconds Rated work load at full height maximum GS 1530 and GS 1532 600 lbs 272 kg GS 1930 GS 1932 GS 2632 and GS 3232 500 lbs 227 kg GS 1930PAR 400 lbs 181 kg GS 2032 800 lbs 363 kg GS 20...

Page 23: ...Hydrolube HP 5046 Note Genie specifications require additional equipment and special installation instructions for the approved optional fluids Consult Genie Product Support before use Optional fluids may not have the same hydraulic lifespan and may result in component damage Note Extended machine operation can cause the hydraulic fluid temperature to increase beyond it s maximum allowable range I...

Page 24: ... below 0 F 18 C Note Do not operate the machine when the ambient temperature is below 20 F 29 C with Rando HD Premium MV Chevron 5606A Hydraulic Oil Fluid Properties ISO Grade 15 Viscosity index 300 Kinematic Viscosity cSt 200 F 100 C cSt 104 F 40 C cSt 40 F 40 C 5 5 15 0 510 Flash point 180 F 82 C Pour point 81 F 63 C Maximum continuous operating temperature 124 F 51 C Note Use of Chevron 5606A h...

Page 25: ...Shell Tellus S4 VX Fluid Properties ISO Grade 32 Viscosity index 300 Kinematic Viscosity cSt 200 F 100 C cSt 104 F 40 C 9 33 8 Brookfield Viscosity cSt 4 F 20 C cSt 13 F 25 C cSt 40 F 40 C 481 702 4 2624 Flash point 100 Pour point 76 F 60 C Maximum continuous operating temperature 103 F 75 C UCON Hydrolube HP 5046 Fluid Properties ISO Grade 46 Viscosity index 192 Kinematic Viscosity cSt 149 F 65 C...

Page 26: ...15 L min Hydraulic tank return filter 10 micron with 25 psi 1 7 bar bypass Function manifold All models except GS 4047 System relief valve pressure maximum 3700 psi 255 bar Lift relief valve pressure 1800 to 3700 psi 142 to 241 bar Steer relief valve pressure 1500 psi 103 bar Function manifold GS 4047 System relief valve pressure maximum 3500 psi 241 bar Platform relief valve pressure 3000 psi 206...

Page 27: ...mperature increases or decreases from 68 F 20 C Description Specification Solenoid valve 3 position 4 way 20V DC with diode schematic items F AC or DC 27 2Ω Solenoid valve 3 position 4 way 20V DC with diode schematic item E 19Ω Solenoid valve 2 position 4 way 20V DC with diode schematic items H AI or DI 19Ω Solenoid valve 2 position 2 way N C 20V DC with diode schematic item N 25Ω Solenoid valve 2...

Page 28: ... 16 18 1 8 3 4 16 1 10 7 8 14 1 12 1 1 16 12 1 16 1 5 16 12 1 20 1 5 8 12 1 24 1 7 8 12 1 SAE O ring Boss Port tube fitting installed into Aluminum all types SAE Dash Size Torque 4 14 ft lbs 19 Nm 6 23 ft lbs 31 2 Nm 8 36 ft lbs 54 2 Nm 10 62 ft lbs 84 Nm 12 84 ft lbs 114 Nm 16 125 ft lbs 169 5 Nm 20 151 ft lbs 204 7 Nm 24 184 ft lbs 249 5 Nm Adjustable Fitting Non adjustable fitting 1 jam nut SAE...

Page 29: ...seated and retained properly 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight 5 Tighten the nut or fitting to the appropriate torque Refer to the appropriate torque chart in this section 6 Operate all machine functions and inspect the hose fittings and related components to confirm there are no leaks JIC 37 fittings 1 Align the tube flare he...

Page 30: ...rrect number of flats for the proper tightening position Note The marks indicate the correct tightening positions have been determined Use the second mark on the body hex fitting to properly tighten the joint after it has been loosened Illustration 2 1 body hex fitting 2 reference mark 3 second mark 4 Tighten the hex nut until the mark on the hex nut is aligned with the second mark on the body hex...

Page 31: ...propriate operator s manual on your machine Be sure that all necessary tools and parts are available and ready for use Use only Genie approved replacement parts Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Machine Configuration Unless otherwise specified perform each repair procedure with the machine in the following configurat...

Page 32: ...o alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates a imminently hazardous situation which if not avoided will result in death or serious injury Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous situation which if n...

Page 33: ...e function mode the platform controls are used to operate the various machine functions The platform controls consist of an Emergency Stop button electronic circuit board proportional control handle drive steer enable switch alarm function buttons and LED display For further information or assistance contact Genie Product Support a red Emergency Stop button P2 b platform controls circuit board U3 ...

Page 34: ...eset the system Platform Controls LED Readout Code Condition LL Off level OL Platform Overload CE and Australia CH Chassis Mode Operation PHS Pothole Guard Stuck nd No Drive option Ld Lifting Disabled GS 3232 only Note The Ld Operation Indicator Code will appear when the outriggers are not fully retracted the machine is not auto leveled an outrigger has lost contact with the ground or either level...

Page 35: ...y charged circuits could result in death or serious injury Remove all rings watches and other jewelry Component damage hazard Electrostatic discharge ESD can damage printed circuit board components Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap 9 Carefully remove the platform controls circuit b...

Page 36: ...imes when handling printed circuit boards OR use a grounded wrist strap 7 Carefully remove the joystick fasteners 8 Carefully remove the joystick from the platform control box Torque specifications Joystick fasteners 9 in lbs 1 Nm 1 3 Platform Controls Alarm 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 control...

Page 37: ...atform control box Open the control box 5 Disconnect the white wires from the Emergency Stop base Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Component damage hazard Electrostatic discharge ESD can damage printed circuit board components Maintain firm contact with a metal part of the machine...

Page 38: ...is allows the platform to be raised or lowered at the ground controls Note Steer and drive functions are not available at the ground controls When the ECM is in the set up mode the ground controls are used to adjust the function speed parameters machine models or machine options For further information or assistance contact Genie Product Support 1 machine setup escape button 2 machine setup scroll...

Page 39: ... example below Result The display at the ground controls will show the machine model and hour meter information After 3 seconds the machine model will not show on the display See example below 2 Press the ground control scroll down button Result The ground control LCD display will indicate the software revision and hour meter information After 5 seconds the ground controls LCD display will display...

Page 40: ...resulting in death or serious injury Tip over hazard This procedure must only be performed by a trained service professional Attempting this procedure without the necessary skills could result in death or serious injury Note Select a test area that is firm level and free of obstructions 1 Turn the key switch to ground controls 2 Press and hold the ground control scroll up and scroll down buttons G...

Page 41: ... into the Bootloader Choose this mode if the GCON ECM is not opertaing correctly Machine Application Mode The machine Application mode is available with the key switch in the GCON or PCON position This mode of machine software update requires the user to enter the Machine Service Tool Choose this mode if the machine is operating correctly and you are updating the machine software Bootloader Mode 1...

Page 42: ... a PC or laptop Result The ground controls LCD display will show the following 7 Read and record the IP address 8 Launch a web browser such as Internet Explorer Chrome or Firefox on your PC or laptop Type the IP address from step 7 into the web browser address bar and press enter Result The following screen will be displayed 9 Select the Choose File button and navigate to the downloaded Genie Flas...

Page 43: ...ip over hazard Updating the SmartLink software may have impacted the machines default drive speeds Tipping over the machine will result in death or serious injury Perform drive speed test Refer to the Maintenance Manual that is appropriate for your machine 15 Perform a function test Refer to the Operator s Manual on your machine 16 Return the machine to service Machine Application Mode 1 Open the ...

Page 44: ...o the web browser address bar and press enter Result The following screen will be displayed 7 Enter the following username and password then select OK Username smart link Password SL1000 Note The username and password are case sensitive Result The following screen will be displayed 8 Select the Software tab at the header bar Result The following screen will be displayed 9 Select the Update Machine...

Page 45: ...on and disconnect the CAT5 cable from the GCON 15 Secure the diagnostic port cover using the retaining fasteners removed in step 5 Do not over tighten Note Machines equipped with AGM batteries will need to select the AGM battery type using the GCON set parameters screen Refer to the Machine Setup procedure in the Service and Repair manual that is appropriate for your machine Tip over hazard Updati...

Page 46: ...uire opening the ground control box to access the GCON 2 Turn the key switch to ground controls or platform controls and pull out the red Emergency Stop button to the on position at both ground and platform controls Result The display at the platform controls will show CH See example below 3 Locate the diagnostic port on the side of the GCON Remove one of the fasteners securing the cover and set a...

Page 47: ...lowing screen will be displayed 9 Enter the following username and password then select OK Username smart link Password SL1000 Note The username and password are case sensitive Result The following screen will be displayed 10 After using the Smart Link Service Tool web site push in the red Emergency Stop button and disconnect the CAT5 cable from the GCON 11 Secure the diagnostic port cover using t...

Page 48: ...ble alarm will sound Note Before entering Service Override mode fault codes or the malfunction affecting the operation of the machine should be fully understood to ensure Service Override mode is required Note Perform this operation on a firm level surface and if equipped with the outriggers auto leveled or fully retracted Tip over hazard Operating the machine on a surface that is not level while ...

Page 49: ...wn buttons after the ground controller powers up 5 At the ground controls use the Scroll Down button to scroll to SVC Override Result The ground controls LCD display will show the following 6 Press the Enter button Result The ground controls LCD display will show an alternating message every 1 5 seconds 7 Press the Enter button Result The ground controls LCD display will show the following 8 Press...

Page 50: ...t and drive functions and activate an alarm when a signal is received from the level sensor The tilt alarm sounds when the incline of the chassis exceeds 1 5 to the side and 3 to the front or rear Use the illustrations to verify which type of level sensor is installed and perform the procedure that is appropriate for your machine Procedure 1 Procedure 2 Procedure 3 1 X axis 2 Y axis ...

Page 51: ...ols 4 Raise the platform 7 to 8 feet 2 1 to 2 4 m 5 Lift the safety arm move it to the center of the scissor arm and rotate down to a vertical position 6 Lower the platform onto the safety arm Crushing hazard Keep hands clear of the safety arm when lowering the platform If you are not installing a new level sensor proceed to step 15 7 Turn the key switch to the off position and push in the red Eme...

Page 52: ...s and into the mount bracket Tighten the fasteners and measure the distance between the level sensor and the level sensor mount bracket Result The measurement should be approximately 0 375 inch 10 mm 14 Connect the chassis wire harness to the level sensor wire harness 15 Turn the key switch to the ground control and pull out the red Emergency Stop button to the on position at the ground controls 1...

Page 53: ...er both wheels 28 Lower the machine and remove the blocks 29 Center a lifting jack under the drive chassis at the battery pack side of the machine 30 Raise the machine approximately 2 inches 5 cm Place blocks under the chassis for support 31 GS 1530 and GS 1930 Place a 0 77 x 6 x 6 inch 19 6 mm x 15 cm x 15 cm thick steel block under both wheels at the battery pack side of the machine GS 1532 and ...

Page 54: ...ound control and pull out the red Emergency Stop button to the on position at both ground and platform controls 4 Raise the platform 7 to 8 feet 2 1 to 2 4 m 5 Lift the safety arm move it to the center of the scissor arm and rotate down to a vertical position 6 Lower the platform onto the safety arm Crushing hazard Keep hands clear of the safety arm when lowering the platform 7 Turn the key switch...

Page 55: ...sensor mount bracket 3 level sensor S7 4 scissor chassis 5 alarm H5 12 Install the level sensor retaining fasteners through the level sensor and into the mount bracket 13 Connect the chassis wire harness to the level sensor 14 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both ground and platform controls Result GCON will display a C051 SYST...

Page 56: ...roll to Tilt Sensor 22 Press the Enter button 23 Press and hold the Enter button to start calibration Result An audible alarm will sound when calibration is complete Note The machine will not calibrate if it is on a slope of one degree or greater Note If the level sensor has been replaced continue with step 24 If the level sensor was not replaced skip to step 27 24 Raise the platform 7 to 8 feet 2...

Page 57: ...o the stowed position 34 Drive the non steer end of the machine up a ramp until it is just under 3 35 Raise the platform 7 to 8 feet 2 1 to 2 4 m Result No audible alarm is heard Result The platform stops an audible alarm is heard and Fault LL is displayed Repeat this procedure starting at step 15 on a firm level surface 36 Lower the platform to the stowed position 37 Continue driving the machine ...

Page 58: ...his procedure starting at step 15 on a firm level surface 46 Lower the platform to the stowed position 47 Drive the battery compartment side of the machine onto a ramp until it is just under 1 5 48 Raise the platform 7 to 8 feet 2 1 to 2 4 m Result No audible alarm is heard Result The platform stops an audible alarm is heard and Fault LL is displayed Repeat this procedure starting at step 15 on a ...

Page 59: ...ound control and pull out the red Emergency Stop button to the on position at both ground and platform controls 4 Raise the platform 7 to 8 feet 2 1 to 2 4 m 5 Lift the safety arm move it to the center of the scissor arm and rotate down to a vertical position 6 Lower the platform onto the safety arm Crushing hazard Keep hands clear of the safety arm when lowering the platform 7 Turn the key switch...

Page 60: ...ensor mount bracket 3 level sensor S7 4 scissor chassis 5 alarm H5 12 Install the level sensor retaining fasteners through the level sensor and into the mount bracket 13 Connect the chassis wire harness to the level sensor 14 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both ground and platform controls Result GCON will display a C051 SYSTE...

Page 61: ...roll to Tilt Sensor 22 Press the Enter button 23 Press and hold the Enter button to start calibration Result An audible alarm will sound when calibration is complete Note The machine will not calibrate if it is on a slope of one degree or greater Note If the level sensor has been replaced continue with step 24 If the level sensor was not replaced skip to step 27 24 Raise the platform 7 to 8 feet 2...

Page 62: ...o the stowed position 34 Drive the non steer end of the machine up a ramp until it is just under 3 35 Raise the platform 7 to 8 feet 2 1 to 2 4 m Result No audible alarm is heard Result The platform stops an audible alarm is heard and Fault LL is displayed Repeat this procedure starting at step 15 on a firm level surface 36 Lower the platform to the stowed position 37 Continue driving the machine ...

Page 63: ...his procedure starting at step 15 on a firm level surface 46 Lower the platform to the stowed position 47 Drive the battery compartment side of the machine onto a ramp until it is just under 1 5 48 Raise the platform 7 to 8 feet 2 1 to 2 4 m Result No audible alarm is heard Result The platform stops an audible alarm is heard and Fault LL is displayed Repeat this procedure starting at step 15 on a ...

Page 64: ...ide of the machine 4 Tag and disconnect the outrigger level sensor wire harness from the outrigger level sensor 5 Remove the outrigger level sensor retaining fasteners and remove the outrigger level sensor from the machine 6 Place the new outrigger level sensor onto the outrigger level sensor base with the flat side of the outrigger level sensor closest to the battery side access door Refer to the...

Page 65: ...o 2 4 m 2 Lift the safety arm move it to the center of the scissor arm and rotate down to a vertical position 3 Lower the platform onto the safety arm Crushing hazard Keep hands clear of the safety arm when lowering the platform 4 Pull the handle of the manual platform lowering cable out until considerable resistance is felt Release the handle 5 Measure the distance between the base of the handle ...

Page 66: ...e or counterclockwise to increase the distance Tighten the upper lock nut 1 manual lowering cable sheath 2 upper lock nut 3 cable mounting bracket 4 lower lock nut 5 cable mounting nut 6 end of lowering cable 7 manual lowering valve hydraulic schematic item N 7 Repeat this procedure beginning with step 4 8 Raise the platform and rotate the safety arm to the stowed position 9 Pull the manual loweri...

Page 67: ...the ground controller powers up 6 Use the Menu Up or Menu Down buttons to scroll to Machine Options 7 Press the Enter button to select Machine Options 8 Use the Menu Up or Menu Down buttons to scroll to Outriggers 9 Press the Enter button to select Outriggers 10 Use the Menu Up or Menu Down buttons to scroll to Calibrate Outriggers 11 Press the Enter button to select Calibrate Outriggers 12 Press ...

Page 68: ...e platform in the stowed position 1 Disconnect the battery pack from the machine Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 2 Tag and disconnect the hydraulic tank return hard line from the filter Remove the hard line from the machine Cap the fitting on the filter head 3 Tag and disconnect ...

Page 69: ...aulic hose from the hydraulic pump 2 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the high pressure port on the pump 3 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both ground and platform controls 4 Activate the platform up function from the ground controls Result If the pressure gauge reads 3200 psi 221 bar immediately stop The ...

Page 70: ... from the filter head mounting bracket Rotate the filter out and away from the hydraulic power unit 4 Remove the hydraulic power unit retaining fasteners 5 Tag disconnect and plug the hydraulic tank hard line from the pump Cap the fitting on the pump 6 Tag disconnect and plug the high pressure hose from the pump Cap the fitting on the pump Bodily injury hazard Spraying hydraulic oil can penetrate ...

Page 71: ...April 2017 Service and Repair Manual Part No 1272217 GS 30 GS 32 GS 46 GS 47 55 This page intentionally left blank ...

Page 72: ... psi 0 7 bar D Drive circuit 20 ft lbs 27 Nm 5 Solenoid valve 3 position 4 way E Drive forward reverse 25 ft lbs 34 Nm 6 Solenoid valve 3 position 4 way F Steer left right 25 ft lbs 34 Nm 7 Flow regulator and relief valve 0 75 gpm 2 8 L min 1500 psi 130 bar G Steer circuit 26 ft lbs 35 Nm 8 Solenoid valve 2 position 4 way H Platform up 25 ft lbs 34 Nm 9 Relief valve 3700 psi 255 bar maximum I Syst...

Page 73: ...epair Manual Manifolds Part No 1272217 GS 30 GS 32 GS 46 GS 47 57 Note alpha callouts refer to corresponding notes on the hydraulic schematic Note alpha numeric callouts refer to corresponding notes on the electrical schematic ...

Page 74: ... Lift circuit 23 ft lbs 31 Nm 5 Check disc AD Steer circuit 18 ft lbs 24 Nm 6 Solenoid valve 2 position 4 way AE Drive speed select circuit 25 ft lbs 34 Nm 7 Relief valve 50 psi 3 4 bar AF Brake release 20 ft lbs 27 Nm 8 Solenoid valve 3 position 5 way AG Drive forward reverse 25 ft lbs 34 Nm 9 Flow regulator and relief valve 0 75 gpm 2 8 L min 1500 psi 103 bar AH Steer circuit 26 ft lbs 35 Nm 10 ...

Page 75: ...epair Manual Manifolds Part No 1272217 GS 30 GS 32 GS 46 GS 47 59 Note alpha callouts refer to corresponding notes on the hydraulic schematic Note alpha numeric callouts refer to corresponding notes on the electrical schematic ...

Page 76: ...18 ft lbs 24 Nm 5 Solenoid valve 2 position 4 way DE Drive speed select circuit 25 ft lbs 34 Nm 6 Relief valve 50 psi 3 4 bar DF Brake release 20 ft lbs 27 Nm 7 Solenoid valve 3 position 5 way DG Drive forward reverse 25 ft lbs 34 Nm 8 Flow regulator and relief valve 0 75 gpm 2 8 L min 1500 psi 103 bar DH Steer circuit 26 ft lbs 35 Nm 9 Solenoid valve 2 position 4 way DI Platform up 25 ft lbs 34 N...

Page 77: ...epair Manual Manifolds Part No 1272217 GS 30 GS 32 GS 46 GS 47 61 Note alpha callouts refer to corresponding notes on the hydraulic schematic Note alpha numeric callouts refer to corresponding notes on the electrical schematic ...

Page 78: ...Function Torque 1 Check valve 200 psi 13 8 bar S Drive circuit 20 ft lbs 27 Nm Note alpha callouts refer to corresponding notes on the hydraulic schematic How to Install a Valve Cartridge 1 Dip the cartridge in clean oil to lube the O rings 2 Screw the cartridge in by hand until the top O ring is met then torque to specifications 3 If required install the valve coil s onto the valve stem Install t...

Page 79: ...ctor valve 200 psi 138 bar DM Lift relief 20 ft lbs 27 Nm 2 Solenoid valve 2 position 2 way DN Lift circuit 20 ft lbs 27 Nm Note alpha callouts refer to corresponding notes on the hydraulic schematic Note alpha numeric callouts refer to corresponding notes on the electrical schematic How to Install a Valve Cartridge 1 Dip the cartridge in clean oil to lube the O rings 2 Screw the cartridge in by h...

Page 80: ...ers extend retract 25 ft lbs 34 Nm 2 Relief valve 3500 psi 241 bar maximum BB Outrigger circuit 20 ft lbs 27 Nm Note alpha callouts refer to corresponding notes on the hydraulic schematic Note alpha numeric callouts refer to corresponding notes on the electrical schematic How to Install a Valve Cartridge 1 Dip the cartridge in clean oil to lube the O rings 2 Screw the cartridge in by hand until th...

Page 81: ...4 mm CE Outrigger retract 3 Check Valve pilot operated CF Retract flow control 20 ft lbs 27 1 Nm 4 Pressure transducer CG Outrigger auto level 16 ft lbs 21 7 Nm Front Outriggers Rear Outriggers Note alpha callouts refer to corresponding notes on the hydraulic schematic Note alpha numeric callouts refer to corresponding notes on the electrical schematic How to Install a Valve Cartridge 1 Dip the ca...

Page 82: ... the test port on the function manifold schematic item A AA or DA 3 Chock both sides of the wheels at the steer end of the machine 4 Remove the platform controls from the platform 5 Turn the key switch to platform controls and pull out the red Emergency Stop button to the on position at both ground and platform controls GS 1530 32 and GS 1930 32 1 test port 2 system relief valve 6 Move and hold th...

Page 83: ...valve 4 lift relief valve How to Adjust the Platform Lift Relief Valve Note Perform this test from the ground with the platform controls Do not stand in the platform Note Verify the hydraulic oil level is at the FULL mark on the hydraulic tank 1 Locate the system relief valve on the function manifold schematic item I AB or DB 2 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the test port o...

Page 84: ...chine Specifications GS 32 GS 46 and GS 47 1 test port 2 system relief valve 3 steer relief valve 4 lift relief valve 12 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both ground and platform controls 13 Hold the lift relief valve with a wrench and remove the cap schematic item C AJ or DJ 14 While activating the platform up function adjust t...

Page 85: ...le lifting device place and secure the maximum rated load in the center of the platform deck Maximum load GS 4047 GS 4047 CE and AS models 770 lbs 350 kg GS 4047 ANSI and CSA models 550 lbs 250 kg 4 Remove the platform controls from the platform 5 Turn the key switch to platform controls and pull out the red Emergency Stop button to the on position at both ground and platform controls 6 Press and ...

Page 86: ... rises Perform steps 7 through 10 to decrease the pressure in small increments until the platform does not rise 13 Fully lower the platform to the stowed position 14 Using a suitable lifting device remove the weight from the platform How to Adjust the Steer Relief Valve Note Perform this test from the ground with the platform controls Do not stand in the platform Note Verify the hydraulic oil leve...

Page 87: ...the left Allow the wheels to completely turn to the left Continue holding the switch while observing the pressure reading on the pressure gauge 7 Turn the machine off Hold the steer relief valve with a wrench and remove the cap schematic item G AH or DH 8 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Component damage hazard D...

Page 88: ...tested 2 Test the coil resistance using a multimeter set to resistance W Refer to the Valve Coil Resistance Specification table Result If the resistance is not within the adjusted specification plus or minus 10 replace the coil Valve Coil Resistance Specifications Note The following coil resistance specifications are at an ambient temperature of 68 F 20 C As valve coil resistance is sensitive to c...

Page 89: ...ery should read 9V DC or more when measured across the terminals Resistor 10Ω Genie part number 27287 3 Set a multimeter to read DC amperage Note The multimeter when set to read DC amperage should be capable of reading up to 800 mA 4 Connect the negative lead to the other terminal on the coil Note If testing a single terminal coil connect the negative lead to the internal metallic ring at either e...

Page 90: ...ot properly supported 6 Remove the wheel castle nut Remove the wheel 7 Tag disconnect and plug the hydraulic hoses on the drive motor Cap the fittings on the drive motor Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Component damage hazard Hoses ca...

Page 91: ...ft lbs 101 7 Nm Drive motor mounting fasteners lubricated 56 ft lbs 76 3 Nm 6 2 Steer Cylinder How to Remove the Steer Cylinder Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Block the n...

Page 92: ...nder the drive chassis at the steer end of the machine 4 Raise the machine approximately 14 inches 36 cm Place blocks under the chassis for support Crushing hazard The chassis will fall if not properly supported 5 Turn the yokes to the side so the bellcrank can be removed 6 Remove the bellcrank from the machine 1 apply removable thread lock to fastener threads Note While removing the bellcrank fro...

Page 93: ... removing the castle nut 5 Loosen the wheel castle nut Do not remove it 6 Center a lifting jack under the drive chassis at the non steer end of the machine 7 Raise the machine approximately 2 inches 5 cm Place blocks under the chassis for support Crushing hazard The chassis will fall if not properly supported 8 Remove the wheel castle nut Remove the wheel 9 Tag disconnect and plug the hydraulic ho...

Page 94: ...Hand Pump Components The brake release hand pump manifold is mounted behind the entry ladder Index No Description Schematic Item Function Torque 1 Hand pump L Manual brake release 30 ft lbs 41 Nm 2 Needle valve M Manual brake release enable 45 50 in lbs 5 Nm Note alpha callouts refer to corresponding notes on the hydraulic schematic ...

Page 95: ...1 Number 3 outer arm 3 Lift cylinder rod end pivot pin 12 Number 3 pivot pin non steer end 4 Number 3 pivot pin steer end 13 Number 2 inner arm 5 Number 2 center pivot pin Qty 2 14 Number 2 outer arm 6 Number 2 pivot pin steer end 15 Number 2 pivot pin non steer end 7 Number 1 center pivot pin Qty 2 16 Lift cylinder barrel end pivot pin 8 Number 1 inner arm 17 Number 1 outer arm 9 Number 1 pivot p...

Page 96: ...m move it to the center of the scissor arm and rotate down to a vertical position 4 Lower the platform onto the safety arm Crushing hazard Keep hands clear of the safety arm when lowering the platform 5 At the ground controls turn the key switch to the off position and push in the red Emergency Stop button to the off position 6 Disconnect the battery pack from the machine Electrocution burn hazard...

Page 97: ...How to Remove the Platform 25 Remove the cables from the number 3 outer arm index 11 at the ground controls side Component damage hazard Cables can be damaged if they are kinked or pinched 26 Remove the cables from the number 3 cable bridge and lay them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched 27 Attach a lifting strap from an overhead crane to th...

Page 98: ...r 2 center pivot pin index 5 at the ground controls side 41 Remove the number 2 cable bridge mounting fasteners and remove the cable bridge from the machine 42 Attach a lifting strap from an overhead crane to the number 2 outer arm index 14 at the ground controls side 43 Use a soft metal drift to remove the number 2 center pivot pin index 5 at the ground controls side 44 Remove the retaining faste...

Page 99: ...arms onto the safety arm Bodily injury hazard Keep hands clear of moving parts when lowering the scissor arms onto the safety arm 56 Attach a lifting strap from an overhead crane to the lug on the rod end of the lift cylinder index 3 Raise the lift cylinder approximately 3 ft 1 m 57 Tag disconnect and plug the hydraulic hoses on the lift cylinder Cap the fittings on the cylinder Bodily injury haza...

Page 100: ... an overhead crane to the number 1 outer arm index 17 Do not apply any lifting pressure 68 Remove the external snap rings and retaining fasteners from the number 1 center pivot pins index 7 69 Remove the number 1 cable bridge from the machine 70 Use a soft metal drift to remove the number 1 center pivot pins index 7 Bodily injury hazard The number 1 outer arm may become unbalanced and fall if not ...

Page 101: ...teer end 4 Number 3 center pivot pin Qty 2 15 Number 3 inner arm 5 Lower lift cylinder rod end pivot pin 16 Number 3 outer arm 6 Number 3 pivot pin steer end 17 Number 3 pivot pin non steer end 7 Number 2 center pivot pin Qty 2 18 Number 2 inner arm 8 Number 2 pivot pin steer end 19 Number 2 outer arm 9 Number 1 center pivot pin Qty 2 20 Number 2 pivot pin non steer end 10 Number 1 inner arm 21 Lo...

Page 102: ... 7 to 8 feet 2 1 to 2 4 m 3 Lift the safety arm move it to the center of the scissor arm and rotate down to a vertical position 4 Lower the platform onto the safety arm Crushing hazard Keep hands clear of the safety arm when lowering the platform 5 At the ground controls turn the key switch to the off position and push in the red Emergency Stop button to the off position 6 Disconnect the battery p...

Page 103: ...buttons navigate to Service Override Mode Select Service Override Mode Note The machine must be in Service Override Mode to raise the platform While in Service Override Mode only the GCON will operate with limited functionality The platform will raise a predetermined amount of time and stop 22 Raise the platform and rotate the safety arm to the stowed position 23 Fully lower the platform to the st...

Page 104: ...strap from an overhead crane to the number 4 inner arm index 12 34 Remove the retaining fasteners from the number 4 pivot pin index 3 35 Use a soft metal drift to remove the number 4 pivot pin index 3 at the steer end Remove the number 4 inner arm index 12 from the machine Crushing hazard The number 4 inner arm may become unbalanced and fall if not properly supported when removed from the machine ...

Page 105: ...he non steer end of the machine 47 Attach a lifting strap from an overhead crane to the lug on the rod end of the lift cylinder for support Do not apply any lifting pressure 48 Remove the pin retaining fasteners from the lift cylinder rod end pivot pin index 5 Use a soft metal drift to remove the pin Bodily injury hazard The cylinder may fall when the rod end pivot pin is removed if not properly s...

Page 106: ...y pack side 62 Use a soft metal drift to remove the number 2 center pivot pin index 7 at the battery pack side Bodily injury hazard The number 2 outer arm at the battery pack side may become unbalanced and fall if not properly supported when removed from the machine 63 Use a soft metal drift to tap the number 2 pivot pin index 20 in the other direction at the non steer end Remove the number 2 oute...

Page 107: ...fter replacing the scissor assembly the platform overload system must be calibrated Refer to Repair Procedure How to Calibrate the Platform Overload System if equipped 75 Raise the lift cylinder to a vertical position 76 Remove the pin retaining fasteners from the lift cylinder barrel end pin index 21 Use a soft metal drift to remove the pin Remove the lift cylinder from the machine Crushing hazar...

Page 108: ... 1 outer arm may become unbalanced and fall if not properly supported when the pin is removed 86 Slide the number 1 outer arm index 22 to the non steer end and remove it from the machine Bodily injury hazard The number 1 outer arm may become unbalanced and fall if not properly supported when removed from the machine 87 Attach the strap from an overhead crane to the number 1 inner arm index 10 Do n...

Page 109: ...1 Number 3 outer arm 3 Lift cylinder rod end pivot pin 12 Number 3 pivot pin non steer end 4 Number 3 pivot pin steer end 13 Number 2 inner arm 5 Number 2 center pivot pin Qty 2 14 Number 2 outer arm 6 Number 2 pivot pin steer end 15 Number 2 pivot pin non steer end 7 Number 1 center pivot pin Qty 2 16 Lift cylinder barrel end pivot pin 8 Number 1 inner arm 17 Number 1 outer arm 9 Number 1 pivot p...

Page 110: ... safety arm move it to the center of the scissor arm and rotate down to a vertical position 4 Lower the platform onto the safety arm Crushing hazard Keep hands clear of the safety arm when lowering the platform 5 At the ground controls turn the key switch to the off position and push in the red Emergency Stop button to the off position 6 Disconnect the battery pack from the machine Electrocution b...

Page 111: ...ervice Override Mode Select Service Override Mode Note The machine must be in Service Override Mode to raise the platform While in Service Override Mode only the GCON will operate with limited functionality The platform will raise a predetermined amount of time and stop 22 Raise the platform and rotate the safety arm to the stowed position 23 Fully lower the platform to the stowed position Cable b...

Page 112: ...Crushing hazard The number 3 outer arm at the ground control side index 11 may become unbalanced and fall if not properly supported when removed from the machine 36 Attach a lifting strap from an overhead crane to the number 3 outer arm at the battery side index 11 37 Remove the retaining fasteners from the number 3 center pivot pin index 2 at the battery side 38 Place a rod through the number 3 c...

Page 113: ...at the ground control side index 5 and twist to remove the pin 53 Remove the retaining fasteners from the number 2 pivot pin index 15 at the non steer end 54 Use a soft metal drift to remove the number 2 pivot pin index 15 from the non steer end of the machine Remove the number 2 outer arm at the ground control side index 14 from the machine The number 2 outer arm at the ground control side index ...

Page 114: ...lift cylinder 67 Tag disconnect and plug the hydraulic hose on the lower lift cylinder Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 68 Tag and disconnect the wire harness from the solenoid valve on the cylinder 69 ...

Page 115: ...hazard Keep hands clear of moving parts when lowering the scissor arms 78 Secure the ends of the scissor arms together at the steer end of the machine with a strap or other suitable device 79 Secure the ends of the scissor arms together at the non steer end of the machine with a strap or other suitable device 80 Remove the retaining fasteners securing the chassis mount bracket to the chassis 81 Re...

Page 116: ... non steer end 4 Number 3 center pivot pin Qty 2 15 Number 3 inner arm 5 Lift cylinder rod end pivot pin 16 Number 3 outer arm 6 Number 3 pivot pin steer end 17 Number 3 pivot pin non steer end 7 Number 2 center pivot pin Qty 2 18 Number 2 inner arm 8 Number 2 pivot pin steer end 19 Number 2 outer arm 9 Number 1 center pivot pin Qty 2 20 Number 2 pivot pin non steer end 10 Number 1 inner arm 21 Li...

Page 117: ...m move it to the center of the scissor arm and rotate down to a vertical position 4 Lower the platform onto the safety arm Crushing hazard Keep hands clear of the safety arm when lowering the platform 5 At the ground controls turn the key switch to the off position and push in the red Emergency Stop button to the off position 6 Disconnect the battery pack from the machine Electrocution burn hazard...

Page 118: ...l down buttons 20 Pull out the red Emergency Stop button to the on position at the ground controls 21 Using the ground control menu buttons navigate to Service Override Mode Select Service Override Mode Note The machine must be in Service Override Mode to raise the platform While in Service Override Mode only the GCON will operate with limited functionality The platform will raise a predetermined ...

Page 119: ... from the number 4 center pivot pin index 2 at the ground control side 33 Place a rod through the number 4 center pivot pin at the ground control side index 2 and twist to remove the pin 34 Remove the retaining fasteners from the number 4 pivot pin index 15 at the non steer end 35 Use a soft metal drift to remove the number 4 pivot pin index 14 from the non steer end of the machine Remove the numb...

Page 120: ... the number 3 center pivot pin at the ground control side index 4 and twist to remove the pin 48 Remove the retaining fasteners from the number 3 pivot pin index 17 at the non steer end 49 Use a soft metal drift to remove the number 3 pivot pin index 17 from the non steer end of the machine Remove the number 3 outer arm at the ground control side index 16 from the machine Crushing hazard The numbe...

Page 121: ...emove the cables from the number 2A and 2B cable bridge and lay them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched 63 Disconnect the number 2A and 2B cable bridges from the scissor linkset and remove both cable bridges from the machine 64 Attach a lifting strap from an overhead crane to the number 2 outer arm at the ground control side index 19 65 Remo...

Page 122: ...rhead crane to the number 1 inner arm index 10 77 Raise the number 1 inner arm index 10 approximately 2 feet 60 cm 78 Place a 4 x 4 x 48 inch 10 cm x 10 cm x 1 2 m long block across both sides of the chassis under the number 1 center pivot pin index 9 79 Lower the scissor arms onto the block that was placed across the chassis Bodily injury hazard Keep hands clear of moving parts when lowering the ...

Page 123: ... the cable bridge from the machine 89 Attach a lifting strap from an overhead crane to the number 1 inner arm index 10 90 Raise the arm slightly and remove the block 91 Lower the arm to the stowed position Bodily injury hazard Keep hands clear of moving parts when lowering the scissor arms 92 Secure the ends of the scissor arms together at the steer end of the machine with a strap or other suitabl...

Page 124: ...uter arm 6 Number 4 pivot pin steer end 21 Number 4 pivot pin non steer end 7 Number 3 outer arm 22 Upper lift cylinder barrel end pivot pin 8 Number 3 center pivot pin Qty 2 23 Number 3 inner arm 9 Lift cylinder rod end pivot pin 24 Number 3 pivot pin non steer end 10 Number 3 pivot pin steer end 25 Number 2 inner arm 11 Number 2 center pivot pin Qty 2 26 Number 2 outer arm 12 Number 2 pivot pin ...

Page 125: ...mergency Stop button to the on position at both ground and platform controls 2 Raise the platform 7 to 8 feet 2 1 to 2 4 m 3 Lift the safety arm move it to the center of the scissor arm and rotate down to a vertical position 4 Lower the platform onto the safety arm Crushing hazard Keep hands clear of the safety arm when lowering the platform 5 At the ground controls turn the key switch to the off ...

Page 126: ...attery pack to the machine 18 Turn the key switch to ground controls 19 Press and hold the ground control scroll up and scroll down buttons 20 Pull out the red Emergency Stop button to the on position at the ground controls 21 Using the ground control menu buttons navigate to Service Override Mode Select Service Override Mode Note The machine must be in Service Override Mode to raise the platform ...

Page 127: ...ough the number 5 center pivot pin at the ground control side index 2 and twist to remove the pin 34 Remove the retaining fasteners from the number 5 pivot pin index 18 at the non steer end 35 Use a soft metal drift to remove the number 5 pivot pin index 18 from the non steer end of the machine Remove the number 5 outer arm at the ground control side index 17 from the machine Crushing hazard The n...

Page 128: ...end of the upper lift cylinder 48 Remove the retaining fasteners from the upper lift cylinder rod end pivot pin index 3 49 Use a soft metal drift to remove the upper lift cylinder rod end pivot pin index 3 from the machine Crushing hazard The lift cylinder will fall if not properly supported when the pivot pin is removed 50 Lower the cylinder onto the linkset 51 Attach a lifting strap from an over...

Page 129: ... the scissor linkset and remove both cable bridges from the machine 65 Attach a lifting strap from an overhead crane to the number 3 outer arm at the ground control side index 7 66 Remove the retaining fasteners from the number 3 center pivot pin index 8 at the ground control side 67 Place a rod through the number 3 center pivot pin at the ground control side index 8 and twist to remove the pin 68...

Page 130: ... onto the block Bodily injury hazard Keep hands clear of moving parts when lowering the cylinder 82 Attach a lifting strap from an overhead crane to the number 3 inner arm index 23 Raise the arm to a vertical position 83 Remove the retaining fasteners from the number 3 pivot pin at the steer end of the machine index 10 84 Use a soft metal drift to remove the number 3 pivot pin index 10 from the st...

Page 131: ...o the number 2 inner arm index 25 Raise the arm to a vertical position 97 Remove the retaining fasteners from the number 2 pivot pin at the steer end of the machine index 12 98 Use a soft metal drift to remove the number 2 pivot pin index 12 from the steer end of the machine Remove the number 2 inner arm index 25 from the machine Crushing hazard The number 2 inner arm index 25 may become unbalance...

Page 132: ...ay them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched 110 Disconnect the number 1 cable bridge from the number 1 outer arm index 29 and remove the cable bridge from the machine 111 Attach a lifting strap from an overhead crane to the number 1 inner arm index 14 112 Raise the arm slightly and remove the block 113 Lower the arm to the stowed position Bod...

Page 133: ... inner arm 5 Upper lift cylinder rod end pivot pin 17 Number 1 pivot pin steer end Qty 2 29 Number 3 pivot pin non steer end 6 Number 5 pivot pin steer end 18 Number 6 inner arm 30 Number 2 inner arm 7 Number 4 center pivot pin Qty 2 19 Number 6 outer arm 31 Number 2 inner arm 8 Number 4 pivot pin steer end 20 Number 6 pivot pin non steer end 32 Number 2 pivot pin non steer end 9 Number 3 outer ar...

Page 134: ... Stop button to the on position at both ground and platform controls 2 Raise the platform 7 to 8 feet 2 1 to 2 4 m 3 Lift the safety arm move it to the center of the scissor arm and rotate down to a vertical position 4 Lower the platform onto the safety arm Crushing hazard Keep hands clear of the safety arm when lowering the platform 5 At the ground controls turn the key switch to the off position...

Page 135: ... Turn the key switch to ground controls 19 Press and hold the ground control scroll up and scroll down buttons 20 Pull out the red Emergency Stop button to the on position at the ground controls 21 Using the ground control menu buttons navigate to Service Override Mode Select Service Override Mode Note The machine must be in Service Override Mode to raise the platform While in Service Override Mod...

Page 136: ...strap from an overhead crane to the number 6 outer arm at the battery side index 19 34 Remove the retaining fasteners from the number 6 center pivot pin index 2 at the battery side 35 Place a rod through the number 6 center pivot pin at the battery side index 2 and twist to remove the pin 36 Remove the number 6 outer arm index 19 from the machine Crushing hazard The number 6 outer arm index 19 may...

Page 137: ...from the solenoid valve on the cylinder Component damage hazard Cables can be damaged if they are kinked or pinched 49 Attach a lifting strap from an overhead crane to the lug of the rod end of the upper lift cylinder 50 Remove the retaining fasteners from the upper lift cylinder rod end pivot pin index 5 51 Use a soft metal drift to remove the upper lift cylinder rod end pivot pin index 5 from th...

Page 138: ...nent damage hazard Cables can be damaged if they are kinked or pinched 66 Attach a lifting strap from an overhead crane to the number 3 outer arm at the ground control side index 9 67 Remove the retaining fasteners from the number 3 center pivot pin index 10 at the ground control side 68 Place a rod through the number 3 center pivot pin at the ground control side index 10 and twist to remove the p...

Page 139: ...end pivot pin index 11 from the machine Crushing hazard The lift cylinder will fall if not properly supported when the pivot pin is removed 82 Place a 4 x 4 x 10 inch 10 x 10 x 25 cm block onto the number 1 inner arm cylinder plate index 16 83 Lower the cylinder onto the block Bodily injury hazard Keep hands clear of moving parts when lowering the cylinder 84 Attach a lifting strap from an overhea...

Page 140: ... crane to the number 2 inner arm index 30 Raise the arm to a vertical position 97 Remove the retaining fasteners from the number 2 pivot pin at the steer end of the machine index 14 98 Use a soft metal drift to remove the number 2 pivot pin index 14 from the steer end of the machine Remove the number 2 inner arm index 30 from the machine Crushing hazard The number 2 inner arm index 30 may become u...

Page 141: ...e bridge and lay them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched 111 Remove the cables from the number 1 cable bridge and lay them off to the side 112 Disconnect the number 1 cable bridge from the number 1 outer arm index 34 and remove the cable bridge from the machine 113 Attach a lifting strap from an overhead crane to the number 1 inner arm index...

Page 142: ...m height sensor cover to the large platform height sensor bracket 8 Remove the platform height sensor cover 9 Tag and disconnect the platform height sensor from the platform height sensor harness 10 Remove the fastener securing the platform height sensor assembly to the number 1 inner arm 11 Remove the platform height sensor assembly from the number 1 pivot pin 12 Remove the plastic nut securing t...

Page 143: ...ap or other suitable device 28 Secure the ends of the scissor arms together at the non steer end of the machine with a strap or other suitable device 29 Remove the retaining fasteners securing the chassis mount bracket to the chassis at the steer end of the machine 30 Attach a lifting strap from an overhead crane to the scissor arm assembly 31 Raise the scissor arm assembly at the steer end with t...

Page 144: ... Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 6 Remove the fasteners securing the large platform height sensor cover to the large platform height sensor bracket 7 Remove the platform height sensor cover Steer End 1 fasteners platform height sensor cover 2 platform height sensor cover 8 Tag an...

Page 145: ... retaining screw 5 squeeze connector 6 lever arm 7 platform height sensor harness connection 8 platform height sensor 9 fastener large platform height sensor bracket 10 fastener platform height sensor 11 platform height sensor assembly 18 Remove the fasteners securing the large platform height bracket to the number 1 inner arm pivot bracket 19 Remove the large platform height sensor bracket from t...

Page 146: ...s GS 1530 GS 1532 GS 1930 and GS 1932 Note Models without a pressure transducer follow steps 1 through 23 27 and 28 Models equipped with a pressure transducer follow steps 1 through 28 1 Turn the key switch to ground controls and pull out the red Emergency Stop button to the on position at both ground and platform controls 2 Raise the platform 7 to 8 feet 2 1 to 2 4 m 3 Lift the safety arm move it...

Page 147: ...draulic hoses on the lift cylinder Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 13 Attach a lifting strap from an overhead crane to the rod end of the lift cylinder for support 14 Remove the fasteners from the lift...

Page 148: ...e platform will raise a predetermined amount of time and stop 27 Raise the platform and rotate the safety arm to the stowed position 28 Fully lower the platform to the stowed position Note Models with a pressure transducer calibrate the Platform Overload System Refer to Repair Procedure How to Calibrate the Platform Overload System if equipped GS 2032 GS 2632 GS 2046 and GS 2646 Bodily injury haza...

Page 149: ...esult in death or serious injury Remove all rings watches and other jewelry 8 Tag and disconnect the wiring from the solenoid valve coil at the barrel end of the lift cylinder 9 If equipped tag and disconnect the three pin connector from the pressure transducer harness To remove the pressure transducer refer to Repair Procedure How to Remove the Pressure Transducer if equipped 10 Loosen the adjust...

Page 150: ...ings on the cylinder while removing it from the machine 20 Install new cylinder fittings hoses and pressure transducer if equipped Torque specifications Solenoid valve 2 position 2 way N C schematic item N 20 ft lbs 27 Nm Coil nut 5 ft lbs 7 Nm Pressure transducer if equipped schematic item R 27 ft lbs 37 Nm 21 Remove the lifting device supporting the link stack at the steer end of the machine 22 ...

Page 151: ...o specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications Note Models without a pressure transducer follow steps 1 through 21 25 and 26 Models equipped with a pressure transducer follow steps 1 through 26 1 Turn the key switch to ground controls and pull out the red Emergency Stop button to the on position at both ground and platform controls 2 Ra...

Page 152: ...ness To remove the pressure transducer refer to Repair Procedure How to Remove the Pressure Transducer if equipped 10 Loosen the adjustment nuts on the solenoid valve and disconnect the manual lowering cable from the valve Note During assembly the manual platform lowering cable needs to be properly adjusted Refer to Repair Procedure How to Adjust the Manual Platform Lowering Cable 11 Remove the fa...

Page 153: ...achine Crushing hazard The lift cylinder will become unbalanced and fall if not properly supported and secured to the lifting device Component damage hazard Be careful not to damage the valve or fittings on the cylinder while removing it from the machine 20 Install new cylinder fittings hoses and pressure transducer if equipped Upper Lift Cylinder 1 lift cylinder 2 connector fitting 3 hydraulic ho...

Page 154: ...mount of time and stop 27 Raise the platform and rotate the safety arm to the stowed position 28 Fully lower the platform to the stowed position Note Models with a pressure transducer calibrate the Platform Overload System Refer to Repair Procedure How to Calibrate the Platform Overload System if equipped GS 4047 Bodily injury hazard The procedures in this section require specific repair skills li...

Page 155: ...ition 7 Disconnect the battery pack from the machine Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 8 Tag and disconnect the wiring from the solenoid valve coil at the barrel end of the lift cylinder Skip to step 13 if removing the upper cylinder 9 If equipped tag and disconnect the three pin c...

Page 156: ...ner arm cylinder plate 16 Attach a lifting strap from an overhead crane or similar lifting device to the barrel end of the lift cylinder for support 17 Remove the fasteners from the lift cylinder barrel end pivot pin Use a soft metal drift to remove the pin Crushing hazard The lift cylinder will fall if not properly supported when the pivot pin is removed 18 Support and secure the lift cylinder to...

Page 157: ...ssure transducer calibrate the Platform Overload System Refer to Repair Procedure How to Calibrate the Platform Overload System if equipped 9 10 Pressure Transducer How to Remove the Pressure Transducer if equipped Note Calibrating the platform overload system is not required if the pressure transducer is the only component replaced on the machine lift structure In the event of frequent nuisance t...

Page 158: ...the ground controls 14 Using the ground control menu buttons navigate to Service Override Mode Select Service Override Mode Note The machine must be in Service Override Mode to raise the platform While in Service Override Mode only the GCON will operate with limited functionality The platform will raise a predetermined amount of time and stop 15 Raise the platform and rotate the safety arm to the ...

Page 159: ...s outdoors Perform this procedure after confirming that the platform height sensor is not damaged and functions correctly There are two options to the platform overload calibration procedure in this section Full Load Calibration and No Load Calibration Full Load Calibration has two steps requiring calibration with and without rated load in the platform No Load Calibration does not require rated lo...

Page 160: ...d Menu Down buttons after the ground controller powers up 9 Use the Menu Up or Menu Down buttons to scroll to Select Option Press the Enter button 10 Use the Menu Up or Menu Down buttons to scroll to Platform Overload 11 Press the Enter button to select Platform Overload 12 Use the Menu Up or Menu Down buttons to scroll to Platform Overload Calibrate 13 Press the Enter button to select Platform Ov...

Page 161: ...nction Enable or Platform Up buttons are released while the machine is collecting data the GCON LCD will prompt the user to lower the platform for 5 seconds before prompting to raise the platform to full height again 23 When prompted press and hold the Function Enable and Platform Down buttons until the platform is fully stowed When the platform reaches the stowed position press the enter button N...

Page 162: ...tons throughout the lowering and data gathering sequence The machine will stop to gather data and lower several times before the machine reaches the stowed position When the platform reaches the stowed position press the Enter button Note Software revision H or prior and GS 2032 GS 2646 and GS 4047 models continue to step 32 Note All other models with software revision J or higher continue with st...

Page 163: ...confirm no load is in the platform 16 At the ground controls press and hold the Function Enable and Platform Up buttons until the platform reaches maximum height 17 All Models except GS 4047 When the platform reaches maximum height press the ground controls Enter button Allow the ground controls to gather data GS 4047 only Press and hold the Menu Enter button to determine the maximum height The ma...

Page 164: ... is collecting data the GCON LCD will prompt the user to raise the platform for 5 seconds before prompting to lower the platform to the stowed position again 22 When prompted push the red Emergency Stop button in to complete the No Load Calibration procedure 9 12 Platform Overload Recovery Message If the ground controls LCD screen displays OL PLATFORM OVERLOADED the emergency lowering system has b...

Page 165: ...he enter button Result The ground control LCD display will show the following 7 Press and hold the scroll down button for 5 seconds Result The ground control LCD display will show the following 8 Press the enter button Result The ground control LCD display will show the following 9 Press the buttons in the following sequence down down up enter Note After each key press an asterisk will appear on t...

Page 166: ... air line to platform option Disconnect the air line from the platform Pull the air line free of the platform 9 Support the platform with a forklift at the non steer end Do not apply any lifting pressure 10 Attach a strap from the lanyard anchorage point on the platform railings to the carriage on the forklift to help support the platform 11 GS 1530 32 and GS 1930 32 Lift the steer end of the plat...

Page 167: ...move the fasteners from each platform extension roller bracket assembly Remove each assembly from the machine Note Do not remove the platform roller bolt 1 roller bracket assembly 2 assembly retaining fastener 3 platform roller bolt 7 Remove the platform roller wheels from the machine 8 Carefully slide the platform extension out from the platform and place it on a structure capable of supporting i...

Page 168: ...cific to each battery type The charging profile must be programmed to match the specific battery type on the machine Charger status indicators 1 Error Fault indicator 2 AC status indicator 3 Charging status 4 USB port 5 Charging indicator 6 Charger display 7 Charge profile selection button Remote charger status indicators 1 Error Fault indicator 2 Error Fault 3 Charge complete 4 Charging high stat...

Page 169: ...w Profile Description P001 Scissor GR GRC QS does not include GS 4047 Flooded lead acid batteries Temperature compensated P003 Scissor GR GRC QS does not include GS 4047 Flooded lead acid batteries Not temperature compensated P007 GS 4047 Flooded lead acid batteries Not temperature compensated P043 All Scissors GR GRC QS AGM batteries Temperature compensated Temperature compensated Battery tempera...

Page 170: ...Service and Repair Manual April 2017 154 GS 30 GS 32 GS 46 GS 47 Part No 1272217 This page intentionally left blank ...

Page 171: ...ns in the appropriate operator s manual on your machine Be sure that all necessary tools and test equipment are available and ready for use Read each appropriate fault code thoroughly Attempting short cuts may produce hazardous conditions Be aware of the following hazards and follow generally accepted safe workshop practices Crushing hazard When testing or replacing any hydraulic component always ...

Page 172: ...n aid in troubleshooting the machine by pinpointing the area or component affected Models are listed below each code to assist in the troubleshooting codes for a specific model Genie SmartLink Diagnostic System This machine is equipped with the Genie SmartLink Diagnostic System GSDS The GSDS indicates a machine malfunction has happened by displaying Operational Indicator Codes OIC and Diagnostic T...

Page 173: ...Service and Repair Manual Diagnostics Part No 1272217 GS 30 GS 32 GS 46 GS 47 157 GCON ECM Connector Layout Rear of Ground Controls ECM models without outriggers Rear of Ground Controls ECM models with outriggers ...

Page 174: ...al Output 18 OR J2 02 Platform Down Coil Digital Output 18 OR BK J2 03 Steer Left Coil Digital Output 18 BL BK J2 04 Steer Right Coil Digital Output 18 BL J2 05 Parallel Coil GS 32 GS 46 Digital Output 18 RD WH J2 06 Drive Forward Coil Digital Output 18 WH J2 07 No Circuit N A N A J2 08 Motor Controller Enable Digital Output 18 GR WH J2 09 No Circuit N A N A J2 10 Drive Reverse Coil Digital Output...

Page 175: ...Output 18 OR BK J2 03 Steer Left Coil Digital Output 18 BL BK J2 04 Steer Right Coil Digital Output 18 BL J2 05 Parallel Coil GS 32 GS 46 GS 47 Digital Output 18 RD WH J2 06 Drive Forward Coil Digital Output 18 WH J2 07 Ground GS 4047 Ground Input 18 BR J2 08 Motor Controller Enable Digital Output 18 GR WH J2 09 Lift Pressure Selector GS 4047 N A N A J2 10 Drive Reverse Coil Digital Output 18 WH B...

Page 176: ...ode Digital Input 18 BK J1 09 Key Switch GCON Mode Digital Input 18 WH J1 10 GCON Emergency Mode Digital Input 18 WH BK J1 11 No Circuit N A N A J1 12 Driver Power Power Input 14 RD J 2 Connector Black J2 01 Platform Up Coil Digital Output 18 OR J2 02 Platform Down Coil Digital Output 18 OR BK J2 03 Steer Left Coil Digital Output 18 BL BK J2 04 Steer Right Coil Digital Output 18 BL J2 05 Parallel ...

Page 177: ... Input 18 BK J3 10 Ground Ground Input 18 BK J3 11 No Circuit N A N A J3 12 Load Sense Ground Ground Input 18 BK J 4 Connector Brown J4 01 Left Front Pressure Transducer Analog Input 18 WH J4 02 Right Front Pressure Transducer Analog Input 18 OR J4 03 Left Rear Pressure Transducer Analog Input 18 BL J4 04 Right Rear Pressure Transducer Analog Input 18 GR J4 05 Lever Sensor X Axis Analog Input 18 O...

Page 178: ...K J1 09 Key Switch GCON Mode Digital Input 18 WH J1 10 GCON Emergency Mode Digital Input 18 WH BK J1 11 No Circuit N A N A J1 12 Driver Power Power Input 14 RD J 2 Connector Black J2 01 Platform Up Coil Digital Output 18 OR J2 02 Platform Down Coil Digital Output 18 OR BK J2 03 Steer Left Coil Digital Output 18 BL BK J2 04 Steer Right Coil Digital Output 18 BL J2 05 Parallel Coil GS 32 GS 46 GS 47...

Page 179: ...und Input 18 BL WH J3 10 Platform Height Sensor Ground Input 18 OR WH J3 11 No Circuit N A N A J3 12 Load Sense Ground Ground Input 18 BK J 4 Connector Brown J4 01 Left Front Pressure Transducer Analog Input 18 WH J4 02 Right Front Pressure Transducer Analog Input 18 OR J4 03 Left Rear Pressure Transducer Analog Input 18 BL J4 04 Right Rear Pressure Transducer Analog Input 18 GR J4 05 Lever Sensor...

Page 180: ...e electrical system The types of Diagnostic Trouble Codes that may occur are explained below Type HXXX Indicate a malfunction associated with devices that control hydraulic functions in the electrical system The HXXX faults are divided into short circuit battery negative short circuit to battery positive open circuit and generic shorts Examples of these devices are solenoid controlled hydraulic va...

Page 181: ...arness or connector between Ground Controls and faulted device No Good Repair or replace harness an or connector Good 3 Check GCON Electronic Control Module ECM No Good Replace ECM Wiring Diagram The wiring diagram shown below illustrates how fault type HXXX and PXXX devices are typically wired The signal of these types of devices originates at the Ground Controls and terminates at system ground G...

Page 182: ...1 0 Ω Motor Controller Enable 5 7k Ω Motor Controller Throttle 5 7k Ω Contactor Coil 47 Ω OK Go to step 2 No Good Replace faulted device 2 Check the harness between the ground controls and the faulted device 1 Disconnect the GCON ECM connectors J1 J2 and J3 2 Disconnect the faulted device connector 3 Check the continuity between the GCON ECM connector and the signal side of the faulted device Resu...

Page 183: ... pin associated with the fault code Refer to the GCON I O Map in this section to identify the faulted out circuit pin 3 Short to ground resistance should be greater than 5k Ω 4 For short to B type faults measure resistance between pins J1 12 driver power and the GCON pin associated with the fault code Refer to the GCON I O Map in this section to identify the faulted out circuit pin 5 Short to powe...

Page 184: ...ward function inhibited H015 GS30 GS32 GS46 GS47 H015 COILFAULT DRIVE FWD1 BAT Short circuit of the drive forward 1 circuit to battery positive Short circuit in drive forward 1 harness Drive forward 1 coil short circuit GCON ECM All functions inhibited except platform down H019 GS30 GS32 GS46 GS47 H019 COILFAULT DRIVE REV1 BAT Short circuit of the drive reverse 1 circuit to battery negative Short ...

Page 185: ...xcept platform down H057 GS 3232 H057 COILFAULT LF RIGGER BAT Short circuit of the left front outrigger coil to battery positive Short circuit in left front outrigger coil harness Left front outrigger coil short circuit GCON ECM All functions inhibited except platform down H060 GS 3232 H060 COILFAULT LR RIGGER BAT Short circuit of the left rear outrigger coil to battery positive Short circuit in l...

Page 186: ...t of the platform down 1 circuit to battery positive negative or open circuit Short or open circuit in platform down 1 harness Platform down 1 coil short or open circuit GCON ECM Platform down function inhibited H079 GS32 GS46 GS47 H079 COILFAULT HI LO SPEED Short circuit of the HI LO speed circuit to battery positive negative or open circuit Short circuit in HI LO speed harness HI LO speed coil s...

Page 187: ...tions inhibited H109 GS 2646AV H109 COILFAULT DECK RETRACT BAT Short circuit of the platform retract circuit to battery negative Short circuit in PED harness PED retract valve coil short circuit GCON ECM All functions inhibited H110 GS 2646AV H110 COILFAULT DECK RETRACT OPEN Open circuit in the platform retract circuit Open circuit in PED harness PED retract valve coil open circuit GCON ECM All fu...

Page 188: ...HORN BAT Short circuit of the automotive horn circuit to battery positive Short circuit in automotive horn harness Automotive horn short circuit GCON ECM Automotive horn inhibited P007 GS30 GS32 GS46 GS47 P007 DEVICEFAULT GCON ALARM BAT Short circuit of the GCON alarm circuit to battery negative Short circuit in GCON alarm harness GCON alarm short circuit GCON ECM GCON alram inhibited P009 GS30 GS...

Page 189: ... startup Short circuit of the GCON LCD enter switch GCON ECM All GCON LCD menu functions inhibited U007 GS30 GS32 GS46 GS47 U007 SWITCHFAULT GCON LCD ESCAPE Short circuit of the GCON LCD escape switch at system startup Short circuit of the GCON LCD escape switch GCON ECM All GCON LCD menu functions inhibited U014 GS30 GS32 GS46 GS47 U014 SWITCHFAULT PCON DRIVE EN Short circuit of the PCON drive en...

Page 190: ...ited U034 GS30 GS32 GS46 GS47 U034 JSTICKFAULT OUT OF RANGE HI Short circuit of the PCON drive joystick signal to battery positive at system startup Short circuit of the PCON drive joystick signal circuit PCON joystick GCON ECM All PCON drive and steer functions inhibited U035 GS30 GS32 GS46 GS47 U035 JSTICKFAULT OUT OF RANGE LO Short circuit of the PCON drive joystick signal to battery negative a...

Page 191: ...em startup PCON ECM Drive functions inhibited U043 GS 3232 U043 SWITCHFAULT PCON OR MODE PCON outrigger mode switch stuck closed or depressed at system startup PCON outrigger mode switch stuck closed PCON outrigger mode switch depressed at system startup PCON ECM Outrigger extend retract functions inhibited U045 GS30 GS32 GS46 GS47 U045 SWITCHFAULT PCON FUNCTION EN PCON function enable switch stuc...

Page 192: ...s digital tilt switch short circuit GCON ECM All functions inhibited except platform down as long as machine is in the elevated position If machine is in stowed position all functionality is resumed F008 GS30 GS32 GS46 GS47 F008 SENSORFAULT OVLD XDUCER BAT Short circuit of the Platform Overload Transducer circuit to battery positive Short circuit in the transducer circuit Faulty pressure transduce...

Page 193: ...t outrigger sensor circuit Faulty pressure transducer GCON ECM Left front outrigger inhibited if outrigger extend is activated Outrigger can still be retracted F018 GS 3232 F018 SENSORFAULT RF RIGGER BAT Short circuit of the Right Front Outrigger Sensor circuit to battery positive Short circuit in the right front outrigger sensor circuit Faulty pressure transducer GCON ECM Right front outrigger in...

Page 194: ...inhibited F035 GS30 GS32 GS46 GS47 F035 SENSORFAULT OVLD RANGE LOW Height Sensor setting is lower than calibrated stowed height Height sensor not calibrated for stowed height correctly GCON or PCON ECM All functions inhibited F036 GS30 GS32 GS46 GS47 F036 SENSORFAULT OVLD RANGE HI Height Sensor setting is higher than calibrated maximum height Height sensor not calibrated for maximum height correct...

Page 195: ... GS46 GS47 C007 GCON ECM FAULT TYPE 7 GCON ECM inter processor communication error Incorrectly programmed device Error in loading software on device GCON ECM All functions inhibited C009 GS30 GS32 GS46 GS47 C009 GCON ECM FAULT FAULT TYPE 9 GCON fault type 9 Contact Genie support All functions inhibited C010 GS30 GS32 GS46 GS47 C010 SECONDARY NOT PROGRAMMED GCON secondary processor not programmed I...

Page 196: ...aximum elevate time of XX seconds Elevate time XX depends on machine model C029 GS 3232 C029 SYSTEMFAULT O R SENSOR NOCAL Outrigger not calibrated Outrigger not calibrated GCON ECM All functions operate Will not lift above the down limit switch C053 GS30 GS32 GS46 GS47 C053 PCON GCOM SOFTWARE MISMATCH Software revisions do not match between the PCON and GCON Short circuit in the safety switch circ...

Page 197: ...e P code Indicates charger programming mode is active This will occur when the charger profile is being configured Type USB code Indicates the USB interface is active and the USB should not be removed This will occur when the charger firmware is being updated Solid red Internal fault condition Type F fault code Flashing amber External fault condition Type E error code Flashing green USB interface ...

Page 198: ...s Charger Fault Codes Fault Code Description Possible Causes Solution F 0 0 1 DC DC failure LLC excessive leakage fault Internal charger fault Disconnect AC input and battery pack for 30 seconds If fault does not clear contact Genie Product Support F 0 0 2 PFC failure PFC excessive leakage fault F 0 0 3 PFC taken too long to boost F 0 0 4 Charger unable to calibrate current offset F 0 0 5 Output r...

Page 199: ...n safe time limit Charge output reduced due to high temperature Charge at lower temperature Check battery condition Replace damaged battery Check battery connections Battery pack deep discharge Disconnect battery pack for 30 seconds to clear fault when condition has been corrected E 0 0 4 Defective battery Battery pack could not be trickle charged up to the minimum voltage Check battery condition ...

Page 200: ... type Installed from a different machine with different battery type Disconnect battery pack for 30 seconds to clear fault when condition has been corrected E 0 1 6 Software update failed Software update failed Confirm USB Flash Drive is formatted with correct software If software update continues to fail contact Genie Product support E 0 1 7 USB error USB not connected correctly Remove and re ins...

Page 201: ...etween 85 270 VAC 45 65 Hz Self clearing when condition has been corrected E 0 2 4 Failure to initialize Charger failed to turn on correctly Disconnect AC input and battery pack for 30 seconds Contact Genie Product Support E 0 2 5 Low AC voltage oscillation AC voltage unstable Connect to a stable AC source between 85 270 VAC 45 65 Hz Using an undersized generator Self clearing when condition has b...

Page 202: ... E 0 3 1 Vref for ADC measurements triggered alarm Internal charger error Disconnect AC input and battery pack for 30 seconds Contact Genie Product Support E 0 3 2 CAN Bus heartbeat error CAN Bus heartbeat error CAN Bus devices not functioning correctly E 0 3 6 Battery temperature sensor charge profile Battery temperature sensor is required by charger profile but is not installed Check battery tem...

Page 203: ...y 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 About This Section There are two groups of schematics in this section Electrical Schematics Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings...

Page 204: ...fold Ground Bus GS 332 C33 Outrigger Sensor Power Bus GS 3232 C34 Outrigger Level Sensor Ground Bus GS 3232 C35 Left Front Outrigger Pressure Transducer GS 3232 C36 Right Front Outrigger Pressure Transducer GS 3232 ELECTRICAL COMPONENT LEGEND cont Item Description C Connector C37 Left Rear Outrigger Pressure Transducer GS 3232 C38 Right Rear Outrigger Pressure Transducer GS 3232 C39 Outrigger Sens...

Page 205: ...r 20 Ohm 10W S Sensor S7 Level Sensor S8 Outrigger Level Sensor GS 3232 S14 Platform Height Sensor U Electronic Component U3 PCON Printed Circuit Board U5 Electronic Control Module U6 Motor Controller U9 Battery Charger U13 Voltage Inverter option Y Valve Coil Y1 Parallel GS 32 GS 46 GS47 models Y2 Lift Pressure Selector GS 4047 Y3 Steer Right Y4 Steer Left Y5 Drive Reverse Y6 Drive Forward Y7 Pla...

Page 206: ...Service and Repair Manual April 2017 Wiring Diagram Ground and Platform Controls 190 GS 30 GS 32 GS 46 GS 47 Part No 1272217 ...

Page 207: ...Manual Limit Switch Legend Part No 1272217 GS 30 GS 32 GS 46 GS 47 191 Limit Switch Legend a down limit switch LS6 b pothole limit switches LS7 LS8 c 22ft 6 7 m maximum drive height when outriggers are not deployed LS1 LS10 GS 3232 ...

Page 208: ...or Limit Switch Motor controller Key switch Circuits crossing no connection Emergency Stop button Motor Solenoid valve with diode Diode Circuit breaker Battery charger Level sensor Circuit connection Fuse 6V or 12V DC battery Deutsch connector Resistor Contactor Horn or alarm Flashing beacon Platform height sensor Pressure transducer ...

Page 209: ...operated 2 position 4 way directional valve Priority flow regulator Brake Solenoid operated 2 position 2 way valve normally closed Proportional solenoid operated 2 position 2 way directional valve normally closed Accumulator Check valve Solenoid operated 2 position 2 way directional valve normally closed Solenoid operated 3 position 5 way directional valve Fixed displacement pump Shuttle valve Sol...

Page 210: ...on Manifold GS 2032 GS 2632 GS 3232 GS 2046 GS 2646 and GS 3246 Function Manifold GS 4047 Function Manifold GS 1530 GS 1532 GS 1930 and GS 1932 Lift Pressure Selector Manifold GS 4047 Brake Release Manifold All Models Outrigger Manifold GS 3232 Front Outrigger Cylinder GS 3232 Rear Outrigger Cylinder GS 3232 ...

Page 211: ...alve brake circuit AG Drive forward reverse AH Flow regulator relive valve AI Platform up AJ Relief valve lift AK Check valve lift GS 3232 and GS 3246 equipped with load sense only Item Description BA 3 position 4 way directional valve outrigger cylinder extend retract BB Relief valve outrigger circuit CA Right front outrigger extend retract CB Left front outrigger extend retract CC Right rear out...

Page 212: ...nd Repair Manual April 2017 Hydraulic Schematics 196 GS 30 GS 32 GS 46 GS 47 Part No 1272217 Hydraulic Schematic GS 1530 1532 1930 1932 from serial number GS3010A 110000 GS3011C 10000 GS3014D 101 GS3016P 142281 ...

Page 213: ...t No 1272217 GS 30 GS 32 GS 46 GS 47 197 Hydraulic Schematic GS 2032 2632 3232 from serial number GS3211A 110000 to GS3214A 119070 GS3212C 10000 to GS3214C 11873 GS 2046 2646 3246 from serial number GS4612A 110000 to GS4614A 117177 GS4614C 10000 to GS4614C 12073 ...

Page 214: ...2017 Hydraulic Schematics 198 GS 30 GS 32 GS 46 GS 47 Part No 1272217 Hydraulic Schematic GS 2032 2632 3232 from serial number GS3214A 119071 GS3214C 11874 GS 2046 2646 3246 from serial number GS4614A 117178 GS4614C 12074 GS4614D 101 ...

Page 215: ...April 2017 Service and Repair Manual Hydraulic Schematics Part No 1272217 GS 30 GS 32 GS 46 GS 47 199 Hydraulic Schematic GS 3232 from serial number GS3211A 110000 GS3212C 10000 GS3216P 142677 ...

Page 216: ...Service and Repair Manual April 2017 Hydraulic Schematics 200 GS 30 GS 32 GS 46 GS 47 Part No 1272217 Hydraulic Schematic GS 4047 from serial number GS4712C 101 to GS4714C 1459 ...

Page 217: ...April 2017 Service and Repair Manual Hydraulic Schematics Part No 1272217 GS 30 GS 32 GS 46 GS 47 201 Hydraulic Schematic GS 4047 from serial number GS4714C 1460 GS4714D 101 GS4716P 101 ...

Page 218: ...Service and Repair Manual April 2017 202 GS 30 GS 32 GS 46 GS 47 Part No 1272217 This page intentionally left blank ...

Page 219: ...April 2017 Service and Repair Manual 203 Electrical Schematic GS 1530 GS 1930 ANSI CSA from serial number GS3010A 110000 to GS3011A 110827 ...

Page 220: ...Service and Repair Manual April 2017 204 GS 30 GS 32 GS 46 GS 47 Part No 1272217 Electrical Schematic GS 1530 GS 1930 ANSI CSA from serial number GS3010A 110000 to GS3011A 110827 ...

Page 221: ...April 2017 Service and Repair Manual Part No 1272217 GS 30 GS 32 GS 46 GS 47 205 Electrical Schematic GS 1530 GS 1930 ANSI CSA from serial number GS3010A 110000 to GS3011A 110827 ...

Page 222: ...Service and Repair Manual April 2017 206 Electrical Schematic GS 1530 GS 1930 ANSI CSA from serial number GS3010A 110000 to GS3011A 110827 ...

Page 223: ...April 2017 Service and Repair Manual 207 Electrical Schematic GS 1530 GS 1930 ANSI CSA from serial numbers GS3011A 110828 to GS3014A 136972 GS3014D 101 to GS3015D 1113 ...

Page 224: ...vice and Repair Manual April 2017 208 GS 30 GS 32 GS 46 GS 47 Part No 1272217 Electrical Schematic GS 1530 GS 1930 ANSI CSA from serial numbers GS3011A 110828 to GS3014A 136972 GS3014D 101 to GS3015D 1113 ...

Page 225: ...il 2017 Service and Repair Manual Part No 1272217 GS 30 GS 32 GS 46 GS 47 209 Electrical Schematic GS 1530 GS 1930 ANSI CSA from serial numbers GS3011A 110828 to GS3014A 136972 GS3014D 101 to GS3015D 1113 ...

Page 226: ...Service and Repair Manual April 2017 210 Electrical Schematic GS 1530 GS 1930 ANSI CSA from serial numbers GS3011A 110828 to GS3014A 136972 GS3014D 101 to GS3015D 1113 ...

Page 227: ...April 2017 Service and Repair Manual 211 Electrical Schematic GS 1530 GS 1930 ANSI CSA from serial numbers GS3014A 136973 GS3015D 1114 to GS3016D 5426 GS3016P 142281 to GS3016P 158208 ...

Page 228: ... Repair Manual April 2017 212 GS 30 GS 32 GS 46 GS 47 Part No 1272217 Electrical Schematic GS 1530 GS 1930 ANSI CSA from serial numbers GS3014A 136973 GS3015D 1114 to GS3016D 5426 GS3016P 142281 to GS3016P 158208 ...

Page 229: ...Service and Repair Manual Part No 1272217 GS 30 GS 32 GS 46 GS 47 213 Electrical Schematic GS 1530 GS 1930 ANSI CSA from serial numbers GS3014A 136973 GS3015D 1114 to GS3016D 5426 GS3016P 142281 to GS3016P 158208 ...

Page 230: ...Service and Repair Manual April 2017 214 Electrical Schematic GS 1530 GS 1930 ANSI CSA from serial numbers GS3014A 136973 GS3015D 1114 to GS3016D 5426 GS3016P 142281 to GS3016P 158208 ...

Page 231: ...April 2017 Service and Repair Manual 215 Electrical Schematic GS 1530 GS 1930 ANSI CSA from serial numbers GS3016D 5427 GS301P 158209 ...

Page 232: ...Service and Repair Manual April 2017 216 GS 30 GS 32 GS 46 GS 47 Part No 1272217 Electrical Schematic GS 1530 GS 1930 ANSI CSA from serial numbers GS3016D 5427 GS3016P 158209 ...

Page 233: ...April 2017 Service and Repair Manual 217 Electrical Schematic GS 3232 ANSI CSA from serial number GS3211A 110000 to GS3214A 135714 ...

Page 234: ...Service and Repair Manual April 2017 218 GS 30 GS 32 GS 46 GS 47 Part No 1272217 Electrical Schematic GS 3232 ANSI CSA from serial number GS3211A 110000 to GS3214A 135714 ...

Page 235: ...April 2017 Service and Repair Manual Part No 1272217 GS 30 GS 32 GS 46 GS 47 219 Electrical Schematic GS 3232 ANSI CSA from serial number GS3211A 110000 to GS3214A 135714 ...

Page 236: ...Service and Repair Manual April 2017 220 Electrical Schematic GS 3232 ANSI CSA from serial number GS3211A 110000 to GS3214A 135714 ...

Page 237: ...April 2017 Service and Repair Manual 221 Electrical Schematic GS 3232 ANSI CSA from serial number GS3214A 135715 to GS3215A 141898 ...

Page 238: ...Service and Repair Manual April 2017 222 GS 30 GS 32 GS 46 GS 47 Part No 1272217 Electrical Schematic GS 3232 ANSI CSA from serial number GS3214A 135715 to GS3215A 141898 ...

Page 239: ...April 2017 Service and Repair Manual Part No 1272217 GS 30 GS 32 GS 46 GS 47 223 Electrical Schematic GS 3232 ANSI CSA from serial number GS3214A 135715 to GS3215A 141898 ...

Page 240: ...Service and Repair Manual April 2017 224 Electrical Schematic GS 3232 ANSI CSA from serial number GS3214A 135715 to GS3215A 141898 ...

Page 241: ...April 2017 Service and Repair Manual 225 Electrical Schematic GS 3232 ANSI CSA from serial numbers GS3215A 141899 GS3216P 142677 to GS3216P 146462 ...

Page 242: ...Service and Repair Manual April 2017 226 GS 30 GS 32 GS 46 GS 47 Part No 1272217 Electrical Schematic GS 3232 ANSI CSA from serial numbers GS3215A 141899 GS3216P 142677 to GS3216P 146462 ...

Page 243: ...April 2017 Service and Repair Manual Part No 1272217 GS 30 GS 32 GS 46 GS 47 227 Electrical Schematic GS 3232 ANSI CSA from serial numbers GS3215A 141899 GS3216P 142677 to GS3216P 146462 ...

Page 244: ...Service and Repair Manual April 2017 228 Electrical Schematic GS 3232 ANSI CSA from serial numbers GS3215A 141899 GS3216P 142677 to GS3216P 146462 ...

Page 245: ...April 2017 Service and Repair Manual 229 Electrical Schematic GS 3232 ANSI CSA from serial number GS3216P 146463 ...

Page 246: ...Service and Repair Manual April 2017 230 GS 30 GS 32 GS 46 GS 47 Part No 1272217 Electrical Schematic GS 3232 ANSI CSA from serial numbers GS3216P 146463 ...

Page 247: ...April 2017 Service and Repair Manual Part No 1272217 GS 30 GS 32 GS 46 GS 47 231 Electrical Schematic GS 3232 ANSI CSA from serial number GS3216P 146463 ...

Page 248: ...Service and Repair Manual April 2017 232 Electrical Schematic GS 3232 ANSI CSA from serial number GS3216P 146463 ...

Page 249: ...il 2017 Service and Repair Manual 233 Electrical Schematic GS 2032 2632 2046 2646 ANSI CSA from serial numbers GS3211A 110000 to GS3214A 135714 GS4612A 110000 to GS4614A 135366 GS4613D 101 to GS4615D 1303 ...

Page 250: ...al April 2017 234 GS 30 GS 32 GS 46 GS 47 Part No 1272217 Electrical Schematic GS 2032 2632 2046 2646 ANSI CSA from serial numbers GS3211A 110000 to GS3214A 135714 GS4612A 110000 to GS4614A 135366 GS4613D 101 to GS4615D 1303 ...

Page 251: ... Repair Manual Part No 1272217 GS 30 GS 32 GS 46 GS 47 235 Electrical Schematic GS 2032 2632 2046 2646 ANSI CSA from serial numbers GS3211 110000 to GS3214A 135714 GS4612A 110000 to GS4614A 135366 GS4613D 101 to GS4615D 1303 ...

Page 252: ...vice and Repair Manual April 2017 236 Electrical Schematic GS 2032 2632 2046 2646 ANSI CSA from serial numbers GS3211A 110000 to GS3214A 135714 GS4612A 110000 to GS4614A 135366 GS4613D 101 to GS4615D 1303 ...

Page 253: ...April 2017 Service and Repair Manual 237 Electrical Schematic GS 2032 2632 2046 2646 ANSI CSA from serial numbers GS3214A 135715 to GS3215A 141898 GS4614A 135367 to GS4615A 137959 GS4615D 1304 ...

Page 254: ...r Manual April 2017 238 GS 30 GS 32 GS 46 GS 47 Part No 1272217 Electrical Schematic GS 2032 GS 2632 2046 2646 ANSI CSA from serial numbers GS3214A 135715 to GS3215A 141898 GS4614A 135367 to GS4615A 137959 GS4615D 1304 ...

Page 255: ...ce and Repair Manual Part No 1272217 GS 30 GS 32 GS 46 GS 47 239 Electrical Schematic GS 2032 2632 2046 2646 ANSI CSA from serial numbers GS3214A 1135715 to GS3215A 1141898 GS4614A 135367 to GS4615A 137959 GS4615D 1304 ...

Page 256: ...Service and Repair Manual April 2017 240 Electrical Schematic GS 2032 2632 2046 2646 ANSI CSA from serial numbers GS3214A 135715 to GS3215A 141898 GS4614A 135367 to GS4615A 137959 GS4615D 1304 ...

Page 257: ... and Repair Manual 241 Electrical Schematic GS 2032 2632 2046 2646 ANSI CSA from serial numbers GS3215A 141899 GS3216P 142676 to GS3216P 146462 GS4615A 137960 GS4615D 1305 to GS4616D 4432 GS4616P 138362 to GS4616P 139710 ...

Page 258: ...42 GS 30 GS 32 GS 46 GS 47 Part No 1272217 Electrical Schematic GS 2032 2632 2046 2646 ANSI CSA from serial numbers GS3215A 141899 GS3216P 142676 to GS3216P 146462 GS4615A 137960 GS4615D 1305 to GS4616D 4432 GS4616P 138362 to GS4616P 139710 ...

Page 259: ...art No 1272217 GS 30 GS 32 GS 46 GS 47 243 Electrical Schematic GS 2032 2632 2046 2646 ANSI CSA from serial numbers GS3215A 141899 GS3216P 142676 to GS3216P 146462 GS4615A 137960 GS4615D 1305 to GS4616D 4432 GS4616P 138362 to GS4616P 139710 ...

Page 260: ... Manual April 2017 244 Electrical Schematic GS 2032 2632 2046 2646 ANSI CSA from serial numbers GS3215A 14189 GS3216P 142676 to GS3216P 146462 GS4615A 137960 GS4615D 1305 to GS4616D 4432 GS4616P 138362 to GS4616P 139710 ...

Page 261: ...April 2017 Service and Repair Manual 245 Electrical Schematic GS 2032 2632 2046 2646 ANSI CSA from serial numbers GS3216P 146463 GS4616D 4433 GS4616P 139711 ...

Page 262: ...Service and Repair Manual April 2017 246 GS 30 GS 32 GS 46 GS 47 Part No 1272217 Electrical Schematic GS 2032 2632 2046 2646 ANSI CSA from serial numbers GS3216P 146463 GS4616D 4433 GS4616P 139711 ...

Page 263: ...April 2017 Service and Repair Manual 247 Electrical Schematic GS 3246 GS 4047 ANSI CSA from serial numbers GS4612A 110000 to GS4614A 135366 GS4614D 101 to GS4615D 1303 GS4714D 101 to GS4715D 749 ...

Page 264: ...ir Manual April 2017 248 GS 30 GS 32 GS 46 GS 47 Part No 1272217 Electrical Schematic GS 3246 GS 4047 ANSI CSA from serial numbers GS4612A 110000 to GS4614A 135366 GS4614D 101 to GS4615D 1303 GS4714D 101 to GS4715D 749 ...

Page 265: ...ce and Repair Manual Part No 1272217 GS 30 GS 32 GS 46 GS 47 249 Electrical Schematic GS 3246 GS 4047 ANSI CSA from serial numbers GS4621A 110000 to GS4614A 135366 GS4614D 101 to GS4615D 1303 GS4714D 101 to GS4715D 749 ...

Page 266: ...Service and Repair Manual April 2017 250 Electrical Schematic GS 3246 GS 4047 ANSI CSA from serial numbers GS4612A 110000 to GS4614A 135366 GS4614D 101 to GS4615D 1303 GS4714D 101 to GS4715D 749 ...

Page 267: ...vice and Repair Manual 251 Electrical Schematic GS 3246 GS 4047 ANSI CSA from serial numbers GS4614A 135367 to GS4615A 137959 GS4615D 1304 to GS4616D 4432 GS4616P 138362 to GS4616P 139710 GS4715D 750 to GS4716D 3101 ...

Page 268: ...17 252 GS 30 GS 32 GS 46 GS 47 Part No 1272217 Electrical Schematic GS 3246 GS 4047 ANSI CSA from serial numbers GS4614A 135367 to GS4615A 137959 GS4615D 1304 to GS4616D 4432 GS4616P 138362 to GS4616P 139710 GS4715D 750 to GS4716D 3101 ...

Page 269: ...al Part No 1272217 GS 30 GS 32 GS 46 GS 47 253 Electrical Schematic GS 3246 GS 4047 ANSI CSA from serial numbers GS4614A 135367 to GS4615A 137959 GS4615D 1304 to GS4616D 4432 GS4616P 138362 to GS4616P 139710 GS4715D 750 to GS4716D 3101 ...

Page 270: ...pair Manual April 2017 254 Electrical Schematic GS 3246 GS 4047 ANSI CSA from serial numbers GS4614A 135367 to GS4615A 137959 GS4615D 1304 to GS4616D 4432 GS4616P 138362 to GS4616P 139710 GS4715D 750 to GS4716D 3101 ...

Page 271: ...April 2017 Service and Repair Manual 255 Electrical Schematic GS 3246 GS 4047 ANSI CSA from serial numbers GS4616D 4433 GS4616P 139711 GS4716D 3102 GS4716P 101 ...

Page 272: ...Service and Repair Manual April 2017 256 GS 30 GS 32 GS 46 GS 47 Part No 1272217 Electrical Schematic GS 3246 GS 4047 ANSI CSA from serial numbers GS4616D 4433 GS4616P 139711 GS4716D 3102 GS4716P 101 ...

Page 273: ...April 2017 Service and Repair Manual 257 Electrical Schematic GS 1530 1532 1930 1932 AS CE from serial number GS3010A 110000 to GS3011A 110827 ...

Page 274: ...Service and Repair Manual April 2017 258 GS 30 GS 32 GS 46 GS 47 Part No 1272217 Electrical Schematic GS 1530 1532 1930 1932 AS CE from serial number GS3010A 110000 to GS3011A 110827 ...

Page 275: ...April 2017 Service and Repair Manual Part No 1272217 GS 30 GS 32 GS 46 GS 47 259 Electrical Schematic GS 1530 1532 1930 1932 AS CE from serial number GS3010A 110000 to GS3011A 110827 ...

Page 276: ...Service and Repair Manual April 2017 260 Electrical Schematic GS 1530 1532 1930 1932 AS CE from serial number GS3010A 110000 to GS3011A 110827 ...

Page 277: ...April 2017 Service and Repair Manual 261 Electrical Schematic GS 1530 1530 1930 1932 AS CE from serial numbers GS3011A 110828 to GS3014A 136972 GS3011C 10000 to GS3015C 18038 GS3014D 101 to GS3015D 1113 ...

Page 278: ...anual April 2017 262 GS 30 GS 32 GS 46 GS 47 Part No 1272217 Electrical Schematic GS 1530 1532 1930 1932 AS CE from serial numbers GS3011A 110828 to GS3014A 136972 GS3011C 10000 to GS3015C 18038 GS3014D 101 to GS3015D 1113 ...

Page 279: ...nd Repair Manual Part No 1272217 GS 30 GS 32 GS 46 GS 47 263 Electrical Schematic GS 1530 1532 1930 1932 AS CE from serial numbers GS3011A 110828 to GS3014A 136972 GS3011C 10000 to GS3015C 18038 GS3014D 101 to GS3015D 1113 ...

Page 280: ...Service and Repair Manual April 2017 264 Electrical Schematic GS 1530 1532 1930 1932 AS CE from serial numbers GS3011A 110828 to GS3014A 136972 GS3011C 10000 to GS3015C 18038 GS3014D 101 to GS3015D 1113 ...

Page 281: ...April 2017 Service and Repair Manual 265 Electrical Schematic GS 1530 1532 1930 1932 AS CE from serial numbers GS3014A 136973 GS3015C 18039 GS3015D 1114 to GS3016D 5426 GS3016P 142281 to GS3016P 158208 ...

Page 282: ...anual April 2017 266 GS 30 GS 32 GS 46 GS 47 Part No 1272217 Electrical Schematic GS 1530 1532 1930 1932 AS CE from serial numbers GS3014A 136973 GS3015C 18039 GS3015D 1114 to GS3016D 5426 GS3016P 142281 to GS3016P 158208 ...

Page 283: ...nd Repair Manual Part No 1272217 GS 30 GS 32 GS 46 GS 47 267 Electrical Schematic GS 1530 1532 1930 1932 AS CE from serial numbers GS3014A 136973 GS3015C 18039 GS3015D 1114 to GS3016D 5426 GS3016P 142281 to GS3016P 158208 ...

Page 284: ...Service and Repair Manual April 2017 268 Electrical Schematic GS 1530 1532 1930 1932 AS CE from serial numbers GS3014A 136973 GS3015C 18039 GS3015D 1114 to GS3016D 5426 GS3016P 142281 to GS3016P 158208 ...

Page 285: ...April 2017 Service and Repair Manual 269 Electrical Schematic GS 1530 1532 1930 1932 AS CE from serial number GS3016D 5427 GS3016P 158209 ...

Page 286: ...Service and Repair Manual April 2017 270 GS 30 GS 32 GS 46 GS 47 Part No 1272217 Electrical Schematic GS 1530 1532 1930 1932 AS CE from serial numbers GS3016D 5427 GS3016P 158209 ...

Page 287: ...April 2017 Service and Repair Manual Part No 1272217 GS 30 GS 32 GS 46 GS 47 271 Electrical Schematic GS 3232 AS CE from serial number GS3211A 110000 to GS3214A 135714 GS3212C 10000 to GS3215C 14503 ...

Page 288: ...Service and Repair Manual April 2017 272 GS 30 GS 32 GS 46 GS 47 Part No 1272217 Electrical Schematic GS 3232 AS CE from serial number GS3211A 110000 to GS3214A 135714 GS3212C 10000 to GS3215C 14503 ...

Page 289: ...April 2017 Service and Repair Manual Part No 1272217 GS 30 GS 32 GS 46 GS 47 273 Electrical Schematic GS 3232 AS CE from serial number GS3211A 110000 to GS3214A 135714 GS3212C 10000 to GS3215C 14503 ...

Page 290: ...Service and Repair Manual April 2017 274 Electrical Schematic GS 3232 AS CE from serial number GS3211A 110000 to GS3214A 135714 GS3212C 10000 to GS3215C 14503 ...

Page 291: ...April 2017 Service and Repair Manual 275 Electrical Schematic GS 3232 AS CE from serial number GS3214A 135715 to GS3215A 141898 GS3215C 14504 ...

Page 292: ...Service and Repair Manual April 2017 276 GS 30 GS 32 GS 46 GS 47 Part No 1272217 Electrical Schematic GS 3232 AS CE from serial number GS3214A 135715 to GS3215A 141898 GS3215C 14504 ...

Page 293: ...April 2017 Service and Repair Manual Part No 1272217 GS 30 GS 32 GS 46 GS 47 277 Electrical Schematic GS 3232 AS CE from serial number GS3214A 135715 to GS3215A 141898 GS3215C 14504 ...

Page 294: ...Service and Repair Manual April 2017 278 Electrical Schematic GS 3232 AS CE from serial number GS3214A 135715 to GS3215A 141898 GS32115C 14504 ...

Page 295: ...April 2017 Service and Repair Manual 279 Electrical Schematic GS 3232 AS CE from serial numbers GS3215A 141899 GS3216P 142676 to GS3216P 146462 ...

Page 296: ...Service and Repair Manual April 2017 280 GS 30 GS 32 GS 46 GS 47 Part No 1272217 Electrical Schematic GS 3232 AS CE from serial numbers GS3215A 141899 GS3216P 142676 to GS3216P 146462 ...

Page 297: ...April 2017 Service and Repair Manual Part No 1272217 GS 30 GS 32 GS 46 GS 47 281 Electrical Schematic GS 3232 AS CE from serial numbers GS3215A 141899 GS3216P 142676 to GS3216P 146462 ...

Page 298: ...Service and Repair Manual April 2017 282 Electrical Schematic GS 3232 AS CE from serial numbers GS3215A 141899 GS3216P 142676 to GS3216P 146462 ...

Page 299: ...April 2017 Service and Repair Manual 283 Electrical Schematic GS 3232 AS CE from serial number GS3216P 146463 ...

Page 300: ...Service and Repair Manual April 2017 284 GS 30 GS 32 GS 46 GS 47 Part No 1272217 Electrical Schematic GS 3232 AS CE from serial number GS3216P 146463 ...

Page 301: ...April 2017 Service and Repair Manual Part No 1272217 GS 30 GS 32 GS 46 GS 47 285 Electrical Schematic GS 3232 ANSI CSA from serial number GS3216P 146463 ...

Page 302: ...Service and Repair Manual April 2017 286 Electrical Schematic GS 3232 AS CE from serial number GS3216P 143463 ...

Page 303: ...nual 287 Electrical Schematic GS 2032 2632 2046 2646 AS CE from serial number GS3211A 110000 to GS3214A 135715 GS3212C 10000 to GS3215C 14377 GS4612A 110000 to GS4614A 135366 GS4612C 10000 to GS4615C 14503 GS4613D 101 to GS4615D 1303 ...

Page 304: ... GS 46 GS 47 Part No 1272217 Electrical Schematic GS 2032 2632 2046 2646 AS CE from serial number GS3211A 110000 to GS3214A 1135714 GS3212C 10000 to GS3215C 14377 GS4612A 110000 to GS4614A 135366 GS4612C 10000 to GS4615C 14503 GS4613D 101 to GS4615D 1303 ...

Page 305: ... GS 30 GS 32 GS 46 GS 47 289 Electrical Schematic GS 2032 2632 2046 2646 AS CE from serial number GS3211A 110000 to GS3214A 135714 GS3212C 10000 to GS3215C 14377 GS4612A 110000 to GS4614A 135366 GS4612C 10000 to GS4615C 14503 GS4613D 101 to GS4615D 1303 ...

Page 306: ...2017 290 Electrical Schematic GS 2032 2632 2046 2646 AS CE from serial number GS3211A 110000 to GS3214A 1135714 GS3215C 10000 to GS3215C 14377 GS4612A 110000 to GS4614A 135366 GS4612C 10000 to GS4615C 14503 GS4613D 101 to GS4615D 1303 ...

Page 307: ...017 Service and Repair Manual 291 Electrical Schematic GS 2032 2632 2046 2646 AS CE from serial numbers GS3214A 135715 to GS3215A 141898 GS3215C 14378 GS4614A 135367 to GS4615A 137959 GS46C 14504 GS4615D 1304 ...

Page 308: ...ril 2017 292 GS 30 GS 32 GS 46 GS 47 Part No 1272217 Electrical Schematic GS 2032 2632 2046 2646 AS CE from serial numbers GS3214A 135715 to GS3215A 141898 GS3215C 14378 GS4614A 135367 to GS4615A 137959 GS4615C 14504 GS4615D 1304 ...

Page 309: ... Manual Part No 1272217 GS 30 GS 32 GS 46 GS 47 293 Electrical Schematic GS 2032 2632 2046 2646 AS CE from serial numbers GS3214A 1135715 to GS3215A 1141898 GS3215C 14378 GS4614A 135367 to GS4615A 137959 GS4615C 14504 GS4615D 1304 ...

Page 310: ...and Repair Manual April 2017 294 Electrical Schematic GS 2032 2632 2046 2646 AS CE from serial numbers GS3214A 135715 to GS3215A 141898 GS3215C 14378 GS4614A 135367 to GS4615A 137959 GS4615C 14504 GS4615D 1304 ...

Page 311: ...ril 2017 Service and Repair Manual 295 Electrical Schematic GS 2032 2632 2046 2646 AS CE from serial numbers GS3215A 141899 GS3216P 142676 to GS3216P 146462 GS4615A 137960 GS4616P 138362 to GS4616P 139710 ...

Page 312: ...ual April 2017 296 GS 30 GS 32 GS 46 GS 47 Part No 1272217 Electrical Schematic GS 2032 2632 2046 2646 AS CE from serial numbers GS3215A 141899 GS3216P 142676 to GS3216P 146462 GS4615A 137960 GS4616P 138362 to GS4616P 139710 ...

Page 313: ... Repair Manual Part No 1272217 GS 30 GS 32 GS 46 GS 47 297 Electrical Schematic GS 2032 2632 2046 2646 AS CE from serial numbers GS3215A 141899 GS3216P 142676 to GS3216P 146462 GS4615A 137960 GS4616P 138362 to GS4616P 139710 ...

Page 314: ...rvice and Repair Manual April 2017 298 Electrical Schematic GS 2032 2632 2046 2646 AS CE from serial numbers GS3215A 141899 GS3216P 142676 to GS3216P 146462 GS4615A 137960 GS4616P 138362 to GS4616P 139710 ...

Page 315: ...April 2017 Service and Repair Manual 299 Electrical Schematic GS 2032 2632 2046 2646 AS CE from serial numbers GS3216P 146463 GS4616P 139711 ...

Page 316: ...Service and Repair Manual April 2017 300 GS 30 GS 32 GS 46 GS 47 Part No 1272217 Electrical Schematic GS 2032 2632 2046 2646 AS CE from serial numbers GS3216P 146463 GS4616P 139711 ...

Page 317: ...April 2017 Service and Repair Manual 301 Electrical Schematic GS 3246 AS CE from serial numbers GS4612A 110000 to GS4614A 135366 GS4612C 10000 to GS4615C 14503 GS4614D 101 to GS4615D 1303 ...

Page 318: ...epair Manual April 2017 302 GS 30 GS 32 GS 46 GS 47 Part No 1272217 Electrical Schematic GS 3246 AS CE from serial numbers GS4612A 110000 to GS4614A 135366 GS4612C 10000 to GS4615C 14503 GS4614D 101 to GS4615D 1303 ...

Page 319: ...rvice and Repair Manual Part No 1272217 GS 30 GS 32 GS 46 GS 47 303 Electrical Schematic GS 3246 AS CE from serial numbers GS4621A 110000 to GS4614A 135366 GS4612C 10000 to GS4615C 14503 GS4614D 101 to GS4615D 1303 ...

Page 320: ...Service and Repair Manual April 2017 304 Electrical Schematic GS 3246 AS CE from serial numbers GS4612A 110000 to GS4614A 135366 GS4612C 10000 to GS4615C 14503 GS4614D 101 to GS4615D 1303 ...

Page 321: ...April 2017 Service and Repair Manual 305 Electrical Schematic GS 3246 AS CE from serial numbers GS4614A 135367 to GS4615A 137959 GS4615C 14504 GS4615D 1304 ...

Page 322: ...Service and Repair Manual April 2017 306 GS 30 GS 32 GS 46 GS 47 Part No 1272217 Electrical Schematic GS 3246 AS CE from serial numbers GS4614A 135367 to GS4615A 137959 GS4615C 14504 GS4615D 1304 ...

Page 323: ...April 2017 Service and Repair Manual Part No 1272217 GS 30 GS 32 GS 46 GS 47 307 Electrical Schematic GS 3246 AS CE from serial numbers GS4614A 135367 to GS4615A 137959 GS4615C 14504 GS4615D 1304 ...

Page 324: ...Service and Repair Manual April 2017 308 Electrical Schematic GS 3246 AS CE from serial numbers GS4614A 135368 to GS4615A 137959 GS4615C 14504 GS4615D 1304 to GS4616D 4432 ...

Page 325: ...April 2017 Service and Repair Manual 309 Electrical Schematic GS 3246 AS CE from serial number GS4615A 137960 GS4616P 138362 to GS4616P 139710 ...

Page 326: ...Service and Repair Manual April 2017 310 GS 30 GS 32 GS 46 GS 47 Part No 1272217 Electrical Schematic GS 3246 AS CE from serial number GS4615A 137960 GS4616P 138362 to GS4616P 139710 ...

Page 327: ...April 2017 Service and Repair Manual Part No 1272217 GS 30 GS 32 GS 46 GS 47 311 Electrical Schematic GS 3246 AS CE from serial number GS4615A 137960 GS4616P 138362 to GS4616P 139710 ...

Page 328: ...Service and Repair Manual April 2017 312 Electrical Schematic GS 3246 AS CE from serial number GS4615A 137960 GS4616P 138362 to GS4616P 139710 ...

Page 329: ...April 2017 Service and Repair Manual 313 Electrical Schematic GS 3246 AS CE from serial number GS4616D 4433 GS4616P 139711 ...

Page 330: ...Service and Repair Manual April 2017 314 GS 30 GS 32 GS 46 GS 47 Part No 1272217 Electrical Schematic GS 3246 AS CE from serial number GS4616D 4433 GS4616P 139711 ...

Page 331: ...April 2017 Service and Repair Manual Part No 1272217 GS 30 GS 32 GS 46 GS 47 315 Electrical Schematic GS 4047 AS CE from serial numbers GS4712C 101 to GS4715C 2130 GS4714D 101 to GS4715D 749 ...

Page 332: ...Service and Repair Manual April 2017 316 GS 30 GS 32 GS 46 GS 47 Part No 1272217 Electrical Schematic GS 4047 AS CE from serial numbers GS4712C 101 to GS4715C 2130 GS4714D 101 to GS4715D 749 ...

Page 333: ...April 2017 Service and Repair Manual Part No 1272217 GS 30 GS 32 GS 46 GS 47 317 Electrical Schematic GS 4047 AS CE from serial numbers GS4712C 101 to GS4715C 2130 GS4714D 101 to GS4715D 749 ...

Page 334: ...Service and Repair Manual April 2017 318 Electrical Schematic GS 4047 AS CE from serial numbers GS4712C 101 to GS4715C 2130 GS4714D 101 to GS4715D 749 ...

Page 335: ...April 2017 Service and Repair Manual 319 Electrical Schematic GS 4047 AS CE from serial number GS4715C 2131 GS4715D 750 to GS4716D 3101 ...

Page 336: ...Service and Repair Manual April 2017 320 GS 30 GS 32 GS 46 GS 47 Part No 1272217 Electrical Schematic GS 4047 AS CE from serial number GS4715C 2131 GS4715D 750 to GS4716D 3101 ...

Page 337: ...April 2017 Service and Repair Manual Part No 1272217 GS 30 GS 32 GS 46 GS 47 321 Electrical Schematic GS 4047 AS CE from serial number GS4715C 2131 GS4715D 750 to GS4716D 3101 ...

Page 338: ...Service and Repair Manual April 2017 322 Electrical Schematic GS 4047 AS CE from serial numbers GS4715C 2131 GS4715D 750 to GS4716D 3101 ...

Page 339: ...April 2017 Service and Repair Manual 323 Electrical Schematic GS 4047 AS CE from serial number GS4716D 3102 ...

Page 340: ...Service and Repair Manual April 2017 324 GS 30 GS 32 GS 46 GS 47 Part No 1272217 Electrical Schematic GS 4047 AS CE from serial number GS4716D 3102 ...

Page 341: ...April 2017 Service and Repair Manual 325 Electrical Schematic Foot Switch option All Models ...

Page 342: ...ice and Repair Manual April 2017 326 GS 30 GS 32 GS 46 GS 47 Part No 1272217 Electrical Schematic Foot Switch option All Models GS 30 GS 32 GS 46 GS 47 Part No 1272217 Service and R epair M anual April 2017 ...

Page 343: ...ia to cause cancer and birth defects or other reproductive harm These chemicals can be emitted from or contained in othervariouspartsandsystems fluidsandsome component wear by products To minimize exposure avoid breathing exhaust do not idle the engine except as necessary service your equipment and vehicle in a well ventilated area and wear gloves or wash your hands frequently when servicing your ...

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