Genie GS-1530 Service Manual Download Page 151

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REV F

Section 4 • Repair Procedures

February 2009

Part No. 97385

GS-30 • GS-32 • GS-46

4 - 91

A I

INSIDE

COIL

Inside Coil (closest to manifold)

Before

After serial number GS3206-80131: drive reverse coil Y5

After serial number GS4606-79027: drive reverse coil Y5

Outside Coil (furthest from manifold)

serial number GS3206-80132: drive forward coil Y6

Before serial number GS4606-79028: drive forward coil Y6

Before serial number GS3206-80132: drive reverse coil Y5

Before serial number GS4606-79028: drive reverse coil Y5

After serial number GS3206-80131: drive forward coil Y6

After serial number GS4606-79027: drive forward coil Y6

Note: 'alpha-numeric' callouts

refer to corresponding notes

on the electrical schematic

Note: 'alpha' callouts refer

to corresponding notes on

the hydraulic schematic

OUTSIDE

COIL

MANIFOLDS

Summary of Contents for GS-1530

Page 1: ...6000 to GS3009B 98941 from GS3008C 101 to GS3011C 9999 GS 2032 GS 2632 GS 3232 GS 2046 GS 2646 GS 3246 from GS3205 75407 to GS3209 94602 from GS3209A 94603 to GS3212A 109999 from GS3205B 76000 to GS3209B 98941 from GS3208C 101 to GS3212C 9999 from GS4605 75438 to GS4609 95192 from GS4609A 95193 to GS4611A 109999 from GS4608C 101 to GS4612C 9999 ...

Page 2: ... other manuals Contact Us www genielift com e mail techpub terex com Copyright 2011 by Terex Corporation 97385 Rev E March 2007 Fifth Edition Second Printing Genie is a registered trademark of Terex South Dakota in the U S A and many other countries GS is a trademark of Terex South Dakota Inc Printed on recycled paper Printed in U S A Serial Number Information Genie offers the following Service Ma...

Page 3: ...February 2012 Part No 97385 GS 30 GS 32 GS 46 iii INTRODUCTION Serial Number Legend ...

Page 4: ...February 2012 GS 30 GS 32 GS 46 This page intentionally left blank iv ...

Page 5: ...or s manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless You are trained and qualified to perform maintenance on this machine You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations You have the appropriate tools lifting equipment ...

Page 6: ...well lit vi SAFETY RULES Section 1 Safety Rules Personal 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 Read each procedure thoroughly This manual and the decals on the machine use signal words to identify the following Safety alert symbol used to alert personnel ...

Page 7: ...raulic Specifications 2 3 Manifold Component Specifications 2 4 Hydraulic Hose and Fitting Torque Specifications 2 5 SAE and Metric Fasteners Torque Charts 2 7 Section 3 Rev Scheduled Maintenance Procedures Introduction 3 1 Pre delivery Preparation Report 3 3 Maintenance Inspection Report 3 5 C Checklist A Procedures A 1 Inspect the Manuals and Decals 3 6 A 2 Perform Pre operation Inspection 3 7 A...

Page 8: ...st the Slow Drive Speed 3 21 B 12 Perform Hydraulic Oil Analysis 3 22 B 13 Inspect the Hydraulic Tank Cap Venting System 3 22 B 14 Check the Module Tray Latch Components 3 23 B 15 Inspect the Voltage Inverter if equipped 3 24 B 16 Test the Down Limit Switch and the Pothole Limit Switches 3 25 B 17 Test the Up Limit Switch if equipped and the Outrigger Limit Switches if equipped 3 28 C Checklist C ...

Page 9: ...form Components 2 1 Platform 4 34 2 2 Platform Extension 4 35 C Scissor Components 3 1 Scissor Assembly GS 1530 and GS 1532 4 36 3 2 Scissor Assembly GS 1930 and GS 1932 4 42 3 3 Scissor Assembly GS 2032 and GS 2046 4 50 3 4 Scissor Assembly GS 2632 and GS 2646 4 56 3 5 Scissor Assembly GS 3232 and GS 3246 4 64 3 6 Lift Cylinder 4 72 3 7 Platform Overload System 4 77 D Ground Controls 4 1 Manual P...

Page 10: ... Manifold Components GS 3232 4 93 6 5 Check Valve Manifold Components GS 1530 GS 1532 GS 1930 and GS 1932 4 94 6 6 Valve Adjustments Function Manifold 4 95 6 7 Valve Coils 4 99 B Hydraulic Tank 7 1 Hydraulic Tank 4 101 B Steer Axle Components 8 1 Yoke and Drive Motor 4 102 8 2 Steer Cylinder 4 103 8 3 Steer Bellcrank 4 104 A Non steer Axle Components 9 1 Drive Brake 4 105 A Brake Release Hand Pump...

Page 11: ... 1530 1532 1930 1932 from serial number GS3005A 76000 to GS3006A 83067 from serial number GS3005B 76000 to GS3006B 79659 6 10 C GS 1530 1532 1930 1932 from serial number GS3006A 83068 to GS3007A 87490 from serial number GS3006B 79660 to GS3007B 82543 6 14 B GS 1530 1532 1930 1932 from serial number GS3007A 87491 to GS3007A 89537 from serial number GS3007B 82544 to GS3007B 84599 6 18 D GS 1530 1532...

Page 12: ...2646 3246 from serial number GS4611A 97983 to GS4612A 109999 6 50 Electrical Schematics CE Models E GS 1530 1532 1930 1932 from serial number GS3005A 76000 to GS3005A 76388 from serial number GS3005B 76000 to GS3005B 76030 6 54 E GS 1530 1532 1930 1932 from serial number GS3005A 76389 to GS3005A 79394 from serial number GS3005B 76031 to GS3005B 76920 6 58 D GS 1530 1532 1930 1932 from serial numbe...

Page 13: ...535 6 94 B GS 2032 2632 from serial number GS3207 83651 to GS32007 84866 GS 2046 2646 3246 from serial number GS4607 82536 to GS4607 84839 6 98 G GS 2032 2632 GS 3232 from serial number GS3207 84867 to GS3210A 94974 from serial number GS3208C 101 to GS3210C 378 GS 2046 2646 3246 from serial number GS4607 84840 to GS4610A 95454 from serial number GS4609C 101 to GS4610C 118 102 A GS 2032 2632 GS 323...

Page 14: ...GS3008C 101 6 117 D GS 2032 2632 from serial number GS3205 75407 to GS3206 80131 GS 2046 2646 3246 from serial number GS4605 75438 to GS4606 79027 6 118 A GS 2032 2632 from serial number GS3206 80132 to GS3207 84866 GS 2046 2646 3246 form serial number GS4606 79028 to GS4607 84839 6 119 D GS 2032 2632 3232 after serial number GS3207 84866 and from GS3208C 101 GS 2046 2646 3246 after serial number ...

Page 15: ...ns GS 3232 and GS 3246 19 liters Hydraulic system including tank 4 5gallons All other models 18 liters For operational specifications refer to the Operator s Manual 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 263...

Page 16: ...nd GS 2646 30 Airborne noise emissions 70 dB Maximum sound level at normal operation workstations A weighted Function speed maximum from platform controls with 1 person in platform GS 1530 and GS 1532 Platform up 15 to 17 seconds Platform down 16 to 18 seconds GS 1930 and GS 1932 Platform up 15 to 17 seconds Platform down 22 to 24 seconds GS 2032 and GS 2046 Platform up 28 to 32 seconds Platform d...

Page 17: ...ntinued use of Chevron Aviation A hydraulic fluid when ambient temperatures are consistently above 32 F 0 C may result in component damage Note Use Chevron Aviation A hydraulic fluid when ambient temperatures consistently below 0 F 17 C Note Use Shell Tellus T46 hydraulic oil when oil temperatures consistently exceed 205 F 96 C Note Genie specifications require additional equipment and special ins...

Page 18: ...creases or decreases from 68 F 20 C Description Specification Solenoid valve 3 position 4 way 27 2Ω 20V DC with diode schematic items F and AC Solenoid valve 3 position 4 way 19Ω 20V DC with diode schematic item E Solenoid valve 2 position 4 way 19Ω 20V DC with diode schematic item H and AI Solenoid valve 2 position 2 way N C 25Ω 20V DC with diode schematic item N Solenoid valve 2 position 4 way 1...

Page 19: ...ize Flats 4 7 16 20 2 6 9 16 18 1 1 4 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 SAE Dash size Torque 4 11 ft lbs 14 9 Nm 6 23 ft lbs 31 2 Nm 8 40 ft lbs 54 2 Nm 10 69 ft lbs 93 6 Nm 12 93 ft lbs 126 1 Nm 16 139 ft lbs 188 5 Nm 20 172 ft lbs 233 2 Nm 24 208 ft lbs 282 Nm SAE O ring Boss Port tube fittin...

Page 20: ...osened Figure 1 a hydraulic hose b hex nut c reference mark d body hex fitting b c a d Torque Procedure JIC 37 fittings 1 Align the tube flare hex nut against the nose of the fitting body body hex fitting and tighten the hex nut to the body hex fitting to hand tight approximately 30 in lbs 3 4 Nm 2 Make a reference mark on one of the flats of the hex nut and continue it on to the body hex fitting ...

Page 21: ...THREAD in lbs N m in lbs N m in lbs N m in lbs N m in lbs N m 20 80 9 100 11 3 110 12 4 140 15 8 130 14 7 28 90 10 1 120 13 5 120 13 5 160 18 140 15 8 ft lbs N m ft lbs N m ft lbs N m ft lbs N m ft lbs N m 18 13 17 6 17 23 18 24 25 33 9 21 28 4 24 14 19 19 25 7 20 27 1 27 36 6 24 32 5 16 23 31 2 31 42 33 44 7 44 59 6 38 51 5 24 26 35 2 35 47 4 37 50 1 49 66 4 43 58 3 14 37 50 1 49 66 4 50 67 8 70 ...

Page 22: ...February 2009 Section 2 Specifications 2 8 GS 30 GS 32 GS 46 Part No 97385 This page intentionally left blank ...

Page 23: ...uration Machine parked on a firm level surface Platform in the stowed position Key switch in the off position with the key removed The red Emergency Stop button in the off position at both ground and platform controls Wheels chocked All external AC power supply disconnected from the machine About This Section This section contains detailed procedures for each scheduled maintenance inspection Each ...

Page 24: ...tion report to use for each inspection Store completed forms as required Maintenance Schedule There are five types of maintenance inspections that must be performed according to a schedule daily quarterly semi annually annually and two year The Scheduled Maintenance Procedures Section and the Maintenance Inspection Report have been divided into five subsections A B C D and E Use the following char...

Page 25: ...Tests Use this form to record the results Place a check in the appropriate box after each part is completed Follow the instructions in the operator s manual If any inspection receives an N remove the machine from service repair and reinspect it After repair place a check in the R box Legend Y yes completed N no unable to complete R repaired Comments Fundamentals It is the responsibility of the dea...

Page 26: ...Section 3 Scheduled Maintenance Procedures April 2008 3 4 GS 30 GS 32 GS 46 Part No 97385 This page intentionally left blank ...

Page 27: ... R A 1 Inspect the manuals and decals A 2 Pre operation inspection A 3 Function tests Perform after 40 hours A 4 30 day service Perform every 100 hours A 5 Grease steer yokes Instructions Make copies of this report to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hours Inspection A Quarterly or 250 hours Inspection A B Semi annuall...

Page 28: ...t the operator s and safety manuals are present and complete in the storage container on the platform 2 Examine the pages of each manual to be sure that they are legible and in good condition Result The operator s manual is appropriate for the machine and all manuals are legible and in good condition Result The operator s manual is not appropriate for the machine or all manuals are not in good con...

Page 29: ...to determine if routine maintenance procedures are required Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine A 3 Perform Function Tests Completing the function tests is essential to safe machine operation Function tests are designed to discover any malfunctions before the machine is put into service A ma...

Page 30: ... the Hydraulic Tank Return Filter Element A 5 Grease the Steer Yokes Genie specifications require that this procedure be performed every 100 hours of operation Regular application of lubrication to the steer yokes is essential to good machine performance and service life Continued use of an insufficiently greased steer yoke will result in component damage 1 Locate the grease fitting on the top of ...

Page 31: ...a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables 4 Be sure that the battery retainers and cable connections are tight 5 Fully charge the batteries Allow the batteries to rest 24 hours before performing this procedure to allow the battery cells to equalize Models without maintenance free or sealed batteries 6 Remove the battery vent caps and check t...

Page 32: ...specific gravity from 1 269 to 1 218 The battery is still usable but at a lower performance so will need to be recharged more often Proceed to step 11 Result One or more battery cells display a specific gravity from 1 217 to 1 173 The battery is approaching the end of its life Proceed to step 11 Result The difference in specific gravity readings between cells is greater than 0 1 OR the specific gr...

Page 33: ...he charger connections at the fuse and battery The charger will then operate correctly and begin charging the batteries If simultaneously the charger alarm sounds and the LEDs blink two times the input voltage is too low or too high Correct the voltage issue The charger will then operate correctly and begin charging the batteries If simultaneously the charger alarm sounds and the LEDs blink three ...

Page 34: ...dule tray Scissor arms Platform controls 3 Inspect for a liberal coating of dielectric grease in the following locations Between the ECM and platform controls All wire harness connectors Level sensor 4 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 5 Raise the platform approximately 8 feet 2 4 m from the ...

Page 35: ...ution burn hazard Contact with hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry Note Replace the contactor if any damage is found B 4 Inspect the Tires and Wheels including castle nut torque Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the tires and wheels in good condition is e...

Page 36: ...op button at the platform controls to the off position Result No machine functions should operate Note The red Emergency Stop button at the ground controls will stop all machine operation even if the key switch is switched to platform control B 6 Test the Key Switch Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Proper key switch action and respo...

Page 37: ...ctivated at the platform controls and sounds at the ground as a warning to ground personnel An improperly functioning horn will prevent the operator from alerting ground personnel of hazards or unsafe conditions 1 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Push down the horn button at the platform...

Page 38: ...speed before reaching the test line Release the function enable switch or the joystick when your reference point on the machine crosses the test line 7 Measure the distance between the test line and your machine reference point Refer to Section 2 Specifications Result The machine stops within the specified braking distance No action required Result The machine does not stop within the specified br...

Page 39: ... indicates the machine is equipped with a dynamic brake valve Proceed to step 13 Result SV10 4727 is not stamped on the hex portion of the drive forward reverse valve This indicates the machine is not equipped with a dynamic brake valve Proceed to step 18 13 Install the drive forward reverse valve removed in step 11 into the function manifold and torque to 25 ft lbs 34 Nm 14 In order install the r...

Page 40: ...ll the reverse valve coil with white black and brown wires spacer washer and the forward valve coil with white and brown wires onto the valve Note For the machine to function correctly the reverse valve coil must be closest to the manifold 25 Install the coil nut onto the valve and torque to 60 in lbs 7 Nm 26 Connect the battery pack to the machine 27 Replace the brakes and repeat this procedure b...

Page 41: ...s 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 2 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 3 Lower the platform to the stowed position 4 Press the drive function select button a drive function select button BN8 a 5 Choose a point on the machine i e contact...

Page 42: ...2 2 m apart 2 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 3 Press the lift function select button 4 Press and hold the function enable switch on the joystick 5 Raise the platform approximately 4 feet 1 2 m from the ground 6 Press the drive function select button 7 Choose a point on the machine i e co...

Page 43: ... 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 2 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 3 Lower the platform to the stowed position 4 Press the slow speed select button a slow speed select button BN6 5 Choose a point on the machine i e contact patch of a...

Page 44: ...e the oil when it fails the test See E 1 Test or Replace the Hydraulic Oil B 13 Inspect the Hydraulic Tank Cap Venting System Genie requires that this procedure be performed quarterly or every 250 hours whichever comes first Perform this procedure more often if dusty conditions exist A free breathing hydraulic tank cap is essential for good machine performance and service life A dirty or clogged c...

Page 45: ...components in good condition is essential to good performance and service life Failure to detect worn out latch components may result in module trays opening unexpectedly creating an unsafe operating condition 1 Inspect each module tray rotary latch and related components for wear Tighten any loose fasteners 2 Lubricate each module tray rotary latch Using light oil apply a few drops to each of the...

Page 46: ... requires too much power to operate or is being used at or near the limit of the inverter for an extended period of time Reduce the power draw The inverter will then operate correctly and begin supplying AC power If the right fault LED 123 blinks two times the Ground Fault Interrupt GFI has been activated A short circuit or partial short exists between the AC hot and ground in the tool or outlet C...

Page 47: ...m control cable down the scissor stack to the alarm bracket on the chassis deck Tag and disconnect the platform control cable from the ECM cable at the 6 pin Deutsch connector GS 2032 GS 2632 GS 3232 GS 2046 GS 2646 and GS 3246 Follow the platform control cable down the scissor stack to the underside of the chassis deck Tag and disconnect the platform cable from the ECM cable at the 6 pin Deutsch ...

Page 48: ... the alarm does not sound The machine is functioning properly Result The diagnostic display shows code 18 and an alarm sounds Replace the down limit switch 16 Raise the platform 7 to 8 feet 2 1 to 2 4 m 17 Lift the safety arm move it to the center of the scissor arm and rotate down to a vertical position 18 Lower the platform onto the safety arm Crushing hazard Keep hands clear of the safety arm w...

Page 49: ... stowed position Move the machine onto a firm level surface 31 Place a wooden block approximately 2 inches 5 cm tall under the right pothole guard 32 Press the lift function select button Attempt to raise the platform approximately 8 feet 2 4 m Result The pothole guard contacts the block and does not fully deploy the diagnostic display shows code 18 an alarm sounds and the platform will lift to 8 ...

Page 50: ...ep hands clear of the safety arm when lowering the platform 4 While raising the platform from the ground controls push the arm of the up limit switch towards the steer end of the machine to activate the limit switch Result The platform stops raising The machine is functioning properly Result The platform continues to raise Adjust or replace the up limit switch Outrigger Limit Switches if equipped ...

Page 51: ...latform overload option are provided with two additional machine control components the overload pressure switch and a maximum height limit switch The overload pressure switch which is adjustable and located at the barrel end of the lift cylinder is used to determine when the hydraulic lift cylinder requires too much pressure to support the load inside the platform When this occurs the pressure sw...

Page 52: ... Result models with software revision A2 and higher The alarm should not sound The system is functioning correctly Result all models The alarm sounds The system is not functioning correctly Troubleshoot the limit switch limit switch wire harness or limit switch mount bracket OR the platform overload system needs to be calibrated Refer to Repair Procedure 3 7 Calibrate the Platform Overload System ...

Page 53: ... semi annually whichever comes first The hydraulic tank is a vented type tank The breather cap has an internal air filter that can become clogged or over time can deteriorate If the breather cap is faulty or improperly installed impurities can enter the hydraulic system which may cause component damage Extremely dirty conditions may require that the cap be inspected more often 1 Remove and discard...

Page 54: ... GS3005B 76000 to GS3006B 80468 Measure the distance between the number one outer arm cross tube and the chassis deck at the ground controls side of the non steer end of the machine Refer to illustration 1 After serial numbers GS3006A 85006 GS3006B 80468 and GS3008C 101 Measure the distance between the number one inner arm cross tube and the chassis deck at the ground controls side of the non stee...

Page 55: ...tube and the chassis deck at the battery pack side of the non steer end of the machine Refer to illustration 2 Result The measurement is 0 90 inch 22 9 mm or more Proceed to step 3 Result The measurement is less than 0 90 inch 22 9 mm Replace both wear pads Refer to Repair Procedure 3 1 or 3 2 How to Replace the Scissor Arm Wear Pads 3 Apply a thin layer of dry film lubricant to the area of the ch...

Page 56: ... How to Replace the Scissor Arm Wear Pads 2 Measure the distance between the number one outer arm cross tube and the fork lift tube at the battery pack side of the non steer end of the machine Result The measurement is 0 88 inch 22 4 mm or more Proceed to step 3 Result The measurement is less than 0 88 inch 22 4 mm Replace both wear pads Refer to Repair Procedure 3 3 3 4 or 3 5 How to Replace the ...

Page 57: ...he hydraulic tank return filter is mounted on the function manifold next to the hydraulic power unit 1 Clean the area around the oil filter Remove the filter with an oil filter wrench 2 Apply a thin layer of oil to the new oil filter gasket 3 Install the new filter and tighten it securely by hand 4 Use a permanent ink marker to write the date and number of hours from the hour meter onto the filter...

Page 58: ...lt in death or serious injury Remove all rings watches and other jewelry 2 Open the power unit module tray 3 Tag and disconnect the hydraulic tank return hard line from the hydraulic filter head and remove the hard line from the tank Cap the fitting on the filter head 4 Tag and disconnect the hydraulic pump inlet hard line and remove the hard line from the tank Cap the fitting on the pump 5 Remove...

Page 59: ...hydraulic filter head and torque to specification Refer to Section 2 Specifications 12 Fill the tank with hydraulic oil until the fluid is at the FULL indicator on the hydraulic tank Do not overfill 13 Activate the pump to fill the hydraulic system with oil and bleed the system of air Component damage hazard The pump can be damaged if operated without oil Be careful not to empty the hydraulic tank...

Page 60: ...Section 3 Scheduled Maintenance Procedures April 2008 3 38 GS 30 GS 32 GS 46 Part No 97385 This page intentionally left blank ...

Page 61: ...oth ground and platform controls Wheels chocked All external AC power supply disconnected from the machine About This Section Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop Select the appropriate repair procedure after troubleshooting the problem Perform disassembly procedures to the point where repairs can be compl...

Page 62: ...he control box 5 Carefully disconnect the wire harness connectors from the circuit board 6 Carefully remove the circuit board retaining fasteners and remove the circuit board from the control box The platform controls used to operate the machine from the platform or while standing on the ground can also be used to tune the performance of the machine Moving the joystick or activating a button sends...

Page 63: ...d green or solid red light f left rear outrigger L53 solid green or solid red light g outrigger extend BN105 h function enable BN106 i outrigger retract BN107 j outrigger control circuit board U36 How to Remove the Outrigger Control Pad Circuit Board 1 Push in the red Emergency Stop button to the off position at both the ground and platform controls 2 Remove the fasteners securing the outrigger co...

Page 64: ... this procedure without the necessary skills will result in death or serious injury Note Select a test area that is firm level and free of obstructions How to Determine the Software Revision Level 1 Remove the platform controls from the platform 2 Place the platform controls close to the diagnostic display on the power unit side of the machine PLATFORM CONTROLS a joystick controller JC1 b lift fun...

Page 65: ...d in this procedure Setting the function speeds greater than specifications could cause the machine to tip over 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 will result in death or serious injury 1 Pull out the red Emergency Stop button to the on position at the gr...

Page 66: ...y Stop button to the off position at the platform controls 3 Turn the key switch to platform control 4 At the platform controls press and hold the lift function select and horn buttons and pull out the red Emergency Stop button to the on position Result The diagnostic display will show PS 5 Release the lift function select and horn buttons Result The diagnostic display will show the maximum lift s...

Page 67: ...the off position at the platform controls 3 Turn the key switch to platform control 4 At the platform controls press and hold the lift function select and horn buttons and pull out the red Emergency Stop button to the on position Result The diagnostic display will show PS 5 Release the lift function select and horn buttons Result The diagnostic display will show the maximum lift speed percentage a...

Page 68: ...he platform controls 3 Turn the key switch to platform control 4 At the platform controls press and hold the lift function select and horn buttons and pull out the red Emergency Stop button to the on position Result The diagnostic display will show PS 5 Release the lift function select and horn buttons Result The diagnostic display will show the maximum lift speed percentage a joystick controller ...

Page 69: ... red Emergency Stop button to the off position at both the ground and platform controls and turn the key switch to the off position Machine Option Feature Definitions Motion Alarm The motion alarm will sound when operating any function Lift Drive Cut Out In addition to an alarm sounding lift and drive functions are disabled when the platform is raised above the down limit switch and the incline of...

Page 70: ...sh in the diagnostic display Use the steering thumb rocker switch on the joystick to increase or decrease the value See 1 3 Machine Configuration Code Chart for configuration settings 7 Press and hold the lift function select button for a minimum of 3 seconds to set the tens value a joystick controller JC1 with thumb steering rocker SW6 b lift function select button BN9 c diagnostic display d red ...

Page 71: ...serial number GS3008C 101 A mark in the four right columns indicates the machine configuration code in the left column includes this feature Machine Function Code at Diagnostic Display Motion Alarm Lift Drive Cut Out Platform Overload Descent Delay 00 01 02 03 04 06 07 08 10 11 13 16 21 22 24 28 ECMs with software revisins A0 to A4 GS 1530 GS 1532 GS 1930 GS 1932 Machine Function Code at Diagnosti...

Page 72: ...ncludes this feature A mark in the four right columns indicates that the machine configuration code in the left column includes this feature Machine Function Code at Diagnostic Display Motion Alarm Lift Drive Cut Out Platform Overload Descent Delay 32 33 34 35 36 38 39 40 42 43 45 48 53 54 56 60 ECMs with software revisins A0 to A4 GS 2046 GS 2646 GS 3246 GS 2032 GS 2632 Machine Function Code at D...

Page 73: ...ow will become illuminated This indicates that the battery drain alarm option has been activated 8 Press and hold the speed select button for a minimum of 3 seconds or until the ones setting stops flashing 9 Turn the key switch to the off position Note To deactivate the battery drain alarm option on a machine which has the option activated repeat this procedure When the ECM is in the SC mode and t...

Page 74: ...platform controls Result The lift error light turns red on the outrigger control pad 6 Continue to hold the function enable outrigger extend and outrigger retract buttons Result After approximately 3 seconds at the outrigger control pad the right rear outrigger and left front outrigger lights turn red The right front outrigger and left rear outrigger lights turn green and the lift error light rema...

Page 75: ...n at the ground controls 4 Push in the red Emergency Stop button to the off position at the platform controls 5 Press and hold the outrigger extend and retract buttons and pull out the red Emergency Stop button to the on position at the platform controls Result The lift error light turns red at the outrigger control pad 6 Continue to hold the outrigger extend and retract buttons Result After appro...

Page 76: ... outrigger d right rear outrigger e outrigger extend f function enable g outrigger retract h left rear outrigger i left front outrigger How to Activate the Outrigger Motion Alarm Option 1 Turn the key switch to platform control 3 Pull out the red Emergency Stop button to the on position at the ground controls 4 Push in the red Emergency Stop button to the off position at the platform controls 5 Pr...

Page 77: ...abnormal operation of the outrigger controls system How to Remove and Disassemble the Outrigger Control Pad 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 Push in the red Emergency Stop button to the off position at both the ground and platform c...

Page 78: ... b coil cord c bottom enclosure d printed circuit board e control pad decal hidden from view f button cap 7 Locate the printed circuit board mounted to the bottom enclosure of the outrigger control pad and remove the button caps Refer to Illustration 2 8 Using a set of pliers grasp the connector of the coil cord and slowly pull the coil cord away from the printed circuit board Refer to Illustratio...

Page 79: ...et the fasteners to the side 13 Remove the fasteners securing the bottom cover to the ECM enclosure Set the cover and the fasteners to the side Refer to Illustration 5 14 Carefully remove the printed circuit board from the ECM enclosure Refer to Illustration 5 Component damage hazard Electrostatic discharge ESD can damage printed circuit board components Maintain firm contact with a metal part of ...

Page 80: ...enie part number 125132 and the updated Hex files for the outrigger ECM Genie part number 125131 must be installed on a PC or laptop 16 Plug the USB end of the PSoC MiniProg cable into a PC or laptop Note A window may ask to find a driver for the PSoC MiniProg cable Click Yes until finished 17 Plug the PSoc MiniProg cable into the printed circuit board of the ECM or the control pad making sure the...

Page 81: ...e Idle Red Background Green Background All Green Backgrounds Not Powered Connected Idle PLATFORM CONTROLS 19 Select MINIProg1 048E47470618 from the Port drop down menu Result All the boxes in the lower right corner of the PSoC Programmer window should have a green background and show as being Connected ...

Page 82: ...REV J October 2009 Section 4 Repair Procedures 4 22 GS 30 GS 32 GS 46 Part No 97385 All Green Backgrounds Not Powered Connected Idle PLATFORM CONTROLS 20 Click the File Load button ...

Page 83: ...132 hex REV A1 DATE CODE SERIAL FIRMWARE FILE NUMBER PLATFORM CONTROLS 21 Browse the folder containing the appropriate hex file select the file and click Open Result All the boxes in the lower right hand corner of the PSoC Programmer window should have a green background Note To ensure the correct file is selected for either the ECM or control pad update refer to the decals located in Illustration...

Page 84: ...S 32 GS 46 Part No 97385 All Green Backgrounds Connected Idle Not Powered Pass PLATFORM CONTROLS 22 With the background of all boxes in the lower right corner of the PSoc Programmer window green in color locate the Device Family drop down menu and select 29x66 ...

Page 85: ...9 R58 R57 R56 R55 R54 R53 R52 R51 R50 R49 R48 R47 R46 R45 R44 R43 R42 R41 R40 R39 R38 R37 R14 R13 R12 R11 R10 R9 R8 R7 R6 R5 R4 R3 R2 R1 LED2 LED1 L2 L1 JP1 F2 F1 D47 D46 D45 D44 D43 D42 D41 D40 D39 D38 D37 D36 D35 D34 D33 D32 D31 D30 D29 D28 D27 D26 D25 D24 D23 D22 D21 D9 D8 D7 D6 D5 D4 D3 D2 D1 C21 C20 C19 C18 C17 C16 C15 C14 C13 C12 C11 C10 C9 C8 C7 C6 C5 C4 C3 C2 C1 R36 R35 R34 R33 R32 R31 R30...

Page 86: ...2 GS 46 Part No 97385 All Green Backgrounds Connected Idle Not Powered Pass PLATFORM CONTROLS 23 At the Device drop down menu select CY8C29666 if the outrigger ECM firmware is being updated OR select CY8C29466 if the outrigger control pad firmware is being updated ...

Page 87: ...REV J Section 4 Repair Procedures October 2009 Part No 97385 GS 30 GS 32 GS 46 4 27 All Green Backgrounds Connected Idle Not Powered Pass PLATFORM CONTROLS 24 At Programming Mode select the Reset bullet ...

Page 88: ...e Device Power button Result A portion of the lower right hand corner in the PSoC Programmer window should now be red and show as being Powered Result The red light labeled Target Power on the MiniProg cable should be on 26 Click the Program button to update the firmware of either the ECM or the control pad Result The main PSoC Programmer window will indicate a successful program ...

Page 89: ...ndow should have a green background and should indicate Not Powered 28 Carefully disconnect the MiniProg cable from the printed circuit board 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 Note Repea...

Page 90: ...ponents 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 32 Install the control pad top enclosure onto the control pad bottom enclosure Refer to Illustration 2 Illustration 2 a top enclosure b coil cord c bottom enclosure d printed circuit board e control pad decal hidden from view f button cap 3...

Page 91: ...rostatic 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 36 Using the fasteners removed in step 13 securely install the ECM bottom cover to the ECM enclosure Do not over tighten Refer to Illustration 5 Illustration 5 a ECM enclosure b pri...

Page 92: ...battery pack to the machine Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 41 Calibrate the outrigger level sensor See 1 4 How to Calibrate the Outrigger Level Sensor 42 Calibrate the outrigger pressure transducers See 1 4 How to Calibrate the Outrigger Pressure Transducers 43 Perform the funct...

Page 93: ...Section 4 Repair Procedures October 2009 Part No 97385 GS 30 GS 32 GS 46 4 33 This page intentionally left blank ...

Page 94: ...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 platf...

Page 95: ...e platform extension 6 Remove the two retaining fasteners from each platform extension roller bracket assembly Remove each assembly from the machine Note Do not remove the platform roller bolt a roller bracket assembly b assembly retaining fastener c 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...

Page 96: ...2 pins 3 Lift cylinder rod end pivot pin 4 Number 3 pivot pin steer end 5 Number 2 center pivot pin 2 pins 6 Number 2 pivot pin steer end 7 Number 1 center pivot pin 2 pins 8 Number 1 inner arm 9 Number 1 pivot pin 10 Number 3 inner arm 11 Number 3 outer arm 12 Number 3 pivot pin non steer end 13 Number 2 inner arm 14 Number 2 outer arm 15 Number 2 pivot pin non steer end 16 Lift cylinder barrel e...

Page 97: ...rom 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 Models with dual number 3 outer arms 4 Attach a lifting strap from an overhead crane to the number 3 outer arm at the ground controls side of the machine index 11 Cable bridge legend a cable bridge 3 b cable bridge 2 c cable bridge 1 5 Remove the external snap ring...

Page 98: ...bridge from the machine 19 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 20 Remove the pin retaining fasteners from the lift cylinder rod end pivot pin index 3 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 supported...

Page 99: ...e machine 36 Attach a lifting strap from an overhead crane to the number 2 inner arm index 13 37 Remove the retaining fasteners from the number 2 pivot pin index 6 at the steer end of the machine 38 Use a soft metal drift to remove the number 2 pivot pin index 6 Remove the number 2 inner arm index 13 from the machine Bodily injury hazard The number 2 inner arm may become unbalanced and fall if not...

Page 100: ...fting device 52 Remove the fasteners from the entry ladder and remove the entry ladder from the machine Crushing hazard The entry ladder may become unbalanced and fall if not properly supported and secured to the lifting device 53 Attach a lifting strap from an overhead crane to the number 1 outer arm index 17 Do not apply any lifting pressure 54 Remove the external snap rings and retaining fasten...

Page 101: ...is mount bracket to the chassis at the steer end of the machine 7 Attach a lifting strap from an overhead crane to the scissor arm assembly 8 Raise the scissor arm assembly at the steer end with the overhead crane until the chassis mount bracket will clear the level sensor 9 Remove the scissor assembly from the machine just enough to access both wear pads Crushing hazard The scissor assembly will ...

Page 102: ... pins 5 Lift cylinder rod end pivot pin 6 Number 3 pivot pin steer end 7 Number 2 center pivot pin 2 pins 8 Number 2 pivot pin steer end 9 Number 1 center pivot pin 2 pins 10 Number 1 inner arm 11 Number 1 pivot pin 12 Number 4 inner arm 13 Number 4 outer arm 14 Number 4 pivot pin non steer end 15 Number 3 inner arm 16 Number 3 outer arm 17 Number 3 pivot pin non steer end 18 Number 2 inner arm 19...

Page 103: ...1 How to Remove the Platform 2 Remove the cables from the number 4 outer arm index 13 at the ground controls side Component damage hazard Cables can be damaged if they are kinked or pinched 3 Remove the cables from the number 4 cable bridge and lay them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched Cable bridge legend a cable bridge 4 b cable bridge 3 ...

Page 104: ...he external snap rings and retaining fasteners from the number 4 center pivot pins index 2 15 Use a soft metal drift to remove the number 4 center pivot pins index 2 16 Remove the retaining fasteners from the number 4 pivot pin index 14 at the non steer end of the machine 17 Use a soft metal drift to remove the number 4 pivot pin index 14 from the non steer end of the machine Remove the number 4 o...

Page 105: ...achine Bodily injury hazard The number 3 outer arm at the battery pack side may become unbalanced and fall if not properly supported when removed from the machine 32 Remove the number 3 pivot pin index 17 from the non steer end of the machine 33 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 34 Remove the p...

Page 106: ...ide may become unbalanced and fall if not properly supported when removed from the machine 49 Use a soft metal drift to tap the number 2 pivot pin at the non steer end index 20 in the other direction Remove the number 2 outer arm index 19 from the battery pack side of the machine Bodily injury hazard The number 2 outer arm at the battery pack side may become unbalanced and fall if not properly sup...

Page 107: ...moving it from the machine 63 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 11 64 Attach a lifting strap from an overhead crane to the number 1 inner arm index 10 at the non steer end Raise the number 1 inner arm and remove the safety arm Lower the number 1 inner arm index 10 onto the block that was placed across...

Page 108: ...nents when the number 1 inner arm is removed from the machine How to Replace the Scissor Arm Wear Pads 1 Remove the platform See 2 1 How to Remove the Platform 2 Support and secure the entry ladder to an appropriate lifting device 3 Remove the fasteners from the entry ladder and remove the entry ladder from the machine Crushing hazard The entry ladder may become unbalanced and fall if not properly...

Page 109: ... hazard Be careful not to damage the level sensor or limit switch while moving the scissor assembly 10 Remove both old wear pads 11 Install two new wear pads 12 Slide the scissor assembly back into the drive chassis 13 Lower the scissor assembly into position and install the chassis mount bracket onto the chassis Securely install and tighten the fasteners Do not over tighten Component damage hazar...

Page 110: ...2 pins 3 Lift cylinder rod end pivot pin 4 Number 3 pivot pin steer end 5 Number 2 center pivot pin 2 pins 6 Number 2 pivot pin steer end 7 Number 1 center pivot pin 2 pins 8 Number 1 inner arm 9 Number 1 pivot pin 10 Number 3 inner arm 11 Number 3 outer arm 12 Number 3 pivot pin non steer end 13 Number 2 inner arm 14 Number 2 outer arm 15 Number 2 pivot pin non steer end 16 Lift cylinder barrel e...

Page 111: ...y ladder from the machine Crushing hazard The entry ladder may become unbalanced and fall if not properly supported and secured to the lifting device 4 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 Cable bridge legend a cable bridge 3 b cable bridge 2A c cable bridge 2B d cable bridge 1 5 Di...

Page 112: ... The lift cylinder will fall if not properly supported when the pivot pin is removed 20 Place a 2 x 4 x 10 inch 10 x 10 x 25 cm block onto the number 1 inner arm cylinder plate index 8 21 Lower the cylinder onto the block Bodily injury hazard Keep hands clear of moving parts when lowering the cylinder onto the block 22 Attach a lifting strap from an overhead crane to the number 3 inner arm index 1...

Page 113: ...an overhead crane to the number 2 inner arm index 13 Raise the arm to a vertical position 37 Remove the retaining fasteners from the number 2 pivot pin at the steer end of the machine index 6 38 Use a soft metal drift to remove the number 2 pivot pin index 6 from the steer end of the machine Remove the number 2 inner arm index 13 from the machine Crushing hazard The number 2 inner arm index 13 may...

Page 114: ...re kinked or pinched 51 Disconnect the number 1 cable bridge from the number 1 outer arm index 17 and remove the cable bridge from the machine 52 Attach a lifting strap from an overhead crane to the number 1 inner arm index 8 53 Raise the arm slightly and remove the block 54 Lower the arm to the stowed position Bodily injury hazard Keep hands clear of moving parts when lowering the scissor arms 55...

Page 115: ...will clear the level sensor 9 Move the scissor assembly towards the non steer end of the machine slightly and to one side of the machine until one of the scissor arm wear pads is accessible Do not allow both wear pads to slide out of the drive chassis Component damage hazard Be careful not to damage the level sensor or limit switch while moving the scissor assembly 10 Remove the old wear pad 11 In...

Page 116: ... pins 5 Lift cylinder rod end pivot pin 6 Number 3 pivot pin steer end 7 Number 2 center pivot pin 2 pins 8 Number 2 pivot pin steer end 9 Number 1 center pivot pin 2 pins 10 Number 1 inner arm 11 Number 1 pivot pin 12 Number 4 inner arm 13 Number 4 outer arm 14 Number 4 pivot pin non steer end 15 Number 3 inner arm 16 Number 3 outer arm 17 Number 3 pivot pin non steer end 18 Number 2 inner arm 19...

Page 117: ...o Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform See 2 1 How to Remove the Platform 2 Support and secure the entry ladder to an appropriate lifting device 3 Remove the fasteners from the entry ladder and remove the entry ladder from the machine Crushing hazard The entry ladder may become unbalanced and fall if not properly supported and secured to the lifting devi...

Page 118: ...number 4 outer arm at the battery side index 13 14 Remove the retaining fasteners from the number 4 center pivot pin index 2 at the battery side 15 Place a rod through the number 4 center pivot pin at the battery side index 2 and twist to remove the pin 16 Remove the number 4 outer arm index 13 from the machine Crushing hazard The number 4 outer arm index 13 may become unbalanced and fall if not p...

Page 119: ...steners from the number 3 center pivot pin index 4 at the battery side 29 Place a rod through the number 3 center pivot pin at the battery side index 4 and twist to remove the pin 30 Remove the number 3 outer arm index 16 from the machine Crushing hazard The number 3 outer arm index 16 may become unbalanced and fall if not properly supported when removed from the machine 31 Attach a lifting strap ...

Page 120: ...n at the ground control side index 7 and twist to remove the pin 44 Remove the retaining fasteners from the number 2 pivot pin index 20 at the non steer end 45 Use a soft metal drift to remove the number 2 pivot pin index 20 from the non steer end of the machine Remove the number 2 outer arm at the ground control side index 19 from the machine Crushing hazard The number 2 outer arm at the ground c...

Page 121: ... Keep hands clear of moving parts when lowering the scissor arms 57 Attach a lifting strap from an overhead crane to the lug of the rod end of the lower lift cylinder 58 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 o...

Page 122: ...mit switch or level sensor box components when the number 1 inner and outer arms index 10 and 22 is removed from the machine How to Replace the Scissor Arm Wear Pads 1 Remove the platform See 2 1 How to Remove the Platform 2 Support and secure the entry ladder to an appropriate lifting device 3 Remove the fasteners from the entry ladder and remove the entry ladder from the machine Crushing hazard ...

Page 123: ...ill fall if both wear pads are allowed to slide out of the drive chassis Component damage hazard Be careful not to damage the level sensor or limit switch while moving the scissor assembly 13 Remove the old wear pad 14 Install the new wear pad 15 Slide the scissor assembly back into the drive chassis 16 Lower the scissor assembly into position and install the chassis mount bracket onto the chassis...

Page 124: ...t pin 2 pins 9 Lower lift cylinder rod end pivot pin 10 Number 3 pivot pin steer end 11 Number 2 center pivot pin 2 pins 12 Number 2 pivot pin steer end 13 Number 1 center pivot pin 2 pins 14 Number 1 inner arm 15 Number 1 pivot pin steer end 2 pins 16 Number 5 inner arm 17 Number 5 outer arm 18 Number 5 pivot pin non steer end 19 Number 4 inner arm 20 Number 4 outer arm 21 Number 4 pivot pin non ...

Page 125: ... appropriate lifting device 3 Remove the fasteners from the entry ladder and remove the entry ladder from the machine Crushing hazard The entry ladder may become unbalanced and fall if not properly supported and secured to the lifting device 4 Remove the cables from the number 5 cable bridge and lay them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched Ca...

Page 126: ...perly supported when removed from the machine 17 Attach a lifting strap from an overhead crane to the number 5 inner arm index 16 Raise the arm to a vertical position 18 Remove the retaining fasteners from the number 5 pivot pin at the steer end of the machine index 4 19 Use a soft metal drift to remove the number 5 pivot pin index 18 from the steer end of the machine Remove the number 5 inner arm...

Page 127: ...y side 35 Place a rod through the number 4 center pivot pin at the battery side index 5 and twist to remove the pin 36 Remove the number 4 outer arm index 20 from the machine Crushing hazard The number 4 outer arm index 20 may become unbalanced and fall if not properly supported when removed from the machine 37 Attach a lifting strap from an overhead crane to the number 4 inner arm index 19 Raise ...

Page 128: ... if not properly supported when the pivot pin is removed Component damage hazard Be careful not to damage the valve or fittings on the cylinder while removing it from the machine 54 Attach a lifting strap from an overhead crane to the lug of the rod end of the lower lift cylinder 55 Remove the retaining fasteners from the lower lift cylinder rod end pivot pin index 9 56 Use a soft metal drift to r...

Page 129: ...at the battery side index 11 and twist to remove the pin Crushing hazard The number 2 outer arm index 26 may become unbalanced and fall if not properly supported when the pivot pin is removed 72 Remove the number 2 outer arm index 26 from the machine Crushing hazard The number 2 outer arm index 26 may become unbalanced and fall if not properly supported when removed from the machine 73 Attach a li...

Page 130: ...gs on the cylinder while removing it from the machine 87 Remove the cables from the number 1 cable bridge and lay them off to the side Component damage hazard Cables can be damaged if they are kinked or pinched 88 Disconnect the number 1 cable bridge from the number 1 outer arm index 29 and remove the cable bridge from the machine 89 Attach a lifting strap from an overhead crane to the number 1 in...

Page 131: ...ill clear the level sensor 9 Move the scissor assembly towards the non steer end of the machine slightly and to one side of the machine until one of the scissor arm wear pads is accessible Do not allow both wear pads to slide out of the drive chassis Component damage hazard Be careful not to damage the level sensor or limit switch while moving the scissor assembly 10 Remove the old wear pad 11 Ins...

Page 132: ...ty arm when lowering the platform 4 Tag and disconnect the wiring from the solenoid valve coil at the barrel end of the lift cylinder 5 Models with platform overload option Tag and disconnect the wiring from the platform overload switch a lift cylinder b orifice schematic item O c connector fitting d hydraulic hose e manual lowering cable f solenoid valve schematic item N g cable mount bracket 6 L...

Page 133: ...issor arms at the steer end of the machine Crushing hazard The lift cylinder may become unbalanced and fall if not properly supported and secured to the lifting device Component damage hazard Be careful not to damage the valve or fittings on the cylinder while removing it from the machine Torque specification Solenoid valve 2 position 2 way N C 20 ft lbs schematic item N 27 Nm Coil nut 5 ft lbs 7 ...

Page 134: ...od end pivot pin Use a soft metal drift to remove the pin Crushing hazard The lift cylinder will fall if not properly supported 11 Lower the cylinder onto the number 1 inner arm cylinder plate Bodily injury hazard Keep hands clear of moving parts when lowering the cylinder 12 Attach a lifting strap from an overhead crane or similar lifting device to the barrel end of the lift cylinder for support ...

Page 135: ...lowering cable mount bracket to the cylinder Remove the bracket from the cylinder 8 Tag disconnect and plug the hydraulic 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 9 Attach a lifting s...

Page 136: ...e pin is removed 14 Support and secure the lift cylinder to an appropriate lifting device 15 Remove the lift cylinder through the scissor arms at the steer end of the machine Y9 e N O b c f Q a d Upper Lift Cylinder after serial GS4607 83691 a lift cylinder b orifice fitting schematic item O c connector fitting d hydraulic hose e solenoid valve schematic item N f relief valve schematic item Q Note...

Page 137: ...ing to the maximum load as indicated on the capacity indicator decal in the center of the platform floor Secure the weight to the platform Refer to the chart below GS 1532 484 kg GS 1932 435 kg GS 2032 693 kg GS 2632 479 kg GS 3232 498 kg GS 2046 985 kg GS 2646 798 kg GS 3246 699 kg 7 Apply a piece of tape onto the side of the platform at a point which corresponds to the maximum load position of t...

Page 138: ...he platform overload system delay wait 3 seconds between each quarter turn of the nut or adjustment screw 12 Turn the nut or adjustment screw one quarter turn into the hydraulic line 13 Return the safety arm to the stowed position 14 Using the manual lowering knob lower the platform to the stowed position and remove all test weight from the platform 15 Using a suitable lifting device place a test ...

Page 139: ...derable resistance is felt Release the handle 5 Measure the distance between the base of the handle and cable mounting nut Result The measurement should be no greater than 1 8 inch 3 mm Platform manual lowering cable specification Gap lowering handle to mounting nut 0 to 1 8 inch 0 to 3 mm Skip to step 8 if the measurement is correct 6 To adjust loosen the upper lock nut on the cable mounting brac...

Page 140: ... switch to platform control and pull out the red Emergency Stop button to the on position at both the 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 If...

Page 141: ...and springs 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 3 8 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 co...

Page 142: ...does sound and fault code LL appears in the diagnostic display Adjust the level sensor retaining fasteners just until the level sensor alarm does not sound 25 Lower the platform to the stowed position 26 Raise the machine approximately 2 inches 5 cm 27 Remove the blocks from under both wheels 28 Lower the machine and remove the jack 29 Center a lifting jack under the drive chassis at the battery p...

Page 143: ... until the alarm just begins to sound OR the down limit switch may need to be adjusted 34 Lift the safety arm move it to the center of the scissor arm and rotate down to a vertical position 35 Lower the scissor arms onto the safety arm Crushing hazard Keep hands clear of the safety arm when lowering the platform 36 Raise the platform 7 to 8 feet 2 1 to 2 4 m 37 Return the safety arm to the stowed ...

Page 144: ...connect 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 Illustration 1 Illustration 1 7 Sec...

Page 145: ...Section 4 Repair Procedures March 2007 Part No 97385 GS 30 GS 32 GS 46 4 85 This page intentionally left blank GROUND CONTROLS ...

Page 146: ...rt 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 the 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 pump is good Result If pressure fails to reach 3200 psi 221 bar the pump is bad and will need to be serviced...

Page 147: ... 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 hard line from the pump Cap the fitting on the pump 6 Tag disconnect and plug the high pressure hose at the pump Cap the fitting on the pump Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connec...

Page 148: ...ition 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 103 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 System relief 20 ft lbs 27 Nm 6 1 Function Manifold Components GS 1530 GS 1532 GS 1930 and GS 1932 The function manifold is mounted under the mac...

Page 149: ... Y6 After serial number GS3005B 76084 drive forward coil Y6 Before serial number GS3005A 76492 drive forward coil Y6 Before serial number GS3005B 76085 drive forward coil Y6 After serial number GS3005A 76491 drive reverse coil Y5 After serial number GS3005B 76084 drive reverse coil Y5 Note alpha callouts refer to corresponding notes on the hydraulic schematic Note alpha numeric callouts refer to c...

Page 150: ...AE Drive speed select circuit 25 ft lbs 34 Nm 6 Relief valve Before serial number GS3206 80132 and GS4606 79028 130 psi 9 bar After serial number GS3206 80131 and GS4606 79027 50 psi 3 4 bar AF Brake release 20 ft lbs 27 Nm 7 Solenoid valve 3 position 5 way AG 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 AH Steer circuit 26 ft lbs 35 N...

Page 151: ...st from manifold serial number GS3206 80132 drive forward coil Y6 Before serial number GS4606 79028 drive forward coil Y6 Before serial number GS3206 80132 drive reverse coil Y5 Before serial number GS4606 79028 drive reverse coil Y5 After serial number GS3206 80131 drive forward coil Y6 After serial number GS4606 79027 drive forward coil Y6 Note alpha numeric callouts refer to corresponding notes...

Page 152: ...en torque to specification 3 If required install the valve coil s onto the valve stem Install the coil nut onto the valve stem and torque to specification Index Schematic No Description Item Function Torque Coil nut item BA 4 5 ft lbs 5 7 Nm 1 Solenoid valve 3 position 4 way BA Outrigger extend retract 25 ft lbs 34 Nm 2 Relief valve 3500 psi 241 bar maximum BB Outrigger circuit 20 ft lbs 27 Nm INS...

Page 153: ...all the valve coil s onto the valve stem Install the coil nut onto the valve stem and torque to specification Index Schematic No Description Item Function Torque Coil nut item CA CB CC CD 4 5 ft lbs 5 7 Nm 1 Solenoid valve 2 position 2 way CA CB CC CD Outrigger extend retract 25 ft lbs 34 Nm 2 Orifice plug 0 037 inch 0 94 mm CE Outrigger retract 3 Check valve pilot operated CF Retract flow control...

Page 154: ...d GS 1932 The check valve manifold is mounted on the function manifold MANIFOLDS S Note alpha callouts refer to corresponding notes on the hydraulic schematic 1 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 specification 3 If required install the valve coil s onto the valve stem Inst...

Page 155: ...o the on position at both the ground and platform controls GS 1530 32 and GS 1930 32 a test port b system relief valve 6 Press and hold the function enable switch 7 Move and hold the joystick fully in either direction while observing the pressure reading on the pressure gauge Note the pressure Refer to Section 2 Specifications 8 Turn the machine off Hold the system relief valve with a wrench and r...

Page 156: ...e switch GS 1530 32 and GS 1930 32 a test port b system relief valve c lift relief valve 7 Move and hold the joystick fully in either direction while observing the pressure reading on the pressure gauge Note the pressure Refer to Section 2 Specifications 8 Turn the machine off Hold the system relief valve with a wrench and remove the cap hydraulic schematic item I or AB 9 Adjust the internal hex s...

Page 157: ...ditional 50 pounds 22 7 kg to the platform Secure the additional weight 18 Attempt to raise the platform Result The power unit should not be able to lift the platform Result If the power unit lifts the platform adjust the internal hex socket counterclockwise until the platform will not raise 19 Install the relief valve cap 20 Remove the weight from the platform 21 Bleed the hydraulic system by rai...

Page 158: ...the function enable switch and press and hold the steer thumb rocker switch to the right Allow the wheels to completely turn to the right Continue holding the switch while observing the pressure reading on the pressure gauge Note the pressure Refer to Section 2 Specifications 6 Press and hold the steer thumb rocker switch to the left Allow the wheels to completely turn to the left Continue holding...

Page 159: ...ect the wiring from the coil to be tested 2 Test the coil resistance using a multimeter set to resistance Ω 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 Specification Note The following coil resistance specifications are at an ambient temperature of 68 F 20 C As valve...

Page 160: ...coil Note The battery should read 9V DC or more when measured across the terminals Resistor 10Ω Ω Ω Ω Ω 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...

Page 161: ...chine Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 2 Remove the drain plug from the hydraulic tank and allow all of the oil from the tank to drain into a suitable container Refer to Section 2 Specifications Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraul...

Page 162: ...move 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 can be damaged if they are k...

Page 163: ...or Torque specifications Drive motor mounting fasteners dry 75 ft lbs 101 7 Nm Drive motor mounting fasteners lubricated 56 ft lbs 76 3 Nm 8 2 Steer Cylinder How to Remove the Steer Cylinder When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque ...

Page 164: ...r links 3 Center a lifting jack under the drive chassis at the steer end 4 Raise the machine approximately 14 inches 36 cm Place blocks under the chassis for support Crushing hazard The chassis could 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 Note While removing the bellcrank from the machine take note of the ...

Page 165: ...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 7 Raise the machine approximately 2 inches 5 cm Place blocks under the chassis for support Crushing hazard The chassis could fall if not properly supported 8 Remove the wheel castle nut Remove the wheel 9 Tag disconnect and plug the hydraulic hose from the brake Cap the fi...

Page 166: ...nd pump L Manual brake release 30 ft lbs 41 Nm 2 Needle valve M Manual brake release enable 45 50 in lbs 5 Nm Brake Release Hand Pump Components 10 1 Brake Release Hand Pump Components The brake release hand pump manifold is mounted behind the entry ladder L M Note alpha callouts refer to corresponding notes on the hydraulic schematic 1 2 ...

Page 167: ...isconnect the pressure transducer from the outrigger cylinder Plug the fitting on the cylinder 6 Tag disconnect and plug the hydraulic hoses from the outrigger 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 ...

Page 168: ...he 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 7 Support and secure the outrigger cylinder to a suitable lifting device 8 Remove the outrigger cylinder mounting fasteners 9 Remove the outrigger cylinder from the machine C...

Page 169: ...ove all rings watches and other jewelry 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 Fault Codes Observe and Obey Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately ...

Page 170: ...a fault code is displayed The codes listed in the Fault Code Chart describe malfunctions and can aid in troubleshooting the machine by pinpointing the area or component affected Malfunction discovered Identify symptoms Troubleshoot Perform repair Return to service problem solved problem still exists Inspect and test Fault Code Note If the machine will not drive or lift but the readout is powered a...

Page 171: ...oning drive enable switch Troubleshoot drive enable switch 47 Platform joystick fault Joystick potentiometer not centered Verify potentiometer setting 52 Forward coil fault Malfunctioning coil OR wire disconnected from coil Troubleshoot coil OR inspect wire connection 53 Reverse coil fault Malfunctioning coil OR wire disconnected from coil Troubleshoot coil OR inspect wire connection 54 Up coil fa...

Page 172: ... a audible alarm that provide information about the outrigger operating status and about malfunctions The codes listed in the Outrigger Fault Code Chart describe malfunctions and can aid in troubleshooting the machine by pinpointing the area or component affected Outrigger Control Pad a lift enable b lift error c right front outrigger d right rear outrigger e left rear outrigger f left front outri...

Page 173: ...oot coil OR inspect wire connection Left front outrigger light blinks red 3 times Left front outrigger pressure transducer fault Ground short OR wire disconnected from pressure transducer Inspect wire connection Right front outrigger light blinks red 3 times Right front outrigger pressure transducer fault Ground short OR wire disconnected from pressure transducer Inspect wire connection Right rear...

Page 174: ... wire connection All lights turn red on initial power up and the alarm sounds No calibration data Outrigger level sensor and pressure transducers not calibrated Calibrate the outrigger level sensor and pressure transducers During operation all lights turn red and all functions cut out Motor controller fault Motor controller throttle short Troubleshoot the harness to the motor controller OR replace...

Page 175: ...tools and test equipment are available and ready for use AboutThis Section There are two groups of schematics in this section An illustration legend precedes each group of drawings Electrical Schematics Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Hydraulic Schematics Bodily injury hazard Spr...

Page 176: ...d NCHO Normally closed held open NOHC Normally open held closed ELECTRICAL COMPONENT LEGEND cont Item Description Power switch P P1 Emergency Stop button at ground controls P2 Emergency Stop button at platform controls PS2 Platform overload pressure switch option Pressure transducer PT PT1 Left front outrigger GS 3232 PT2 Right front outrigger GS 3232 PT3 Right rear outrigger GS 3232 PT4 Left rear...

Page 177: ...LOR LEGEND Color Description BK Black BL Blue BL BK Blue Black BL WH Blue White BN Brown GN Green GN BK Green Black GN WH Green White GY Gray OR Orange OR BK Orange Black OR WH Orange White PP Purple RD Red RD BK Red Black RD WH Red White WH White WH BK White Black Wire Color Legend ...

Page 178: ... B1 Platform data link high input Blue wire at platform controls B2 Plug B3 ECM ground output B4 Plug B5 Plug B6 Platform down coil Y7 output B7 Steer left coil Y4 output B8 Automotive style horn H2 option output B9 Multi function alarm H5 output B10 Pothole limit switch input B11 Drive enable power up limit switch input B12 Platform up TS66 input C1 Platform data link low input Orange wire at pla...

Page 179: ...controller output A12 Ground for platform controller output B1 Outrigger ECM ground input B2 Plug B3 Plug B4 Motor controller throttle output B5 Motor controller enable input B6 Height limit signal input B7 Down limit switch LS66 input B8 Key switch KS1 input B9 Up signal from Gen 5 ECM U5 input B10 Drive reverse Y5 input B11 Drive forward Y6 input B12 24V A C1 24V B C2 Plug C3 Outrigger retract Y...

Page 180: ...M PIN C11 GROUND RD BK RD GN BN BK NOT USED CR48 TERMINAL 87 LEVEL SENSOR HARNESS CE MODELS AND ANSI CSA MODELS WITH PLATFORM OVERLOAD 21 22 NCHO ECM PIN B6 CR27D TERMINALS 85 87 AND 87A 2 LS6 DOWN LIMIT SWITCH SHOWN IN STOWED POSITION 13 14 S7 LEVEL SENSOR BK RD WH OR BK H5 MULTI FUNCTION ALARM 1 ECM PIN B9 BL BK WH CR48 TERMINAL 87 G6 HOUR METER NC P1 EMERGENCY STOP TS66 PLATFORM UP DOWN TOGGLE ...

Page 181: ...C1 JOYSTICK CONTROLLER RD BK OR WH WH BL PP BL GY BN YL GY WH RD BL OR TO COIL CORD RD BK RD BK PLATFORM CONTROLS GEN 5 TO COIL CORD U36 OUTRIGGER PLATFORM CONTROL CIRCUIT BOARD BN105 OUTRIGGER EXTEND BN106 FUNCTION ENABLE BN107 OUTRIGGER RETRACT L51 LF OUTRIGGER L52 RF OUTRIGGER L53 LR OUTRIGGER L54 RR OUTRIGGER L69 LIFT ENABLE L70 LIFT ERROR BK WH GN RD OUTRIGGER CONTROL PAD GS 3232 ...

Page 182: ...aximum height limit switch LS5 CE models b down limit switch LS6 c pothole switches LS7 LS8 d 22 ft 6 7 m maximum drive height when outriggers are not deployed LS5A GS 3232 Limit Switch Legend c GS 2032 GS 2632 GS 3232 GS 2046 GS 2646 GS 3246 GS 1530 GS 1532 GS 1930 GS 1932 ALL MODELS c c d a b b a ...

Page 183: ...ts crossing no connection Diode Circuits connection Hourmeter Light or flashingbeacon Pressure switch normallyopen Limit switch Button or switch Emergency stop button Circuitbreaker Motorcontroller Toggle switch Connector Fuse Hornoralarm Motor Batterycharger 6V DC Battery Level sensor Solenoidvalve Solenoid valve with diode Capacitor Key switch Joystick Contactor Resistor ...

Page 184: ...08 6 10 GS 30 GS 32 GS 46 Part No 97385 Electrical Schematic ANSI CSA and Australia Models GS 1530 1532 1930 1932 from serial number GS3005A 76000 to GS3006A 83067 GS 1530 1532 1930 1932 from serial number GS3005B 76000 to GS3006B 79659 ...

Page 185: ...RSE Y6 DRIVE FORWARD Y7 PLATFORM DOWN Y8 PLATFORM UP GND 85 87 86 30 GND FROM JOYSTICK IN A2 DRIVER POWER A4 IN LVL SNSR WHT LVL SNSR RED IN OUT C11 A5 RD WH BK S7 LEVEL SENSOR LEVEL SENSOR CIRCUIT BOARD 3 1 2 5 RD 4 WH DATA LINK LOW DATA LINK HIGH IN IN B1 C1 UP LIMIT SWITCH 3 1 2 5 4 QD4 4 NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF U5 ELECTRONIC CONTROL MODULE BL BK RD OR WH WH...

Page 186: ...PIN3 LIFT ENABLE BN9 PIN4 DRIVE LED L17 LIFT LED L16 POUT4 POUT2 POUT3 HIGH TORQUE LED L21 POUT1 PLATFORM CONTROLS MEMBRANE DECAL H1 ALARM POUT11 PIN11 RD BK BK P2 EMERGENCY STOP BK RD PIO3 PIO5 PIO4 DATA LINK LOW DATA LINK HIGH GROUND POWER TO GROUND POWER TO PLATFORM BK 3 3 RD 4 4 WH 1 1 BL 2 2 OR 5 5 QD3 D7 VOLTAGE REGULATOR 5V DC 24V DC PIO2 U3 PLATFORM CONTROLS PRINTED CIRCUIT BOARD GY GN BN ...

Page 187: ...Section 6 Schematics April 2008 Part No 97385 GS 30 GS 32 GS 46 6 13 This page intentionally left blank ...

Page 188: ...08 6 14 GS 30 GS 32 GS 46 Part No 97385 Electrical Schematic ANSI CSA and Australia Models GS 1530 1532 1930 1932 from serial number GS3006A 83068 to GS3007A 87490 GS 1530 1532 1930 1932 from serial number GS3006B 79660 to GS3007B 82543 ...

Page 189: ...RSE Y6 DRIVE FORWARD Y7 PLATFORM DOWN Y8 PLATFORM UP GND 85 87 86 30 GND FROM JOYSTICK IN A2 DRIVER POWER A4 IN LVL SNSR WHT LVL SNSR RED IN OUT C11 A5 RD WH BK N O S7 LEVEL SENSOR LEVEL SENSOR CIRCUIT BOARD 3 1 2 5 RD 4 WH DATA LINK LOW DATA LINK HIGH IN IN B1 C1 UP LIMIT SWITCH 3 1 2 5 4 QD4 4 NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF U5 ELECTRONIC CONTROL MODULE BL BK RD OR W...

Page 190: ...PIN3 LIFT ENABLE BN9 PIN4 DRIVE LED L17 LIFT LED L16 POUT4 POUT2 POUT3 HIGH TORQUE LED L21 POUT1 PLATFORM CONTROLS MEMBRANE DECAL H1 ALARM POUT11 PIN11 RD BK BK P2 EMERGENCY STOP BK RD PIO3 PIO5 PIO4 DATA LINK LOW DATA LINK HIGH GROUND POWER TO GROUND POWER TO PLATFORM BK 3 3 RD 4 4 WH 1 1 BL 2 2 OR 5 5 QD3 D7 VOLTAGE REGULATOR 5V DC 24V DC PIO2 U3 PLATFORM CONTROLS PRINTED CIRCUIT BOARD GY GN BN ...

Page 191: ...Section 6 Schematics April 2008 Part No 97385 GS 30 GS 32 GS 46 6 17 This page intentionally left blank ...

Page 192: ...08 6 18 GS 30 GS 32 GS 46 Part No 97385 Electrical Schematic ANSI CSA and Australia Models GS 1530 1532 1930 1932 from serial number GS3007A 87491 to GS3007A 89537 GS 1530 1532 1930 1932 from serial number GS3007B 82544 to GS3007B 84599 ...

Page 193: ...EVERSE Y6 DRIVE FORWARD Y7 PLATFORM DOWN Y8 PLATFORM UP GND 85 87 86 30 GND FROM JOYSTICK IN A2 ECM POWER C2 IN LVL SNSR WHT LVL SNSR RED IN OUT C11 A5 RD WH BK N O S7 LEVEL SENSOR LEVEL SENSOR CIRCUIT BOARD 3 1 2 5 RD 4 WH DATA LINK LOW DATA LINK HIGH IN IN B1 C1 UP LIMIT SWITCH 3 1 2 5 4 QD4 4 NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF U5 ELECTRONIC CONTROL MODULE BL BK RD OR W...

Page 194: ...PIN3 LIFT ENABLE BN9 PIN4 DRIVE LED L17 LIFT LED L16 POUT4 POUT2 POUT3 HIGH TORQUE LED L21 POUT1 PLATFORM CONTROLS MEMBRANE DECAL H1 ALARM POUT11 PIN11 RD BK BK P2 EMERGENCY STOP BK RD PIO3 PIO5 PIO4 DATA LINK LOW DATA LINK HIGH GROUND POWER TO GROUND POWER TO PLATFORM BK 3 3 RD 4 4 WH 1 1 BL 2 2 OR 5 5 QD3 D7 VOLTAGE REGULATOR 5V DC 24V DC PIO2 U3 PLATFORM CONTROLS PRINTED CIRCUIT BOARD GY GN BN ...

Page 195: ...Section 6 Schematics April 2008 Part No 97385 GS 30 GS 32 GS 46 6 21 This page intentionally left blank ...

Page 196: ...2012 6 22 GS 30 GS 32 GS 46 Part No 97385 Electrical Schematic ANSI CSA and Australia Models GS 1530 1532 1930 1932 from serial number GS3007A 89538 to GS3010A 99455 GS 1530 1532 1930 1932 from serial number GS3007B 84600 to GS3009B 98941 ...

Page 197: ...RONIC CONTROL MODULE WH BL RD BK WH BK C8 OUT Y1 PARALLEL GN BK Y9 PLATFORM DOWN GS 3246 IN B11 GND FROM JOYSTICK IN A2 LVL SNSR WHT LVL SNSR RED IN OUT C11 A5 RD WH BK N O S7 LEVEL SENSOR LEVEL SENSOR CIRCUIT BOARD 3 1 2 5 RD 4 WH DATA LINK LOW DATA LINK HIGH IN IN B1 C1 UP LIMIT SWITCH 3 1 2 5 4 QD4 BL BK RD OR WH BL BK OR GN RD OR BK C2 IN BK IN A4 WH ECM POWER DRIVER POWER UP COIL REVERSE FORW...

Page 198: ...5 IN MC THROTTLE GROUND MC ENABLE 24V KS1 DRIVE ENABLE DOWN LIM UP IN FORWARD REVERSE UP COIL L69 LIFT ENABLE L52 FR OUTRIGGER L54 RR OUTRIGGER L53 RL OUTRIGGER L51 FL OUTRIGGER U39 CPU U40 POWER SUPPLY CHIP BN105 BN107 BN106 LS5A UP LIMIT SWITCH N C A1 IN SWITCH POWER A11 OUT A10 IN A9 IN GROUND TO PLAT POWER TO PLAT DATA LOW DATA HIGH IN B12 C9 OUT C1 IN 1 4 3 2 WH GN RD BL BL OR BL WH OR WH RD ...

Page 199: ...D POWER TO GROUND POWER TO PLATFORM BK 3 3 RD 4 4 WH 1 1 BL 2 2 OR 5 5 QD3 D7 VOLTAGE REGULATOR 5V DC 24V DC PIO2 U3 PLATFORM CONTROLS PRINTED CIRCUIT BOARD GY GN BN WH PP PIN8 PIN10 PIN9 OR BK RD JC1 JOYSTICK CONTROLLER BL SW6 STEER LEFT RIGHT LEFT RIGHT SW5 FUNCTION ENABLE HALL EFFECT GENERATOR G8 DIAGNOSTIC DISPLAY ES0141P NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF Electrical ...

Page 200: ...REV A Section 6 Schematics February 2012 6 26 GS 30 GS 32 GS 46 Part No 97385 Electrical Schematic ANSI CSA and Australia Models GS 1530 1532 1930 1932 from serial number GS3010A 99456 to GS3011A 109999 ...

Page 201: ...REV A Section 6 Schematics February 2012 Part No 97385 GS 30 GS 32 GS 46 6 27 Electrical Schematic ANSI CSA and Australia Models GS 1530 1532 1930 1932 from serial number GS3010A 99456 to GS3011A 109999 ...

Page 202: ...REV A Section 6 Schematics February 2012 6 28 GS 30 GS 32 GS 46 Part No 97385 Electrical Schematic ANSI CSA and Australia Models GS 1530 1532 1930 1932 from serial number GS3010A 99456 to GS3011A 109999 ...

Page 203: ...REV A Section 6 Schematics February 2012 Part No 97385 GS 30 GS 32 GS 46 6 29 Electrical Schematic ANSI CSA and Australia Models GS 1530 1532 1930 1932 from serial number GS3010A 99456 to GS3011A 109999 ...

Page 204: ...s April 2008 6 30 GS 30 GS 32 GS 46 Part No 97385 Electrical Schematic ANSI CSA and Australia Models GS 2032 2632 from serial number GS3205 75407 to GS3206 79991 GS 2046 2646 3246 from serial number GS4605 75438 to GS4606 78915 ...

Page 205: ...VE FORWARD Y7 PLATFORM DOWN Y8 PLATFORM UP GND 85 87 86 30 GND FROM JOYSTICK IN A2 DRIVER POWER A4 IN LVL SNSR WHT LVL SNSR RED IN OUT C11 A5 RD WH BK S7 LEVEL SENSOR LEVEL SENSOR CIRCUIT BOARD 3 1 2 5 RD 4 WH DATA LINK LOW DATA LINK HIGH IN IN B1 C1 UP LIMIT SWITCH 3 1 2 5 4 QD4 4 NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF U5 ELECTRONIC CONTROL MODULE BL BK RD OR WH WH BL BK OR ...

Page 206: ... ENABLE BN9 PIN4 DRIVE LED L17 LIFT LED L16 POUT4 POUT2 POUT3 HIGH TORQUE LED L21 POUT1 PLATFORM CONTROLS MEMBRANE DECAL H1 ALARM POUT11 PIN11 RD BK BK P2 EMERGENCY STOP BK RD PIO3 PIO5 PIO4 DATA LINK LOW DATA LINK HIGH GROUND POWER TO GROUND POWER TO PLATFORM BK 3 3 RD 4 4 WH 1 1 BL 2 2 OR 5 5 QD3 D7 VOLTAGE REGULATOR 5V DC 24V DC PIO2 U3 PLATFORM CONTROLS PRINTED CIRCUIT BOARD GY GN BN WH PP PIN...

Page 207: ...Section 6 Schematics April 2008 Part No 97385 GS 30 GS 32 GS 46 6 33 This page intentionally left blank ...

Page 208: ...s April 2008 6 34 GS 30 GS 32 GS 46 Part No 97385 Electrical Schematic ANSI CSA and Australia Models GS 2032 2632 from serial number GS3206 79992 to GS3207 83650 GS 2046 2646 3246 from serial number GS4606 78916 to GS4607 82535 ...

Page 209: ...VE FORWARD Y7 PLATFORM DOWN Y8 PLATFORM UP GND 85 87 86 30 GND FROM JOYSTICK IN A2 DRIVER POWER A4 IN LVL SNSR WHT LVL SNSR RED IN OUT C11 A5 RD WH BK N O S7 LEVEL SENSOR LEVEL SENSOR CIRCUIT BOARD 3 1 2 5 RD 4 WH DATA LINK LOW DATA LINK HIGH IN IN B1 C1 UP LIMIT SWITCH 3 1 2 5 4 QD4 4 NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF U5 ELECTRONIC CONTROL MODULE BL BK RD OR WH WH BL BK...

Page 210: ... ENABLE BN9 PIN4 DRIVE LED L17 LIFT LED L16 POUT4 POUT2 POUT3 HIGH TORQUE LED L21 POUT1 PLATFORM CONTROLS MEMBRANE DECAL H1 ALARM POUT11 PIN11 RD BK BK P2 EMERGENCY STOP BK RD PIO3 PIO5 PIO4 DATA LINK LOW DATA LINK HIGH GROUND POWER TO GROUND POWER TO PLATFORM BK 3 3 RD 4 4 WH 1 1 BL 2 2 OR 5 5 QD3 D7 VOLTAGE REGULATOR 5V DC 24V DC PIO2 U3 PLATFORM CONTROLS PRINTED CIRCUIT BOARD GY GN BN WH PP PIN...

Page 211: ...Section 6 Schematics April 2008 Part No 97385 GS 30 GS 32 GS 46 6 37 This page intentionally left blank ...

Page 212: ...s April 2008 6 38 GS 30 GS 32 GS 46 Part No 97385 Electrical Schematic ANSI CSA and Australia Models GS 2032 2632 from serial number GS3207 83651 to GS3207 84866 GS 2046 2646 3246 from serial number GS4607 82536 to GS4607 84839 ...

Page 213: ...DRIVE FORWARD Y7 PLATFORM DOWN Y8 PLATFORM UP GND 85 87 86 30 GND FROM JOYSTICK IN A2 ECM POWER C2 IN LVL SNSR WHT LVL SNSR RED IN OUT C11 A5 RD WH BK N O S7 LEVEL SENSOR LEVEL SENSOR CIRCUIT BOARD 3 1 2 5 RD 4 WH DATA LINK LOW DATA LINK HIGH IN IN B1 C1 UP LIMIT SWITCH 3 1 2 5 4 QD4 4 NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF U5 ELECTRONIC CONTROL MODULE BL BK RD OR WH WH BL BK...

Page 214: ... ENABLE BN9 PIN4 DRIVE LED L17 LIFT LED L16 POUT4 POUT2 POUT3 HIGH TORQUE LED L21 POUT1 PLATFORM CONTROLS MEMBRANE DECAL H1 ALARM POUT11 PIN11 RD BK BK P2 EMERGENCY STOP BK RD PIO3 PIO5 PIO4 DATA LINK LOW DATA LINK HIGH GROUND POWER TO GROUND POWER TO PLATFORM BK 3 3 RD 4 4 WH 1 1 BL 2 2 OR 5 5 QD3 D7 VOLTAGE REGULATOR 5V DC 24V DC PIO2 U3 PLATFORM CONTROLS PRINTED CIRCUIT BOARD GY GN BN WH PP PIN...

Page 215: ...Section 6 Schematics April 2008 Part No 97385 GS 30 GS 32 GS 46 6 41 This page intentionally left blank ...

Page 216: ...uary 2012 6 42 GS 30 GS 32 GS 46 Part No 97385 Electrical Schematic ANSI CSA and Australia Models GS 2032 2632 3232 from serial number GS3207A 84867 to GS3210A 94974 GS 2046 2646 3246 from serial number GS4607A 84840 to GS4610A 95454 ...

Page 217: ... CONTROL MODULE WH BL RD BK WH BK C8 OUT Y1 PARALLEL GN BK Y9 PLATFORM DOWN GS 3246 IN B11 GND FROM JOYSTICK IN A2 LVL SNSR WHT LVL SNSR RED IN OUT C11 A5 RD WH BK N O S7 LEVEL SENSOR LEVEL SENSOR CIRCUIT BOARD 3 1 2 5 RD 4 WH DATA LINK LOW DATA LINK HIGH IN IN B1 C1 UP LIMIT SWITCH 3 1 2 5 4 QD4 BL BK RD OR WH BL BK OR GN RD OR BK C2 IN BK IN A4 WH ECM POWER DRIVER POWER UP COIL REVERSE FORWARD U...

Page 218: ...OIL B5 IN MC THROTTLE GROUND MC ENABLE 24V KS1 DRIVE ENABLE DOWN LIM UP IN FORWARD REVERSE UP COIL L69 LIFT ENABLE L52 FR OUTRIGGER L54 RR OUTRIGGER L53 RL OUTRIGGER L51 FL OUTRIGGER U39 CPU U40 POWER SUPPLY CHIP BN105 BN107 BN106 LS5A UP LIMIT SWITCH N C A1 IN SWITCH POWER A11 OUT A10 IN A9 IN GROUND TO PLAT POWER TO PLAT DATA LOW DATA HIGH IN B12 C9 OUT C1 IN 1 4 3 2 WH GN RD BL BL OR BL WH OR W...

Page 219: ...GROUND POWER TO GROUND POWER TO PLATFORM BK 3 3 RD 4 4 WH 1 1 BL 2 2 OR 5 5 QD3 D7 VOLTAGE REGULATOR 5V DC 24V DC PIO2 U3 PLATFORM CONTROLS PRINTED CIRCUIT BOARD GY GN BN WH PP PIN8 PIN10 PIN9 OR BK RD JC1 JOYSTICK CONTROLLER BL SW6 STEER LEFT RIGHT LEFT RIGHT SW5 FUNCTION ENABLE HALL EFFECT GENERATOR G8 DIAGNOSTIC DISPLAY ES0141P NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF Electr...

Page 220: ...uary 2012 6 46 GS 30 GS 32 GS 46 Part No 97385 Electrical Schematic ANSI CSA and Australia Models GS 2032 2632 3232 from serial number GS3210A 94975 to GS3211A 97903 GS 2046 2646 3246 from serial number GS4610A 95455 to GS4611A 97982 ...

Page 221: ...uary 2012 Part No 97385 GS 30 GS 32 GS 46 6 47 Electrical Schematic ANSI CSA and Australia Models GS 2032 2632 3232 from serial number GS3210A 94975 to GS3211A 97903 GS 2046 2646 3246 from serial number GS4610A 95455 to GS4611A 97982 ...

Page 222: ...uary 2012 6 48 GS 30 GS 32 GS 46 Part No 97385 Electrical Schematic ANSI CSA and Australia Models GS 2032 2632 3232 from serial number GS3210A 94975 to GS3211A 97903 GS 2046 2646 3246 from serial number GS4610A 95455 to GS4611A 97982 ...

Page 223: ...uary 2012 Part No 97385 GS 30 GS 32 GS 46 6 49 Electrical Schematic ANSI CSA and Australia Models GS 2032 2632 3232 from serial number GS3210A 94975 to GS3211A 97903 GS 2046 2646 3246 from serial number GS4610A 95455 to GS4611A 97982 ...

Page 224: ...ary 2012 6 50 GS 30 GS 32 GS 46 Part No 97385 Electrical Schematic ANSI CSA and Australia Models GS 2032 2632 3232 from serial number GS3211A 97904 to GS3212A 109999 GS 2046 2646 3246 from serial number GS4611A 97983 to GS4612A 109999 ...

Page 225: ...ary 2012 Part No 97385 GS 30 GS 32 GS 46 6 51 Electrical Schematic ANSI CSA and Australia Models GS 2032 2632 3232 from serial number GS3211A 97904 to GS3212A 109999 GS 2046 2646 3246 from serial number GS4611A 97983 to GS4612A 109999 ...

Page 226: ...ary 2012 6 52 GS 30 GS 32 GS 46 Part No 97385 Electrical Schematic ANSI CSA and Australia Models GS 2032 2632 3232 from serial number GS3211A 97904 to GS3212A 109999 GS 2046 2646 3246 from serial number GS4611A 97983 to GS4612A 109999 ...

Page 227: ...ary 2012 Part No 97385 GS 30 GS 32 GS 46 6 53 Electrical Schematic ANSI CSA and Australia Models GS 2032 2632 3232 from serial number GS3211A 97904 to GS3212A 109999 GS 2046 2646 3246 from serial number GS4611A 97983 to GS4612A 109999 ...

Page 228: ...s April 2008 6 54 GS 30 GS 32 GS 46 Part No 97385 Electrical Schematic CE Models GS 1530 1532 1930 1932 from serial number GS3005A 76000 to GS3005A 76388 GS 1530 1532 1930 1932 from serial number GS3005B 76000 to GS3005B 76030 ...

Page 229: ...VERLOAD MOTOR CONT LS6 DOWN LIMIT SWITCH IN IN IN C12 DWN LIMIT N C H O N O H C B11 OUT A6 85 87 86 30 85 87 86 30 CR27C OVERLOAD DOWN COIL CR27D OVERLOAD DOWN DELAY OUT B6 85 87 86 30 85 87A 87 86 30 N C N C IN A10 CR27B OVERLOAD LOAD SENSE 85 87A 86 30 GND FROM JOYSTICK IN A2 IN LVL SNSR WHT LVL SNSR RED IN OUT C11 A5 RD WH BK S7 LEVEL SENSOR LEVEL SENSOR CIRCUIT BOARD 3 1 2 5 RD 4 WH LS5 UP LIM...

Page 230: ...ENABLE BN9 PIN4 DRIVE LED L17 LIFT LED L16 POUT4 POUT2 POUT3 HIGH TORQUE LED L21 POUT1 PLATFORM CONTROLS MEMBRANE DECAL H1 ALARM POUT11 PIN11 RD BK BK P2 EMERGENCY STOP BK RD PIO3 PIO5 PIO4 DATA LINK LOW DATA LINK HIGH GROUND POWER TO GROUND POWER TO PLATFORM BK 3 3 RD 4 4 WH 1 1 BL 2 2 OR 5 5 QD3 D7 VOLTAGE REGULATOR 5V DC 24V DC PIO2 U3 PLATFORM CONTROLS PRINTED CIRCUIT BOARD GY GN BN WH PP PIN8...

Page 231: ...Section 6 Schematics April 2008 Part No 97385 GS 30 GS 32 GS 46 6 57 This page intentionally left blank ...

Page 232: ...s April 2008 6 58 GS 30 GS 32 GS 46 Part No 97385 Electrical Schematic CE Models GS 1530 1532 1930 1932 from serial number GS3005A 76389 to GS3005A 79394 GS 1530 1532 1930 1932 from serial number GS3005B 76031 to GS3005B 76920 ...

Page 233: ...AD MOTOR CONT LS6 DOWN LIMIT SWITCH IN IN C12 DWN LIMIT N C H O N O H C B11 OUT A9 OUT A6 85 87 86 30 85 87 86 30 CR27C OVERLOAD DOWN COIL CR27D OVERLOAD DOWN DELAY OUT B6 85 87 86 30 85 87A 87 86 30 N C N C IN A10 CR27B OVERLOAD LOAD SENSE 85 87A 86 30 GND FROM JOYSTICK IN A2 LVL SNSR WHT LVL SNSR RED IN OUT C11 A5 RD WH BK S7 LEVEL SENSOR LEVEL SENSOR CIRCUIT BOARD 3 1 2 5 RD 4 WH LS5 UP LIMIT S...

Page 234: ...N9 PIN4 DRIVE LED L17 LIFT LED L16 POUT4 POUT2 POUT3 HIGH TORQUE LED L21 POUT1 PLATFORM CONTROLS MEMBRANE DECAL H1 ALARM POUT11 PIN11 RD BK BK P2 EMERGENCY STOP BK RD PIO3 PIO5 PIO4 DATA LINK LOW DATA LINK HIGH GROUND POWER TO GROUND POWER TO PLATFORM BK 3 3 RD 4 4 WH 1 1 BL 2 2 OR 5 5 QD3 D7 VOLTAGE REGULATOR 5V DC 24V DC PIO2 U3 PLATFORM CONTROLS PRINTED CIRCUIT BOARD GY GN BN WH PP PIN8 PIN10 P...

Page 235: ...Section 6 Schematics April 2008 Part No 97385 GS 30 GS 32 GS 46 6 61 This page intentionally left blank ...

Page 236: ...s April 2008 6 62 GS 30 GS 32 GS 46 Part No 97385 Electrical Schematic CE Models GS 1530 1532 1930 1932 from serial number GS3005A 79395 to GS3006A 83067 GS 1530 1532 1930 1932 from serial number GS3005B 76921 to GS3006B 79659 ...

Page 237: ... LIMIT SWITCH IN IN C12 DWN LIMIT N C H O N O H C B11 OUT A6 85 87 86 30 85 87 86 30 CR27C OVERLOAD DOWN COIL CR27D OVERLOAD DOWN DELAY OUT B6 85 87 86 30 85 87A 87 86 30 N C N C IN A10 CR27B OVERLOAD LOAD SENSE 85 87A 86 30 GND FROM JOYSTICK IN A2 LVL SNSR WHT LVL SNSR RED IN OUT C11 A5 RD WH BK N O S7 LEVEL SENSOR LEVEL SENSOR CIRCUIT BOARD 3 1 2 5 RD 4 WH LS5 UP LIMIT SWITCH DATA LINK LOW DATA ...

Page 238: ...ENABLE BN9 PIN4 DRIVE LED L17 LIFT LED L16 POUT4 POUT2 POUT3 HIGH TORQUE LED L21 POUT1 PLATFORM CONTROLS MEMBRANE DECAL H1 ALARM POUT11 PIN11 RD BK BK P2 EMERGENCY STOP BK RD PIO3 PIO5 PIO4 DATA LINK LOW DATA LINK HIGH GROUND POWER TO GROUND POWER TO PLATFORM BK 3 3 RD 4 4 WH 1 1 BL 2 2 OR 5 5 QD3 D7 VOLTAGE REGULATOR 5V DC 24V DC PIO2 U3 PLATFORM CONTROLS PRINTED CIRCUIT BOARD GY GN BN WH PP PIN8...

Page 239: ...Section 6 Schematics April 2008 Part No 97385 GS 30 GS 32 GS 46 6 65 This page intentionally left blank ...

Page 240: ...s April 2008 6 66 GS 30 GS 32 GS 46 Part No 97385 Electrical Schematic CE Models GS 1530 1532 1930 1932 from serial number GS3006A 83068 to GS3007A 87490 GS 1530 1532 1930 1932 from serial number GS3006B 79660 to GS3007B 82543 ...

Page 241: ...N LIMIT N C H O N O H C B11 OUT A6 85 87 86 30 85 87 86 30 CR27C OVERLOAD DOWN COIL CR27D OVERLOAD DOWN DELAY OUT B6 85 87 86 30 85 87A 87 86 30 N C N C IN A10 CR27B OVERLOAD LOAD SENSE 85 87A 86 30 GND FROM JOYSTICK IN A2 LVL SNSR WHT LVL SNSR RED IN OUT C11 A5 RD WH BK N O S7 LEVEL SENSOR LEVEL SENSOR CIRCUIT BOARD 3 1 2 5 RD 4 WH LS5 UP LIMIT SWITCH DATA LINK LOW DATA LINK HIGH IN IN B1 C1 UP L...

Page 242: ...ENABLE BN9 PIN4 DRIVE LED L17 LIFT LED L16 POUT4 POUT2 POUT3 HIGH TORQUE LED L21 POUT1 PLATFORM CONTROLS MEMBRANE DECAL H1 ALARM POUT11 PIN11 RD BK BK P2 EMERGENCY STOP BK RD PIO3 PIO5 PIO4 DATA LINK LOW DATA LINK HIGH GROUND POWER TO GROUND POWER TO PLATFORM BK 3 3 RD 4 4 WH 1 1 BL 2 2 OR 5 5 QD3 D7 VOLTAGE REGULATOR 5V DC 24V DC PIO2 U3 PLATFORM CONTROLS PRINTED CIRCUIT BOARD GY GN BN WH PP PIN8...

Page 243: ...Section 6 Schematics April 2008 Part No 97385 GS 30 GS 32 GS 46 6 69 This page intentionally left blank ...

Page 244: ...s April 2008 6 70 GS 30 GS 32 GS 46 Part No 97385 Electrical Schematic CE Models GS 1530 1532 1930 1932 from serial number GS3007A 87491 to GS3007A 89537 GS 1530 1532 1930 1932 from serial number GS3007B 82544 to GS3007B 84599 ...

Page 245: ...N LIMIT N C H O N O H C B11 OUT A6 85 87 86 30 85 87 86 30 CR27C OVERLOAD DOWN COIL CR27D OVERLOAD DOWN DELAY OUT B6 85 87 86 30 85 87A 87 86 30 N C N C IN A10 CR27B OVERLOAD LOAD SENSE 85 87A 86 30 GND FROM JOYSTICK IN A2 LVL SNSR WHT LVL SNSR RED IN OUT C11 A5 RD WH BK N O S7 LEVEL SENSOR LEVEL SENSOR CIRCUIT BOARD 3 1 2 5 RD 4 WH LS5 UP LIMIT SWITCH DATA LINK LOW DATA LINK HIGH IN IN B1 C1 UP L...

Page 246: ...ENABLE BN9 PIN4 DRIVE LED L17 LIFT LED L16 POUT4 POUT2 POUT3 HIGH TORQUE LED L21 POUT1 PLATFORM CONTROLS MEMBRANE DECAL H1 ALARM POUT11 PIN11 RD BK BK P2 EMERGENCY STOP BK RD PIO3 PIO5 PIO4 DATA LINK LOW DATA LINK HIGH GROUND POWER TO GROUND POWER TO PLATFORM BK 3 3 RD 4 4 WH 1 1 BL 2 2 OR 5 5 QD3 D7 VOLTAGE REGULATOR 5V DC 24V DC PIO2 U3 PLATFORM CONTROLS PRINTED CIRCUIT BOARD GY GN BN WH PP PIN8...

Page 247: ...Section 6 Schematics April 2008 Part No 97385 GS 30 GS 32 GS 46 6 73 This page intentionally left blank ...

Page 248: ...atics February 2012 6 74 GS 30 GS 32 GS 46 Part No 97385 Electrical Schematic CE Models GS 1530 32 1930 32 from serial number GS3007A 89538 to GS3010A 99455 and GS3007B 84600 to GS3009B 98941 and GS3008C 101 to GS3010C 2189 ...

Page 249: ... B6 85 87 86 30 85 87A 87 86 30 N C N C IN A10 CR27B OVERLOAD LOAD SENSE 85 87A 86 30 GND FROM JOYSTICK IN A2 LVL SNSR WHT LVL SNSR RED IN OUT C11 A5 RD WH BK N O S7 LEVEL SENSOR LEVEL SENSOR CIRCUIT BOARD 3 1 2 5 RD 4 WH LS5 UP LIMIT SWITCH DATA LINK LOW DATA LINK HIGH IN IN B1 C1 UP LIMIT SWITCH 3 1 2 5 4 QD4 1 4 2 3 5 BL BK RD OR WH BL BK OR GN RD BL BK WH GN BK RD BK C5 4700 uF ES0142P R24 25 ...

Page 250: ...MC ENABLE MC THROTTLE UP COIL B5 IN MC THROTTLE GROUND MC ENABLE 24V KS1 DRIVE ENABLE DOWN LIM UP IN FORWARD REVERSE UP COIL L69 LIFT ENABLE L52 FR OUTRIGGER L54 RR OUTRIGGER L53 RL OUTRIGGER L51 FL OUTRIGGER U39 CPU U40 POWER SUPPLY CHIP BN107 BN106 BN105 A1 IN A11 OUT A10 IN A9 IN GROUND TO PLAT POWER TO PLAT DATA LOW DATA HIGH IN B12 C9 OUT C1 IN 1 4 3 2 WH GN RD BL BN BL OR BL WH OR WH RD WH G...

Page 251: ... LINK LOW DATA LINK HIGH GROUND POWER TO GROUND POWER TO PLATFORM BK 3 3 RD 4 4 WH 1 1 BL 2 2 OR 5 5 QD3 D7 VOLTAGE REGULATOR 5V DC 24V DC PIO2 U3 PLATFORM CONTROLS PRINTED CIRCUIT BOARD GY GN BN WH PP PIN8 PIN10 PIN9 OR BK RD JC1 JOYSTICK CONTROLLER BL SW6 STEER LEFT RIGHT LEFT RIGHT SW5 FUNCTION ENABLE HALL EFFECT GENERATOR G8 DIAGNOSTIC DISPLAY ES0142P NOTE MACHINE SHOWN IN THE STOWED POSITION ...

Page 252: ...tics February 2012 6 78 GS 30 GS 32 GS 46 Part No 97385 Electrical Schematic CE Models GS 1530 32 1930 32 from serial number GS3010A 99456 to GS3011A 109999 GS 1530 32 1930 32 from serial number GS3010C 2190 to GS3011C 5059 ...

Page 253: ...atics February 2012 Part No 97385 GS 30 GS 32 GS 46 6 79 ElectricalSchematic CE Models GS 1530 32 1930 32 from serial number GS3010A 99456 to GS3011A 109999 GS 1530 32 1930 32 from serial number GS3010C 2190 to GS3011C 5059 ...

Page 254: ...tics February 2012 6 80 GS 30 GS 32 GS 46 Part No 97385 Electrical Schematic CE Models GS 1530 32 1930 32 from serial number GS3010A 99456 to GS3011A 109999 GS 1530 32 1930 32 from serial number GS3010C 2190 to GS3011C 5059 ...

Page 255: ...atics February 2012 Part No 97385 GS 30 GS 32 GS 46 6 81 ElectricalSchematic CE Models GS 1530 32 1930 32 from serial number GS3010A 99456 to GS3011A 109999 GS 1530 32 1930 32 from serial number GS3010C 2190 to GS3011C 5059 ...

Page 256: ...REV A Section 6 Schematics February 2012 6 82 GS 30 GS 32 GS 46 Part No 97385 Electrical Schematic CE Models GS 1530 32 1930 32 from serial number GS3012C 5060 to GS3012C 5311 ...

Page 257: ...REV A Section 6 Schematics February 2012 Part No 97385 GS 30 GS 32 GS 46 6 83 ElectricalSchematic CE Models GS 1530 32 1930 32 from serial number GS3012C 5060 to GS3012C 5311 ...

Page 258: ...REV A Section 6 Schematics February 2012 6 84 GS 30 GS 32 GS 46 Part No 97385 Electrical Schematic CE Models GS 1530 32 1930 32 from serial number GS3012C 5060 to GS3012C 5311 ...

Page 259: ...REV A Section 6 Schematics February 2012 Part No 97385 GS 30 GS 32 GS 46 6 85 ElectricalSchematic CE Models GS 1530 32 1930 32 from serial number GS3012C 5060 to GS3012C 5311 ...

Page 260: ... Schematics April 2008 6 86 GS 30 GS 32 GS 46 Part No 97385 Electrical Schematic CE Models GS 2032 2632 from serial number GS3205 75407 to GS3205 77290 GS 2046 2646 3246 from serial number GS4605 75438 to GS4605 76734 ...

Page 261: ...ONT LS6 DOWN LIMIT SWITCH IN IN C12 DWN LIMIT N C H O N O H C B11 OUT A9 OUT A6 85 87 86 30 85 87 86 30 CR27C OVERLOAD DOWN COIL CR27D OVERLOAD DOWN DELAY OUT B6 85 87 86 30 85 87A 87 86 30 N C N C IN A10 CR27B OVERLOAD LOAD SENSE 85 87A 86 30 GND FROM JOYSTICK IN A2 LVL SNSR WHT LVL SNSR RED IN OUT C11 A5 RD WH BK S7 LEVEL SENSOR LEVEL SENSOR CIRCUIT BOARD 3 1 2 5 RD 4 WH LS5 UP LIMIT SWITCH DATA...

Page 262: ...RIVE LED L17 LIFT LED L16 POUT4 POUT2 POUT3 HIGH TORQUE LED L21 POUT1 PLATFORM CONTROLS MEMBRANE DECAL H1 ALARM POUT11 PIN11 RD BK BK P2 EMERGENCY STOP BK RD PIO3 PIO5 PIO4 DATA LINK LOW DATA LINK HIGH GROUND POWER TO GROUND POWER TO PLATFORM BK 3 3 RD 4 4 WH 1 1 BL 2 2 OR 5 5 QD3 D7 VOLTAGE REGULATOR 5V DC 24V DC PIO2 U3 PLATFORM CONTROLS PRINTED CIRCUIT BOARD GY GN BN WH PP PIN8 PIN10 PIN9 OR BK...

Page 263: ...Section 6 Schematics April 2008 Part No 97385 GS 30 GS 32 GS 46 6 89 This page intentionally left blank ...

Page 264: ... Schematics April 2008 6 90 GS 30 GS 32 GS 46 Part No 97385 Electrical Schematic CE Models GS 2032 2632 from serial number GS3205 77291 to GS3206 79991 GS 2046 2646 3246 from serial number GS4605 76735 to GS4606 78915 ...

Page 265: ...ITCH IN IN C12 DWN LIMIT N C H O N O H C B11 OUT A6 85 87 86 30 85 87 86 30 CR27C OVERLOAD DOWN COIL CR27D OVERLOAD DOWN DELAY OUT B6 85 87 86 30 85 87A 87 86 30 N C N C IN A10 CR27B OVERLOAD LOAD SENSE 85 87A 86 30 GND FROM JOYSTICK IN A2 LVL SNSR WHT LVL SNSR RED IN OUT C11 A5 RD WH BK N O S7 LEVEL SENSOR LEVEL SENSOR CIRCUIT BOARD 3 1 2 5 RD 4 WH LS5 UP LIMIT SWITCH DATA LINK LOW DATA LINK HIGH...

Page 266: ...9 PIN4 DRIVE LED L17 LIFT LED L16 POUT4 POUT2 POUT3 HIGH TORQUE LED L21 POUT1 PLATFORM CONTROLS MEMBRANE DECAL H1 ALARM POUT11 PIN11 RD BK BK P2 EMERGENCY STOP BK RD PIO3 PIO5 PIO4 DATA LINK LOW DATA LINK HIGH GROUND POWER TO GROUND POWER TO PLATFORM BK 3 3 RD 4 4 WH 1 1 BL 2 2 OR 5 5 QD3 D7 VOLTAGE REGULATOR 5V DC 24V DC PIO2 U3 PLATFORM CONTROLS PRINTED CIRCUIT BOARD GY GN BN WH PP PIN8 PIN10 PI...

Page 267: ...Section 6 Schematics April 2008 Part No 97385 GS 30 GS 32 GS 46 6 93 This page intentionally left blank ...

Page 268: ... Schematics April 2008 6 94 GS 30 GS 32 GS 46 Part No 97385 Electrical Schematic CE Models GS 2032 2632 from serial number GS3206 79992 to GS3207 83650 GS 2046 2646 3246 from serial number GS4606 78916 to GS4607 82535 ...

Page 269: ... C H O N O H C B11 OUT A6 85 87 86 30 85 87 86 30 CR27C OVERLOAD DOWN COIL CR27D OVERLOAD DOWN DELAY OUT B6 85 87 86 30 85 87A 87 86 30 N C N C IN A10 CR27B OVERLOAD LOAD SENSE 85 87A 86 30 GND FROM JOYSTICK IN A2 LVL SNSR WHT LVL SNSR RED IN OUT C11 A5 RD WH BK N O S7 LEVEL SENSOR LEVEL SENSOR CIRCUIT BOARD 3 1 2 5 RD 4 WH LS5 UP LIMIT SWITCH DATA LINK LOW DATA LINK HIGH IN IN B1 C1 UP LIMIT SWIT...

Page 270: ...9 PIN4 DRIVE LED L17 LIFT LED L16 POUT4 POUT2 POUT3 HIGH TORQUE LED L21 POUT1 PLATFORM CONTROLS MEMBRANE DECAL H1 ALARM POUT11 PIN11 RD BK BK P2 EMERGENCY STOP BK RD PIO3 PIO5 PIO4 DATA LINK LOW DATA LINK HIGH GROUND POWER TO GROUND POWER TO PLATFORM BK 3 3 RD 4 4 WH 1 1 BL 2 2 OR 5 5 QD3 D7 VOLTAGE REGULATOR 5V DC 24V DC PIO2 U3 PLATFORM CONTROLS PRINTED CIRCUIT BOARD GY GN BN WH PP PIN8 PIN10 PI...

Page 271: ...Section 6 Schematics April 2008 Part No 97385 GS 30 GS 32 GS 46 6 97 This page intentionally left blank ...

Page 272: ... Schematics April 2008 6 98 GS 30 GS 32 GS 46 Part No 97385 Electrical Schematic CE Models GS 2032 2632 from serial number GS3207 83651 to GS3207 84866 GS 2046 2646 3246 from serial number GS4607 82536 to GS4607 84839 ...

Page 273: ... C H O N O H C B11 OUT A6 85 87 86 30 85 87 86 30 CR27C OVERLOAD DOWN COIL CR27D OVERLOAD DOWN DELAY OUT B6 85 87 86 30 85 87A 87 86 30 N C N C IN A10 CR27B OVERLOAD LOAD SENSE 85 87A 86 30 GND FROM JOYSTICK IN A2 LVL SNSR WHT LVL SNSR RED IN OUT C11 A5 RD WH BK N O S7 LEVEL SENSOR LEVEL SENSOR CIRCUIT BOARD 3 1 2 5 RD 4 WH LS5 UP LIMIT SWITCH DATA LINK LOW DATA LINK HIGH IN IN B1 C1 UP LIMIT SWIT...

Page 274: ...9 PIN4 DRIVE LED L17 LIFT LED L16 POUT4 POUT2 POUT3 HIGH TORQUE LED L21 POUT1 PLATFORM CONTROLS MEMBRANE DECAL H1 ALARM POUT11 PIN11 RD BK BK P2 EMERGENCY STOP BK RD PIO3 PIO5 PIO4 DATA LINK LOW DATA LINK HIGH GROUND POWER TO GROUND POWER TO PLATFORM BK 3 3 RD 4 4 WH 1 1 BL 2 2 OR 5 5 QD3 D7 VOLTAGE REGULATOR 5V DC 24V DC PIO2 U3 PLATFORM CONTROLS PRINTED CIRCUIT BOARD GY GN BN WH PP PIN8 PIN10 PI...

Page 275: ...Section 6 Schematics April 2008 Part No 97385 GS 30 GS 32 GS 46 6 101 This page intentionally left blank ...

Page 276: ...S 30 GS 32 GS 46 Part No 97385 Electrical Schematic CE Models CE Models GS 2032 2632 3232 fromserialnumberGS3207 84867toGS3210A 94974andGS3208C 101toGS3210C 378 GS 2046 2646 3246 fromserialnumberGS4607 84840toGS4610A 95454andGS4609C 101toGS4610C 118 ...

Page 277: ...VERLOAD DOWN DELAY OUT B6 85 87 86 30 85 87A 87 86 30 N C N C IN A10 CR27B OVERLOAD LOAD SENSE 85 87A 86 30 GND FROM JOYSTICK IN A2 LVL SNSR WHT LVL SNSR RED IN OUT C11 A5 RD WH BK N O S7 LEVEL SENSOR LEVEL SENSOR CIRCUIT BOARD 3 1 2 5 RD 4 WH LS5 UP LIMIT SWITCH DATA LINK LOW DATA LINK HIGH IN IN B1 C1 UP LIMIT SWITCH 3 1 2 5 4 QD4 1 4 2 3 5 BL BK RD OR WH BL BK OR GN RD BL BK WH GN BK RD BK C5 4...

Page 278: ...OIL B5 IN MC THROTTLE GROUND MC ENABLE 24V KS1 DRIVE ENABLE DOWN LIM UP IN FORWARD REVERSE UP COIL L69 LIFT ENABLE L52 FR OUTRIGGER L54 RR OUTRIGGER L53 RL OUTRIGGER L51 FL OUTRIGGER U39 CPU U40 POWER SUPPLY CHIP BN107 BN106 BN105 A1 IN A11 OUT A10 IN A9 IN GROUND TO PLAT POWER TO PLAT DATA LOW DATA HIGH IN B12 C9 OUT C1 IN 1 4 3 2 WH GN RD BL BN BL OR BL WH OR WH RD WH GN GN BK BN BK BK BK WH WH ...

Page 279: ...ER TO GROUND POWER TO PLATFORM BK 3 3 RD 4 4 WH 1 1 BL 2 2 OR 5 5 QD3 D7 VOLTAGE REGULATOR 5V DC 24V DC PIO2 U3 PLATFORM CONTROLS PRINTED CIRCUIT BOARD GY GN BN WH PP PIN8 PIN10 PIN9 OR BK RD JC1 JOYSTICK CONTROLLER BL SW6 STEER LEFT RIGHT LEFT RIGHT SW5 FUNCTION ENABLE HALL EFFECT GENERATOR G8 DIAGNOSTIC DISPLAY ES0142P NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF Electrical Schem...

Page 280: ...30 GS 32 GS 46 Part No 97385 Electrical Schematic CE Models CE Models GS 2032 2632 3232 fromserialnumberGS3210A 94975toGS3211A 97903andGS3210C 379toGS3212C 1386 GS 2046 2646 3246 fromserialnumberGS4610A 95455toGS4611A 97982andGS4610C 119toGS4612C 1385 ...

Page 281: ... No 97385 GS 30 GS 32 GS 46 6 107 Electrical Schematic CE Models GS 2032 2632 3232 fromserialnumberGS3210A 94975toGS3211A 97903andGS3210C 379toGS3212C 1386 GS 2046 2646 3246 fromserialnumberGS4610A 95455toGS4611A 97982andGS4610C 119toGS4612C 1385 ...

Page 282: ...30 GS 32 GS 46 Part No 97385 Electrical Schematic CE Models CE Models GS 2032 2632 3232 fromserialnumberGS3210A 94975toGS3211A 97903andGS3210C 379toGS3212C 1386 GS 2046 2646 3246 fromserialnumberGS4610A 95455toGS4611A 97982andGS4610C 119toGS4612C 1385 ...

Page 283: ... No 97385 GS 30 GS 32 GS 46 6 109 Electrical Schematic CE Models GS 2032 2632 3232 fromserialnumberGS3210A 94975toGS3211A 97903andGS3210C 379toGS3212C 1386 GS 2046 2646 3246 fromserialnumberGS4610A 95455toGS4611A 97982andGS4610C 119toGS4612C 1385 ...

Page 284: ... GS 32 GS 46 Part No 97385 Electrical Schematic CE Models CE Models GS 2032 2632 3232 fromserialnumberGS3211A 97904toGS3212A 109999andGS3212C 1387toGS3212C 9999 GS 2046 2646 3246 fromserialnumberGS4611A 97983toGS4612A 109999andGS4612C 1386toGS4612C 9999 ...

Page 285: ...o 97385 GS 30 GS 32 GS 46 6 111 Electrical Schematic CE Models GS 2032 2632 3232 fromserialnumberGS3211A 97904toGS3212A 109999andGS3212C 1387toGS3212C 9999 GS 2046 2646 3246 fromserialnumberGS4611A 97983toGS4612A 109999andGS4612C 1386toGS4612C 9999 ...

Page 286: ... GS 32 GS 46 Part No 97385 Electrical Schematic CE Models CE Models GS 2032 2632 3232 fromserialnumberGS3211A 97904toGS3212A 109999andGS3212C 1387toGS3212C 9999 GS 2046 2646 3246 fromserialnumberGS4611A 97983toGS4612A 109999andGS4612C 1386toGS4612C 9999 ...

Page 287: ...o 97385 GS 30 GS 32 GS 46 6 113 Electrical Schematic CE Models GS 2032 2632 3232 fromserialnumberGS3211A 97904toGS3212A 109999andGS3212C 1387toGS3212C 9999 GS 2046 2646 3246 fromserialnumberGS4611A 97983toGS4612A 109999andGS4612C 1386toGS4612C 9999 ...

Page 288: ...orm overload pressure switch Brake Shuttle valve Solenoid operated 2 position 4 way directional valve Accumulator Filter Component Reference and Hydraulic Symbols Legend Solenoid operated 2 position 2 way valve normally closed Check valve Pilot operated check valve with needle valve Solenoid operated 3 position 4 way directional valve Solenoid operated 3 position 4 way directional valve Solenoid o...

Page 289: ...GS 1532 GS 1930 and GS 1932 Outrigger manifold GS 3232 Front outrigger cylinder GS 3232 Function manifold GS 2032 GS 2632 GS 3232 GS 2046 GS 2646 and GS 3246 Brake release manifold all models Rear outrigger cylinder GS 3232 A B C I H G E F D Y8 Y4 Y3 Y39 Y40 BA BB AB AC AA AD AF AG AH A I AJ AE Y3 Y4 Y1 Y8 J M L K CA and CB CE CF CG CC and CD CE CF CG ...

Page 290: ...n circuit P Accumulator R Pressure switch platform overload S Check valve drive circuit HS0035F 3500 psi maximum 241 bar maximum TP 1800 to 3500 psi 124 to 241 bar A L Y8 V S1 S2 0 75 gpm 2 8 L min 1500 psi 103 bar FUNCTION MANIFOLD M1 LEFT DRIVE MOTOR M4 RIGHT DRIVE MOTOR FORWARD REVERSE 10 psi 0 7 bar B AC Y3 Y4 10 MICRON WITH 25 psi 1 7 bar BYPASS HYDRAULIC TANK P T Y7 PS2 PLATFORM OVERLOAD CE ...

Page 291: ...umulator R Pressure switch platform overload S Check valve drive circuit HS0035J A L M I H C F B G E R N O P D S Y5 Y6 0 25 gpm 3700 psi 0 95 L min 255 bar TP 0 25 gpm 1800 to 3700 psi 0 95 L min 124 to 255 bar L Y8 V S1 S2 0 75 gpm 2 8 L min 1500 psi 103 bar FUNCTION MANIFOLD M1 LEFT DRIVE MOTOR M4 RIGHT DRIVE MOTOR FORWARD REVERSE B AC Y3 Y4 10 MICRON WITH 25 psi 1 7 bar BYPASS HYDRAULIC TANK P ...

Page 292: ...P 1800 to 3500 psi 124 to 241 bar AA Y8 L V S1 S2 0 75 gpm 2 8 L min 1500 psi 103 bar FUNCTION MANIFOLD M1 M4 10 psi 0 7 bar B AC Y3 Y4 10 MICRON WITH 25 psi 1 7 bar BYPASS HYDRAULIC TANK P T M POWER UNIT 4 gpm 2500 psi 15 L min 172 bar Y1 130 psi 9 bar Y5 Y6 0 040 in 1 mm AB AI AJ AC AD AH AF AG AE Y9 2500 psi maximum 172 bar maximum UPPER LIFT CYLINDER GS 3246 MODELS N O 0 059 inch 1 17 mm Q THE...

Page 293: ...36L AA AB AI AJ AC AD AH AF AG AE R N O L M P N O Q 3500 psi maximum 241 bar maximum TP 1800 to 3500 psi 124 to 241 bar Y8 L V S1 S2 0 75 gpm 2 8 L min 1500 psi 103 bar FUNCTION MANIFOLD M1 M4 B AC Y3 Y4 10 MICRON WITH 25 psi 1 7 bar BYPASS HYDRAULIC TANK P T M POWER UNIT 4 gpm 2500 psi 15 L min 172 bar Y7 PS2 PLATFORM OVERLOAD CE MODELS LIFT CYLINDER ALL MODELS 0 059 inch 1 5 mm 50 psi 3 4 bar Y9...

Page 294: ...B AC Y3 Y4 10 MICRON WITH 25 psi 1 7 bar BYPASS HYDRAULIC TANK P T M POWER UNIT 4 gpm 2500 psi 15 L min 172 bar Y7 PS2 PLATFORM OVERLOAD CE MODELS LIFT CYLINDER ALL MODELS 0 059 inch 1 5 mm 50 psi 3 4 bar Y9 2500 psi maximum 172 bar maximum UPPER LIFT CYLINDER GS 3232 and GS 3246 MODELS 0 037 inch 0 94 mm STEER LEFT STEER RIGHT LEFT DRIVE MOTOR RIGHT DRIVE MOTOR FORWARD REVERSE HP BRAKE RIGHT LEFT...

Page 295: ...form lowering valve O Orifice platform down circuit P Accumulator Q Relief valve platform down R Pressure switch platform overload HS0040B EXTEND RETRACT EXTEND RETRACT B2 B3 B1 R3 R1 R2 OUTRIGGER MANIFOLD Y39 Y40 3500 psi maximum 241 bar maximum IN OUT EXTEND RETRACT EXTEND RETRACT Y33 0 037 in 0 94 mm LR OUTRIGGER CYLINDER RR OUTRIGGER CYLINDER 0 037 in 0 94 mm Y34 0 035 in 0 9 mm From Pump 0 25...

Page 296: ...Section 6 Schematics March 2007 6 122 GS 30 GS 32 GS 46 Part No 97385 ...

Page 297: ...1 53852570 86 21 53852569 65 98 480 775 65 67 533 544 81 3 3453 6082 81 3 3453 6083 82 25 587 267 82 25 583 910 55 11 41 665 755 55 11 41 665 754 31 183 581 102 31 183 581 566 Genie Scandinavia Genie France Genie Iberica Genie Germany Genie U K Genie Mexico City Phone Fax Phone Fax Phone Fax Phone Fax Phone Fax Phone Fax 46 31 575100 33 0 2 37 26 09 99 33 0 2 37 26 09 98 34 93 579 5042 34 93 579 5...

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