Terex Genie GS-1530 Service Manual Download Page 121

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Section 4 • Repair Procedures

October 2008

Part No. 96316

GS-30 • GS-32 • GS-46

4 - 67

REV C

MANIFOLDS

Note: 'alpha' callouts refer
to corresponding notes on
the hydraulic schematic

Note: 'alpha-numeric' callouts
refer to corresponding notes
on the electrical schematic

Summary of Contents for Genie GS-1530

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

Page 2: ...ations will be carefully considered for future printings of this and all other manuals Copyright 1997 by Genie Industries 96316 Rev E September 2005 Third Edition Fourth Printing Genie is a registered trademark of Genie Industries in the USA and many other countries GS is a trademark of Genie Industries Printed on recycled paper Printed in U S A Contact Us www genieindustries com e mail techpub te...

Page 3: ...cluding occupants Genie Industries 18340 NE 76th Street Redmond WA 98052 USA Electrical schematic number Gradeability Maximum allowable side force Maximum number of platform occupants Machine unladen weight ANSI A92 6 1999 B354 2 01 GS 1930 GS3005 12345 04 12 05 ES0141 2 714 lb 1 231 kg 500 lb 227 kg N A N A 100 lb 445 N 2 2005 Serial number stamped on chassis Serial number stamped on chassis Seri...

Page 4: ...September 2005 GS 30 GS 32 GS 46 Part No 96316 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: ...kshop or work area is properly ventilated and well lit 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 per...

Page 7: ...ulic 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 3...

Page 8: ...e Speed Raised Position 3 18 B 10 Perform Hydraulic Oil Analysis 3 19 B 11 Inspect the Hydraulic Cap Venting System 3 19 B 12 Check the Module Tray Latch Components 3 20 B 13 Inspect the Voltage Inverter if equipped 3 21 B 14 Test the Down Limit Switch and the Pothole Limit Switches 3 22 B 15 Test the Up Limit Switch if equipped 3 25 C Checklist C Procedures C 1 Test the Platform Overload System i...

Page 9: ... after serial numbers GS3005 74999 GS3205 74999 and GS4605 74999 4 12 A Platform Components 2 1 Platform 4 16 2 2 Platform Extension 4 17 C Scissor Components 3 1 Scissor Assembly GS 1530 and GS 1532 4 18 3 2 Scissor Assembly GS 1930 and GS 1932 4 24 3 3 Scissor Assembly GS 2032 and GS 2046 4 32 3 4 Scissor Assembly GS 2632 and GS 2646 4 38 3 5 Scissor Assembly GS 3246 4 46 3 6 Lift Cylinder 4 54 ...

Page 10: ...1530 GS 1532 GS 1930 and GS 1932 after serial number GS3004 66986 4 70 6 4 Valve Adjustments Function Manifold 4 71 6 5 Valve Coils 4 75 B Hydraulic Tank 7 1 Hydraulic Tank 4 77 B Steer Axle Components 8 1 Yoke and Drive Motor 4 78 8 2 Steer Cylinder 4 79 8 3 Steer Bellcrank 4 80 A Non steer Axle Components 9 1 Drive Brake 4 81 A Brake Release Hand Pump Components 10 1 Brake Release Hand Pump Comp...

Page 11: ...75000 to 75999 6 12 D GS 2032 2632 from serial number GS3204 60000 to GS3205 74999 GS 2046 2646 3246 from serial number GS4604 60000 to GS4605 74999 6 16 B GS 2032 2632 from serial number GS3205 75000 to 75406 GS 2046 2646 3246 from serial number GS4605 75000 to 75437 6 20 Electrical Schematics CE Models models with platform overload C GS 1530 1532 1930 1932 from serial number GS3003 60000 to GS30...

Page 12: ...ematic GS 1530 1532 1930 1932 from serial number GS3004 65105 to 66986 6 42 A Hydraulic Schematic GS 1530 1532 1930 1932 from serial number GS3004 66987 to GS3005 75999 6 44 A Hydraulic Schematic GS 2032 2632 from serial number GS3204 60000 to GS3205 75406 6 46 B Hydraulic Schematic GS 2046 2646 3246 from serial number GS4604 60000 to GS4604 60878 6 48 A Hydraulic Schematic GS 2046 2646 3246 from ...

Page 13: ... liters Hydraulic system including tank 4 5 gallons 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 2632 GS 2046 GS 2646 GS 324...

Page 14: ... 70 dB Maximum sound level at normal operation workstations A weighted Function speed maximum from platform controls with 1 person in platform GS 1530 GS 1532 Platform up 15 to 17 seconds Platform down 16 to 18 seconds GS 1930 GS 1932 Platform up 15 to 17 seconds Platform down 22 to 24 seconds GS 2032 GS 2046 Platform up 28 to 32 seconds Platform down 26 to 30 seconds GS 2632 GS 2646 Platform up 2...

Page 15: ...viation A Continued 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...

Page 16: ...ally increase or decrease by 4 for each 18 F 7 7 C that your air temperature increases or decreases from 68 F 20 C Description Specification Solenoid valve 3 position 4 way 27 2Ω 20V DC with diode schematic item E and AC Solenoid valve 3 position 4 way 19Ω 20V DC with diode schematic item F Solenoid valve 2 position 4 way 19Ω 20V DC with diode schematic item H Solenoid valve 2 position 2 way N C 2...

Page 17: ...e 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 fitting ...

Page 18: ...ened 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 wi...

Page 19: ...READ 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 94...

Page 20: ...June 2009 Section 2 Specifications 2 8 GS 30 GS 32 GS 46 Part No 96316 This page intentionally left blank ...

Page 21: ...urface 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 procedure includes a description safety ...

Page 22: ...ation 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 cha...

Page 23: ...se 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 re inspect 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 dealer to...

Page 24: ...Section 3 Scheduled Maintenance Procedures 3 4 GS 30 GS 32 GS 46 Part No 96316 October 2008 This page intentionally left blank ...

Page 25: ...ion 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 annually or 500 hours Inspection A B C Annually or 1000 hours Inspection A B C D Tw...

Page 26: ... 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 conditio...

Page 27: ... Inspection also serves 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 ...

Page 28: ...c Tank Return Filter 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 the steer yoke 2 Pump...

Page 29: ...ctive clothing and eye wear Models without maintenance free or sealed batteries 6 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results 7 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows Add 0 004 to the reading of each cell for every 10 5 5 C above 80 F 26 7 C Subtract 0 004 from the re...

Page 30: ...ingle phase AC power supply Result The charger should operate and begin charging the batteries If simultaneously the charger alarm sounds and the LEDs blink one time correct the 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 t...

Page 31: ...m 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 ground 6 Rotate the safety arm...

Page 32: ... Emergency Stop Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first A properly functioning Emergency Stop is essential for safe machine operation An improperly operating red Emergency Stop button will fail to shut off power and stop all machine functions resulting in a hazardous situation Note As a safety feature selecting and operating the ground con...

Page 33: ...s 2 Turn the key switch to platform control 3 Check the platform up down function from the ground controls Result The machine functions should not operate 4 Turn the key switch to ground control 5 Check the machine functions from the platform controls Result The machine functions should not operate 6 Turn the key switch to the off position Result No function should operate B 6 Test the Automotive ...

Page 34: ...ring the machine to top drive 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 no...

Page 35: ...es 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 securely tighten Torque to 25 ft lbs 34 Nm 14 In order inst...

Page 36: ...rder install 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 tighten Torque to 60 in lbs 7 Nm 26 Connect the battery pack to the machine 27 Replace the brakes and repea...

Page 37: ...e that is free of obstructions 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 5 Choose a point...

Page 38: ...wo 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 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 Choo...

Page 39: ... oil quarterly Replace the oil when it fails the test See E 1 Test or Replace the Hydraulic Oil B 11 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...

Page 40: ...he module tray latch 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...

Page 41: ...orrectly and begin supplying AC power If the right fault LED 123 blinks one time the power draw is too high The tool being used 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...

Page 42: ...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 co...

Page 43: ...he alarm does not sound The machine is functioning correctly 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 wh...

Page 44: ...towed 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 fe...

Page 45: ...chine on a firm level surface that is free of obstructions Up Limit Switch if equipped 1 Turn the key switch to ground control and raise the platform approximately 8 feet 2 4 m from the ground 2 Rotate the safety arm away from the machine and let it hang down 3 Lower the platform onto the safety arm Crushing hazard Keep hands clear of the safety arm when lowering the platform 4 While raising the p...

Page 46: ...atform 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 swi...

Page 47: ...ctly 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 11 1 Calibrate the Platform Overload Sy...

Page 48: ...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 49: ... non steer end of the machine Result The measurement is 0 90 inch 22 9 mm or more Proceed to step 2 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 Repair Pads 2 Measure the distance between the number one outer arm cross tube and the chassis deck at the battery pack side of the non steer end of the ma...

Page 50: ...o Replace the Scissor Arm Repair 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 Scis...

Page 51: ...ydraulic 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 5 T...

Page 52: ...circuits could result 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 o...

Page 53: ...e 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 ta...

Page 54: ...Section 3 Scheduled Maintenance Procedures 3 34 GS 30 GS 32 GS 46 Part No 96316 October 2008 This page intentionally left blank ...

Page 55: ...both 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 comp...

Page 56: ...rm controls consist of an electronic circuit board joystick membrane decal buttons LEDs and on models with a Gen 5 controller a diagnostic display For further information or assistance consult the Genie Industries Service Department Gen 4 platform controller a joystick controller JC1 b red Emergency Stop button P2 c DIP switch SW25 d circuit board retaining fastener e platform controls circuit boa...

Page 57: ...atform control box Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Component damage hazard Electrostatic discharge ESD can damage printed circuit board components Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a gr...

Page 58: ...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 3 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 PLATFORM CONTROLS 4 Press the lift function select button Gen 4 platform contr...

Page 59: ...l result in death or serious injury 1 Pull out the red Emergency Stop button to the on position at the ground controls 2 Push in the red Emergency Stop button to the off position at the platform controls 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 T...

Page 60: ...d 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 6 Press the drive function select button Result The diagnostic display will show the stowed drive speed percentage Gen 4 platform controller a function enable switch SW5 b joystick control...

Page 61: ...e 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 6 Press and hold the horn button Result The diagnostic display will show the raised drive speed percentage Gen 4 platform controller a function enable switch SW5 b joystick controller ...

Page 62: ...uttons 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 6 Press the drive function select button Result The diagnostic display will show the stowed drive speed percentage Gen 4 platform controller a function enable swi...

Page 63: ...e lift function select button 5 Slowly move the joystick in the direction indicated by the blue arrow Result The DIP switch configuration will appear in the diagnostic display PLATFORM CONTROLS Machine Option Definitions Motion Beacon The motion beacon option flashes only when operating a function Motion Alarm The motion alarm will sound when operating any function Lift Drive Cut Out This cuts out...

Page 64: ...fy the configuration of the DIP switch settings 4 Locate the DIP switch on the circuit board Move the DIP switch settings to correspond with the configuration of the machine options indicated in the DIP Switch Code Chart 5 Close the lid and install the fasteners 6 Confirm the settings See 1 3 How to Determine the DIP Switch Configuration 7 Push in the red Emergency Stop button to the off position ...

Page 65: ...000 56 10111000 57 11011000 58 11101000 59 11111000 60 10110000 61 11010000 62 11110000 63 11100000 Diagnostic Display Code DIP Switch Code OFF for 1530 1532 1930 1932 models Motion Beacon Motion Alarm Lift Drive Cut Out Overload Cut Out Descent Delay Battery Drain Alarm OFF for all models 00 00000000 01 00000100 02 00001000 03 00010000 04 00100000 05 01000000 06 00001100 07 00010100 08 00100100 0...

Page 66: ...the current configuration 5 Push in the 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 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 ...

Page 67: ... in the diagnostic display Use the steering thumb rocker switch on the joystick to increase or decrease the value See 1 4 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 Em...

Page 68: ...n the four right columns indicates that the machine configuration at left includes this option 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 GS 2046 GS 2646 GS 3246 GS 2032 GS 2632 Machine Function Code at Diagnostic Display Motion Alarm Lift Drive Cut Out Platform Overload Descent Delay 0...

Page 69: ...stic display window will become illuminated This indicates that the battery drain alarm option has been activated 8 Turn the key switch to the off position Note Any change in software settings will not take effect until the key switch is turned 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 ...

Page 70: ... with 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...

Page 71: ...on 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 on a structure ca...

Page 72: ...n steer end 6 Number 2 center pivot pin 2 pins 7 Number 2 pivot pin steer end 8 Number 1 center pivot pin 2 pins 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 end pivot pin 17 Number 1 outer arm Non steer End Steer End 16 17 13 4 5 14 15 2 9...

Page 73: ... ground controls side Component damage hazard Cables can be damaged if they are kinked or pinched 3 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 SCISSOR COMPONENTS Cable bridge legend a cable bridge 3 b cable bridge 2 c cable bridge 1 4 Attach a lifting strap from an overhead crane to the n...

Page 74: ...ables can be damaged if they are kinked or pinched 17 Remove the external snap rings and retaining fasteners from the number 2 center pivot pin index 5 at the ground controls side 18 Remove the number 2 cable bridge mounting fasteners and remove the cable bridge from the machine 19 Attach a lifting strap from an overhead crane to the number 2 outer arm index 14 at the ground controls side 20 Use a...

Page 75: ... onto the safety arm Bodily injury hazard Keep hands clear of moving parts when lowering the scissor arms onto the safety arm 33 Attach a lifting strap from an overhead crane to the lug on the rod end of the lift cylinder index 3 Raise the lift cylinder approximately 3 ft 1 m 34 Tag disconnect and plug the hydraulic hoses on the lift cylinder Cap the fittings on the cylinder Bodily injury hazard S...

Page 76: ...o not apply any lifting pressure 45 Remove the external snap rings and retaining fasteners from the number 1 center pivot pins index 7 46 Remove the number 1 cable bridge from the machine 47 Use a soft metal drift to remove the number 1 center pivot pins index 7 Bodily injury hazard The number 1 outer arm may become unbalanced and fall if not properly supported when the pin is removed 48 Slide the...

Page 77: ...o 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 SCISSOR COMPONENTS 9 Remove the scissor assembly from the machine just enough to access both wear pads Crushing hazard The scissor assembly will...

Page 78: ...in 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 Number 2 outer arm 20 Number 2 pivot pin non steer end 21 Lift cylinder barrel end pivot pin 22...

Page 79: ...o specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform See 2 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 Cable bridge legend a cable bridge 4 b cable bridge 3 c cable bridge 2 d cable...

Page 80: ...ne Crushing hazard The number 4 inner arm may become unbalanced and fall if not properly supported when removed from the machine 13 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 14 Remove the number 3 cable bridge mounting fasteners and remove the cable bridge from the machine 15 Attach a li...

Page 81: ...ed 26 Lower the cylinder onto the number 1 inner arm index 9 Component damage hazard Cables can be damaged if they are kinked or pinched 27 Attach a lifting strap from an overhead crane to the number 3 inner arm index 15 28 Remove the retaining fasteners from the number 3 pivot pin index 6 at the steer end 29 Use a soft metal drift to remove the number 3 pivot pin index 6 Remove the number 3 inner...

Page 82: ...ly injury hazard The number 2 outer arm at the battery pack side may become unbalanced and fall if not properly supported when removed from the machine 41 Remove the number 3 pivot pin index 17 from the non steer end of the machine 42 Attach a lifting strap from an overhead crane to the number 2 inner arm index 18 43 Remove the retaining fasteners from the number 2 pivot pin index 8 at the steer e...

Page 83: ...ile removing it from the machine 54 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 55 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 ...

Page 84: ... the machine Component damage hazard Be sure not to damage the limit switch or level sensor box components 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 la...

Page 85: ...mage 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 h...

Page 86: ...pins 4 Lift cylinder rod end pivot pin 5 Number 3 pivot pin steer end 6 Number 2 center pivot pin 2 pins 7 Number 2 pivot pin steer end 8 Number 1 center pivot pin 2 pins 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 end pivot pin 17 Number ...

Page 87: ...ry 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 D...

Page 88: ...d 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 ...

Page 89: ... 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 ma...

Page 90: ...are 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 5...

Page 91: ... 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 I...

Page 92: ...od 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 Number 2 outer arm 20 ...

Page 93: ...er to 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 ...

Page 94: ... 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 ...

Page 95: ...asteners 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 96: ...in 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 ...

Page 97: ...d 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 ...

Page 98: ...imit 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 99: ...will 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 chassi...

Page 100: ...ylinder 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 steer end 22 Upper lift cyl...

Page 101: ... 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 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 k...

Page 102: ...operly 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 ar...

Page 103: ...ry 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 104: ...l 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 ...

Page 105: ... 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 l...

Page 106: ...ngs 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 i...

Page 107: ...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 108: ...nds clear of the safety 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 ca...

Page 109: ...cissor 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 110: ...rod 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 111: ...ing 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 strap ...

Page 112: ...s from the lift cylinder barrel end pivot pin Use a soft metal drift to remove the pin Crushing hazard The lift cylinder will fall if not properly supported when the pin is removed Y9 f N O b d e c g Q a 14 Support and secure the lift cylinder to an appropriate lifting device 15 Remove the lift cylinder through the scissor arms at the steer end of the machine Crushing hazard The lift cylinder may ...

Page 113: ... 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 Skip to step 8 if the measurement is correct 6 To adjust loosen the upper lock nut on the cable mounting bracket at the cylinder Turn the lower lock nut clockwise to decrease the distance or counterclockwise to increase the distance...

Page 114: ...ombination and check for continuity Terminals 85 and 86 represent the coil and should not be tested in any other combination Test Desired result terminal 85 to 86 with resistor 310 to 330Ω terminal 87 to 87a and 30 no continuity infinite Ω terminal 87a to 30 continuity zero Ω 3 Connect 24V DC and a ground wire to terminals 85 and 86 then test the following terminal combinations Test Desired result...

Page 115: ...orm 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 you are not ins...

Page 116: ...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 controls 16 Adjust the level sens...

Page 117: ...ely 2 inches 5 cm GROUND CONTROLS 31 GS 1530 and GS 1930 Place a 0 77 x 6 x 6 inch 19 6 mm x 15 cm x 15 cm thick steel block under both wheels at the battery pack side of the machine GS 1532 and GS 1932 Place a 0 83 x 6 x 6 inch 21 1 mm x 15 cm x 15 cm thick steel block under both wheels at the battery pack side of the machine GS 2032 and GS 2632 Place a 0 8 x 6 x 6 inch 20 3 mm x 15 cm x 15 cm th...

Page 118: ...port on the pump 3 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both 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 servic...

Page 119: ...tate 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 HYDRAULIC 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 co...

Page 120: ... 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 3500 psi 241 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 machine between the mo...

Page 121: ...16 GS 30 GS 32 GS 46 4 67 REV C MANIFOLDS A B C D E F G H I Y8 Y4 Y3 Y5 Y6 Note alpha callouts refer to corresponding notes on the hydraulic schematic Note alpha numeric callouts refer to corresponding notes on the electrical schematic 1 2 5 6 7 8 9 3 4 ...

Page 122: ...m 5 Solenoid valve 2 position 4 way AE Drive speed select circuit 25 ft lbs 34 Nm 6 Relief valve 130 psi 9 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 Nm 9 Solenoid valve 2 position 4 way AI Platform up 25 ft lbs 34 Nm 10 Relief val...

Page 123: ...GS 32 GS 46 4 69 REV C AB AC AA AD AE AF AG AH A I AJ 6 1 2 3 4 8 7 9 10 5 Y3 Y4 Y5 Y6 Y1 Y8 Note alpha callouts refer to corresponding notes on the hydraulic schematic Note alpha numeric callouts refer to corresponding notes on the electrical schematic MANIFOLDS ...

Page 124: ...erial number GS3004 66986 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...

Page 125: ...ground and platform controls 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 remove the cap schematic item I or AB 9 Adjust the internal hex socket Turn it clockwise to...

Page 126: ...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 socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Tip over ha...

Page 127: ...0 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 raising the p...

Page 128: ...rease the pressure Component damage hazard Do not adjust the relief valve pressures higher than specifications 9 Install the relief valve cap 10 Repeat steps 5 through 6 to confirm the relief valve pressure c a b d GS 32 and GS 46 a test port b system relief valve c steer relief valve d lift relief valve MANIFOLDS How to Adjust the Steer Relief Valve Perform this test from the ground with the plat...

Page 129: ...o cool at least 3 hours before performing this test 1 Tag and disconnect 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 resistan...

Page 130: ...oss 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 metallic ring at either end of the coil MANIFOLDS a multimeter b...

Page 131: ...d 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 hydraulic connections very slowly to allow the oil pressure to dissipat...

Page 132: ...e 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 kink...

Page 133: ...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 Spe...

Page 134: ...ng 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 STEER AXLE COMPONENTS Note While removing the bellcrank from the machine take note of the qu...

Page 135: ...e 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 ...

Page 136: ...ke Release Hand Pump Components 10 1 Brake Release Hand Pump Components The brake release hand pump manifold is mounted behind the entry ladder GS 1530 GS 1532 GS 1930 GS 1932 before serial number GS 3004 65105 GS 2046 GS 2646 GS 3246 before serial number GS 4604 60879 GS 1530 GS 1532 GS 1930 GS 1932 after serial number GS 3004 65104 GS 2032 GS 2632 after serial number GS 3204 52788 GS 2046 GS 264...

Page 137: ...mum 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 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 the capacity indicator decal on...

Page 138: ...e 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 w...

Page 139: ... ADJUSTMENT TURN THE PRESSURE SWITCH NUT INTO THE HYDRAULIC LINE 1 4 TURN BATTERIES ARE NOT FULLY CHARGED CHARGE BATTERIES OVERLOAD SYSTEM NOT ADJUSTED PROPERLY REPEAT CALIBRATION PROCEDURE SLIDER CHANNEL NOT LUBRICATED LUBRICATE SLIDER CHANNELS AT DOWN LIMIT THE PRESSURE SWITCH ALARM CONTINUES TO SOUND AFTER ADJUSTMENT SYSTEM NEEDS TO BE RESET TURN OFF RED EMERGENCY STOP BUTTON WAIT THREE SECONDS...

Page 140: ...October 2008 Section 4 Repair Procedures 4 86 GS 30 GS 32 GS 46 Part No 96316 This page intentionally left blank ...

Page 141: ...emove 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 Immediatel...

Page 142: ...eter pressure gauges Malfunction discovered Identify symptoms Troubleshoot Perform repair Return to service problem solved problem still exists Inspect and test LED Diagnostic Readout FAULT CODES The diagnostic readout displays numerical codes that provide information about the machine operating status and about malfunctions The dot to the right of the numbers remain on when a fault code is displa...

Page 143: ...latform drive enable switch fault Malfunctioning 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 co...

Page 144: ...September 2005 Section 5 Fault Codes 5 4 GS 30 GS 32 GS 46 Part No 96316 This page intentionally left blank ...

Page 145: ...y tools and test equipment are available and ready for use About This 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 ...

Page 146: ...7 Pothole LS8 Pothole M5 Hydraulic power unit NC Normally closed NCHO Normally closed held open NOHC Normally open held closed Power switch P P1 Emergency Stop button at ground controls P2 Emergency Stop button at platform controls PS2 Platform overload pressure switch option Quick disconnect QD QD1 Battery quick disconnect QD3 Control cable to ground QD4 Control cable to platform Switch SW SW5 Fu...

Page 147: ...put A12 Platform down TS66 input 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 l...

Page 148: ...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 SW...

Page 149: ...WH BL PP BL GY BN YL GY WH RD BL OR TO COIL CORD RD BK RD BK PLATFORM CONTROLS GEN 5 BL WH OR RD BK TO COIL CORD ASSEMBLY RD RD BK SW25 DIP SWITCH U3 PLATFORM CONTROLS CIRCUIT BOARD 1 4 2 5 2 1 NC 1 9F 2 3 4 5 6 7 8 ON ALCO ADF085 P N 000000 Date 0000 S N Al 00000000 GY OR BL BK WH RD JC1 JOYSTICK CONTROLLER RD BK OR WH WH BL PP BL GY BN YL H1 ALARM P2 EMERGENCY STOP BUTTON PLATFORM CONTROLS GEN 4...

Page 150: ...ion 6 Schematics October 2008 6 6 GS 30 GS 32 GS 46 Part No 96316 REV B Limit Switch Legend a maximum height limit switch LS5 CE models b down limit switch LS6 c pothole switches LS7 LS8 Limit Switch Legend ...

Page 151: ...NABLE N O PLATFORM CONTROL GROUND CONTROL B B1 3 4 2 1 KS1 KEY SWITCH OR WH Inductor noise suppression LED Control relay Wire with description Circuits crossing no connection Diode Circuits connection Hour meter Light or flashing beacon Pressure switch normally open Limit switch Button or switch Emergency stop button Circuit breaker Motor controller Toggle switch Connector Fuse Horn or alarm Motor...

Page 152: ...Section 6 Schematics October 2008 6 8 GS 30 GS 32 GS 46 Part No 96316 REV C Electrical Schematic ANSI CSA and Australia Models GS 1530 1532 1930 1932 from serial number GS3003 60000 to GS3005 74999 ...

Page 153: ...OWN Y8 PLATFORM UP GND 85 87 86 30 GND FROM JOYSTICK IN A2 ECM POWER A4 IN LVL SNSR WHT LVL SNSR RED IN OUT C11 A5 RD WH BK N C 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 GN RD BK OR BK WH BL RD...

Page 154: ...POUT8 POUT10 HIGH TORQUE LED L21 POUT1 BATTERY LEVEL 1 BATTERY LEVEL 2 BATTERY LEVEL 3 BATTERY LEVEL 4 BATTERY LEVEL 5 G7 PLATFORM CONTROLS MEMBRANE DECAL H1 ALARM POUT11 PIN11 RD BK BK P2 EMERGENCY STOP BK RD SW25 DIP SWITCH 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...

Page 155: ...Section 6 Schematics October 2008 Part No 96316 GS 30 GS 32 GS 46 6 11 This page intentionally left blank ...

Page 156: ...5 4 6V BATTERY GND U9 BATTERY CHARGER AC INPUT QD1 LS7 POTHOLE GUARD SWITCH LS8 POTHOLE GUARD SWITCH IN B10 POTHOLE LIMIT SWITCH H5 ALARM OUT B9 ALARM N C H O N C H O TS66 PLATFORM UP DOWN UP DOWN CR5 HORN RELAY H2 OPTION 87 30 85 86 U13 DC AC INVERTER OPTION CB2 7A CIRCUIT BREAKER A8 OUT B8 OUT A1 OUT FB FLASHING BEACONS OPTION P1 EMERGENCY STOP NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE ...

Page 157: ...N Y8 PLATFORM UP GND 85 87 86 30 GND FROM JOYSTICK IN A2 ECM POWER A4 IN LVL SNSR WHT LVL SNSR RED IN OUT C11 A5 RD WH BK N C 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 GN RD BK OR BK WH BL RD B...

Page 158: ... 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 RD JC1 JOYS...

Page 159: ...Section 6 Schematics September 2005 Part No 96316 GS 30 GS 32 GS 46 6 15 This page intentionally left blank ...

Page 160: ... 2009 6 16 GS 30 GS 32 GS 46 Part No 96316 REV D Electrical Schematic ANSI CSA and Australia Models GS 2032 2632 from serial number GS3204 60000 to GS3205 74999 GS 2046 2646 3246 from serial number GS4604 60000 to GS4605 74999 ...

Page 161: ...DRIVE FORWARD Y7 PLATFORM DOWN Y8 PLATFORM UP GND 85 87 86 30 GND FROM JOYSTICK IN A2 ECM POWER A4 IN LVL SNSR WHT LVL SNSR RED IN OUT C11 A5 RD WH BK N C 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 162: ...5 POUT5 POUT6 POUT7 POUT9 POUT8 POUT10 HIGH TORQUE LED L21 POUT1 BATTERY LEVEL 1 BATTERY LEVEL 2 BATTERY LEVEL 3 BATTERY LEVEL 4 BATTERY LEVEL 5 G7 PLATFORM CONTROLS MEMBRANE DECAL H1 ALARM POUT11 PIN11 RD BK BK P2 EMERGENCY STOP BK RD SW25 DIP SWITCH 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 ...

Page 163: ...Section 6 Schematics June 2009 Part No 96316 GS 30 GS 32 GS 46 6 19 This page intentionally left blank ...

Page 164: ...1 QD1 M5 MOTOR A1 D1 M5 B5 4 6V BATTERY GND U9 BATTERY CHARGER AC INPUT QD1 LS7 POTHOLE GUARD SWITCH LS8 POTHOLE GUARD SWITCH IN B10 POTHOLE LIMIT SWITCH H5 ALARM OUT B9 ALARM N C H O N C H O TS66 PLATFORM UP DOWN UP DOWN CR5 HORN RELAY H2 OPTION 87 30 85 86 U13 DC AC INVERTER OPTION CB2 7A CIRCUIT BREAKER A8 OUT B8 OUT A1 OUT FB FLASHING BEACONS OPTION P1 EMERGENCY STOP NOTE MACHINE SHOWN IN THE ...

Page 165: ... FORWARD Y7 PLATFORM DOWN Y8 PLATFORM UP GND 85 87 86 30 GND FROM JOYSTICK IN A2 ECM POWER A4 IN LVL SNSR WHT LVL SNSR RED IN OUT C11 A5 RD WH BK N C 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 G...

Page 166: ...LE 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 PIN...

Page 167: ...Section 6 Schematics September 2005 Part No 96316 GS 30 GS 32 GS 46 6 23 This page intentionally left blank ...

Page 168: ...Section 6 Schematics October 2008 6 24 GS 30 GS 32 GS 46 Part No 96316 REV C Electrical Schematic CE Models GS 1530 1532 1930 1932 from serial number GS3003 60000 to GS3005 74999 ...

Page 169: ...DOWN LIMIT SWITCH IN IN C2 IN C12 DWN LIMIT N C H O N O H C B11 OUT A9 PS2 PLATFORM OVERLOAD PRESSURE SWITCH 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 ECM POWER A4 IN LVL SNSR WHT LVL SNSR RED IN OUT C11 A5 RD WH BK N C S7 LEVEL SENSOR LEVEL SENSO...

Page 170: ...EVEL 5 G7 PLATFORM CONTROLS MEMBRANE DECAL H1 ALARM POUT11 PIN11 RD BK BK P2 EMERGENCY STOP BK RD SW25 DIP SWITCH 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 1 2 3 4 5 6 7 8 GY GN BN WH PP PIN8 PIN10 PIN9 OR BK RD JC1 JOYSTICK CONTROLLER ...

Page 171: ...Section 6 Schematics October 2008 Part No 96316 GS 30 GS 32 GS 46 6 27 This page intentionally left blank ...

Page 172: ...ATTERY CHARGER AC INPUT QD1 LS7 POTHOLE GUARD SWITCH LS8 POTHOLE GUARD SWITCH IN B10 POTHOLE LIMIT SWITCH H5 ALARM OUT B9 ALARM N C H O N C H O TS66 PLATFORM UP DOWN UP DOWN U27 47 mH INDUCTOR NOISE SUPPRESSION CR5 HORN RELAY H2 OPTION 87 30 85 86 U13 DC AC INVERTER OPTION CB2 7A CIRCUIT BREAKER A8 OUT B8 OUT A1 OUT FB FLASHING BEACONS OPTION P1 EMERGENCY STOP NOTE MACHINE SHOWN IN THE STOWED POSI...

Page 173: ...N LIMIT SWITCH IN IN C2 IN C12 DWN LIMIT N C H O N O H C B11 OUT A9 PS2 PLATFORM OVERLOAD PRESSURE SWITCH 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 ECM POWER A4 IN LVL SNSR WHT LVL SNSR RED IN OUT C11 A5 RD WH BK N C S7 LEVEL SENSOR LEVEL SENSOR C...

Page 174: ...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 RD JC1 JOYSTICK CONTR...

Page 175: ...Section 6 Schematics September 2005 Part No 96316 GS 30 GS 32 GS 46 6 31 This page intentionally left blank ...

Page 176: ...atics June 2009 6 32 GS 30 GS 32 GS 46 Part No 96316 REV D Electrical Schematic CE Models GS 2032 2632 from serial number GS3204 60000 to GS3205 74999 GS 2046 2646 3246 from serial number GS4604 60000 to GS4605 74999 ...

Page 177: ...TOR CONT DRIVER POWER LS6 DOWN LIMIT SWITCH IN IN C2 IN C12 DWN LIMIT N C H O N O H C B11 OUT A9 PS2 PLATFORM OVERLOAD PRESSURE SWITCH 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 ECM POWER A4 IN LVL SNSR WHT LVL SNSR RED IN OUT C11 A5 RD WH BK N C S...

Page 178: ...UT6 POUT7 POUT9 POUT8 POUT10 HIGH TORQUE LED L21 POUT1 BATTERY LEVEL 1 BATTERY LEVEL 2 BATTERY LEVEL 3 BATTERY LEVEL 4 BATTERY LEVEL 5 G7 PLATFORM CONTROLS MEMBRANE DECAL H1 ALARM POUT11 PIN11 RD BK BK P2 EMERGENCY STOP BK RD SW25 DIP SWITCH 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 ...

Page 179: ...Section 6 Schematics June 2009 Part No 96316 GS 30 GS 32 GS 46 6 35 This page intentionally left blank ...

Page 180: ...B5 4 6V BATTERY GND U9 BATTERY CHARGER AC INPUT QD1 LS7 POTHOLE GUARD SWITCH LS8 POTHOLE GUARD SWITCH IN B10 POTHOLE LIMIT SWITCH H5 ALARM OUT B9 ALARM N C H O N C H O TS66 PLATFORM UP DOWN UP DOWN U27 47 mH INDUCTOR NOISE SUPPRESSION CR5 HORN RELAY H2 OPTION 87 30 85 86 U13 DC AC INVERTER OPTION CB2 7A CIRCUIT BREAKER A8 OUT B8 OUT A1 OUT FB FLASHING BEACONS OPTION P1 EMERGENCY STOP NOTE MACHINE ...

Page 181: ...CONT DRIVER POWER LS6 DOWN LIMIT SWITCH IN IN C2 IN C12 DWN LIMIT N C H O N O H C B11 OUT A9 PS2 PLATFORM OVERLOAD PRESSURE SWITCH 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 ECM POWER A4 IN LVL SNSR WHT LVL SNSR RED IN OUT C11 A5 RD WH BK N C S7 LE...

Page 182: ...4 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 PIN9 OR...

Page 183: ...r Relief valve Solenoid operated 2 position 2 way directional valve normally closed Orifice Platform overload pressure switch Brake Shuttle valve Solenoid operated 2 position 4 way directional valve Accumulator Pilot operated check valve with needle valve Solenoid operated 3 position 4 way directional valve Solenoid operated 3 position 4 way directional valve Filter Function manifold GS 1530 GS 15...

Page 184: ...K 1800 to 3500 psi 124 to 241 bar A C H I GS 1530 0 046 1 17 mm GS 1930 0 037 0 94 mm LIFT LIFT CYLINDER Y7 PS2 The lift cylinder orifice is located underneath the fitting on the lift cylinder N O R PLATFORM OVERLOAD CE MODELS FUNCTION MANIFOLD Y8 4 gpm 2500 psi 15 L min 172 bar HS0035C Hydraulic Schematic GS 1530 1532 1930 1932 from serial number GS3003 60000 to GS3004 65104 ...

Page 185: ... Hand pump manual brake release M Needle valve manual brake release N Platform lowering valve O Orifice platform down circuit P Accumulator R Pressure switch platform overload S Check valve drive circuit FUNCTION MANIFOLD STEER LEFT STEER RIGHT S1 S2 Y3 Y4 0 75 gpm 2 8 L min 1500 psi 103 bar B G F Y5 Y6 10 psi 0 7 bar D E M1 LEFT DRIVE MOTOR M4 RIGHT DRIVE MOTOR HP B L K P BRAKE RELEASE MANIFOLD M...

Page 186: ...ASS TANK 1800 to 3500 psi 124 to 241 bar A C H I GS 1530 0 046 1 17 mm GS 1930 0 037 0 94 mm LIFT LIFT CYLINDER Y7 PS2 The lift cylinder orifice is located underneath the fitting on the lift cylinder N O R PLATFORM OVERLOAD CE MODELS FUNCTION MANIFOLD 4 gpm 2500 psi 15 L min 172 bar HS0035D Hydraulic Schematic GS 1530 1532 1930 1932 from serial number GS3004 65105 to 66986 ...

Page 187: ...ease L Hand pump manual brake release M Needle valve manual brake release N Platform lowering valve O Orifice platform down circuit P Accumulator R Pressure switch platform overload S Check valve drive circuit FUNCTION MANIFOLD STEER LEFT STEER RIGHT S1 S2 Y3 Y4 0 75 gpm 2 8 L min 1500 psi 103 bar B G F Y5 Y6 10 psi 0 7 bar D E M1 LEFT DRIVE MOTOR M4 RIGHT DRIVE MOTOR HP B P 1 03 cu in 16 9 cc AC ...

Page 188: ...to 3500 psi 124 to 241 bar A C H I GS 1530 0 046 1 17 mm GS 1930 0 037 0 94 mm LIFT LIFT CYLINDER Y7 PS2 The lift cylinder orifice is located underneath the fitting on the lift cylinder N O R PLATFORM OVERLOAD CE MODELS FUNCTION MANIFOLD V 200 psi 13 8 bar S 4 gpm 2500 psi 15 L min 172 bar HS0035E Hydraulic Schematic GS 1530 1532 1930 1932 from serial number GS3004 66987 to GS3005 75999 ...

Page 189: ... L Hand pump manual brake release M Needle valve manual brake release N Platform lowering valve O Orifice platform down circuit P Accumulator R Pressure switch platform overload S Check valve drive circuit FUNCTION MANIFOLD STEER LEFT STEER RIGHT S1 S2 Y3 Y4 0 75 gpm 2 8 L min 1500 psi 103 bar B G F Y5 Y6 10 psi 0 7 bar D E M1 LEFT DRIVE MOTOR M4 RIGHT DRIVE MOTOR HP B P 1 03 cu in 16 9 cc AC BRAK...

Page 190: ...the lift cylinder TP 10 MICRON WITH 25 psi 1 7 bar BYPASS TANK 1800 to 3500 psi 124 to 241 bar AA O AJ AI AB UPPER LIFT CYLINDER GS 3246 The lift cylinder orifice is located underneath the fitting on the lift cylinder N O Q 0 037 0 94 mm V Y9 Y7 2500 psi 172 bar R N FUNCTION MANIFOLD PLATFORM OVERLOAD CE MODELS Y8 4 gpm 2500 psi 15 L min 172 bar HS0036G Hydraulic Schematic GS 2032 2632 from serial...

Page 191: ...release L Hand pump manual brake release M Needle valve manual brake release N Platform lowering valve O Orifice platform down circuit P Accumulator Q Relief valve platform down R Pressure switch platform overload FUNCTION MANIFOLD P 130 psi 9 bar AF STEER LEFT STEER RIGHT 0 040 1 mm S1 S2 Y3 Y4 0 75 gpm 2 8 L min 1500 psi 103 bar AD AH AC M1 LEFT DRIVE MOTOR M4 RIGHT DRIVE MOTOR HP 1 03 CU IN 16 ...

Page 192: ...ift cylinder TP 10 MICRON WITH 25 psi 1 7 bar BYPASS TANK 1800 to 3500 psi 124 to 241 bar AA O AJ AI AB UPPER LIFT CYLINDER GS 3246 The lift cylinder orifice is located underneath the fitting on the lift cylinder N O Q 0 037 0 94 mm V Y9 Y7 2500 psi 172 bar R N FUNCTION MANIFOLD PLATFORM OVERLOAD CE MODELS Y8 4 gpm 2500 psi 15 L min 172 bar HS0036F Hydraulic Schematic GS 2046 2646 3246 from serial...

Page 193: ... Hand pump manual brake release M Needle valve manual brake release N Platform lowering valve O Orifice platform down circuit P Accumulator Q Relief valve platform down R Pressure switch platform overload FUNCTION MANIFOLD L M P 130 psi 9 bar AF STEER LEFT STEER RIGHT 0 040 1 mm S1 S2 Y3 Y4 0 75 gpm 2 8 L min 1500 psi 103 bar AD AH AC M1 LEFT DRIVE MOTOR M4 RIGHT DRIVE MOTOR BRAKE RELEASE MANIFOLD...

Page 194: ... lift cylinder TP 10 MICRON WITH 25 psi 1 7 bar BYPASS TANK 1800 to 3500 psi 124 to 241 bar AA O AJ AI AB UPPER LIFT CYLINDER GS 3246 The lift cylinder orifice is located underneath the fitting on the lift cylinder N O Q 0 037 0 94 mm V Y9 Y7 2500 psi 172 bar R PLATFORM OVERLOAD CE MODELS N FUNCTION MANIFOLD Y8 4 gpm 2500 psi 15 L min 172 bar HS0036G Hydraulic Schematic GS 2046 2646 3246 from seri...

Page 195: ...ease L Hand pump manual brake release M Needle valve manual brake release N Platform lowering valve O Orifice platform down circuit P Accumulator Q Relief valve platform down R Pressure switch platform overload FUNCTION MANIFOLD P 130 psi 9 bar AF STEER LEFT STEER RIGHT 0 040 1 mm S1 S2 Y3 Y4 0 75 gpm 2 8 L min 1500 psi 103 bar AD AH AC M1 LEFT DRIVE MOTOR M4 RIGHT DRIVE MOTOR HP 1 03 CU IN 16 9 c...

Page 196: ...Section 6 Schematics September 2005 6 52 GS 30 GS 32 GS 46 Part No 96316 This page intentionally left blank ...

Page 197: ... 544 Phone 81 3 3453 6082 Fax 81 3 3453 6083 Phone 82 25 587 267 Fax 82 25 583 910 Phone 55 11 41 665 755 Fax 55 11 41 665 754 Phone 31 183 581 102 Fax 31 183 581 566 Genie Scandinavia Genie France Genie Iberica Genie Germany Genie U K Genie Mexico City Phone 46 31 575100 Fax Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Phone 34 93 579 5042 Fax 34 93 579 5059 Phone 0800 180 9017 Fax 49 422 149 ...

Page 198: ...Service Manual GS 30 GS 32 GS 46 from serial number GS3003 60000 to GS3005 75999 Rev E5 Part No 96316 from serial number GS3204 60000 to GS3205 75406 from serial number GS4604 60000 to GS4605 75437 ...

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