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Introduction
Basic mechanical, hydraulic and electrical Genie GS-1530 and GS-1930 Service Manual,
skills are required to perform most procedures. First Edition
However, several procedures require specialized (before serial number 17408) ............................... 39528
skills, tools, lifting equipment and a suitable Genie GS-1530 and GS-1930 Service Manual,
workshop. In these instances, we strongly Second Edition
recommend that maintenance and repair be (from serial number 17408 to 59999) ................... 72876
performed at an authorized Genie dealer Genie GS-1530 and GS-1930 Service Manual,
service center. Third Edition
(from serial number 60000 to 75999) ................... 96316
Compliance
Genie GS-2032 Service Manual,
Machine Classification First Edition
Group A/Type 3 as defined by ISO 16368 (before serial number 17408) ............................... 46326
Genie GS-2032 and GS-2632 Service Manual,
Machine Design Life
Second Edition
Unrestricted with proper operation, inspection and (from serial number 17408 to 59999) ................... 72963
scheduled maintenance.
Genie GS-2032 and GS-2632 Service Manual,
Third Edition
Technical Publications (from serial number 60000 to 75406) ................... 96316
Contact Us:
Copyright © 1997 by Genie Industries
www.genieindustries.com
e-mail: techpub@terex.com 97385 Rev E March 2007
Fourth Edition, Fifth Printing
Printed in U.S.A.
INTRODUCTION
Model: GS-1930
Serial number: GS3005A-12345
Model year: 2005 Manufacture date: 04/12/05
Electrical schematic number: ES0141
Machine unladen weight: 2,714 lb / 1,231 kg
ANSI A92.6-1999
B354.2-01
Genie Industries
18340 NE 76th Street
Redmond, WA 98052
USA
PN - 77055
Serial label
Serial number
(stamped on chassis)
Serial number
(stamped on chassis)
Safety Rules
Danger
Failure to obey the instructions and safety rules
in this manual and the appropriate Operator's
Manual on your machine will result in death or
serious injury.
Many of the hazards identified in the
operator’s manual are also safety hazards
when maintenance and repair procedures
are performed.
SAFETY RULES
Read each procedure thoroughly. This Be sure that all tools and working areas
manual and the decals on the machine, are properly maintained and ready for
use signal words to identify the following: use. Keep work surfaces clean and free of
debris that could get into machine components and
Safety alert symbol—used to alert cause damage.
personnel to potential personal
injury hazards. Obey all safety Be sure any forklift, overhead crane or
messages that follow this symbol other lifting or supporting device is fully
to avoid possible injury or death. capable of supporting and stabilizing the
weight to be lifted. Use only chains or straps that
Indicates an imminently hazardous
are in good condition and of ample capacity.
situation which, if not avoided, will
result in death or serious injury. Be sure that fasteners intended for one
Indicates a potentially hazardous time use (i.e., cotter pins and self-locking
situation which, if not avoided, nuts) are not reused. These components
could result in death or serious may fail if they are used a second time.
injury. Be sure to properly dispose of old oil or
Indicates a potentially hazardous other fluids. Use an approved container.
situation which, if not avoided, Please be environmentally safe .
may cause minor or moderate Be sure that your workshop or work area
injury. is properly ventilated and well lit.
Indicates a potentially hazardous
situation which, if not avoided,
may result in property damage.
Be sure to wear protective eye wear and
other protective clothing if the situation
warrants it.
Table of Contents
Introduction
Important Information ......................................................................................... ii
Serial Number Information ................................................................................. ii
Serial Number Legend ...................................................................................... iii
TABLE OF CONTENTS
TABLE OF CONTENTS
TABLE OF CONTENTS
TABLE OF CONTENTS
TABLE OF CONTENTS
TABLE OF CONTENTS
REV G
Specifications
Machine Specifications Tires and wheels
Battery capacity, maximum 200AH Castle nut torque, lubricated 225 ft-lbs
305 Nm
Reserve capacity @ 25A rate 380 minutes
SPECIFICATIONS REV G
Platform stowed, slow 1.1 mph GS-1530 and GS-1532 600 lbs
40 ft / 24.8 sec 272 kg
1.8 km/h GS-1930, GS-1932, GS-2632 and GS-3232 500 lbs
12.2 m / 24.8 sec 227 kg
Platform raised 0.5 mph GS-2032 800 lbs
40 ft / 55 sec 363 kg
0.8 km/h
12.2 m / 55 sec GS-2046 1200 lbs
544 kg
Braking distance, maximum
GS-2646 1000 lbs
High range on paved surface 24 in ± 12 in 454 kg
61 cm ± 30 cm
GS-3246 700 lbs
Gradeability 317 kg
GS-1930, GS-1932, GS-2632, GS-3232 Outrigger leveling capacity, maximum
GS-3232 and GS-3246 25%
Side to side 5°
GS-1530, GS-1532, GS-2032, Front to rear 3°
GS-2046 and GS-2646 30%
REV G SPECIFICATIONS
Hydraulic oil type Chevron Rando HD equivalent Displacement per revolution 0.244 cu in
Viscosity grade Multi-viscosity 4 cc
Viscosity index 200 Flow rate @ 2500 psi / 172 bar 4 gpm
Cleanliness level, minimum 15/13 15 L/min
Water content, maximum 200 ppm Hydraulic tank return filter 10 micron with
25 psi / 1.7 bar bypass
Chevron Rando HD oil is fully compatible and
mixable with Shell Donax TG (Dexron III) oils. Function manifold
Genie specifications require hydraulic oils which are System relief valve pressure, maximum 3700 psi
designed to give maximum protection to hydraulic 255 bar
systems, have the ability to perform over a wide
temperature range, and the viscosity index should Lift relief valve pressure 1800 to 3700 psi
exceed 140. They should provide excellent antiwear, 124 to 241 bar
oxidation, corrosion inhibition, seal conditioning, and
foam and aeration suppression properties. Steer relief valve pressure 1500 psi
103 bar
Optional fluids
Outrigger manifold
Biodegradable Petro Canada Environ MV 46
Statoil Hydra Way Bio Pa 32 Relief valve pressure, maximum 3500 psi
BP Biohyd SE-S 241 bar
Mineral based Shell Tellus T32 Check valve pressure, maximum 200 psi
Shell Tellus T46 13.8 bar
Chevron Aviation A
SPECIFICATIONS REV G
REV G SPECIFICATIONS
SAE Dash size Torque SAE Dash size Thread Size Flats
-4 16 ft-lbs / 21.7 Nm
-6 35 ft-lbs / 47.5 Nm
-8 60 ft-lbs / 81.3 Nm
SPECIFICATIONS REV G
b
b
a
c
d c
b
Figure 1 Figure 2
REV G SPECIFICATIONS
Size Class 4.6 4.6 Class 8.8 8.8 Class 10.9 10.9 Class 12.9 12.9
Maintenance Schedule
Indicates that tools will be required to
perform this procedure. 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
Indicates that new parts will be required
Section and the Maintenance Inspection Report
to perform this procedure.
have been divided into five subsections—A, B, C,
D, and E. Use the following chart to determine
which group(s) of procedures are required to
Indicates that a cold motor or pump will perform a scheduled inspection.
be required to perform this procedure.
Inspection Checklist
Fundamentals Instructions
It is the responsibility of the dealer to perform the Use the operator’s manual on your machine.
Pre-delivery Preparation.
The Pre-delivery Preparation consists of completing
The Pre-delivery Preparation is performed prior to the Pre-operation Inspection, the Maintenance items
each delivery. The inspection is designed to discover if and the Function Tests.
anything is apparently wrong with a machine before it
is put into service. Use this form to record the results. Place a check in
the appropriate box after each part is completed.
A damaged or modified machine must never be used. Follow the instructions in the operator’s manual.
If damage or any variation from factory delivered
condition is discovered, the machine must be tagged If any inspection receives an N, remove the machine
and removed from service. from service, repair and re-inspect it. After repair,
place a check in the R box.
Repairs to the machine may only be made by a
qualified service technician, according to the Legend
manufacturer's specifications. Y = yes, completed
Scheduled maintenance inspections shall be N = no, unable to complete
performed by qualified service technicians, according R = repaired
to the manufacturer's specifications and the Comments
requirements listed in the responsibilities manual.
Pre-Delivery Preparation Y N R
Pre-operation inspection
completed
Maintenance items completed
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
A-2 A-3
Perform Pre-operation Inspection Perform Function Tests
Completing a Pre-operation Inspection is essential Completing the function tests is essential to safe
to safe machine operation. The Pre-operation machine operation. Function tests are designed to
Inspection is a visual inspection performed by the discover any malfunctions before the machine is
operator prior to each work shift. The inspection is put into service. A malfunctioning machine must
designed to discover if anything is apparently never be used. If malfunctions are discovered, the
wrong with a machine before the operator performs machine must be tagged and removed from
the function tests. The Pre-operation Inspection service.
also serves to determine if routine maintenance
procedures are required. Complete information to perform this procedure is
available in the appropriate operator's manual.
Complete information to perform this procedure is Refer to the Operator's Manual on your machine.
available in the appropriate operator's manual.
Refer to the Operator's Manual on your machine.
A-4 A-5
Perform 30 Day Service Grease the Steer Yokes
The 30 day maintenance procedure is a one time Genie specifications require that this procedure be
procedure to be performed after the first 30 days or performed every 100 hours of operation.
40 hours of usage. After this interval, refer to the
maintenance tables for continued scheduled Regular application of lubrication to the steer yokes
maintenance. is essential to good machine performance and
service life. Continued use of an insufficiently
1 Perform the following maintenance procedures: greased steer yoke will result in component
damage.
· B-3 Inspect the Tires, Wheels and
Castle Nut Torque 1 Locate the grease fitting on the top of the steer
· D-2 Replace the Hydraulic Tank yoke.
Return Filter Element 2 Pump multipurpose grease into the steer yoke
until the steer yoke is full and grease is being
forced past the bearings. Repeat this step for
the other steer yoke.
Grease Specification
REV J
Checklist B Procedures
B-1 Models without maintenance-free or sealed
batteries:
Inspect the Batteries
6 Remove the battery vent caps and check the
specific gravity of each battery cell with a
hydrometer. Note the results.
Genie requires that this procedure be performed 7 Check the ambient air temperature and adjust
every 250 hours or quarterly, whichever comes the specific gravity reading for each cell as
first. follows:
Proper battery condition is essential to good • Add 0.004 to the reading of each cell for
machine performance and operational safety. every 10° / 5.5° C above 80° F / 26.7° C.
Improper fluid levels or damaged cables and
• Subtract 0.004 from the reading of each cell for
connections can result in component damage and
every 10° / 5.5° C below 80° F / 26.7° C.
hazardous conditions.
Result: All battery cells display an adjusted
Electrocution/burn hazard. Contact specific gravity of 1.277 or higher. The battery
with electrically charged circuits is fully charged. Proceed to step 11.
could result in death or serious
injury. Remove all rings, watches Result: One or more battery cells display a
and other jewelry. specific gravity of 1.217 or below. Proceed to
step 8.
Bodily injury hazard. Batteries
contain acid. Avoid spilling or 8 Perform an equalizing charge OR fully charge
contacting battery acid. Neutralize the batteries and allow the batteries to rest at
battery acid spills with baking soda least 6 hours.
and water. 9 Remove the battery vent caps and check the
1 Release the battery pack latch and rotate the specific gravity of each battery cell with a
battery pack out and away from the chassis. hydrometer. Note the results.
2 Be sure that the battery cable connections are 10 Check the ambient air temperature and adjust
free of corrosion. the specific gravity reading for each cell as
follows:
Note: Adding terminal protectors and a corrosion
preventative sealant will help eliminate corrosion • Add 0.004 to the reading of each cell for
on the battery terminals and cables. every 10° / 5.5° C above 80° F / 26.7° C.
3 Be sure that the battery retainers and cable • Subtract 0.004 from the reading of each cell for
connections are tight. every 10° / 5.5° C below 80° F / 26.7° C.
4 Fully charge the batteries. Allow the batteries to Result: All battery cells display a specific gravity
rest 24 hours before performing this procedure of 1.277 or greater. The battery is fully charged.
to allow the battery cells to equalize. Proceed to step 11.
5 Put on protective clothing and eye wear. Result: The difference in specific gravity
readings between cells is greater than 0.1 OR
the specific gravity of one or more cells is less
than 1.177. Replace the battery.
12 Install the vent caps and neutralize any 14 Inspect the battery charger plug and pigtail for
electrolyte that may have spilled. damage or excessive insulation wear. Replace
as required.
+
QD1 c
is too low or too high. Correct the voltage issue.
The charger will then operate correctly and
BK RD begin charging the batteries.
U9
Battery Charger d If, simultaneously, the charger alarm sounds
and the LEDs blink three times, the charger is
overheated. Allow the charger to cool. The
charger will then operate correctly and begin
a batteries B5
b 275A fuse F6 charging the batteries.
c quick disconnect QD1
d battery charger U9
Note: For best results, use an extension of
adequate size with a length no longer than
50 feet / 15 m.
Maintaining electrical wiring in good condition is 7 Lower the platform onto the safety arm.
essential to safe operation and good machine Crushing hazard. Keep hands
performance. Failure to find and replace burnt, clear of the safety arm when
chafed, corroded or pinched wires could result in lowering the platform.
unsafe operating conditions and may cause
component damage. 8 Inspect the center chassis area and scissor
arms for burnt, chafed and pinched cables.
Electrocution/burn hazard. Contact
with electrically charged circuits 9 Inspect the following areas for burnt, chafed,
could result in death or serious corroded, pinched and loose wires:
injury. Remove all rings, watches · Scissor arms
and other jewelry.
· ECM to platform controls
1 Inspect the underside of the chassis for
· Power to platform wiring
damaged or missing ground strap(s).
10 Inspect for a liberal coating of dielectric grease
2 Inspect the following areas for burnt, chafed, in all connections between the ECM and the
corroded and loose wires: platform controls.
· Ground control panel 11 Raise the platform and return the safety arm to
· Hydraulic power unit module tray the stowed position.
· Battery pack module tray 12 Lower the platform to the stowed position and
· Scissor arms turn the machine off.
· 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
B-3 B-4
Inspect the Tires and Wheels Test the Emergency Stop
(including castle nut torque) Genie requires that this procedure be performed
every 250 hours or quarterly, whichever comes
first.
B-5 B-6
Test the Key Switch Test the Automotive-style Horn
Genie requires that this procedure be performed (if equipped)
every 250 hours or quarterly, whichever comes Genie requires that this procedure be performed
first. every 250 hours or quarterly, whichever comes
Proper key switch action and response is essential first.
to safe machine operation. The machine can be The horn is activated at the platform controls and
operated from the ground or platform controls and sounds at the ground as a warning to ground
the activation of one or the other is accomplished personnel. An improperly functioning horn will
with the key switch. Failure of the key switch to prevent the operator from alerting ground
activate the appropriate control panel could cause personnel of hazards or unsafe conditions.
a hazardous operating situation.
1 Turn the key switch to platform control and
Perform this procedure from the ground using the pull out the red Emergency Stop button to the
platform controls. Do not stand in the platform. on position at both the ground and
1 Pull out the red Emergency Stop button to the platform controls.
on position at both the ground and platform 2 Push down the horn button at the platform
controls. controls.
2 Turn the key switch to platform control. Result: The horn should sound.
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.
Perform this procedure with the machine on a firm Note: The brakes must be able to hold the machine
level surface that is free of obstructions, with the on any slope it is able to climb.
platform extension deck fully retracted and the 8 Disconnect the battery pack from the machine.
platform in the stowed position.
Electrocution/burn hazard. Contact
1 Mark a test line on the ground for reference. with electrically charged circuits
2 Turn the key switch to platform control and pull could result in death or serious
out the red Emergency Stop button to the on injury. Remove all rings, watches
position at both the ground and platform and other jewelry.
controls. 9 Locate the drive forward/reverse valve on the
3 Lower the platform to the stowed position. function manifold. Refer to Illustrations 2 and 3.
Illustration 1
5 Choose a point on the machine; i.e., contact GS-1530 • GS-1532 • GS-1930 • GS-1932
patch of a tire, as a visual reference for use
Illustration 2
when crossing the test line.
a drive forward/reserve valve
For GS-2032 and GS-2632 after serial number 20 Repeat this procedure beginning with step 1.
GS3204-51607 and from GS3208C-101 proceed If the machine fails to stop within the specified
to step 21. stopping distance after installing new brakes,
For GS-2046, GS-2646 and GS-3246 after please contact the Genie Industries Scissors
serial number GS4604-59999 and from Service Department, 1-800-536-1800 Ext. 8710.
GS4609-101 proceed to step 21.
21 Remove the drive forward/reverse valve from 25 Install the coil nut onto the valve and torque to
the function manifold. Plug the open port of the 60 in-lbs 7 Nm.
manifold.
26 Connect the battery pack to the machine.
22 Carefully inspect the hex portion of the valve for
27 Replace the brakes and repeat this procedure
an identification stamp.
beginning with step 1. Refer to Repair
Result: SV10-5905 is stamped on the hex Procedure 9-1, How to Remove a Drive Brake.
portion of the drive forward/reverse valve. Repeat this procedure beginning with step 1.
This indicates the machine is equipped with
28 Contact the Genie Industries Service Parts
a dynamic brake valve. Proceed to step 23.
Department and order kit part number 105458.
Result: SV10-5905 is not stamped on the hex
29 Install the new valve received in the kit and
portion of the drive forward/reverse valve. This
mark the new valve with a white paint pen to
indicates the machine is not equipped with a
identify new valve installation.
dynamic brake valve. Proceed to step 28.
30 Repeat this procedure beginning with step 1.
23 Install the drive forward/reverse valve removed
in step 21 into the function manifold and torque If the machine fails to stop within the specified
to 25 ft-lbs / 34 Nm. stopping distance after installing new brakes,
please contact the Genie Industries Scissors
24 In order, install the reverse valve coil (with
Service Department, 1-800-536-1800 Ext. 8710.
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.
a b
B-11 B-12
Perform Hydraulic Oil Analysis Inspect the Hydraulic Tank Cap
Venting System
B-13
Check the Module Tray Latch
Components
Genie requires that this procedure be performed If the left fault LED (REV_POL) is illuminated,
every 250 hours or quarterly, whichever comes the inverter is connected to batteries with the
first. incorrect polarity. Correct the polarity issue with
the red wire to battery positive and the black
1 Inspect the inverter plug and pigtail for damage wire to battery negative. The inverter will then
or excessive insulation wear. Replace as operate correctly and begin supplying AC
required. power.
2 Turn the key switch to the on position and pull If the right fault LED (123) blinks one time, the
out the red Emergency Stop button to the on power draw is too high. The tool being used
position at both the ground and platform requires too much power to operate or is being
controls. used at or near the limit of the inverter for an
extended period of time. Reduce the power
b a
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
FAUL
T OUT
between the AC hot and ground in the tool or
PUT
POW
ER IN outlet. Check the tool for burnt, chafed,
c VERT
ER
25V corroded and loose wires, and inspect the tool
24V-2
21V
2V for internal moisture. Correct the short circuit or
d moisture issue OR inspect the wiring in the
PART
N UM
BER
XXX
power-to-platform box. The inverter will then
operate correctly and begin supplying AC
power.
If right fault LED (123) blinks three times, the
inverter is overheated. Allow the inverter to
a right fault LED cool. The inverter will then operate correctly
b left fault LED
and begin supplying AC power.
c 25V LED
d 21V LED If the battery 25 volt fault LED (25V) blinks one
time, the battery voltage is over 30V. Operate
the machine to lower the voltage level. The
inverter will then operate correctly and begin
supplying AC power.
If the battery 21 volt fault LED (21V) blinks one
time, the battery voltage is less than 20V DC.
The inverter will continue to operate until the
battery voltage falls to 17.8V DC.
13 Press the drive function select button. Attempt 19 Turn the key switch to the off position.
to drive the machine.
20 Disconnect the platform controls from the ECM
Result: The diagnostic display will show code cable.
18, an alarm sounds, and the steer and drive
21 Securely install the connector of the ECM cable
functions should not operate. The machine is
into the platform control cable.
functioning properly.
22 Working at the platform, securely install the
Result: The diagnostic display does not show
connector of the platform controls into the
code 18, the alarm does not sound, and the
platform control cable.
steer and drive functions operate. Replace the
down limit switch. 23 Enable the down limit switch. Loosen the
fastener securing the roller arm to the limit
14 Press the lift function select button. Raise the
switch, and rotate the roller arm 90 degrees in
platform approximately 12 inches / 0.3 m.
a upwards direction. Do not activate the switch
Result: The diagnostic display will show code contacts.
18 and an alarm sounds. The machine is
24 Turn the key switch to platform control.
functioning properly.
25 Raise the platform and return the safety arm to
Result: The diagnostic display does not show
the stowed position.
code 18 and the alarm does not sound.
Replace the down limit switch. 26 Lower the platform to the stowed position.
15 Raise the platform until the pothole guards are
deployed.
Result: The diagnostic display does not show
code 18 and 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 when
lowering the platform.
Pothole Limit Switches 32 Press the lift function select button. Attempt to
raise the platform approximately 8 feet / 2.4 m.
27 Move the machine onto a grade which exceeds
the rating of the level sensor. Refer to the serial Result: The pothole guard contacts the block
label on the machine. and does not fully deploy, the diagnostic display
shows code 18, an alarm sounds and the
28 Press the lift function select button. Standing on platform will lift to 8 feet / 2.4 m or beyond. The
the up-hill side of the machine, attempt to raise machine is functioning properly.
the platform to approximately 8 feet / 2.4 m.
Result: The pothole guard contacts the block
Result: The diagnostic display shows code LL, and does not fully deploy, the diagnostic display
an alarm sounds, and the machine stops lifting does not show code 18, the alarm does not
after the pothole guards are deployed. The sound and the machine will continue to lift the
machine is functioning properly. platform after the pothole guards are deployed.
Result: The diagnostic display does not show Adjust or replace the pothole limit switch.
code LL, the alarm does not sound and the 33 Press the drive function select button. Attempt
machine will continue to lift the platform after to steer or drive the machine.
the pothole guards are deployed. Adjust or
replace the pothole limit switch. Result: The diagnostic display shows code 18,
an alarm sounds, and the machine will not steer
29 Press the drive function select button. Standing or drive. The machine is functioning properly.
on the up-hill side of the machine, attempt to
steer and drive the machine. Result: The diagnostic display does not show
code 18, the alarm does not sound and the
Result: The diagnostic display shows code LL, steer and drive functions operate. Adjust or
an alarm sounds, and the machine will not steer replace the down limit switch.
or drive. The machine is functioning properly.
34 Lower the platform to the stowed position and
Result: The diagnostic display does not show remove the block under the right pothole guard.
code LL, the alarm does not sound and the
steer and drive functions operate. Adjust or 35 Repeat this procedure beginning with step 31
replace the pothole limit switch. for the left pothole guard.
30 Lower the platform to the stowed position. Move 36 Lower the platform to the stowed position,
the machine onto a firm, level surface. remove the block under the left pothole guard.
31 Place a wooden block approximately 37 Turn off the machine.
2 inches / 5 cm tall under the right pothole
guard.
REV C
Checklist C Procedures
C-1 The maximum height limit switch, located in the
middle of the drive chassis under the scissor arms,
Test the is used to disable the lift valve coil when the
Platform Overload System platform is near maximum height. When activated,
the limit switch keeps the lift cylinder from going
(if equipped) over lift relief which would cause the pressure
switch to falsely indicate an overload condition.
1 Locate the lift valve coil on the function 5 Fully raise the platform. Release the toggle
manifold. switch.
a Result: The alarm should sound.
Result: The alarm does not sound. Calibrate the
platform overload system. Refer to Repair
• GS-1532 Procedure 3-7, Calibrate the Platform Overload
• GS-1932 System (if equipped).
b
6 Using the manual lowering knob, lower the
platform to the stowed position.
7 Disconnect the two blue/black wires of the
manifold wire harness at the lift valve coil on the
manifold.
C-2
Replace the
Hydraulic Tank Breather Cap -
Models with Optional Hydraulic Oil
D-1
Check the
Scissor Arm Wear Pads
Illustration 2
a wear pad
b inner arm cross tube
c chassis deck
c b a
Illustration 2
a wear pad
b inner arm cross tube
c chassis deck
1 Disconnect the battery pack from the machine. 9 Install the hydraulic tank and install and tighten
the hydraulic tank retaining fasteners. Torque to
Electrocution/burn hazard. Contact specification.
with electrically charged circuits
could result in death or serious
Torque specifications
injury. Remove all rings, watches
and other jewelry. Hydraulic tank retaining fasteners, dry 35 in-lbs
4 Nm
2 Open the power unit module tray.
Hydraulic tank retaining fasteners, lubricated 26 in-lbs
2.9 Nm
Repair Procedures
About This Section
Most of the procedures in this section should only
be performed by a trained service professional
in a suitably equipped workshop. Select the
appropriate repair procedure after troubleshooting
the problem.
Observe and Obey:
Perform disassembly procedures to the point
Repair procedures shall be completed by a where repairs can be completed. Then to
person trained and qualified on the repair of this re-assemble, perform the disassembly steps in
machine. reverse order.
Immediately tag and remove from service a Symbols Legend
damaged or malfunctioning machine.
Safety alert symbol—used to alert
Repair any machine damage or malfunction personnel to potential personal
before operating the machine. injury hazards. Obey all safety
messages that follow this symbol
Before Repairs Start: to avoid possible injury or death.
Read, understand and obey the safety rules Indicates an imminently hazardous
and operating instructions in the appropriate situation which, if not avoided, will
operator's manual on your machine. result in death or serious injury.
Be sure that all necessary tools and parts are Indicates a potentially hazardous
available and ready for use. situation which, if not avoided,
could result in death or serious
Use only Genie approved replacement parts.
injury.
Read each procedure completely and adhere to
Indicates a potentially hazardous
the instructions. Attempting shortcuts may
situation which, if not avoided,
produce hazardous conditions.
may cause minor or moderate
Unless otherwise specified, perform each repair injury.
procedure with the machine in the following
Indicates a potentially hazardous
configuration:
situation which, if not avoided,
· Machine parked on a firm, level surface may result in property damage.
· Platform in the stowed position Indicates that a specific result is expected after
· Key switch in the off position with the key performing a series of steps.
removed Indicates that an incorrect result has occurred
· The red Emergency Stop button in the off after performing a series of steps.
position at both ground and platform controls
· Wheels chocked
· All external AC power supply disconnected
from the machine
The platform controls consist of an electronic 3 Locate the circuit board mounted to the top half
circuit board, joystick, membrane decal, buttons, of the platform control box.
LEDs and a diagnostic display. Electrocution/burn hazard. Contact
For further information or assistance, consult the with electrically charged circuits
Genie Industries Service Department. could result in death or serious
injury. Remove all rings, watches
and other jewelry.
Component damage hazard.
a Electrostatic discharge (ESD) can
JC1 damage printed circuit board
JOYSTICK
CONTROLLER components. Maintain firm contact
b H1
ALARM
with a metal part of the machine
that is grounded at all times when
handling printed circuit boards OR
U3
c PLATFORM CONTROLS
CIRCUIT BOARD
use a grounded wrist strap.
4 Remove the alarm and the red Emergency Stop
button assemblies from the control box.
P2
d EMERGENCY
STOP 5 Carefully disconnect the wire harness
connectors from the circuit board.
a joystick controller JC1
6 Carefully remove the circuit board retaining
b alarm H1
c platform controls circuit board U3 fasteners and remove the circuit board from the
d red Emergency Stop button P2 control box.
The outrigger control pad is used to operate the How to Remove the Outrigger
outriggers from the platform or while standing on
the ground and can also be used to calibrate the Control Pad Circuit Board
outrigger ECM and the outrigger level sensor. 1 Push in the red Emergency Stop button to the
off position at both the ground and platform
Activating buttons on the outrigger control pad controls.
sends a signal to the outrigger Electronic Control
Module (ECM). When the outrigger ECM receives 2 Remove the fasteners securing the outrigger
a signal, it enables the outrigger control pad to control pad to the outrigger control pad bracket.
extend, retract or autolevel the outriggers. When Set the fasteners to the side.
calibrating the outrigger ECM and the outrigger 3 Carefully remove the top half of the control pad
level sensor, the outrigger control pad buttons are and set to the side.
used in a specific sequence to achieve calibration.
4 Locate the circuit board mounted to the bottom
The outrigger control pad consist of an electronic half of the outrigger control pad.
circuit board, membrane decal, buttons and LEDs.
Electrocution/burn hazard. Contact
For further information or assistance, consult the with electrically charged circuits
Genie Industries Service Department. could result in death or serious
injury. Remove all rings, watches
a and other jewelry.
4 At the platform controls, press and hold the lift 8 Turn the key switch to the off position.
function select and horn buttons and pull out Note: Any change in software settings will not take
the red Emergency Stop button to the on effect until the key switch is turned to the off
position. 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 lift function select button.
On machines with software revision A4 and higher, 6 Press the drive function select button.
setting the raised drive speed percentage to zero
will result in the steer function being disabled when Result: The diagnostic display will show the
the platform is above the down limit switch. stowed drive speed percentage.
Refer to 1-2, How to Determine the Software 7 Use the steering thumb rocker switch on the
Revision Level. joystick to increase or decrease the stowed
drive speed percentage. Refer to Section 2,
1 Pull out the red Emergency Stop button to the
Specifications, for drive speeds.
on position at the ground controls.
8 Turn the key switch to the off position.
2 Push in the red Emergency Stop button to the
off position at the platform controls. Note: Any change in software settings will not take
effect until the key switch is turned to the off
3 Turn the key switch to platform control.
position.
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.
On machines with software revision A4 and higher, 6 Press the drive function select button.
setting the raised drive speed percentage to zero 7 Press and hold the horn button.
will result in the steer function being disabled when
the platform is above the down limit switch. Result: The diagnostic display will show the
Refer to 1-2, How to Determine the Software raised drive speed percentage.
Revision Level. 8 Use the steering thumb rocker switch on the
1 Pull out the red Emergency Stop button to the joystick to increase or decrease the raised drive
on position at the ground controls. speed percentage. Refer to Section 2,
Specifications, for drive speeds.
2 Push in the red Emergency Stop button to the
off position at the platform controls. 9 Turn the key switch to the off position.
3 Turn the key switch to platform control. Note: Any change in software settings will not take
effect until the key switch is turned to the off
4 At the platform controls, press and hold the lift position.
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.
On machines with software revision A4 and higher, 6 Press the drive function select button.
setting the raised drive speed percentage to zero
will result in the steer function being disabled when Result: The diagnostic display will show the
the platform is above the down limit switch. stowed drive speed percentage.
Refer to 1-2, How to Determine the Software 7 Press and hold the speed select button.
Revision Level.
Result: The diagnostic display will show the
1 Pull out the red Emergency Stop button to the stowed high torque drive speed percentage.
on position at the ground controls.
8 Use the steering thumb rocker switch on the
2 Push in the red Emergency Stop button to the joystick to increase or decrease the stowed
off position at the platform controls. high torque drive speed percentage.
3 Turn the key switch to platform control. 9 Turn the key switch to the off position.
4 At the platform controls, press and hold the lift Note: Any change in software settings will not take
function select and horn buttons and pull out effect until the key switch is turned to the off
the red Emergency Stop button to the on position.
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.
1-3
Software Configuration
The Electronic Control Module (ECM) contains
programming for all configurations of the Genie a d
GS-30, GS-32 and GS-46. The machine can be
adjusted to a different configuration using the
b
buttons at the platform controls.
c
How to Determine the a lift function select button BN9
Software Configuration b diagnostic display
c red Emergency Stop button P2
1 Remove the platform controls from the platform. d speed select button BN6
2 Pull out the red Emergency Stop button to the 5 Release the lift function select and speed select
on position at the ground controls. buttons.
3 Push in the red Emergency Stop button to the Result: The diagnostic display will show the
off position at the platform controls. current configuration.
4 At the platform controls, press and hold the lift 6 Push in the red Emergency Stop button to the
function select and speed select buttons, and off position at both the ground and platform
pull out the red Emergency Stop button to the controls and turn the key switch to the off
on position. position.
Result: The diagnostic display, at the platform
controls and the ECM, will show "SC."
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 the chassis exceeds the rating on the
serial plate. Configured on all machines.
Platform Overload: When the platform overload limit switch is tripped, signaling an overload condition
in the platform, all machine functions are disabled. The additional weight must be removed from the
platform and the power cycled from off to on before any function can be resumed. Required for CE
models.
Descent Delay: This option halts descent for 4 to 6 seconds. All controls must be released and re-
engaged before descent is re-enabled. Required for CE models.
Battery Drain Alarm: When the machine is turned on and in the stowed position, and no function is
activated for 2 minutes, an alarm will sound once every 3 seconds.
When this option is configured, a dot in the diagnostic display window will remain continuously
illuminated when the ECM is in the 'SC' mode OR when the platform up function is activated.
5 Release the lift function select and speed select 8 Press the speed select button.
buttons. Result: The 'ones' digit setting will be activated
Result: The diagnostic display will show the and the current 'ones' setting will flash in the
current configuration. diagnostic display. Use the steering thumb
rocker switch on the joystick to increase or
6 Press the lift function select button. decrease the value. See 1-3, Machine
Result: The 'tens' digit setting will be activated Configuration Code Chart for configuration
and the current 'tens' setting will flash in the settings.
diagnostic display. Use the steering thumb 9 Press and hold the speed select button for a
rocker switch on the joystick to increase or minimum of 3 seconds to set the 'ones' value.
decrease the value. See 1-3, Machine
Configuration Code Chart for configuration 10 Turn the key switch to the off position.
settings. Note: Any change in software settings will not take
7 Press and hold the lift function select button for effect until the key switch is turned to the off
a minimum of 3 seconds to set the 'tens' value. position.
Outrigger Control Pad 5 Press and hold the outrigger extend and retract
buttons and pull out the red Emergency Stop
a lift enable
b lift error
button to the on position at the platform
c right front outrigger controls.
d right rear outrigger
e outrigger extend Result: The lift error light turns red at the
f function enable outrigger control pad.
g outrigger retract
h left rear outrigger 6 Continue to hold the outrigger extend and
i left front outrigger retract buttons.
Result: After approximately 3 seconds at the
outrigger control pad, the right front outrigger,
right rear outrigger, left rear outrigger and left
front outrigger lights turn red. The lift error light
remains red.
7 Continue to hold the outrigger retract button
and release the outrigger extend button.
Result: After approximately 5 seconds at the
outrigger control pad, the lift enable light turns
green. The right front outrigger, right rear
outrigger, left rear outrigger and left front
outrigger lights remain red.
8 Press and hold the function enable and How to Activate the
outrigger extend buttons until the outriggers
are fully extended. Continue to hold the Outrigger Motion Alarm Option
outrigger extend button and release the 1 Turn the key switch to platform control.
function enable button.
3 Pull out the red Emergency Stop button to the
Result: After approximately 5 seconds at the on position at the ground controls.
outrigger control pad, the right front outrigger,
right rear outrigger, left rear outrigger and left 4 Push in the red Emergency Stop button to the
front outrigger lights turn green. off position at the platform controls.
Result: The outrigger controls alarm will sound 5 Press and hold the outrigger extend button and
for approximately 1 second. pull out the red Emergency Stop button to the
on position at the platform controls.
9 Press and hold the function enable and
outrigger retract buttons until the outriggers Result: After approximately 5 seconds, the
are fully retracted. Push in the red Emergency outrigger controls alarm will sound twice. The
Stop button to the off position at the platform outrigger motion alarm is now activated.
controls. The pressure transducers are now
calibrated. How to Deactivate the
Note: After installing a new cylinder or pressure
Outrigger Motion Alarm Option
transducer, the pressure transducers on the 1 Turn the key switch to platform control.
machine must be calibrated.
3 Pull out the red Emergency Stop button to the
on position at the ground controls.
a 4 Push in the red Emergency Stop button to the
off position at the platform controls.
b
5 Press and hold the outrigger extend button and
pull out the red Emergency Stop button to the
on position at the platform controls.
i c
Result: After approximately 5 seconds, the
h d outrigger controls alarm will sound twice. The
outrigger motion alarm is now deactivated.
g e
a lift enable
b lift error
c right front outrigger
d right rear outrigger
e outrigger extend
f function enable
g outrigger retract
h left rear outrigger
i left front outrigger
6 Remove the top enclosure of the control pad 8 Using a set of pliers, grasp the connector of
and set to the side. Refer to Illustration 2. the coil cord and slowly pull the coil cord away
from the printed circuit board. Refer to
Component damage hazard.
Illustration 3.
Electrostatic discharge (ESD) can
damage printed circuit board Component damage hazard.
components. Maintain firm Attempting to disconnect the coil
contact with a metal part of the cord from the printed circuit board
machine that is grounded at all at the cord wires, may result in
times when handling printed the cord wires pulling out of the
circuit boards OR use a grounded connector.
wrist strap.
a
a
c b
c
Illustration 3
f
a coil cord
d
b coil cord connector
c printed circuit board
e
9 Proceed to step 16 to update the firmware.
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
Illustration 4
a outrigger ECM
How to Update the Firmware 17 Plug the PSoc MiniProg cable into the printed
circuit board of the ECM or the control pad,
Note: The PSoC Programmer (Genie part number making sure the "VDD" on the PSoC MiniProg
125324), updated Hex files for the outrigger cable line up with the "+" on the printed circuit
control pad (Genie part number 125132) and the board. Refer to Illustration 6.
updated Hex files for the outrigger ECM (Genie
part number 125131) must be installed on a PC or
laptop.
MTG1 MTG2
R20
1 4
VDD
JP1
C7 C8
U2
TP17
TP12
TP11 TP1
TP16 D1
+ R C D 24V
TP7
LED5 LED4
R17
D2
Illustration 6
19 Select "MINIProg1/048E47470618" from the Result: All the boxes in the lower right corner
"Port" drop down menu. of the "PSoC Programmer" window should
have a green background and show as being
"Connected."
Red
Background
Green
Background
All Green
Backgrounds
All Green
Backgrounds
21 Browse the folder containing the appropriate Note: To ensure the correct file is selected for
.hex file, select the file and click "Open." either the ECM or control pad update, refer to
the decals located in Illustrations 2 and 5. An
Result: All the boxes in the lower right hand
example of the firmware file number and revision
corner of the "PSoC Programmer" window
level can be found on the decals as shown below.
should have a green background.
DESCRIPTION: ECU O/R CONTROLS, GS3232P DESCRIPTION: PCON, O/R CONTROLS, GS3232P
SERIAL #: 125320 A
SERIAL #:
125321 A
All Green
Backgrounds
Note: The ECM printed circuit board will be Note: The control pad printed circuit board will be
labeled with Genie part number 105368 and will labeled with Genie part number 105370 and will
serve as the identifier when for selecting "29x66" serve as the identifier when for selecting "29x66"
from the "Device Family" drop-down menu. Refer from the "Device Family" drop-down menu. Refer
to Illustration 7. to Illustration 8.
L1
C14
MTG1
PCB P / N: 105369 REV: A
PCBA P / N: 105370 REV: A
C1
C9
LIFT
PCB P / N: 105367 REV: A
C9 C2
JP1
C8
U1
C7
U2
L2
VCC TP12
R98 R101
+ - R C D TP7
LED5
R90
D6
GREEN
LED1
R14
MTG1 MTG2
PCB P/N: 105369 REV: A
PCBA P/N: 105370 REV: RED J1
C9
LIFT LED0 1 4
R20
J1 D5
D1
F1 F2
JP1
C7 C8
D3
U2
SGND TP17
A12 TP12
CONTROL PAD
TP11 TP1
TP16 D1
A1 D2
+ - R C D 24V
B12 B1 TP7
C1
C12 LED5 LED4
R17
D2
C6
GND
D42 D43 D29 D30 D27 D28 D25 D26 D23 D24 D37 D38 D35 D36 D33 D34 D31 D32
L1
LF TP6
TP13
C11
TP14
C12 C13 RF
R87
R67
R70
R12
U4 U5 C14
U3
PCBA P/N: 105368 REV:
U14
U11
U13
U12
R6 R7
L1
C10
C7
R4 R8
24VCC_A
C5 R9 TP15
24VCC_C 24VCC_B R19
D4 D49 D48
C4 C33 C5 C14 R3
TP10
LR
R10 R11 Q2 R13
C1
C6
C34
C8
RR C3
R16 R15
R75 R74 R71 R72 R82 R81 R77 R78 R38 R37 R40 R41 R44 R43 R47 R48 R53 R52 R56 R57 R60 R59 R63 R64
ECM
D22
C9 C2
R2 Q3
C1
PCB P/N: 105367 REV A
U1
R76
R83 R79 R73 R84 R86 R85 R80 R39 R45 R49 R42 R46 R51 R54 R50 R55 R61 R65 R58 R62 R68 R69 R66
LED3 LED2
D5
L2 R5
VCC D6
D39 D21 LS1
R101
D50
C2
R7
U1
R98
C12
R14
R88
U8
R8
U3
L2
C10
R99 R90
R13
D6
C21
D7 TP4
R5
R11 D7
R100
C20
R4 R3
LED2 C16
C19 JP1
R9 R10
ENABLE
R1
C15 S2 S3 S1
U9
U5
C4
U2
C18
R2
TP8
U6
TP9
C13 D4 D3
C3
VCC
C17 + - R C D
R29
R27
R28
R17
R16
R96
R94
R19
R18
R26
R30
R15
R25
R92
SGND
D18
D17
D11
D51
D53
D13
D20
D16
D15
C31 D19
D10
D12
D14
D52
C30
MTG4 MTG3
C29
C26
C37
C25
C28
C27
C35
C22
C36
C23
C32
R22 C24
R32
R31
R1
R97
R95
R24
R36
R35
R34
R33
R93
R20
R23
D9 D8 TP3 TP2
Illustration 7 Illustration 8
All Green
Backgrounds
All Green
Backgrounds
25 Click the "Toggle Device Power" button. 26 Click the "Program" button to update the
firmware of either the ECM or the control pad.
Result: A portion of the lower right hand corner
in the "PSoC Programmer" window should now Result: The main "PSoC Programmer" window
be red and show as being "Powered". will indicate a successful program.
Result: The red light labeled "Target Power" on
the MiniProg cable should be on.
Red Green
Background Backgrounds
27 Click the "Toggle Device Power" button to 28 Carefully disconnect the "MiniProg" cable from
power down the printed circuit board. the printed circuit board.
Result: All the boxes in the lower right hand Component damage hazard.
corner of the "PSoC Programmer" window Electrostatic discharge (ESD) can
should have a green background and should damage printed circuit board
indicate "Not Powered." 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: Repeat this procedure beginning with step
16 if updates are required of the outrigger ECM
AND the outrigger control pad.
All Green
Backgrounds
How to Assemble and Install the 33 Install the control pad onto the control pad
bracket and secure using the fasteners
Outrigger Control Pad removed in step 4. Do not over tighten the
30 Carefully connect the control pad coil cord to fasteners. Refer to Illustration 1.
the control pad printed circuit board. Refer to a
Illustration 2.
31 Install the button caps removed in step 7 onto
the buttons of the control pad printed circuit
board. Refer to Illustration 2.
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.
32 Install the control pad top enclosure onto the
control pad bottom enclosure. Refer to
Illustration 2.
a
c
d
c
Illustration 1
f a control pad
d b control pad bracket
c washer
d screw
e
Illustration 2
34 Connect the outrigger controls coil cord to the
outrigger controls cable.
a top enclosure
b coil cord
c bottom enclosure
d printed circuit board
e control pad decal (hidden from view)
f button cap
b
d
Illustration 5
a ECM enclosure
b printed circuit board
c torx screw
d bottom cover
e mounting bracket
f ECM decal
37 Using the fasteners removed in step 12, How to Finish the Outrigger
securely install the ECM assembly onto the
ECM bracket. Do not over tighten. Refer to Controls Software Update
Illustration 9. 40 Connect the 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 function tests. Refer to the
Operator's Manual on your machine.
44 Return the machine to service.
If you have any further questions regarding these
instructions or need assistance, please contact
the Genie Industries Scissors Service
Department,
1-800-536-1800 Ext. 8710
Illustration 9
a ECM assembly
b ECM bracket
10
2
3 11
4 12
13
5
14
6 15
7 16
8 17
GS-1530
GS-1532
Steer End Non-steer End
1 Number 4 pivot pin 10 Number 3 inner arm
2 Number 3 center pivot pin (2 pins) 11 Number 3 outer arm
3 Lift cylinder rod-end pivot pin 12 Number 3 pivot pin (non-steer end)
4 Number 3 pivot pin (steer end) 13 Number 2 inner arm
5 Number 2 center pivot pin (2 pins) 14 Number 2 outer arm
6 Number 2 pivot pin (steer end) 15 Number 2 pivot pin (non-steer end)
7 Number 1 center pivot pin (2 pins) 16 Lift cylinder barrel-end pivot pin
8 Number 1 inner arm 17 Number 1 outer arm
9 Number 1 pivot pin
3-1
Scissor Assembly,
GS-1530 and GS-1532 a
10 Remove the external snap rings and retaining 20 Remove the pin retaining fasteners from the lift
fasteners from the number 3 center pivot pin at cylinder rod-end pivot pin (index #3). Use a soft
the battery pack side of the machine (index #2). metal drift to remove the pin.
11 Use a soft metal drift to remove the number 3 Bodily injury hazard. The cylinder
center pivot pin at the battery pack side of the may fall when the rod-end pivot
machine (index #2). pin is removed if not properly
supported.
12 Remove the number 3 outer arm at the battery
pack side (index #11) from the machine. 21 Lower the cylinder onto the number 1 inner arm
(index #8).
Crushing hazard. The number 3
outer arm may become Component damage hazard.
unbalanced and fall if not properly Cables can be damaged if they
supported when removed from the are kinked or pinched.
machine.
22 Attach a lifting strap from an overhead crane to
Models with a single the number 3 inner arm (index #10).
number 3 outer arm assembly:
23 Remove the retaining fasteners from the
13 Attach a lifting strap from an overhead crane to number 3 pivot pin (index #4) at the steer end.
the number 3 outer arm (index #11).
24 Use a soft metal drift to remove the number 3
14 Remove the external snap rings and retaining pivot pin (index #4). Remove the number 3
fasteners from the number 3 center pivot pins inner arm (index #10) from the machine.
(index #2).
Bodily injury hazard. The number
15 Use a soft metal drift to remove the number 3 3 inner arm may become
center pivot pins (index #2). unbalanced and fall if not properly
supported when removed from the
16 Remove the retaining fasteners from the machine.
number 3 pivot pin (index #12) at the non-steer
end of the machine. 25 Remove the cables from the number 2 cable
bridge and lay them off to the side.
17 Use a soft metal drift to remove the number 3
pivot pin (index #12) from the non-steer end of Component damage hazard.
the machine. Remove the number 3 outer arm Cables can be damaged if they
(index #11) from the machine. are kinked or pinched.
Crushing hazard. The number 3 26 Remove the external snap rings and retaining
outer arm may become fasteners from the number 2 center pivot pin
unbalanced and fall if not properly (index #5) at the ground controls side.
supported when removed from the 27 Remove the number 2 cable bridge mounting
machine. fasteners and remove the cable bridge from the
All models: machine.
18 Remove the number 3 cable bridge mounting 28 Attach a lifting strap from an overhead crane to
fasteners and remove the cable bridge from the the number 2 outer arm (index #14) at the
machine. ground controls side.
19 Attach a lifting strap from an overhead crane to 29 Use a soft metal drift to remove the number 2
the lug on the rod end of the lift cylinder for center pivot pin (index #5) at the ground
support. Do not apply any lifting pressure. controls side.
30 Remove the retaining fasteners from the 38 Use a soft metal drift to remove the number 2
number 2 pivot pin (index #15) at the non-steer pivot pin (index #6). Remove the number 2
end of the machine. inner arm (index #13) from the machine.
31 Use a soft metal drift to tap the number 2 pivot Bodily injury hazard. The number
pin (index #15) halfway out at the non-steer end 2 inner arm may become
of the machine. Remove the number 2 outer unbalanced and fall if not properly
arm (index #14) from the ground controls side supported when removed from the
of the machine. machine.
Bodily injury hazard. The number 39 Remove the safety arm from the number 2 inner
2 outer arm at the ground controls arm (index #13) that was just removed.
side may become unbalanced and
40 Attach a lifting strap from an overhead crane to
fall if not properly supported when
the number 1 inner arm (index #8).
removed from the machine.
41 Raise the number 1 inner arm (index #8)
32 Attach a lifting strap from an overhead crane to
approximately 2 feet / 60 cm and install the
the number 2 outer arm (index #14) at the
safety arm between the number 1 inner arm
battery pack side.
(index #8) and the number 1 outer arm (index
33 Remove the external snap rings and retaining #17). Lower the scissor arms onto the safety
fasteners from the number 2 center pivot pin arm.
(index #5) at the battery pack side.
Bodily injury hazard. Keep hands
34 Use a soft metal drift to remove the number 2 clear of moving parts when
center pivot pin (index #5) at the battery pack lowering the scissor arms onto the
side. safety arm.
Bodily injury hazard. The number 42 Attach a lifting strap from an overhead crane to
2 outer arm at the battery pack the lug on the rod end of the lift cylinder
side may become unbalanced and (index #3). Raise the lift cylinder approximately
fall if not properly supported when 3 ft / 1 m.
removed from the machine.
43 Tag, disconnect and plug the hydraulic hoses
35 Use a soft metal drift to tap the number 2 pivot on the lift cylinder. Cap the fittings on the
pin (index #15) in the other direction at the non- cylinder.
steer end. Remove the number 2 outer arm
Bodily injury hazard. Spraying
(index #14) from the battery pack side of the
hydraulic oil can penetrate and
machine.
burn skin. Loosen hydraulic
Bodily injury hazard. The number connections very slowly to allow
2 outer arm at the battery pack the oil pressure to dissipate
side may become unbalanced and gradually. Do not allow oil to squirt
fall if not properly supported when or spray.
removed from the machine.
44 Tag and disconnect the wires and manual
36 Attach a lifting strap from an overhead crane to lowering cable from the solenoid valve on the
the number 2 inner arm (index #13). cylinder.
37 Remove the retaining fasteners from the 45 Models with platform overload option: Tag
number 2 pivot pin (index #6) at the steer end and disconnect the wire harness from the
of the machine. platform overload switch.
46 Raise the lift cylinder to a vertical position. 53 Attach a lifting strap from an overhead crane to
the number 1 outer arm (index #17). Do not
47 Remove the pin retaining fasteners from the lift
apply any lifting pressure.
cylinder barrel-end pin (index #16). Use a soft
metal drift to remove the pin. Remove the lift 54 Remove the external snap rings and retaining
cylinder from the machine. fasteners from the number 1 center pivot pins
(index #7).
Crushing hazard. The lift cylinder
could become unbalanced and fall 55 Remove the number 1 cable bridge from the
when it is removed from the machine.
machine if not properly attached to
56 Use a soft metal drift to remove the number 1
the overhead crane.
center pivot pins (index #7).
Component damage hazard. Be
Bodily injury hazard. The number
careful not to damage the valve or
1 outer arm may become
fittings on the cylinder while
unbalanced and fall if not properly
removing it from the machine.
supported when the pin is
48 Place a 4 x 4 x 48 inch / 10 cm x 10 cm x 1.2 m removed.
long block across both sides of the chassis
57 Slide the number 1 outer arm (index #17) to the
under the number 1 center pivot pin
non-steer end and remove it from the machine.
(index #7).
Bodily injury hazard. The number
49 Attach a lifting strap from an overhead crane to
1 outer arm may become
the number 1 inner arm (index #8) at the non-
unbalanced and fall if not properly
steer end. Raise the number 1 inner arm and
supported when removed from the
remove the safety arm. Lower the number 1
machine.
inner arm (index #8) onto the block that was
placed across the chassis. 58 Attach the strap from an overhead crane to the
number 1 inner arm (index #8). Do not lift it.
Bodily injury hazard. Keep hands
clear of moving parts when 59 Remove the upper fasteners securing the
lowering the arms onto the block. number 1 inner arm pivot bracket to the end of
the chassis. Loosen the lower fasteners.
50 Remove the cables from the number 1 cable
bridge and lay them off to the side. 60 Remove the number 1 inner arm (index #8)
from the machine.
Component damage hazard.
Cables can be damaged if they Bodily injury hazard. The number
are kinked or pinched. 1 inner arm may become
unbalanced and fall if not properly
51 Support and secure the entry ladder to an
supported when removed from the
appropriate lifting device.
machine.
52 Remove the fasteners from the entry ladder and
Component damage hazard. Be
remove the entry ladder from the machine.
sure not to damage the limit switch
Crushing hazard. The entry ladder or level sensor box components
may become unbalanced and fall if when the number 1 inner arm is
not properly supported and removed from the machine.
secured to the lifting device.
How to Replace the Scissor Arm 9 Remove the scissor assembly from the
machine just enough to access both wear pads.
Wear Pads
Crushing hazard. The scissor
1 Remove the platform. See 2-1, How to Remove assembly will fall if not properly
the Platform. supported when removed from the
2 Support and secure the entry ladder to an drive chassis.
appropriate lifting device. Component damage hazard. Be
3 Remove the fasteners from the entry ladder and careful not to damage the level
remove the entry ladder from the machine. sensor or limit switch while moving
the scissor assembly.
Crushing hazard. The entry ladder
may become unbalanced and fall if 10 Remove both old wear pads.
not properly supported and 11 Install two new wear pads.
secured to the lifting device.
12 Slide the scissor assembly back into the drive
4 Secure the ends of the scissor arms together at chassis.
the steer end of the machine with a strap or
other suitable device. 13 Lower the scissor assembly into position and
install the chassis mount bracket onto the
5 Secure the ends of the scissor arms together at chassis. Securely install and tighten the
the non-steer end of the machine with a strap or fasteners. Do not overtighten.
other suitable device.
Component damage hazard. Be
6 Remove the retaining fasteners securing the careful not to damage the level
chassis mount bracket to the chassis at the sensor or limit switch while moving
steer end of the machine. the scissor assembly.
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.
12
2
13
3 14
4 15
5 16
6 17
18
7
19
8 20
9 21
10 22
11
GS-1930
GS-1932
Steer End Non-steer End
1 Number 5 pivot pin 12 Number 4 inner arm
2 Number 4 center pivot pin (2 pins) 13 Number 4 outer arm
3 Number 4 pivot pin (steer end) 14 Number 4 pivot pin (non-steer end)
4 Number 3 center pivot pin (2 pins) 15 Number 3 inner arm
5 Lift cylinder rod-end pivot pin 16 Number 3 outer arm
6 Number 3 pivot pin (steer end) 17 Number 3 pivot pin (non-steer end)
7 Number 2 center pivot pin (2 pins) 18 Number 2 inner arm
8 Number 2 pivot pin (steer end) 19 Number 2 outer arm
9 Number 1 center pivot pin (2 pins) 20 Number 2 pivot pin (non-steer end)
10 Number 1 inner arm 21 Lift cylinder barrel-end pivot pin
11 Number 1 pivot pin 22 Number 1 outer arm
3-2
Scissor Assembly,
a
GS-1930 and GS-1932
b
How to Disassemble the
Scissor Assembly,
GS-1930 and GS-1932
Bodily injury hazard. The
c
procedures in this section require
specific repair skills, lifting
equipment and a suitable d
workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant GS-1930
component damage. Dealer GS-1932
service is required.
Cable bridge legend
When removing a hose assembly or fitting, the
O-ring on the fitting and/or hose end must be a cable bridge 4
replaced and then torqued to specification during b cable bridge 3
c cable bridge 2
installation. Refer to Section 2, Hydraulic Hose and d cable bridge 1
Fitting Torque Specifications.
Models with dual
1 Remove the platform. See 2-1, How to Remove number 4 outer arms:
the Platform.
4 Attach a lifting strap from an overhead crane to
2 Remove the cables from the number 4 outer
the number 4 outer arm at the ground controls
arm (index #13) at the ground controls side.
side of the machine (index #13).
Component damage hazard.
5 Remove the external snap rings and retaining
Cables can be damaged if they
fasteners from the number 4 center pivot pin at
are kinked or pinched.
the ground control side of the machine (index
3 Remove the cables from the number 4 cable #2).
bridge and lay them off to the side.
6 Use a soft metal drift to remove the number 4
Component damage hazard. center pivot pin at the ground control side of the
Cables can be damaged if they machine (index #2).
are kinked or pinched.
7 Remove the retaining fasteners from the
number 4 pivot pin (index #14) at the non-steer
end of the machine.
8 Use a soft metal drift to remove the number 4 16 Remove the retaining fasteners from the
pivot pin (index #14) from the non-steer end of number 4 pivot pin (index #14) at the non-steer
the machine. Remove the number 4 outer arm end of the machine.
at the ground control side (index #13) from the
17 Use a soft metal drift to remove the number 4
machine.
pivot pin (index #14) from the non-steer end of
Crushing hazard. The number 3 the machine. Remove the number 4 outer arm
outer arm may become (index #13) from the machine.
unbalanced and fall if not properly
Crushing hazard. The number 4
supported when removed from the
outer arm may become
machine.
unbalanced and fall if not properly
9 Attach a lifting strap from an overhead crane to supported when removed from the
the number 4 outer arm at the battery pack side machine.
of the machine (index #13).
All models:
10 Remove the external snap rings and retaining
fasteners from the number 4 center pivot pin at 18 Remove the number 4 cable bridge mounting
the battery pack side of the machine (index #2). fasteners and remove the cable bridge from the
machine.
11 Use a soft metal drift to remove the number 4
center pivot pin at the battery pack side of the 19 Attach a lifting strap from an overhead crane to
machine (index #2). the number 4 inner arm (index #12).
12 Remove the number 4 outer arm at the battery 20 Remove the retaining fasteners from the
pack side (index #13) from the machine. number 4 pivot pin (index #3).
Crushing hazard. The number 4 21 Use a soft metal drift to remove the number 4
outer arm may become pivot pin (index #3) at the steer end. Remove
unbalanced and fall if not properly the number 4 inner arm (index #12) from the
supported when removed from the machine.
machine. Crushing hazard. The number 4
Models with a single inner arm may become
number 4 outer arm assembly: unbalanced and fall if not properly
supported when removed from the
13 Attach a lifting strap from an overhead crane to machine.
the number 4 outer arm (index #13).
22 Remove the cables from the number 3 cable
14 Remove the external snap rings and retaining bridge and lay them off to the side.
fasteners from the number 4 center pivot pins
Component damage hazard.
(index #2).
Cables can be damaged if they
15 Use a soft metal drift to remove the number 4 are kinked or pinched.
center pivot pins (index #2).
23 Remove the number 3 cable bridge mounting
fasteners and remove the cable bridge from the
machine.
24 Attach a lifting strap from an overhead crane to 32 Remove the number 3 pivot pin (index #17)
the number 3 outer arm (index #4) at the from the non-steer end of the machine.
ground controls side.
33 Attach a lifting strap from an overhead crane to
25 Remove the external snap rings and retaining the lug on the rod end of the lift cylinder for
fasteners from the number 3 center pivot pins support. Do not apply any lifting pressure.
(index #4).
34 Remove the pin retaining fasteners from the lift
26 Use a soft metal drift to remove the number 3 cylinder rod-end pivot pin (index #5). Use a soft
center pivot pin (index #4) at the ground control metal drift to remove the pin.
side.
Bodily injury hazard. The cylinder
27 Remove the retaining fasteners from the may fall when the rod-end pivot
number 3 pivot pin (index #17) at the non-steer pin is removed if not properly
end of the machine. supported.
28 Use a soft metal drift to tap the number 3 pivot 35 Lower the cylinder onto the number 1 inner arm
pin (index #17) halfway out at the non-steer end (index #9).
of the machine. Remove the number 3 outer
Component damage hazard.
arm (index #16) at the ground controls side
Cables can be damaged if they
from the machine.
are kinked or pinched.
Bodily injury hazard. The number
36 Attach a lifting strap from an overhead crane to
3 outer arm at the ground controls
the number 3 inner arm (index #15).
side may become unbalanced and
fall if not properly supported when 37 Remove the retaining fasteners from the
removed from the machine. number 3 pivot pin (index #6) at the steer end.
29 Attach a lifting strap from an overhead crane to 38 Use a soft metal drift to remove the number 3
the number 3 outer arm (index #16) at the pivot pin (index #6). Remove the number 3
battery pack side. inner arm (index #15) from the machine.
30 Use a soft metal drift to remove the number 3 Bodily injury hazard. The number
center pivot pin (index #4) at the battery pack 3 inner arm may become
side of the machine. unbalanced and fall if not properly
supported when removed from the
31 Use a soft metal drift to tap the number 3 pivot
machine.
pin (index #17) in the other direction. Remove
the number 3 outer arm (index #16) from the 39 Remove the cables from the number 2 cable
battery pack side of the machine. bridge and lay them off to the side.
Bodily injury hazard. The number Component damage hazard.
3 outer arm at the battery pack Cables can be damaged if they
side may become unbalanced and are kinked or pinched.
fall if not properly supported when
removed from the machine. 40 Remove the external snap rings and retaining
fasteners from the number 2 center pivot pin
(index #7) at the ground controls side.
41 Remove the number 2 cable bridge mounting 49 Use a soft metal drift to tap the number 2 pivot
fasteners and remove the cable bridge from the pin at the non-steer end (index #20) in the other
machine. direction. Remove the number 2 outer arm
(index #19) from the battery pack side of the
42 Attach a lifting strap from an overhead crane to
machine.
the number 2 outer arm (index #19) at the
ground controls side. Bodily injury hazard. The number
2 outer arm at the battery pack
43 Use a soft metal drift to remove the number 2
side may become unbalanced and
center pivot pin (index #7) at the ground
fall if not properly supported when
controls side.
removed from the machine.
44 Remove the retaining fasteners from the
50 Remove the number 3 pivot pin (index #17)
number 2 pivot pin (index #20) at the non-steer
from the non-steer end of the machine.
end of the machine.
51 Attach a lifting strap from an overhead crane to
45 Use a soft metal drift to tap the number 2 pivot
the number 2 inner arm (index #18).
pin (index #20) halfway out at the non-steer end
of the machine. Remove the number 2 outer 52 Remove the retaining fasteners from the
arm (index #19) from the ground controls side number 2 pivot pin (index #8) at the steer end
of the machine. of the machine.
Bodily injury hazard. The number 53 Use a soft metal drift to remove the number 2
2 outer arm at the ground controls pivot pin (index #8). Remove the number 2
side may become unbalanced and inner arm (index #18) from the machine.
fall if not properly supported when
Bodily injury hazard. The number
removed from the machine.
2 inner arm may become
46 Attach a lifting strap from an overhead crane to unbalanced and fall if not properly
the number 2 outer arm (index #19) at the supported when removed from the
battery pack side. machine.
47 Remove the external snap rings and retaining 54 Remove the safety arm from the number 2 inner
fasteners from the number 2 center pivot pin arm (index #18) that was just removed.
(index #7) at the battery pack side.
55 Attach a lifting strap from an overhead crane to
48 Use a soft metal drift to remove the number 2 the number 1 inner arm (index #10).
center pivot pin (index #7) at the battery pack
56 Raise the number 1 inner arm (index #10)
side.
approximately 2 feet / 60 cm and install the
Bodily injury hazard. The number safety arm between the number 1 inner arm
2 outer arm at the battery pack (index #10) and the number 1 outer arm (index
side may become unbalanced and #22) at the non-steer end of the machine.
fall if not properly supported when Lower the scissor arms onto the safety arm.
removed from the machine.
Bodily injury hazard. Keep hands
clear of moving parts when
lowering the scissor arms onto the
safety arm.
57 Attach a lifting strap from an overhead crane to 64 Attach a lifting strap from an overhead crane to
the lug on the rod end of the lift cylinder the number 1 inner arm (index #10) at the non-
(index #5). Raise the lift cylinder approximately steer end. Raise the number 1 inner arm and
3 ft / 1 m. remove the safety arm. Lower the number 1
inner arm (index #10) onto the block that was
58 Tag, disconnect and plug the hydraulic hoses
placed across the chassis.
on the lift cylinder. Cap the fittings on the
cylinder. Bodily injury hazard. Keep hands
clear of moving parts when
Bodily injury hazard. Spraying
lowering the arms onto the block.
hydraulic oil can penetrate and
burn skin. Loosen hydraulic 65 Remove the cables from the number 1 cable
connections very slowly to allow bridge and lay them off to the side.
the oil pressure to dissipate
Component damage hazard.
gradually. Do not allow oil to squirt
Cables can be damaged if they
or spray.
are kinked or pinched.
59 Tag and disconnect the wires and manual
66 Support and secure the entry ladder to an
lowering cable from the solenoid valve on the
appropriate lifting device.
cylinder.
67 Remove the fasteners from the entry ladder and
60 Models with platform overload option: Tag
remove the entry ladder from the machine.
and disconnect the wire harness from the
platform overload switch. Crushing hazard. The entry ladder
may become unbalanced and fall if
61 Raise the lift cylinder to a vertical position.
not properly supported and
62 Remove the pin retaining fasteners from the lift secured to the lifting device.
cylinder barrel-end pin (index #21). Use a soft
68 Attach a lifting strap from an overhead crane to
metal drift to remove the pin. Remove the lift
the number 1 outer arm (index #22). Do not
cylinder from the machine.
apply any lifting pressure.
Crushing hazard. The lift cylinder
69 Remove the external snap rings and retaining
may become unbalanced and fall
fasteners from the number 1 center pivot pins
when it is removed from the
(index #11).
machine if not properly attached to
the overhead crane. 70 Remove the number 1 cable bridge from the
machine.
Component damage hazard. Be
careful not to damage the valve or 71 Use a soft metal drift to remove the number 1
fittings on the cylinder while center pivot pins (index #9).
removing it from the machine.
Bodily injury hazard. The number
63 Place a 4 x 4 x 48 inch / 10 cm x 10 cm x 1.2 m 1 outer arm may become
long block across both sides of the chassis unbalanced and fall if not properly
under the number 1 center pivot pin supported when the pin is
(index #11). removed.
REV C
72 Slide the number 1 outer arm (index #22) to the How to Replace the Scissor Arm
non-steer end and remove it from the machine.
Wear Pads
Bodily injury hazard. The number
1 outer arm may become 1 Remove the platform. See 2-1, How to Remove
unbalanced and fall if not properly the Platform.
supported when removed from the 2 Support and secure the entry ladder to an
machine. appropriate lifting device.
73 Attach the strap from an overhead crane to the 3 Remove the fasteners from the entry ladder and
number 1 inner arm (index #10). Do not lift it. remove the entry ladder from the machine.
74 Remove the upper fasteners securing the Crushing hazard. The entry ladder
number 1 inner arm pivot bracket to the end of may become unbalanced and fall if
the chassis. Loosen the lower fasteners. not properly supported and
75 Remove the number 1 inner arm (index #10) secured to the lifting device.
from the machine. 4 Secure the ends of the scissor arms together at
Bodily injury hazard. The number the steer end of the machine with a strap or
1 inner arm may become other suitable device.
unbalanced and fall if not properly 5 Secure the ends of the scissor arms together at
supported when removed from the the non-steer end of the machine with a strap or
machine. other suitable device.
Component damage hazard. Be 6 Remove the retaining fasteners securing the
sure not to damage the limit switch chassis mount bracket to the chassis at the
or level sensor box components steer end of the machine.
when the number 1 inner arm is
removed from 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.
REV C
10
2
3 11
4 12
13
5
14
6 15
7 16
8 17
GS-2032
Steer end
GS-2046
Non-steer end
1 Number 4 pivot pin 10 Number 3 inner arm
2 Number 3 center pivot pin (2 pins 11 Number 3 outer arm
3 Lift cylinder rod-end pivot pin 12 Number 3 pivot pin (non-steer end)
4 Number 3 pivot pin (steer end) 13 Number 2 inner arm
5 Number 2 center pivot pin (2 pins) 14 Number 2 outer arm
6 Number 2 pivot pin (steer end 15 Number 2 pivot pin (non-steer end)
7 Number 1 center pivot pin (2 pins) 16 Lift cylinder barrel-end pivot pin
8 Number 1 inner arm 17 Number 1 outer arm
9 Number 1 pivot pin
3-3
Scissor Assembly,
a
GS-2032 and GS-2046
b
How to Disassemble the
c
Scissor Assembly,
GS-2032 and GS-2046
d
Bodily injury hazard. The
procedures in this section require
specific repair skills, lifting
equipment and a suitable GS-2032
workshop. Attempting this GS-2046
procedure without these skills and
tools could result in death or Cable bridge legend
serious injury and significant
a cable bridge 3
component damage. Dealer
b cable bridge 2A
service is required. c cable bridge 2B
d cable bridge 1
When removing a hose assembly or fitting, the 5 Disconnect the number 3 cable bridge from the
O-ring on the fitting and/or hose end must be number 3 outer arm (index #11) and remove
replaced and then torqued to specification during the cable bridge from the machine.
installation. Refer to Section 2, Hydraulic Hose and
Fitting Torque Specifications. 6 Remove the retaining fasteners from the
number 4 pivot pin (index #1).
1 Remove the platform. See 2-1, How to Remove
7 Use a soft metal drift to remove the number 4
the Platform.
pivot pin (index #1). Remove the platform
2 Support and secure the entry ladder to an mount bracket from the machine.
appropriate lifting device.
8 Attach a lifting strap from an overhead crane to
3 Remove the fasteners from the entry ladder and the number 3 outer arm at the ground control
remove the entry ladder from the machine. side (index #11).
Crushing hazard. The entry ladder 9 Remove the retaining fasteners from the
may become unbalanced and fall if number 3 center pivot pin (index #2) at the
not properly supported and ground control side.
secured to the lifting device.
10 Place a rod through the number 3 center pivot
4 Remove the cables from the number 3 cable pin at the ground control side (index #2) and
bridge and lay them off to the side. twist to remove the pin.
Component damage hazard. 11 Remove the retaining fasteners from the
Cables can be damaged if they number 3 pivot pin (index #12) at the non-steer
are kinked or pinched. end.
12 Use a soft metal drift to remove the number 3 21 Lower the cylinder onto the block.
pivot pin (index #12) from the non-steer end of
Bodily injury hazard. Keep hands
the machine. Remove the number 3 outer arm
clear of moving parts when
at the ground control side (index #11) from the
lowering the cylinder onto the
machine.
block.
Crushing hazard. The number 3
22 Attach a lifting strap from an overhead crane to
outer arm at the ground control
the number 3 inner arm (index #10). Raise the
side (index #11) may become
arm to a vertical position.
unbalanced and fall if not properly
supported when removed from the 23 Remove the retaining fasteners from the
machine. number 3 pivot pin at the steer end of the
machine (index #4).
13 Attach a lifting strap from an overhead crane to
the number 3 outer arm at the battery side 24 Use a soft metal drift to remove the number 3
(index #11). pivot pin (index #4) from the steer end of the
machine. Remove the number 3 inner arm
14 Remove the retaining fasteners from the
(index #10) from the machine.
number 3 center pivot pin (index #2) at the
battery side. Crushing hazard. The number 3
inner arm (index #10) may
15 Place a rod through the number 3 center pivot
become unbalanced and fall if not
pin at the battery side (index #2) and twist to
properly supported when the pivot
remove the pin.
pin is removed.
16 Remove the number 3 outer arm (index #11)
25 Remove the cables from the number 2A and 2B
from the machine.
cable bridge and lay them off to the side.
Crushing hazard. The number 3
Component damage hazard.
outer arm (index #11) may
Cables can be damaged if they
become unbalanced and fall if not
are kinked or pinched.
properly supported when removed
from the machine. 26 Disconnect the number 2A and 2B cable
bridges from the scissor linkset and remove
17 Attach a lifting strap from an overhead crane to
both cable bridges from the machine.
the lug of the rod end of the lift cylinder.
27 Attach a lifting strap from an overhead crane to
18 Remove the retaining fasteners from the lift
the number 2 outer arm at the ground control
cylinder rod end pivot pin (index #3).
side (index #14).
19 Use a soft metal drift to remove the lift cylinder
28 Remove the retaining fasteners from the
rod end pivot pin (index #3) from the machine.
number 2 center pivot pin (index #5) at the
Crushing hazard. The lift cylinder ground control side.
will fall if not properly supported
29 Place a rod through the number 2 center pivot
when the pivot pin is removed.
pin at the ground control side (index #5) and
20 Place a 2 x 4 x 10 inch / 10 x 10 x 25 cm block twist to remove the pin.
onto the number 1 inner arm cylinder plate
(index #8).
30 Remove the retaining fasteners from the 37 Remove the retaining fasteners from the
number 2 pivot pin (index #15) at the non-steer number 2 pivot pin at the steer end of the
end. machine (index #6).
31 Use a soft metal drift to remove the number 2 38 Use a soft metal drift to remove the number 2
pivot pin (index #15) from the non-steer end of pivot pin (index #6) from the steer end of the
the machine. Remove the number 2 outer arm machine. Remove the number 2 inner arm
at the ground control side (index #14) from the (index #13) from the machine.
machine.
Crushing hazard. The number 2
Crushing hazard. The number 2 inner arm (index #13) may
outer arm at the ground control become unbalanced and fall if not
side (index #14) may become properly supported when the pivot
unbalanced and fall if not properly pin is removed.
supported when the pivot pin is
39 Attach a lifting strap from an overhead crane to
removed.
the number 1 inner arm (index #8).
32 Attach a lifting strap from an overhead crane to
40 Raise the number 1 inner arm (index #8)
the number 2 outer arm at the battery side
approximately 2 feet / 60 cm.
(index #14).
41 Place a 4 x 4 x 48 inch / 10 cm x 10 cm x 1.2 m
33 Remove the retaining fasteners from the
long block across both sides of the chassis
number 2 center pivot pin (index #5) at the
under the number 1 center pivot pin (index #7).
battery side.
42 Lower the scissor arms onto the block that was
34 Place a rod through the number 2 center pivot
placed across the chassis.
pin at the battery side (index #5) and twist to
remove the pin. Bodily injury hazard. Keep hands
clear of moving parts when
Crushing hazard. The number 2
lowering the scissor arms.
outer arm (index #14) may
become unbalanced and fall if not 43 Attach a lifting strap from an overhead crane to
properly supported when the pivot the lug of the rod end of the lower lift cylinder.
pin is removed.
44 Tag, disconnect and plug the hydraulic hose on
35 Remove the number 2 outer arm (index #14) the lower lift cylinder. Cap the fittings on the
from the machine. cylinder.
Crushing hazard. The number 2 Bodily injury hazard. Spraying
outer arm (index #14) may hydraulic oil can penetrate and
become unbalanced and fall if not burn skin. Loosen hydraulic
properly supported when removed connections very slowly to allow
from the machine. the oil pressure to dissipate
gradually. Do not allow oil to squirt
36 Attach a lifting strap from an overhead crane to
or spray.
the number 2 inner arm (index #13). Raise the
arm to a vertical position. 45 Tag and disconnect the wire harness from the
solenoid valve on the cylinder.
46 Tag and disconnect the wires and manual 54 Lower the arm to the stowed position.
lowering cable from the solenoid valve on the
Bodily injury hazard. Keep hands
cylinder.
clear of moving parts when
47 Models with platform overload option: Tag lowering the scissor arms.
and disconnect the wire harness from the
55 Secure the ends of the scissor arms together at
platform overload switch.
the steer end of the machine with a strap or
48 Raise the lift cylinder to a vertical position. other suitable device.
49 Remove the pin retaining fasteners from the lift 56 Secure the ends of the scissor arms together at
cylinder barrel-end pivot pin (index #16). Use a the non-steer end of the machine with a strap or
soft metal drift to remove the pin. Remove the other suitable device.
lift cylinder from the machine.
57 Remove the retaining fasteners securing the
Crushing hazard. The lift cylinder chassis mount bracket to the chassis.
will fall if not properly supported
58 Remove the linkset from the machine
when the pivot pin is removed.
Bodily injury hazard. The number
Component damage hazard. Be
1 inner and outer arms (index #8
careful not to damage the valve or
and #17) may become unbalanced
fittings on the cylinder while
and fall if not properly supported
removing it from the machine.
when removed from the machine.
50 Remove the cables from the number 1 cable
Component damage hazard. Be
bridge and lay them off to the side.
sure not to damage the limit switch
Component damage hazard. or level sensor box components
Cables can be damaged if they when the number 1 inner and
are kinked or pinched. outer arms (index #8 and #17) is
removed from the machine.
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.
How to Replace the Scissor Arm 9 Move the scissor assembly towards the
non-steer end of the machine slightly and to
Wear Pads one side of the machine until one of the scissor
1 Remove the platform. See 2-1, How to Remove arm wear pads is accessible. Do not allow both
the Platform. wear pads to slide out of the drive chassis.
8 Raise the scissor arm assembly at the steer 14 Install the new wear pad.
end with the overhead crane until the chassis 15 Slide the scissor assembly back into the drive
mount bracket will clear the level sensor. chassis.
16 Lower the scissor assembly into position and
install the chassis mount bracket onto the
chassis. Securely install and tighten the
fasteners. Do not overtighten.
Component damage hazard. Be
careful not to damage the level
sensor or limit switch while moving
the scissor assembly.
12
2
13
3 14
4 15
5 16
6 17
18
7
19
8 20
9 21
10 22
11
GS-2632
Steer end
GS-2646
Non-steer end
1 Number 5 pivot pin 12 Number 4 inner arm
2 Number 4 center pivot pin (2 pins) 13 Number 4 outer arm
3 Number 4 pivot pin (steer end) 14 Number 4 pivot pin (non-steer end)
4 Number 3 center pivot pin (2 pins) 15 Number 3 inner arm
5 Lift cylinder rod end pivot pin 16 Number 3 outer arm
6 Number 3 pivot pin (steer end) 17 Number 3 pivot pin (non-steer end)
7 Number 2 center pivot pin (2 pins) 18 Number 2 inner arm
8 Number 2 pivot pin (steer end) 19 Number 2 outer arm
9 Number 1 center pivot pin (2 pins) 20 Number 2 pivot pin (non-steer end)
10 Number 1 inner arm 21 Lift cylinder barrel-end pivot pin
11 Number 1 pivot pin 22 Number 1 outer arm
3-4
Scissor Assembly,
a
GS-2632 and GS-2646
b
How to Disassemble the
c
Scissor Assembly,
GS-2632 and GS-2646
d
Bodily injury hazard. The
e
procedures in this section require
specific repair skills, lifting
equipment and a suitable f
workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant GS-2632
component damage. Dealer GS-2646
service is required.
Cable bridge legend
When removing a hose assembly or fitting, the
O-ring on the fitting and/or hose end must be a cable bridge 4
replaced and then torqued to specification during b cable bridge 3A
c cable bridge 3B
installation. Refer to Section 2, Hydraulic Hose and d cable bridge 2A
Fitting Torque Specifications. e cable bridge 2B
f cable bridge 1
1 Remove the platform. See 2-1, How to Remove
the Platform. 4 Remove the cables from the number 4 cable
bridge and lay them off to the side.
2 Support and secure the entry ladder to an
appropriate lifting device. Component damage hazard.
Cables can be damaged if they
3 Remove the fasteners from the entry ladder and are kinked or pinched.
remove the entry ladder from the machine.
5 Disconnect the number 4 cable bridge from the
Crushing hazard. The entry ladder number 4 outer arm (index #13) and remove
may become unbalanced and fall if the cable bridge from the machine.
not properly supported and
secured to the lifting device. 6 Remove the retaining fasteners from the
number 5 pivot pin (index #1).
7 Use a soft metal drift to remove the number 5 15 Place a rod through the number 4 center pivot
pivot pin (index #1). Remove the platform pin at the battery side (index #2) and twist to
mount bracket from the machine. remove the pin.
8 Attach a lifting strap from an overhead crane to 16 Remove the number 4 outer arm (index #13)
the number 4 outer arm at the ground control from the machine.
side (index #13).
Crushing hazard. The number 4
9 Remove the retaining fasteners from the outer arm (index #13) may
number 4 center pivot pin (index #2) at the become unbalanced and fall if not
ground control side. properly supported when removed
from the machine.
10 Place a rod through the number 4 center pivot
pin at the ground control side (index #2) and 17 Attach a lifting strap from an overhead crane to
twist to remove the pin. the number 4 inner arm (index #12). Raise the
arm to a vertical position.
11 Remove the retaining fasteners from the
number 4 pivot pin (index #15) at the non-steer 18 Remove the retaining fasteners from the
end. number 4 pivot pin at the steer end of the
machine (index #3).
12 Use a soft metal drift to remove the number 4
pivot pin (index #14) from the non-steer end of 19 Use a soft metal drift to remove the number 4
the machine. Remove the number 4 outer arm pivot pin (index #3) from the steer end of the
at the ground control side (index #13) from the machine. Remove the number 4 inner arm
machine. (index #12) from the machine.
Crushing hazard. The number 4 Crushing hazard. The number 4
outer arm at the ground control inner arm (index #12) may
side (index #13) may become become unbalanced and fall if not
unbalanced and fall if not properly properly supported when removed
supported when removed from the from the machine.
machine.
20 Remove the cables from the number 3A and 3B
13 Attach a lifting strap from an overhead crane to cable bridge and lay them off to the side.
the number 4 outer arm at the battery side
Component damage hazard.
(index #13).
Cables can be damaged if they
14 Remove the retaining fasteners from the are kinked or pinched.
number 4 center pivot pin (index #2) at the
21 Disconnect the number 3A and 3B cable
battery side.
bridges from the scissor linkset and remove
both cable bridges from the machine.
22 Attach a lifting strap from an overhead crane to 30 Remove the number 3 outer arm (index #16)
the number 3 outer arm at the ground control from the machine.
side (index #16).
Crushing hazard. The number 3
23 Remove the retaining fasteners from the outer arm (index #16) may
number 3 center pivot pin (index #4) at the become unbalanced and fall if not
ground control side. properly supported when removed
from the machine.
24 Place a rod through the number 3 center pivot
pin at the ground control side (index #4) and 31 Attach a lifting strap from an overhead crane to
twist to remove the pin. the lug of the rod end of the lift cylinder.
25 Remove the retaining fasteners from the 32 Remove the retaining fasteners from the lift
number 3 pivot pin (index #17) at the non-steer cylinder rod end pivot pin (index #5).
end.
33 Use a soft metal drift to remove the lift cylinder
26 Use a soft metal drift to remove the number 3 rod end pivot pin (index #5) from the machine.
pivot pin (index #17) from the non-steer end of
Crushing hazard. The lift cylinder
the machine. Remove the number 3 outer arm
will fall if not properly supported
at the ground control side (index #16) from the
when the pivot pin is removed.
machine.
34 Place a 2 x 4 x 10 inch / 10 x 10 x 25 cm block
Crushing hazard. The number 3
onto the number 1 inner arm cylinder plate
outer arm at the ground control
(index #10).
side (index #16) may become
unbalanced and fall if not properly 35 Lower the cylinder onto the block.
supported when removed from the
machine. Bodily injury hazard. Keep hands
clear of moving parts when
27 Attach a lifting strap from an overhead crane to lowering the cylinder onto the
the number 3 outer arm at the battery side block.
(index #16).
36 Attach a lifting strap from an overhead crane to
28 Remove the retaining fasteners from the the number 3 inner arm (index #15). Raise the
number 3 center pivot pin (index #4) at the arm to a vertical position.
battery side.
37 Remove the retaining fasteners from the
29 Place a rod through the number 3 center pivot number 3 pivot pin at the steer end of the
pin at the battery side (index #4) and twist to machine (index #6).
remove the pin.
38 Use a soft metal drift to remove the number 3 45 Use a soft metal drift to remove the number 2
pivot pin (index #6) from the steer end of the pivot pin (index #20) from the non-steer end of
machine. Remove the number 3 inner arm the machine. Remove the number 2 outer arm
(index #15) from the machine. at the ground control side (index #19) from the
machine.
Crushing hazard. The number 3
inner arm (index #15) may Crushing hazard. The number 2
become unbalanced and fall if not outer arm at the ground control
properly supported when the pivot side (index #19) may become
pin is removed. unbalanced and fall if not properly
supported when the pivot pin is
39 Remove the cables from the number 2A and 2B
removed.
cable bridge and lay them off to the side.
46 Attach a lifting strap from an overhead crane to
Component damage hazard.
the number 2 outer arm at the battery side
Cables can be damaged if they
(index #19).
are kinked or pinched.
47 Remove the retaining fasteners from the
40 Disconnect the number 2A and 2B cable
number 2 center pivot pin (index #7) at the
bridges from the scissor linkset and remove
battery side.
both cable bridges from the machine.
48 Place a rod through the number 2 center pivot
41 Attach a lifting strap from an overhead crane to
pin at the battery side (index #7) and twist to
the number 2 outer arm at the ground control
remove the pin.
side (index #19).
Crushing hazard. The number 2
42 Remove the retaining fasteners from the
outer arm (index #19) may
number 2 center pivot pin (index #7) at the
become unbalanced and fall if not
ground control side.
properly supported when the pivot
43 Place a rod through the number 2 center pivot pin is removed.
pin at the ground control side (index #7) and
49 Remove the number 2 outer arm (index #19)
twist to remove the pin.
from the machine.
44 Remove the retaining fasteners from the
Crushing hazard. The number 2
number 2 pivot pin (index #20) at the non-steer
outer arm (index #19) may
end.
become unbalanced and fall if not
properly supported when removed
from the machine.
50 Attach a lifting strap from an overhead crane to 58 Tag, disconnect and plug the hydraulic hose on
the number 2 inner arm (index #18). Raise the the lower lift cylinder. Cap the fittings on the
arm to a vertical position. cylinder.
51 Remove the retaining fasteners from the Bodily injury hazard. Spraying
number 2 pivot pin at the steer end of the hydraulic oil can penetrate and
machine (index #8). burn skin. Loosen hydraulic
connections very slowly to allow
52 Use a soft metal drift to remove the number 2
the oil pressure to dissipate
pivot pin (index #8) from the steer end of the
gradually. Do not allow oil to squirt
machine. Remove the number 2 inner arm
or spray.
(index #18) from the machine.
59 Tag and disconnect the wire harness from the
Crushing hazard. The number 2
solenoid valve on the cylinder.
inner arm (index #18) may
become unbalanced and fall if not 60 Tag and disconnect the wires and manual
properly supported when the pivot lowering cable from the solenoid valve on the
pin is removed. cylinder.
53 Attach a lifting strap from an overhead crane to 61 Models with platform overload option: Tag
the number 1 inner arm (index #10). and disconnect the wire harness from the
platform overload switch.
54 Raise the number 1 inner arm (index #10)
approximately 2 feet / 60 cm. 62 Raise the lift cylinder to a vertical position.
55 Place a 4 x 4 x 48 inch / 10 cm x 10 cm x 1.2 m 63 Remove the pin retaining fasteners from the lift
long block across both sides of the chassis cylinder barrel-end pivot pin (index #21). Use a
under the number 1 center pivot pin (index #9). soft metal drift to remove the pin. Remove the
lift cylinder from the machine.
56 Lower the scissor arms onto the block that was
placed across the chassis. Crushing hazard. The lift cylinder
will fall if not properly supported
Bodily injury hazard. Keep hands
when the pivot pin is removed.
clear of moving parts when
lowering the scissor arms. Component damage hazard. Be
careful not to damage the valve or
57 Attach a lifting strap from an overhead crane to
fittings on the cylinder while
the lug of the rod end of the lower lift cylinder.
removing it from the machine.
64 Remove the cables from the number 1 cable How to Replace the Scissor Arm
bridge and lay them off to the side.
Wear Pads
Component damage hazard.
Cables can be damaged if they 1 Remove the platform. See 2-1, How to Remove
are kinked or pinched. the Platform.
65 Disconnect the number 1 cable bridge from the 2 Support and secure the entry ladder to an
number 1 outer arm (index #22) and remove appropriate lifting device.
the cable bridge from the machine. 3 Remove the fasteners from the entry ladder and
66 Attach a lifting strap from an overhead crane to remove the entry ladder from the machine.
the number 1 inner arm (index #10). Crushing hazard. The entry ladder
67 Raise the arm slightly and remove the block. may become unbalanced and fall if
not properly supported and
68 Lower the arm to the stowed position. secured to the lifting device.
Bodily injury hazard. Keep hands 4 Secure the ends of the scissor arms together at
clear of moving parts when the steer end of the machine with a strap or
lowering the scissor arms. other suitable device.
69 Secure the ends of the scissor arms together at 5 Secure the ends of the scissor arms together at
the steer end of the machine with a strap or the non-steer end of the machine with a strap or
other suitable device. other suitable device.
70 Secure the ends of the scissor arms together at 6 Remove the retaining fasteners securing the
the non-steer end of the machine with a strap or chassis mount bracket to the chassis at the
other suitable device. steer end of the machine.
71 Remove the retaining fasteners securing the 7 Attach a lifting strap from an overhead crane to
chassis mount bracket to the chassis. the scissor arm assembly.
72 Remove the linkset from the machine 8 Raise the scissor arm assembly at the steer
Bodily injury hazard. The number end with the overhead crane until the chassis
1 inner and outer arms (index #10 mount bracket will clear the level sensor.
and #22) may become unbalanced 9 Move the scissor assembly towards the
and fall if not properly supported non-steer end of the machine slightly and to
when removed from the machine. one side of the machine until one of the scissor
Component damage hazard. Be arm wear pads is accessible. Do not allow both
sure not to damage the limit switch wear pads to slide out of the drive chassis.
or level sensor box components Component damage hazard. Be
when the number 1 inner and careful not to damage the level
outer arms (index #10 and 22) is sensor or limit switch while moving
removed from the machine. the scissor assembly.
2 16
3 17
4 18
19
5
20
6
21
7
8 22
9 23
10 24
25
11
26
12 27
13 28
14 29
15
GS-3232
Steer end GS-3246 Non-steer end
1 Number 6 pivot pin 16 Number 5 inner arm
2 Number 5 center pivot pin (2 pins) 17 Number 5 outer arm
3 Upper lift cylinder rod-end pivot pin 18 Number 5 pivot pin (non-steer end)
4 Number 5 pivot pin (steer end) 19 Number 4 inner arm
5 Number 4 center pivot pin (2 pins) 20 Number 4 outer arm
6 Number 4 pivot pin (steer end) 21 Number 4 pivot pin (non-steer end)
7 Number 3 outer arm 22 Upper lift cylinder barrel-end pivot pin
8 Number 3 center pivot pin (2 pins) 23 Number 3 inner arm
9 Lower lift cylinder rod-end pivot pin 24 Number 3 pivot pin (non-steer end)
10 Number 3 pivot pin (steer end) 25 Number 2 inner arm
11 Number 2 center pivot pin (2 pins) 26 Number 2 outer arm
12 Number 2 pivot pin (steer end) 27 Number 2 pivot pin (non-steer end)
13 Number 1 center pivot pin (2 pins) 28 Lower lift cylinder barrel-end pivot pin
14 Number 1 inner arm 29 Number 1 outer arm
15 Number 1 pivot pin (steer end) (2 pins)
3-5
Scissor Assembly, a
9 Remove the retaining fasteners from the 18 Remove the retaining fasteners from the
number 5 center pivot pin (index #2) at the number 5 pivot pin at the steer end of the
ground control side. machine (index #4).
10 Place a rod through the number 5 center pivot 19 Use a soft metal drift to remove the number 5
pin at the ground control side (index #2) and pivot pin (index #18) from the steer end of the
twist to remove the pin. machine. Remove the number 5 inner arm
(index #16) from the machine.
11 Remove the retaining fasteners from the
number 5 pivot pin (index #18) at the non-steer Crushing hazard. The number 5
end. inner arm (index #16) may
become unbalanced and fall if not
12 Use a soft metal drift to remove the number 5
properly supported when removed
pivot pin (index #18) from the non-steer end of
from the machine.
the machine. Remove the number 5 outer arm
at the ground control side (index #17) from the 20 Tag, disconnect and plug the hydraulic hose on
machine. the upper lift cylinder. Cap the fittings on the
cylinder.
Crushing hazard. The number 5
outer arm at the ground control Bodily injury hazard. Spraying
side (index #17) may become hydraulic oil can penetrate and
unbalanced and fall if not properly burn skin. Loosen hydraulic
supported when removed from the connections very slowly to allow
machine. the oil pressure to dissipate
gradually. Do not allow oil to squirt
13 Attach a lifting strap from an overhead crane to
or spray.
the number 5 outer arm at the battery side
(index #17). 21 Tag and disconnect the wire harness from the
solenoid valve on the cylinder.
14 Remove the retaining fasteners from the
number 5 center pivot pin (index #2) at the 22 Remove the cables from the number 4A and 4B
battery side. cable bridges and lay them off to the side.
15 Place a rod through the number 5 center pivot Component damage hazard.
pin at the battery side (index #2) and twist to Cables can be damaged if they
remove the pin. are kinked or pinched.
16 Remove the number 5 outer arm (index #17) 23 Disconnect the number 4A and 4B cable
from the machine. bridges from the scissor linkset and remove
both cable bridges from the machine.
Crushing hazard. The number 5
outer arm (index #17) may 24 Attach a lifting strap from an overhead crane to
become unbalanced and fall if not the lug of the rod end of the upper lift cylinder.
properly supported when removed
25 Remove the retaining fasteners from the upper
from the machine.
lift cylinder rod end pivot pin (index #3).
17 Attach a lifting strap from an overhead crane to
the number 5 inner arm (index #16). Raise the
arm to a vertical position.
26 Use a soft metal drift to remove the upper lift 36 Remove the number 4 outer arm (index #20)
cylinder rod end pivot pin (index #3) from the from the machine.
machine.
Crushing hazard. The number 4
Crushing hazard. The lift cylinder outer arm (index #20) may
may become unbalanced and fall if become unbalanced and fall if not
not properly supported when the properly supported when removed
pivot pin is removed. from the machine.
27 Lower the cylinder onto the linkset. 37 Attach a lifting strap from an overhead crane to
the number 4 inner arm (index #19). Raise the
28 Attach a lifting strap from an overhead crane to
arm to a vertical position.
the number 4 outer arm at the ground control
side (index #20). 38 Remove the retaining fasteners from the
number 4 pivot pin at the steer end of the
29 Remove the retaining fasteners from the
machine (index #6).
number 4 center pivot pin (index #5) at the
ground control side. 39 Use a soft metal drift to remove the number 4
pivot pin (index #6) from the steer end of the
30 Place a rod through the number 4 center pivot
machine. Remove the number 4 inner arm
pin at the ground control side (index #5) and
(index #19) from the machine.
twist to remove the pin.
Crushing hazard. The number 4
31 Remove the retaining fasteners from the
inner arm (index #19) may
number 4 pivot pin (index #21) at the non-steer
become unbalanced and fall if not
end.
properly supported when removed
32 Use a soft metal drift to remove the number 4 from the machine.
pivot pin (index #21) from the non-steer end of
40 Remove the cables from the number 3A and 3B
the machine. Remove the number 4 outer arm
cable bridges and lay them off to the side.
at the ground control side (index #20) from the
machine. Component damage hazard.
Cables can be damaged if they
Crushing hazard. The number 4
are kinked or pinched.
outer arm at the ground control
side (index #20) may become 41 Disconnect the number 3A and 3B cable
unbalanced and fall if not properly bridges from the scissor linkset and remove
supported when removed from the both cable bridges from the machine.
machine.
42 Attach a lifting strap from an overhead crane to
33 Attach a lifting strap from an overhead crane to the number 3 outer arm at the ground control
the number 4 outer arm at the battery side side (index #7).
(index #20).
43 Remove the retaining fasteners from the
34 Remove the retaining fasteners from the number 3 center pivot pin (index #8) at the
number 4 center pivot pin (index #5) at the ground control side.
battery side.
44 Place a rod through the number 3 center pivot
35 Place a rod through the number 4 center pivot pin at the ground control side (index #8) and
pin at the battery side (index #5) and twist to twist to remove the pin.
remove the pin.
45 Remove the retaining fasteners from the
number 3 pivot pin (index #24) at the non-steer
end.
46 Use a soft metal drift to remove the number 3 54 Attach a lifting strap from an overhead crane to
pivot pin (index #24) from the non-steer end of the lug of the rod end of the lower lift cylinder.
the machine. Remove the number 3 outer arm
55 Remove the retaining fasteners from the lower
at the ground control side (index #7) from the
lift cylinder rod end pivot pin (index #9).
machine.
56 Use a soft metal drift to remove the lower lift
Crushing hazard. The number 3
cylinder rod end pivot pin (index #9) from the
outer arm at the ground control
machine.
side (index #7) may become
unbalanced and fall if not properly Crushing hazard. The lower lift
supported when removed from the cylinder will fall if not properly
machine. supported when the pivot pin is
removed.
47 Attach a lifting strap from an overhead crane to
the number 3 outer arm at the battery side 57 Place a 2 x 4 x 10 inch / 10 x 10 x 25 cm block
(index #7). onto the number 1 inner arm cylinder plate
(index #14).
48 Remove the retaining fasteners from the
number 3 center pivot pin (index #8) at the 58 Lower the cylinder onto the block.
battery side.
Bodily injury hazard. Keep hands
49 Place a rod through the number 3 center pivot clear of moving parts when
pin at the battery side (index #8) and twist to lowering the cylinder.
remove the pin.
59 Attach a lifting strap from an overhead crane to
50 Remove the number 3 outer arm (index #7) the number 3 inner arm (index #23). Raise the
from the machine. arm to a vertical position.
Crushing hazard. The number 3 60 Remove the retaining fasteners from the
outer arm (index #7) may become number 3 pivot pin at the steer end of the
unbalanced and fall if not properly machine (index #10).
supported when removed from the
machine. 61 Use a soft metal drift to remove the number 3
pivot pin (index #10) from the steer end of the
51 Attach a lifting strap from an overhead crane to machine. Remove the number 3 inner arm
the lug of the rod end of the upper lift cylinder. (index #23) from the machine.
52 Raise the lift cylinder to a vertical position. Crushing hazard. The number 3
inner arm (index #23) may
53 Remove the pin retaining fasteners from the lift
become unbalanced and fall if not
cylinder barrel-end pivot pin (index #22).
properly supported when the pivot
Remove the lift cylinder from the machine.
pin is removed.
Crushing hazard. The lift cylinder
62 Remove the cables from the number 2A and 2B
will fall if not properly supported
cable bridges and lay them off to the side.
when the pivot pin is removed.
Component damage hazard.
Component damage hazard. Be
Cables can be damaged if they
careful not to damage the valve or
are kinked or pinched.
fittings on the cylinder while
removing it from the machine.
63 Disconnect the number 2A and 2B cable 72 Remove the number 2 outer arm (index #26)
bridges from the scissor linkset and remove from the machine.
both cable bridges from the machine.
Crushing hazard. The number 2
64 Attach a lifting strap from an overhead crane to outer arm (index #26) may
the number 2 outer arm at the ground control become unbalanced and fall if not
side (index #26). properly supported when removed
from the machine.
65 Remove the retaining fasteners from the
number 2 center pivot pin (index #11) at the 73 Attach a lifting strap from an overhead crane to
ground control side. the number 2 inner arm (index #25). Raise the
arm to a vertical position.
66 Place a rod through the number 2 center pivot
pin at the ground control side (index #11) and 74 Remove the retaining fasteners from the
twist to remove the pin. number 2 pivot pin at the steer end of the
machine (index #12).
67 Remove the retaining fasteners from the
number 2 pivot pin (index #27) at the non-steer 75 Use a soft metal drift to remove the number 2
end. pivot pin (index #12) from the steer end of the
machine. Remove the number 2 inner arm
68 Use a soft metal drift to remove the number 2
(index #25) from the machine.
pivot pin (index #27) from the non-steer end of
the machine. Remove the number 2 outer arm Crushing hazard. The number 2
at the ground control side (index #26) from the inner arm (index #25) may
machine. become unbalanced and fall if not
properly supported when the pivot
Crushing hazard. The number 2
pin is removed.
outer arm at the ground control
side (index #26) may become 76 Attach a lifting strap from an overhead crane to
unbalanced and fall if not properly the number 1 inner arm (index #14).
supported when the pivot pin is
77 Raise the number 1 inner arm (index #14)
removed.
approximately 2 feet / 60 cm.
69 Attach a lifting strap from an overhead crane to
78 Place a 4 x 4 x 48 inch / 10 cm x 10 cm x 1.2 m
the number 2 outer arm at the battery side
long block across both sides of the chassis
(index #26).
under the number 1 center pivot pin
70 Remove the retaining fasteners from the (index #13).
number 2 center pivot pin (index #11) at the
79 Lower the scissor arms onto the block that was
battery side.
placed across the chassis.
71 Place a rod through the number 2 center pivot
Bodily injury hazard. Keep hands
pin at the battery side (index #11) and twist to
clear of moving parts when
remove the pin.
lowering the scissor arms.
Crushing hazard. The number 2
80 Attach a lifting strap from an overhead crane to
outer arm (index #26) may
the lug of the rod end of the lower lift cylinder.
become unbalanced and fall if not
properly supported when the pivot
pin is removed.
81 Tag, disconnect and plug the hydraulic hose on 88 Disconnect the number 1 cable bridge from the
the lower lift cylinder. Cap the fittings on the number 1 outer arm (index #29) and remove
cylinder. the cable bridge from the machine.
Bodily injury hazard. Spraying 89 Attach a lifting strap from an overhead crane to
hydraulic oil can penetrate and the number 1 inner arm (index #14).
burn skin. Loosen hydraulic
90 Raise the arm slightly and remove the block.
connections very slowly to allow
the oil pressure to dissipate 91 Lower the arm to the stowed position.
gradually. Do not allow oil to squirt
or spray. Bodily injury hazard. Keep hands
clear of moving parts when
82 Tag and disconnect the wire harness from the lowering the scissor arms.
solenoid valve on the cylinder.
92 Secure the ends of the scissor arms together at
83 Tag and disconnect the wires and manual the steer end of the machine with a strap or
lowering cable from the solenoid valve on the other suitable device.
cylinder.
93 Secure the ends of the scissor arms together at
84 Models with platform overload option: Tag the non-steer end of the machine with a strap or
and disconnect the wire harness from the other suitable device.
platform overload switch.
94 Remove the retaining fasteners securing the
85 Raise the lift cylinder to a vertical position. chassis mount bracket to the chassis.
86 Remove the pin retaining fasteners from the lift 95 Remove the linkset from the machine
cylinder barrel-end pivot pin (index #28). Use a
soft metal drift to remove the pin. Remove the Bodily injury hazard. The number
lift cylinder from the machine. 1 inner and outer arms (index #14
and #29) may become unbalanced
Crushing hazard. The lift cylinder and fall if not properly supported
will fall if not properly supported when removed from the machine.
when the pivot pin is removed.
Component damage hazard. Be
Component damage hazard. Be sure not to damage the limit switch
careful not to damage the valve or or level sensor box components
fittings on the cylinder while when the number 1 inner and
removing it from the machine. outer arms (index #14 and 29) is
removed 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.
How to Replace the Scissor Arm 10 Remove the old wear pad.
Wear Pads 11 Install the new wear pad.
1 Remove the platform. See 2-1, How to Remove 12 Rotate the scissor assembly towards the other
the Platform. side of the machine until the other scissor arm
wear pad is accessible. Do not allow both wear
2 Support and secure the entry ladder to an pads to slide out of the drive chassis.
appropriate lifting device.
Crushing hazard. The scissor
3 Remove the fasteners from the entry ladder and assembly will fall if both wear pads
remove the entry ladder from the machine. are allowed to slide out of the drive
Crushing hazard. The entry ladder chassis.
may become unbalanced and fall if Component damage hazard. Be
not properly supported and careful not to damage the level
secured to the lifting device. sensor or limit switch while moving
4 Secure the ends of the scissor arms together at the scissor assembly.
the steer end of the machine with a strap or 13 Remove the old wear pad.
other suitable device.
14 Install the new wear pad.
5 Secure the ends of the scissor arms together at
the non-steer end of the machine with a strap or 15 Slide the scissor assembly back into the drive
other suitable device. chassis.
6 Remove the retaining fasteners securing the 16 Lower the scissor assembly into position and
chassis mount bracket to the chassis at the install the chassis mount bracket onto the
steer end of the machine. chassis. Securely install and tighten the
fasteners. Do not over tighten.
7 Attach a lifting strap from an overhead crane to
the scissor arm assembly. Component damage hazard. Be
careful not to damage the level
8 Raise the scissor arm assembly at the steer sensor or limit switch while moving
end with the overhead crane until the chassis the scissor assembly.
mount bracket 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.
3-6
Lift Cylinder
g
How to Remove the Lift Cylinder
Bodily injury hazard. This
a
procedure requires specific repair
skills, lifting equipment and a N
suitable workshop. Attempting this f Y7
9 Attach a lifting strap from an overhead crane to GS-2032, GS-2632, GS-2046 and GS-2646:
the rod end of the lift cylinder for support.
1 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
10 Remove the retaining fasteners from the lift
cylinder rod-end pivot pin. Use a soft metal drift 2 Lift the safety arm, move it to the center of the
to remove the pin. scissor arm and rotate down to a vertical
position.
Crushing hazard. The lift cylinder
will fall if not properly supported. 3 Lower the platform onto the safety arm.
11 Lower the cylinder onto the number 2 inner arm. Crushing hazard. Keep hands
clear of the safety arm when
12 Attach a lifting strap from an overhead crane or lowering the platform.
similar lifting device to the barrel end of the lift
cylinder for support. 4 Tag and disconnect the wiring from the solenoid
valve coil at the barrel end of the lift cylinder.
13 Remove the retaining fasteners from the lift
cylinder barrel-end pivot pin. Use a soft metal
drift to remove the pin.
Crushing hazard. The lift cylinder g
will fall if not properly supported
when the pin is removed.
14 Support and secure the lift cylinder to an a
appropriate lifting device.
N
15 Remove the lift cylinder through the scissor f Y7
6 Loosen the adjustment nuts on the solenoid 12 Attach a lifting strap from an overhead crane or
valve and disconnect the manual lowering cable similar lifting device to the barrel end of the lift
from the valve. cylinder for support.
Note: During assembly, the manual platform 13 Remove the retaining fasteners from the lift
lowering cable needs to be properly adjusted. cylinder barrel-end pivot pin. Use a soft metal
See 4-1, How to Adjust the Manual Platform drift to remove the pin.
Lowering Cable.
Crushing hazard. The lift cylinder
7 Remove the fasteners securing the manual will fall if not properly supported
lowering cable mount bracket to the cylinder. when the pin is removed.
Remove the bracket from the cylinder. 14 Support and secure the lift cylinder to an
8 Tag, disconnect and plug the hydraulic hoses appropriate lifting device.
on the lift cylinder. Cap the fittings on the 15 Remove the lift cylinder through the scissor
cylinder. arms at the steer end of the machine.
Bodily injury hazard. Spraying Crushing hazard. The lift cylinder
hydraulic oil can penetrate and may become unbalanced and fall if
burn skin. Loosen hydraulic not properly supported and
connections very slowly to allow secured to the lifting device.
the oil pressure to dissipate
gradually. Do not allow oil to squirt Component damage hazard. Be
or spray. careful not to damage the valve or
fittings on the cylinder while
9 Attach a lifting strap from an overhead crane to removing it from the machine.
the rod end of the lift cylinder for support.
10 Remove the retaining fasteners from the lift Torque specification
cylinder rod-end pivot pin. Use a soft metal drift Solenoid valve, 2 position 2 way N.C. 20 ft-lbs
to remove the pin. (schematic item N) 27 Nm
Crushing hazard. The lift cylinder Coil nut 5 ft-lbs
will fall if not properly supported. 7 Nm
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.
4 Tag and disconnect the wiring from the solenoid 7 Remove the fasteners securing the manual
valve coil at the barrel end of the lift cylinder. lowering cable mount bracket to the cylinder.
Remove the bracket from the cylinder.
Skip to step 9 if removing the upper cylinder.
8 Tag, disconnect and plug the hydraulic hoses
on the lift cylinder. Cap the fittings on the
cylinder.
g Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
a connections very slowly to allow
the oil pressure to dissipate
N gradually. Do not allow oil to squirt
f Y7
or spray.
Q Q
g f
a
O
b
a
c
N N
f Y9
d e Y9
O
b
10 Models with round pressure switch: Remove 15 Using a suitable lifting device, place a test
the retaining ring securing the cover to the weight in the center of the platform floor.
pressure switch and remove the cover. Using a Secure the weight to the platform. Refer to the
flat blade, turn the slotted switch adjustment chart below.
screw of the platform overload pressure switch
into the hydraulic line in 90° increments until the GS-1532 272 kg
overload alarm does not sound.
GS-1932 227 kg
Models with box-shaped pressure switch:
Remove the fasteners securing the cover to the GS-2032 363 kg
pressure switch and remove the cover. Using a
wrench, turn the nut of the platform overload GS-2632 227 kg
pressure switch into the hydraulic line in 90° GS-3232 227 kg
increments until the overload alarm does not
sound. GS-2046 544 kg
Note: Turning the nut or slotted switch adjustment 16 Raise the platform to 25 cm less than full height.
screw into the hydraulic line will deactivate the 17 Lift the safety arm, move it to the center of the
alarm; turning the nut or slotted switch adjustment scissor arm and rotate down to a vertical
screw out of the hydraulic line will activate the position.
alarm.
18 Raise the platform in 5 cm increments until the
11 Slowly turn the nut or adjustment screw of the overload alarm sounds. Adjust the up limit
platform overload pressure switch out of the switch until it actuates just before this point was
hydraulic line just until the overload alarm reached.
sounds.
19 Install the cover onto the platform overload
Note: To allow for the platform overload system pressure switch and install and tighten the
delay, wait 3 seconds between each quarter turn of cover retaining fastener(s). Do not over tighten.
the nut or adjustment screw.
20 Apply Sentry Seal to the fastener(s) securing
12 Turn the nut or adjustment screw one quarter the cover onto the platform overload pressure
turn into the hydraulic line. switch.
13 Return the safety arm to the stowed position. 21 Return the safety arm to the stowed position.
14 Using the manual lowering knob, lower the 22 Using the machine controls, lower the platform
platform to the stowed position and remove all to the stowed position and remove all test
test weight from the platform. weight from the platform.
23 Calibrate the lift relief valve. See 6-6, How to
Adjust the Platform Lift Relief Valve.
REV D
Ground Controls
4-1 Skip to step 8 if the measurement is correct.
Manual Platform Lowering Cable 6 To adjust, loosen the upper lock nut on the
cable mounting bracket at the cylinder. Turn the
The manual platform lowering cable lowers the lower lock nut clockwise to decrease the
platform in the event of a main power failure. The distance or counterclockwise to increase the
manual platform lowering cable is attached to the distance. Tighten the upper lock nut.
barrel end of the lift cylinder and is activated next
to the ground controls. a
The Electronic Control Module (ECM) is 6 Lower the platform onto the safety arm.
programmed to deactivate the lift and drive Crushing hazard. Keep hands
functions and activate an alarm when a signal is clear of the safety arm when
received from the level sensor. lowering the platform.
The tilt alarm sounds when the incline of the If you are not installing a new level sensor,
chassis exceeds 1.5° to the side and 3° to the front proceed to step 15.
or rear.
7 Turn the key switch to the off position and push
How to Install and Calibrate the in the red Emergency Stop button to the off
position at the ground controls.
1.5° Level Sensor
8 Tag and disconnect the level sensor wire
Tip-over hazard. Failure to install harness from the chassis wire harness.
or calibrate the level sensor as
instructed will compromise Note: The wire harness connection is located next
machine stability and cause the to the level sensor, on top of the chassis at the
machine to tip over, resulting in steer end of the machine.
death or serious injury. Do not
install or calibrate the level sensor 9 Remove the level sensor retaining fasteners.
other than specified in this Remove the level sensor from the machine.
procedure. 10 Tag and disconnect the level sensor wires from
1 Move the machine to an area that has a firm, the level sensor connector plug.
level surface and is free of obstructions. 11 Securely install the wires of the new level
2 Remove the platform controls from the platform. sensor into the level sensor connector plug.
12 Place the new level sensor onto the level Steer end
sensor mount bracket with the "X" on the level
sensor base closest to the long side of the level a
sensor mount and the "Y" on the level sensor
base closest to the short side of the level
f b
sensor mount. Y
X
Result: The tilt sensor alarm should not sound. 20 Center a lifting jack under the drive chassis at
the ground controls side of the machine.
21 Raise the machine approximately
2 inches / 5 cm.
22 GS-1530 and GS-1930: Place a 0.64 x 6 x 6 25 Lower the platform to the stowed position.
inch / 16.2 mm x 15 cm x 15 cm thick steel
26 Raise the machine approximately
block under both wheels at the ground controls
2 inches / 5 cm.
side of the machine.
27 Remove the blocks from under both wheels.
GS-1532 and GS-1932: Place a 0.68 x 6 x 6
inch / 17.2 mm x 15 cm x 15 cm thick steel 28 Lower the machine and remove the jack.
block under both wheels at the ground controls
side of the machine. 29 Center a lifting jack under the drive chassis at
the battery pack side of the machine.
GS-2032, GS-2632 and GS-3232: Place a
0.66 x 6 x 6 inch / 16.8 mm x 15 cm x 15 cm 30 Raise the machine approximately
thick steel block under both wheels at the 2 inches / 5 cm.
ground controls side of the machine. 31 GS-1530 and GS-1930: Place a 0.77 x 6 x 6
GS-2046, GS-2646 and GS-3246: Place a 1 x 6 inch / 19.6 mm x 15 cm x 15 cm thick steel
x 6 inch / 25.4 mm x 15 cm x 15 cm thick steel block under both wheels at the battery pack
block under both wheels at the ground controls side of the machine.
side of the machine. GS-1532 and GS-1932: Place a 0.83 x 6 x 6
23 Lower the machine onto the blocks. inch / 21.1 mm x 15 cm x 15 cm thick steel
block under both wheels at the battery pack
24 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. side of the machine.
Result: The level sensor alarm should not GS-2032, GS-2632 and GS-3232: Place a
sound. 0.8 x 6 x 6 inch / 20.3 mm x 15 cm x 15 cm
thick steel block under both wheels at the
Result: The level sensor alarm does sound and
battery pack side of the machine.
fault code LL appears in the diagnostic display.
Adjust the level sensor retaining fasteners just GS-2046, GS-2646 and GS-3246: Place a
until the level sensor alarm does not sound. 1.22 x 6 x 6 inch / 31 mm x 15 cm x 15 cm thick
steel block under both wheels at the battery
pack side of the machine.
How to Install the Outrigger 6 Place the new outrigger level sensor onto the
outrigger level sensor base with the flat side of
Level Sensor the outrigger level sensor closest to the battery
Tip-over hazard. Failure to install side access door. Refer to Illustration 1.
the outrigger level sensor as
instructed will compromise
machine stability and cause the
machine to tip over, resulting in
death or serious injury. Do not
install the outrigger level sensor
other than specified in this
procedure.
1 Move the machine to an area that has a firm,
level surface and is free of obstructions.
2 Turn the key switch to the off position and push
in the red Emergency Stop button to the off
position at both the ground and platform
controls.
Illustration 1
3 Open the access door at the battery side of the
machine. 7 Secure the outrigger level sensor onto the base
with the retaining fasteners removed in step 5.
4 Tag and disconnect the outrigger level sensor
wire harness from the outrigger level sensor. 8 Adjust the outrigger level sensor retaining
fasteners until the bubble in the top of the level
5 Remove the outrigger level sensor retaining
sensor is centered in the circles.
fasteners and remove the outrigger level sensor
from the machine. 9 Connect the outrigger level sensor wire harness
to the new outrigger level sensor.
10 Close the access door at the battery side of the
machine.
11 Calibrate the new outrigger level sensor. Refer
to Section 1-4, How to Calibrate the Outrigger
Level Sensor.
GROUND CONTROLS
How to Remove the 6 Tag, disconnect and plug the high pressure
hose at the pump. Cap the fitting on the pump.
Hydraulic Pump
Bodily injury hazard. Spraying
When removing a hose assembly or fitting, the hydraulic oil can penetrate and
O-ring on the fitting and/or hose end must be burn skin. Loosen hydraulic
replaced and then torqued to specification during connections very slowly to allow
installation. the oil pressure to dissipate
Refer to Section Two, Hydraulic Hose and Fitting gradually. Do not allow oil to squirt
Torque Specifications. or spray.
1 Disconnect the battery pack from the machine. 7 Remove the hydraulic power unit from the
machine.
Electrocution/burn hazard. Contact
with electrically charged circuits 8 Remove the pump mounting bolts. Carefully
could result in death or serious remove the pump.
injury. Remove all rings, watches
and other jewelry. Tip-over hazard. After replacing
the hydraulic pump, it is critical to
2 Tag and disconnect the hydraulic power unit return the function speed settings
cables at the motor controller. to original factory specifications.
Failure to restore the machine to
3 Disconnect the filter head from the filter head
original factory specifications
mounting bracket. Rotate the filter out and away
could cause the machine to tip
from the hydraulic power unit.
over resulting in death or serious
4 Remove the hydraulic power unit retaining injury.
fasteners.
5 Tag, disconnect and plug the hydraulic hard line
from the pump. Cap the fitting on the pump.
Manifolds REV F
6-1
Function Manifold Components -
GS-1530, GS-1532, GS-1930 and GS-1932
The function manifold is mounted under the machine, between the module trays.
Index Schematic
No. Description Item Function Torque
— Coil nut (item F) .................................................................................................................... 4-5 ft-lbs / 5-7 Nm
— Coil nut (items E and H) ....................................................................................................... 5-7 ft-lbs / 7-9 Nm
1 Diagnostic nipple ....................................... A ......................... Testing
2 Check disc ................................................. B ......................... Steer circuit ............................ 18 ft-lbs / 24 Nm
3 Relief valve,
1800 to 3700 psi / 124 to 255 bar ............. C ......................... Lift relief .................................. 20 ft-lbs / 27 Nm
4 Check valve, 10 psi / 0.7 bar ..................... D ......................... Drive circuit ............................. 20 ft-lbs / 27 Nm
5 Solenoid valve, 3 position 4 way ............... E ......................... Drive forward/reverse ............. 25 ft-lbs / 34 Nm
6 Solenoid valve, 3 position 4 way ............... F ......................... Steer left/right ......................... 25 ft-lbs / 34 Nm
7 Flow regulator and relief valve,
0.75 gpm / 2.8 L/min,
1500 psi / 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
REV F MANIFOLDS
1 2
I
9
C
3
Y8
H
8
Y4
G Y3
7
D
4
F INSIDE
6 COIL
OUTSIDE
COIL
E
5
MANIFOLDS REV F
6-2
Function Manifold Components -
GS-2032, GS-2632, GS-3232, GS-2046, GS-2646 and GS-3246
The function manifold is mounted behind an inspection door on the ground control side of the machine.
Index Schematic
No. Description Item Function Torque
— Coil nut (item AC) ................................................................................................................. 4-5 ft-lbs / 5-7 Nm
— Coil nut (items AE, AG and AI) ............................................................................................. 5-7 ft-lbs / 7-9 Nm
1 Diagnostic nipple ....................................... AA ...................... Testing
2 Relief valve,
3700 psi / 255 bar maximum ..................... AB ...................... System relief ........................... 20 ft-lbs / 27 Nm
3 Solenoid valve, 3 position 4 way ............... AC ...................... Steer left/right ......................... 25 ft-lbs / 34 Nm
4 Check disc ................................................. AD ...................... Steer circuit ............................ 18 ft-lbs / 24 Nm
5 Solenoid valve, 2 position 4 way ............... 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 Nm
9 Solenoid valve, 2 position 4 way ............... AI ........................ Platform up ............................. 25 ft-lbs / 34 Nm
10 Relief valve,
1800 to 3700 psi / 124 to 255 bar ............. AJ ....................... Lift relief .................................. 20 ft-lbs / 27 Nm
REV F MANIFOLDS
1 2 3 4 5
AD
Note: 'alpha-numeric' callouts
refer to corresponding notes
AB AC on the electrical schematic
AE
AA
Y4
Y3
INSIDE Y1
COIL
OUTSIDE
COIL
Y8
AJ AI AH AG
AF
6
10 9 8 7
MANIFOLDS REV F
6-3
Outrigger Function Manifold Components -
GS-3232
The outrigger function manifold is mounted behind an inspection door on the battery side of the machine.
Index Schematic
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
INSIDE
COIL
OUTSIDE Y39
COIL
BB Y40
2
BA
1
REV F MANIFOLDS
6-4
Outrigger Cylinder Manifold Components -
GS-3232
The front outrigger cylinders are located behind the inspection doors at the battery side and at the ground
control side of the machine. The rear outrigger cylinders are located inside the outrigger enclosures at the
rear of the machine.
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 ............. 20 ft-lbs / 27.1 Nm
4 Pressure Transducer ................................. CG ...................... Outrigger autolevel .............. 16 ft-lbs / 21.7 Nm
CF CF 4
3 3
CG
4
CG
nd
CE
Ex
te 2 te
nd
CE Ex
Re
trac
t
FRONT Re
tr ac
t
REAR
OUTRIGGERS OUTRIGGERS
MANIFOLDS REV F
6-5
Check Valve Manifold Components -
GS-1530, GS-1532, GS-1930 and GS-1932
The check valve manifold is mounted on the function manifold.
Index Schematic
No. Description Item Function Torque
1 Check valve, 200 psi / 13.8 bar ................. S ......................... Drive circuit ............................. 20 ft-lbs / 27 Nm
REV F MANIFOLDS
4 Remove the platform controls from the platform. 11 Repeat steps 5 through 7 to confirm the relief
valve pressure.
5 Turn the key switch to platform control and pull
out the red Emergency Stop button to the on a b
position at both the ground and platform
controls.
a test port
b system relief valve
c steer relief valve
d lift relief valve
a test port
b system relief valve
MANIFOLDS REV F
How to Adjust the 7 Move and hold the joystick fully in either
direction while observing the pressure reading
Platform Lift Relief Valve on the pressure gauge. Note the pressure.
Perform this test from the ground with the platform Refer to Section 2, Specifications.
controls. Do not stand in the platform. 8 Turn the machine off. Hold the system relief
valve with a wrench and remove the cap
Be sure that the hydraulic oil level is at the FULL
(hydraulic schematic item I or AB).
mark on the hydraulic tank.
9 Adjust the internal hex socket. Turn it clockwise
1 Locate the system relief valve on the function to increase the pressure or counterclockwise to
manifold (item I). decrease the pressure.
2 Connect a 0 to 5000 psi / 0 to 350 bar Tip-over hazard. Failure to adjust
pressure gauge to the test port on the function the relief valves to specification
manifold (schematic item A or AA). could result in the machine tipping
3 Chock both sides of the wheels at the steer end over, causing death or serious
of the machine. injury. Do not adjust the relief
valve pressures higher than
4 Remove the platform controls from the platform. specifications.
5 Turn the key switch to platform control and pull 10 Install the relief valve cap.
out the red Emergency Stop button to the on
position at both the ground and platform 11 Repeat steps 4 through 7 to confirm the relief
controls. valve pressure.
6 Press and hold the function enable switch. 12 Place maximum rated load into the platform.
Secure the load to the platform. Refer to
a Section 2, Specifications.
a b
b
c
c
GS-1530/32 and GS-1930/32
GS-32 and GS-46
a test port
a test port
b system relief valve
b system relief valve
c lift relief valve
c steer relief valve
d lift relief valve
REV F MANIFOLDS
MANIFOLDS REV F
How to Adjust the Steer Relief 5 Activate the function enable switch and press
and hold the steer thumb rocker switch to the
Valve right. Allow the wheels to completely turn to the
Perform this test from the ground with the platform right. Continue holding the switch while
controls. Do not stand in the platform. observing the pressure reading on the pressure
gauge. Note the pressure. Refer to Section 2,
Be sure that the hydraulic oil level is at the FULL Specifications.
mark on the hydraulic tank.
6 Press and hold the steer thumb rocker switch to
1 Locate the steer relief valve on the function the left. Allow the wheels to completely turn to
manifold (schematic item G or AH). the left. Continue holding the switch while
observing the pressure reading on the pressure
2 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge.
gauge to the test port (schematic item A or AA)
on the function manifold. 7 Turn the machine off. Hold the steer relief valve
with a wrench and remove the cap (schematic
3 Remove the platform controls from the platform. item G or AH).
4 Turn the key switch to platform control and pull 8 Adjust the internal hex socket. Turn it clockwise
out the red Emergency Stop button to the on to increase the pressure or counterclockwise to
position at both the ground and platform decrease the pressure.
controls.
Component damage hazard.
a 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.
a b
a test port
b system relief valve
c steer relief valve
d lift relief valve
REV F MANIFOLDS
MANIFOLDS REV F
+
b
electrical system, resulting in a tripped circuit 10 W 9V
breaker or component damage. RESISTOR BATTERY
+
with electrically charged circuits
-
could result in death or serious
injury. Remove all rings, watches a multimeter
and other jewelry. b 9V DC battery
c 10Ω resistor
1 Test the coil for resistance. See 6-7 How to d coil
Test a Coil.
Note: Dotted lines in illustration indicate a reversed
2 Connect a 10Ω resistor to the negative terminal connection as specified in step 6
of a known good 9V DC battery. Connect the
other end of the resistor to a terminal on the 5 Momentarily connect the positive lead from the
coil. multimeter to the positive terminal on the 9V
battery. Note and record the current reading.
Note: The battery should read 9V DC or more
when measured across the terminals. 6 At the battery or coil terminals, reverse the
connections. Note and record the current
Ω
Resistor, 10Ω reading.
Genie part number 27287 Result: Both current readings are greater than
0 mA and are different by a minimum of 20%.
The coil is good.
3 Set a multimeter to read DC amperage.
Result: If one or both of the current readings are
Note: The multimeter, when set to read DC 0 mA, or if the two current readings do not differ
amperage, should be capable of reading up to by a minimum of 20%, the coil and/or its
800 mA. internal diode are faulty and the coil should be
4 Connect the negative lead to the other terminal replaced.
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.
REV B
Hydraulic Tank
7-1 2 Remove the drain plug from the hydraulic tank
and allow all of the oil from the tank to drain into
Hydraulic Tank a suitable container. Refer to Section 2,
Specifications.
The primary functions of the hydraulic tank are to
cool and deaerate the hydraulic fluid during Bodily injury hazard. Spraying
operation. It utilizes internal suction strainers for hydraulic oil can penetrate and
the pump supply lines and has an external return burn skin. Loosen hydraulic
line filter. connections very slowly to allow
the oil pressure to dissipate
How to Remove the gradually. Do not allow oil to squirt
or spray.
Hydraulic Tank
3 Tag and disconnect the hydraulic tank return
Component damage hazard. The hard line from the filter. Remove the hard line
work area and surfaces where this from the machine. Cap the fitting on the filter
procedure will be performed must head.
be clean and free of debris that
could get into the hydraulic 4 Tag and disconnect the hydraulic tank hard line
system. from the pump. Remove the hard line from the
machine. Cap the fitting on the pump.
When removing a hose assembly or fitting, the
fitting and/or hose end must be torqued to 5 Remove the hydraulic tank retaining fasteners
specification during installation. and remove the hydraulic tank from the
Refer to Section 2, Hydraulic Hose and Fitting machine.
Torque Specifications.
Torque specifications
Perform this procedure with the platform in the
Hydraulic tank retaining fasteners, dry 35 in-lbs
stowed position.
4 Nm
1 Disconnect the battery pack from the machine. Hydraulic tank retaining fasteners, lubricated 26 in-lbs
Electrocution/burn hazard. Contact 2.9 Nm
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
4 Center a lifting jack under the drive chassis at Note: While removing the retaining fasteners, take
the steer end of the machine. note of the quantity and location of the spacers
when disconnecting the steer link from the yoke
5 Raise the machine approximately assembly.
6 inches / 15 cm. Place blocks under the
chassis for support. 10 Remove the retaining fastener from the top of
the yoke pivot shaft.
Crushing hazard. The chassis
could fall if not properly supported. Note: The pivot shaft retaining fastener is located
above the main deck.
6 Remove the wheel castle nut. Remove the
wheel. 11 Lower the yoke assembly out of the chassis.
Bodily injury hazard. The yoke/
motor assembly may fall if not
properly supported when it is
removed from the chassis.
REV A
Non-steer Axle Components
9-1 9 Tag, disconnect and plug the hydraulic hose
from the brake. Cap the fitting on the brake.
Drive Brake
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
How to Remove a Drive Brake burn skin. Loosen hydraulic
When removing a hose assembly or fitting, the connections very slowly to allow
fitting and/or hose end must be torqued to the oil pressure to dissipate
specification during installation. gradually. Do not allow oil to squirt
Refer to Section 2, Hydraulic Hose and Fitting or spray.
Torque Specifications. 10 Place a lifting jack under the brake for support.
1 Support and secure the entry ladder to an 11 Remove the fasteners that attach the brake to
appropriate lifting device. the drive chassis. Remove the brake.
2 Remove the entry ladder mounting fasteners. Crushing hazard. The brake will
Remove the entry ladder from the machine. fall if not properly supported when
Crushing hazard. The entry ladder the mounting fasteners are
may become unbalanced and fall if removed.
it is not properly supported and
Torque specifications
secured to the lifting device.
3 Block the steer wheels. Brake mounting fasteners, dry 75 ft-lbs
102 Nm
4 Remove the cotter pin from the wheel castle
Brake mounting fasteners, lubricated 56 ft-lbs
nut.
76 Nm
Note: Always replace the cotter pin with a new one
when removing the castle nut.
5 Loosen the wheel castle nut. Do not remove it.
6 Center a lifting jack under the drive chassis at
the non-steer end.
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.
10-1
Brake Release Hand Pump Components
The brake release hand pump manifold is mounted behind the entry ladder.
Index Schematic
No. Description Item Function Torque
1 Hand pump ....................................... L ............... Manual brake release .............................. 30 ft-lbs / 41 Nm
2 Needle valve ..................................... M ............... Manual brake release enable .............. 45-50 in-lbs / 5 Nm
2
M
REV A
Outrigger Components
11-1 7 Support and secure the outrigger cylinder to a
suitable lifting device.
Outrigger Cylinder
8 Remove the outrigger cylinder mounting
fasteners.
How to Remove an Outrigger
Cylinder 9 Remove the outrigger cylinder from the
machine.
Perform this procedure with the platform in the
Crushing hazard. The outrigger
stowed position and the outriggers fully retracted.
cylinder may become unbalanced
and fall if not properly supported
When removing a hose assembly or fitting, the when it is removed from the
O-ring on the fitting and/or hose end must be machine.
replaced and then torqued to specification during Note: After installing a new cylinder or pressure
installation. Refer to Section 2, Hydraulic Hose and transducer, the pressure transducers on the
Fitting Torque Specifications. machine must be calibrated. Refer to Section 1-4,
Steer End: How to Calibrate the Outrigger Pressure
Transducers.
1 Chock the wheels at the non-steer end of the
CF
machine. e
Non-steer End: e
CF
Fault Codes
Before Troubleshooting:
Read, understand and obey the safety rules
and operating instructions in the appropriate
operator's manual on your machine.
Be sure that all necessary tools and test
equipment are available and ready for use.
Observe and Obey:
Read each appropriate fault code thoroughly.
Troubleshooting and repair procedures shall be Attempting short cuts may produce hazardous
completed by a person trained and qualified on conditions.
the repair of this machine.
Be aware of the following hazards and follow
Immediately tag and remove from service a generally accepted safe workshop practices.
damaged or malfunctioning machine.
Crushing hazard. When testing
Repair any machine damage or malfunction or replacing any hydraulic
before operating the machine. component, always support
the structure and secure it
Unless otherwise specified, perform each from movement.
repair procedure with the machine in the
following configuration: Electrocution/burn hazard. Contact
· Machine parked on a firm, level surface with electrically charged circuits
could result in death or serious
· Platform in the stowed position injury. Remove all rings, watches
· Key switch in the off position with the key and other jewelry.
removed
Bodily injury hazard. Spraying
· The red Emergency Stop button in the off hydraulic oil can penetrate and
position at both ground and platform controls burn skin. Loosen hydraulic
· Wheels chocked connections very slowly to allow
the oil pressure to dissipate
· All external AC power supply disconnected gradually. Do not allow oil to
from the machine squirt or spray.
FAULT CODES
REV C
Fault Code Chart
Platform left turn switch Malfunctioning steer left Troubleshoot steer left
42 fault. microswitch. microswitch.
Platform right turn switch Malfunctioning steer right Troubleshoot steer right
43 fault. microswitch. microswitch.
Platform drive enable Malfunctioning drive enable Troubleshoot drive enable
46 switch fault. switch. switch.
Joystick potentiometer not
47 Platform joystick fault.
centered.
Verify potentiometer setting.
f c
e d
a lift enable
b lift error
c right front outrigger
d right rear outrigger
e left rear outrigger
f left front outrigger
REV B
Outrigger Fault Code Chart
Fault Code Problem Possible Causes Solution
Lift error light Up coil fault. Malfunctioning coil OR Troubleshoot coil OR
blinks red 2 wire disconnected from inspect wire connection.
times. coil.
Left front Left front outrigger Malfunctioning coil OR Troubleshoot coil OR
outrigger light coil fault. wire disconnected from inspect wire connection.
blinks red 2 coil.
times.
Right front Right front Malfunctioning coil OR Troubleshoot coil OR
outrigger light outrigger coil fault. wire disconnected from inspect wire connection.
blinks red 2 coil.
times.
Right rear Right rear Malfunctioning coil OR Troubleshoot coil OR
outrigger light outrigger coil fault. wire disconnected from inspect wire connection.
blinks red 2 coil.
times.
Left rear Left rear outrigger Malfunctioning coil OR Troubleshoot coil OR
outrigger light coil fault. wire disconnected from inspect wire connection.
blinks red 2 coil.
times.
Left front Left front outrigger Ground short OR wire Inspect wire connection.
outrigger light pressure disconnected from
blinks red 3 transducer fault. pressure transducer.
times.
Right front Right front Ground short OR wire Inspect wire connection.
outrigger light outrigger pressure disconnected from
blinks red 3 transducer fault. pressure transducer.
times.
Right rear Right rear Ground short OR wire Inspect wire connection.
outrigger light outrigger pressure disconnected from
blinks red 3 transducer fault. pressure transducer.
times.
Left rear Left rear outrigger Ground short OR wire Inspect wire connection.
outrigger light pressure disconnected from
blinks red 3 transducer fault. pressure transducer.
times.
Left front Left front outrigger Short to power. Troubleshoot the harness to
outrigger light pressure the pressure transducer OR
blinks red 4 transducer fault. replace the harness.
times.
Right front Right front Short to power. Troubleshoot the harness to
outrigger light outrigger pressure the pressure transducer OR
blinks red 4 transducer fault. replace the harness.
times.
Schematics
About This Section
There are two groups of schematics in this section.
An illustration legend precedes each group of
drawings.
Electrical Schematics
problem
still exists
C1 24V B
C2 Plug
C3 Outrigger retract Y39 (output)
C4 Outrigger extend Y40 (output)
C5 Left front outrigger Y35 (output)
C6 Right front outrigger Y36 (output)
C7 Left rear outrigger Y33 (output)
C8 Right rear outrigger Y34 (output)
C9 Motor controller enable (output)
C10 Outrigger transducer, 2 axis tilt level sensor S8
and up limit switch LS5A power (output)
C11 Platform up Y8 (output)
C12 Drive enable
Wiring Diagram
Ground Controls and Level Sensor Harness REV B
WH
GROUND CONTROLS
MOTOR CONTROLLER B
TERMINAL B+
RD 1 2 CB2 KS1
7A CIRCUIT KEY SWITCH 3 WH 1
BREAKER
B1
4 2
MOTOR CONTROLLER WH
TERMINAL 1 +
RD
6-PIN CONNECTOR
G6
WH/BK HOUR METER
PIN 1 (J7) -
RD
ECM PIN B12 (J1) 1 (UP)
WH TS66
2 PLATFORM UP/DOWN
BL TOGGLE SWITCH
ECM PIN A12 (J1) 3 (DOWN)
CR48
RD
TERMINAL 30
OR
ECM PIN A1(J1)
P1
1 2 EMERGENCY STOP
WH
NC
2
+ OR/BK
CR48 TERMINAL 87
13 14 WH 3 BK
CR48 TERMINAL 87
NOHC
BK 4 RD/BK
ECM PIN C12
RD BK WH
5 GN
ECM PIN C11
6 BN
GROUND
7 RD
ECM PIN A5
8
NOT USED
2
+ OR/BK
CR48 TERMINAL 87
13 14 WH 3 BK
CR48 TERMINAL 87
NOHC
21 22
RD BK WH
NCHO
BK 4 RD/BK
ECM PIN C12
5 GN
ECM PIN C11
6 BN
GROUND
7 RD
ECM PIN A5
8
NOT USED
WH
CR27D TERMINALS
85, 87 AND 87A
BK
ECM PIN B6
Wiring Diagram
REV B Platform Control Box and Outrigger Control Pad
PLATFORM
CONTROLS
(GEN 5)
RD
BK
JC1
JOYSTICK
H1 CONTROLLER
ALARM
TO COIL CORD
BK RD GY BK
WH
RD
BL
OR
RD
1 4.
WH/BL
NC 1
WH
OR
RD
GY
BN
BK
PP
BL
YL
P2
2 5.
EMERGENCY
STOP
TO COIL CORD
WH
GN
RD
BK
L69
LIFT ENABLE
L70
U36 LIFT ERROR
OUTRIGGER
PLATFORM CONTROL
CIRCUIT BOARD
GS-3232
L53 L54
LR OUTRIGGER RR OUTRIGGER
a b b a d
GS-2032
GS-2632
GS-3232
GS-2046
GS-2646
GS-3246
GS-1530
GS-1532
GS-1930
GS-1932
ALL MODELS
c
N.C.
T2 B+
N.O.
A2 3
MOTOR CONTR. ENABLE
Pressure switch, B- 1
LEVEL SENSOR
CIRCUIT BOARD
normally open
S7
Motor controller LEVEL
N.C. N.O. N.C.H.O. N.O.H.C. SENSOR
D1 Level sensor
M5
Limit switch
Wire with description
A1
Motor
Circuits crossing no
connection
Battery charger
Toggle switch Solenoid valve with diode
Diode -
+
6V DC Battery
Emergency stop button
Capacitor
Circuits connection
CB2
WH B 1 OR
Circuit breaker
2
Connector KS1
KEY PLATFORM
SWITCH CONTROL
30 86
B1 4
87A 87 85
3
Control relay
GROUND
CONTROL
JC1
HALL JOYSTICK
GENERATOR CONTROLLER
flashing beacon
RIGHT
LEFT
SW5
FUNCTION
ENABLE
Joystick
Inductor, LED
noise suppression
Electrical Schematic
ANSI, CSA and Australia Models REV E
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)
Electrical Schematic
REV E 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)
- NOTE -
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF QD4
RD RD 4 4
WH WH 3 3
BL 1 1
30 4 86
CR48
POWER BK 2 2
RELAY TO U5
87 85 OR 5 5
(E-STOP)
N.O.H.C.
LS6
DOWN
LIMIT
SWITCH
RD
WH
N.O.
LEVEL
SENSOR
CIRCUIT
BOARD
ECM POWER
UP LIMIT SWITCH
DWN LIMIT
OVERLOAD POWER
DRIVER POWER
BK
OR/BK
RD/BK
BL/BK
WH
OR
GN
RD
BK
BK
BL
U5
ELECTRONIC CONTROL MODULE
WH/BK
WH
GN/BK
GN/BK
RD/BK
BL/BK
Y1 Y3 Y4 Y5 Y6 Y9 Y7 Y8
PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM
RIGHT LEFT REVERSE FORWARD DOWN DOWN UP
(GS-3246)
GND
ES0141H
Electrical Schematic
ANSI, CSA and Australia Models REV E
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)
P2
EMERGENCY
QD3 STOP
BK
4 4 BK POWER TO PLATFORM
RD
3 3 RD POWER TO GROUND
1 1 WH GROUND PIO3
PIO2
2 2 BL DATA LINK (HIGH) PIO4
U3 D7 5V DC
GN
WH
BL
SW5 SW6
PP FUNCTION ENABLE STEER
LEFT/ RIGHT
OR
LEFT
RIGHT
PIN9
BK
PIN8
RD
PIN10
BK
PLATFORM CONTROLS
MEMBRANE DECAL
POUT1 LIFT LED L16
POUT2 DRIVE LED L17
POUT3 HIGH TORQUE LED L21
G8
POUT4 DIAGNOSTIC
DISPLAY
RD
POUT11 +
BK
H1
ALARM
PLATFORM
PIN11 - CONTROLLER
ES0141H
Electrical Schematic
ANSI, CSA and Australia Models REV C
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)
Electrical Schematic
REV C 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)
- NOTE -
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF QD4
RD RD 4 4
WH WH 3 3
BL 1 1
30 4 86
CR48
POWER BK 2 2
RELAY TO U5
87 85 OR 5 5
(E-STOP)
N.O.H.C.
LS6
DOWN
LIMIT
SWITCH
RD
WH
N.O.
LEVEL
SENSOR
CIRCUIT
BOARD
ECM POWER
UP LIMIT SWITCH
DWN LIMIT
OVERLOAD POWER
DRIVER POWER
BK
OR/BK
RD/BK
BL/BK
WH
OR
GN
RD
BK
BK
BL
U5
ELECTRONIC CONTROL MODULE
WH/BK
WH
GN/BK
GN/BK
RD/BK
BL/BK
Y1 Y3 Y4 Y5 Y6 Y9 Y7 Y8
PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM
RIGHT LEFT REVERSE FORWARD DOWN DOWN UP
(GS-3246)
GND
ES0141K
Electrical Schematic
ANSI, CSA and Australia Models REV C
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)
P2
EMERGENCY
QD3 STOP
BK
4 4 BK POWER TO PLATFORM
RD
3 3 RD POWER TO GROUND
1 1 WH GROUND PIO3
PIO2
2 2 BL DATA LINK (HIGH) PIO4
U3 D7 5V DC
GN
WH
BL
SW5 SW6
PP FUNCTION ENABLE STEER
LEFT/ RIGHT
OR
LEFT
RIGHT
PIN9
BK
PIN8
RD
PIN10
BK
PLATFORM CONTROLS
MEMBRANE DECAL
POUT1 LIFT LED L16
POUT2 DRIVE LED L17
POUT3 HIGH TORQUE LED L21
G8
POUT4 DIAGNOSTIC
DISPLAY
RD
POUT11 +
BK
H1
ALARM
PLATFORM
PIN11 - CONTROLLER
ES0141K
Electrical Schematic
ANSI, CSA and Australia Models REV B
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)
Electrical Schematic
REV B 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)
- NOTE -
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF QD4
RD RD 4 4
WH WH 3 3
BL 1 1
30 4 86
CR48
POWER BK 2 2
RELAY TO U5
87 85 OR 5 5
(E-STOP)
N.O.H.C.
LS6
DOWN
LIMIT
SWITCH
RD
WH
N.O.
LEVEL
SENSOR
CIRCUIT
BOARD
DRIVER POWER
UP LIMIT SWITCH
DWN LIMIT
OVERLOAD POWER
ECM POWER
BK
OR/BK
RD/BK
BL/BK
WH
OR
GN
RD
BK
BK
BL
U5
ELECTRONIC CONTROL MODULE
WH/BK
WH
GN/BK
GN/BK
RD/BK
BL/BK
Y1 Y3 Y4 Y5 Y6 Y9 Y7 Y8
PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM
RIGHT LEFT REVERSE FORWARD DOWN DOWN UP
(GS-3246)
GND
ES0141M
Electrical Schematic
ANSI, CSA and Australia Models REV B
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)
P2
EMERGENCY
QD3 STOP
BK
4 4 BK POWER TO PLATFORM
RD
3 3 RD POWER TO GROUND
1 1 WH GROUND PIO3
PIO2
2 2 BL DATA LINK (HIGH) PIO4
U3 D7 5V DC
GN
WH
BL
SW5 SW6
PP FUNCTION ENABLE STEER
LEFT/ RIGHT
OR
LEFT
RIGHT
PIN9
BK
PIN8
RD
PIN10
BK
PLATFORM CONTROLS
MEMBRANE DECAL
POUT1 LIFT LED L16
POUT2 DRIVE LED L17
POUT3 HIGH TORQUE LED L21
G8
POUT4 DIAGNOSTIC
DISPLAY
RD
POUT11 +
BK
H1
ALARM
PLATFORM
PIN11 - CONTROLLER
ES0141M
Electrical Schematic
ANSI, CSA and Australia Models REV C
GS-1530/1532/1930/1932 (after serial number GS3007A-89537)
GS-1530/1532/1930/1932 (after serial number GS3007B-84599)
Electrical Schematic
REV C ANSI, CSA and Australia Models
GS-1530/1532/1930/1932 (after serial number GS3007A-89537)
GS-1530/1532/1930/1932 (after serial number GS3007B-84599)
QD4
GS-3232 ONLY
RD RD 4 4
WH WH 3 3
BL 1 1
BK 2 2
OR 5 5
30 86 GN MC THROTTLE
4
CR48 BK MC ENABLE (IN)
POWER BK 24V
87 85 RELAY TO U5 OR KS1
(E-STOP)
OR/BK DRIVE ENABLE
GS-3232 ONLY
GROUND
BK MC ENABLE (OUT)
RD/BK DOWN LIM
N.O.H.C.
BN GROUND
LS6
DOWN
LIMIT
SWITCH
UP IN
FORWARD
REVERSE
UP COIL
RD
WH
N.O.
BL/BK
WH
WH/BK
BL/BK
LEVEL
SENSOR
UP LIMIT SWITCH (GS-3232 ONLY)
CIRCUIT
BOARD
OVERLOAD POWER
UP LIMIT SWITCH
SENSOR
BK
OR/BK
RD/BK
BL/BK
WH
OR
GN
RD
BK
BK
BL
NOT CONNECTED
ON GS-3232
NOT CONNECTED
U5 ON GS-3232
ELECTRONIC CONTROL MODULE
WH/BK
WH
GN/BK
RD/BK
BL/BK
GS-3232 ONLY
Y1 Y3 Y4 Y5 Y6 Y9 Y7 Y8
PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM
RIGHT LEFT REVERSE FORWARD DOWN DOWN UP
(GS-3246)
GND
ES0141P
Electrical Schematic
ANSI, CSA and Australia Models REV C
GS-1530/1532/1930/1932 (after serial number GS3007A-89537)
GS-1530/1532/1930/1932 (after serial number GS3007B-84599)
GS-3232 ONLY +
L70
MC THROTTLE BN105 LIFT ERROR L69
MC ENABLE (IN) H8 LIFT ENABLE
24V
EXTEND - ALARM
KS1 BN107
DRIVE ENABLE U39
GN
25 OHMS RETRACT
GROUND BK CPU
10 WATT BN106
R24 L51 L52
MC ENABLE (OUT) AUTOLEVEL
FL OUTRIGGER FR OUTRIGGER
DOWN LIM OUTRIGGER
BK
UP IN CONTROL
U36 PRINTED
OR
FORWARD
OR/BK
CIRCUIT
RD/BK
REVERSE
BOARD
L53 L54
BL/BK
UP COIL
U41
U40
WH
TX / RX RL OUTRIGGER RR OUTRIGGER
WH/BK
POWER CHIP
BL/BK
SUPPLY
CHIP
1 4 3 2
BN
WH
QD20 GN
BK RD
BL
S8
2 AXIS
TILT LEVEL
MC ENABLE SENSOR
MC THROTTLE
GROUND TO PLAT
POWER TO PLAT
DATA (LOW)
DATA (HIGH)
GROUND
KEYSWITCH
MC ENABLE
DRIVE ENABLE
SWITCH POWER
POWER
PITCH
LS5A
ROLL
N.C.
UP
DOWN LIM
LIMIT
SWITCH
WH
BL
OR
BN
PT1 LS5B
RD/BK
N.C.
UP COIL
REVERSE
FORWARD
UP IN
(LF) UP
LIMIT
SWITCH
RD/BK
PT2
WH/BK
OR/BK
RD/BK
(RF)
BL/BK
BL/BK
WH
WH
OR
GN
GN
RD
BK
BK
BK
BL
BK
BK
GN/BK
GN
RD/WH
OR/WH
BL/WH
GN/WH
REGEN COIL (N/A ON 3232)
24V MAIN
GND
BK
GND BN
ES0141P
Electrical Schematic
REV C ANSI, CSA and Australia Models
GS-1530/1532/1930/1932 (after serial number GS3007A-89537)
GS-1530/1532/1930/1932 (after serial number GS3007B-84599)
P2
EMERGENCY
QD3 STOP
BK
4 4 BK POWER TO PLATFORM
RD
- NOTE -
3 3 RD POWER TO GROUND
MACHINE SHOWN IN THE STOWED
1 1 WH GROUND PIO3
PIO2 POSITION WITH THE POWER OFF
2 2 BL DATA LINK (HIGH) PIO4
U3 D7 5V DC
GN
WH
BL
SW5 SW6
PP FUNCTION ENABLE STEER
LEFT/ RIGHT
OR
LEFT
RIGHT
PIN9
BK
PIN8
RD
PIN10
BK
PLATFORM CONTROLS
MEMBRANE DECAL
POUT1 LIFT LED L16
POUT2 DRIVE LED L17
POUT3 HIGH TORQUE LED L21
G8
POUT4 DIAGNOSTIC
DISPLAY
RD
POUT11 +
BK
H1
ALARM
PLATFORM
PIN11 - CONTROLLER
ES0141P
Electrical Schematic
ANSI, CSA and Australia Models REV E
GS-2032/2632 (from serial number GS3205-75407 to GS3206-79991)
GS-2046/2646/3246 (from serial number GS4605-75438 to GS4606-78915)
Electrical Schematic
REV E 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)
- NOTE -
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF QD4
RD RD 4 4
WH WH 3 3
BL 1 1
30 4 86
CR48
POWER BK 2 2
RELAY TO U5
87 85 OR 5 5
(E-STOP)
N.O.H.C.
LS6
DOWN
LIMIT
SWITCH
RD
WH
N.O.
LEVEL
SENSOR
CIRCUIT
BOARD
ECM POWER
UP LIMIT SWITCH
DWN LIMIT
OVERLOAD POWER
DRIVER POWER
BK
OR/BK
RD/BK
BL/BK
WH
OR
GN
RD
BK
BK
BL
U5
ELECTRONIC CONTROL MODULE
WH/BK
WH
GN/BK
GN/BK
RD/BK
BL/BK
Y1 Y3 Y4 Y5 Y6 Y9 Y7 Y8
PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM
RIGHT LEFT REVERSE FORWARD DOWN DOWN UP
(GS-3246)
GND
ES0141H
Electrical Schematic
ANSI, CSA and Australia Models REV E
GS-2032/2632 (from serial number GS3205-75407 to GS3206-79991)
GS-2046/2646/3246 (from serial number GS4605-75438 to GS4606-78915)
P2
EMERGENCY
QD3 STOP
BK
4 4 BK POWER TO PLATFORM
RD
3 3 RD POWER TO GROUND
1 1 WH GROUND PIO3
PIO2
2 2 BL DATA LINK (HIGH) PIO4
U3 D7 5V DC
GN
WH
BL
SW5 SW6
PP FUNCTION ENABLE STEER
LEFT/ RIGHT
OR
LEFT
RIGHT
PIN9
BK
PIN8
RD
PIN10
BK
PLATFORM CONTROLS
MEMBRANE DECAL
POUT1 LIFT LED L16
POUT2 DRIVE LED L17
POUT3 HIGH TORQUE LED L21
G8
POUT4 DIAGNOSTIC
DISPLAY
RD
POUT11 +
BK
H1
ALARM
PLATFORM
PIN11 - CONTROLLER
ES0141H
Electrical Schematic
ANSI, CSA and Australia Models REV C
GS-2032/2632 (from serial number GS3206-79992 to GS3207-83650)
GS-2046/2646/3246 (from serial number GS4606-78916 to GS4607-82535)
Electrical Schematic
REV C 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)
- NOTE -
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF QD4
RD RD 4 4
WH WH 3 3
BL 1 1
30 4 86
CR48
POWER BK 2 2
RELAY TO U5
87 85 OR 5 5
(E-STOP)
N.O.H.C.
LS6
DOWN
LIMIT
SWITCH
RD
WH
N.O.
LEVEL
SENSOR
CIRCUIT
BOARD
ECM POWER
UP LIMIT SWITCH
DWN LIMIT
OVERLOAD POWER
DRIVER POWER
BK
OR/BK
RD/BK
BL/BK
WH
OR
GN
RD
BK
BK
BL
U5
ELECTRONIC CONTROL MODULE
WH/BK
WH
GN/BK
GN/BK
RD/BK
BL/BK
Y1 Y3 Y4 Y5 Y6 Y9 Y7 Y8
PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM
RIGHT LEFT REVERSE FORWARD DOWN DOWN UP
(GS-3246)
GND
ES0141K
Electrical Schematic
ANSI, CSA and Australia Models REV C
GS-2032/2632 (from serial number GS3206-79992 to GS3207-83650)
GS-2046/2646/3246 (from serial number GS4606-78916 to GS4607-82535)
P2
EMERGENCY
QD3 STOP
BK
4 4 BK POWER TO PLATFORM
RD
3 3 RD POWER TO GROUND
1 1 WH GROUND PIO3
PIO2
2 2 BL DATA LINK (HIGH) PIO4
U3 D7 5V DC
GN
WH
BL
SW5 SW6
PP FUNCTION ENABLE STEER
LEFT/ RIGHT
OR
LEFT
RIGHT
PIN9
BK
PIN8
RD
PIN10
BK
PLATFORM CONTROLS
MEMBRANE DECAL
POUT1 LIFT LED L16
POUT2 DRIVE LED L17
POUT3 HIGH TORQUE LED L21
G8
POUT4 DIAGNOSTIC
DISPLAY
RD
POUT11 +
BK
H1
ALARM
PLATFORM
PIN11 - CONTROLLER
ES0141K
Electrical Schematic
ANSI, CSA and Australia Models REV B
GS-2032/2632 (from serial number GS3207-83651 to GS3207-84866)
GS-2046/2646/3246 (from serial number GS4607-82536 to GS4607-84839)
Electrical Schematic
REV B 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)
- NOTE -
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF QD4
RD RD 4 4
WH WH 3 3
BL 1 1
30 4 86
CR48
POWER BK 2 2
RELAY TO U5
87 85 OR 5 5
(E-STOP)
N.O.H.C.
LS6
DOWN
LIMIT
SWITCH
RD
WH
N.O.
LEVEL
SENSOR
CIRCUIT
BOARD
DRIVER POWER
UP LIMIT SWITCH
DWN LIMIT
OVERLOAD POWER
ECM POWER
BK
OR/BK
RD/BK
BL/BK
WH
OR
GN
RD
BK
BK
BL
U5
ELECTRONIC CONTROL MODULE
WH/BK
WH
GN/BK
GN/BK
RD/BK
BL/BK
Y1 Y3 Y4 Y5 Y6 Y9 Y7 Y8
PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM
RIGHT LEFT REVERSE FORWARD DOWN DOWN UP
(GS-3246)
GND
ES0141M
Electrical Schematic
ANSI, CSA and Australia Models REV B
GS-2032/2632 (from serial number GS3207-83651 to GS3207-84866)
GS-2046/2646/3246 (from serial number GS4607-82536 to GS4607-84839)
P2
EMERGENCY
QD3 STOP
BK
4 4 BK POWER TO PLATFORM
RD
3 3 RD POWER TO GROUND
1 1 WH GROUND PIO3
PIO2
2 2 BL DATA LINK (HIGH) PIO4
U3 D7 5V DC
GN
WH
BL
SW5 SW6
PP FUNCTION ENABLE STEER
LEFT/ RIGHT
OR
LEFT
RIGHT
PIN9
BK
PIN8
RD
PIN10
BK
PLATFORM CONTROLS
MEMBRANE DECAL
POUT1 LIFT LED L16
POUT2 DRIVE LED L17
POUT3 HIGH TORQUE LED L21
G8
POUT4 DIAGNOSTIC
DISPLAY
RD
POUT11 +
BK
H1
ALARM
PLATFORM
PIN11 - CONTROLLER
ES0141M
Electrical Schematic
ANSI, CSA and Australia Models REV C
GS-2032/2632/3232 (after serial number GS3207-84866)
GS-2046/2646/3246 (after serial number GS4607-84839)
Electrical Schematic
REV C ANSI, CSA and Australia Models
GS-2032/2632/3232 (after serial number GS3207-84866)
GS-2046/2646/3246 (after serial number GS4607-84839)
QD4
GS-3232 ONLY
RD RD 4 4
WH WH 3 3
BL 1 1
BK 2 2
OR 5 5
30 86 GN MC THROTTLE
4
CR48 BK MC ENABLE (IN)
POWER BK 24V
87 85 RELAY TO U5 OR KS1
(E-STOP)
OR/BK DRIVE ENABLE
GS-3232 ONLY
GROUND
BK MC ENABLE (OUT)
RD/BK DOWN LIM
N.O.H.C.
BN GROUND
LS6
DOWN
LIMIT
SWITCH
UP IN
FORWARD
REVERSE
UP COIL
RD
WH
N.O.
BL/BK
WH
WH/BK
BL/BK
LEVEL
SENSOR
UP LIMIT SWITCH (GS-3232 ONLY)
CIRCUIT
BOARD
OVERLOAD POWER
UP LIMIT SWITCH
SENSOR
BK
OR/BK
RD/BK
BL/BK
WH
OR
GN
RD
BK
BK
BL
NOT CONNECTED
ON GS-3232
NOT CONNECTED
U5 ON GS-3232
ELECTRONIC CONTROL MODULE
WH/BK
WH
GN/BK
RD/BK
BL/BK
GS-3232 ONLY
Y1 Y3 Y4 Y5 Y6 Y9 Y7 Y8
PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM
RIGHT LEFT REVERSE FORWARD DOWN DOWN UP
(GS-3246)
GND
ES0141P
Electrical Schematic
ANSI, CSA and Australia Models REV C
GS-2032/2632/3232 (after serial number GS3207-84866)
GS-2046/2646/3246 (after serial number GS4607-84839)
GS-3232 ONLY +
L70
MC THROTTLE BN105 LIFT ERROR L69
MC ENABLE (IN) H8 LIFT ENABLE
24V
EXTEND - ALARM
KS1 BN107
DRIVE ENABLE U39
GN
25 OHMS RETRACT
GROUND BK CPU
10 WATT BN106
R24 L51 L52
MC ENABLE (OUT) AUTOLEVEL
FL OUTRIGGER FR OUTRIGGER
DOWN LIM OUTRIGGER
BK
UP IN CONTROL
U36 PRINTED
OR
FORWARD
OR/BK
CIRCUIT
RD/BK
REVERSE
BOARD
L53 L54
BL/BK
UP COIL
U41
U40
WH
TX / RX RL OUTRIGGER RR OUTRIGGER
WH/BK
POWER CHIP
BL/BK
SUPPLY
CHIP
1 4 3 2
BN
WH
QD20 GN
BK RD
BL
S8
2 AXIS
TILT LEVEL
MC ENABLE SENSOR
MC THROTTLE
GROUND TO PLAT
POWER TO PLAT
DATA (LOW)
DATA (HIGH)
GROUND
KEYSWITCH
MC ENABLE
DRIVE ENABLE
SWITCH POWER
POWER
PITCH
LS5A
ROLL
N.C.
UP
DOWN LIM
LIMIT
SWITCH
WH
BL
OR
BN
PT1 LS5B
RD/BK
N.C.
UP COIL
REVERSE
FORWARD
UP IN
(LF) UP
LIMIT
SWITCH
RD/BK
PT2
WH/BK
OR/BK
RD/BK
(RF)
BL/BK
BL/BK
WH
WH
OR
GN
GN
RD
BK
BK
BK
BL
BK
BK
GN/BK
GN
RD/WH
OR/WH
BL/WH
GN/WH
REGEN COIL (N/A ON 3232)
24V MAIN
GND
BK
GND BN
ES0141P
Electrical Schematic
REV C ANSI, CSA and Australia Models
GS-2032/2632/3232 (after serial number GS3207-84866)
GS-2046/2646/3246 (after serial number GS4607-84839)
P2
EMERGENCY
QD3 STOP
BK
4 4 BK POWER TO PLATFORM
RD
- NOTE -
3 3 RD POWER TO GROUND
MACHINE SHOWN IN THE STOWED
1 1 WH GROUND PIO3
PIO2 POSITION WITH THE POWER OFF
2 2 BL DATA LINK (HIGH) PIO4
U3 D7 5V DC
GN
WH
BL
SW5 SW6
PP FUNCTION ENABLE STEER
LEFT/ RIGHT
OR
LEFT
RIGHT
PIN9
BK
PIN8
RD
PIN10
BK
PLATFORM CONTROLS
MEMBRANE DECAL
POUT1 LIFT LED L16
POUT2 DRIVE LED L17
POUT3 HIGH TORQUE LED L21
G8
POUT4 DIAGNOSTIC
DISPLAY
RD
POUT11 +
BK
H1
ALARM
PLATFORM
PIN11 - CONTROLLER
ES0141P
Electrical Schematic
CE Models REV E
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)
Electrical Schematic
REV E 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)
- NOTE -
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF QD4
RD RD 4 4
WH WH 3 3
BL 1 1
30 4 86
CR48
POWER BK 2 2
RELAY TO U5
87 85 OR 5 5
(E-STOP)
N.C.
N.O.H.C.
RD
WH
CR27A CR27B CR27C
OVERLOAD OVERLOAD OVERLOAD
(MOTOR CONT) (LOAD SENSE) (DOWN COIL)
N.O.
30 86 30 86 30 86 N.C.
1 2 3
LEVEL
87 85 87A 85 87 85
LS5 SENSOR
CIRCUIT
UP BOARD
LIMIT
C5 SWITCH
4700 uF
DWN LIMIT
UP LIMIT SWITCH
SENSOR
87A 87 85
BK
CR27D
OVERLOAD
(DOWN DELAY)
OR/BK
RD/BK
BL/BK
GN/BK
WH
WH
GN
OR
GN
RD
BK
BK
BL
U5
ELECTRONIC CONTROL MODULE
WH/BK
WH
GN/BK
RD/BK
Y1 Y3 Y4 Y5 Y6 Y9 Y7 Y8
PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM
RIGHT LEFT REVERSE FORWARD DOWN DOWN UP
(GS-3246)
GND
ES0142D
Electrical Schematic
CE Models REV E
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)
P2
EMERGENCY
QD3 STOP
BK
4 4 BK POWER TO PLATFORM
RD
3 3 RD POWER TO GROUND
1 1 WH GROUND PIO3
PIO2
2 2 BL DATA LINK (HIGH) PIO4
U3 D7 5V DC
GN
WH
BL
SW5 SW6
PP FUNCTION ENABLE STEER
LEFT/ RIGHT
OR
LEFT
RIGHT
PIN9
BK
PIN8
RD
PIN10
BK
PLATFORM CONTROLS
MEMBRANE DECAL
POUT1 LIFT LED L16
POUT2 DRIVE LED L17
POUT3 HIGH TORQUE LED L21
G8
POUT4 DIAGNOSTIC
DISPLAY
RD
POUT11 +
BK
H1
ALARM
PLATFORM
PIN11 - CONTROLLER
ES0142D
Electrical Schematic
CE Models REV E
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)
Electrical Schematic
REV E 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)
- NOTE -
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF QD4
RD RD 4 4
WH WH 3 3
BL 1 1
30 4 86
CR48
POWER BK 2 2
RELAY TO U5
87 85 OR 5 5
(E-STOP)
R24
25 OHM
N.C.
N.O.H.C.
RD
WH
CR27A CR27B CR27C
OVERLOAD OVERLOAD OVERLOAD
(MOTOR CONT) (LOAD SENSE) (DOWN COIL)
N.O.
30 86 30 86 30 86 N.C.
1 2 3
LEVEL
87 85 87A 85 87 85
LS5 SENSOR
CIRCUIT
UP BOARD
LIMIT
C5 SWITCH
4700 uF
DWN LIMIT
UP LIMIT SWITCH
SENSOR
87A 87 85
BK
CR27D
OVERLOAD
(DOWN DELAY)
OR/BK
RD/BK
BL/BK
GN/BK
WH
WH
GN
OR
GN
RD
BK
BK
BL
U5
ELECTRONIC CONTROL MODULE
WH/BK
WH
GN/BK
RD/BK
Y1 Y3 Y4 Y5 Y6 Y9 Y7 Y8
PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM
RIGHT LEFT REVERSE FORWARD DOWN DOWN UP
(GS-3246)
GND
ES0142G
Electrical Schematic
CE Models REV E
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)
P2
EMERGENCY
QD3 STOP
BK
4 4 BK POWER TO PLATFORM
RD
3 3 RD POWER TO GROUND
1 1 WH GROUND PIO3
PIO2
2 2 BL DATA LINK (HIGH) PIO4
U3 D7 5V DC
GN
WH
BL
SW5 SW6
PP FUNCTION ENABLE STEER
LEFT/ RIGHT
OR
LEFT
RIGHT
PIN9
BK
PIN8
RD
PIN10
BK
PLATFORM CONTROLS
MEMBRANE DECAL
POUT1 LIFT LED L16
POUT2 DRIVE LED L17
POUT3 HIGH TORQUE LED L21
G8
POUT4 DIAGNOSTIC
DISPLAY
RD
POUT11 +
BK
H1
ALARM
PLATFORM
PIN11 - CONTROLLER
ES0142G
Electrical Schematic
CE Models REV D
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)
Electrical Schematic
REV D 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)
- NOTE -
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF QD4
RD RD 4 4
WH WH 3 3
BL 1 1
CR28 30 6 86 30 4 86
CR48
CUT OUT POWER BK 2 2
(MOTOR CONT) RELAY TO U5
87A 85 87 85 OR 5 5
(E-STOP)
R24
25 OHM
N.C.
N.O.H.C.
RD
WH
CR27A CR27B CR27C
OVERLOAD OVERLOAD OVERLOAD
(MOTOR CONT) (LOAD SENSE) (DOWN COIL)
N.O.
30 86 30 86 30 86 N.C.
1 2 3
LEVEL
87 85 87A 85 87 85
LS5 N.O.
SENSOR
CIRCUIT
UP BOARD
LIMIT
C5 SWITCH
4700 uF
DWN LIMIT
UP LIMIT SWITCH
SENSOR
87A 87 85
BK
CR27D
OVERLOAD
(DOWN DELAY)
OR/BK
RD/BK
BL/BK
GN/BK
WH
WH
GN
OR
GN
RD
BK
BK
BL
U5
ELECTRONIC CONTROL MODULE
WH/BK
WH
GN/BK
RD/BK
Y1 Y3 Y4 Y5 Y6 Y9 Y7 Y8
PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM
RIGHT LEFT REVERSE FORWARD DOWN DOWN UP
(GS-3246)
GND
ES0142J
Electrical Schematic
CE Models REV D
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)
P2
EMERGENCY
QD3 STOP
BK
4 4 BK POWER TO PLATFORM
RD
3 3 RD POWER TO GROUND
1 1 WH GROUND PIO3
PIO2
2 2 BL DATA LINK (HIGH) PIO4
U3 D7 5V DC
GN
WH
BL
SW5 SW6
PP FUNCTION ENABLE STEER
LEFT/ RIGHT
OR
LEFT
RIGHT
PIN9
BK
PIN8
RD
PIN10
BK
PLATFORM CONTROLS
MEMBRANE DECAL
POUT1 LIFT LED L16
POUT2 DRIVE LED L17
POUT3 HIGH TORQUE LED L21
G8
POUT4 DIAGNOSTIC
DISPLAY
RD
POUT11 +
BK
H1
ALARM
PLATFORM
PIN11 - CONTROLLER
ES0142J
Electrical Schematic
CE Models REV C
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)
Electrical Schematic
REV C 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)
- NOTE -
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF QD4
RD RD 4 4
WH WH 3 3
BL 1 1
CR28 30 6 86 30 4 86
CR48
CUT OUT POWER BK 2 2
(MOTOR CONT) RELAY TO U5
87A 85 87 85 OR 5 5
(E-STOP)
R24
25 OHM
N.C.
N.O.H.C.
RD
WH
CR27A CR27B CR27C
OVERLOAD
OVERLOAD OVERLOAD
(MOTOR CONT) (LOAD SENSE) (DOWN COIL)
N.O.
30 86 30 86 30 86 N.C.
1 2 3
LEVEL
87 85 87A 85 87 85
LS5 N.O.
SENSOR
CIRCUIT
UP BOARD
LIMIT
C5 SWITCH
4700 uF
DWN LIMIT
UP LIMIT SWITCH
SENSOR
87A 87 85
BK
CR27D
OVERLOAD
(DOWN DELAY)
OR/BK
RD/BK
BL/BK
GN/BK
WH
WH
GN
OR
GN
RD
BK
BK
BL
U5
ELECTRONIC CONTROL MODULE
WH/BK
WH
GN/BK
RD/BK
Y1 Y3 Y4 Y5 Y6 Y9 Y7 Y8
PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM
RIGHT LEFT REVERSE FORWARD DOWN DOWN UP
(GS-3246)
GND
ES0142K
Electrical Schematic
CE Models REV C
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)
P2
EMERGENCY
QD3 STOP
BK
4 4 BK POWER TO PLATFORM
RD
3 3 RD POWER TO GROUND
1 1 WH GROUND PIO3
PIO2
2 2 BL DATA LINK (HIGH) PIO4
U3 D7 5V DC
GN
WH
BL
SW5 SW6
PP FUNCTION ENABLE STEER
LEFT/ RIGHT
OR
LEFT
RIGHT
PIN9
BK
PIN8
RD
PIN10
BK
PLATFORM CONTROLS
MEMBRANE DECAL
POUT1 LIFT LED L16
POUT2 DRIVE LED L17
POUT3 HIGH TORQUE LED L21
G8
POUT4 DIAGNOSTIC
DISPLAY
RD
POUT11 +
BK
H1
ALARM
PLATFORM
PIN11 - CONTROLLER
ES0142K
Electrical Schematic
CE Models REV B
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)
Electrical Schematic
REV B 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)
- NOTE -
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF QD4
RD RD 4 4
WH WH 3 3
BL 1 1
CR28 30 6 86 30 4 86
CR48
CUT OUT POWER BK 2 2
(MOTOR CONT) RELAY TO U5
87A 85 87 85 OR 5 5
(E-STOP)
R24
25 OHM
N.C.
N.O.H.C.
RD
WH
CR27A CR27B CR27C
OVERLOAD OVERLOAD OVERLOAD
(MOTOR CONT) (LOAD SENSE) (DOWN COIL)
N.O.
30 86 30 86 30 86 N.C.
1 2 3
LEVEL
87 85 87A 85 87 85
LS5 N.O.
SENSOR
CIRCUIT
UP BOARD
LIMIT
C5 SWITCH
4700 uF
DWN LIMIT
UP LIMIT SWITCH
SENSOR
87A 87 85
BK
CR27D
OVERLOAD
(DOWN DELAY)
OR/BK
RD/BK
BL/BK
GN/BK
WH
WH
GN
OR
GN
RD
BK
BK
BL
U5
ELECTRONIC CONTROL MODULE
WH/BK
WH
GN/BK
RD/BK
Y1 Y3 Y4 Y5 Y6 Y9 Y7 Y8
PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM
RIGHT LEFT REVERSE FORWARD DOWN DOWN UP
(GS-3246)
GND
ES0142M
Electrical Schematic
CE Models REV B
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)
P2
EMERGENCY
QD3 STOP
BK
4 4 BK POWER TO PLATFORM
RD
3 3 RD POWER TO GROUND
1 1 WH GROUND PIO3
PIO2
2 2 BL DATA LINK (HIGH) PIO4
U3 D7 5V DC
GN
WH
BL
SW5 SW6
PP FUNCTION ENABLE STEER
LEFT/ RIGHT
OR
LEFT
RIGHT
PIN9
BK
PIN8
RD
PIN10
BK
PLATFORM CONTROLS
MEMBRANE DECAL
POUT1 LIFT LED L16
POUT2 DRIVE LED L17
POUT3 HIGH TORQUE LED L21
G8
POUT4 DIAGNOSTIC
DISPLAY
RD
POUT11 +
BK
H1
ALARM
PLATFORM
PIN11 - CONTROLLER
ES0142M
Electrical Schematic
CE Models REV F
GS-1530/1532/1930/1932 (after serial number GS3007A-89537 and GS3007B-84599)
GS-1530/1532/1930/1932 (from serial number GS3008C-101)
Electrical Schematic
REV F CE Models
GS-1530/1532/1930/1932 (after serial number GS3007A-89537 and GS3007B-84599)
GS-1530/1532/1930/1932 (from serial number GS3008C-101)
QD4
GS-3232 ONLY
RD RD 4 4
WH WH 3 3
BL 1 1
BK 2 2
OR 5 5
GN MC THROTTLE
30 6 86 30 4 86
CR48 BK MC ENABLE (IN)
POWER
BK 24V
RELAY TO U5
87A 85 87 85 OR KS1
(E-STOP)
OR/BK DRIVE ENABLE
GS-3232 ONLY
CR28 R24 GROUND
CUT OUT 25 OHM
(MOTOR CONT) BK MC ENABLE (OUT)
N.C. RD/BK DOWN LIM
N.O.H.C.
UP IN
FORWARD
REVERSE
UP COIL
RD
WH
CR27A CR27B CR27C
OVERLOAD
OVERLOAD OVERLOAD
(MOTOR CONT) (LOAD SENSE) (DOWN COIL)
N.O.
30 86 30 86 30 86 N.C.
1 2 3
BL/BK
WH
WH/BK
BL/BK
LEVEL
87 85 87A 85 87 85
LS5 SENSOR
UP LIMIT SWITCH (GS-3232 ONLY)
N.O. CIRCUIT
UP BOARD
LIMIT
C5 SWITCH
4700 uF
DWN LIMIT
UP LIMIT SWITCH
SENSOR ONLY
87A 87 85
BK
CR27D
OVERLOAD
(DOWN DELAY)
OR/BK
OR/BK
RD/BK
BL/BK
GN/BK
WH
WH
GN
OR
GN
RD
BK
BK
BL
NOT CONNECTED
ON GS-3232
U5
ELECTRONIC CONTROL MODULE NOT CONNECTED
ON GS-3232
WH/BK
WH
GN/BK
RD/BK
GS-3232 ONLY
Y1 Y3 Y4 Y5 Y6 Y9 Y7 Y8
PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM
RIGHT LEFT REVERSE FORWARD DOWN DOWN UP
(GS-3232/GS-3246)
GND
ES0142P
Electrical Schematic
CE Models REV F
GS-1530/1532/1930/1932 (after serial number GS3007A-89537 and GS3007B-84599)
GS-1530/1532/1930/1932 (from serial number GS3008C-101)
24V ALARM
KS1 BN106 -
DRIVE ENABLE U39
GN
25 OHMS FUNCTION ENABLE
GROUND BK CPU
R24
10 WATT BN105 L51 L52
FL OUTRIGGER FR OUTRIGGER
MC ENABLE (OUT) EXTEND
UP IN CONTROL
U36 PRINTED
OR
FORWARD
OR/BK
CIRCUIT
RD/BK
REVERSE
BOARD
L53 L54
BL/BK
UP COIL
U41
U40
WH
RL OUTRIGGER RR OUTRIGGER
TX / RX
WH/BK
POWER CHIP
BL/BK
SUPPLY
CHIP
1 4 3 2
BN
WH
QD20 GN
BK RD
BL
S8
2 AXIS
TILT LEVEL
MC ENABLE SENSOR
MC THROTTLE
GROUND TO PLAT
POWER TO PLAT
DATA (LOW)
DATA (HIGH)
GROUND
KEYSWITCH
MC ENABLE
DRIVE ENABLE
SWITCH POWER
POWER
PITCH
LS5A
ROLL
N.C.
UP
DOWN LIM
LIMIT
SWITCH
WH
BL
OR
BN
PT1 LS5B
RD/BK
N.C.
UP COIL
REVERSE
FORWARD
UP IN
(LF) UP
LIMIT
SWITCH
RD/BK
PT2
WH/BK
OR/BK
RD/BK
(RF)
BL/BK
BL/BK
WH
WH
OR
GN
GN
RD
BK
BK
BK
BL
BK
BK
GN/BK
GN
RD/WH
OR/WH
BL/WH
GN/WH
REGEN COIL (N/A ON 3232)
24V MAIN
GND
BK
GND BN
ES0142P
Electrical Schematic
REV F CE Models
GS-1530/1532/1930/1932 (after serial number GS3007A-89537 and GS3007B-84599)
GS-1530/1532/1930/1932 (from serial number GS3008C-101)
P2
EMERGENCY
QD3 STOP
BK
4 4 BK POWER TO PLATFORM
RD
- NOTE -
3 3 RD POWER TO GROUND
MACHINE SHOWN IN THE STOWED
1 1 WH GROUND PIO3
PIO2 POSITION WITH THE POWER OFF
2 2 BL DATA LINK (HIGH) PIO4
U3 D7 5V DC
GN
WH
BL
SW5 SW6
PP FUNCTION ENABLE STEER
LEFT/ RIGHT
OR
LEFT
RIGHT
PIN9
BK
PIN8
RD
PIN10
BK
PLATFORM CONTROLS
MEMBRANE DECAL
POUT1 LIFT LED L16
POUT2 DRIVE LED L17
POUT3 HIGH TORQUE LED L21
G8
POUT4 DIAGNOSTIC
DISPLAY
RD
POUT11 +
BK
H1
ALARM
PLATFORM
PIN11 - CONTROLLER
ES0142P
Electrical Schematic
CE Models REV E
GS-2032/2632 (from serial number GS3205-75407 to GS3205-77290)
GS-2046/2646/3246 (from serial number GS4605-75438 to GS4605-76734)
Electrical Schematic
REV E 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)
- NOTE -
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF QD4
RD RD 4 4
WH WH 3 3
BL 1 1
30 4 86
CR48
POWER BK 2 2
RELAY TO U5
87 85 OR 5 5
(E-STOP)
R24
25 OHM
N.C.
N.O.H.C.
RD
WH
CR27A CR27B CR27C
OVERLOAD OVERLOAD OVERLOAD
(MOTOR CONT) (LOAD SENSE) (DOWN COIL)
N.O.
30 86 30 86 30 86 N.C.
1 2 3
LEVEL
87 85 87A 85 87 85
LS5 SENSOR
CIRCUIT
UP BOARD
LIMIT
C5 SWITCH
4700 uF
DWN LIMIT
UP LIMIT SWITCH
SENSOR
87A 87 85
BK
CR27D
OVERLOAD
(DOWN DELAY)
OR/BK
RD/BK
BL/BK
GN/BK
WH
WH
GN
OR
GN
RD
BK
BK
BL
U5
ELECTRONIC CONTROL MODULE
WH/BK
WH
GN/BK
RD/BK
Y1 Y3 Y4 Y5 Y6 Y9 Y7 Y8
PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM
RIGHT LEFT REVERSE FORWARD DOWN DOWN UP
(GS-3246)
GND
ES0142G
Electrical Schematic
CE Models REV E
GS-2032/2632 (from serial number GS3205-75407 to GS3205-77290)
GS-2046/2646/3246 (from serial number GS4605-75438 to GS4605-76734)
P2
EMERGENCY
QD3 STOP
BK
4 4 BK POWER TO PLATFORM
RD
3 3 RD POWER TO GROUND
1 1 WH GROUND PIO3
PIO2
2 2 BL DATA LINK (HIGH) PIO4
U3 D7 5V DC
GN
WH
BL
SW5 SW6
PP FUNCTION ENABLE STEER
LEFT/ RIGHT
OR
LEFT
RIGHT
PIN9
BK
PIN8
RD
PIN10
BK
PLATFORM CONTROLS
MEMBRANE DECAL
POUT1 LIFT LED L16
POUT2 DRIVE LED L17
POUT3 HIGH TORQUE LED L21
G8
POUT4 DIAGNOSTIC
DISPLAY
RD
POUT11 +
BK
H1
ALARM
PLATFORM
PIN11 - CONTROLLER
ES0142G
Electrical Schematic
CE Models REV D
GS-2032/2632 (from serial number GS3205-77291 to GS3206-79991)
GS-2046/2646/3246 (from serial number GS4605-76735 to GS4606-78915)
Electrical Schematic
REV D 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)
- NOTE -
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF QD4
RD RD 4 4
WH WH 3 3
BL 1 1
CR28 30 6 86 30 4 86
CR48
CUT OUT POWER BK 2 2
(MOTOR CONT) RELAY TO U5
87A 85 87 85 OR 5 5
(E-STOP)
R24
25 OHM
N.C.
N.O.H.C.
RD
WH
CR27A CR27B CR27C
OVERLOAD OVERLOAD OVERLOAD
(MOTOR CONT) (LOAD SENSE) (DOWN COIL)
N.O.
30 86 30 86 30 86 N.C.
1 2 3
LEVEL
87 85 87A 85 87 85
LS5 N.O.
SENSOR
CIRCUIT
UP BOARD
LIMIT
C5 SWITCH
4700 uF
DWN LIMIT
UP LIMIT SWITCH
SENSOR
87A 87 85
BK
CR27D
OVERLOAD
(DOWN DELAY)
OR/BK
RD/BK
BL/BK
GN/BK
WH
WH
GN
OR
GN
RD
BK
BK
BL
U5
ELECTRONIC CONTROL MODULE
WH/BK
WH
GN/BK
RD/BK
Y1 Y3 Y4 Y5 Y6 Y9 Y7 Y8
PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM
RIGHT LEFT REVERSE FORWARD DOWN DOWN UP
(GS-3246)
GND
ES0142J
Electrical Schematic
CE Models REV D
GS-2032/2632 (from serial number GS3205-77291 to GS3206-79991)
GS-2046/2646/3246 (from serial number GS4605-76735 to GS4606-78915)
P2
EMERGENCY
QD3 STOP
BK
4 4 BK POWER TO PLATFORM
RD
3 3 RD POWER TO GROUND
1 1 WH GROUND PIO3
PIO2
2 2 BL DATA LINK (HIGH) PIO4
U3 D7 5V DC
GN
WH
BL
SW5 SW6
PP FUNCTION ENABLE STEER
LEFT/ RIGHT
OR
LEFT
RIGHT
PIN9
BK
PIN8
RD
PIN10
BK
PLATFORM CONTROLS
MEMBRANE DECAL
POUT1 LIFT LED L16
POUT2 DRIVE LED L17
POUT3 HIGH TORQUE LED L21
G8
POUT4 DIAGNOSTIC
DISPLAY
RD
POUT11 +
BK
H1
ALARM
PLATFORM
PIN11 - CONTROLLER
ES0142J
Electrical Schematic
CE Models REV C
GS-2032/2632 (from serial number GS3206-79992 to GS3207-83650)
GS-2046/2646/3246 (from serial number GS4606-78916 to GS4607-82535)
Electrical Schematic
REV C 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)
- NOTE -
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF QD4
RD RD 4 4
WH WH 3 3
BL 1 1
CR28 30 6 86 30 4 86
CR48
CUT OUT POWER BK 2 2
(MOTOR CONT) RELAY TO U5
87A 85 87 85 OR 5 5
(E-STOP)
R24
25 OHM
N.C.
N.O.H.C.
RD
WH
CR27A CR27B CR27C
OVERLOAD
OVERLOAD OVERLOAD
(MOTOR CONT) (LOAD SENSE) (DOWN COIL)
N.O.
30 86 30 86 30 86 N.C.
1 2 3
LEVEL
87 85 87A 85 87 85
LS5 N.O.
SENSOR
CIRCUIT
UP BOARD
LIMIT
C5 SWITCH
4700 uF
DWN LIMIT
UP LIMIT SWITCH
SENSOR
87A 87 85
BK
CR27D
OVERLOAD
(DOWN DELAY)
OR/BK
RD/BK
BL/BK
GN/BK
WH
WH
GN
OR
GN
RD
BK
BK
BL
U5
ELECTRONIC CONTROL MODULE
WH/BK
WH
GN/BK
RD/BK
Y1 Y3 Y4 Y5 Y6 Y9 Y7 Y8
PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM
RIGHT LEFT REVERSE FORWARD DOWN DOWN UP
(GS-3246)
GND
ES0142K
Electrical Schematic
CE Models REV C
GS-2032/2632 (from serial number GS3206-79992 to GS3207-83650)
GS-2046/2646/3246 (from serial number GS4606-78916 to GS4607-82535)
P2
EMERGENCY
QD3 STOP
BK
4 4 BK POWER TO PLATFORM
RD
3 3 RD POWER TO GROUND
1 1 WH GROUND PIO3
PIO2
2 2 BL DATA LINK (HIGH) PIO4
U3 D7 5V DC
GN
WH
BL
SW5 SW6
PP FUNCTION ENABLE STEER
LEFT/ RIGHT
OR
LEFT
RIGHT
PIN9
BK
PIN8
RD
PIN10
BK
PLATFORM CONTROLS
MEMBRANE DECAL
POUT1 LIFT LED L16
POUT2 DRIVE LED L17
POUT3 HIGH TORQUE LED L21
G8
POUT4 DIAGNOSTIC
DISPLAY
RD
POUT11 +
BK
H1
ALARM
PLATFORM
PIN11 - CONTROLLER
ES0142K
Electrical Schematic
CE Models REV B
GS-2032/2632 (from serial number GS3207-83651 to GS3207-84866)
GS-2046/2646/3246 (from serial number GS4607-82536 to GS4607-84839)
Electrical Schematic
REV B 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)
- NOTE -
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF QD4
RD RD 4 4
WH WH 3 3
BL 1 1
CR28 30 6 86 30 4 86
CR48
CUT OUT POWER BK 2 2
(MOTOR CONT) RELAY TO U5
87A 85 87 85 OR 5 5
(E-STOP)
R24
25 OHM
N.C.
N.O.H.C.
RD
WH
CR27A CR27B CR27C
OVERLOAD OVERLOAD OVERLOAD
(MOTOR CONT) (LOAD SENSE) (DOWN COIL)
N.O.
30 86 30 86 30 86 N.C.
1 2 3
LEVEL
87 85 87A 85 87 85
LS5 N.O.
SENSOR
CIRCUIT
UP BOARD
LIMIT
C5 SWITCH
4700 uF
DWN LIMIT
UP LIMIT SWITCH
SENSOR
87A 87 85
BK
CR27D
OVERLOAD
(DOWN DELAY)
OR/BK
RD/BK
BL/BK
GN/BK
WH
WH
GN
OR
GN
RD
BK
BK
BL
U5
ELECTRONIC CONTROL MODULE
WH/BK
WH
GN/BK
RD/BK
Y1 Y3 Y4 Y5 Y6 Y9 Y7 Y8
PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM
RIGHT LEFT REVERSE FORWARD DOWN DOWN UP
(GS-3246)
GND
ES0142M
Electrical Schematic
CE Models REV B
GS-2032/2632 (from serial number GS3207-83651 to GS3207-84866)
GS-2046/2646/3246 (from serial number GS4607-82536 to GS4607-84839)
P2
EMERGENCY
QD3 STOP
BK
4 4 BK POWER TO PLATFORM
RD
3 3 RD POWER TO GROUND
1 1 WH GROUND PIO3
PIO2
2 2 BL DATA LINK (HIGH) PIO4
U3 D7 5V DC
GN
WH
BL
SW5 SW6
PP FUNCTION ENABLE STEER
LEFT/ RIGHT
OR
LEFT
RIGHT
PIN9
BK
PIN8
RD
PIN10
BK
PLATFORM CONTROLS
MEMBRANE DECAL
POUT1 LIFT LED L16
POUT2 DRIVE LED L17
POUT3 HIGH TORQUE LED L21
G8
POUT4 DIAGNOSTIC
DISPLAY
RD
POUT11 +
BK
H1
ALARM
PLATFORM
PIN11 - CONTROLLER
ES0142M
Electrical Schematic
CE Models REV F
GS-2032/2632/3232 (after serial number GS3207-84866 and from GS3208C-101)
GS-2046/2646/3246 (after serial number GS4607-84839 and from GS4609C-101)
Electrical Schematic
REV F CE Models
GS-2032/2632/3232 (after serial number GS3207-84866 and from GS3208C-101)
GS-2046/2646/3246 (after serial number GS4607-84839 and from GS4609C-101)
QD4
GS-3232 ONLY
RD RD 4 4
WH WH 3 3
BL 1 1
BK 2 2
OR 5 5
GN MC THROTTLE
30 6 86 30 4 86
CR48 BK MC ENABLE (IN)
POWER
BK 24V
RELAY TO U5
87A 85 87 85 OR KS1
(E-STOP)
OR/BK DRIVE ENABLE
GS-3232 ONLY
CR28 R24 GROUND
CUT OUT 25 OHM
(MOTOR CONT) BK MC ENABLE (OUT)
N.C. RD/BK DOWN LIM
N.O.H.C.
UP IN
FORWARD
REVERSE
UP COIL
RD
WH
CR27A CR27B CR27C
OVERLOAD
OVERLOAD OVERLOAD
(MOTOR CONT) (LOAD SENSE) (DOWN COIL)
N.O.
30 86 30 86 30 86 N.C.
1 2 3
BL/BK
WH
WH/BK
BL/BK
LEVEL
87 85 87A 85 87 85
LS5 SENSOR
UP LIMIT SWITCH (GS-3232 ONLY)
N.O. CIRCUIT
UP BOARD
LIMIT
C5 SWITCH
4700 uF
DWN LIMIT
UP LIMIT SWITCH
SENSOR ONLY
87A 87 85
BK
CR27D
OVERLOAD
(DOWN DELAY)
OR/BK
OR/BK
RD/BK
BL/BK
GN/BK
WH
WH
GN
OR
GN
RD
BK
BK
BL
NOT CONNECTED
ON GS-3232
U5
ELECTRONIC CONTROL MODULE NOT CONNECTED
ON GS-3232
WH/BK
WH
GN/BK
RD/BK
GS-3232 ONLY
Y1 Y3 Y4 Y5 Y6 Y9 Y7 Y8
PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM
RIGHT LEFT REVERSE FORWARD DOWN DOWN UP
(GS-3232/GS-3246)
GND
ES0142P
Electrical Schematic
CE Models REV F
GS-2032/2632/3232 (after serial number GS3207-84866 and from GS3208C-101)
GS-2046/2646/3246 (after serial number GS4607-84839 and from GS4609C-101)
24V ALARM
KS1 BN106 -
DRIVE ENABLE U39
GN
25 OHMS FUNCTION ENABLE
GROUND BK CPU
R24
10 WATT BN105 L51 L52
FL OUTRIGGER FR OUTRIGGER
MC ENABLE (OUT) EXTEND
UP IN CONTROL
U36 PRINTED
OR
FORWARD
OR/BK
CIRCUIT
RD/BK
REVERSE
BOARD
L53 L54
BL/BK
UP COIL
U41
U40
WH
RL OUTRIGGER RR OUTRIGGER
TX / RX
WH/BK
POWER CHIP
BL/BK
SUPPLY
CHIP
1 4 3 2
BN
WH
QD20 GN
BK RD
BL
S8
2 AXIS
TILT LEVEL
MC ENABLE SENSOR
MC THROTTLE
GROUND TO PLAT
POWER TO PLAT
DATA (LOW)
DATA (HIGH)
GROUND
KEYSWITCH
MC ENABLE
DRIVE ENABLE
SWITCH POWER
POWER
PITCH
LS5A
ROLL
N.C.
UP
DOWN LIM
LIMIT
SWITCH
WH
BL
OR
BN
PT1 LS5B
RD/BK
N.C.
UP COIL
REVERSE
FORWARD
UP IN
(LF) UP
LIMIT
SWITCH
RD/BK
PT2
WH/BK
OR/BK
RD/BK
(RF)
BL/BK
BL/BK
WH
WH
OR
GN
GN
RD
BK
BK
BK
BL
BK
BK
GN/BK
GN
RD/WH
OR/WH
BL/WH
GN/WH
REGEN COIL (N/A ON 3232)
24V MAIN
GND
BK
GND BN
ES0142P
Electrical Schematic
REV F CE Models
GS-2032/2632/3232 (after serial number GS3207-84866 and from GS3208C-101)
GS-2046/2646/3246 (after serial number GS4607-84839 and from GS4609C-101)
P2
EMERGENCY
QD3 STOP
BK
4 4 BK POWER TO PLATFORM
RD
- NOTE -
3 3 RD POWER TO GROUND
MACHINE SHOWN IN THE STOWED
1 1 WH GROUND PIO3
PIO2 POSITION WITH THE POWER OFF
2 2 BL DATA LINK (HIGH) PIO4
U3 D7 5V DC
GN
WH
BL
SW5 SW6
PP FUNCTION ENABLE STEER
LEFT/ RIGHT
OR
LEFT
RIGHT
PIN9
BK
PIN8
RD
PIN10
BK
PLATFORM CONTROLS
MEMBRANE DECAL
POUT1 LIFT LED L16
POUT2 DRIVE LED L17
POUT3 HIGH TORQUE LED L21
G8
POUT4 DIAGNOSTIC
DISPLAY
RD
POUT11 +
BK
H1
ALARM
PLATFORM
PIN11 - CONTROLLER
ES0142P
M
Hydraulic cylinder
Variable speed motor Brake
Pilot operated
check valve with
needle valve
Shuttle valve
Fixed displacement
Relief valve pump Y4 Y3
Solenoid operated
Y7 3 position 4 way
directional valve
Y1
Solenoid operated Bi-directional motor
2 position 2 way Solenoid operated
directional valve 2 position 4 way
normally closed directional valve
Y6 Y5
Solenoid operated
2 position 2 way valve,
normally closed
A B AC
AB AD
AA
Y4
Y3
H Y8 Y1
Y4
Y3
G Y8
F C
AJ AI AH
D AF
AG AE
E
Function manifold,
GS-1530, GS-1532, Function manifold,
GS-1930 and GS-1932 GS-2032, GS-2632, GS-3232
GS-2046, GS-2646 and GS-3246
M
Y39
Y40
K
L
BB BA
Outrigger manifold,
GS-3232 Brake release manifold,
all models
CF CF
CG
CE CE
CG
CA and CB CC and CD
Hydraulic Schematic
GS-1530/1532/1930/1932 (from serial number GS3005A-76000 to GS3005A-76491) REV B
GS-1530/1532/1930/1932 (from serial number GS3005B-76000 to GS3005B-76084)
LEFT RIGHT
LIFT CYLINDER
(ALL MODELS)
BRAKE RELEASE BRAKE
PRESSURE
370 to 450 psi
26 to 31 bar M MANUAL
N RELEASE
PLATFORM
OVERLOAD HAND
(CE MODELS) Y7 PUMP
BRAKE
PS2 RELEASE
0.059 inch MANIFOLD L
1.17 mm
R O B1
THE ORIFICE IS LOCATED
UNDERNEATH THE FITTING STEER STEER LEFT RIGHT
ON THE LIFT CYLINDER LEFT RIGHT 1.03 CU. IN. DRIVE DRIVE
P 16.9 cc MOTOR
MOTOR
FORWARD
REVERSE
L V S1 S2 HP B AC M1 M4
Y4 Y3
B 10 psi
0.7 bar
Y6 Y5
E
1500 psi
103 bar
H
A 0.75 gpm 10 psi
2.8 L/min G 0.7 bar
TP D
C
I
Y8 FUNCTION MANIFOLD
1800 to 3500 psi
124 to 241 bar
3500 psi maximum
241 bar maximum
ABBREVIATION LEGEND
P T Item Description
A Test port
200 psi S B Check valve, steer circuit
13.8 bar C Relief valve, lift
D Check valve, brake circuit
E Drive forward/reverse
F Steer left/right
M 10 MICRON WITH G Flow regulator/relief valve
4 gpm @ 2500 psi 25 psi / 1.7 bar
POWER UNIT 15 L/min @ 172 bar BYPASS H Platform up
I Relief valve, system
HYDRAULIC TANK 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
HS0035F S Check valve, drive circuit
Hydraulic Schematic
REV D GS-1530/1532/1930/1932 (after serial number GS3005A-76491)
GS-1530/1532/1930/1932 (after serial number GS3005B-76084)
GS-1530/1532/1930/1932 (from serial number GS3008C-101)
LEFT RIGHT
LIFT CYLINDER
(ALL MODELS)
BRAKE RELEASE BRAKE
PRESSURE
370 to 450 psi
26 to 31 bar M MANUAL
N RELEASE
PLATFORM 0.037 inch
OVERLOAD 0.94 mm HAND
(CE MODELS) Y7 PUMP
BRAKE
PS2 RELEASE
0.037 inch MANIFOLD L
R 0.94 mm
O B1
THE ORIFICE IS LOCATED
UNDERNEATH THE STEER STEER LEFT RIGHT
HOSE FITTING ON THE LEFT RIGHT 4.75 CU. IN. DRIVE DRIVE
LIFT CYLINDER P 78 cc MOTOR
MOTOR
FORWARD
REVERSE
L V S1 S2 HP B AC M1 M4
Y4 Y3
0.25 gpm Y6 Y5
0.95 L/min
E
1500 psi
103 bar
H
A 0.75 gpm 10 psi
2.8 L/min G 0.7 bar
TP D
C
I
Y8 FUNCTION MANIFOLD
0.25 gpm @ 1800 to 3700 psi
0.95 L/min @ 124 to 255 bar
Hydraulic Schematic
GS-2032/2632 (from serial number GS3205-75407 to GS3206-80131) REV D
GS-2046/2646/3246 (from serial number GS4605-75438 to GS4606-79027)
LEFT RIGHT
PLATFORM LIFT CYLINDER
OVERLOAD (ALL MODELS)
BRAKE RELEASE BRAKE
(CE MODELS)
PRESSURE
370 to 450 psi
26 to 31 bar M MANUAL
N RELEASE
PS2
0.037 inch
0.94 mm HAND
R Y7 PUMP
BRAKE
RELEASE
0.059 inch MANIFOLD L
THE ORIFICE IS LOCATED 1.5 mm
UNDERNEATH THE HOSE O B1
FITTING ON THE LIFT CYLINDER
FORWARD
REVERSE
Y9
N
V S1 S2 HP B AC M1 M3 M2 M4
0.059 inch
1.17 mm
O AC
2500 psi maximum
Q 172 bar maximum
THE ORIFICE IS LOCATED UNDERNEATH Y4 Y3
THE FITTING ON THE LIFT CYLINDER AE
L
Y1
AD 10 psi
0.7 bar
0.040 in
Y6 Y5
1 mm
AG
1500 psi
103 bar AF
AI
AA 0.75 gpm
2.8 L/min AH
TP 130 psi
9 bar
AJ
AB
Y8 FUNCTION MANIFOLD
1800 to 3500 psi
124 to 241 bar
Hydraulic Schematic
REV A GS-2032/2632 (from serial number GS3206-80132 to GS3207-84866)
GS- 2046/2646/3246 (from serial number GS4606-79028 to GS4607-84839)
LEFT RIGHT
PLATFORM LIFT CYLINDER
OVERLOAD (ALL MODELS)
BRAKE RELEASE BRAKE
(CE MODELS)
PRESSURE
370 to 450 psi
26 to 31 bar M MANUAL
N RELEASE
PS2
0.037 inch
0.94 mm HAND
R Y7 PUMP
BRAKE
0.059 inch
RELEASE L
THE ORIFICE IS LOCATED 1.5 mm
O
MANIFOLD
UNDERNEATH THE HOSE
FITTING ON THE LIFT CYLINDER
B1
STEER STEER LEFT RIGHT
LEFT RIGHT 4.75 CU. IN. DRIVE DRIVE
P 78 cc MOTOR
MOTOR
UPPER LIFT CYLINDER
(GS-3246 MODELS)
FORWARD
REVERSE
Y9
N
V S1 S2 HP B AC M1 M3 M2 M4
0.037 inch
0.94 mm AC
O
AD
L
Y6 Y5
AG
1500 psi
103 bar
AI
AA 0.75 gpm
2.8 L/min AH 50 psi
AF
TP
3.4 bar
AJ
AB
Y8 FUNCTION MANIFOLD
1800 to 3500 psi
124 to 241 bar
Hydraulic Schematic
GS-2032/2632/3232 (after serial number GS3207-84866 and from GS3208C-101) REV D
GS-2046/2646/3246 (after serial number GS4607-84839 and from GS4609C-101)
LEFT RIGHT
PLATFORM LIFT CYLINDER
OVERLOAD (ALL MODELS)
BRAKE RELEASE BRAKE
(CE MODELS)
PRESSURE
370 to 450 psi
26 to 31 bar M MANUAL
N RELEASE
PS2
0.037 inch
0.94 mm HAND
R Y7 PUMP
BRAKE
0.059 inch
RELEASE L
THE ORIFICE IS LOCATED 1.5 mm
O
MANIFOLD
UNDERNEATH THE HOSE
FITTING ON THE LIFT CYLINDER
B1
STEER STEER LEFT RIGHT
LEFT RIGHT 4.75 CU. IN. DRIVE DRIVE
P 78 cc MOTOR
MOTOR
UPPER LIFT CYLINDER
(GS-3232 and GS-3246 MODELS)
FORWARD
REVERSE
Y9
N
V S1 S2 HP B AC M1 M3 M2 M4
0.037 inch
0.94 mm AC
O
AD
L
0.25 gpm Y6 Y5
0.95 L/min
AG
1500 psi
103 bar
AI
AA 0.75 gpm
2.8 L/min AH 50 psi
AF
TP
3.4 bar
AJ
AB
Y8
FUNCTION MANIFOLD
0.25 gpm @ 1800 to 3700 psi
0.95 L/min @ 124 to 255 bar
P T
NOT CONNECTED
ON GS-3232
ABBREVIATION LEGEND
Item Description
M AA Test port
POWER UNIT
AB Relief valve, system
10 MICRON WITH
4 gpm @ 2500 psi 25 psi / 1.7 bar AC Steer left/right
15 L/min @ 172 bar BYPASS
AD Check valve, steer circuit
AE Drive speed
AF Relief valve, brake release
HYDRAULIC TANK AG Drive forward/reverse
To Outrigger Manifold In Port GS-3232 Models
AH Flow regulator/relief valve
To Outrigger Manifold Out Port GS-3232 Models AI Platform up
AJ Relief valve, lift
BA 3 position, 4 way directional valve –
outrigger cylinder extend/retract
HS0036N BB Relief valve, outrigger circuit
Hydraulic Schematic
REV D GS-3232 (from serial number GS3207-84867)
(from serial number GS3208C-101)
CF CF
LF OUTRIGGER RF OUTRIGGER
CYLINDER
CB CA CYLINDER
EXTEND EXTEND
0.037 in 0.037 in
0.94 mm 0.94 mm
Y35 Y36
0.035 in CE CE 0.035 in
0.9 mm RETRACT RETRACT 0.9 mm
PRESSURE B2 B3 B1 R3 R1 R2 PRESSURE
SENSE PORT SENSE PORT
CG CG
OUTRIGGER
BA MANIFOLD
Y39 Y40
CF CF
LR OUTRIGGER RR OUTRIGGER
CYLINDER
CD CC CYLINDER
EXTEND EXTEND
0.037 in 0.037 in
0.94 mm 0.94 mm
Y33 Y34
0.035 in CE CE 0.035 in
0.9 mm RETRACT RETRACT 0.9 mm
PRESSURE PRESSURE
SENSE PORT SENSE PORT
CG CG
800.536.1800
Fax 425.883.3475
Part No.
(from serial number GS3005A-7600)
Rev E9
97385
(from serial number GS3005B-7600)
GS-30•GS-32•GS-46
(from serial number GS3205-75407)
(from serial number GS4605-75438)