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June 2012

Introduction

Important Serial Number Information


Read, understand and obey the safety rules and Genie offers the following Service Manuals for
operating instructions in the appropriate Operator's these models:
Manual on your machine before attempting any
maintenance procedure. Title Part No.

Basic mechanical, hydraulic and electrical Genie GS-1530 and GS-1930 Service Manual
(before serial number 17408) ........................................... 39528
skills are required to perform most procedures.
However, several procedures require specialized Genie GS-1530 and GS-1930 Service Manual
(from serial number 17408 to 59999) ............................... 72876
skills, tools, lifting equipment and a suitable
Genie GS-1530 and GS-1930 Service Manual
workshop. In these instances, we strongly (from serial number 60000 to 75999) ............................... 96316
recommend that maintenance and repair be
Genie GS-1530 and GS-1930 Service Manual
performed at an authorized Genie dealer (from serial number A-76000 to A-109999,
service center. B-76000 to B-98941 and C-101 to C-9999) ..................... 97385

Genie GS-2032 Service Manual


Compliance (before serial number 17408) ........................................... 46326

Machine Classification Genie GS-2032 and GS-2632 Service Manual


(from serial number 17408 to 59999) ............................... 72963
Group A/Type 3 as defined by ISO 16368
Genie GS-2032 and GS-2632 Service Manual
Machine Design Life (from serial number 60000 to 75406) ............................... 96316
Unrestricted with proper operation, inspection and Genie GS-2032, GS-2632 and GS-3232 Service Manual
scheduled maintenance. (from serial number 75407 to A109999 and
C-101 to C9999) ............................................................... 97385

Technical Publications Genie GS-2046, GS-2646 and GS-3246 Service Manual


(before serial number 17408) ........................................... 48339
Genie has endeavored to deliver the highest Genie GS-2046, GS-2646 and GS-3246 Service Manual
degree of accuracy possible. However, continuous (from serial number 17408 to 59999) ............................... 72972
improvement of our products is a Genie policy. Genie GS-2046, GS-2646 and GS-3246 Service Manual
Therefore, product specifications are subject to (from serial number 60000 to 75437) ............................... 96316
change without notice. Genie GS-2046, GS-2646 and GS-3249 Service Manual
(from serial number 75438 to A109999) and
Readers are encouraged to notify Genie of errors C101 to C9999 ................................................................. 97385
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.

Contact Us:
Copyright 2011 by Terex Corporation
www.genielift.com
e-mail: techpub@terex.com 228901 Rev B January 2012
Fifth Edition, Second Printing

"Genie" is a registered trademark of Terex South


Dakota in the U.S.A. and many other countries.
"GS" is a trademark of Terex South Dakota, Inc.

Printed on recycled paper

Printed in U.S.A.

ii GS-30 GS-32 GS-46 GS-47 Part No. 228901


June 2012

Revision History
Revision Date Section Procedure / Schematic Page / Description
A 4/2011 New release
B 1/2012 2 - Spec. Machine, Performance, Hydraulic

3 - Maint. Inspection report, B-1, B-3, B-17, C-1, D-1

4 - Repair 4-2, 4-12, 4-13, 4-14, 4-20, 4-22, 4-25, 4-26, 4-27,
4-28, 4-29, 4-30, 4-32, 4-33, 4-60, 4-68, 4-78, 4-90,
4-103, 4-105, 4-108, 4-111, 4-115, 4-119, 4-120
5 - Diagnos. 5-2, 5-4, 5-5, 5-6, 5-7, 5-8, 5-10, 5-12, 5-15, 5-16,
5-18, 5-21

6 - Schem. All legends, diagrams and schematics

B1 06/2012 3 - Maint. C-1

REFERENCE EXAMPLES:

Section 3_Maintenance, B-3. Electronic Version


Section 4_Repair Procedure, 4-2.
Section 5_Diagnostic Codes, All charts. Click on any procedure or page number
Section 6_Schematics, Legends diagrams and highlighted in blue to view the update.
schematics.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 iii


June 2012

REVISION HISTORY, CONTINUED

Revision Date Section Procedure / Schematic Page / Description

REFERENCE EXAMPLES:

Section 3_Maintenance, B-3. Electronic Version


Section 4_Repair Procedure, 4-2.
Section 5_Diagnostic Codes, All charts. Click on any procedure or page number
Section 6_Schematics, Legends diagrams and highlighted in blue to view the update.
schematics.

iv GS-30 GS-32 GS-46 GS-47 Part No. 228901


June 2012

INTRODUCTION

Serial Number Legend

Part No. 228901 GS-30 GS-32 GS-46 GS-47 v


Section 1 Safety Rules June 2012

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
operators manual are also safety hazards
when maintenance and repair procedures
are performed.

Do Not Perform Maintenance


Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
- manufacturers instructions and safety rules
- employers safety rules and worksite
regulations
- applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.

vi GS-30 GS-32 GS-46 GS-47 Part No. 228901


June 2012 Section 1 Safety Rules

SAFETY RULES

Personal Safety Workplace Safety


Any person working on or around a machine must Be sure to keep sparks, flames and
be aware of all known safety hazards. Personal lighted tobacco away from flammable and
safety and the continued safe operation of the combustible materials like battery gases
machine should be your top priority. and engine fuels. Always have an approved fire
extinguisher within easy reach.

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 symbolused 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.

Be aware of potential crushing hazards


such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved steel-toed
shoes.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 vii


June 2012

Table of Contents

Introduction
Important Information ......................................................................................... ii
Serial Number Information ................................................................................. ii
Revision History ................................................................................................ iii
Serial Number Legend ...................................................................................... v

Section 1 Safety Rules


General Safety Rules ........................................................................................ vi

Section 2 Specifications
Machine Specifications ................................................................................ 2 - 1
Performance Specifications ......................................................................... 2 - 3
Hydraulic Specifications ............................................................................... 2 - 5
Manifold Component Specifications ............................................................. 2 - 6
Hydraulic Hose and Fitting Torque Specifications ........................................ 2 - 8
SAE and Metric Fasteners Torque Charts ................................................. 2 - 10

Section 3 Scheduled Maintenance Procedures


Introduction .................................................................................................. 3 - 1
Pre-delivery Preparation Report .................................................................. 3 - 3
Maintenance Inspection Report ................................................................... 3 - 5
Checklist A Procedures
A-1 Inspect the Manuals and Decals ......................................................... 3 - 6
A-2 Perform Pre-operation Inspection ....................................................... 3 - 7
A-3 Perform Function Tests ...................................................................... 3 - 7
A-4 Perform 30 Day Service ..................................................................... 3 - 8
A-5 Grease the Steer Yokes ..................................................................... 3 - 8

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June 2012

TABLE OF CONTENTS

Section 3 Scheduled Maintenance Procedures, continued


Checklist B Procedures
B-1 Inspect the Batteries ........................................................................... 3 - 9
B-2 Inspect the Electrical Wiring ............................................................. 3 - 12
B-3 Inspect the Electrical Contactor ........................................................ 3 - 13
B-4 Inspect the Tires, Wheels and Castle Nut Torque ............................ 3 - 13
B-5 Test the Emergency Stop ................................................................. 3 - 14
B-6 Test the Key Switch .......................................................................... 3 - 15
B-7 Test the Automotive-style Horn (if equipped) .................................... 3 - 15
B-8 Test the Drive Brakes ....................................................................... 3 - 16
B-9 Test the Drive Speed - Stowed Position ........................................... 3 - 17
B-10 Test the Drive Speed - Raised Position ............................................ 3 - 18
B-11 Test the Slow Drive Speed ............................................................... 3 - 19
B-12 Perform Hydraulic Oil Analysis ......................................................... 3 - 20
B-13 Inspect the Hydraulic Tank Cap Venting System .............................. 3 - 20
B-14 Check the Module Tray Latch Components ...................................... 3 - 21
B-15 Inspect the Voltage Inverter (if equipped) ......................................... 3 - 22
B-16 Test the Down Limit Switch, Level Sensor
and the Pothole Limit Switches ......................................................... 3 - 23
B-17 Test the Up Limit Switch (if equipped)
and the Maximum Drive Height Limit Switches (if equipped) ............ 3 - 27
Checklist C Procedures
C-1 Test the Platform Overload Pressure Transducer and
Platform Height Sensor (if equipped) ................................................ 3 - 28
C-2 Calibrate the Platform Overload System (if equipped) ...................... 3 - 30
C-3 Replace the Hydraulic Tank Breather Cap -
Models with Optional Hydraulic Oil ................................................... 3 - 31
Checklist D Procedures
D-1 Check the Scissor Arm Wear Pads .................................................. 3 - 32
D-2 Replace the Hydraulic Tank Return Filter Element ........................... 3 - 34
Checklist E Procedure
E-1 Test or Replace the Hydraulic Oil ..................................................... 3 - 35

Part No. 228901 GS-30 GS-32 GS-46 GS-47 xi


June 2012

TABLE OF CONTENTS

Section 4 Repair Procedures


Introduction .................................................................................................. 4 - 1
Platform Controls
1-1 Circuit Boards .................................................................................... 4 - 3
1-2 Joystick .............................................................................................. 4 - 4
1-3 Platform Controls Alarm ..................................................................... 4 - 4
1-4 Platform Emergency Stop Button ....................................................... 4 - 5
Ground Controls
2-1 Software Revision Level ..................................................................... 4 - 7
2-2 Machine Setup ................................................................................... 4 - 8
2-3 Manual Platform Lowering Cable ....................................................... 4 - 9
2-4 Level Sensors .................................................................................. 4 - 10
2-5 Outrigger Calibration ........................................................................ 4 - 14
Hydraulic Tank
3-1 Hydraulic Tank ................................................................................. 4 - 15
Hydraulic Pump
4-1 Function Pump ................................................................................. 4 - 16
Manifolds
5-1 Function Manifold Components -
GS-1530, GS-1532, GS-1930 and GS-1932 .................................... 4 - 18
5-2 Function Manifold Components -
GS-2032, GS-2632, GS-3232, GS-2046, GS-2646 and GS-3246 .... 4 - 20
5-3 Function Manifold Components -
GS-4047 .......................................................................................... 4 - 22
5-4 Check Valve Manifold Components -
GS-1530, GS-1532, GS-1930 and GS-1932 .................................... 4 - 24
5-5 Lift Pressure Selector Manifold Components - GS-4047 .................. 4 - 25
5-6 Outrigger Function Manifold Components - GS-3232 ....................... 4 - 26
5-7 Outrigger Cylinder Manifold Components - GS-3232 ....................... 4 - 27
5-8 Valve Adjustments - Function Manifold ............................................ 4 - 28
5-9 Valve Coils ....................................................................................... 4 - 33

x GS-30 GS-32 GS-46 GS-47 Part No. 228901


June 2012

TABLE OF CONTENTS

Section 4 Repair Procedures, continued


Steer Axle Components
6-1 Yoke and Drive Motor ...................................................................... 4 - 35
6-2 Steer Cylinder .................................................................................. 4 - 36
6-3 Steer Bellcrank ................................................................................. 4 - 37
Non-steer Axle Components
7-1 Drive Brake ...................................................................................... 4 - 38
Brake Release Hand Pump Components
8-1 Brake Release Hand Pump Components ......................................... 4 - 39
Scissor Components
9-1 Scissor Assembly, GS-1530 and GS-1532 ...................................... 4 - 41
9-2 Scissor Assembly, GS-1930 and GS-1932 ...................................... 4 - 51
9-3 Scissor Assembly, GS-2032 and GS-2046 ...................................... 4 - 61
9-4 Scissor Assembly, GS-2632 and GS-2646 ...................................... 4 - 69
9-5 Scissor Assembly, GS-3232 and GS-3246 ...................................... 4 - 79
9-6 Scissor Assembly, GS-4047 ............................................................ 4 - 91
9-7 Platform Height Sensor .................................................................. 4 - 101
9-8 Lift Cylinder .................................................................................... 4 - 103
9-9 Pressure Transducer ..................................................................... 4 - 114
9-10 Platform Overload System ............................................................. 4 - 115
Platform Components
10-1 Platform ......................................................................................... 4 - 119
10-2 Platform Extension ......................................................................... 4 - 120

Part No. 228901 GS-30 GS-32 GS-46 GS-47 xi


June 2012

TABLE OF CONTENTS

Section 5 Diagnostics
Introduction .................................................................................................. 5 - 1
GCON I/O Map without Load Sense - (all machines except GS-3232) ........ 5 - 4
GCON I/O Map with Load Sense (all machines except GS-3232) ............... 5 - 5
GCON I/O Map without Load Sense - (GS-3232 only) ................................. 5 - 6
GCON I/O Map with Load Sense (GS-3232 only) ........................................ 5 - 7
Operational Indicator Codes ........................................................................ 5 - 8
Diagnostic Trouble Codes ............................................................................ 5 - 8
Troubleshooting "HXX" and "PXXX" Faults ................................................. 5 - 9
Fault Inspection Procedure ........................................................................ 5 - 10
Type "HXXX" Faults .................................................................................. 5 - 12
Type "PXXX" Faults ................................................................................... 5 - 15
Type "UXXX" Faults .................................................................................. 5 - 16
Type "FXXX" Faults ................................................................................... 5 - 18
Type "CXXX" Faults .................................................................................. 5 - 21

xii GS-30 GS-32 GS-46 GS-47 Part No. 228901


June 2012

TABLE OF CONTENTS

Section 6 Schematics
Introduction .................................................................................................. 6 - 1
Electrical Component and Wire Color Legend ............................................. 6 - 2
Wiring Diagram - Ground and Platform Controls .......................................... 6 - 4
Limit Switch Legend ..................................................................................... 6 - 5
Electrical Symbols Legend ........................................................................... 6 - 6
Electrical Schematics - ANSI and CSA Models
GS-1530/1532/1930/1932
(from serial number GS3010A-110000 to GS3011A-110827) ...................... 6 - 8
GS-1530/1532/1930/1932
(from serial number GS3011A-110828) ..................................................... 6 - 12
GS-2032 and GS-2632
(from serial number GS3211A-110000) ..................................................... 6 - 16
GS-3232
(from serial number GS3211A-110000) ..................................................... 6 - 20
GS-2046 and GS-2646
(from serial number GS4611A-110000) ..................................................... 6 - 24
GS-3246
(from serial number GS4611A-110000) ..................................................... 6 - 28

Part No. 228901 GS-30 GS-32 GS-46 GS-47 xiii


June 2012

TABLE OF CONTENTS

Section 6 Schematics, continued


Electrical Schematics - CE and Australia Models
GS-1530/1532/1930/1932
(from serial number GS3010A-110000 to GS3011A-110827) .................... 6 - 32
GS-1530/1532/1930/1932
(from serial number GS3011A-110828)
(from serial number GS3011C-10000) ....................................................... 6 - 36
GS-2032 and GS-2632
(from serial number GS3211A-110000)
(from serial number GS3212C-10000) ....................................................... 6 - 40
GS-3232
(from serial number GS3211A-110000)
(from serial number GS3212C-10000) ....................................................... 6 - 44
GS-2046 and GS-2646
(from serial number GS4611A-110000)
(from serial number GS4612C-10000) ....................................................... 6 - 48
GS-3246
(from serial number GS4611A-110000)
(from serial number GS4612C-10000) ....................................................... 6 - 52
GS-4047
(from serial number GS4712C-101) ........................................................... 6 - 56

xiv GS-30 GS-32 GS-46 GS-47 xv


Part No. 228901
June 2012

TABLE OF CONTENTS

Section 6 Schematics, continued


Hydraulic Schematics
Component Reference and Hydraulic Symbols Legend ............................. 6 - 59
GS-1530/1532/1930/1932
(from serial number GS3010A-110000)
(from serial number GS3011C-10000) ....................................................... 6 - 61
GS-2032, GS-2632 and GS-3232
(from serial number GS3211A-110000)
(from serial number GS3212C-10000)
GS-2046, GS-2646 and GS-3246
(from serial number GS4611A-110000)
(from serial number GS4612C-10000) ....................................................... 6 - 62
GS-3232
(from serial number GS3211A-110000)
(from serial number GS3212C-10000) ....................................................... 6 - 63
GS-4047
(from serial number GS4712C-101) ........................................................... 6 - 64

Part No. 228901 GS-30 GS-32 GS-46 GS-47 xv


June 2012

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xvi GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 2 Specifications

Specifications
Machine Specifications Platform Overload Pressure Transducer, if equipped
All models except GS-3232 and GS-4047
Batteries, Standard
All models except GS-4047 Input voltage 8 to 30 VDC
Signal voltage 1 to 5 V
Voltage 6V DC
Platform Overload Pressure Transducer, if equipped
Group GC2 GS-3232 and GS-4047

Type T-105 Input voltage 8 to 30 VDC


Signal voltage .25 to 6.25 V
Quantity 4
Angle Sensor, if equipped
Battery capacity, maximum C20 = 225AH
Input voltage 8 to 30 VDC
Reserve capacity @ 25A rate 447 minutes Signal voltage 3 to 4 V, PMW output
Weight, each 62 lbs Outrigger Pressure Transducer, GS-3232 only
28 kg
Input voltage 8 to 30 VDC
Batteries, Standard GS-4047 Signal voltage 1 to 5 V
Voltage 12V DC

Group GC2 For operational specifications, refer to the


Operator's Manual.
Type T-1275

Quantity 4

Battery capacity, maximum C20 = 150AH

Reserve capacity @ 25A rate 280 minutes

Weight, each 82 lbs


37 kg

Batteries, Maintenance-free (option)


All models except GS-4047

Voltage 6V DC

Group GC2

Type 6V-AGM

Quantity 4

Battery capacity, maximum C20 = 200AH

Reserve capacity @ 25A rate 380 minutes

Weight, each 62 lbs


28 kg

Part No. 228901 GS-30 GS-32 GS-46 GS-47 2-1


Section 2 Specifications January 2012

SPECIFICATIONS

Fluid capacities Tires and wheels

Hydraulic tank 3.75 gallons GS-1530, GS-1532, GS-1930, GS-1932


All models except GS-4047 14.2 liters
Tire size (solid rubber) 12 x 4.5 in
Hydraulic tank 6.5 gallons 30.5 x 11.4 cm
GS-4047 24.6 liters
Tire contact area 9 sq in
Hydraulic system (including tank) 5 gallons 58 cm2
GS-3232 and GS-3246 19 liters
Castle nut torque, dry 300 ft-lbs
Hydraulic system (including tank) 7.5 gallons 406.7 Nm
GS-4047 28.4 liters
Castle nut torque, lubricated 225 ft-lbs
Hydraulic system (including tank) 4.5 gallons 305 Nm
All other models 18 liters
GS-2032, GS-2632, GS-3232, GS-2046, GS-2646,
GS-3246, GS-4047

Tire size (solid rubber) 15 x 5 in


38.1 x 12.7 cm

Tire contact area 15 sq in


96.7 cm2

Castle nut torque, dry 300 ft-lbs


406.7 Nm

Castle nut torque, lubricated 225 ft-lbs


305 Nm

Continuous improvement of our products is a


Genie policy. Product specifications are
subject to change without notice.

2-2 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 2 Specifications

SPECIFICATIONS

Performance Specifications GS-4047

Drive speed, maximum Platform stowed, fast 2.0 mph


40 ft / 13.7 sec
GS-1530, GS-1532, GS-1930 and GS-1932 3.2 km/h
12.2 m / 13.7 sec
Platform stowed, fast 2.5 mph
40 ft / 10.7 sec Platform stowed, slow 1.0 mph
4 km/h 40 ft / 27.4 sec
12.2 m / 10.7 sec 1.6 km/h
12.2 m / 27.4 sec
Platform stowed, slow 1.1 mph
40 ft / 24.8 sec Platform raised 0.5 mph
1.8 km/h 40 ft / 55 sec
12.2 m / 24.8 sec 0.8 km/h
12.2 m / 55 sec
Platform raised 0.5 mph
40 ft / 55 sec Braking distance, maximum
0.8 km/h
12.2 m / 55 sec High range on paved surface 24 in 12 in
61 cm 30 cm
GS-2032, GS-2632, GS-3232, GS-2046, GS-2646 and
GS-3246 Gradeability

Platform stowed, fast 2.2 mph GS-1930, GS-1932, GS-2632,


40 ft / 12.4 sec GS-3232, GS-3246 and GS-4047 25%
3.5 km/h GS-1530, GS-1532, GS-2032,
12.2 m / 12.4 sec GS-2046 and GS-2646 30%
Platform stowed, slow 1.1 mph Airborne noise emissions
40 ft / 24.8 sec
1.8 km/h Sound pressure level at ground workstation < 70 dBA
12.2 m / 24.8 sec
Sound pressure level at platform workstation < 70 dBA
Platform raised 0.5 mph
40 ft / 55 sec
0.8 km/h Continuous improvement of our products is a
12.2 m / 55 sec Genie policy. Product specifications are
subject to change without notice.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 2-3


Section 2 Specifications January 2012

SPECIFICATIONS

Function speed, maximum from platform controls Rated work load at full height, maximum
(with 1 person in platform)
GS-1530 and GS-1532 600 lbs
GS-1530 and GS-1532 272 kg

Platform up (fast mode) 15 to 17 seconds GS-1930, GS-1932, GS-2632 and GS-3232 500 lbs
Platform up (slow mode) 31 to 33 seconds 227 kg
Platform down 28 to 30 seconds
GS-2032 800 lbs
GS-1930 and GS-1932 363 kg

Platform up (fast mode) 15 to 17 seconds GS-2046 1200 lbs


Platform up (slow mode) 31 to 33 seconds 544 kg
Platform down 28 to 30 seconds
GS-2646 1000 lbs
GS-2032 and GS-2046 454 kg

Platform up (fast mode) 28 to 32 seconds GS-3246 700 lbs


Platform up (slow mode) 58 to 62 seconds 317 kg
Platform down 26 to 30 seconds
GS-4047 770 lbs
GS-2632 and GS-2646 349 kg

Platform up (fast mode) 28 to 32 seconds GS-3232 Outrigger leveling capacity, maximum


Platform up (slow mode) 58 to 62 seconds
Platform down 22 to 26 seconds Side to side 5
Front to rear 3
GS-3232 and GS-3246

Platform up (fast mode) 55 to 59 seconds Continuous improvement of our products is a


Platform up (slow mode) 108 to 112 seconds
Genie policy. Product specifications are
Platform down 38 to 42 seconds
subject to change without notice.
GS-4047

Platform up (fast mode) 69 to 73 seconds


Platform up (slow mode) 118 to 122 seconds
Platform down 39 to 43 seconds

2-4 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 2 Specifications

SPECIFICATIONS

Hydraulic Specifications Continued use of Chevron


Aviation A hydraulic fluid when
Hydraulic Oil Specifications ambient temperatures are
consistently above 32F / 0C may
Hydraulic oil type Chevron Rando HD equivalent result in component damage.
Viscosity grade Multi-viscosity
Viscosity index 200 Note: Use Chevron Aviation A hydraulic fluid
when ambient temperatures consistently below
Cleanliness level, minimum ISO 15/13 0F / -17C.
Water content, maximum 200 ppm Note: Use Shell Tellus S2 V 46 hydraulic oil when
Chevron Rando HD oil is fully compatible and oil temperatures consistently exceed 205F / 96C.
mixable with Shell Donax TG (Dexron III) oils.
Note: Genie specifications require additional
Genie specifications require hydraulic oils which are
designed to give maximum protection to hydraulic
equipment and special installation instructions for
systems, have the ability to perform over a wide the approved optional fluids. Consult the Genie
temperature range, and the viscosity index should Service Department before use.
exceed 140. They should provide excellent antiwear,
oxidation, corrosion inhibition, seal conditioning, and Function pump - All models except GS-4047
foam and aeration suppression properties.
Type Gear
Optional fluids
Displacement per revolution 0.244 cu in
Biodegradable Petro Canada Environ MV 46 4 cc
Statoil Hydra Way Bio SE 32
BP Biohyd SE-S Flow rate @ 2500 psi / 172 bar 3 gpm
11.3 L/min
Fire resistant UCON Hydrolube HP-5046
Quintolubric 822 Hydraulic tank return filter 10 micron with
25 psi / 1.7 bar bypass
Mineral based Shell Tellus S2 V 32
Shell Tellus S2 V 46 Function pump - GS-4047
Chevron Aviation A
Type Gear
Arnica 32
Displacement per revolution 0.335 cu in
5.5 cc

Flow rate @ 2500 psi / 172 bar 4 gpm


15 L/min

Hydraulic tank return filter 10 micron with


25 psi / 1.7 bar bypass

Continuous improvement of our products is a


Genie policy. Product specifications are
subject to change without notice.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 2-5


Section 2 Specifications January 2012

SPECIFICATIONS

Manifold Component Plug torque


Specifications SAE No. 2 50 in-lbs / 6 Nm

Function manifold - All models except GS-4047 SAE No. 4 13 ft-lbs / 18 Nm

System relief valve pressure, maximum 3700 psi SAE No. 6 18 ft-lbs / 24 Nm
255 bar
SAE No. 8 50 ft-lbs / 68 Nm
Lift relief valve pressure 1800 to 3700 psi
124 to 241 bar SAE No. 10 55 ft-lbs / 75 Nm

Steer relief valve pressure 1500 psi SAE No. 12 75 ft-lbs / 102 Nm
103 bar

Function manifold - GS-4047 Continuous improvement of our products is a


Genie policy. Product specifications are
System relief valve pressure, maximum 3500 psi
subject to change without notice.
241 bar

Platform relief valve pressure 3000 psi


206 bar

Steer relief valve pressure 1500 psi


103 bar

Outrigger manifold

Relief valve pressure, maximum 3500 psi


241 bar

Check valve manifold -


GS-1530, GS-1532, GS-1930, GS-1932

Check valve pressure, maximum 200 psi


13.8 bar

Lift pressure selector manifold - GS-4047

Platform relief valve pressure, maximum 2000 psi


138 bar

2-6 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 2 Specifications

SPECIFICATIONS

Valve Coil Resistance

Note: The following coil resistance specifications are at


an ambient temperature of 68F / 20C. As valve coil
resistance is sensitive to changes in air temperature,
the coil resistance will typically increase or decrease by
4% for each 18F / -7.7C that your air temperature
increases or decreases from 68F / 20C.

Description Specification

Solenoid valve, 3 position 4 way 27.2


20V DC with diode (schematic items F and AC)

Solenoid valve, 3 position 4 way 19


20V DC with diode (schematic item E)

Solenoid valve, 2 position 4 way 19


20V DC with diode (schematic item H and AI)

Solenoid valve, 2 position 2 way N.C. 25


20V DC with diode (schematic item N)

Solenoid valve, 2 position 4 way 19


20V DC with diode (schematic items AE)

Solenoid valve, 3 position 5 way 19


20V DC with diode (schematic item AG)

Solenoid valve, 2 position 2 way 27.2


20V DC with diode (schematic item CA, CB, CC
and CD)

Solenoid valve, 3 position 4 way 19


20V DC with diode (schematic item BA)

Solenoid valve, 2 position 2 way 23.9


20V DC with diode (schematic item DO)

Continuous improvement of our products is a


Genie policy. Product specifications are
subject to change without notice.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 2-7


Section 2 Specifications January 2012

SPECIFICATIONS

Hydraulic Hose and Fitting


Torque Specifications
Your machine is equipped with JIC 37 flared
fittings and hose ends. Genie specifications require
that fittings and hose ends be torqued to
specification when they are removed and installed
or when new hoses or fittings are installed.

SAE O-ring Boss Port JIC 37 Fittings


(tube fitting - installed into Aluminum) (swivel nut or hose connection)

SAE Dash size Torque SAE Dash size Thread Size Flats

-4 11 ft-lbs / 14.9 Nm -4 7/16-20 2

-6 23 ft-lbs / 31.2 Nm -6 9/16-18 1 1/4

-8 40 ft-lbs / 54.2 Nm -8 3/4-16 1

-10 69 ft-lbs / 93.6 Nm -10 7/8-14 1

-12 93 ft-lbs / 126.1 Nm -12 1 1/16-12 1

-16 139 ft-lbs / 188.5 Nm -16 1 5/16-12 1

-20 172 ft-lbs / 233.2 Nm -20 1 5/8-12 1

-24 208 ft-lbs / 282 Nm -24 1 7/8-12 1

SAE O-ring Boss Port


(tube fitting - installed into Steel)

SAE Dash size Torque

-4 16 ft-lbs / 21.7 Nm

-6 35 ft-lbs / 47.5 Nm

-8 60 ft-lbs / 81.3 Nm

-10 105 ft-lbs / 142.4 Nm

-12 140 ft-lbs / 190 Nm

-16 210 ft-lbs / 284.7 Nm

-20 260 ft-lbs / 352.5 Nm

-24 315 ft-lbs / 427.1 Nm

2-8 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 2 Specifications

SPECIFICATIONS

Torque Procedure 3 Working clockwise on the body hex fitting, make


a second mark with a permanent ink marker to
JIC 37 fittings indicate the proper tightening position. Refer to
Figure 2.
1 Align the tube flare (hex nut) against the nose of
the fitting body (body hex fitting) and tighten the Note: Use the JIC 37 Fittings table on the
hex nut to the body hex fitting to hand-tight, previous page to determine the correct number of
approximately 30 in-lbs / 3.4 Nm. flats for the proper tightening position.
2 Make a reference mark on one of the flats of the Note: The marks indicate that the correct tightening
hex nut, and continue it on to the body hex positions have been determined. Use the second
fitting with a permanent ink marker. Refer to mark on the body hex fitting to properly tighten the
Figure 1. joint after it has been loosened.
a

b
b
a
c
d c
b

Figure 1 Figure 2

a hydraulic hose a body hex fitting


b hex nut b reference mark
c reference mark c second mark
d body hex fitting
4 Tighten the hex nut until the mark on the hex
nut is aligned with the second mark on the body
hex fitting.
5 Operate all machine functions and inspect the
hoses and fittings and related components to
confirm that there are no leaks.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 2-9


Section 2 Specifications January 2012

SPECIFICATIONS

SAE FASTENER TORQUE CHART


This chart is to be used as a guide only unless noted elsewhere in this manual
A574 High Strength
SIZE THREAD Grade 5 Grade 8 Black Oxide Bolts
LUBED DRY LUBED DRY LUBED
in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm
1/4 20 80 9 100 11.3 110 12.4 140 15.8 130 14.7
28 90 10.1 120 13.5 120 13.5 160 18 140 15.8
LUBED DRY LUBED DRY LUBED
ft - lbs Nm f t - lbs Nm f t - lbs Nm f t - lbs Nm f t - lbs Nm
5/16 18 13 17.6 17 23 18 24 25 33.9 21 28.4
24 14 19 19 25.7 20 27.1 27 36.6 24 32.5
3/8 16 23 31.2 31 42 33 44.7 44 59.6 38 51.5
24 26 35.2 35 47.4 37 50.1 49 66.4 43 58.3
7/16 14 37 50.1 49 66.4 50 67.8 70 94.7 61 82.7
20 41 55.5 55 74.5 60 81.3 80 108.4 68 92.1
1/2 13 57 77.3 75 101.6 80 108.4 110 149 93 126
20 64 86.7 85 115 90 122 120 162 105 142
9/16 12 80 108.4 110 149 120 162 150 203 130 176
18 90 122 120 162 130 176 170 230 140 189
5/8 11 110 149 150 203 160 217 210 284 180 244
18 130 176 170 230 180 244 240 325 200 271
3/4 10 200 271 270 366 280 379 380 515 320 433
16 220 298 300 406 310 420 420 569 350 474
7/8 9 320 433 430 583 450 610 610 827 510 691
14 350 474 470 637 500 678 670 908 560 759
8 480 650 640 867 680 922 910 1233 770 1044
1
12 530 718 710 962 750 1016 990 1342 840 1139
7 590 800 790 1071 970 1315 1290 1749 1090 1477
1 1/8
12 670 908 890 1206 1080 1464 1440 1952 1220 1654
7 840 1138 1120 1518 1360 1844 1820 2467 1530 2074
1 1/4
12 930 1260 1240 1681 1510 2047 2010 2725 1700 2304
6 1460 1979 1950 2643 2370 3213 3160 4284 2670 3620
1 1/2
12 1640 2223 2190 2969 2670 3620 3560 4826 3000 4067

METRIC FASTENER TORQUE CHART


This chart is to be used as a guide only unless noted elsewhere in this manual

Size Class 4.6 4.6 Class 8.8 8.8 Class 10.9 10.9 Class 12.9 12.9

(m m ) LUBED DRY LUBED DRY LUBED DRY LUBED DRY


in- lbs Nm in- lbs Nm in-lbs Nm in-lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm
5 16 1.8 21 2.4 41 4.63 54 6.18 58 6.63 78 8.84 68 7.75 91 10.3
6 19 3.05 36 4.07 69 7.87 93 10.5 100 11.3 132 15 116 13.2 155 17.6
7 45 5.12 60 6.83 116 13.2 155 17.6 167 18.9 223 25.2 1.95 22.1 260 29.4
LUBED DRY LUBED DRY LUBED DRY LUBED DRY
f t- lbs Nm f t- lbs Nm f t -lbs Nm f t -lbs Nm f t - lbs Nm f t - lbs Nm f t - lbs Nm ft - lbs Nm
8 5.4 7.41 7.2 9.88 14 19.1 18.8 25.5 20.1 27.3 26.9 36.5 23.6 32 31.4 42.6
10 10.8 14.7 14.4 19.6 27.9 37.8 37.2 50.5 39.9 54.1 53.2 72.2 46.7 63.3 62.3 84.4
12 18.9 25.6 25.1 34.1 48.6 66 64.9 88 69.7 94.5 92.2 125 81 110 108 147
14 30.1 40.8 40 54.3 77.4 105 103 140 110 150 147 200 129 175 172 234
16 46.9 63.6 62.5 84.8 125 170 166 226 173 235 230 313 202 274 269 365
18 64.5 87.5 86.2 117 171 233 229 311 238 323 317 430 278 377 371 503
20 91 124 121 165 243 330 325 441 337 458 450 610 394 535 525 713
22 124 169 166 225 331 450 442 600 458 622 612 830 536 727 715 970
24 157 214 210 285 420 570 562 762 583 791 778 1055 682 925 909 1233

2 - 10 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 3 Scheduled Maintenance Procedures

Scheduled Maintenance Procedures


About This Section
This section contains detailed procedures for each
scheduled maintenance inspection.

Each procedure includes a description, safety


warnings and step-by-step instructions.
Observe and Obey:
Symbols Legend
Maintenance inspections shall be completed
by a person trained and qualified on the Safety alert symbolused to alert
maintenance of this machine. personnel to potential personal
injury hazards. Obey all safety
Scheduled maintenance inspections shall be messages that follow this symbol
completed daily, quarterly, semi-annually, to avoid possible injury or death.
annually and every 2 years as specified on the
Maintenance Inspection Report. Indicates an imminently hazardous
situation which, if not avoided, will
Failure to properly complete each result in death or serious injury.
inspection when required may
cause death, serious injury or Indicates a potentially hazardous
substantial machine damage. situation which, if not avoided,
could result in death or serious
Immediately tag and remove from service a injury.
damaged or malfunctioning machine.
Indicates a potentially hazardous
Repair any machine damage or malfunction situation which, if not avoided,
before operating the machine. may cause minor or moderate
injury.
Use only Genie approved replacement parts.
Indicates a potentially hazardous
Machines that have been out of service for a situation which, if not avoided,
period longer than 3 months must complete the may result in property damage.
quarterly inspection.
Indicates that a specific result is expected after
Unless otherwise specified, perform each performing a series of steps.
procedure with the machine in the following
configuration: Indicates that an incorrect result has occurred
after performing a series of steps.
Machine parked on a firm, level surface
Platform in the stowed position
Key switch in the off position with the key
removed
The red Emergency Stop button in the off
position at both ground and platform controls
Wheels chocked
All external AC power supply disconnected
from the machine

Part No. 228901 GS-30 GS-32 GS-46 GS-47 3-1


Section 3 Scheduled Maintenance Procedures January 2012

SCHEDULED MAINTENANCE PROCEDURES

Maintenance Symbols Legend Pre-delivery Preparation Report


Note: The following symbols have been used in The pre-delivery preparation report contains
this manual to help communicate the intent of the checklists for each type of scheduled inspection.
instructions. When one or more of the symbols
appears at the beginning of a maintenance Make copies of the Pre-delivery Preparation report
procedure, it conveys the meaning below. to use for each inspection. Store completed forms
as required.

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 subsectionsA, 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

Indicates that dealer service will be Daily or every 8 hours A


required to perform this procedure.
Quarterly or every 250 hours A+B

Semi-annually or every 500 hours A+B+C

Annually or every 1000 hours A+B+C+D

Two year or every 2000 hours A+B+C+D+E

Maintenance Inspection Report

The maintenance inspection report contains


checklists for each type of scheduled inspection.
Make copies of the Maintenance Inspection Report
to use for each inspection. Maintain completed
forms for a minimum of 4 years or in compliance
with your employer, jobsite and governmental
regulations and requirements.

3-2 GS-30 GS-32 GS-46 GS-47 Part No. 228901


Pre-Deliver
Pre-Deliveryy Preparation
January 2012 Section 3 Scheduled Maintenance Procedures

Fundamentals Instructions
It is the responsibility of the dealer to perform the Use the operators 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 operators 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 reinspect 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

Terex South Dakota, Inc USA Genie UK


500 Oak Wood Road The Maltings, Wharf Road
PO Box 1150 Grantham, Lincolnshire
Watertown, SD 57201-6150 NG31- 6BH England
(605) 882-4000 (44) 1476-584333
Copyright 2011 Terex Corporation. Genie is a registered trademark of Terex South
Dakota, Inc. 133192 Rev D
Part No. 228901 GS-30 GS-32 GS-46 GS-47 3-3
Section 3 Scheduled Maintenance Procedures January 2012

This page intentionally left blank.

3-4 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 3 Scheduled Maintenance Procedures

Maintenance Inspection Report


Model Checklist A Y N R Checklist B Y N R
A-1 Inspect the manuals B-1 Batteries
Serial number and decals B-2 Electrical wiring
Date A-2 Pre-operation B-3 Electrical contactor
inspection
B-4 Tires and wheels
Hour meter A-3 Function tests
B-5 Emergency stop
Perform after 40 hours:
Machine owner B-6 Key switch
A-4 30 day service
B-7 Horn (if equipped)
Inspected by (print) Perform every 100 hours:
B-8 Drive brakes
A-5 Grease steer yokes
B-9 Drive speed - stowed
Inspector signature
B-10 Drive speed - raised
Inspector title B-11 Drive speed - slow
B-12 Hydraulic oil analysis
Inspector company
B-13 Tank venting system

Instructions B-14 Latch components


Make copies of this report to use for B-15 Voltage inverter
each inspection. (if equipped)
Select the appropriate checklist(s) for B-16 Down limit switch and
the type of inspection to be pothole limit switches
performed. B-17 Up limit switch and
max. drive height limit
Daily or 8 hours switches (if equipped)
Inspection: A
Quarterly or 250 hours Checklist C Y N R
Inspection: A+B
C-1 Pressure transducer
Semi-annually or and platform height
500 hours sensor (if equipped)
Inspection: A+B+C
C-2 Platform overload
Annually or (if equipped)
1000 hours
C-3 Breather cap - models
Inspection: A+B+C+D
with optional oil
Two year or
2000 hours
Inspection: A+B+C+D+E Checklist D Y N R
D-1 Scissor arm wear pads
Place a check in the appropriate box
after each inspection procedure is D-2 Hydraulic filter
completed.
Use the step-by-step procedures in Checklist E Y N R
this section to learn how to perform
E-1 Hydraulic oil
these inspections.
If any inspection receives an N, tag
and remove the machine from service, Comments
repair and re-inspect it. After repair,
place a check in the R box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired

Part No. 228901 GS-30 GS-32 GS-46 GS-47 3-5


Section 3 Scheduled Maintenance Procedures January 2012

Checklist A Procedures
A-1 3 Open the operator's manual to the decals
inspection section. Carefully and thoroughly
Inspect the Manuals and Decals inspect all decals on the machine for legibility
Maintaining the operators and safety manuals in and damage.
good condition is essential to safe machine Result: The machine is equipped with all
operation. Manuals are included with each required decals, and all decals are legible and
machine and should be stored in the container in good condition.
provided in the platform. An illegible or missing
manual will not provide safety and operational Result: The machine is not equipped with all
information necessary for a safe operating required decals, or one or more decals are
condition. illegible or in poor condition. Remove the
machine from service until the decals are
In addition, maintaining all of the safety and replaced.
instructional decals in good condition is mandatory
for safe machine operation. Decals alert operators 4 Always return the manuals to the storage
and personnel to the many possible hazards container after use.
associated with using this machine. They also Note: Contact your authorized Genie distributor or
provide users with operation and maintenance Genie, if replacement manuals or decals are
information. An illegible decal will fail to alert needed.
personnel of a procedure or hazard and could
result in unsafe operating conditions.
1 Check to make sure that the operator's and
safety manuals are present and complete in the
storage container on the platform.
2 Examine the pages of each manual to be sure
that they are legible and in good condition.
Result: The operator's manual is appropriate for
the machine and all manuals are legible and in
good condition.
Result: The operator's manual is not
appropriate for the machine or all manuals are
not in good condition or is illegible. Remove the
machine from service until the manual is
replaced.

3-6 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 3 Scheduled Maintenance Procedures

CHECKLIST A PROCEDURES

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.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 3-7


Section 3 Scheduled Maintenance Procedures January 2012

CHECKLIST A PROCEDURES

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-4 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

Chevron Ultra-duty grease, EP NLGI 1 (lithium based)


or equivalent

3-8 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 3 Scheduled Maintenance Procedures

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 +/- 0.007. 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 Put on protective clothing and eye wear. specific gravity of each battery cell with a
hydrometer. Note the results.
2 Release the battery pack latch and rotate the
battery pack out and away from the chassis.
3 Be sure that the battery cable connections are
free of corrosion.
Note: Adding terminal protectors and a corrosion
preventative sealant will help eliminate corrosion
on the battery terminals and cables.
4 Be sure that the battery retainers and cable
connections are tight.
5 Fully charge the batteries. Allow the batteries to
rest 24 hours before performing this procedure
to allow the battery cells to equalize.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 3-9


Section 3 Scheduled Maintenance Procedures January 2012

CHECKLIST B PROCEDURES

10 Check the ambient air temperature and adjust


the specific gravity reading for each cell as
follows:
Add 0.004 to the reading of each cell for
every 10 / 5.5 C above 80 F / 26.7 C.
Subtract 0.004 from the reading of each cell for
every 10 / 5.5 C below 80 F / 26.7 C.
Result: All battery cells display a specific gravity
of 1.277 +/- 0.007. The battery is fully charged.
Proceed to step 11.
Result: One or more battery cells display a
specific gravity from 1.269 to 1.218. The battery
is still usable, but at a lower performance so will
need to be recharged more often. Proceed to
step 11.
Result: One or more battery cells display a
specific gravity from 1.217 to 1.173. The battery
is approaching the end of its life. Proceed to
step 11.
All models except GS-4047
Result: The difference in specific gravity
readings between cells is greater than 0.1 OR a batteries B5
the specific gravity of one or more cells is 1.172 b 275A fuse F6
c quick disconnect QD1
or less. Replace the battery.
11 Check the battery acid level. If needed,
replenish with distilled water to 1/8 inch / 3 mm
below the bottom of the battery fill tube. Do not
overfill.
12 Install the vent caps and neutralize any
electrolyte that may have spilled.

3 - 10 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 3 Scheduled Maintenance Procedures

CHECKLIST B PROCEDURES

All models:
13 Check each battery pack and verify that the
+

+
batteries are wired correctly.
14 Inspect the battery charger plug and pigtail for
- - damage or excessive insulation wear. Replace
as required.
15 Connect the battery charger to a properly
grounded single phase AC power supply.
+

Result: The charger should operate and begin


charging the batteries.
If, simultaneously, the charger alarm sounds
- - a
and the LEDs blink one time, correct the
charger connections at the fuse and battery.
The charger will then operate correctly and
b
begin charging the batteries.
F6
275A Fuse If, simultaneously, the charger alarm sounds
+ -

QD1 c and the LEDs blink two times, the input voltage
is too low or too high. Correct the voltage issue.
GS-4047 only The charger will then operate correctly and
begin charging the batteries.
a batteries B5
b 275A fuse F6 If, simultaneously, the charger alarm sounds
c quick disconnect QD1 and the LEDs blink three times, the charger is
overheated. Allow the charger to cool. The
charger will then operate correctly and begin
charging the batteries.
Note: For best results, use an extension of
adequate size with a length no longer than
50 feet / 15 m.

Note: If you have any further questions regarding


the battery charger operation, please contact the
Genie Service Department.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 3 - 11


Section 3 Scheduled Maintenance Procedures January 2012

CHECKLIST B PROCEDURES

B-2 4 Turn the key switch to ground control and pull


out the red Emergency Stop button to the on
Inspect the Electrical Wiring position at both the ground and platform
controls.
5 Raise the platform approximately 8 feet / 2.4 m
from the ground.
Genie requires that this procedure be performed
every 250 hours or quarterly, whichever comes 6 Rotate the safety arm away from the machine
first. and let it hang down.

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

3 - 12 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 3 Scheduled Maintenance Procedures

CHECKLIST B PROCEDURES

B-3 B-4
Inspect the Electrical Contactor Inspect the Tires and Wheels
(including castle nut torque)

Genie requires that this procedure be performed


every 250 hours or quarterly, whichever comes Genie requires that this procedure be performed
first. every 250 hours or quarterly, whichever comes
first.
Maintaining the electrical contactor in good
condition is essential to safe machine operation. Maintaining the tires and wheels in good
Failure to locate a worn or damaged contactor condition is essential to safe operation and good
could result in an unsafe working condition and performance. Tire and/or wheel failure could result
component damage. in a machine tip-over. Component damage may
also result if problems are not discovered and
1 At the ground controls, turn the key switch to
repaired in a timely fashion.
the off position.
2 Push in the red Emergency Stop button at the 1 Check the tire surface and sidewalls for cuts,
ground controls to the off position. cracks, punctures and unusual wear.

3 Open the battery tray and disconnect the 2 Check each wheel for damage, bends and
Anderson connector. cracks.

4 Locate the electrical contactor mounted on the 3 Remove the cotter pin and check each castle
fuse bracket. nut for proper torque. Refer to Section 2,
Specifications.
5 Visually inspect the contact points of the
contactor for the following items: Note: Always replace the cotter pin with a new one
when removing the castle nut or when checking
Excessive burns the torque of the castle nut.
Excessive arcs
4 Install a new cotter pin. Bend the cotter pin to
Excessive pitting lock it in place.
Electrocution/burn hazard. Contact
with hot or live circuits could result
in death or serious injury. Remove
all rings, watches and other
jewelry.
Note: Replace the contactor if any damage is
found.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 3 - 13


Section 3 Scheduled Maintenance Procedures January 2012

CHECKLIST B PROCEDURES

B-5 3 Turn the key switch to platform control and pull


out the red Emergency Stop button to the on
Test the Emergency Stop position at both the ground and platform
Genie requires that this procedure be performed controls.
every 250 hours or quarterly, whichever comes 4 Push down the red Emergency Stop button at
first. the platform controls to the off position.
A properly functioning Emergency Stop is essential Result: No machine functions should operate.
for safe machine operation. An improperly
operating red Emergency Stop button will fail to Note: The red Emergency Stop button at the
shut off power and stop all machine functions, ground controls will stop all machine operation,
resulting in a hazardous situation. even if the key switch is switched to platform
control.
As a safety feature, selecting and operating the
ground controls will override the platform controls, Note: If in ground controls mode and the red
except the platform red Emergency Stop button. Emergency Stop button at the platform controls is
pushed in, the ground controls LCD will display,
1 Turn the key switch to ground control and pull Platform EStop Depressed. The machine alarm will
out the red Emergency Stop button to the on sound at 1 beep per second.
position at both the ground and platform
controls.
2 Push in the red Emergency Stop button at the
ground controls to the off position.
Result: No machine functions should operate.

3 - 14 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 3 Scheduled Maintenance Procedures

CHECKLIST B PROCEDURES

B-6 B-7
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.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 3 - 15


Section 3 Scheduled Maintenance Procedures January 2012

CHECKLIST B PROCEDURES

B-8
Test the Drive Brakes

Genie specifications require that this procedure be


performed every 250 hours or quarterly, whichever
comes first.
Proper brake action is essential to safe machine
operation. The drive brake function should operate
smoothly, free of hesitation, jerking and unusual
noise. Hydraulically-released individual wheel
brakes can appear to operate normally when not
fully operational.

Note: Perform this procedure with the machine on


a drive/steer function enable switch
a firm, level surface that is free of obstructions. b blue arrow
Note: Be sure the platform extension deck is fully 6 Move the control handle in the direction
retracted and the platform is in the stowed position. indicated by the blue arrow on the control panel
1 Mark a test line on the ground for reference. until the machine begins to move forward.

2 Turn the key switch to platform control and pull 7 Bring the machine to top drive speed before
out the red Emergency Stop button to the on reaching the test line. Release the drive/steer
position at both the ground and platform function enable switch or the joystick when your
controls. reference point on the machine crosses the test
line.
3 Lower the platform to the stowed position.
8 Measure the distance between the test line and
4 Choose a point on the machine; i.e., contact your machine reference point. Refer to Section
patch of a tire, as a visual reference for use 2, Specifications.
when crossing the test line.
Note: The brakes must be able to hold the machine
5 Press and hold the drive/steer function enable on any slope it is able to climb.
switch on the control handle.

3 - 16 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 3 Scheduled Maintenance Procedures

CHECKLIST B PROCEDURES

B-9
Test the Drive Speed -
Platform Stowed, Fast

Genie requires that this procedure be performed


every 250 hours or quarterly, whichever comes
first.
Proper drive functions are essential to safe
machine operation. The drive function should
respond quickly and smoothly to operator control.
Drive performance should also be free of
hesitation, jerking and unusual noise over the
entire proportionally controlled speed range.
a drive/steer function enable switch
Note: Perform this procedure with the machine on b slow drive speed button
a firm, level surface that is free of obstructions. c blue arrow

1 Create start and finish lines by marking two 7 Move the control handle in the direction
lines on the ground 40 feet / 12.2 m apart. indicated by the blue arrow on the control panel
until the machine begins to move forward.
2 Turn the key switch to platform control and pull
out the red Emergency Stop button to the on 8 Bring the machine to top drive speed before
position at both the ground and platform reaching the start line. Begin timing when the
controls. selected reference point on the machine
crosses the start line.
3 Lower the platform to the stowed position.
9 Continue at full speed and note the time when
4 Choose a point on the machine; i.e., contact your reference point on the machine passes the
patch of a tire, as a visual reference for use finish line. Refer to Section 2, Specifications.
when crossing the test line.
5 Check to make sure the low drive speed light is
off. If the low dive speed light is on, press the
drive speed select button to turn off the low
drive speed function.
6 Press and hold the drive/steer function enable
switch on the control handle.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 3 - 17


Section 3 Scheduled Maintenance Procedures January 2012

CHECKLIST B PROCEDURES

B-10
Test the Drive Speed -
Platform Raised

Genie specifications require that this procedure be


performed every 250 hours or quarterly, whichever
comes first.
Proper drive functions are essential to safe
machine operation. The drive function should
respond quickly and smoothly to operator control.
Drive performance should also be free of
hesitation, jerking and unusual noise over the
entire proportionally controlled speed range.
a drive/steer function enable switch
Note: Perform this procedure with the machine on b platform up button
a firm, level surface that is free of obstructions. c low speed lift enable button
d high speed lift enable button
1 Create start and finish lines by marking two e blue arrow
lines on the ground 40 feet / 12.2 m apart. 8 Move the control handle in the direction
2 Turn the key switch to platform control and pull indicated by the blue arrow on the control panel
out the red Emergency Stop button to the on until the machine begins to move forward.
position at both the ground and platform 9 Bring the machine to top drive speed before
controls. reaching the start line. Begin timing when the
3 Press and hold the high or low speed lift enable selected reference point on the machine
button. crosses the start line.

4 Press the platform up button. 10 Continue at full speed and note the time when
your reference point on the machine passes the
5 Raise the platform approximately 4 feet / 1.2 m finish line. Refer to Section 2, Specifications.
from the ground.
6 Choose a point on the machine; i.e., contact
patch of a tire, as a visual reference for use
when crossing the start and finish lines.
7 Press and hold the drive/steer function enable
switch on the control handle.

3 - 18 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 3 Scheduled Maintenance Procedures

CHECKLIST B PROCEDURES

B-11
Test the Drive Speed -
Platform Stowed, Slow

Genie specifications require that this procedure be


performed every 250 hours or quarterly, whichever
comes first.
Proper drive functions are essential to safe
machine operation. The drive function should
respond quickly and smoothly to operator control.
Drive performance should also be free of
hesitation, jerking and unusual noise over the
entire proportionally controlled speed range.
a drive/steer function enable switch
Note: Perform this procedure with the machine on b drive speed select button
a firm, level surface that is free of obstructions. c blue arrow

1 Create start and finish lines by marking two 7 Move the control handle in the direction
lines on the ground 40 feet / 12.2 m apart. indicated by the blue arrow on the control
panel until the machine begins to move
2 Turn the key switch to platform control and pull forward.
out the red Emergency Stop button to the on
position at both the ground and platform 8 Bring the machine to top drive speed before
controls. reaching the start line. Begin timing when the
selected reference point on the machine
3 Lower the platform to the stowed position. crosses the start line.
4 Press the drive speed select button until the low 9 Continue at full speed and note the time when
drive speed light is on. your reference point on the machine passes
5 Choose a point on the machine; i.e., contact over the finish line. Refer to Section 2,
patch of a tire, as a visual reference for use Specifications.
when crossing the start and finish lines.
6 Press and hold the drive/steer function enable
switch on the control handle.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 3 - 19


Section 3 Scheduled Maintenance Procedures January 2012

CHECKLIST B PROCEDURES

B-12 B-13
Perform Hydraulic Oil Analysis Inspect the Hydraulic Tank Cap
Venting System

Genie requires that this procedure be performed


every 250 hours or quarterly, whichever comes Genie requires that this procedure be performed
first. quarterly or every 250 hours, whichever comes
Replacement or testing of the hydraulic oil is first. Perform this procedure more often if dusty
essential for good machine performance and conditions exist.
service life. Dirty oil may cause the machine to A free-breathing hydraulic tank cap is essential for
perform poorly and continued use may cause good machine performance and service life. A dirty
component damage. Extremely dirty conditions or clogged cap may cause the machine to perform
may require oil changes to be performed more poorly. Extremely dirty conditions may require that
often. Refer to Section 2, Specifications. the cap be inspected more often.
Before replacing the hydraulic oil, the oil may be 1 Remove the breather cap from the hydraulic
tested by an oil distributor for specific levels of tank.
contamination to verify that changing the oil is
necessary. 2 Check for proper venting.
If the hydraulic oil is not replaced at the two
Result: Air passes through the breather cap.
year inspection, test the oil quarterly. Replace
the oil when it fails the test. See E-1, Test or Result: If air does not pass through the cap,
Replace the Hydraulic Oil. clean or replace the cap. Proceed to step 3.
Note: When checking for positive tank cap venting,
air should pass freely through the cap.

3 Using a mild solvent, carefully wash the cap


venting system. Dry using low pressure
compressed air. Repeat step 2.
4 Install the breather cap onto the hydraulic tank.

3 - 20 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 3 Scheduled Maintenance Procedures

CHECKLIST B PROCEDURES

B-14
Check the Module Tray Latch
Components

Genie requires that this procedure be performed


every 250 hours or quarterly, whichever comes
first.
Maintaining the module tray latch components in
good condition is essential to good performance
and service life. Failure to detect worn out latch
components may result in module trays opening
unexpectedly, creating an unsafe operating
condition.

1 Inspect each module tray rotary latch and


related components for wear. Tighten any loose
fasteners.
2 Lubricate each module tray rotary latch. Using
light oil, apply a few drops to each of the
springs and to the sides of the rotary latch
mechanism.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 3 - 21


Section 3 Scheduled Maintenance Procedures January 2012

CHECKLIST B PROCEDURES

B-15 3 Connect an appropriate power tool to the


inverter. Activate the tool.
Inspect the Voltage Inverter
Result: The power tool should operate. There
(if equipped)
may be a brief (0.5 second) delay if the power
tool has not been used in the previous 10
minutes.

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
between the AC hot and ground in the tool or
T OUT
PUT
POW
outlet. Check the tool for burnt, chafed,
ER IN
c VERT
ER corroded and loose wires, and inspect the tool
25V
24V-2
2V
for internal moisture. Correct the short circuit or
21V

d
moisture issue OR inspect the wiring in the
PART
NUM
power-to-platform box. The inverter will then
BER
XXX
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.

3 - 22 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 3 Scheduled Maintenance Procedures

CHECKLIST B PROCEDURES

B-16 Down Limit Switch


Test the Down Limit Switch, 9 Disable the down limit switch. Loosen the
Level Sensor and Pothole Limit fastener securing the roller arm to the limit
switch, and rotate the roller arm 90 degrees in a
Switches downwards direction. Do not activate the switch
contacts.
10 Turn the key switch to platform control.

Genie requires that this procedure be performed 11 Raise the platform and return the safety arm to
every 250 hours or quarterly, whichever comes the stowed position.
first. 12 Working at the platform controls, press the lift
function select button. Lower the platform to the
Maintaining the limit switches is essential to safe stowed position.
operation and good machine performance.
Operating the machine with a faulty limit switch Result: The ground controls LCD displays
could result in reduced machine performance and "PHS: POTHOLE GUARDS STUCK" and the
a potentially unsafe operating condition. platform controls LED displays "PHS". The
alarm sounds and the lift function operates.
Perform these procedures with the machine on a The machine is functioning properly.
firm, level surface that is free of obstructions. Refer to the Operation Indicator Codes below.
1 Remove the platform controls from the platform. Result: The ground controls LCD does not
2 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. display "PHS: POTHOLE GUARDS STUCK"
and the platform controls LED does not display
3 Lift the safety arm, move it to the center of the "PHS". The alarm does not sound and the lift
scissor arm and rotate down to a vertical function does not operate. Replace the down
position. limit switch.
4 Lower the platform onto the safety arm.
Crushing hazard. Keep hands
clear of the safety arm when
lowering the platform.
5 Turn the key switch to the off position. LCD display
6 Tag and disconnect the platform control box at
the platform.
7 Follow the platform control cable down the
scissor stack to the alarm bracket on the
chassis deck. Tag and disconnect the platform
control cable from the ECM cable at the 6-pin
Deutsch connector.
LED display
8 Securely install the platform control box harness
plug into the 6-pin Deutsch connector of the
ECM cable.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 3 - 23


Section 3 Scheduled Maintenance Procedures January 2012

CHECKLIST B PROCEDURES

13 Press and hold the drive/steer function enable 16 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
switch on the control handle. Attempt to drive
17 Lift the safety arm, move it to the center of the
and steer the machine.
scissor arm and rotate down to a vertical
Result: The ground controls LCD displays position.
"PHS: POTHOLE GUARDS STUCK" and the
18 Lower the platform onto the safety arm.
platform controls LED displays "PHS". The
alarm sounds, and the drive and steer functions Crushing hazard. Keep hands
do not operate. The machine is functioning clear of the safety arm when
properly. lowering the platform.
Result: The ground controls LCD does not 19 Turn the key switch to the off position.
display "PHS: POTHOLE GUARDS STUCK"
and the platform controls LED does not display 20 Disconnect the platform controls from the ECM
"PHS". The alarm does not sound, and the cable.
steer and drive functions operate. Replace the 21 Securely install the connector of the ECM cable
down limit switch. into the platform control cable.
14 Press and hold the high or low speed lift enable 22 Working at the platform, securely install the
button. connector of the platform controls into the
15 Press the platform up button. Raise the platform platform control cable.
approximately 12 inches / 0.3 m. 23 Enable the down limit switch. Loosen the
Result: The ground controls LCD displays fastener securing the roller arm to the limit
"PHS: POTHOLE GUARDS STUCK" and the switch, and rotate the roller arm 90 degrees in
platform controls LED displays "PHS". The a upwards direction. Do not activate the switch
alarm sounds. The machine is functioning contacts.
properly. 24 Turn the key switch to platform control.
Result: The ground controls LCD does not 25 Raise the platform and return the safety arm to
display "PHS: POTHOLE GUARDS STUCK" the stowed position.
and the platform controls LED does not display
"PHS". The alarm does not sound. Replace the 26 Lower the platform to the stowed position.
down limit switch.

3 - 24 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 3 Scheduled Maintenance Procedures

CHECKLIST B PROCEDURES

Level Sensor 30 Standing on the up-hill side of the machine,


press and hold the drive/steer function enable
27 Move the machine onto a grade which exceeds switch on the control handle. Attempt to drive
the rating of the level sensor. Refer to the serial and steer the machine.
label on the machine.
Result: The ground controls LCD displays
28 Standing on the up-hill side of the machine, "LL: MACHINE TILTED" and the platform
press and hold the high or low speed lift enable controls LED displays "LL". The alarm sounds,
button. and the machine will not steer or drive. The
29 Press the platform up button and attempt machine is functioning properly.
to raise the platform to approximately Result: The ground controls LCD does not
8 feet / 2.4 m. display "LL: MACHINE TILTED" and the
Result: The ground controls LCD displays platform controls LED does not display "LL".
"LL: MACHINE TILTED" and the platform The alarm does not sound and the steer and
controls LED displays "LL". The alarm sounds drive functions operate. Adjust or replace the
and the platform stops lifting after the pothole level sensor.
guards are deployed. The machine is 31 Lower the platform to the stowed position. Move
functioning properly. Refer to the Operation the machine onto a firm, level surface.
Indicator Codes below.
Result: The ground controls LCD does not
display "LL: MACHINE TILTED" and the
platform controls LED does not display "LL".
The alarm does not sound and the platform
continues to lift after the pothole guards are
deployed. Adjust or replace the level sensor.

LCD display

LED display

Part No. 228901 GS-30 GS-32 GS-46 GS-47 3 - 25


Section 3 Scheduled Maintenance Procedures January 2012

CHECKLIST B PROCEDURES

Pothole Limit Switches 35 Press and hold the drive/steer function enable
switch on the control handle. Attempt to drive
32 Place a wooden block approximately and steer the machine.
2 inches / 5 cm tall under the right pothole
guard. Result: The ground controls LCD displays
"PHS: POTHOLE GUARDS STUCK" and the
33 Press and hold the high or low speed lift enable platform controls LED displays "PHS". The
button. alarm sounds, and the machine will not steer or
34 Press the platform up button and attempt drive. The machine is functioning properly.
to raise the platform to approximately Result: The ground controls LCD does not
8 feet / 2.4 m. display "PHS: POTHOLE GUARDS STUCK"
Result: The pothole guard contacts the block and the platform controls LED does not display
and does not fully deploy. The ground controls "PHS". The alarm does not sound and the steer
LCD displays "PHS: POTHOLE GUARDS and drive functions operate. Adjust or replace
STUCK" and the platform controls LED displays the down limit switch.
"PHS". The alarm sounds and the platform will 36 Lower the platform to the stowed position and
lift to 8 feet / 2.4 m or beyond. The machine is remove the block under the right pothole guard.
functioning properly. Refer to the Operation
Indicator Codes below. 37 Repeat this procedure beginning with step 33
for the left pothole guard.
Result: The pothole guard contacts the block
and does not fully deploy. The ground controls 38 Lower the platform to the stowed position,
LCD does not display "PHS: POTHOLE remove the block under the left pothole guard.
GUARDS STUCK" and the platform controls 39 Turn off the machine.
LED does not display "PHS". The alarm does
not sound and the machine will continue to lift
the platform after the pothole guards are
deployed. Adjust or replace the pothole limit
switch.

LCD display

LED display

3 - 26 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 3 Scheduled Maintenance Procedures

CHECKLIST B PROCEDURES

B-17 Maximum Drive Height Limit Switches


(if equipped)
Test the
Up Limit Switch (if equipped) and 5 Lower the platform onto the safety arm.

the Maximum Drive Height Limit 6 While raising the platform from the ground
controls and working with the maximum drive
Switches (if equipped) height limit switch at the battery side of the
machine, push the arm of the maximum drive
height limit switch towards the steer end of the
machine to activate the limit switch.
Genie requires that this procedure be performed
Result: The platform stops raising. The machine
every 250 hours or quarterly, whichever comes
is functioning properly.
first.
Result: The platform continues to raise. Adjust
Maintaining the limit switches is essential to safe or replace the maximum drive height limit
operation and good machine performance. switch.
Operating the machine with a faulty limit switch
Note: Repeat this procedure for the maximum
could result in reduced machine performance and
drive height limit switch at ground controls side of
a potentially unsafe operating condition.
the machine.
Perform these procedures with the machine on a
firm, level surface that is free of obstructions. 7 Return the safety arm to the stowed position.

Up Limit Switch (if equipped) 8 Lower the platform to the stowed position and
turn off the machine.
1 Turn the key switch to ground control and raise
the platform approximately 8 feet / 2.4 m from
the ground.
2 Rotate the safety arm away from the machine
and let it hang down.
3 Lower the platform onto the safety arm.
Crushing hazard. Keep hands
clear of the safety arm when
lowering the platform.
4 While raising the platform from the ground
controls, push the arm of the up limit switch
towards the steer end of the machine to
activate the limit switch.
Result: The platform stops raising. The machine
is functioning properly.
Result: The platform continues to raise. Adjust
or replace the up limit switch.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 3 - 27


Section 3 Scheduled Maintenance Procedures June 2012

Checklist C Procedures
C-1 Pressure Transducer
Test the Platform Overload 6 Working at the barrel end of the lift cylinder,
Pressure Transducer and follow the pressure transducer cable down the
scissor stack to its end point, at the chassis
Platform Height Sensor deck.
(if equipped) 7 Using the positive post of a multimeter probe,
securely fit the post into pin C of the pressure
transducer cable rubber boot. Refer to the
illustration below.
Genie specifications require that this procedure be 8 Using the negative post of a multimeter probe,
performed every 500 hours or six months, securely fit the post into pin B of the pressure
whichever comes first OR when the machine fails transducer cable rubber boot. Refer to the
to lift the maximum rated load. illustration below.
Testing the platform overload pressure transducer
and platform height sensor regularly is essential
to safe machine operation. Continued use of an
improperly operating platform overload pressure
transducer or platform height sensor, could result
in the system not sensing an overloaded platform
condition. Machine stability could be compromised
resulting in the machine tipping over.

Note: Perform this procedure with the machine on


a firm, level surface the is free of obstructions.
9 Turn the key switch to ground control and pull
1 Turn the key switch to ground control and pull out the red Emergency Stop button to the on
out the red Emergency Stop button to the on position.
position at both the ground and platform 10 Using the multimeter, measure the voltage
controls. reading of the pressure transducer at pin
2 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. C and B.

3 Lift the safety arm, move it to the center of the GS-1532, GS-1932, GS-2032, GS-2632, GS-2046,
scissor arm and rotate down to a vertical GS-2646 and GS-3246
position.
Result: The voltage reading of the pressure
4 Lower the platform onto the safety arm. transducer is between 1V and 5V. The pressure
transducer is functioning properly.
Crushing hazard. Keep hands
clear of the safety arm when Result: The voltage reading of the pressure
lowering the platform. transducer is between 0V and 1V. The pressure
transducer is not functioning properly. Replace
5 At the ground control, turn the key switch to the the pressure transducer. Refer to Repair
off position and push in the red Emergency Procedure 9-9, How to Remove the Pressure
Stop button to the off position. Transducer (if equipped).

3 - 28 GS-30 GS-32 GS-46 GS-47 Part No. 228901


June 2012 Section 3 Scheduled Maintenance Procedures

CHECKLIST C PROCEDURES

GS-3232 and GS-4047 16 Turn the key switch to ground control and pull
out the red Emergency Stop button to the on
Result: The voltage reading of the pressure position.
transducer is between 0.2V and 6.25V. The
pressure transducer is functioning properly. 17 Using the multimeter, measure the voltage
reading of the pressure transducer at pin
Result: The voltage reading of the pressure C and B.
transducer is between 0V and 0.2V or greater
than 6.25V. The pressure transducer is not Result: The voltage reading of the platform
functioning properly. Replace the pressure height sensor is between 1V and 4V. The
transducer. Refer to Repair Procedure 9-5, platform height sensor is functioning properly.
How to Remove the Pressure Transducer (if
Result: The voltage reading of the platform
equipped). height sensor is 0V or above 5V. The platform
11 At the ground control, turn the key switch to the height sensor is not functioning properly.
off position and push in the red Emergency Replace the platform height sensor. Refer to
Stop button to the off position. Repair Procedure 9-7, How to Disassemble the
Platform Height Sensor Assembly (if equipped).
12 Remove the probes from the rubber boot of the
pressure transducer cable. 18 At the ground control, turn the key switch to the
off position and push in the red Emergency
Platform Height Sensor Stop button to the off position.
13 Working at platform height sensor assembly, 19 Remove the probes from the rubber boot of the
follow the platform height sensor cable to its platform height sensor cable.
end point at the chassis deck.
20 Turn the key switch to ground control and pull
14 Using the positive post of a multimeter probe, out the red Emergency Stop button to the on
securely fit the post into pin C of the platform position.
height sensor cable rubber boot. Refer to the
illustration below. 21 Raise the platform 12 inches / 30.5 cm.

15 Using the negative post of a multimeter probe, 22 Return the safety arm to the stowed position.
securely fit the post into pin B of the platform 23 Lower the platform to the stowed position.
height sensor cable rubber boot. Refer to the
illustration below. 24 Turn the key switch to the off position.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 3 - 29


Section 3 Scheduled Maintenance Procedures June 2012

CHECKLIST C PROCEDURES

C-2 The overload pressure transducer, located at the


barrel-end of the lift cylinder, is used to determine
Calibrate the Platform Overload the pressure inside the lift cylinder.
System (if equipped)
The platform height sensor, located at the steer
end of the chassis, battery side, is used to
determine the height of the platform.

Genie specifications require that this procedure be The overload pressure transducer and the platform
performed every 500 hours or six months, height sensor provide the ECM with necessary
whichever comes first OR when the machine fails information to determine the load in the platform.
to lift the maximum rated load. Note: The overload system will not measure loads
Calibrating the platform overload system regularly at, or below the height of the Down Limit Switch.
is essential to safe machine operation. Continued Refer to Repair Procedure 9-10, How to Calibrate
use of an improperly operating platform overload the Platform Overload System (if equipped).
system could result in the system not sensing an
overloaded platform condition. Machine stability
could be compromised resulting in the machine
tipping over.

The platform overload system is designed to


prevent machine operation in the event the
platform is overloaded. Models equipped with the
platform overload option are provided with two
additional machine control components: the
overload pressure transducer and the platform
height sensor.

a overload pressure transducer


b platform height sensor

3 - 30 GS-30 GS-32 GS-46 GS-47 Part No. 228901


June 2012 Section 3 Scheduled Maintenance Procedures

CHECKLIST C PROCEDURES

C-3
Replace the Hydraulic Tank
Breather Cap - Models with
Optional Hydraulic Oil

Genie requires that this procedure be performed


every 500 hours or semi-annually, whichever
comes first.
The hydraulic tank is a vented-type tank. The
breather cap has an internal air filter that can
become clogged or, over time, can deteriorate. If
the breather cap is faulty or improperly installed,
impurities can enter the hydraulic system which
may cause component damage. Extremely dirty
conditions may require that the cap be inspected
more often.

1 Remove and discard the hydraulic tank breather


cap.
2 Install a new cap onto the tank.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 3 - 31


Section 3 Scheduled Maintenance Procedures January 2012

Checklist D Procedures
D-1
Check the Scissor Arm
Wear Pads

Genie requires that this procedure be performed


every 1000 hours or annually, whichever comes
first.
Maintaining the condition of the scissor arm
wearpads is essential to safe machine operation.
Continued use of worn out wear pads may result in
component damage and unsafe operating
conditions.

Note: Perform this procedure with the platform in


the stowed position.

1 Measure the distance between the number one


inner arm cross tube and the chassis deck at
the ground controls side of the non-steer end of
the machine. Refer to illustration 1.
Result: The measurement is Illustration 1
0.90 inch / 22.9 mm or more. Proceed to step 2. a wear pad
b inner arm cross tube
Result: The measurement is less than c chassis deck
0.90 inch / 22.9 mm. Replace both wear pads.
Refer to Repair Procedure 9-1 or 9-2, How to 3 Apply a thin layer of dry film lubricant to the
Replace the Scissor Arm Wear Pads. area of the chassis where the scissor arm wear
pads make contact.
2 Measure the distance between the number one
inner arm cross tube and the chassis deck at
Cross tube to chassis specification
the battery pack side of the non-steer end of
the machine. Refer to illustration 1.
Measurement, minimum 0.90 inch
Result: The measurement is 22.9 mm
0.90 inch / 22.9 mm or more. Proceed to step 3.
Result: The measurement is less than
0.90 inch / 22.9 mm. Replace both wear pads.
Refer to Repair Procedure 9-1 or 9-2, How to
Replace the Scissor Arm Wear Pads.

3 - 32 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 3 Scheduled Maintenance Procedures

CHECKLIST D PROCEDURES

GS-2032, GS-2632, GS-3232, GS-2046, GS-2646,


GS-3246 and GS-4047:
1 Measure the distance between the number one
outer arm cross tube and the fork lift tube at the
ground controls side of the non-steer end of the
machine.
Result: The measurement is
0.88 inch / 22.4 mm or more. Proceed to step 2.
Result: The measurement is less than
0.88 inch / 22.4 mm. Replace both wear pads.
Refer to Repair Procedure 9-3, 9-4, 9-5 or 9-6,
How to Replace the Scissor Arm Wear Pads.
2 Measure the distance between the number one
outer arm cross tube and the fork lift tube at the
battery pack side of the non-steer end of the
machine.
Result: The measurement is
0.88 inch / 22.4 mm or more. Proceed to step 3.
Result: The measurement is less than
0.88 inch / 22.4 mm. Replace both wear pads.
Refer to Repair Procedure 9-3, 9-4, 9-5 or 9-6
How to Replace the Scissor Arm Wear Pads.
3 Apply a thin layer of dry film lubricant to the
area of the chassis where the scissor arm wear
pads make contact.

Cross tube to chassis specification

Measurement, minimum 0.88 inch a outer arm cross tube


22.4 mm b fork lift tube
c wear pad

Part No. 228901 GS-30 GS-32 GS-46 GS-47 3 - 33


Section 3 Scheduled Maintenance Procedures January 2012

CHECKLIST D PROCEDURES

D-2 5 Turn the key switch to ground control and pull


out the red Emergency Stop button to the on
Replace the Hydraulic Tank position at both the ground and platform
Return Filter Element controls.
6 Activate and hold the platform up toggle switch.
7 Inspect the filter and related components to
be sure that there are no leaks.
Genie requires that this procedure be performed
every 1000 hours or annually, whichever comes 8 Clean up any oil that may have spilled.
first.
Torque specifications
Replacement of the hydraulic tank return filter is
essential for good machine performance and Hydraulic tank drain plug, dry 40 in-lbs
service life. A dirty or clogged filter may cause the 4.5 Nm
machine to perform poorly and continued use may Hydraulic tank drain plug, lubricated 30 in-lbs
cause component damage. Extremely dirty 3.4 Nm
conditions may require that the filter be replaced
more often.

Beware of hot oil. Contact with


hot oil may cause severe burns.
Note: The hydraulic tank return filter is mounted on
the function manifold next to the hydraulic power
unit.

1 Clean the area around the oil filter. Remove the


filter with an oil filter wrench.
2 Apply a thin layer of oil to the new oil filter
gasket.
3 Install the new filter and tighten it securely by
hand.
4 Use a permanent ink marker to write the date
and number of hours from the hour meter onto
the filter.

3 - 34 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 3 Scheduled Maintenance Procedures

Checklist E Procedure
E-1 3 Tag and disconnect the hydraulic tank return
hard line from the hydraulic filter head and
Test or Replace the Hydraulic Oil remove the hard line from the tank. Cap the
fitting on the filter head.
4 Tag and disconnect the hydraulic pump inlet
hard line and remove the hard line from the
Genie requires that this procedure be performed tank. Cap the fitting on the pump.
every 2000 hours or every two years, whichever
comes first. 5 Remove the hydraulic tank retaining fasteners
and remove the hydraulic tank from the
Replacement or testing of the hydraulic oil is machine.
essential for good machine performance and
service life. Dirty oil may cause the machine to 6 Drain all of the oil into a suitable container.
perform poorly and continued use may cause Refer to Section 2, Specifications, for capacity
component damage. Extremely dirty conditions information.
may require oil changes to be performed more Bodily injury hazard. Spraying
often. Refer to Section 2, Specifications. hydraulic oil can penetrate and
burn skin. Loosen hydraulic
Before replacing the hydraulic oil, the oil may be
connections very slowly to allow
tested by an oil distributor for specific levels of
the oil pressure to dissipate
contamination to verify that changing the oil is
gradually. Do not allow oil to squirt
necessary.
or spray.
If the hydraulic oil is not replaced at the two
year inspection, test the oil quarterly. Replace 7 Clean up any oil that may have spilled. Properly
the oil when it fails the test. discard the used oil.
Note: Perform this procedure with the platform in 8 Clean the inside of the hydraulic tank using a
the stowed position. mild solvent. Allow the tank to dry completely.

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

Part No. 228901 GS-30 GS-32 GS-46 GS-47 3 - 35


Section 3 Scheduled Maintenance Procedures January 2012

CHECKLIST E PROCEDURE

10 Install the hydraulic pump inlet hard line into the


tank. Install the fitting onto the pump and torque
to specification. Refer to Section 2,
Specifications.
11 Install the hydraulic pump return hard line into
the tank. Install the fitting onto the hydraulic
filter head and torque to specification. Refer to
Section 2, Specifications.
12 Fill the tank with hydraulic oil until the fluid is at
the FULL indicator on the hydraulic tank. Do not
overfill.
13 Activate the pump to fill the hydraulic system
with oil and bleed the system of air.
Component damage hazard. The
pump can be damaged if operated
without oil. Be careful not to empty
the hydraulic tank while in the
process of filling the hydraulic
system. Do not allow the pump to
cavitate.
14 Repeat steps 12 through 13 until the hydraulic
system and tank are both full.

3 - 36 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 4 Repair Procedures

Repair Procedures
About This Section
Most of the procedures in this section should only
be performed by a trained service professional
in a suitably equipped workshop. Select the
appropriate repair procedure after troubleshooting
the problem.
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 symbolused 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

Part No. 228901 GS-30 GS-32 GS-46 GS-47 4-1


Section 4 Repair Procedures January 2012

Platform Controls
The platform controls are used to operate the Operational Indicator Codes
machine from the platform.
These codes are generated by the electrical
Activating a function button sends a signal to the system to indicate machine operating status.
Electronic Control Module (ECM). When the ECM During normal operation a code will appear in the
is in the function mode, the platform controls are platform controls LED readout if a condition such
used to operate the various machine functions. as off-level, overload cutout, chassis mode
The platform controls consist of an Emergency operation or pothole guards stuck occurs.
Stop button, electronic circuit board, proportional If the platform controls LED readout displays an
control handle, drive/steer enable switch, alarm, operational indicator code such as LL, the fault
function buttons and LED display. condition must be repaired or removed before
For further information or assistance, consult the resuming machine operation. Push in and pull out
Genie Service Department. the red Emergency Stop button to reset the
system.

Platform Controls LED Readout

Code Condition

LL Off-Level

OL Platform Overloaded (CE and Australia)

CH Chassis Mode Operation

PHS Pothole Guard Stuck


a red Emergency Stop button P2
b platform controls circuit board U3 nd No Drive (option)
c proportional control handle and
drive/steer enable switch JC9 Ld Lifting Disabled (GS-3232 only)
d alarm H1

Note: A code and a description of a code can also


be viewed at the ground controls LCD display.

4-2 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 4 Repair Procedures

PLATFORM CONTROLS

1-1 9 Carefully remove the platform controls circuit


board fasteners.
Circuit Board
10 Carefully remove the platform controls circuit
board from the platform control box.
How to Remove the Platform
Controls Circuit Board 11 Remove the transparent caps from the platform
controls circuit board and save.
1 Push in the red Emergency Stop button to the
off position at both the ground and platform Circuit board fastener torque specifications
controls. Hand tighten until screw seats < 5 in-lbs
2 Disconnect the platform controls from the < 0.6 Nm
control cable at the platform.
3 Remove the fasteners securing the platform Note: Before installing a circuit board, place the
control box to the platform control bracket. transparent caps removed in step 11, over the
circuit board buttons.
4 Remove the fasteners securing the bottom
cover to the platform control box. Open the Note: After installing the circuit board, check for
control box. proper button operation. Excessive torque of the
circuit board fasteners will cause the buttons to
5 Remove the ties securing the wire harness. bind. Moderate torque of the circuit board fasteners
6 Disconnect the red and black wires from the will not allow the buttons to engage.
alarm.
7 Carefully remove the alarm from the platform
control box.
8 Carefully disconnect all wire harness
connectors from the platform controls circuit
board.
Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
Component damage hazard.
Electrostatic discharge (ESD) can
damage printed circuit board
components. Maintain firm contact
with a metal part of the machine
that is grounded at all times when
handling printed circuit boards OR
use a grounded wrist strap.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 4-3


Section 4 Repair Procedures January 2012

PLATFORM CONTROLS

1-2 1-3
Joystick Platform Controls Alarm

How to Remove the Joystick How to Remove the Platform


1 Push in the red Emergency Stop button to the Controls Alarm
off position at both the ground and platform 1 Push in the red Emergency Stop button to the
controls. off position at both the ground and platform
2 Disconnect the platform controls from the controls.
control cable at the platform. 2 Disconnect the platform controls from the
3 Remove the fasteners securing the platform control cable at the platform.
control box to the platform control bracket. 3 Remove the fasteners securing the platform
4 Remove the fasteners securing the bottom control box to the platform control bracket.
cover to the platform control box. Open the 4 Remove the fasteners securing the bottom
control box. cover to the platform control box. Open the
5 Remove the ties securing the joystick wire control box.
harness. 5 Disconnect the red and black wires from the
6 Carefully disconnect the joystick wire harness alarm.
from the platform controls circuit board. Electrocution/burn hazard. Contact
Electrocution/burn hazard. Contact with electrically charged circuits
with electrically charged circuits could result in death or serious
could result in death or serious injury. Remove all rings, watches
injury. Remove all rings, watches and other jewelry.
and other jewelry. Component damage hazard.
Component damage hazard. Electrostatic discharge (ESD) can
Electrostatic discharge (ESD) can damage printed circuit board
damage printed circuit board components. Maintain firm contact
components. Maintain firm contact with a metal part of the machine
with a metal part of the machine that is grounded at all times when
that is grounded at all times when handling printed circuit boards OR
handling printed circuit boards OR use a grounded wrist strap.
use a grounded wrist strap. 6 Carefully remove the alarm from the platform
7 Carefully remove the joystick fasteners. control box.

8 Carefully remove the joystick from the platform


control box.

Torque specifications
Joystick fasteners 9 in-lbs
1 Nm

4-4 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 4 Repair Procedures

PLATFORM CONTROLS

1-4 6 Carefully remove the Emergency Stop base


from the Emergency Stop button.
Platform Emergency Stop Button
7 Carefully remove the retaining ring from the
Emergency Stop button.
How to Remove the Platform
Controls Emergency Stop Button 8 Carefully remove the Emergency Stop button
from the platform control box.
1 Push in the red Emergency Stop button to the
off position at both the ground and platform
controls.
2 Disconnect the platform controls from the
control cable at the platform.
3 Remove the fasteners securing the platform
control box to the platform control bracket.
4 Remove the fasteners securing the bottom
cover to the platform control box. Open the
control box.
5 Disconnect the white wires from the Emergency
Stop base.
Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
Component damage hazard.
Electrostatic discharge (ESD) can
damage printed circuit board
components. Maintain firm contact
with a metal part of the machine
that is grounded at all times when
handling printed circuit boards OR
use a grounded wrist strap.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 4-5


Section 4 Repair Procedures January 2012

Ground Controls
The ground controls, used to operate the machine
from the ground, can also be used to tune the
performance of the machine.
The ground controls consist of an Electronic
Control Module (ECM), emergency stop button,
key switch and circuit breaker.

Activating the function enable button and the up


or down at the same time, sends a signal to the
(ECM). This allows the platform to be raised or
lowered at the ground controls.

Note: Steer and drive functions are not available at


the ground controls.
When the ECM is in the set up mode, the ground
controls are used to adjust the function speed
parameters, machine models, or machine options.
a machine setup, escape button
For further information or assistance, consult the b machine setup, scroll up button
c LCD readout
Genie Service Department. d machine setup, scroll down button
e machine setup, enter button
f key switch KS1
g red Emergency Stop P1
h circuit breaker CB2
i ECM U5
j platform down button
k lift function enable button
l platform up button

4-6 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 4 Repair Procedures

GROUND CONTROLS

2-1 2 Press the ground control scroll down button.


Software Revision Level Result: The ground control LCD display will
indicate the software revision and hour meter
information. After 5 seconds, the ground
How to Determine the controls LCD display will display machine
Software Revision Level model and hour meter information again.
See example below.
The machine software revision level is displayed at
the ground controls LCD display.

1 Turn the key switch to the ground controls or


platform controls position. Pull out the red
Emergency Stop button to the on position at
both ground and platform controls. 3 Push in the red Emergency Stop button to the
Result: The display at the platform controls will off position at both the ground and platform
show "CH". See example below. controls and turn the key switch to the off
position.

Result: The display at the ground controls will


show the machine model and hour meter
information. After 3 seconds, the machine
model will not show on the display. See
example below.
a ground control LCD display
b ground control scroll down button

Part No. 228901 GS-30 GS-32 GS-46 GS-47 4-7


Section 4 Repair Procedures January 2012

GROUND CONTROLS

2-2 1 Turn the key switch to the ground controls


position and pull out the red Emergency Stop
Machine Setup button to the on position at the platform
controls.
How to Setup the Machine from 2 Press and hold the ground control scroll up and
Ground Controls scroll down buttons.
The ground controls can be used to setup the
machine parameters from the ground. Features
that can be adjusted from the ground controls
include machine Model, Options and Speed setup.
This menu can only be entered from ground
controls with the key switch in the ground controls
position.

Tip-over hazard. Do not adjust


function speeds higher than
specified in this procedure. Setting
the function speeds greater than Ground Control Menu Buttons
specifications could cause the
machine to tip over resulting in a scroll down button
b enter button
death or serious injury. c scroll up button
d escape button
Tip-over hazard. This procedure e LCD display
must only be performed by a
trained service professional. 3 Pull out the red Emergency Stop button to the
Attempting this procedure without on position at the ground controls.
the necessary skills could result in
Result: The ground controls LCD display will
death or serious injury.
show the following:
Note: Select a test area that is firm, level and free
of obstructions.

4 Use the ground control menu buttons to select


machine Model, Options and Speed Setup
parameters. Follow the menu structure
indicated on the ground control LCD display.

4-8 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 4 Repair Procedures

GROUND CONTROLS

2-3 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

How to Adjust the Manual


b
Platform Lowering Cable
1 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
c
2 Lift the safety arm, move it to the center of the
scissor arm and rotate down to a vertical d
position.
3 Lower the platform onto the safety arm.
e
Crushing hazard. Keep hands
clear of the safety arm when
lowering the platform. f
4 Pull the handle of the manual platform lowering
cable out until considerable resistance is felt.
Release the handle. Y7 N g

5 Measure the distance between the base of the


handle and cable mounting nut. a manual lowering cable sheath
b upper lock nut
Result: The measurement should be no greater c cable mounting bracket
than 1/8 inch / 3 mm. d lower lock nut
e cable mounting nut
f end of the lowering cable
g manual lowering valve
(hydraulic schematic item N)

7 Repeat this procedure beginning with step 4.


8 Raise the platform and rotate the safety arm to
the stowed position.
9 Pull the manual lowering handle at the ground
controls 2 to 3 times to ensure it is functioning
correctly.

Platform manual lowering cable specification

Gap, lowering handle to mounting nut 0 to 1/8 inch


0 to 3 mm

Part No. 228901 GS-30 GS-32 GS-46 GS-47 4-9


Section 4 Repair Procedures January 2012

GROUND CONTROLS

2-4 If you are not installing a new level sensor,


proceed to step 15.
Level Sensors
7 Turn the key switch to the off position and push
The Electronic Control Module (ECM) is in the red Emergency Stop button to the off
programmed to deactivate the lift and drive position at the ground controls.
functions and activate an alarm when a signal is
8 Tag and disconnect the level sensor wire
received from the level sensor.
harness from the chassis wire harness.
The tilt alarm sounds when the incline of the Note: The wire harness connection is located next
chassis exceeds 1.5 to the side and 3 to the front to the level sensor, on top of the chassis at the
or rear. steer end of the machine.
How to Install and Calibrate the 9 Remove the level sensor retaining fasteners.
1.5 Level Sensor Remove the level sensor from the machine.
10 Tag and disconnect the level sensor wires from
Tip-over hazard. Failure to install
the level sensor connector plug.
or calibrate the level sensor as
instructed will compromise 11 Securely install the wires of the new level
machine stability and cause the sensor into the level sensor connector plug.
machine to tip over, resulting in
death or serious injury. Do not 12 Place the new level sensor onto the level
install or calibrate the level sensor sensor mount bracket with the "X" on the level
other than specified in this sensor base closest to the long side of the level
procedure. sensor mount, and the "Y" on the level sensor
base closest to the short side of the level
1 Move the machine to an area that has a firm, sensor mount.
level surface and is free of obstructions.
Tip-over hazard. The level sensor
2 Remove the platform controls from the platform. must be installed with the "X" on
the level sensor base closest to
3 Turn the key switch to platform control and pull
the long side of the tilt level sensor
out the red Emergency Stop button to the on
box, and the "Y" on the level
position at both the ground and platform
sensor base closest to the short
controls.
side of the tilt level sensor box.
4 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. Failure to install the level sensor
as instructed, could result in the
5 Lift the safety arm, move it to the center of the
machine tipping over, causing
scissor arm and rotate down to a vertical
death or serious injury.
position.
6 Lower the platform onto the safety arm.
Crushing hazard. Keep hands
clear of the safety arm when
lowering the platform.

4 - 10 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 4 Repair Procedures

GROUND CONTROLS

13 Install the level sensor retaining fasteners Steer end


through the level sensor and springs, and into
the mount bracket. Tighten the fasteners and
a
measure the distance between the level sensor
and the level sensor mount bracket.
f b
Y
Result: The measurement should be X

approximately 3/8 inch / 10 mm. e


c
14 Connect the chassis wire harness to the level
sensor wire harness.
15 Turn the key switch to the ground control and
d
pull out the red Emergency Stop button to the
on position at the ground controls.
16 Adjust the level sensor retaining fasteners until
the bubble at the top of the level sensor is
centered in the circles.
Result: The tilt sensor alarm should not sound.
17 Raise the platform slightly.
18 Return the safety arm to the stowed position.
19 Lower the platform to the stowed position.
20 Center a lifting jack under the drive chassis at Non-steer end
the ground controls side of the machine.
a limit switch
21 Raise the machine approximately b level sensor mount bracket
2 inches / 5 cm. c level sensor S7
d alarm H5
e level sensor retaining fastener
f scissor chassis

Part No. 228901 GS-30 GS-32 GS-46 GS-47 4 - 11


Section 4 Repair Procedures January 2012

GROUND CONTROLS

22 GS-1530 and GS-1930: Place a 0.64 x 6 x 6 31 GS-1530 and GS-1930: Place a 0.77 x 6 x 6
inch / 16.2 mm x 15 cm x 15 cm thick steel inch / 19.6 mm x 15 cm x 15 cm thick steel
block under both wheels at the ground controls block under both wheels at the battery pack
side of the machine. side of the machine.
GS-1532 and GS-1932: Place a 0.68 x 6 x 6 GS-1532 and GS-1932: Place a 0.83 x 6 x 6
inch / 17.2 mm x 15 cm x 15 cm thick steel inch / 21.1 mm x 15 cm x 15 cm thick steel
block under both wheels at the ground controls block under both wheels at the battery pack
side of the machine. side of the machine.
GS-2032, GS-2632 and GS-3232: Place a 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 0.8 x 6 x 6 inch / 20.3 mm x 15 cm x 15 cm
thick steel block under both wheels at the thick steel block under both wheels at the
ground controls side of the machine. battery pack side of the machine.
GS-2046, GS-2646, GS-3246 and GS-4047: GS-2046, GS-2646, GS-3246 and GS-4047:
Place a 1 x 6 x 6 inch / 25.4 mm x 15 cm x 15 Place a 1.22 x 6 x 6 inch / 31 mm x 15 cm x 15
cm thick steel block under both wheels at the cm thick steel block under both wheels at the
ground controls side of the machine. battery pack side of the machine.
23 Lower the machine onto the blocks. 32 Lower the machine onto the blocks.
24 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. 33 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
Result: The level sensor alarm should not Result: The platform should stop, an alarm
sound. should sound and fault code LL appears in the
diagnostic display.
Result: The level sensor alarm does sound and
fault code LL appears in the diagnostic display. Result: The platform does not stop or the level
Adjust the level sensor retaining fasteners just sensor alarm does not sound. Adjust the level
until the level sensor alarm does not sound. sensor until the alarm just begins to sound OR
the down limit switch may need to be adjusted.
25 Lower the platform to the stowed position.
34 Lift the safety arm, move it to the center of the
26 Raise the machine approximately
scissor arm and rotate down to a vertical
2 inches / 5 cm.
position.
27 Remove the blocks from under both wheels.
35 Lower the scissor arms onto the safety arm.
28 Lower the machine and remove the jack.
Crushing hazard. Keep hands
29 Center a lifting jack under the drive chassis at clear of the safety arm when
the battery pack side of the machine. lowering the platform.
30 Raise the machine approximately 36 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
2 inches / 5 cm.
37 Return the safety arm to the stowed position.
38 Lower the platform to the stowed position.
39 Raise the machine approximately
2 inches / 5 cm.
40 Remove the blocks from under both wheels.
41 Lower the machine and remove the jack.

4 - 12 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 4 Repair Procedures

GROUND CONTROLS

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.
3 Open the access door at the battery side of the Illustration 1
machine. 7 Secure the outrigger level sensor onto the base
4 Tag and disconnect the outrigger level sensor with the retaining fasteners removed in step 5.
wire harness from the outrigger level sensor. 8 Adjust the outrigger level sensor retaining
5 Remove the outrigger level sensor retaining fasteners until the bubble in the top of the level
fasteners and remove the outrigger level sensor sensor is centered in the circles.
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 2-5, How to Calibrate the Outrigger
System.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 4 - 13


Section 4 Repair Procedures January 2012

GROUND CONTROLS

2-5 10 Use the Menu Up or Menu Down buttons to


scroll to Calibrate Outriggers.
Outrigger Calibration
11 Press the Enter button to select Calibrate
The Electronic Control Module (ECM) is Outriggers.
programmed to deactivate the drive and steer 12 Press and hold the Enter button while the
functions while the outriggers are deployed and system gathers data to calibrate the outrigger
activate an alarm when a signal is received from level sensor.
the outrigger level sensor, indicating the outriggers
are not deployed or the machine is out of level. Crushing hazard. Keep body parts
away from outriggers during
The ECM is also used to calibrate the outrigger outrigger movement.
level sensor to achieve a levelness of 0 +/- 0.5
front to back and side to side, while the outriggers 13 Continue holding the Enter button after the
are deployed. outrigger level sensor is calibrated. The
outriggers will retract while the outrigger system
For further information or assistance, consult the gathers and saves data.
Genie Industries Service Department.
14 Continue holding the Enter button after the
How to Calibrate the Outrigger outriggers retract. The outriggers will now
extend and the system will gather and save
System data to calibrate the outriggers.
1 Move the machine to a firm level surface that 15 Continue holding the Enter button after the
is free of obstructions. Use a digital level to outriggers extend. The outriggers will now
confirm. retract while the outrigger system gathers and
2 Turn the key switch to ground control. saves data.

3 At the ground controls, press and hold the Result: The alarms at the ground and platform
Menu Up and Menu Down buttons. controls should sound for 1 second. The
outrigger system is calibrated.
4 While pressing both buttons down, pull out the
red Emergency Stop Button. Note: After installing a new outrigger level sensor,
the new outrigger level sensor must be calibrated
5 Release the Menu Up and Menu Down buttons following this procedure.
after the ground controller powers up.
6 Use the Menu Up or Menu Down buttons to
scroll to Machine Options.
7 Press the Enter button to select Machine
Options.
8 Use the Menu Up or Menu Down buttons to
scroll to Outriggers.
9 Press the Enter button to select Outriggers.

4 - 14 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 4 Repair Procedures

Hydraulic Tank
3-1 2 Tag and disconnect the hydraulic tank return
hard line from the filter. Remove the hard line
Hydraulic Tank from the machine. Cap the fitting on the filter
head.
The primary functions of the hydraulic tank are to
cool and deaerate the hydraulic fluid during 3 Tag and disconnect the hydraulic tank hard line
operation. It utilizes internal suction strainers for from the pump. Remove the hard line from the
the pump supply lines and has an external return machine. Cap the fitting on the pump.
line filter. 4 Remove the hydraulic tank retaining fasteners
and remove the hydraulic tank from the
How to Remove the machine.
Hydraulic Tank Bodily injury hazard. Spraying
Component damage hazard. The hydraulic oil can penetrate and
work area and surfaces where this burn skin. Loosen hydraulic
procedure will be performed must connections very slowly to allow
be clean and free of debris that the oil pressure to dissipate
could get into the hydraulic gradually. Do not allow oil to squirt
system. or spray.

When removing a hose assembly or fitting, the 5 Remove the hydraulic tank cap and drain the
fitting and/or hose end must be torqued to tank into a suitable container.
specification during installation.
Refer to Section 2, Hydraulic Hose and Fitting Torque specifications
Torque Specifications. Hydraulic tank retaining fasteners, dry 35 in-lbs
4 Nm
Perform this procedure with the platform in the
stowed position. Hydraulic tank retaining fasteners, lubricated 26 in-lbs
2.9 Nm
1 Disconnect the battery pack from the machine.
Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 4 - 15


Section 4 Repair Procedures January 2012

Hydraulic Pump
4-1 4 Activate the platform up function from the
ground controls.
Function Pump
Result: If the pressure gauge reads
The hydraulic pump is attached to the motor which 3200 psi / 221 bar, immediately stop. The pump
makes up the hydraulic power unit. is good.
Result: If pressure fails to reach
How to Test the Hydraulic Pump 3200 psi / 221 bar, the pump is bad and will
When removing a hose assembly or fitting, the need to be serviced or replaced.
fitting and/or hose end must be torqued to Component damage hazard.
specification during installation. There is no relief valve in the
Refer to Section 2, Hydraulic Hose and Fitting hydraulic pump and the pump can
Torque Specifications. be damaged if the pressure is
allowed to exceed
1 Tag, disconnect and plug the high pressure
3200 psi / 221 bar. When testing
hydraulic hose from the hydraulic pump.
the pump, activate the pump in
Bodily injury hazard. Spraying one second intervals until
hydraulic oil can penetrate and 3200 psi / 221 bar is confirmed.
burn skin. Loosen hydraulic Do not over-pressurize the pump.
connections very slowly to allow
5 Remove the pressure gauge and reconnect the
the oil pressure to dissipate
hydraulic hose. Torque to specification.
gradually. Do not allow oil to squirt
or spray. Bodily injury hazard. Spraying
hydraulic oil can penetrate and
2 Connect a 0 to 5000 psi / 0 to 350 bar pressure
burn skin. Loosen hydraulic
gauge to the high pressure port on the pump.
connections very slowly to allow
3 Turn the key switch to ground control and pull the oil pressure to dissipate
out the red Emergency Stop button to the on gradually. Do not allow oil to squirt
position at both the ground and platform or spray.
controls.

4 - 16 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 4 Repair Procedures

HYDRAULIC PUMP

How to Remove the 6 Tag, disconnect and plug the high pressure
hose at the pump. Cap the fitting on the pump.
Hydraulic Pump
Bodily injury hazard. Spraying
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.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 4 - 17


Section 4 Repair Procedures January 2012

Manifolds
5-1
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

How to Install a Valve Cartridge


1 Dip the cartridge in clean oil to lube the O-rings.
2 Screw the cartridge in by hand until the top
O-ring is met, then torque to specification.
3 If required, install the valve coil(s) onto the
valve stem. Install the coil nut onto the valve
stem and torque to specification.

4 - 18 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 4 Repair Procedures

MANIFOLDS

Part No. 228901 GS-30 GS-32 GS-46 GS-47 4 - 19


Section 4 Repair Procedures January 2012

MANIFOLDS

5-2
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 valve (GS-3232 and GS-3246
with load sense installed) .......................... AD ...................... Lift ........................................... 23 ft-lbs / 31 Nm
5 Check disc ................................................. AE ...................... Steer circuit ............................ 18 ft-lbs / 24 Nm
6 Solenoid valve, 2 position 4 way ............... AF ....................... Drive speed select circuit ....... 25 ft-lbs / 34 Nm
7 Relief valve ................................................ AG ...................... Brake release ......................... 20 ft-lbs / 27 Nm
8 Solenoid valve, 3 position 5 way ............... AH ...................... Drive forward/reverse ............. 25 ft-lbs / 34 Nm
9 Flow regulator and relief valve,
0.75 gpm / 2.8 L/min,
1500 psi / 103 bar ...................................... AI ........................ Steer circuit ............................ 26 ft-lbs / 35 Nm
10 Solenoid valve, 2 position 4 way ............... AJ ....................... Platform up ............................. 25 ft-lbs / 34 Nm
11 Relief valve,
1800 to 3700 psi / 124 to 255 bar ............. AK ...................... Lift relief .................................. 20 ft-lbs / 27 Nm

How to Install a Valve Cartridge


1 Dip the cartridge in clean oil to lube the O-rings.
2 Screw the cartridge in by hand until the top
O-ring is met, then torque to specification.
3 If required, install the valve coil(s) onto the
valve stem. Install the coil nut onto the valve
stem and torque to specification.

4 - 20 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 4 Repair Procedures

MANIFOLDS

Part No. 228901 GS-30 GS-32 GS-46 GS-47 4 - 21


Section 4 Repair Procedures January 2012

MANIFOLDS

5-3
Function Manifold Components -
GS-4047
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 DC) ................................................................................................................. 4-5 ft-lbs / 5-7 Nm
Coil nut (items DE, DG and DI) ............................................................................................ 5-7 ft-lbs / 7-9 Nm
1 Diagnostic nipple ....................................... DA ...................... Testing
2 Relief valve,
3500 psi / 241 bar maximum ..................... DB ...................... System relief ........................... 20 ft-lbs / 27 Nm
3 Solenoid valve, 3 position 4 way ............... DC ...................... Steer left/right ......................... 25 ft-lbs / 34 Nm
4 Check disc ................................................. DD ...................... Steer circuit ............................ 18 ft-lbs / 24 Nm
5 Solenoid valve, 2 position 4 way ............... DE ...................... Drive speed select circuit ....... 25 ft-lbs / 34 Nm
6 Relief valve ................................................ DF ...................... Brake release ......................... 20 ft-lbs / 27 Nm
7 Solenoid valve, 3 position 5 way ............... DG ...................... Drive forward/reverse ............. 25 ft-lbs / 34 Nm
8 Flow regulator and relief valve,
0.75 gpm / 2.8 L/min,
1500 psi / 103 bar ...................................... DH ...................... Steer circuit ............................ 26 ft-lbs / 35 Nm
9 Solenoid valve, 2 position 4 way ............... DI ........................ Platform up ............................. 25 ft-lbs / 34 Nm
10 Relief valve,
3000 psi / 207 bar ...................................... DJ ....................... Lift relief .................................. 20 ft-lbs / 27 Nm

How to Install a Valve Cartridge


1 Dip the cartridge in clean oil to lube the O-rings.
2 Screw the cartridge in by hand until the top
O-ring is met, then torque to specification.
3 If required, install the valve coil(s) onto the
valve stem. Install the coil nut onto the valve
stem and torque to specification.

4 - 22 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 4 Repair Procedures

MANIFOLDS

Part No. 228901 GS-30 GS-32 GS-46 GS-47 4 - 23


Section 4 Repair Procedures January 2012

MANIFOLDS

5-4
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

How to Install a Valve Cartridge


1 Dip the cartridge in clean oil to lube the O-rings.
2 Screw the cartridge in by hand until the top
O-ring is met, then torque to specification.
3 If required, install the valve coil(s) onto the
valve stem. Install the coil nut onto the valve
stem and torque to specification.

4 - 24 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 4 Repair Procedures

MANIFOLDS

5-5
Lift Pressure Selector Manifold Components -
GS-4047
The check valve manifold is mounted on the function manifold.
Index Schematic
No. Description Item Function Torque
Coil nut (item DN) ................................................................................................................. 4-5 ft-lbs / 5-7 Nm
Plug ......................................................................................................................................... 13 ft-lbs / 18 Nm
1 Lift pressure selector valve,
200 psi / 138 bar ........................................ DM ...................... Lift relief .................................. 20 ft-lbs / 27 Nm
2 Solenoid valve, 2 position 2 way ............... DN ...................... Lift circuit ................................ 20 ft-lbs / 27 Nm

How to Install a Valve Cartridge


1 Dip the cartridge in clean oil to lube the O-rings.
2 Screw the cartridge in by hand until the top
O-ring is met, then torque to specification.
3 If required, install the valve coil(s) onto the
valve stem. Install the coil nut onto the valve
stem and torque to specification.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 4 - 25


Section 4 Repair Procedures January 2012

MANIFOLDS

5-6
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

Note: 'alpha-numeric' callouts


refer to corresponding notes
on the electrical schematic

BA
1

How to Install a Valve Cartridge


1 Dip the cartridge in clean oil to lube the O-rings.
2 Screw the cartridge in by hand until the top
O-ring is met, then torque to specification.
Note: 'alpha' callouts refer
3 If required, install the valve coil(s) onto the to corresponding notes on
valve stem. Install the coil nut onto the valve the hydraulic schematic

stem and torque to specification.

4 - 26 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 4 Repair Procedures

MANIFOLDS

5-7
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 auto level ............. 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

CA and CB Y35 CC and CD Y33


1 Y36 1 Y34

How to Install a Valve Cartridge


Note: 'alpha-numeric' callouts
1 Dip the cartridge in clean oil to lube the O-rings. refer to corresponding notes
on the electrical schematic

2 Screw the cartridge in by hand until the top


O-ring is met, then torque to specification.
Note: 'alpha' callouts refer
3 If required, install the valve coil(s) onto the to corresponding notes on
valve stem. Install the coil nut onto the valve the hydraulic schematic

stem and torque to specification.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 4 - 27


Section 4 Repair Procedures January 2012

MANIFOLDS

6 Move and hold the joystick fully in either


5-8 direction while observing the pressure reading
Valve Adjustments - on the pressure gauge. Note the pressure.
Function Manifold Refer to Section 2, Specifications.
7 Turn the machine off. Hold the system relief
How to Adjust the valve with a wrench and remove the cap
(schematic item I, AB or DB).
System Relief Valve
8 Adjust the internal hex socket. Turn it clockwise
Perform this test from the ground with the platform to increase the pressure or counterclockwise to
controls. Do not stand in the platform. decrease the pressure.
Be sure that the hydraulic oil level is at the FULL Tip-over hazard. Failure to adjust
mark on the hydraulic tank. the relief valves to specification
1 Locate the system relief valve on the function could result in the machine tipping
manifold (schematic item I). over, causing death or serious
injury. Do not adjust the relief
2 Connect a 0 to 5000 psi / 0 to 350 bar valve pressures higher than
pressure gauge to the test port on the function specifications.
manifold (schematic item A, AA or DA).
9 Install the relief valve cap.
3 Chock both sides of the wheels at the steer end
of the machine. 10 Repeat steps 5 and 6 to confirm the relief valve
pressure.
4 Remove the platform controls from the platform.
a b
5 Turn the key switch to platform control and pull
out the red Emergency Stop button to the on
position at both the ground and platform
controls.

GS-32, GS-46 and GS-47

a test port
b system relief valve
c steer relief valve
d lift relief valve

GS-1530/32 and GS-1930/32

a test port
b system relief valve

4 - 28 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 4 Repair Procedures

MANIFOLDS

How to Adjust the 6 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. 7 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, AB or DB).
mark on the hydraulic tank.
8 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, AA or DA). 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 9 Install the relief valve cap.
out the red Emergency Stop button to the on
position at both the ground and platform 10 Repeat steps 5 and 6 to confirm the relief valve
controls. pressure.
11 Place maximum rated load into the platform.
Secure the load to the platform. Refer to
Section 2, Specifications.

a b

GS-1530/32 and GS-1930/32 c

a test port
GS-32, GS-46 and GS-47
b system relief valve
c lift relief valve a test port
b system relief valve
c steer relief valve
d lift relief valve

Part No. 228901 GS-30 GS-32 GS-46 GS-47 4 - 29


Section 4 Repair Procedures January 2012

MANIFOLDS

12 Turn the key switch to ground control and pull How to Adjust the
out the red Emergency Stop button to the on
position at both the ground and platform Lift Pressure Selector Valve
controls. (GS-4047 only)
13 Hold the lift relief valve with a wrench and Note: The System Relief Valve and Platform Lift
remove the cap (schematic item C). Relief Valve must be adjusted before making and
14 While activating the platform up function, adjust an adjustment to the Lift Pressure Selector Valve.
the internal hex socket clockwise, just until the Refer to How to Adjust the System Relief Valve
platform fully raises. and How to Adjust the Platform Lift Relief Valve in
this section.
15 Fully lower the platform.
Perform this test from the ground with the platform
16 Add an additional 50 pounds / 22.7 kg to the controls. Do not stand in the platform.
platform. Secure the additional weight.
Be sure that the hydraulic oil level is at the FULL
17 Attempt to raise the platform. mark on the hydraulic tank.
Result: The power unit should not be able to lift
1 Locate the pressure selector relief valve on
the platform.
the pressure selector manifold (schematic item
Result: If the power unit lifts the platform, adjust DM).
the internal hex socket counterclockwise until
2 Connect a 0 to 5000 psi / 0 to 350 bar
the platform will not raise.
pressure gauge to the test port on the function
18 Install the relief valve cap. manifold (schematic item DA).
19 Remove the weight from the platform. a b

20 Bleed the hydraulic system by raising the


platform to full height. If the pump cavitates or
the platform fails to reach full height, add
hydraulic oil until the pump is functioning
correctly. Do not overfill the hydraulic tank.
Component damage hazard. Do
d
not continue to operate the
machine if the hydraulic pump is
cavitating.

GS-4047

a test port
b system relief valve
c steer relief valve
d lift relief valve

4 - 30 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 4 Repair Procedures

MANIFOLDS

3 Using a suitable lifting device, place and secure 8 Adjust the internal hex socket. Turn it clockwise
the maximum rated load in the center of the to increase pressure and counterclockwise to
platform deck. decrease pressure.

Maximum load, GS-4047 Tip-over hazard. Failure to adjust


the relief valves to specification
GS-4047 350 kg could result in the machine tipping
over, causing death or serious
injury. Do not adjust the relief
4 Remove the platform controls from the platform. valve pressures higher than
5 Turn the key switch to platform control and pull specifications.
out the red Emergency Stop button to the on 9 Install the relief valve cap.
position at both the ground and platform
controls. 10 Fully lower the platform

6 Press and hold the lift function enable button 11 Using a suitable lifting device, add and secure
and the press the platform up button to raise an additional 150 lbs / 68kg to the platform
the platform 4 ft / 1.2 m above the stowed deck.
position. 12 Raise the platform.
Result: The platform does not raise. Perform Result: The platform does not raise. Proceed to
steps 7 through 10 to increase the pressure in step 13.
small increments until the platform raises. Then
proceed to step 12. Result: The platform raises. Repeat steps 7
through 10 to decrease the pressure in small
Result: The platform raises. Perform steps 7 increments until the platform does not raise.
through 10 to decrease the pressure in small
increments until the platform does not raise. 13 Fully lower the platform and using a suitable
Then follow steps 7 through 10 again to lifting device, remove the weight from the
increase the pressure in small increments until platform.
the platform is able to raise.
7 Turn the machine off. Hold the lift pressure
selector valve with a wrench and remove the
cap (schematic item DM).

GS-4047

a lift pressure selector valve


b solenoid valve

Part No. 228901 GS-30 GS-32 GS-46 GS-47 4 - 31


Section 4 Repair Procedures January 2012

MANIFOLDS

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). 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, AA or
DA) 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, AH or DH).
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.
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

GS-1530/32 and GS-1930/32


d
a test port
b steer relief valve

GS-32, GS-46 and GS-47

a test port
b system relief valve
c steer relief valve
d lift relief valve

4 - 32 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 4 Repair Procedures

MANIFOLDS

5-9 Valve Coil Resistance


Valve Coils Specification
Note: The following coil resistance specifications
How to Test a Coil are at an ambient temperature of 68F / 20C. As
A properly functioning coil provides an valve coil resistance is sensitive to changes in air
electromagnetic force which operates the solenoid temperature, the coil resistance will typically
valve. Critical to normal operation is continuity increase or decrease by 4% for each 18F / -7.7C
within the coil. Zero resistance or infinite that your air temperature increases or decreases
resistance indicates the coil has failed. from 68F / 20C.

Since coil resistance is sensitive to temperature, Valve Coil Resistance Specifications


resistance values outside specification can
Description Specification
produce erratic operation. When coil resistance
decreases below specification, amperage Solenoid valve, 3 position 4 way 27.2
increases. As resistance rises above specification, 20V DC with diode (schematic items F, AC and DC)
voltage increases.
Solenoid valve, 3 position 4 way 19
While valves may operate when coil resistance is 20V DC with diode (schematic item E)
outside specification, maintaining coils within
Solenoid valve, 2 position 4 way 19
specification will help ensure proper valve function
20V DC with diode (schematic item H, AI and DI)
over a wide range of operating temperatures.
Solenoid valve, 2 position 2 way N.C. 25
Electrocution/burn hazard. Contact 20V DC with diode (schematic item N)
with electrically charged circuits
could result in death or serious Solenoid valve, 2 position 4 way 19
injury. Remove all rings, watches 20V DC with diode (schematic items AE and DE)
and other jewelry.
Solenoid valve, 3 position 5 way 19
Note: If the machine has been in operation, allow 20V DC with diode (schematic item AG and DG)
the coil to cool at least 3 hours before performing
Solenoid valve, 2 position 2 way 27.2
this test. 20V DC with diode (schematic item CA, CB, CC
and CD)
1 Tag and disconnect the wiring from the coil to
be tested. Solenoid valve, 3 position 4 way 19
20V DC with diode (schematic item BA)
2 Test the coil resistance using a multimeter set
to resistance (). Refer to the Valve Coil Proportional solenoid valve, 2 position 2 way 23.9
Resistance Specification table. 20V DC with diode (schematic item DO)
Result: If the resistance is not within the
adjusted specification, plus or minus 10%,
replace the coil.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 4 - 33


Section 4 Repair Procedures January 2012

MANIFOLDS

How to Test a Coil Diode


Genie incorporates spike suppressing diodes in all
of its coils. Properly functioning coil diodes protect
the electrical circuit by suppressing voltage spikes.
Voltage spikes naturally occur within a function
circuit following the interruption of electrical current
to a coil. Faulty diodes can fail to protect the
electrical system, resulting in a tripped circuit
breaker or component damage.

Electrocution/burn hazard. Contact


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 10 resistor
1 Test the coil for resistance. See 4-24 How to d coil
Test a Coil.
Note: Dotted lines in illustration indicate a reversed
2 Connect a 10 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

Resistor, 10 reading.
Genie part number 27287
Result: Both current readings are greater than
0 mA and are different by a minimum of 20%.
3 Set a multimeter to read DC amperage. The coil is good.

Note: The multimeter, when set to read DC Result: If one or both of the current readings are
amperage, should be capable of reading up to 0 mA, or if the two current readings do not differ
800 mA. by a minimum of 20%, the coil and/or its
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.

4 - 34 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 4 Repair Procedures

Steer Axle Components


6-1 7 Tag, disconnect and plug the hydraulic hoses
on the drive motor. Cap the fittings on the drive
Yoke and Drive Motor motor.
Bodily injury hazard. Spraying
How to Remove the Yoke hydraulic oil can penetrate and
and Drive Motor Assembly burn skin. Loosen hydraulic
connections very slowly to allow
When removing a hose assembly or fitting, the
the oil pressure to dissipate
fitting and/or hose end must be torqued to
gradually. Do not allow oil to squirt
specification during installation. Refer to Section 2,
or spray.
Hydraulic Hose and Fitting Torque Specifications.
Component damage hazard.
1 Block the non-steer wheels. Hoses can be damaged if they are
2 Remove the cotter pin from the wheel castle kinked or pinched.
nut. 8 Support and secure the yoke assembly to an
Note: Always replace the cotter pin with a new one appropriate lifting device.
when removing the castle nut. 9 Remove the retaining fastener from the steer
3 Loosen the wheel castle nut. Do not remove it. link at the yoke assembly.

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.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 4 - 35


Section 4 Repair Procedures January 2012

STEER AXLE COMPONENTS

How to Remove a Drive Motor 6-2


1 Block the non-steer wheels. Steer Cylinder
2 Remove the cotter pin from the wheel castle nut
of the motor to be removed.
How to Remove the
Note: Always replace the cotter pin with a new one
Steer Cylinder
when removing the castle nut. When removing a hose assembly or fitting, the
O-ring on the fitting and/or hose end must be
3 Loosen the wheel castle nut. Do not remove it.
replaced and then torqued to specification during
4 Center a lifting jack under the drive chassis at installation.
the steer end of the machine. Refer to Section Two, Hydraulic Hose and Fitting
Torque Specifications.
5 Raise the machine approximately
2 inches / 5 cm. Place blocks under the chassis 1 Block the non-steer wheels.
for support.
2 Remove the pin retaining fasteners from the
Crushing hazard. The chassis rod-end pivot pin. Remove the pivot pin.
could fall if not properly supported.
Note: While removing the pin retaining fasteners,
6 Remove the wheel castle nut. Remove the take note of the quantity and location of the
wheel. spacers when removing the pivot pin.
7 Tag, disconnect and plug the hydraulic hoses 3 Remove the pin retaining fasteners from the
on the drive motor. Cap the fittings on the drive barrel-end pivot pin. Remove the pin.
motor.
Note: While removing the pin retaining fasteners,
Bodily injury hazard. Spraying take note of the quantity and location of the
hydraulic oil can penetrate and spacers when removing the pin.
burn skin. Loosen hydraulic
connections very slowly to 4 Remove the steer cylinder from the machine.
allow the oil pressure to 5 Tag, disconnect and plug the hydraulic hoses
dissipate gradually. Do not from the steer cylinder. Cap the fittings on the
allow oil to squirt or spray. cylinder.
Component damage hazard. Bodily injury hazard. Spraying
Hoses can be damaged if they are hydraulic oil can penetrate and
kinked or pinched. burn skin. Loosen hydraulic
8 Remove the drive motor mounting fasteners. connections very slowly to allow
Remove the motor. the oil pressure to dissipate
gradually. Do not allow oil to
Torque specifications squirt or spray.

Drive motor mounting fasteners, dry 75 ft-lbs Component damage hazard.


101.7 Nm Hoses can be damaged if they are
kinked or pinched.
Drive motor mounting fasteners, lubricated 56 ft-lbs
76.3 Nm

4 - 36 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 4 Repair Procedures

6-3
Steer Bellcrank

How to Remove the Steer


Bellcrank
1 Remove the steer cylinder. See 6-2, How to
Remove the Steer Cylinder.
2 Remove the retaining fasteners from the steer
links at each end of the bellcrank.
Note: While removing the retaining fasteners, take
note of the quantity and location of the spacers
between the bellcrank and the steer links.
3 Center a lifting jack under the drive chassis at Note: While removing the bellcrank from the
the steer end. machine, take note of the quantity and location of
the spacers between the bellcrank and the steer
4 Raise the machine approximately links.
14 inches / 36 cm. Place blocks under the
chassis for support. Note: Before re-installing the steer bellcrank onto
the machine, apply a small amount of Loctite onto
Crushing hazard. The chassis the threads of the fasteners. Torque the fasteners
could fall if not properly supported. to 31 ft-lbs / 42 Nm.
5 Turn the yokes to the side so the bellcrank can
be removed.
6 Remove the bellcrank from the machine.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 4 - 37


Section 4 Repair Procedures January 2012

Non-steer Axle Components


7-1 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 removed.
if 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.

4 - 38 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 4 Repair Procedures

Brake Release Hand Pump Components

8-1
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

Part No. 228901 GS-30 GS-32 GS-46 GS-47 4 - 39


Section 4 Repair Procedures January 2012

Scissor Components

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

4 - 40 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 4 Repair Procedures

SCISSOR COMPONENTS

9-1 4 Lower the platform onto the safety arm.


Scissor Assembly, Crushing hazard. Keep hands
clear of the safety arm when
GS-1530 and GS-1532 lowering the platform.

How to Disassemble the 5 At the ground control, turn the key switch to the
off position and push in the red Emergency
Scissor Assembly, Stop button to the off position.
GS-1530 and GS-1532 6 Disconnect the battery pack from the machine.
Bodily injury hazard. The Electrocution/burn hazard. Contact
procedures in this section require with electrically charged circuits
specific repair skills, lifting could result in death or serious
equipment and a suitable injury. Remove all rings, watches
workshop. Attempting this and other jewelry.
procedure without these skills and
tools could result in death or 7 Remove the fasteners securing the platform
serious injury and significant height sensor cover to the large platform height
component damage. Dealer sensor bracket.
service is required. 8 Remove the platform height sensor cover.
When removing a hose assembly or fitting, the 9 Tag and disconnect the platform height sensor
O-ring on the fitting and/or hose end must be from the platform height sensor harness.
replaced and then torqued to specification during
installation. Refer to Section 2, Hydraulic Hose and 10 Remove the fastener securing the platform
Fitting Torque Specifications. height sensor assembly to the number 1 inner
arm.
Note: Machines equipped with a Platform Height
Sensor, begin the Scissor Disassembly procedure 11 Remove the platform height sensor assembly
at step 1. Machines without a Platform Height from the number 1 pivot pin.
Sensor, begin the Scissor Disassembly procedure 12 Remove the plastic nut securing the squeeze
at step 24. connector to the large platform height sensor
1 Turn the key switch to ground control and pull bracket.
out the red Emergency Stop button to the on 13 Remove the squeeze connector from the large
position at both the ground and platform platform height sensor bracket.
controls.
14 Remove the fasteners securing the large
2 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. platform height sensor bracket to the number 1
3 Lift the safety arm, move it to the center of the inner arm pivot bracket.
scissor arm and rotate down to a vertical 15 Remove the large platform height sensor
position. bracket from the number 1 inner arm pivot
bracket.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 4 - 41


Section 4 Repair Procedures January 2012

SCISSOR COMPONENTS

16 Install the fasteners removed in 14 to the


number 1 inner arm pivot bracket and chassis.
Tip-over hazard. Failure to install
the fasteners securing the number
1 inner arm pivot bracket to the
chassis, could result in the
machine tipping over, causing
death or serious injury.
17 Connect the battery pack to the machine.
18 Turn the key switch to the ground control
position.
19 Press and hold the ground control scroll up and
scroll down buttons.
20 Pull out the red Emergency Stop button to the Cable bridge and platform height sensor
on position at the ground controls. legend
21 Using the ground control menu buttons, a cable bridge 3
navigate to Service Override Mode. Select b cable bridge 2
Service Override Mode. c cable bridge 1
d platform height sensor
Note: The machine must be in Service Override
Mode to raise the platform. While in Service 24 Remove the platform. See 10-1, How to
Override Mode, only the GCON will operate with Remove the Platform.
limited functionality. The platform will raise a 25 Remove the cables from the number 3 outer
predetermined amount of time and stop. arm (index #11) at the ground controls side.
22 Raise the platform and return the safety arm to Component damage hazard.
the stowed position. Cables can be damaged if they
are kinked or pinched.
23 Fully lower the platform to the stowed position.
26 Remove the cables from the number 3 cable
bridge and lay them off to the side.
Component damage hazard.
Cables can be damaged if they
are kinked or pinched.

4 - 42 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 4 Repair Procedures

SCISSOR COMPONENTS

27 Attach a lifting strap from an overhead crane to 35 Lower the cylinder onto the number 1 inner arm
the number 3 outer arm (index #11). (index #8).
28 Remove the external snap rings and retaining Component damage hazard.
fasteners from the number 3 center pivot pins Cables can be damaged if they
(index #2). are kinked or pinched.
29 Use a soft metal drift to remove the number 3 36 Attach a lifting strap from an overhead crane to
center pivot pins (index #2). the number 3 inner arm (index #10).
30 Remove the retaining fasteners from the 37 Remove the retaining fasteners from the
number 3 pivot pin (index #12) at the non-steer number 3 pivot pin (index #4) at the steer end.
end of the machine.
38 Use a soft metal drift to remove the number 3
31 Use a soft metal drift to remove the number 3 pivot pin (index #4). Remove the number 3
pivot pin (index #12) from the non-steer end of inner arm (index #10) from the machine.
the machine. Remove the number 3 outer arm
Bodily injury hazard. The number
(index #11) from the machine.
3 inner arm may become
Crushing hazard. The number 3 unbalanced and fall if not properly
outer arm may become supported when removed from the
unbalanced and fall if not properly machine.
supported when removed from the
39 Remove the cables from the number 2 cable
machine.
bridge and lay them off to the side.
32 Remove the number 3 cable bridge mounting
Component damage hazard.
fasteners and remove the cable bridge from the
Cables can be damaged if they
machine.
are kinked or pinched.
33 Attach a lifting strap from an overhead crane to
40 Remove the external snap rings and retaining
the lug on the rod end of the lift cylinder for
fasteners from the number 2 center pivot pin
support. Do not apply any lifting pressure.
(index #5) at the ground controls side.
34 Remove the pin retaining fasteners from the lift
41 Remove the number 2 cable bridge mounting
cylinder rod-end pivot pin (index #3). Use a soft
fasteners and remove the cable bridge from the
metal drift to remove the pin.
machine.
Bodily injury hazard. The cylinder
42 Attach a lifting strap from an overhead crane to
may fall when the rod-end pivot
the number 2 outer arm (index #14) at the
pin is removed if not properly
ground controls side.
supported.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 4 - 43


Section 4 Repair Procedures January 2012

SCISSOR COMPONENTS

43 Use a soft metal drift to remove the number 2 49 Use a soft metal drift to tap the number 2 pivot
center pivot pin (index #5) at the ground pin (index #15) in the other direction at the non-
controls side. steer end. Remove the number 2 outer arm
(index #14) from the battery pack side of the
44 Remove the retaining fasteners from the
machine.
number 2 pivot pin (index #15) at the non-steer
end of the machine. Bodily injury hazard. The number
2 outer arm at the battery pack
45 Use a soft metal drift to tap the number 2 pivot
side may become unbalanced and
pin (index #15) halfway out at the non-steer end
fall if not properly supported when
of the machine. Remove the number 2 outer
removed from the machine.
arm (index #14) from the ground controls side
of the machine. 50 Attach a lifting strap from an overhead crane to
the number 2 inner arm (index #13).
Bodily injury hazard. The number
2 outer arm at the ground controls 51 Remove the retaining fasteners from the
side may become unbalanced and number 2 pivot pin (index #6) at the steer end
fall if not properly supported when of the machine.
removed from the machine.
52 Use a soft metal drift to remove the number 2
46 Attach a lifting strap from an overhead crane to pivot pin (index #6). Remove the number 2
the number 2 outer arm (index #14) at the inner arm (index #13) from the machine.
battery pack side.
Bodily injury hazard. The number
47 Remove the external snap rings and retaining 2 inner arm may become
fasteners from the number 2 center pivot pin unbalanced and fall if not properly
(index #5) at the battery pack side. supported when removed from the
machine.
48 Use a soft metal drift to remove the number 2
center pivot pin (index #5) at the battery pack 53 Remove the safety arm from the number 2 inner
side. arm (index #13) that was just removed.
Bodily injury hazard. The number 54 Attach a lifting strap from an overhead crane to
2 outer arm at the battery pack the number 1 inner arm (index #8).
side may become unbalanced and
fall if not properly supported when
removed from the machine.

4 - 44 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 4 Repair Procedures

SCISSOR COMPONENTS

55 Raise the number 1 inner arm (index #8) 59 Models with platform overload option: Tag
approximately 2 feet / 60 cm and install the and disconnect the wire harness from the
safety arm between the number 1 inner arm platform overload pressure transducer.
(index #8) and the number 1 outer arm (index
Note: After replacing the scissor assembly, the
#17). Lower the scissor arms onto the safety
platform overload system must be calibrated.
arm.
Refer to Repair Procedure 9-10, How to Calibrate
Bodily injury hazard. Keep hands the Platform Overload System (if equipped).
clear of moving parts when
lowering the scissor arms onto the 60 Raise the lift cylinder to a vertical position.
safety arm. 61 Remove the pin retaining fasteners from the lift
56 Attach a lifting strap from an overhead crane to cylinder barrel-end pin (index #16). Use a soft
the lug on the rod end of the lift cylinder metal drift to remove the pin. Remove the lift
(index #3). Raise the lift cylinder approximately cylinder from the machine.
3 ft / 1 m. Crushing hazard. The lift cylinder
57 Tag, disconnect and plug the hydraulic hoses could become unbalanced and fall
on the lift cylinder. Cap the fittings on the when it is removed from the
cylinder. machine if not properly attached to
the overhead crane.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and Component damage hazard. Be
burn skin. Loosen hydraulic careful not to damage the valve or
connections very slowly to allow fittings on the cylinder while
the oil pressure to dissipate removing it from the machine.
gradually. Do not allow oil to squirt 62 Place a 4 x 4 x 48 inch / 10 cm x 10 cm x 1.2 m
or spray. long block across both sides of the chassis
58 Tag and disconnect the wires and manual under the number 1 center pivot pin
lowering cable from the solenoid valve on the (index #7).
cylinder.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 4 - 45


Section 4 Repair Procedures January 2012

SCISSOR COMPONENTS

63 Attach a lifting strap from an overhead crane to 70 Use a soft metal drift to remove the number 1
the number 1 inner arm (index #8) at the non- center pivot pins (index #7).
steer end. Raise the number 1 inner arm and
Bodily injury hazard. The number
remove the safety arm. Lower the number 1
1 outer arm may become
inner arm (index #8) onto the block that was
unbalanced and fall if not properly
placed across the chassis.
supported when the pin is
Bodily injury hazard. Keep hands removed.
clear of moving parts when
71 Slide the number 1 outer arm (index #17) to the
lowering the arms onto the block.
non-steer end and remove it from the machine.
64 Remove the cables from the number 1 cable
Bodily injury hazard. The number
bridge and lay them off to the side.
1 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.
65 Support and secure the entry ladder to an 72 Attach the strap from an overhead crane to the
appropriate lifting device. number 1 inner arm (index #8). Do not lift it.
66 Remove the fasteners from the entry ladder and 73 Remove the upper fasteners securing the
remove the entry ladder from the machine. number 1 inner arm pivot bracket to the end of
the chassis. Loosen the lower fasteners.
Crushing hazard. The entry ladder
may become unbalanced and fall 74 Remove the number 1 inner arm (index #8)
if not properly supported and from the machine.
secured to the lifting device.
Bodily injury hazard. The number
67 Attach a lifting strap from an overhead crane to 1 inner arm may become
the number 1 outer arm (index #17). Do not unbalanced and fall if not properly
apply any lifting pressure. supported when removed from the
machine.
68 Remove the external snap rings and retaining
fasteners from the number 1 center pivot pins Component damage hazard. Be
(index #7). sure not to damage the limit switch
or level sensor components when
69 Remove the number 1 cable bridge from the
the number 1 inner arm is
machine.
removed from the machine.

4 - 46 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 4 Repair Procedures

SCISSOR COMPONENTS

How to Replace the Scissor Arm 7 Remove the fasteners securing the platform
height sensor cover to the large platform height
Wear Pads sensor bracket.
Note: Machines equipped with a Platform Height 8 Remove the platform height sensor cover.
Sensor, begin at step 1. Machines without a
Platform Height Sensor, begin at step 24. 9 Tag and disconnect the platform height sensor
from the platform height sensor harness.
1 Turn the key switch to ground control and pull
out the red Emergency Stop button to the on 10 Remove the fastener securing the platform
position at both the ground and platform height sensor assembly to the number 1 inner
controls. arm.

2 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. 11 Remove the platform height sensor assembly
from the number 1 pivot pin.
3 Lift the safety arm, move it to the center of the
scissor arm and rotate down to a vertical 12 Remove the plastic nut securing the squeeze
position. connector to the large platform height sensor
bracket.
4 Lower the platform onto the safety arm.
13 Remove the squeeze connector from the large
Crushing hazard. Keep hands platform height sensor bracket.
clear of the safety arm when
lowering the platform. 14 Remove the fasteners securing the large
platform height sensor bracket to the number 1
5 At the ground control, turn the key switch to the inner arm pivot bracket.
off position and push in the red Emergency
Stop button to the off position. 15 Remove the large platform height sensor
bracket from the number 1 inner arm pivot
6 Disconnect the battery pack from the machine. bracket.
Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 4 - 47


Section 4 Repair Procedures January 2012

SCISSOR COMPONENTS

16 Install the fasteners removed in 14 to the 23 Fully lower the platform to the stowed position.
number 1 inner arm pivot bracket and chassis.
24 Remove the platform. See 10-1, How to
Tip-over hazard. Failure to install Remove the Platform.
the fasteners securing the number
25 Support and secure the entry ladder to an
1 inner arm pivot bracket to the
appropriate lifting device.
chassis, could result in the
machine tipping over, causing 26 Remove the fasteners from the entry ladder and
death or serious injury. remove the entry ladder from the machine.
17 Connect the battery pack to the machine. Crushing hazard. The entry ladder
may become unbalanced and fall
18 Turn the key switch to the ground control
if not properly supported and
position.
secured to the lifting device.
19 Press and hold the ground control scroll up and
27 Secure the ends of the scissor arms together at
scroll down buttons.
the steer end of the machine with a strap or
20 Pull out the red Emergency Stop button to the other suitable device.
on position at the ground controls.
28 Secure the ends of the scissor arms together at
21 Using the ground control menu buttons, the non-steer end of the machine with a strap or
navigate to Service Override Mode. Select other suitable device.
Service Override Mode.
29 Remove the retaining fasteners securing the
Note: The machine must be in Service Override chassis mount bracket to the chassis at the
Mode to raise the platform. While in Service steer end of the machine.
Override Mode, only the GCON will operate with
30 Attach a lifting strap from an overhead crane to
limited functionality. The platform will raise a
the scissor arm assembly.
predetermined amount of time and stop.
31 Raise the scissor arm assembly at the steer
22 Raise the platform and return the safety arm to
end with the overhead crane until the chassis
the stowed position.
mount bracket will clear the level sensor.

4 - 48 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 4 Repair Procedures

SCISSOR COMPONENTS

32 Remove the scissor assembly from the


machine just enough to access both wear pads.
Crushing hazard. The scissor
assembly will fall if not properly
supported when removed from the
drive chassis.
Component damage hazard. Be
careful not to damage the level
sensor or limit switch while moving
the scissor assembly.
33 Remove both old wear pads.
34 Install two new wear pads.
35 Slide the scissor assembly back into the drive
chassis.
36 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.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 4 - 49


Section 4 Repair Procedures January 2012

SCISSOR COMPONENTS

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

4 - 50 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 4 Repair Procedures

SCISSOR COMPONENTS

9-2 4 Lower the platform onto the safety arm.


Scissor Assembly, Crushing hazard. Keep hands
clear of the safety arm when
GS-1930 and GS-1932 lowering the platform.

How to Disassemble the 5 At the ground control, turn the key switch to the
off position and push in the red Emergency
Scissor Assembly, Stop button to the off position.
GS-1930 and GS-1932 6 Disconnect the battery pack from the machine.
Bodily injury hazard. The Electrocution/burn hazard. Contact
procedures in this section require with electrically charged circuits
specific repair skills, lifting could result in death or serious
equipment and a suitable injury. Remove all rings, watches
workshop. Attempting this and other jewelry.
procedure without these skills and
tools could result in death or 7 Remove the fasteners securing the platform
serious injury and significant height sensor cover to the large platform height
component damage. Dealer sensor bracket.
service is required. 8 Remove the platform height sensor cover.
When removing a hose assembly or fitting, the 9 Tag and disconnect the platform height sensor
O-ring on the fitting and/or hose end must be from the platform height sensor harness.
replaced and then torqued to specification during
installation. Refer to Section 2, Hydraulic Hose and 10 Remove the fastener securing the platform
Fitting Torque Specifications. height sensor assembly to the number 1 inner
arm.
Note: Machines equipped with a Platform Height
Sensor, begin the Scissor Disassembly procedure 11 Remove the platform height sensor assembly
at step 1. Machines without a Platform Height from the number 1 pivot pin.
Sensor, begin the Scissor Disassembly procedure 12 Remove the plastic nut securing the squeeze
at step 24. connector to the large platform height sensor
1 Turn the key switch to ground control and pull bracket.
out the red Emergency Stop button to the on 13 Remove the squeeze connector from the large
position at both the ground and platform platform height sensor bracket.
controls.
14 Remove the fasteners securing the large
2 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. platform height sensor bracket to the number 1
3 Lift the safety arm, move it to the center of the inner arm pivot bracket.
scissor arm and rotate down to a vertical 15 Remove the large platform height sensor
position. bracket from the number 1 inner arm pivot
bracket.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 4 - 51


Section 4 Repair Procedures January 2012

SCISSOR COMPONENTS

16 Install the fasteners removed in 14 to the


number 1 inner arm pivot bracket and chassis.
Tip-over hazard. Failure to install
the fasteners securing the number
1 inner arm pivot bracket to the
chassis, could result in the
machine tipping over, causing
death or serious injury.
17 Connect the battery pack to the machine.
18 Turn the key switch to the ground control
position.
19 Press and hold the ground control scroll up and
scroll down buttons.
20 Pull out the red Emergency Stop button to the
on position at the ground controls.
21 Using the ground control menu buttons,
navigate to Service Override Mode. Select
Service Override Mode. Cable bridge and platform height sensor
legend
Note: The machine must be in Service Override a cable bridge 4
Mode to raise the platform. While in Service b cable bridge 3
Override Mode, only the GCON will operate with c cable bridge 2
limited functionality. The platform will raise a d cable bridge 1
e platform height sensor
predetermined amount of time and stop.
24 Remove the platform. See 10-1, How to
22 Raise the platform and return the safety arm to
Remove the Platform.
the stowed position.
25 Remove the cables from the number 4 outer
23 Fully lower the platform to the stowed position.
arm (index #13) at the ground controls side.
Component damage hazard.
Cables can be damaged if they
are kinked or pinched.
26 Remove the cables from the number 4 cable
bridge and lay them off to the side.
Component damage hazard.
Cables can be damaged if they
are kinked or pinched.

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January 2012 Section 4 Repair Procedures

SCISSOR COMPONENTS

27 Attach a lifting strap from an overhead crane to 36 Remove the cables from the number 3 cable
the number 4 outer arm (index #13). bridge and lay them off to the side.
28 Remove the external snap rings and retaining Component damage hazard.
fasteners from the number 4 center pivot pins Cables can be damaged if they
(index #2). are kinked or pinched.
29 Use a soft metal drift to remove the number 4 37 Remove the number 3 cable bridge mounting
center pivot pins (index #2). fasteners and remove the cable bridge from the
machine.
30 Remove the retaining fasteners from the
number 4 pivot pin (index #14) at the non-steer 38 Attach a lifting strap from an overhead crane to
end of the machine. the number 3 outer arm (index #4) at the
ground controls side.
31 Use a soft metal drift to remove the number 4
pivot pin (index #14) from the non-steer end of 39 Remove the external snap rings and retaining
the machine. Remove the number 4 outer arm fasteners from the number 3 center pivot pins
(index #13) from the machine. (index #4).
Crushing hazard. The number 4 40 Use a soft metal drift to remove the number 3
outer arm may become center pivot pin (index #4) at the ground control
unbalanced and fall if not properly side.
supported when removed from the
41 Remove the retaining fasteners from the
machine.
number 3 pivot pin (index #17) at the non-steer
32 Remove the number 4 cable bridge mounting end of the machine.
fasteners and remove the cable bridge from the
42 Use a soft metal drift to tap the number 3 pivot
machine.
pin (index #17) halfway out at the non-steer end
33 Attach a lifting strap from an overhead crane to of the machine. Remove the number 3 outer
the number 4 inner arm (index #12). arm (index #16) at the ground controls side
from the machine.
34 Remove the retaining fasteners from the
number 4 pivot pin (index #3). Bodily injury hazard. The number
3 outer arm at the ground controls
35 Use a soft metal drift to remove the number 4
side may become unbalanced and
pivot pin (index #3) at the steer end. Remove
fall if not properly supported when
the number 4 inner arm (index #12) from the
removed from the machine.
machine.
Crushing hazard. The number 4
inner arm may become
unbalanced and fall if not properly
supported when removed from the
machine.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 4 - 53


Section 4 Repair Procedures January 2012

SCISSOR COMPONENTS

43 Attach a lifting strap from an overhead crane to 51 Remove the retaining fasteners from the
the number 3 outer arm (index #16) at the number 3 pivot pin (index #6) at the steer end.
battery pack side.
52 Use a soft metal drift to remove the number 3
44 Use a soft metal drift to remove the number 3 pivot pin (index #6). Remove the number 3
center pivot pin (index #4) at the battery pack inner arm (index #15) from the machine.
side of the machine.
Bodily injury hazard. The number
45 Use a soft metal drift to tap the number 3 pivot 3 inner arm may become
pin (index #17) in the other direction. Remove unbalanced and fall if not properly
the number 3 outer arm (index #16) from the supported when removed from the
battery pack side of the machine. machine.
Bodily injury hazard. The number 53 Remove the cables from the number 2 cable
3 outer arm at the battery pack bridge and lay them off to the side.
side may become unbalanced and
Component damage hazard.
fall if not properly supported when
Cables can be damaged if they
removed from the machine.
are kinked or pinched.
46 Remove the number 3 pivot pin (index #17)
54 Remove the external snap rings and retaining
from the non-steer end of the machine.
fasteners from the number 2 center pivot pin
47 Attach a lifting strap from an overhead crane to (index #7) at the ground controls side.
the lug on the rod end of the lift cylinder for
55 Remove the number 2 cable bridge mounting
support. Do not apply any lifting pressure.
fasteners and remove the cable bridge from the
48 Remove the pin retaining fasteners from the lift machine.
cylinder rod-end pivot pin (index #5). Use a soft
56 Attach a lifting strap from an overhead crane to
metal drift to remove the pin.
the number 2 outer arm (index #19) at the
Bodily injury hazard. The cylinder ground controls side.
may fall when the rod-end pivot
57 Use a soft metal drift to remove the number 2
pin is removed if not properly
center pivot pin (index #7) at the ground
supported.
controls side.
49 Lower the cylinder onto the number 1 inner arm
58 Remove the retaining fasteners from the
(index #9).
number 2 pivot pin (index #20) at the non-steer
Component damage hazard. end of the machine.
Cables can be damaged if they
are kinked or pinched.
50 Attach a lifting strap from an overhead crane to
the number 3 inner arm (index #15).

4 - 54 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 4 Repair Procedures

SCISSOR COMPONENTS

59 Use a soft metal drift to tap the number 2 pivot 64 Remove the number 3 pivot pin (index #17)
pin (index #20) halfway out at the non-steer end from the non-steer end of the machine.
of the machine. Remove the number 2 outer
65 Attach a lifting strap from an overhead crane to
arm (index #19) from the ground controls side
the number 2 inner arm (index #18).
of the machine.
66 Remove the retaining fasteners from the
Bodily injury hazard. The number
number 2 pivot pin (index #8) at the steer end
2 outer arm at the ground controls
of the machine.
side may become unbalanced and
fall if not properly supported when 67 Use a soft metal drift to remove the number 2
removed from the machine. pivot pin (index #8). Remove the number 2
inner arm (index #18) from the machine.
60 Attach a lifting strap from an overhead crane to
the number 2 outer arm (index #19) at the Bodily injury hazard. The number
battery pack side. 2 inner arm may become
unbalanced and fall if not properly
61 Remove the external snap rings and retaining
supported when removed from the
fasteners from the number 2 center pivot pin
machine.
(index #7) at the battery pack side.
68 Remove the safety arm from the number 2 inner
62 Use a soft metal drift to remove the number 2
arm (index #18) that was just removed.
center pivot pin (index #7) at the battery pack
side. 69 Attach a lifting strap from an overhead crane to
the number 1 inner arm (index #10).
Bodily injury hazard. The number
2 outer arm at the battery pack 70 Raise the number 1 inner arm (index #10)
side may become unbalanced and approximately 2 feet / 60 cm and install the
fall if not properly supported when safety arm between the number 1 inner arm
removed from the machine. (index #10) and the number 1 outer arm (index
#22) at the non-steer end of the machine.
63 Use a soft metal drift to tap the number 2 pivot
Lower the scissor arms onto the safety arm.
pin at the non-steer end (index #20) in the other
direction. Remove the number 2 outer arm Bodily injury hazard. Keep hands
(index #19) from the battery pack side of the clear of moving parts when
machine. lowering the scissor arms onto the
safety arm.
Bodily injury hazard. The number
2 outer arm at the battery pack 71 Attach a lifting strap from an overhead crane to
side may become unbalanced and the lug on the rod end of the lift cylinder
fall if not properly supported when (index #5). Raise the lift cylinder approximately
removed from the machine. 3 ft / 1 m.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 4 - 55


Section 4 Repair Procedures January 2012

SCISSOR COMPONENTS

72 Tag, disconnect and plug the hydraulic hoses 77 Place a 4 x 4 x 48 inch / 10 cm x 10 cm x 1.2 m
on the lift cylinder. Cap the fittings on the long block across both sides of the chassis
cylinder. under the number 1 center pivot pin
(index #11).
Bodily injury hazard. Spraying
hydraulic oil can penetrate and 78 Attach a lifting strap from an overhead crane to
burn skin. Loosen hydraulic the number 1 inner arm (index #10) at the non-
connections very slowly to allow steer end. Raise the number 1 inner arm and
the oil pressure to dissipate remove the safety arm. Lower the number 1
gradually. Do not allow oil to squirt inner arm (index #10) onto the block that was
or spray. placed across the chassis.
73 Tag and disconnect the wires and manual Bodily injury hazard. Keep hands
lowering cable from the solenoid valve on the clear of moving parts when
cylinder. lowering the arms onto the block.
74 Models with platform overload option: Tag 79 Remove the cables from the number 1 cable
and disconnect the wire harness from the bridge and lay them off to the side.
platform overload pressure transducer.
Component damage hazard.
Note: After replacing the scissor assembly, the Cables can be damaged if they
platform overload system must be calibrated. are kinked or pinched.
Refer to Repair Procedure 9-10, How to Calibrate
80 Support and secure the entry ladder to an
the Platform Overload System (if equipped).
appropriate lifting device.
75 Raise the lift cylinder to a vertical position.
81 Remove the fasteners from the entry ladder and
76 Remove the pin retaining fasteners from the lift remove the entry ladder from the machine.
cylinder barrel-end pin (index #21). Use a soft
Crushing hazard. The entry ladder
metal drift to remove the pin. Remove the lift
may become unbalanced and fall
cylinder from the machine.
if not properly supported and
Crushing hazard. The lift cylinder secured to the lifting device.
may become unbalanced and fall
82 Attach a lifting strap from an overhead crane to
when it is removed from the
the number 1 outer arm (index #22). Do not
machine if not properly attached to
apply any lifting pressure.
the overhead crane.
83 Remove the external snap rings and retaining
Component damage hazard. Be
fasteners from the number 1 center pivot pins
careful not to damage the valve or
(index #11).
fittings on the cylinder while
removing it from the machine.

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January 2012 Section 4 Repair Procedures

SCISSOR COMPONENTS

84 Remove the number 1 cable bridge from the How to Replace the Scissor Arm
machine.
Wear Pads
85 Use a soft metal drift to remove the number 1
center pivot pins (index #9). Note: Machines equipped with a Platform Height
Sensor, begin at step 1. Machines without a
Bodily injury hazard. The number Platform Height Sensor, begin at step 24.
1 outer arm may become
unbalanced and fall if not properly 1 Turn the key switch to ground control and pull
supported when the pin is out the red Emergency Stop button to the on
removed. position at both the ground and platform
controls.
86 Slide the number 1 outer arm (index #22) to the
non-steer end and remove it from the machine. 2 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
Bodily injury hazard. The number 3 Lift the safety arm, move it to the center of the
1 outer arm may become scissor arm and rotate down to a vertical
unbalanced and fall if not properly position.
supported when removed from the
4 Lower the platform onto the safety arm.
machine.
Crushing hazard. Keep hands
87 Attach the strap from an overhead crane to the
clear of the safety arm when
number 1 inner arm (index #10). Do not lift it.
lowering the platform.
88 Remove the upper fasteners securing the
5 At the ground control, turn the key switch to the
number 1 inner arm pivot bracket to the end of
off position and push in the red Emergency
the chassis. Loosen the lower fasteners.
Stop button to the off position.
89 Remove the number 1 inner arm (index #10)
6 Disconnect the battery pack from the machine.
from the machine.
Electrocution/burn hazard. Contact
Bodily injury hazard. The number
with electrically charged circuits
1 inner arm may become
could result in death or serious
unbalanced and fall if not properly
injury. Remove all rings, watches
supported when removed from the
and other jewelry.
machine.
7 Remove the fasteners securing the platform
Component damage hazard. Be
height sensor cover to the large platform height
sure not to damage the limit switch
sensor bracket.
or level sensor components when
the number 1 inner arm is 8 Remove the platform height sensor cover.
removed from the machine.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 4 - 57


Section 4 Repair Procedures January 2012

SCISSOR COMPONENTS

9 Tag and disconnect the platform height sensor 20 Pull out the red Emergency Stop button to the
from the platform height sensor harness. on position at the ground controls.
10 Remove the fastener securing the platform 21 Using the ground control menu buttons,
height sensor assembly to the number 1 inner navigate to Service Override Mode. Select
arm. Service Override Mode.
11 Remove the platform height sensor assembly Note: The machine must be in Service Override
from the number 1 pivot pin. Mode to raise the platform. While in Service
Override Mode, only the GCON will operate with
12 Remove the plastic nut securing the squeeze
limited functionality. The platform will raise a
connector to the large platform height sensor
predetermined amount of time and stop.
bracket.
13 Remove the squeeze connector from the large 22 Raise the platform and return the safety arm to
platform height sensor bracket. the stowed position.
23 Fully lower the platform to the stowed position.
14 Remove the fasteners securing the large
platform height sensor bracket to the number 1 24 Remove the platform. See 10-1, How to
inner arm pivot bracket. Remove the Platform.
15 Remove the large platform height sensor 25 Support and secure the entry ladder to an
bracket from the number 1 inner arm pivot appropriate lifting device.
bracket.
26 Remove the fasteners from the entry ladder and
16 Install the fasteners removed in 14 to the remove the entry ladder from the machine.
number 1 inner arm pivot bracket and chassis.
Crushing hazard. The entry ladder
Tip-over hazard. Failure to install may become unbalanced and fall
the fasteners securing the number if not properly supported and
1 inner arm pivot bracket to the secured to the lifting device.
chassis, could result in the
machine tipping over, causing 27 Secure the ends of the scissor arms together at
death or serious injury. the steer end of the machine with a strap or
other suitable device.
17 Connect the battery pack to the machine.
28 Secure the ends of the scissor arms together at
18 Turn the key switch to the ground control the non-steer end of the machine with a strap or
position. other suitable device.
19 Press and hold the ground control scroll up and 29 Remove the retaining fasteners securing the
scroll down buttons. chassis mount bracket to the chassis at the
steer end of the machine.

4 - 58 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 4 Repair Procedures

SCISSOR COMPONENTS

30 Attach a lifting strap from an overhead crane to


the scissor arm assembly.
31 Raise the scissor arm assembly at the steer
end with the overhead crane until the chassis
mount bracket will clear the level sensor.
32 Remove the scissor assembly from the
machine just enough to access both wear pads.
Crushing hazard. The scissor
assembly will fall if not properly
supported when removed from the
drive chassis.
Component damage hazard. Be
careful not to damage the level
sensor or limit switch while moving
the scissor assembly.
33 Remove both old wear pads.
34 Install two new wear pads.
35 Slide the scissor assembly back into the drive
chassis.
36 Lower the scissor assembly into position and
install the chassis mount bracket onto the
chassis. Securely install and tighten the
fasteners. Do not over tighten.
Component damage hazard. Be
careful not to damage the level
sensor or limit switch while moving
the scissor assembly.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 4 - 59


Section 4 Repair Procedures January 2012

SCISSOR COMPONENTS

10
2

3 11

4 12

13
5
14
6 15

7 16

8 17

GS-2032
GS-2046
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

4 - 60 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 4 Repair Procedures

SCISSOR COMPONENTS

9-3 4 Lower the platform onto the safety arm.


Scissor Assembly, Crushing hazard. Keep hands
clear of the safety arm when
GS-2032 and GS-2046 lowering the platform.

How to Disassemble the 5 At the ground control, turn the key switch to the
off position and push in the red Emergency
Scissor Assembly, Stop button to the off position.
GS-2032 and GS-2046 6 Disconnect the battery pack from the machine.
Bodily injury hazard. The Electrocution/burn hazard. Contact
procedures in this section require with electrically charged circuits
specific repair skills, lifting could result in death or serious
equipment and a suitable injury. Remove all rings, watches
workshop. Attempting this and other jewelry.
procedure without these skills and
tools could result in death or 7 Remove the fasteners securing the platform
serious injury and significant height sensor cover to the large platform height
component damage. Dealer sensor bracket.
service is required. 8 Remove the platform height sensor cover.
When removing a hose assembly or fitting, the 9 Tag and disconnect the platform height sensor
O-ring on the fitting and/or hose end must be from the platform height sensor harness.
replaced and then torqued to specification during
installation. Refer to Section 2, Hydraulic Hose and 10 Remove the fastener securing the platform
Fitting Torque Specifications. height sensor assembly to the number 1 inner
arm.
Note: Machines equipped with a Platform Height
Sensor, begin the Scissor Disassembly procedure 11 Remove the platform height sensor assembly
at step 1. Machines without a Platform Height from the number 1 pivot pin.
Sensor, begin the Scissor Disassembly procedure 12 Remove the plastic nut securing the squeeze
at step 24. connector to the large platform height sensor
1 Turn the key switch to ground control and pull bracket.
out the red Emergency Stop button to the on 13 Remove the squeeze connector from the large
position at both the ground and platform platform height sensor bracket.
controls.
14 Remove the fasteners securing the large
2 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. platform height sensor bracket to the number 1
3 Lift the safety arm, move it to the center of the inner arm pivot bracket.
scissor arm and rotate down to a vertical 15 Remove the large platform height sensor
position. bracket from the number 1 inner arm pivot
bracket.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 4 - 61


Section 4 Repair Procedures January 2012

SCISSOR COMPONENTS

16 Install the fasteners removed in 14 to the


number 1 inner arm pivot bracket and chassis.
Tip-over hazard. Failure to install
the fasteners securing the number
1 inner arm pivot bracket to the
chassis, could result in the
machine tipping over, causing
death or serious injury.
17 Connect the battery pack to the machine.
18 Turn the key switch to the ground control
position.
19 Press and hold the ground control scroll up and
scroll down buttons.
20 Pull out the red Emergency Stop button to the
Cable bridge legend and platform height
on position at the ground controls. sensor legend
21 Using the ground control menu buttons, a cable bridge 3
navigate to Service Override Mode. Select b cable bridge 2A
Service Override Mode. c cable bridge 2B
d cable bridge 1
Note: The machine must be in Service Override e platform height sensor
Mode to raise the platform. While in Service
24 Remove the platform. See 10-1, How to
Override Mode, only the GCON will operate with
Remove the Platform.
limited functionality. The platform will raise a
predetermined amount of time and stop. 25 Support and secure the entry ladder to an
appropriate lifting device.
22 Raise the platform and return the safety arm to
the stowed position. 26 Remove the fasteners from the entry ladder and
remove the entry ladder from the machine.
23 Fully lower the platform to the stowed position.
Crushing hazard. The entry ladder
may become unbalanced and fall
if not properly supported and
secured to the lifting device.
27 Remove the cables from the number 3 cable
bridge and lay them off to the side.
Component damage hazard.
Cables can be damaged if they
are kinked or pinched.

4 - 62 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 4 Repair Procedures

SCISSOR COMPONENTS

28 Disconnect the number 3 cable bridge from the 39 Remove the number 3 outer arm (index #11)
number 3 outer arm (index #11) and remove from the machine.
the cable bridge from the machine.
Crushing hazard. The number 3
29 Remove the retaining fasteners from the outer arm (index #11) may
number 4 pivot pin (index #1). become unbalanced and fall if not
properly supported when removed
30 Use a soft metal drift to remove the number 4
from the machine.
pivot pin (index #1). Remove the platform
mount bracket from the machine. 40 Attach a lifting strap from an overhead crane to
the lug of the rod end of the lift cylinder.
31 Attach a lifting strap from an overhead crane to
the number 3 outer arm at the ground control 41 Remove the retaining fasteners from the lift
side (index #11). cylinder rod end pivot pin (index #3).
32 Remove the retaining fasteners from the 42 Use a soft metal drift to remove the lift cylinder
number 3 center pivot pin (index #2) at the rod end pivot pin (index #3) from the machine.
ground control side.
Crushing hazard. The lift cylinder
33 Place a rod through the number 3 center pivot will fall if not properly supported
pin at the ground control side (index #2) and when the pivot pin is removed.
twist to remove the pin.
43 Place a 4 x 4 x 10 inch / 10 x 10 x 25 cm block
34 Remove the retaining fasteners from the onto the number 1 inner arm cylinder plate
number 3 pivot pin (index #12) at the non-steer (index #8).
end.
44 Lower the cylinder onto the block.
35 Use a soft metal drift to remove the number 3
Bodily injury hazard. Keep hands
pivot pin (index #12) from the non-steer end of
clear of moving parts when
the machine. Remove the number 3 outer arm
lowering the cylinder onto the
at the ground control side (index #11) from the
block.
machine.
45 Attach a lifting strap from an overhead crane to
Crushing hazard. The number 3
the number 3 inner arm (index #10). Raise the
outer arm at the ground control
arm to a vertical position.
side (index #11) may become
unbalanced and fall if not properly 46 Remove the retaining fasteners from the
supported when removed from the number 3 pivot pin at the steer end of the
machine. machine (index #4).
36 Attach a lifting strap from an overhead crane to 47 Use a soft metal drift to remove the number 3
the number 3 outer arm at the battery side pivot pin (index #4) from the steer end of the
(index #11). machine. Remove the number 3 inner arm
(index #10) from the machine.
37 Remove the retaining fasteners from the
number 3 center pivot pin (index #2) at the Crushing hazard. The number 3
battery side. inner arm (index #10) may
become unbalanced and fall if not
38 Place a rod through the number 3 center pivot
properly supported when the pivot
pin at the battery side (index #2) and twist to
pin is removed.
remove the pin.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 4 - 63


Section 4 Repair Procedures January 2012

SCISSOR COMPONENTS

48 Remove the cables from the number 2A and 2B 57 Place a rod through the number 2 center pivot
cable bridge and lay them off to the side. pin at the battery side (index #5) and twist to
remove the pin.
Component damage hazard.
Cables can be damaged if they Crushing hazard. The number 2
are kinked or pinched. outer arm (index #14) may
become unbalanced and fall if not
49 Disconnect the number 2A and 2B cable
properly supported when the pivot
bridges from the scissor linkset and remove
pin is removed.
both cable bridges from the machine.
58 Remove the number 2 outer arm (index #14)
50 Attach a lifting strap from an overhead crane to
from the machine.
the number 2 outer arm at the ground control
side (index #14). Crushing hazard. The number 2
outer arm (index #14) may
51 Remove the retaining fasteners from the
become unbalanced and fall if not
number 2 center pivot pin (index #5) at the
properly supported when removed
ground control side.
from the machine.
52 Place a rod through the number 2 center pivot
59 Attach a lifting strap from an overhead crane to
pin at the ground control side (index #5) and
the number 2 inner arm (index #13). Raise the
twist to remove the pin.
arm to a vertical position.
53 Remove the retaining fasteners from the
60 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).
54 Use a soft metal drift to remove the number 2
61 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
removed. 62 Attach a lifting strap from an overhead crane to
the number 1 inner arm (index #8).
55 Attach a lifting strap from an overhead crane to
the number 2 outer arm at the battery side 63 Raise the number 1 inner arm (index #8)
(index #14). approximately 2 feet / 60 cm.
56 Remove the retaining fasteners from the 64 Place a 4 x 4 x 48 inch / 10 cm x 10 cm x 1.2 m
number 2 center pivot pin (index #5) at the long block across both sides of the chassis
battery side. under the number 1 center pivot pin (index #7).

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January 2012 Section 4 Repair Procedures

SCISSOR COMPONENTS

65 Lower the scissor arms onto the block that was 73 Remove the cables from the number 1 cable
placed across the chassis. bridge and lay them off to the side.
Bodily injury hazard. Keep hands Component damage hazard.
clear of moving parts when Cables can be damaged if they
lowering the scissor arms. are kinked or pinched.
66 Attach a lifting strap from an overhead crane to 74 Disconnect the number 1 cable bridge from the
the lug of the rod end of the lower lift cylinder. number 1 outer arm (index #17) and remove
the cable bridge from the machine.
67 Tag, disconnect and plug the hydraulic hose on
the lower lift cylinder. Cap the fittings on the 75 Attach a lifting strap from an overhead crane to
cylinder. the number 1 inner arm (index #8).
Bodily injury hazard. Spraying 76 Raise the arm slightly and remove the block.
hydraulic oil can penetrate and
77 Lower the arm to the stowed position.
burn skin. Loosen hydraulic
connections very slowly to allow Bodily injury hazard. Keep hands
the oil pressure to dissipate clear of moving parts when
gradually. Do not allow oil to squirt lowering the scissor arms.
or spray.
78 Secure the ends of the scissor arms together at
68 Tag and disconnect the wire harness from the the steer end of the machine with a strap or
solenoid valve on the cylinder. other suitable device.
69 Tag and disconnect the wires and manual 79 Secure the ends of the scissor arms together at
lowering cable from the solenoid valve on the the non-steer end of the machine with a strap or
cylinder. other suitable device.
70 Models with platform overload option: Tag 80 Remove the retaining fasteners securing the
and disconnect the wire harness from the chassis mount bracket to the chassis.
platform overload pressure transducer.
81 Remove the linkset from the machine
Note: After replacing the scissor assembly, the
platform overload system must be calibrated. Bodily injury hazard. The number
Refer to Repair Procedure 9-10, How to Calibrate 1 inner and outer arms (index #8
the Platform Overload System (if equipped). and #17) may become unbalanced
and fall if not properly supported
71 Raise the lift cylinder to a vertical position. when removed from the machine.
72 Remove the pin retaining fasteners from the lift Component damage hazard. Be
cylinder barrel-end pivot pin (index #16). Use a sure not to damage the limit switch
soft metal drift to remove the pin. Remove the or level sensor box components
lift cylinder from the machine. when the number 1 inner and
outer arms (index #8 and #17) is
Crushing hazard. The lift cylinder
removed from the machine.
will fall if not properly supported
when the pivot pin is removed.
Component damage hazard. Be
careful not to damage the valve or
fittings on the cylinder while
removing it from the machine.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 4 - 65


Section 4 Repair Procedures January 2012

SCISSOR COMPONENTS

How to Replace the Scissor Arm 9 Tag and disconnect the platform height sensor
from the platform height sensor harness.
Wear Pads
10 Remove the fastener securing the platform
Note: Machines equipped with a Platform Height height sensor assembly to the number 1 inner
Sensor, begin at step 1. Machines without a arm.
Platform Height Sensor, begin at step 24.
11 Remove the platform height sensor assembly
1 Turn the key switch to ground control and pull from the number 1 pivot pin.
out the red Emergency Stop button to the on
position at both the ground and platform 12 Remove the plastic nut securing the squeeze
controls. connector to the large platform height sensor
bracket.
2 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
13 Remove the squeeze connector from the large
3 Lift the safety arm, move it to the center of the platform height sensor bracket.
scissor arm and rotate down to a vertical
position. 14 Remove the fasteners securing the large
platform height sensor bracket to the number 1
4 Lower the platform onto the safety arm. inner arm pivot bracket.
Crushing hazard. Keep hands 15 Remove the large platform height sensor
clear of the safety arm when bracket from the number 1 inner arm pivot
lowering the platform. bracket.
5 At the ground control, turn the key switch to the 16 Install the fasteners removed in 14 to the
off position and push in the red Emergency number 1 inner arm pivot bracket and chassis.
Stop button to the off position.
Tip-over hazard. Failure to install
6 Disconnect the battery pack from the machine. the fasteners securing the number
1 inner arm pivot bracket to the
Electrocution/burn hazard. Contact
chassis, could result in the
with electrically charged circuits
machine tipping over, causing
could result in death or serious
death or serious injury.
injury. Remove all rings, watches
and other jewelry. 17 Connect the battery pack to the machine.
7 Remove the fasteners securing the platform 18 Turn the key switch to the ground control
height sensor cover to the large platform height position.
sensor bracket.
19 Press and hold the ground control scroll up and
8 Remove the platform height sensor cover. scroll down buttons.

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20 Pull out the red Emergency Stop button to the 30 Attach a lifting strap from an overhead crane to
on position at the ground controls. the scissor arm assembly.
21 Using the ground control menu buttons, 31 Raise the scissor arm assembly at the steer
navigate to Service Override Mode. Select end with the overhead crane until the chassis
Service Override Mode. mount bracket will clear the level sensor.
Note: The machine must be in Service Override 32 Remove the scissor assembly from the
Mode to raise the platform. While in Service machine just enough to access both wear pads.
Override Mode, only the GCON will operate with
Crushing hazard. The scissor
limited functionality. The platform will raise a
assembly will fall if not properly
predetermined amount of time and stop.
supported when removed from the
22 Raise the platform and return the safety arm to drive chassis.
the stowed position. Component damage hazard. Be
23 Fully lower the platform to the stowed position. careful not to damage the level
sensor or limit switch while moving
24 Remove the platform. See 10-1, How to the scissor assembly.
Remove the Platform.
33 Remove both old wear pads.
25 Support and secure the entry ladder to an
appropriate lifting device. 34 Install two new wear pads.
26 Remove the fasteners from the entry ladder and 35 Slide the scissor assembly back into the drive
remove the entry ladder from the machine. chassis.
Crushing hazard. The entry ladder 36 Lower the scissor assembly into position and
may become unbalanced and fall install the chassis mount bracket onto the
if not properly supported and chassis. Securely install and tighten the
secured to the lifting device. fasteners. Do not over tighten.

27 Secure the ends of the scissor arms together at Component damage hazard. Be
the steer end of the machine with a strap or careful not to damage the level
other suitable device. sensor or limit switch while moving
the scissor assembly.
28 Secure the ends of the scissor arms together at
the non-steer end of the machine with a strap or
other suitable device.
29 Remove the retaining fasteners securing the
chassis mount bracket to the chassis at the
steer end of the machine.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 4 - 67


Section 4 Repair Procedures January 2012

SCISSOR COMPONENTS

12
2
13

3 14

4 15

5 16

6 17

18
7
19

8 20

9 21

10 22

11

GS-2632
GS-2646
Steer end Non-steer end
1 Number 5 pivot pin 12 Number 4 inner arm
2 Number 4 center pivot pin (2 pins) 13 Number 4 outer arm
3 Number 4 pivot pin (steer end) 14 Number 4 pivot pin (non-steer end)
4 Number 3 center pivot pin (2 pins) 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

4 - 68 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 4 Repair Procedures

SCISSOR COMPONENTS

9-4 4 Lower the platform onto the safety arm.


Scissor Assembly, Crushing hazard. Keep hands
clear of the safety arm when
GS-2632 and GS-2646 lowering the platform.

How to Disassemble the 5 At the ground control, turn the key switch to the
off position and push in the red Emergency
Scissor Assembly, Stop button to the off position.
GS-2632 and GS-2646 6 Disconnect the battery pack from the machine.
Bodily injury hazard. The Electrocution/burn hazard. Contact
procedures in this section require with electrically charged circuits
specific repair skills, lifting could result in death or serious
equipment and a suitable injury. Remove all rings, watches
workshop. Attempting this and other jewelry.
procedure without these skills and
tools could result in death or 7 Remove the fasteners securing the platform
serious injury and significant height sensor cover to the large platform height
component damage. Dealer sensor bracket.
service is required. 8 Remove the platform height sensor cover.
When removing a hose assembly or fitting, the 9 Tag and disconnect the platform height sensor
O-ring on the fitting and/or hose end must be from the platform height sensor harness.
replaced and then torqued to specification during
installation. Refer to Section 2, Hydraulic Hose and 10 Remove the fastener securing the platform
Fitting Torque Specifications. height sensor assembly to the number 1 inner
arm.
Note: Machines equipped with a Platform Height
Sensor, begin the Scissor Disassembly procedure 11 Remove the platform height sensor assembly
at step 1. Machines without a Platform Height from the number 1 pivot pin.
Sensor, begin the Scissor Disassembly procedure 12 Remove the plastic nut securing the squeeze
at step 24. connector to the large platform height sensor
1 Turn the key switch to ground control and pull bracket.
out the red Emergency Stop button to the on 13 Remove the squeeze connector from the large
position at both the ground and platform platform height sensor bracket.
controls.
14 Remove the fasteners securing the large
2 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. platform height sensor bracket to the number 1
3 Lift the safety arm, move it to the center of the inner arm pivot bracket.
scissor arm and rotate down to a vertical 15 Remove the large platform height sensor
position. bracket from the number 1 inner arm pivot
bracket.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 4 - 69


Section 4 Repair Procedures January 2012

SCISSOR COMPONENTS

16 Install the fasteners removed in 14 to the


number 1 inner arm pivot bracket and chassis.
Tip-over hazard. Failure to install
the fasteners securing the number
1 inner arm pivot bracket to the
chassis, could result in the
machine tipping over, causing
death or serious injury.
17 Connect the battery pack to the machine.
18 Turn the key switch to the ground control
position.
19 Press and hold the ground control scroll up and
scroll down buttons.
20 Pull out the red Emergency Stop button to the
on position at the ground controls.
21 Using the ground control menu buttons,
navigate to Service Override Mode. Select
Service Override Mode. Cable bridge and platform height sensor
legend
Note: The machine must be in Service Override
a cable bridge 4
Mode to raise the platform. While in Service b cable bridge 3A
Override Mode, only the GCON will operate with c cable bridge 3B
limited functionality. The platform will raise a d cable bridge 2A
predetermined amount of time and stop. e cable bridge 2B
f cable bridge 1
22 Raise the platform and return the safety arm to g platform height sensor
the stowed position. 24 Remove the platform. See 10-1, How to
23 Fully lower the platform to the stowed position. Remove the Platform.
25 Support and secure the entry ladder to an
appropriate lifting device.
26 Remove the fasteners from the entry ladder and
remove the entry ladder from the machine.
Crushing hazard. The entry ladder
may become unbalanced and fall
if not properly supported and
secured to the lifting device.
27 Remove the cables from the number 4 cable
bridge and lay them off to the side.
Component damage hazard.
Cables can be damaged if they
are kinked or pinched.

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January 2012 Section 4 Repair Procedures

SCISSOR COMPONENTS

28 Disconnect the number 4 cable bridge from the 37 Remove the retaining fasteners from the
number 4 outer arm (index #13) and remove number 4 center pivot pin (index #2) at the
the cable bridge from the machine. battery side.
29 Remove the retaining fasteners from the 38 Place a rod through the number 4 center pivot
number 5 pivot pin (index #1). pin at the battery side (index #2) and twist to
remove the pin.
30 Use a soft metal drift to remove the number 5
pivot pin (index #1). Remove the platform 39 Remove the number 4 outer arm (index #13)
mount bracket from the machine. from the machine.
31 Attach a lifting strap from an overhead crane to Crushing hazard. The number 4
the number 4 outer arm at the ground control outer arm (index #13) may
side (index #13). become unbalanced and fall if not
properly supported when removed
32 Remove the retaining fasteners from the
from the machine.
number 4 center pivot pin (index #2) at the
ground control side. 40 Attach a lifting strap from an overhead crane to
the number 4 inner arm (index #12). Raise the
33 Place a rod through the number 4 center pivot
arm to a vertical position.
pin at the ground control side (index #2) and
twist to remove the pin. 41 Remove the retaining fasteners from the
number 4 pivot pin at the steer end of the
34 Remove the retaining fasteners from the
machine (index #3).
number 4 pivot pin (index #15) at the non-steer
end. 42 Use a soft metal drift to remove the number 4
pivot pin (index #3) from the steer end of the
35 Use a soft metal drift to remove the number 4
machine. Remove the number 4 inner arm
pivot pin (index #14) from the non-steer end of
(index #12) from the machine.
the machine. Remove the number 4 outer arm
at the ground control side (index #13) from the Crushing hazard. The number 4
machine. inner arm (index #12) may
become unbalanced and fall if not
Crushing hazard. The number 4
properly supported when removed
outer arm at the ground control
from the machine.
side (index #13) may become
unbalanced and fall if not properly 43 Remove the cables from the number 3A and 3B
supported when removed from the cable bridge and lay them off to the side.
machine.
Component damage hazard.
36 Attach a lifting strap from an overhead crane to Cables can be damaged if they
the number 4 outer arm at the battery side are kinked or pinched.
(index #13).

Part No. 228901 GS-30 GS-32 GS-46 GS-47 4 - 71


Section 4 Repair Procedures January 2012

SCISSOR COMPONENTS

44 Disconnect the number 3A and 3B cable 52 Place a rod through the number 3 center pivot
bridges from the scissor linkset and remove pin at the battery side (index #4) and twist to
both cable bridges from the machine. remove the pin.
45 Attach a lifting strap from an overhead crane to 53 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
46 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.
47 Place a rod through the number 3 center pivot
pin at the ground control side (index #4) and 54 Attach a lifting strap from an overhead crane to
twist to remove the pin. the lug of the rod end of the lift cylinder.
48 Remove the retaining fasteners from the 55 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.
56 Use a soft metal drift to remove the lift cylinder
49 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.
57 Place a 4 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 58 Lower the cylinder onto the block.
supported when removed from the
machine. Bodily injury hazard. Keep hands
clear of moving parts when
50 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).
59 Attach a lifting strap from an overhead crane to
51 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.

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January 2012 Section 4 Repair Procedures

SCISSOR COMPONENTS

60 Remove the retaining fasteners from the 68 Use a soft metal drift to remove the number 2
number 3 pivot pin at the steer end of the pivot pin (index #20) from the non-steer end of
machine (index #6). the machine. Remove the number 2 outer arm
at the ground control side (index #19) from the
61 Use a soft metal drift to remove the number 3
machine.
pivot pin (index #6) from the steer end of the
machine. Remove the number 3 inner arm Crushing hazard. The number 2
(index #15) from the machine. outer arm at the ground control
side (index #19) may become
Crushing hazard. The number 3
unbalanced and fall if not properly
inner arm (index #15) may
supported when the pivot pin is
become unbalanced and fall if not
removed.
properly supported when the pivot
pin is removed. 69 Attach a lifting strap from an overhead crane to
the number 2 outer arm at the battery side
62 Remove the cables from the number 2A and 2B
(index #19).
cable bridge and lay them off to the side.
70 Remove the retaining fasteners from the
Component damage hazard.
number 2 center pivot pin (index #7) at the
Cables can be damaged if they
battery side.
are kinked or pinched.
71 Place a rod through the number 2 center pivot
63 Disconnect the number 2A and 2B cable
pin at the battery side (index #7) and twist to
bridges from the scissor linkset and remove
remove the pin.
both cable bridges from the machine.
Crushing hazard. The number 2
64 Attach a lifting strap from an overhead crane to
outer arm (index #19) may
the number 2 outer arm at the ground control
become unbalanced and fall if not
side (index #19).
properly supported when the pivot
65 Remove the retaining fasteners from the pin is removed.
number 2 center pivot pin (index #7) at the
72 Remove the number 2 outer arm (index #19)
ground control side.
from the machine.
66 Place a rod through the number 2 center pivot
Crushing hazard. The number 2
pin at the ground control side (index #7) and
outer arm (index #19) may
twist to remove the pin.
become unbalanced and fall if not
67 Remove the retaining fasteners from the properly supported when removed
number 2 pivot pin (index #20) at the non-steer from the machine.
end.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 4 - 73


Section 4 Repair Procedures January 2012

SCISSOR COMPONENTS

73 Attach a lifting strap from an overhead crane to 81 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.
74 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
75 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.
82 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 83 Tag and disconnect the wires and manual
properly supported when the pivot lowering cable from the solenoid valve on the
pin is removed. cylinder.
76 Attach a lifting strap from an overhead crane to 84 Models with platform overload option: Tag
the number 1 inner arm (index #10). and disconnect the wire harness from the
platform overload pressure transducer.
77 Raise the number 1 inner arm (index #10)
approximately 2 feet / 60 cm. Note: After replacing the scissor assembly, the
platform overload system must be calibrated.
78 Place a 4 x 4 x 48 inch / 10 cm x 10 cm x 1.2 m
Refer to Repair Procedure 9-10, How to Calibrate
long block across both sides of the chassis
the Platform Overload System (if equipped).
under the number 1 center pivot pin (index #9).
85 Raise the lift cylinder to a vertical position.
79 Lower the scissor arms onto the block that was
placed across the chassis. 86 Remove the pin retaining fasteners from the lift
cylinder barrel-end pivot pin (index #21). Use a
Bodily injury hazard. Keep hands
soft metal drift to remove the pin. Remove the
clear of moving parts when
lift cylinder from the machine.
lowering the scissor arms.
Crushing hazard. The lift cylinder
80 Attach a lifting strap from an overhead crane to
will fall if not properly supported
the lug of the rod end of the lower lift cylinder.
when the pivot pin is removed.
Component damage hazard. Be
careful not to damage the valve or
fittings on the cylinder while
removing it from the machine.

4 - 74 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 4 Repair Procedures

SCISSOR COMPONENTS

87 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 Note: Machines equipped with a Platform Height
are kinked or pinched. Sensor, begin at step 1. Machines without a
Platform Height Sensor, begin at step 24.
88 Disconnect the number 1 cable bridge from the
number 1 outer arm (index #22) and remove 1 Turn the key switch to ground control and pull
the cable bridge from the machine. out the red Emergency Stop button to the on
position at both the ground and platform
89 Attach a lifting strap from an overhead crane to controls.
the number 1 inner arm (index #10).
2 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
90 Raise the arm slightly and remove the block.
3 Lift the safety arm, move it to the center of the
91 Lower the arm to the stowed position. scissor arm and rotate down to a vertical
Bodily injury hazard. Keep hands position.
clear of moving parts when 4 Lower the platform onto the safety arm.
lowering the scissor arms.
Crushing hazard. Keep hands
92 Secure the ends of the scissor arms together at clear of the safety arm when
the steer end of the machine with a strap or lowering the platform.
other suitable device.
5 At the ground control, turn the key switch to the
93 Secure the ends of the scissor arms together at off position and push in the red Emergency
the non-steer end of the machine with a strap or Stop button to the off position.
other suitable device.
6 Disconnect the battery pack from the machine.
94 Remove the retaining fasteners securing the
chassis mount bracket to the chassis. Electrocution/burn hazard. Contact
with electrically charged circuits
95 Remove the linkset from the machine could result in death or serious
Bodily injury hazard. The number injury. Remove all rings, watches
1 inner and outer arms (index #10 and other jewelry.
and #22) may become unbalanced 7 Remove the fasteners securing the platform
and fall if not properly supported height sensor cover to the large platform height
when removed from the machine. sensor bracket.
Component damage hazard. Be 8 Remove the platform height sensor cover.
sure not to damage the limit switch
or level sensor box components
when the number 1 inner and
outer arms (index #10 and 22) is
removed from the machine.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 4 - 75


Section 4 Repair Procedures January 2012

SCISSOR COMPONENTS

9 Tag and disconnect the platform height sensor 20 Pull out the red Emergency Stop button to the
from the platform height sensor harness. on position at the ground controls.
10 Remove the fastener securing the platform 21 Using the ground control menu buttons,
height sensor assembly to the number 1 inner navigate to Service Override Mode. Select
arm. Service Override Mode.
11 Remove the platform height sensor assembly Note: The machine must be in Service Override
from the number 1 pivot pin. Mode to raise the platform. While in Service
Override Mode, only the GCON will operate with
12 Remove the plastic nut securing the squeeze
limited functionality. The platform will raise a
connector to the large platform height sensor
predetermined amount of time and stop.
bracket.
13 Remove the squeeze connector from the large 22 Raise the platform and return the safety arm to
platform height sensor bracket. the stowed position.
23 Fully lower the platform to the stowed position.
14 Remove the fasteners securing the large
platform height sensor bracket to the number 1 24 Remove the platform. See 10-1, How to
inner arm pivot bracket. Remove the Platform.
15 Remove the large platform height sensor 25 Support and secure the entry ladder to an
bracket from the number 1 inner arm pivot appropriate lifting device.
bracket.
26 Remove the fasteners from the entry ladder and
16 Install the fasteners removed in 14 to the remove the entry ladder from the machine.
number 1 inner arm pivot bracket and chassis.
Crushing hazard. The entry ladder
Tip-over hazard. Failure to install may become unbalanced and fall
the fasteners securing the number if not properly supported and
1 inner arm pivot bracket to the secured to the lifting device.
chassis, could result in the
machine tipping over, causing 27 Secure the ends of the scissor arms together at
death or serious injury. the steer end of the machine with a strap or
other suitable device.
17 Connect the battery pack to the machine.
28 Secure the ends of the scissor arms together at
18 Turn the key switch to the ground control the non-steer end of the machine with a strap or
position. other suitable device.
19 Press and hold the ground control scroll up and 29 Remove the retaining fasteners securing the
scroll down buttons. chassis mount bracket to the chassis at the
steer end of the machine.

4 - 76 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 4 Repair Procedures

SCISSOR COMPONENTS

30 Attach a lifting strap from an overhead crane to


the scissor arm assembly.
31 Raise the scissor arm assembly at the steer
end with the overhead crane until the chassis
mount bracket will clear the level sensor.
32 Remove the scissor assembly from the
machine just enough to access both wear pads.
Crushing hazard. The scissor
assembly will fall if not properly
supported when removed from the
drive chassis.
Component damage hazard. Be
careful not to damage the level
sensor or limit switch while moving
the scissor assembly.
33 Remove both old wear pads.
34 Install two new wear pads.
35 Slide the scissor assembly back into the drive
chassis.
36 Lower the scissor assembly into position and
install the chassis mount bracket onto the
chassis. Securely install and tighten the
fasteners. Do not over tighten.
Component damage hazard. Be
careful not to damage the level
sensor or limit switch while moving
the scissor assembly.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 4 - 77


Section 4 Repair Procedures January 2012

SCISSOR COMPONENTS

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
GS-3246
Steer end Non-steer end
1 Number 6 pivot pin 16 Number 5 inner arm
2 Number 5 center pivot pin (2 pins) 17 Number 5 outer arm
3 Upper lift cylinder rod-end pivot pin 18 Number 5 pivot pin (non-steer end)
4 Number 5 pivot pin (steer end) 19 Number 4 inner arm
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)

4 - 78 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 4 Repair Procedures

SCISSOR COMPONENTS

9-5 3 Lift the safety arm, move it to the center of the


scissor arm and rotate down to a vertical
Scissor Assembly, position.
GS-3232 and GS-3246 4 Lower the platform onto the safety arm.

How to Disassemble the Crushing hazard. Keep hands


clear of the safety arm when
Scissor Assembly, lowering the platform.
GS-3232 and GS-3246 5 At the ground control, turn the key switch to the
Bodily injury hazard. The off position and push in the red Emergency
procedures in this section require Stop button to the off position.
specific repair skills, lifting 6 Disconnect the battery pack from the machine.
equipment and a suitable
workshop. Attempting this Electrocution/burn hazard. Contact
procedure without these skills and with electrically charged circuits
tools could result in death or could result in death or serious
serious injury and significant injury. Remove all rings, watches
component damage. Dealer and other jewelry.
service is required. 7 Remove the fasteners securing the platform
When removing a hose assembly or fitting, the height sensor cover to the large platform height
O-ring on the fitting and/or hose end must be sensor bracket.
replaced and then torqued to specification during 8 Remove the platform height sensor cover.
installation. Refer to Section 2, Hydraulic Hose and
Fitting Torque Specifications. 9 Tag and disconnect the platform height sensor
from the platform height sensor harness.
Note: Machines equipped with a Platform Height
Sensor, begin the Scissor Disassembly procedure 10 Remove the fastener securing the platform
at step 1. Machines without a Platform Height height sensor assembly to the number 1 inner
Sensor, begin the Scissor Disassembly procedure arm.
at step 24. 11 Remove the platform height sensor assembly
1 Turn the key switch to ground control and pull from the number 1 pivot pin.
out the red Emergency Stop button to the on 12 Remove the plastic nut securing the squeeze
position at both the ground and platform connector to the large platform height sensor
controls. bracket.
2 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. 13 Remove the squeeze connector from the large
platform height sensor bracket.

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14 Remove the fasteners securing the large


platform height sensor bracket to the number 1
inner arm pivot bracket.
15 Remove the large platform height sensor
bracket from the number 1 inner arm pivot
bracket.
16 Install the fasteners removed in 14 to the
number 1 inner arm pivot bracket and chassis.
Tip-over hazard. Failure to install
the fasteners securing the number
1 inner arm pivot bracket to the
chassis, could result in the
machine tipping over, causing
death or serious injury.
17 Connect the battery pack to the machine.
18 Turn the key switch to the ground control
position.
19 Press and hold the ground control scroll up and
scroll down buttons.
20 Pull out the red Emergency Stop button to the
on position at the ground controls. Cable bridge and platform height sensor
legend
21 Using the ground control menu buttons,
navigate to Service Override Mode. Select a cable bridge 5
Service Override Mode. b cable bridge 4A
c cable bridge 4B
Note: The machine must be in Service Override d cable bridge 3A
Mode to raise the platform. While in Service e cable bridge 3B
f cable bridge 2A
Override Mode, only the GCON will operate with g cable bridge 2B
limited functionality. The platform will raise a h cable bridge 1
predetermined amount of time and stop. i platform height sensor

22 Raise the platform and return the safety arm to 24 Remove the platform. See 10-1, How to
the stowed position. Remove the Platform.

23 Fully lower the platform to the stowed position. 25 Support and secure the entry ladder to an
appropriate lifting device.

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26 Remove the fasteners from the entry ladder and 35 Use a soft metal drift to remove the number 5
remove the entry ladder from the machine. pivot pin (index #18) from the non-steer end of
the machine. Remove the number 5 outer arm
Crushing hazard. The entry ladder
at the ground control side (index #17) from the
may become unbalanced and fall
machine.
if not properly supported and
secured to the lifting device. Crushing hazard. The number 5
outer arm at the ground control
27 Remove the cables from the number 5 cable
side (index #17) may become
bridge and lay them off to the side.
unbalanced and fall if not properly
Component damage hazard. supported when removed from the
Cables can be damaged if they machine.
are kinked or pinched.
36 Attach a lifting strap from an overhead crane to
28 Disconnect the number 5 cable bridge from the the number 5 outer arm at the battery side
number 5 outer arm (index #17) and remove (index #17).
the cable bridge from the machine.
37 Remove the retaining fasteners from the
29 Remove the retaining fasteners from the number 5 center pivot pin (index #2) at the
number 6 pivot pin (index #1). battery side.
30 Use a soft metal drift to remove the number 6 38 Place a rod through the number 5 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.
31 Attach a lifting strap from an overhead crane to 39 Remove the number 5 outer arm (index #17)
the number 5 outer arm at the ground control from the machine.
side (index #17).
Crushing hazard. The number 5
32 Remove the retaining fasteners from the outer arm (index #17) may
number 5 center pivot pin (index #2) at the become unbalanced and fall if not
ground control side. properly supported when removed
from the machine.
33 Place a rod through the number 5 center pivot
pin at the ground control side (index #2) and 40 Attach a lifting strap from an overhead crane to
twist to remove the pin. the number 5 inner arm (index #16). Raise the
arm to a vertical position.
34 Remove the retaining fasteners from the
number 5 pivot pin (index #18) at the non-steer
end.

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41 Remove the retaining fasteners from the 47 Attach a lifting strap from an overhead crane to
number 5 pivot pin at the steer end of the the lug of the rod end of the upper lift cylinder.
machine (index #4).
48 Remove the retaining fasteners from the upper
42 Use a soft metal drift to remove the number 5 lift cylinder rod end pivot pin (index #3).
pivot pin (index #18) from the steer end of the
49 Use a soft metal drift to remove the upper lift
machine. Remove the number 5 inner arm
cylinder rod end pivot pin (index #3) from the
(index #16) from the machine.
machine.
Crushing hazard. The number 5
Crushing hazard. The lift cylinder
inner arm (index #16) may
may become unbalanced and fall
become unbalanced and fall if not
if not properly supported when the
properly supported when removed
pivot pin is removed.
from the machine.
50 Lower the cylinder onto the linkset.
43 Tag, disconnect and plug the hydraulic hose on
the upper lift cylinder. Cap the fittings on the 51 Attach a lifting strap from an overhead crane to
cylinder. the number 4 outer arm at the ground control
side (index #20).
Bodily injury hazard. Spraying
hydraulic oil can penetrate and 52 Remove the retaining fasteners from the
burn skin. Loosen hydraulic number 4 center pivot pin (index #5) at the
connections very slowly to allow ground control side.
the oil pressure to dissipate
gradually. Do not allow oil to squirt 53 Place a rod through the number 4 center pivot
or spray. pin at the ground control side (index #5) and
twist to remove the pin.
44 Tag and disconnect the wire harness from the
solenoid valve on the cylinder. 54 Remove the retaining fasteners from the
number 4 pivot pin (index #21) at the non-steer
45 Remove the cables from the number 4A and 4B end.
cable bridges and lay them off to the side.
55 Use a soft metal drift to remove the number 4
Component damage hazard. pivot pin (index #21) from the non-steer end of
Cables can be damaged if they the machine. Remove the number 4 outer arm
are kinked or pinched. at the ground control side (index #20) from the
machine.
46 Disconnect the number 4A and 4B cable
bridges from the scissor linkset and remove Crushing hazard. The number 4
both cable bridges from the machine. outer arm at the ground control
side (index #20) may become
unbalanced and fall if not properly
supported when removed from the
machine.

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56 Attach a lifting strap from an overhead crane to 63 Remove the cables from the number 3A and 3B
the number 4 outer arm at the battery side cable bridges and lay them off to the side.
(index #20).
Component damage hazard.
57 Remove the retaining fasteners from the Cables can be damaged if they
number 4 center pivot pin (index #5) at the are kinked or pinched.
battery side.
64 Disconnect the number 3A and 3B cable
58 Place a rod through the number 4 center pivot bridges from the scissor linkset and remove
pin at the battery side (index #5) and twist to both cable bridges from the machine.
remove the pin.
65 Attach a lifting strap from an overhead crane to
59 Remove the number 4 outer arm (index #20) the number 3 outer arm at the ground control
from the machine. side (index #7).
Crushing hazard. The number 4 66 Remove the retaining fasteners from the
outer arm (index #20) may number 3 center pivot pin (index #8) at the
become unbalanced and fall if not ground control side.
properly supported when removed
67 Place a rod through the number 3 center pivot
from the machine.
pin at the ground control side (index #8) and
60 Attach a lifting strap from an overhead crane to twist to remove the pin.
the number 4 inner arm (index #19). Raise the
68 Remove the retaining fasteners from the
arm to a vertical position.
number 3 pivot pin (index #24) at the non-steer
61 Remove the retaining fasteners from the end.
number 4 pivot pin at the steer end of the
69 Use a soft metal drift to remove the number 3
machine (index #6).
pivot pin (index #24) from the non-steer end of
62 Use a soft metal drift to remove the number 4 the machine. Remove the number 3 outer arm
pivot pin (index #6) from the steer end of the at the ground control side (index #7) from the
machine. Remove the number 4 inner arm machine.
(index #19) from the machine.
Crushing hazard. The number 3
Crushing hazard. The number 4 outer arm at the ground control
inner arm (index #19) may side (index #7) 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.

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70 Attach a lifting strap from an overhead crane to 77 Attach a lifting strap from an overhead crane to
the number 3 outer arm at the battery side the lug of the rod end of the lower lift cylinder.
(index #7).
78 Remove the retaining fasteners from the lower
71 Remove the retaining fasteners from the lift cylinder rod end pivot pin (index #9).
number 3 center pivot pin (index #8) at the
79 Use a soft metal drift to remove the lower lift
battery side.
cylinder rod end pivot pin (index #9) from the
72 Place a rod through the number 3 center pivot machine.
pin at the battery side (index #8) and twist to
Crushing hazard. The lower lift
remove the pin.
cylinder will fall if not properly
73 Remove the number 3 outer arm (index #7) supported when the pivot pin is
from the machine. removed.
Crushing hazard. The number 3 80 Place a 4 x 4 x 10 inch / 10 x 10 x 25 cm block
outer arm (index #7) may become onto the number 1 inner arm cylinder plate
unbalanced and fall if not properly (index #14).
supported when removed from the
81 Lower the cylinder onto the block.
machine.
Bodily injury hazard. Keep hands
74 Attach a lifting strap from an overhead crane to
clear of moving parts when
the lug of the rod end of the upper lift cylinder.
lowering the cylinder.
75 Raise the lift cylinder to a vertical position.
82 Attach a lifting strap from an overhead crane to
76 Remove the pin retaining fasteners from the lift the number 3 inner arm (index #23). Raise the
cylinder barrel-end pivot pin (index #22). arm to a vertical position.
Remove the lift cylinder from the machine.
83 Remove the retaining fasteners from the
Crushing hazard. The lift cylinder number 3 pivot pin at the steer end of the
will fall if not properly supported machine (index #10).
when the pivot pin is removed.
84 Use a soft metal drift to remove the number 3
Component damage hazard. Be pivot pin (index #10) from the steer end of the
careful not to damage the valve or machine. Remove the number 3 inner arm
fittings on the cylinder while (index #23) from the machine.
removing it from the machine.
Crushing hazard. The number 3
inner arm (index #23) may
become unbalanced and fall if not
properly supported when the pivot
pin is removed.

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85 Remove the cables from the number 2A and 2B 92 Attach a lifting strap from an overhead crane to
cable bridges and lay them off to the side. the number 2 outer arm at the battery side
(index #26).
Component damage hazard.
Cables can be damaged if they 93 Remove the retaining fasteners from the
are kinked or pinched. number 2 center pivot pin (index #11) at the
battery side.
86 Disconnect the number 2A and 2B cable
bridges from the scissor linkset and remove 94 Place a rod through the number 2 center pivot
both cable bridges from the machine. pin at the battery side (index #11) and twist to
remove the pin.
87 Attach a lifting strap from an overhead crane to
the number 2 outer arm at the ground control Crushing hazard. The number 2
side (index #26). outer arm (index #26) may
become unbalanced and fall if not
88 Remove the retaining fasteners from the
properly supported when the pivot
number 2 center pivot pin (index #11) at the
pin is removed.
ground control side.
95 Remove the number 2 outer arm (index #26)
89 Place a rod through the number 2 center pivot
from the machine.
pin at the ground control side (index #11) and
twist to remove the pin. Crushing hazard. The number 2
outer arm (index #26) may
90 Remove the retaining fasteners from the
become unbalanced and fall if not
number 2 pivot pin (index #27) at the non-steer
properly supported when removed
end.
from the machine.
91 Use a soft metal drift to remove the number 2
96 Attach a lifting strap from an overhead crane to
pivot pin (index #27) from the non-steer end of
the number 2 inner arm (index #25). Raise the
the machine. Remove the number 2 outer arm
arm to a vertical position.
at the ground control side (index #26) from the
machine. 97 Remove the retaining fasteners from the
number 2 pivot pin at the steer end of the
Crushing hazard. The number 2
machine (index #12).
outer arm at the ground control
side (index #26) may become
unbalanced and fall if not properly
supported when the pivot pin is
removed.

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Section 4 Repair Procedures January 2012

SCISSOR COMPONENTS

98 Use a soft metal drift to remove the number 2 105 Tag and disconnect the wire harness from the
pivot pin (index #12) from the steer end of the solenoid valve on the cylinder.
machine. Remove the number 2 inner arm
106 Models with platform overload option: Tag
(index #25) from the machine.
and disconnect the wire harness from the
Crushing hazard. The number 2 platform overload pressure transducer.
inner arm (index #25) may
Note: After replacing the scissor assembly, the
become unbalanced and fall if not
platform overload system must be calibrated.
properly supported when the pivot
Refer to Repair Procedure 9-10, How to Calibrate
pin is removed.
the Platform Overload System (if equipped).
99 Attach a lifting strap from an overhead crane to
the number 1 inner arm (index #14). 107 Raise the lift cylinder to a vertical position.

100 Raise the number 1 inner arm (index #14) 108 Remove the pin retaining fasteners from the
approximately 2 feet / 60 cm. lift cylinder barrel-end pivot pin (index #28).
Use a soft metal drift to remove the pin.
101 Place a 4 x 4 x 48 inch / 10 cm x 10 cm x 1.2 Remove the lift cylinder from the machine.
m long block across both sides of the
chassis under the number 1 center pivot Crushing hazard. The lift cylinder
pin (index #13). will fall if not properly supported
when the pivot pin is removed.
102 Lower the scissor arms onto the block that
was placed across the chassis. Component damage hazard. Be
careful not to damage the valve or
Bodily injury hazard. Keep hands fittings on the cylinder while
clear of moving parts when removing it from the machine.
lowering the scissor arms.
109 Remove the cables from the number 1 cable
103 Attach a lifting strap from an overhead crane bridge and lay them off to the side.
to the lug of the rod end of the lower lift
cylinder. Component damage hazard.
Cables can be damaged if they
104 Tag, disconnect and plug the hydraulic hose are kinked or pinched.
on the lower lift cylinder. Cap the fittings on
the cylinder. 110 Disconnect the number 1 cable bridge from
the number 1 outer arm (index #29) and
Bodily injury hazard. Spraying remove the cable bridge from the machine.
hydraulic oil can penetrate and
burn skin. Loosen hydraulic 111 Attach a lifting strap from an overhead crane
connections very slowly to allow to the number 1 inner arm (index #14).
the oil pressure to dissipate 112 Raise the arm slightly and remove the block.
gradually. Do not allow oil to squirt
or spray.

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113 Lower the arm to the stowed position. How to Replace the Scissor Arm
Bodily injury hazard. Keep hands Wear Pads
clear of moving parts when
lowering the scissor arms. Note: Machines equipped with a Platform Height
Sensor, begin at step 1. Machines without a
114 Secure the ends of the scissor arms together Platform Height Sensor, begin at step 24.
at the steer end of the machine with a strap or
other suitable device. 1 Turn the key switch to ground control and pull
out the red Emergency Stop button to the on
115 Secure the ends of the scissor arms together position at both the ground and platform
at the non-steer end of the machine with a controls.
strap or other suitable device.
2 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
116 Remove the retaining fasteners securing the
chassis mount bracket to the chassis. 3 Lift the safety arm, move it to the center of the
scissor arm and rotate down to a vertical
117 Remove the linkset from the machine. position.
Bodily injury hazard. The number 4 Lower the platform onto the safety arm.
1 inner and outer arms (index #14
and #29) may become unbalanced Crushing hazard. Keep hands
and fall if not properly supported clear of the safety arm when
when removed from the machine. lowering the platform.
Component damage hazard. Be 5 At the ground control, turn the key switch to the
sure not to damage the limit switch off position and push in the red Emergency
or level sensor box components Stop button to the off position.
when the number 1 inner and
6 Disconnect the battery pack from the machine.
outer arms (index #14 and 29) is
removed from the machine. Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
7 Remove the fasteners securing the platform
height sensor cover to the large platform height
sensor bracket.
8 Remove the platform height sensor cover.

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9 Tag and disconnect the platform height sensor 19 Press and hold the ground control scroll up and
from the platform height sensor harness. scroll down buttons.
10 Remove the fastener securing the platform 20 Pull out the red Emergency Stop button to the
height sensor assembly to the number 1 inner on position at the ground controls.
arm.
21 Using the ground control menu buttons,
11 Remove the platform height sensor assembly navigate to Service Override Mode. Select
from the number 1 pivot pin. Service Override Mode.
12 Remove the plastic nut securing the squeeze Note: The machine must be in Service Override
connector to the large platform height sensor Mode to raise the platform. While in Service
bracket. Override Mode, only the GCON will operate with
limited functionality. The platform will raise a
13 Remove the squeeze connector from the large
predetermined amount of time and stop.
platform height sensor bracket.
22 Raise the platform and return the safety arm to
14 Remove the fasteners securing the large
the stowed position.
platform height sensor bracket to the number 1
inner arm pivot bracket. 23 Fully lower the platform to the stowed position.
15 Remove the large platform height sensor 24 Remove the platform. See 10-1, How to
bracket from the number 1 inner arm pivot Remove the Platform.
bracket.
25 Support and secure the entry ladder to an
16 Install the fasteners removed in 14 to the appropriate lifting device.
number 1 inner arm pivot bracket and chassis.
26 Remove the fasteners from the entry ladder and
Tip-over hazard. Failure to install remove the entry ladder from the machine.
the fasteners securing the number
1 inner arm pivot bracket to the Crushing hazard. The entry ladder
chassis, could result in the may become unbalanced and fall
machine tipping over, causing if not properly supported and
death or serious injury. secured to the lifting device.

17 Connect the battery pack to the machine. 27 Secure the ends of the scissor arms together at
the steer end of the machine with a strap or
18 Turn the key switch to the ground control other suitable device.
position.
28 Secure the ends of the scissor arms together at
the non-steer end of the machine with a strap or
other suitable device.

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29 Remove the retaining fasteners securing the


chassis mount bracket to the chassis at the
steer end of the machine.
30 Attach a lifting strap from an overhead crane to
the scissor arm assembly.
31 Raise the scissor arm assembly at the steer
end with the overhead crane until the chassis
mount bracket will clear the level sensor.
32 Remove the scissor assembly from the
machine just enough to access both wear pads.
Crushing hazard. The scissor
assembly will fall if not properly
supported when removed from the
drive chassis.
Component damage hazard. Be
careful not to damage the level
sensor or limit switch while moving
the scissor assembly.
33 Remove both old wear pads.
34 Install two new wear pads.
35 Slide the scissor assembly back into the drive
chassis.
36 Lower the scissor assembly into position and
install the chassis mount bracket onto the
chassis. Securely install and tighten the
fasteners. Do not over tighten.
Component damage hazard. Be
careful not to damage the level
sensor or limit switch while moving
the scissor assembly.

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Section 4 Repair Procedures January 2012

SCISSOR COMPONENTS

Steer end Non-steer end


1 Number 7 pivot pin 23 Number 5 pivot pin (non-steer end)
2 Number 6 cylinder pivot pin (2 pins) 24 Number 4 inner arm
3 Number 6 pivot pin (steer end) 13 Number 2 center pivot pin (2 pins) 25 Number 4 outer arm
4 Number 5 center pivot pin 14 Number 2 pivot pin (steer end) 26 Number 4 pivot pin (non-steer end)
5 Upper lift cylinder rod-end pivot pin 15 Number 1 center pivot pin (2 pins) 27 Upper lift cylinder barrel-end pivot pin
6 Number 5 pivot pin (steer end) 16 Number 1 inner arm 28 Number 3 inner arm
7 Number 4 center pivot pin (2 pins) 17 Number 1 pivot pin (steer end) (2 pins) 29 Number 3 pivot pin (non-steer end)
8 Number 4 pivot pin (steer end) 18 Number 6 inner arm 30 Number 2 inner arm
9 Number 3 outer arm 19 Number 6 outer arm 31 Number 2 outer arm
10 Number 3 center pivot pin (2 pins) 20 Number 6 pivot pin (non-steer end) 32 Number 2 pivot pin (non-steer end)
11 Lower lift cylinder rod-end pivot pin 21 Number 5 inner arm 33 Lower lift cylinder barrel-end pivot pin
12 Number 3 pivot pin (steer end) 22 Number 5 outer arm 34 Number 1 outer arm

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9-6 4 Lower the platform onto the safety arm.


Scissor Assembly, Crushing hazard. Keep hands
clear of the safety arm when
GS-4047 lowering the platform.

How to Disassemble the 5 At the ground control, turn the key switch to the
off position and push in the red Emergency
Scissor Assembly, Stop button to the off position.
GS-4047 6 Disconnect the battery pack from the machine.
Bodily injury hazard. The Electrocution/burn hazard. Contact
procedures in this section require with electrically charged circuits
specific repair skills, lifting could result in death or serious
equipment and a suitable injury. Remove all rings, watches
workshop. Attempting this and other jewelry.
procedure without these skills and
tools could result in death or 7 Remove the fasteners securing the platform
serious injury and significant height sensor cover to the large platform height
component damage. Dealer sensor bracket.
service is required. 8 Remove the platform height sensor cover.
When removing a hose assembly or fitting, the 9 Tag and disconnect the platform height sensor
O-ring on the fitting and/or hose end must be from the platform height sensor harness.
replaced and then torqued to specification during
installation. Refer to Section 2, Hydraulic Hose and 10 Remove the fastener securing the platform
Fitting Torque Specifications. height sensor assembly to the number 1 inner
arm.
Note: Machines equipped with a Platform Height
Sensor, begin the Scissor Disassembly procedure 11 Remove the platform height sensor assembly
at step 1. Machines without a Platform Height from the number 1 pivot pin.
Sensor, begin the Scissor Disassembly procedure 12 Remove the plastic nut securing the squeeze
at step 24. connector to the large platform height sensor
1 Turn the key switch to ground control and pull bracket.
out the red Emergency Stop button to the on 13 Remove the squeeze connector from the large
position at both the ground and platform platform height sensor bracket.
controls.
14 Remove the fasteners securing the large
2 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. platform height sensor bracket to the number 1
3 Lift the safety arm, move it to the center of the inner arm pivot bracket.
scissor arm and rotate down to a vertical 15 Remove the large platform height sensor
position. bracket from the number 1 inner arm pivot
bracket.

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Section 4 Repair Procedures January 2012

SCISSOR COMPONENTS

16 Install the fasteners removed in 14 to the


number 1 inner arm pivot bracket and chassis.
Tip-over hazard. Failure to install
the fasteners securing the number
1 inner arm pivot bracket to the
chassis, could result in the
machine tipping over, causing
death or serious injury.
17 Connect the battery pack to the machine.
18 Turn the key switch to the ground control
position.
19 Press and hold the ground control scroll up and
scroll down buttons.
20 Pull out the red Emergency Stop button to the
on position at the ground controls.
21 Using the ground control menu buttons,
navigate to Service Override Mode. Select
Service Override Mode.
Note: The machine must be in Service Override
Mode to raise the platform. While in Service
Override Mode, only the GCON will operate with
limited functionality. The platform will raise a
predetermined amount of time and stop.
22 Raise the platform and return the safety arm to
the stowed position. Links and platform height sensor legend

23 Fully lower the platform to the stowed position. a number 6 outer link
b number 5 inner link
c number 5 outer link
d number 4 inner link
e number 4 outer link
f number 3 inner link
g number 3 outer link
h number 2 inner link
i number 2 outer link
j number 1 cable bridge
k platform height sensor

24 Remove the platform. See 10-1, How to


Remove the Platform.
25 Remove the cables from links a, b and c.
26 Remove the retaining fasteners from the
number 7 pivot pin (index #1).

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27 Use a soft metal drift to remove the number 7 36 Remove the number 6 outer arm (index #19)
pivot pin (index #1). Remove the platform from the machine.
mount bracket from the machine.
Crushing hazard. The number 6
28 Attach a lifting strap from an overhead crane to outer arm (index #19) may
the number 6 outer arm at the ground control become unbalanced and fall if not
side (index #19). properly supported when removed
from the machine.
29 Remove the retaining fasteners from the
number 6 center pivot pin (index #2) at the 37 Attach a lifting strap from an overhead crane to
ground control side. the number 6 inner arm (index #18). Raise the
arm to a vertical position.
30 Place a rod through the number 6 center pivot
pin at the ground control side (index #2) and 38 Remove the retaining fasteners from the
twist to remove the pin. number 6 pivot pin at the steer end of the
machine (index #3).
31 Remove the retaining fasteners from the
number 6 pivot pin (index #20) at the non-steer 39 Use a soft metal drift to remove the number 6
end. pivot pin (index #3) from the steer end of the
machine. Remove the number 6 inner arm
32 Use a soft metal drift to remove the number 6
(index #18) from the machine.
pivot pin (index #20) from the non-steer end of
the machine. Remove the number 6 outer arm Crushing hazard. The number 5
at the ground control side (index #19) from the inner arm (index #16) may
machine. become unbalanced and fall if not
properly supported when removed
Crushing hazard. The number 6
from the machine.
outer arm at the ground control
side (index #19) may become 40 Tag, disconnect and plug the hydraulic hose on
unbalanced and fall if not properly the upper lift cylinder. Cap the fittings on the
supported when removed from the cylinder.
machine.
Bodily injury hazard. Spraying
33 Attach a lifting strap from an overhead crane to hydraulic oil can penetrate and
the number 6 outer arm at the battery side burn skin. Loosen hydraulic
(index #19). connections very slowly to allow
the oil pressure to dissipate
34 Remove the retaining fasteners from the
gradually. Do not allow oil to squirt
number 6 center pivot pin (index #2) at the
or spray.
battery side.
41 Attach a lifting strap from an overhead crane to
35 Place a rod through the number 6 center pivot
the number 5 outer arm at the ground control
pin at the battery side (index #2) and twist to
side (index #22).
remove the pin.

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42 Remove the retaining fasteners from the 49 Attach a lifting strap from an overhead crane to
number 5 center pivot pin (index #4) at the the lug of the rod end of the upper lift cylinder.
ground control side.
50 Remove the retaining fasteners from the upper
43 Place a rod through the number 5 center pivot lift cylinder rod end pivot pin (index #5).
pin at the ground control side (index #4) and
51 Use a soft metal drift to remove the upper lift
twist to remove the pin.
cylinder rod end pivot pin (index #5) from the
44 Remove the retaining fasteners from the machine.
number 5 pivot pin (index #23) at the non-steer
Crushing hazard. The lift cylinder
end.
may become unbalanced and fall
45 Use a soft metal drift to remove the number 5 if not properly supported when the
pivot pin (index #23) from the non-steer end of pivot pin is removed.
the machine. Remove the number 5 outer arm
52 Lower the cylinder onto the linkset.
at the ground control side (index #22) from the
machine. 53 Attach a lifting strap from an overhead crane to
the number 4 outer arm at the ground control
Crushing hazard. The number 5
side (index #25).
outer arm at the ground control
side (index #22) may become 54 Remove the retaining fasteners from the
unbalanced and fall if not properly number 4 center pivot pin (index #7) at the
supported when removed from the ground control side.
machine.
55 Place a rod through the number 4 center pivot
46 Attach a lifting strap from an overhead crane to pin at the ground control side (index #7) and
the number 5 outer arm at the battery side twist to remove the pin.
(index #22).
56 Remove the retaining fasteners from the
47 Remove the number 5 outer arm (index #22) number 4 pivot pin (index #26) at the non-steer
from the machine. end.
Crushing hazard. The number 5 57 Use a soft metal drift to remove the number 4
outer arm at the battery side pivot pin (index #26) from the non-steer end of
(index #22) may become the machine. Remove the number 4 outer arm
unbalanced and fall if not properly at the ground control side (index #25) from the
supported when removed from the machine.
machine.
Crushing hazard. The number 4
48 Tag and disconnect the wire harness from the outer arm at the ground control
solenoid valve on the cylinder. side (index #25) may become
unbalanced and fall if not properly
Component damage hazard.
supported when removed from the
Cables can be damaged if they
machine.
are kinked or pinched.

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58 Attach a lifting strap from an overhead crane to 66 Attach a lifting strap from an overhead crane to
the number 4 outer arm at the battery side the number 3 outer arm at the ground control
(index #25). side (index #9).
59 Remove the retaining fasteners from the 67 Remove the retaining fasteners from the
number 4 center pivot pin (index #7) at the number 3 center pivot pin (index #10) at the
battery side. ground control side.
60 Place a rod through the number 4 center pivot 68 Place a rod through the number 3 center pivot
pin at the battery side (index #7) and twist to pin at the ground control side (index #10) and
remove the pin. twist to remove the pin.
61 Remove the number 4 outer arm (index #25) 69 Remove the retaining fasteners from the
from the machine. number 3 pivot pin (index #29) at the non-steer
end.
Crushing hazard. The number 4
outer arm (index #25) may 70 Use a soft metal drift to remove the number 3
become unbalanced and fall if not pivot pin (index #29) from the non-steer end of
properly supported when removed the machine. Remove the number 3 outer arm
from the machine. at the ground control side (index #9) from the
machine.
62 Attach a lifting strap from an overhead crane to
the number 4 inner arm (index #24). Raise the Crushing hazard. The number 3
arm to a vertical position. outer arm at the ground control
side (index #9) may become
63 Remove the retaining fasteners from the
unbalanced and fall if not properly
number 4 pivot pin at the steer end of the
supported when removed from the
machine (index #8).
machine.
64 Use a soft metal drift to remove the number 4
71 Attach a lifting strap from an overhead crane to
pivot pin (index #8) from the steer end of the
the number 3 outer arm at the battery side
machine. Remove the number 4 inner arm
(index #9).
(index #24) from the machine.
72 Remove the number 3 outer arm (index #9)
Crushing hazard. The number 4
from the machine.
inner arm (index #24) may
become unbalanced and fall if not Crushing hazard. The number 3
properly supported when removed outer arm (index #9) may become
from the machine. unbalanced and fall if not properly
supported when removed from the
65 Remove the cables from links d and e.
machine.
Component damage hazard.
Cables can be damaged if they
are kinked or pinched.

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73 Attach a lifting strap from an overhead crane 82 Place a 4 x 4 x 10 inch / 10 x 10 x 25 cm block


to the number 3 inner arm (index #28). onto the number 1 inner arm cylinder plate
Raise the number 3 inner arm and place a (index #16).
4 x 4 x 48 inch / 10 cm x 10 cm x 1.2 m block
83 Lower the cylinder onto the block.
across the link stack to gain access to the
barrel end pivot pin (index 27). Bodily injury hazard. Keep hands
clear of moving parts when
74 Attach a lifting strap from an overhead crane to
lowering the cylinder.
the lug of the rod end of the upper lift cylinder.
84 Attach a lifting strap from an overhead crane to
75 Raise the lift cylinder to a vertical position.
the number 3 inner arm (index #28). Raise the
Crushing hazard. The lift cylinder arm to a vertical position.
will fall if not properly supported
85 Remove the retaining fasteners from the
when the pivot pin is removed.
number 3 pivot pin at the steer end of the
Component damage hazard. Be machine (index #12).
careful not to damage the valve or
86 Use a soft metal drift to remove the number 3
fittings on the cylinder while
pivot pin (index #12) from the steer end of the
removing it from the machine.
machine. Remove the number 3 inner arm
76 Use a soft metal drift to remove the upper lift (index #28) from the machine.
cylinder barrel end pivot pin (index #27) from
Crushing hazard. The number 3
the machine.
inner arm (index #28) may
77 Attach a lifting strap from an overhead crane become unbalanced and fall if not
to the number 3 inner arm (index #28). properly supported when the pivot
Raise the number 3 inner arm and remove the pin is removed.
4 x 4 x 48 inch / 10 cm x 10 cm x 1.2 m block
87 Attach a lifting strap from an overhead crane to
from the link stack.
the number 2 outer arm at the ground control
78 Lower the number 3 inner arm (index #28) and side (index #31).
remove the lifting strap.
88 Remove the retaining fasteners from the
79 Attach a lifting strap from an overhead crane to number 2 center pivot pin (index #13) at the
the lug of the rod end of the lower lift cylinder. ground control side.
80 Remove the retaining fasteners from the lower 89 Place a rod through the number 2 center pivot
lift cylinder rod end pivot pin (index 11). pin at the ground control side (index #13) and
twist to remove the pin.
81 Use a soft metal drift to remove the lower lift
cylinder rod end pivot pin (index 11) from the 90 Remove the retaining fasteners from the
machine. number 2 pivot pin (index #32) at the non-steer
end.
Crushing hazard. The lower lift
cylinder will fall if not properly
supported when the pivot pin is
removed.

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91 Use a soft metal drift to remove the number 2 97 Remove the retaining fasteners from the
pivot pin (index #32) from the non-steer end of number 2 pivot pin at the steer end of the
the machine. Remove the number 2 outer arm machine (index #14).
at the ground control side (index #31) from the
98 Use a soft metal drift to remove the number 2
machine.
pivot pin (index #14) from the steer end of the
Crushing hazard. The number 2 machine. Remove the number 2 inner arm
outer arm at the ground control (index #30) from the machine.
side (index #31) may become
Crushing hazard. The number 2
unbalanced and fall if not properly
inner arm (index #30) may
supported when the pivot pin is
become unbalanced and fall if not
removed.
properly supported when the pivot
92 Attach a lifting strap from an overhead crane to pin is removed.
the number 2 outer arm at the battery side
99 Attach a lifting strap from an overhead crane to
(index #31).
the number 1 inner arm (index #16).
93 Remove the retaining fasteners from the
100 Raise the number 1 inner arm (index #16)
number 2 center pivot pin (index #13) at the
approximately 2 feet / 60 cm.
battery side.
101 Place a 4 x 4 x 48 inch / 10 cm x 10 cm x 1.2
94 Place a rod through the number 2 center pivot
m long block across both sides of the chassis
pin at the battery side (index #13) and twist to
under the number 1 center pivot pin
remove the pin.
(index #15).
Crushing hazard. The number 2
102 Lower the scissor arms onto the block that
outer arm (index #31) may
was placed across the chassis.
become unbalanced and fall if not
properly supported when the pivot Bodily injury hazard. Keep hands
pin is removed. clear of moving parts when
lowering the scissor arms.
95 Remove the number 2 outer arm (index #31)
from the machine. 103 Attach a lifting strap from an overhead crane
to the lug of the rod end of the lower lift
Crushing hazard. The number 2
cylinder.
outer arm (index #31) may
become unbalanced and fall if not 104 Tag, disconnect and plug the hydraulic hose
properly supported when removed on the lower lift cylinder. Cap the fittings on
from the machine. the cylinder.
96 Attach a lifting strap from an overhead crane to Bodily injury hazard. Spraying
the number 2 inner arm (index #30). Raise the hydraulic oil can penetrate and
arm to a vertical position. burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.

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105 Tag and disconnect the wire harness from the 112 Disconnect the number 1 cable bridge from
solenoid valve on the cylinder. the number 1 outer arm (index #34) and
remove the cable bridge from the machine.
106 Tag and disconnect the wires and manual
lowering cable from the solenoid valve on the 113 Attach a lifting strap from an overhead crane
cylinder. to the number 1 inner arm (index #16).
107 Models with platform overload option: Tag 114 Raise the arm slightly and remove the block.
and disconnect the wire harness from the
115 Lower the arm to the stowed position.
platform overload pressure transducer.
Bodily injury hazard. Keep hands
Note: After replacing the scissor assembly, the
clear of moving parts when
platform overload system must be calibrated.
lowering the scissor arms.
Refer to Repair Procedure 9-10, How to Calibrate
the Platform Overload System (if equipped). 116 Secure the ends of the scissor arms together
at the steer end of the machine with a strap or
108 Raise the lift cylinder to a vertical position.
other suitable device.
109 Remove the pin retaining fasteners from the
117 Secure the ends of the scissor arms together
lift cylinder barrel-end pivot pin (index #28).
at the non-steer end of the machine with a
Use a soft metal drift to remove the pin.
strap or other suitable device.
Remove the lift cylinder from the machine.
118 Remove the retaining fasteners securing the
Crushing hazard. The lift cylinder
chassis mount bracket to the chassis.
will fall if not properly supported
when the pivot pin is removed. 119 Remove the linkset from the machine.
Component damage hazard. Be Bodily injury hazard. The number
careful not to damage the valve or 1 inner and outer arms (index #16
fittings on the cylinder while and #34) may become unbalanced
removing it from the machine. and fall if not properly supported
when removed from the machine.
110 Remove the cables from the number 1 cable
bridge and lay them off to the side. Component damage hazard. Be
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 #16 and 34) is
111 Remove the cables from the number 1 cable removed from the machine.
bridge and lay them off to the side.

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How to Replace the Scissor Arm 10 Remove the fastener securing the platform
height sensor assembly to the number 1 inner
Wear Pads arm.
Note: Machines equipped with a Platform Height 11 Remove the platform height sensor assembly
Sensor, begin at step 1. Machines without a from the number 1 pivot pin.
Platform Height Sensor, begin at step 24.
12 Remove the plastic nut securing the squeeze
1 Turn the key switch to ground control and pull connector to the large platform height sensor
out the red Emergency Stop button to the on bracket.
position at both the ground and platform
controls. 13 Remove the squeeze connector from the large
platform height sensor bracket.
2 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
14 Remove the fasteners securing the large
3 Lift the safety arm, move it to the center of the platform height sensor bracket to the number 1
scissor arm and rotate down to a vertical inner arm pivot bracket.
position.
15 Remove the large platform height sensor
4 Lower the platform onto the safety arm. bracket from the number 1 inner arm pivot
bracket.
Crushing hazard. Keep hands
clear of the safety arm when 16 Install the fasteners removed in 14 to the
lowering the platform. number 1 inner arm pivot bracket and chassis.
5 At the ground control, turn the key switch to the Tip-over hazard. Failure to install
off position and push in the red Emergency the fasteners securing the number
Stop button to the off position. 1 inner arm pivot bracket to the
chassis, could result in the
6 Disconnect the battery pack from the machine.
machine tipping over, causing
Electrocution/burn hazard. Contact death or serious injury.
with electrically charged circuits
17 Connect the battery pack to the machine.
could result in death or serious
injury. Remove all rings, watches 18 Turn the key switch to the ground control
and other jewelry. position.
7 Remove the fasteners securing the platform 19 Press and hold the ground control scroll up and
height sensor cover to the large platform height scroll down buttons.
sensor bracket.
20 Pull out the red Emergency Stop button to the
8 Remove the platform height sensor cover. on position at the ground controls.
9 Tag and disconnect the platform height sensor
from the platform height sensor harness.

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21 Using the ground control menu buttons, 31 Raise the scissor arm assembly at the steer
navigate to Service Override Mode. Select end with the overhead crane until the chassis
Service Override Mode. mount bracket will clear the level sensor.
Note: The machine must be in Service Override 32 Remove the scissor assembly from the
Mode to raise the platform. While in Service machine just enough to access both wear pads.
Override Mode, only the GCON will operate with
Crushing hazard. The scissor
limited functionality. The platform will raise a
assembly will fall if not properly
predetermined amount of time and stop.
supported when removed from the
22 Raise the platform and return the safety arm to drive chassis.
the stowed position. Component damage hazard. Be
23 Fully lower the platform to the stowed position. careful not to damage the level
sensor or limit switch while moving
24 Remove the platform. See 10-1, How to the scissor assembly.
Remove the Platform.
33 Remove both old wear pads.
25 Support and secure the entry ladder to an
appropriate lifting device. 34 Install two new wear pads.
26 Remove the fasteners from the entry ladder and 35 Slide the scissor assembly back into the drive
remove the entry ladder from the machine. chassis.
Crushing hazard. The entry ladder 36 Lower the scissor assembly into position and
may become unbalanced and fall install the chassis mount bracket onto the
if not properly supported and chassis. Securely install and tighten the
secured to the lifting device. fasteners. Do not over tighten.
27 Secure the ends of the scissor arms together at Component damage hazard. Be
the steer end of the machine with a strap or careful not to damage the level
other suitable device. sensor or limit switch while moving
the scissor assembly.
28 Secure the ends of the scissor arms together at
the non-steer end of the machine with a strap or
other suitable device.
29 Remove the retaining fasteners securing the
chassis mount bracket to the chassis at the
steer end of the machine.
30 Attach a lifting strap from an overhead crane to
the scissor arm assembly.

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9-7 7 Remove the platform height sensor cover.


Platform Height Sensor

How to Disassemble the


Platform Height Sensor
Assembly (if equipped)
When a Platform Height Sensor Assembly is
removed or replaced, the platform overload
system must be calibrated. Refer to Repair
Procedure 9-10, How to Calibrate the Platform
Overload System (if equipped).
1 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
a fasteners (platform height sensor
2 Lift the safety arm, move it to the center of the cover)
scissor arm and rotate down to a vertical b platform height sensor cover
position.
8 Tag and disconnect the platform height sensor
3 Lower the platform onto the safety arm. harness from the platform height sensor.
Crushing hazard. Keep hands 9 Remove the fastener securing the platform
clear of the safety arm when height sensor assembly to the number 1 inner
lowering the platform. arm.
4 Turn the key switch to the off position. 10 Remove the platform height sensor assembly
from the number 1 pivot pin.
5 Disconnect the battery pack from the machine.
11 Remove the set screw securing the lever arm to
Electrocution/burn hazard. Contact
the platform height sensor.
with electrically charged circuits
could result in death or serious 12 Remove the lever arm from the platform height
injury. Remove all rings, watches sensor assembly.
and other jewelry.
13 Working with the platform height sensor
6 Remove the fasteners securing the platform assembly, remove the Deustch connector from
height sensor cover to the large platform height the plastic clip.
sensor bracket.

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14 Remove the fasteners securing the platform 18 Remove the fasteners securing the large
height sensor to the small platform height platform height bracket to the number 1 inner
sensor bracket. arm pivot bracket.
15 Remove the platform height sensor from the 19 Remove the large platform height sensor
small angle sensor bracket. bracket from the number 1 inner arm pivot
bracket.
16 Remove the plastic nut securing the squeeze
connector to the large platform height sensor Tip-over hazard. Failure to install
bracket. the fasteners securing the large
platform height sensor bracket and
17 Remove the squeeze connector from the large
number 1 inner arm pivot bracket
platform height sensor bracket.
to the chassis, could result in the
machine tipping over, causing
death or serious injury.

a number 1 inner arm


b fastener
(platform height sensor assembly)
c number 1 pivot pin
d lever arm retaining screw
e squeeze connector
f lever arm
g platform height sensor harness
connection
h platform height sensor
i fastener
(large platform height sensor bracket)
j fastener (platform height sensor)
k platform height sensor assembly

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9-8
Lift Cylinder

How to Remove the Lift Cylinder


Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
When removing a hose assembly or fitting, the
fitting and/or hose end must be torqued to
specification during installation. Refer to Section 2,
Hydraulic Hose and Fitting Torque Specifications.
GS-1530, GS-1532, GS-1930 and GS-1932: a lift cylinder
b orifice (schematic item O)
Note: Models without a pressure transducer follow c connector fitting
steps 1 through 23, 27 and 28. d hydraulic hose
Models equipped with a pressure transducer follow e pressure transducer (schematic R)
steps 1 through 28. (if equipped)
f manual lowering cable
g solenoid valve (schematic item N)
1 Turn the key switch to ground control and pull
h cable mount bracket
out the red Emergency Stop button to the on
position at both the ground and platform 4 Lower the platform onto the safety arm.
controls.
Crushing hazard. Keep hands
2 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. clear of the safety arm when
lowering the platform.
3 Lift the safety arm, move it to the center of the
scissor arm and rotate down to a vertical 5 Using a suitable lifting device, support the link
position. stack at the steer end of the machine.

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6 At the ground control, turn the key switch to the 14 Remove the retaining fasteners from the lift
off position and push in the red Emergency cylinder rod-end pivot pin. Use a soft metal drift
Stop button to the off position. to remove the pin.
7 Disconnect the battery pack from the machine. Crushing hazard. The lift cylinder
will fall if not properly supported.
Electrocution/burn hazard. Contact
with electrically charged circuits 15 Lower the cylinder onto the number 2 inner arm.
could result in death or serious
16 Attach a lifting strap from an overhead crane or
injury. Remove all rings, watches
similar lifting device to the barrel end of the lift
and other jewelry.
cylinder for support.
8 Tag and disconnect the wiring from the solenoid
17 Remove the retaining fasteners from the lift
valve coil at the barrel end of the lift cylinder.
cylinder barrel-end pivot pin. Use a soft metal
9 If equipped, tag and disconnect the three-pin drift to remove the pin.
connector from the pressure transducer
Crushing hazard. The lift cylinder
harness. To remove the pressure transducer
will fall if not properly supported
refer to Repair Procedure 9-9, How to Remove
when the pin is removed.
the Pressure Transducer (if equipped).
18 Support and secure the lift cylinder to an
10 Loosen the adjustment nuts on the solenoid
appropriate lifting device.
valve and disconnect the manual lowering cable
from the valve. 19 Remove the lift cylinder through the scissor
arms at the steer end of the machine.
Note: During assembly, the manual platform
lowering cable needs to be properly adjusted. Crushing hazard. The lift cylinder
See 2-3, How to Adjust the Manual Platform may become unbalanced and fall
Lowering Cable. if not properly supported and
secured to the lifting device.
11 Remove the fasteners securing the manual
lowering cable mount bracket to the cylinder. Component damage hazard.
Remove the bracket from the cylinder. Be careful not to damage the
valve or fittings on the cylinder
12 Tag, disconnect and plug the hydraulic hoses while removing it from the
on the lift cylinder. Cap the fittings on the machine.
cylinder.
20 Install new cylinder, fittings, hoses and pressure
Bodily injury hazard. Spraying transducer (if equipped).
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
13 Attach a lifting strap from an overhead crane to
the rod end of the lift cylinder for support.

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Torque specification GS-2032, GS-2632, GS-2046 and GS-2646:

Solenoid valve, 2 position 2 way N.C. 20 ft-lbs Bodily injury hazard. This
(schematic item N) 27 Nm procedure requires specific repair
skills, lifting equipment and a
Coil nut 5 ft-lbs suitable workshop. Attempting this
7 Nm procedure without these skills and
Pressure transducer (if equipped) 27 ft-lbs tools could result in death or
(schematic item R) 37 Nm serious injury and significant
component damage. Dealer
service is strongly recommended.
21 Remove the lifting device supporting the link
When removing a hose assembly or fitting, the
stack at the steer end of the machine.
fitting and/or hose end must be torqued to
22 Connect the battery pack to the machine. specification during installation. Refer to Section 2,
Hydraulic Hose and Fitting Torque Specifications.
23 Turn the key switch to the ground control
position. Models without a pressure Note: Models without a pressure transducer follow
transducer continue at step 27. steps 1 through 23, 27 and 28.
Models with a pressure transducer continue Models equipped with a pressure transducer follow
at step 24. steps 1 through 28.
24 Press and hold the ground control scroll up and 1 Turn the key switch to ground control and pull
scroll down buttons. out the red Emergency Stop button to the on
25 Pull out the red Emergency Stop button to the position at both the ground and platform
on position at the ground controls. controls.

26 Using the ground control menu buttons, 2 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
navigate to Service Override Mode. Select 3 Lift the safety arm, move it to the center of the
Service Override Mode. scissor arm and rotate down to a vertical
Note: The machine must be in Service Override position.
Mode to raise the platform. While in Service
Override Mode, only the GCON will operate with
limited functionality. The platform will raise a
predetermined amount of time and stop.
27 Raise the platform and return the safety arm to
the stowed position.
28 Fully lower the platform to the stowed position.
Note: Models with a pressure transducer, calibrate
the Platform Overload System. Refer to Repair
Procedure 9-10, How to Calibrate the Platform
Overload System (if equipped).

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7 Disconnect the battery pack from the machine.


Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
8 Tag and disconnect the wiring from the solenoid
valve coil at the barrel end of the lift cylinder.
9 If equipped, tag and disconnect the three-pin
connector from the pressure transducer
harness. To remove the pressure transducer
refer to Repair Procedure 9-9, How to Remove
the Pressure Transducer (if equipped).
10 Loosen the adjustment nuts on the solenoid
valve and disconnect the manual lowering cable
from the valve.
Note: During assembly, the manual platform
lowering cable needs to be properly adjusted.
a lift cylinder
b orifice (schematic item O)
See 2-3, How to Adjust the Manual Platform
c connector fitting Lowering Cable.
d hydraulic hose
e pressure transducer (schematic R) 11 Remove the fasteners securing the manual
(if equipped) lowering cable mount bracket to the cylinder.
f manual lowering cable Remove the bracket from the cylinder.
g solenoid valve (schematic item N)
h cable mount bracket 12 Tag, disconnect and plug the hydraulic hoses
4 Lower the platform onto the safety arm. on the lift cylinder. Cap the fittings on the
cylinder.
Crushing hazard. Keep hands
clear of the safety arm when Bodily injury hazard. Spraying
lowering the platform. hydraulic oil can penetrate and
burn skin. Loosen hydraulic
5 Using a suitable lifting device, support the link connections very slowly to allow
stack at the steer end of the machine. the oil pressure to dissipate
gradually. Do not allow oil to squirt
6 At the ground control, turn the key switch to the
or spray.
off position and push in the red Emergency
Stop button to the off position.

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13 Attach a lifting strap from an overhead crane to 20 Install new cylinder, fittings, hoses and pressure
the rod end of the lift cylinder for support. transducer (if equipped).
14 Remove the retaining fasteners from the lift Torque specification
cylinder rod-end pivot pin. Use a soft metal drift
to remove the pin. Solenoid valve, 2 position 2 way N.C. 20 ft-lbs
(schematic item N) 27 Nm
Crushing hazard. The lift cylinder
will fall if not properly supported. Coil nut 5 ft-lbs
7 Nm
15 Lower the cylinder onto the number 1 inner arm
cylinder plate. Pressure transducer (if equipped) 27 ft-lbs
(schematic item R) 37 Nm
Bodily injury hazard. Keep hands
clear of moving parts when
lowering the cylinder. 21 Remove the lifting device supporting the link
stack at the steer end of the machine.
16 Attach a lifting strap from an overhead crane or
similar lifting device to the barrel end of the lift 22 Connect the battery pack to the machine.
cylinder for support.
23 Turn the key switch to the ground control
17 Remove the retaining fasteners from the lift position. Models without a pressure
cylinder barrel-end pivot pin. Use a soft metal transducer continue at step 27.
drift to remove the pin. Models with a pressure transducer continue
at step 24.
Crushing hazard. The lift cylinder
will fall if not properly supported 24 Press and hold the ground control scroll up and
when the pin is removed. scroll down buttons.
18 Support and secure the lift cylinder to an 25 Pull out the red Emergency Stop button to the
appropriate lifting device. on position at the ground controls.
19 Remove the lift cylinder through the scissor 26 Using the ground control menu buttons,
arms at the steer end of the machine. navigate to Service Override Mode. Select
Crushing hazard. The lift cylinder Service Override Mode.
may become unbalanced and fall Note: The machine must be in Service Override
if not properly supported and Mode to raise the platform. While in Service
secured to the lifting device. Override Mode, only the GCON will operate with
Component damage hazard. Be limited functionality. The platform will raise a
careful not to damage the valve or predetermined amount of time and stop.
fittings on the cylinder while 27 Raise the platform and return the safety arm to
removing it from the machine. the stowed position.
28 Fully lower the platform to the stowed position.
Note: Models with a pressure transducer, calibrate
the Platform Overload System. Refer to Repair
Procedure 9-10, How to Calibrate the Platform
Overload System (if equipped).

Part No. 228901 GS-30 GS-32 GS-46 GS-47 4 - 107


Section 4 Repair Procedures January 2012

SCISSOR COMPONENTS

GS-3232 and GS-3246:


Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
When removing a hose assembly or fitting, the
fitting and/or hose end must be torqued to
specification during installation. Refer to Section 2,
Hydraulic Hose and Fitting Torque Specifications.
Note: Models without a pressure transducer follow
steps 1 through 21, 25 and 26.
Models equipped with a pressure transducer follow
steps 1 through 26.

1 Turn the key switch to ground control and pull a lift cylinder
b orifice (schematic item O)
out the red Emergency Stop button to the on c connector fitting
position at both the ground and platform d hydraulic hose
controls. e pressure transducer (schematic R)
(if equipped)
2 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. f manual lowering cable
g solenoid valve (schematic item N)
3 Lift the safety arm, move it to the center of the h cable mount bracket
scissor arm and rotate down to a vertical
position. 4 Lower the platform onto the safety arm.
Crushing hazard. Keep hands
clear of the safety arm when
lowering the platform.
5 Using a suitable lifting device, support the link
stack at the steer end of the machine.
6 At the ground control, turn the key switch to the
off position and push in the red Emergency
Stop button to the off position.

4 - 108 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 4 Repair Procedures

SCISSOR COMPONENTS

7 Disconnect the battery pack from the machine. 13 Attach a lifting strap from an overhead crane to
the rod end of the lift cylinder for support.
Electrocution/burn hazard. Contact
with electrically charged circuits 14 Remove the retaining fasteners from the lift
could result in death or serious cylinder rod-end pivot pin. Use a soft metal drift
injury. Remove all rings, watches to remove the pin.
and other jewelry.
Crushing hazard. The lift cylinder
Note: At the lower lift cylinder, install the orifice will fall if not properly supported.
fitting with the small opening of the orifice fitting
15 Lower the cylinder to a horizontal position.
closest to the supply hose.
16 Attach a lifting strap from an overhead crane or
8 Tag and disconnect the wiring from the solenoid similar lifting device to the barrel end of the lift
valve coil at the barrel end of the lift cylinder. cylinder for support.
Skip to step 13 if removing the upper cylinder.
17 Remove the retaining fasteners from the lift
9 If equipped, tag and disconnect the three-pin cylinder barrel-end pivot pin. Use a soft metal
connector from the pressure transducer drift to remove the pin.
harness. To remove the pressure transducer Crushing hazard. The lift cylinder
refer to Repair Procedure 9-9, How to Remove will fall if not properly supported
the Pressure Transducer (if equipped). when the pin is removed.
10 Loosen the adjustment nuts on the solenoid 18 Support and secure the lift cylinder to an
valve and disconnect the manual lowering cable appropriate lifting device.
from the valve.
19 Remove the lift cylinder through the scissor
Note: During assembly, the manual platform arms at the steer end of the machine.
lowering cable needs to be properly adjusted.
See 2-3, How to Adjust the Manual Platform Crushing hazard. The lift cylinder
Lowering Cable. may become unbalanced and fall
if not properly supported and
11 Remove the fasteners securing the manual secured to the lifting device.
lowering cable mount bracket to the cylinder.
Remove the bracket from the cylinder. Component damage hazard. Be
careful not to damage the valve or
12 Tag, disconnect and plug the hydraulic hoses fittings on the cylinder while
on the lift cylinder. Cap the fittings on the removing it from the machine.
cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 4 - 109


Section 4 Repair Procedures January 2012

SCISSOR COMPONENTS

20 Install new cylinder, fittings, hoses and pressure 21 Remove the lifting device supporting the link
transducer (if equipped). stack at the steer end of the machine.
22 Connect the battery pack to the machine.
23 Turn the key switch to the ground control
position. Models without a pressure
transducer continue at step 27.
Models with a pressure transducer continue
at step 24.
24 Press and hold the ground control scroll up and
scroll down buttons.
25 Pull out the red Emergency Stop button to the
on position at the ground controls.
26 Using the ground control menu buttons,
navigate to Service Override Mode. Select
Service Override Mode.
Note: The machine must be in Service Override
Mode to raise the platform. While in Service
Upper Lift Cylinder
Override Mode, only the GCON will operate with
a lift cylinder limited functionality. The platform will raise a
b orifice fitting (schematic item O) predetermined amount of time and stop.
c connector fitting
d hydraulic hose
27 Raise the platform and return the safety arm to
e solenoid valve (schematic item N)
f relief valve (schematic item Q) the stowed position.
28 Fully lower the platform to the stowed position.
Note: At the upper lift cylinder, install the orifice
fitting with the small opening of the orifice fitting Note: Models with a pressure transducer, calibrate
closest to the supply hose. the Platform Overload System. Refer to Repair
Procedure 9-10, How to Calibrate the Platform
Torque specification Overload System (if equipped).
Solenoid valve, 2 position 2 way N.C. 20 ft-lbs
(schematic item N) 27 Nm

Relief valve 20 ft-lbs


(schematic item Q) 27 Nm

Coil nut 5 ft-lbs


7 Nm

Pressure transducer (if equipped) 27 ft-lbs


(schematic item R) 37 Nm

4 - 110 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 4 Repair Procedures

SCISSOR COMPONENTS

GS-4047:
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
When removing a hose assembly or fitting, the
fitting and/or hose end must be torqued to
specification during installation. Refer to Section 2,
Hydraulic Hose and Fitting Torque Specifications.
1 Turn the key switch to ground control and pull
out the red Emergency Stop button to the on
position at both the ground and platform
controls.
2 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
3 Lift the safety arm, move it to the center of the
a relieve valve (schematic item Q)
scissor arm and rotate down to a vertical b lift cylinder
position. c connector fitting
d hydraulic hose
e pressure transducer (schematic R)
(if equipped)
f manual lowering cable
g solenoid valve (schematic item DO)
h cable mount bracket

4 Lower the platform onto the safety arm.


Crushing hazard. Keep hands
clear of the safety arm when
lowering the platform.
5 Using a suitable lifting device, support the link
stack at the steer end of the machine.
6 At the ground control, turn the key switch to the
off position and push in the red Emergency
Stop button to the off position.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 4 - 111


Section 4 Repair Procedures January 2012

SCISSOR COMPONENTS

7 Disconnect the battery pack from the machine. 13 Attach a lifting strap from an overhead crane to
the rod end of the lift cylinder for support.
Electrocution/burn hazard. Contact
with electrically charged circuits 14 Remove the retaining fasteners from the lift
could result in death or serious cylinder rod-end pivot pin. Use a soft metal drift
injury. Remove all rings, watches to remove the pin.
and other jewelry.
Crushing hazard. The lift cylinder
8 Tag and disconnect the wiring from the solenoid will fall if not properly supported.
valve coil at the barrel end of the lift cylinder.
15 Lower the cylinder to a horizontal position.
Skip to step 13 if removing the upper cylinder.
16 Attach a lifting strap from an overhead crane or
9 If equipped, tag and disconnect the three-pin similar lifting device to the barrel end of the lift
connector from the pressure transducer cylinder for support.
harness. To remove the pressure transducer
17 Remove the retaining fasteners from the lift
refer to Repair Procedure 9-9, How to Remove
cylinder barrel-end pivot pin. Use a soft metal
the Pressure Transducer (if equipped). drift to remove the pin.
10 Loosen the adjustment nuts on the solenoid
Crushing hazard. The lift cylinder
valve and disconnect the manual lowering cable
will fall if not properly supported
from the valve.
when the pin is removed.
Note: During assembly, the manual platform
18 Support and secure the lift cylinder to an
lowering cable needs to be properly adjusted.
appropriate lifting device.
See 2-3, How to Adjust the Manual Platform
Lowering Cable. 19 Remove the lift cylinder through the scissor
arms at the steer end of the machine.
11 Remove the fasteners securing the manual
lowering cable mount bracket to the cylinder. Crushing hazard. The lift cylinder
Remove the bracket from the cylinder. may become unbalanced and fall
if not properly supported and
12 Tag, disconnect and plug the hydraulic hoses secured to the lifting device.
on the lift cylinder. Cap the fittings on the
cylinder. Component damage hazard. Be
careful not to damage the valve or
Bodily injury hazard. Spraying fittings on the cylinder while
hydraulic oil can penetrate and removing it from the machine.
burn skin. Loosen hydraulic
connections very slowly to allow 20 Install new cylinder, fittings, hoses and pressure
the oil pressure to dissipate transducer (if equipped).
gradually. Do not allow oil to squirt
or spray.

4 - 112 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 4 Repair Procedures

SCISSOR COMPONENTS

21 Remove the lifting device supporting the link


stack at the steer end of the machine.
22 Connect the battery pack to the machine.
23 Turn the key switch to the ground control
position.
24 Press and hold the ground control scroll up and
scroll down buttons.
25 Pull out the red Emergency Stop button to the
on position at the ground controls.
26 Using the ground control menu buttons,
navigate to Service Override Mode. Select
Service Override Mode.
Note: The machine must be in Service Override
Mode to raise the platform. While in Service
Override Mode, only the GCON will operate with
limited functionality. The platform will raise a
predetermined amount of time and stop.
Upper Lift Cylinder
27 Raise the platform and return the safety arm to
a relief valve (schematic item Q)
b lift cylinder the stowed position.
c connector fitting
d hydraulic hose 28 Fully lower the platform to the stowed position.
e check valve (schematic item DK)
Note: Models with a pressure transducer, calibrate
the Platform Overload System. Refer to Repair
Torque specification
Procedure 9-10, How to Calibrate the Platform
Solenoid valve, 2 position 2 way N.C. 20 ft-lbs Overload System (if equipped).
(schematic item N) 27 Nm

Relief valve 20 ft-lbs


(schematic item Q) 27 Nm

Coil nut 5 ft-lbs


7 Nm

Pressure transducer (if equipped) 27 ft-lbs


(schematic item R) 37 Nm

Check valve 20 ft-lbs


(schematic item DK) 27 Nm

Part No. 228901 GS-30 GS-32 GS-46 GS-47 4 - 113


Section 4 Repair Procedures January 2012

SCISSOR COMPONENTS

9-9 9 Slowly loosen the pressure transducer from the


lift cylinder and remove. Discard the pressure
Pressure Transducer transducer.
Bodily injury hazard. Spraying
How to Remove the Pressure hydraulic oil can penetrate and
Transducer (if equipped) burn skin. Loosen hydraulic
connections very slowly to allow
1 Turn the key switch to ground control and pull
the oil pressure to dissipate
out the red Emergency Stop button to the on
gradually. Do not allow oil to squirt
position at both the ground and platform
or spray.
controls.
10 Connect the battery pack to the machine.
2 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
11 Turn the key switch to the ground control
3 Lift the safety arm, move it to the center of the
position.
scissor arm and rotate down to a vertical
position. 12 Press and hold the ground control scroll up and
scroll down buttons.
4 Lower the platform onto the safety arm.
13 Pull out the red Emergency Stop button to the
Crushing hazard. Keep hands
on position at the ground controls.
clear of the safety arm when
lowering the platform. 14 Using the ground control menu buttons,
navigate to Service Override Mode. Select
5 At the ground control, turn the key switch to the
Service Override Mode.
off position and push in the red Emergency
Stop button to the off position. Note: The machine must be in Service Override
Mode to raise the platform. While in Service
6 Disconnect the battery pack from the machine.
Override Mode, only the GCON will operate with
Electrocution/burn hazard. Contact limited functionality. The platform will raise a
with electrically charged circuits predetermined amount of time and stop.
could result in death or serious
15 Raise the platform and return the safety arm to
injury. Remove all rings, watches
the stowed position.
and other jewelry.
16 Fully lower the platform to the stowed position.
7 Pull the manual lowering cable and hold for 3
seconds. Note: After replacing the pressure transducer, the
platform overload system must be calibrated.
8 Tag and disconnect the three-pin connector
Refer to Repair Procedure 9-10, How to Calibrate
from the pressure transducer harness.
the Platform Overload System (if equipped).

Torque specification

Pressure transducer (if equipped) 27 ft-lbs


(schematic item R) 37 Nm

4 - 114 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 4 Repair Procedures

SCISSOR COMPONENTS

9-10 Note: To calibrate the platform overload system,


follow the menu structure indicated on the ground
Platform Overload System control LCD display.

How to Calibrate the Platform Full Load Calibration: Part 1

Overload System (if equipped) 1 Fully charge the batteries and check the
hydraulic fluid level.
Perform this procedure with the machine in the
stowed position and on a firm, level surface that is Note: The hydraulic fluid level must be between the
FULL and ADD marks on the hydraulic tank.
free of obstructions.

Perform this procedure in an environment that 2 Apply a thin layer of dry film lubricant to the
allows the platform to be fully raised. Models rated area of the chassis and platform, where the
for inside use only, can only be calibrated inside a scissor arm wear pads make contact.
facility with enough ceiling height to fully raise the 3 Chock both sides of the wheels at the steer end
platform. of the machine.
Perform this procedure after confirming that the 4 Using a suitable lifting device, place a test
platform height sensor is not damaged and weight corresponding to the machine maximum
functions correctly. load, in the center of the platform deck. Secure
the weight to the platform. Refer to the chart
There are two options to the platform overload below.
calibration procedure in this section, Full Load
Calibration and No Load Calibration. Full Load GS-1530 and GS-1532 272 kg
Calibration has two steps requiring calibration with
and without rated load in the platform. No Load GS-1930 and GS-1932 227 kg
Calibration does not require rated load in the
GS-2032 363 kg
platform.
GS-2632 227 kg
Note: No Load Calibration can be completed
stand alone to fulfill the C-2 overload calibration GS-3232 227 kg
requirements, if the machine has completed the
GS-2046 544 kg
Full Load Calibration procedure.
GS-2646 454 kg
Note: If a new Ground Controller is installed on a
machine, the Full Load Calibration procedure is GS-3246 317 kg
required to maintain rated load platform capacity.
If a No Load Calibration is performed, machine GS-4047 350 kg
lifting performance will be significantly reduced.
Note: Ambient temperature must be above
32F / 0C before calibrating the Platform Overload
System.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 4 - 115


Section 4 Repair Procedures January 2012

SCISSOR COMPONENTS

5 Turn the key switch to ground control. 18 At the ground controls, press and hold the
Function Enable and Platform Up buttons until
6 At the ground controls, press and hold the
the platform reaches maximum height.
Menu Up and Menu Down buttons.
19 When the platform reaches maximum height,
7 While pressing both buttons down, pull out the
press the ground controls Enter button. Allow
red Emergency Stop Button.
the ground controls to gather data.
8 Release the Menu Up and Menu Down buttons
20 When prompted, press and hold the
after the ground controller powers up.
Function Enable and Platform Down buttons.
9 Use the Menu Up or Menu Down buttons to The platform will lower, then automatically stop
scroll to, Select Option. Press the Enter button. at a predetermined point to gather data. Allow
the ground controls to gather data.
10 Use the Menu Up or Menu Down buttons to
scroll to Platform Overload. 21 Continue pressing the Function Enable and
Platform Down buttons throughout the lowering
11 Press the Enter button to select Platform and data gathering sequence. The machine will
Overload. stop to gather data and lower several times
12 Use the Menu Up or Menu Down buttons to before the machine reaches the stowed
scroll to Platform Overload Calibrate. position. When the platform reaches the stowed
position, press the Enter button.
13 Press the Enter button to select Platform
Overload Calibrate. Note: If the machine is switched to PCON mode
to drive the machine to an area for weight removal,
14 Confirm the Platform Overload Calibrate step 3 and steps 5 through 14 will have to be
selection by pressing the Enter button again. repeated before Full Load Calibration: Part 2 is
15 Use the Menu Up or Menu Down buttons to performed. Additionally, the CO25 fault will appear.
select Full Load calibration. This is expected and the data collected in Full
Load Calibration: Part 1 has not been lost.
16 Press the Enter button to select Full Load
calibration. 22 Using a suitable lifting device, remove the test
weight from the platform deck.
17 Press the Enter button to confirm rated load is
in the platform. 23 After the weight is removed from the platform
deck, press the Enter button to confirm the
weight has been removed.

4 - 116 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 4 Repair Procedures

SCISSOR COMPONENTS

Full Load Calibration: Part 2 No Load Calibration


24 At the ground controls, press and hold the 1 Fully charge the batteries and check the
Function Enable and Platform Up buttons until hydraulic fluid level.
the platform reaches maximum height.
Note: The hydraulic fluid level must be between the
25 When the platform reaches maximum height, FULL and ADD marks on the hydraulic tank.
press the Enter button. Allow the ground
controls to gather data. 2 Apply a thin layer of dry film lubricant to the
area of the chassis where the scissor arm wear
26 When prompted, press and hold the pads make contact.
Function Enable and Platform Down buttons
to lower the platform. The platform will move 3 Chock both sides of the wheels at the steer end
down, then automatically stop at a of the machine.
predetermined point to gather data. Allow the 4 Turn the key switch to ground control.
ground controls to gather data.
5 At the ground controls, press and hold the
27 Continue pressing the Function Enable and Menu Up and Menu Down buttons.
Platform Down buttons throughout the lowering
and data gathering sequence. The machine will 6 While pressing both buttons down, pull out the
stop to gather data and lower several times red Emergency Stop Button.
before the machine reaches the stowed
7 Release the Menu Up and Menu Down buttons
position. When the platform reaches the stowed
after the ground controller powers up.
position, press the Enter button.
8 At the ground controls, use the Menu Up
28 When prompted, push the red Emergency Stop
or Menu Down buttons to scroll to Platform
button in to complete the Platform Overload
Overload.
Calibration procedure.
9 Press the Enter button to select the Platform
Overload.
10 Use the Menu Up or Menu Down buttons to
scroll to Platform Overload Calibrate.
11 Press the Enter button to select Platform
Overload Calibrate.
12 Confirm the Platform Overload Calibrate
selection by pressing the Enter button again.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 4 - 117


Section 4 Repair Procedures January 2012

SCISSOR COMPONENTS

13 Use the Menu Up or Menu Down buttons to


select No Load calibration.
14 Press the Enter button to select No Load
calibration.
15 Press the Enter button to confirm no load is in
the platform.
16 At the ground controls, press and hold the
Function Enable and Platform Up buttons until
the platform reaches maximum height.
17 When the platform reaches maximum height,
press the ground controls Enter button. Allow
the ground controls to gather data.
18 When prompted, press and hold the
Function Enable and Platform Down buttons
to lower the platform. The platform will move
down, then automatically stop at a
predetermined point to gather data. Allow the
ground controls to gather data.
19 Continue pressing the Function Enable and
Platform Down buttons throughout the lowering
and data gathering sequence. The machine will
stop to gather data and lower several times
before the machine reaches the stowed
position. When the platform reaches the stowed
position, press the Enter button.
20 When prompted, push the red Emergency Stop
button in to complete the No Load Calibration
procedure.

4 - 118 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 4 Repair Procedures

Platform Components
10-1 8 Models with air line to platform option:
Disconnect the air line from the platform. Pull
Platform the air line free of the platform.
9 Support the platform with a forklift at the
How to Remove the Platform non-steer end. Do not apply any lifting
Perform this procedure with the platform extension pressure.
fully retracted and locked in position. 10 Attach a strap from the lanyard anchorage point
1 Raise the platform to approximately 3 ft / 1 m. on the platform railings to the carriage on the
forklift to help support the platform.
2 Remove the retaining fasteners securing the
platform to the platform mount at the steer end 11 GS-1530/32 and GS-1930/32: Lift the steer end
of the machine. of the platform slightly to clear the platform
mount and slide the platform towards the non-
3 Lower the platform to the stowed position. steer end of the machine until the platform slide
4 Disconnect the battery packs from the machine. blocks at the non-steer end of the machine are
visible through the access holes in the bottom
Electrocution/burn hazard. Contact of the platform.
with electrically charged circuits
could result in death or serious All other models: Lift the steer end of the
injury. Remove all rings, watches platform slightly to clear the platform mount and
and other jewelry. slide the platform towards the steer end of the
machine until the platform slide blocks at the
5 Disconnect the platform controls from the non-steer end of the machine are visible
control cable at the platform. through the access holes in the bottom of the
platform.
6 Remove the cover from the AC outlet. Tag and
disconnect the wiring from the outlet. Crushing hazard. The platform will
fall if not properly supported.
Electrocution hazard. Contact with
electrically charged circuits could 12 Carefully lift the platform off of the machine and
result in death or serious injury. place it on a structure capable of supporting it.
Remove all rings, watches and
other jewelry. Note: Take notice of the wear pad position before
the platform is removed. Correct wear pad position
7 Disconnect the wiring from the platform and pull is essential for proper platform functionality.
the wiring free of the platform.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 4 - 119


Section 4 Repair Procedures January 2012

PLATFORM COMPONENTS

10-2 7 Remove the platform roller wheels from the


machine.
Platform Extension
8 Carefully slide the platform extension out from
the platform and place it on a structure capable
How to Remove the of supporting it.
Platform Extension
How to Replace the Platform
1 Lower the platform to the stowed position.
Extension Wear Pads
2 Extend the platform approximately 3 feet / 1 m.
1 Remove the Platform Extension. See 10-2, How
3 Remove the platform controls from the platform to Remove the Platform Extension.
and lay them off to the side of the machine.
2 Drill out the rivets which hold the wear pads in
4 Support the platform extension with a forklift at place.
the steer end of the machine. Do not apply any
lifting pressure. 3 Install the new wear pads using new rivets.
When installing the new rivets, make sure the
5 Attach a strap from the platform extension rivet heads are not above the surface of the
railings to the carriage on the forklift to help wear pad.
support the platform extension.
6 Remove the two retaining fasteners from each
platform extension roller bracket assembly.
Remove each assembly from the machine.
Note: Do not remove the platform roller bolt.

a roller bracket assembly


b assembly retaining fastener
c platform roller bolt

4 - 120 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 5 Diagnostics

Diagnostics
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.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 5-1


Section 5 Diagnostics January 2012

DIAGNOSTICS

About This Section Definitions


When a malfunction is discovered, the fault code GSDS - Genie SmartLink Diagnostic System
TM

charts in this section will help a service


professional pinpoint the cause of the problem. ECM - Electronic Control Module
To use this section, basic hand tools and certain GCON - Ground Controls
pieces of test equipment are required
voltmeter, ohmmeter, pressure gauges. PCON - Platform Controls

OIC - Operational Indicator Codes


General Repair Process
DTC - Diagnostic Trouble Codes

5-2 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 5 Diagnostics

DIAGNOSTICS

GCON LCD Diagnostic Readout Genie SmartLink Diagnostic


System
This machine is equipped with the Genie
TM
SmartLink Diagnostic System (GSDS). The
GSDS indicates a machine malfunction has
The diagnostic readout displays alpha numeric happened by displaying Operational Indicator
codes that provide information about the machine Codes (OIC) and Diagnostic Trouble Codes
operating status and about malfunctions. (DTC). These codes are displayed at the
Platform Controls and the Ground Controls.
The codes listed in the Diagnostic Trouble Code The Ground Controls will display a brief
Charts describe malfunctions and can aid in description of the code at the LCD display as
troubleshooting the machine by pinpointing the well.
area or component affected. Refer to the GCON I/O Maps, Operational
Indicator Codes (OIC) and Diagnostic Trouble
Codes (DTC) in this section, to assist in
troubleshooting faults.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 5-3


Section 5 Diagnostics January 2012

GCON I/O Map without Load Sense


(all models except GS-3232)

Rear of Ground
Controls ECM

5-4 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 5 Diagnostics

GCON I/O Map with Load Sense


(all models except GS-3232)

Part No. 228901 GS-30 GS-32 GS-46 GS-47 5-5


Section 5 Diagnostics January 2012

GCON I/O Map without Load Sense


(GS-3232 only)

Rear of Ground
Controls ECM

5-6 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 5 Diagnostics

GCON I/O Map with Load Sense


(GS-3232 only)

Part No. 228901 GS-30 GS-32 GS-46 GS-47 5-7


Section 5 Diagnostics January 2012

DIAGNOSTICS

Operational Indicator Codes Diagnostic Trouble Codes (DTC)


(OIC) These codes are generated by the system to
These codes are generated by the electrical indicate that a device or circuit malfunction has
system to indicate machine operating status been detected in the electrical system.
such as Off-level, Overload Cutout, Chassis The types of Diagnostic Trouble Codes that may
Mode Operation and Pothole Guard Stuck, occur are explained below.
during normal operation. Type "HXXX" - Indicate a malfunction
These codes are not indicators of a device associated with devices that control hydraulic
malfunction in the electrical system. functions in the electrical system. The "HXXX"
faults are divided into short circuit battery
Code Condition negative, short circuit to battery positive, open
LL Off-Level circuit and generic shorts. Example of these
devices are solenoid controlled hydraulic valves
OL Platform Overloaded (CE and Australia) and motor controller.
CH Chassis Mode Operation Type "PXXX" - Indicate a malfunction associated
with power type devices in the electrical system.
PHS Pothole Guard Stuck
The "PXXX" faults are divided into short circuit to
nd No Drive (option) battery negative, short circuit to battery positive,
open circuit and generic shorts. Example of
Ld Lifting Disabled (Gs-3232 only) these devices are horns, sensor power and
alarms.

Type "UXXX" - Indicate a malfunction associated


with user interface devices in the electrical
system. The "UXXX" faults are divided into short
circuit to battery negative, short circuit to battery
positive, open circuit and generic shorts.
Example of these devices are GCON up and
down switches and PCON drive joystick.
Type "FXXX" - Indicate a malfunction associated
with machine feedback devices in the electrical
system. The "FXXX" faults are divided into short
circuit to battery negative, short circuit to battery
positive, open circuit and generic shorts.
Example of these devices are limit switches,
height sensors and pressure transducers.

Type "CXXX" - Indicate a malfunction associated


with controls devices in the electrical system.
Example of these devices are platform controls
and ground controls ECM.

5-8 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 5 Diagnostics

DIAGNOSTICS

Troubleshooting "HXXX" and "PXXX" Faults


The procedure below illustrates typical steps for diagnosing and fixing faults of type "HXXX and PXXX".
Diagnostic Chart
No Good
1 Check the fault device for a short or open circuit. Replace faulted device.

Good
No Good
Check short or open circuit of the harness or Repair or replace harness and/or connector.
2 connector between Ground Controls and faulted device.

Good
No Good
3 Check GCON Electronic Control Module (ECM). Replace ECM.

Wiring Diagram
The wiring diagram shown below illustrates how fault type "HXXX" or "PXXX" devices are typically wired.
The signal to these types of devices originates at the Ground Controls and terminates at system ground.
Signal Side Return Side

GCON Signal Wire Return Wire


Electronic Control Module DEVICE
(ECM)

In order to successfully troubleshoot "HXXX" or "PXXX" type faults, the entire faulted out circuit needs to
be investigated.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 5-9


Section 5 Diagnostics January 2012

DIAGNOSTICS

Fault Inspection Procedure

5 - 10 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 5 Diagnostics

DIAGNOSTICS

Part No. 228901 GS-30 GS-32 GS-46 GS-47 5 - 11


Section 5 Diagnostics January 2012

Type "HXXX" Faults

5 - 12 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 5 Diagnostics

TYPE "HXXX" FAULTS, CONTINUED

Part No. 228901 GS-30 GS-32 GS-46 GS-47 5 - 13


Section 5 Diagnostics January 2012

TYPE "HXXX" FAULTS, CONTINUED

5 - 14 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 5 Diagnostics

Type "PXXX" Faults

Part No. 228901 GS-30 GS-32 GS-46 GS-47 5 - 15


Section 5 Diagnostics January 2012

Type "UXXX" Faults

5 - 16 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 5 Diagnostics

TYPE "UXXX" FAULTS, CONTINUED

Part No. 228901 GS-30 GS-32 GS-46 GS-47 5 - 17


Section 5 Diagnostics January 2012

Type "FXXX" Faults

5 - 18 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 5 Diagnostics

TYPE "FXXX" FAULTS, CONTINUED

Part No. 228901 GS-30 GS-32 GS-46 GS-47 5 - 19


Section 5 Diagnostics January 2012

TYPE "FXXX" FAULTS, CONTINUED

5 - 20 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 5 Diagnostics

Type "CXXX" Faults

Part No. 228901 GS-30 GS-32 GS-46 GS-47 5 - 21


Section 5 Diagnostics January 2012

TYPE "CXXX" FAULTS, CONTINUED

5 - 22 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 6 Schematics

Schematics

About This Section


There are two groups of schematics in this section.
An illustration legend precedes each group of
drawings.

Electrical Schematics

Observe and Obey: Electrocution/burn hazard. Contact


with electrically charged circuits
Troubleshooting and repair procedures shall be could result in death or serious
completed by a person trained and qualified on injury. Remove all rings, watches
the repair of this machine. and other jewelry.
Immediately tag and remove from service a Hydraulic Schematics
damaged or malfunctioning machine.
Bodily injury hazard. Spraying
Repair any machine damage or malfunction hydraulic oil can penetrate and
before operating the machine. burn skin. Loosen hydraulic
connections very slowly to allow
Before Troubleshooting: the oil pressure to dissipate
gradually. Do not allow oil to squirt
Read, understand and obey the safety rules
or spray.
and operating instructions in the appropriate
operator's manual on your machine. General Repair Process
Be sure that all necessary tools and test
equipment are available and ready for use.

Part No. 228901 GS-30 GS-32 GS-46 GS-47 6-1


Section 6 Schematics January 2012

Electrical Component and Wire Color Legends

6-2 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 6 Schematics

Electrical Component and Wire Color Legends

Part No. 228901 GS-30 GS-32 GS-46 GS-47 6-3


Section 6 Schematics January 2012

Wiring Diagram
Ground and Platform Controls

6-4 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 6 Schematics

Limit Switch Legend

Limit Switch Legend

a down limit switch LS6


b pothole switches LS7, LS8
c 22ft / 6.7 m maximum drive height when outriggers are not deployed (LS5A GS-3232)

Part No. 228901 GS-30 GS-32 GS-46 GS-47 6-5


Section 6 Schematics January 2012

Electrical Symbols Legend

Limit switch
Motor controller Key switch

Emergency Stop button


Wire with
description or color
Motor Solenoid valve
Circuit breaker with diode

Circuits crossing
no connection
Fuse Level sensor

Battery charger
Diode Horn or alarm

Deutsch connector
6V or 12v DC battery
Circuit connection Flashing beacon

Pressure transducer
Resistor Platform height sensor

Contactor

6-6 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 6 Schematics

Electrical Schematic GS-1530/32 and GS-1930/32


ANSI and CSA Models (from serial number GS3010A-110000 to
GS3011A-110827)

6-8
6-7
Section 6 Schematics January 2012

Electrical Schematic GS-1530/32 and GS-1930/32


ANSI and CSA Models (from serial number GS3010A-110000 to GS3011A-110827)
A B C D E F G H I J K L M N

6-8 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 6 Schematics

Electrical Schematic GS-1530/32 and GS-1930/32


ANSI and CSA Models (from serial number GS3010A-110000 to GS3011A-110827)
N M L K J I H G F E D C B A

Part No. 228901 GS-30 GS-32 GS-46 GS-47 6-9


January 2012 Section 6 Schematics

Electrical Schematic GS-1530/32 and GS-1930/32


ANSI and CSA Models (from serial number GS3010A-110000 to
GS3011A-110827)

6-9 6 - 10
January 2012 Section 6 Schematics

Electrical Schematic GS-1530/32 and GS-1930/32


ANSI and CSA Models (from serial number GS3011A-110828)

6 - 11 6 - 12
Section 6 Schematics January 2012

Electrical Schematic GS-1530/32 and GS-1930/32


ANSI and CSA Models (from serial number GS3011A-110828)
A B C D E F G H I J K L M N

6 - 12 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 6 Schematics

Electrical Schematic GS-1530/32 and GS-1930/32


ANSI and CSA Models (from serial number GS3011A-110828)
N M L K J I H G F E D C B A

Part No. 228901 GS-30 GS-32 GS-46 GS-47 6 - 13


January 2012 Section 6 Schematics

Electrical Schematic GS-1530/32 and GS-1930/32


ANSI and CSA Models (from serial number GS3011A-110828)

6 - 13 6 - 14
January 2012 Section 6 Schematics

Electrical Schematic GS-2032 and GS-2632


ANSI and CSA Models (from serial number GS3211A-110000)

6 - 15 6 - 16
Section 6 Schematics January 2012

Electrical Schematic GS-2032 and GS-2632


ANSI and CSA Models (from serial number GS3211A-110000)
A B C D E F G H I J K L M N

6 - 16 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 6 Schematics

Electrical Schematic GS-2032 and GS-2632


ANSI and CSA Models (from serial number GS3011A-110000)
N M L K J I H G F E D C B A

Part No. 228901 GS-30 GS-32 GS-46 GS-47 6 - 17


January 2012 Section 6 Schematics

Electrical Schematic GS-2032 and GS-2632


ANSI and CSA Models (from serial number GS3011A-110000)

6 - 17 6 - 18
January 2012 Section 6 Schematics

Electrical Schematic GS-3232


ANSI and CSA Models (from serial number GS3211A-110000)

6 - 19 6 - 20
Section 6 Schematics January 2012

Electrical Schematic GS-3232


ANSI and CSA Models (from serial number GS3211A-110000)
A B C D E F G H I J K L M N

6 - 20 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 6 Schematics

Electrical Schematic GS-3232


ANSI and CSA Models (from serial number GS3211A-110000)
N M L K J I H G F E D C B A

Part No. 228901 GS-30 GS-32 GS-46 GS-47 6 - 21


January 2012 Section 6 Schematics

Electrical Schematic GS-3232


ANSI and CSA Models (from serial number GS3211A-110000)

6 - 21 6 - 22
January 2012 Section 6 Schematics

Electrical Schematic GS-2046 and GS-2646


ANSI and CSA Models (from serial number GS4611A-110000)

6 - 23 6 - 24
Section 6 Schematics January 2012

Electrical Schematic GS-2046 and GS-2646


ANSI and CSA Models (from serial number GS4611A-110000)
A B C D E F G H I J K L M N

6 - 24 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 6 Schematics

Electrical Schematic GS-2046 and GS-2646


ANSI and CSA Models (from serial number GS4611A-110000)
N M L K J I H G F E D C B A

Part No. 228901 GS-30 GS-32 GS-46 GS-47 6 - 25


January 2012 Section 6 Schematics

Electrical Schematic GS-2046 and GS-2646


ANSI and CSA Models (from serial number GS4611A-110000)

6 - 25 6 - 26
January 2012 Section 6 Schematics

Electrical Schematic GS-3246


ANSI and CSA Models (from serial number GS4611A-110000)

6 - 27 6 - 28
Section 6 Schematics January 2012

Electrical Schematic GS-3246


ANSI and CSA Models (from serial number GS4611A-110000)
A B C D E F G H I J K L M N

6 - 28 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 6 Schematics

Electrical Schematic GS-3246


ANSI and CSA Models (from serial number GS4611A-110000)
N M L K J I H G F E D C B A

Part No. 228901 GS-30 GS-32 GS-46 GS-47 6 - 29


January 2012 Section 6 Schematics

Electrical Schematic GS-3246


ANSI and CSA Models (from serial number GS4611A-110000)

6 - 29 6 - 30
January 2012 Section 6 Schematics

Electrical Schematic GS-1530/32 and GS-1930/32


CE and AUS Models (from serial number GS3010A-110000 to
GS3011A-110827)

6 - 31 6 - 32
Section 6 Schematics January 2012

Electrical Schematic GS-1530/32 and GS-1930/32


CE and AUS Models (from serial number GS3010A-110000 to GS3011A-110827)
A B C D E F G H I J K L M N

6 - 32 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 6 Schematics

Electrical Schematic GS-1530/32 and GS-1930/32


CE and AUS Models (from serial number GS3010A-110000 to GS3011A-110827)
N M L K J I H G F E D C B A

Part No. 228901 GS-30 GS-32 GS-46 GS-47 6 - 33


January 2012 Section 6 Schematics

Electrical Schematic GS-1530/32 and GS-1930/32


CE and AUS Models (from serial number GS3010A-110000 to
GS3011A-110827)

6 - 33 6 - 34
January 2012 Section 6 Schematics

Electrical Schematic GS-1530/32 and GS-1930/32


CE and AUS Models (from serial number GS3011A-110828 and
serial number GS3011C-10000)

6 - 35 6 - 36
Section 6 Schematics January 2012

Electrical Schematic GS-1530/32 and GS-1930/32


CE and AUS Models (from serial number GS3011A-110828 and serial number GS3011C-10000)
A B C D E F G H I J K L M N

6 - 36 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 6 Schematics

Electrical Schematic GS-1530/32 and GS-1930/32


CE and AUS Models (from serial number GS3011A-110828 and serial number GS3011C-10000)
N M L K J I H G F E D C B A

Part No. 228901 GS-30 GS-32 GS-46 GS-47 6 - 37


January 2012 Section 6 Schematics

Electrical Schematic GS-1530/32 and GS-1930/32


CE and AUS Models (from serial number GS3011A-110828 and
serial number GS3011C-10000)

6 - 37 6 - 38
January 2012 Section 6 Schematics

Electrical Schematic GS-2032 and GS-2632


CE and AUS Models (from serial number GS3211A-110000 and
serial number GS-3212C-10000)

6 - 39 6 - 40
Section 6 Schematics January 2012

Electrical Schematic GS-2032 and GS-2632


CE and AUS Models (from serial number GS3211A-110000 and serial number GS-3212C-10000)
A B C D E F G H I J K L M N

6 - 40 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 6 Schematics

Electrical Schematic GS-2032 and GS-2632


CE and AUS Models (from serial number GS3211A-110000 and serial number GS3212C-10000)
N M L K J I H G F E D C B A

Part No. 228901 GS-30 GS-32 GS-46 GS-47 6 - 41


January 2012 Section 6 Schematics

Electrical Schematic GS-2032 and GS-2632


CE and AUS Models (from serial number GS3211A-110000 and serial number
GS3212C-10000)

6 - 41 6 - 42
January 2012 Section 6 Schematics

Electrical Schematic GS-3232


CE and AUS Models (from serial number GS3211A-110000 and
serial number GS3212C-10000)

6 - 43 6 - 44
Section 6 Schematics January 2012

Electrical Schematic GS-3232


CE and AUS Models (from serial number GS3211A-110000 and serial number GS3212C-10000)
A B C D E F G H I J K L M N

6 - 44 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 6 Schematics

Electrical Schematic GS-3232


CE and AUS Models (from serial number GS3211A-110000 and serial number GS3212C-10000)
N M L K J I H G F E D C B A

Part No. 228901 GS-30 GS-32 GS-46 GS-47 6 - 45


January 2012 Section 6 Schematics

Electrical Schematic GS-3232


CE and AUS Models (from serial number GS3211A-110000 and
serial number GS3212C-10000)

6 - 45 6 - 46
January 2012 Section 6 Schematics

Electrical Schematic GS-2046 and GS-2646


CE and AUS Models (from serial number GS4611A-110000 and
serial number GS-4612C-10000)

6 - 47 6 - 48
Section 6 Schematics January 2012

Electrical Schematic GS-2046 and GS-2646


CE and AUS Models (from serial number GS4611A-110000 and serial number GS-4612C-10000)
A B C D E F G H I J K L M N

6 - 48 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 6 Schematics

Electrical Schematic GS-2046 and GS-2646


CE and AUS Models (from serial number GS4611A-110000 and serial number GS4612C-10000)
N M L K J I H G F E D C B A

Part No. 228901 GS-30 GS-32 GS-46 GS-47 6 - 49


January 2012 Section 6 Schematics

Electrical Schematic GS-2046 and GS-2646


CE and AUS Models (from serial number GS4611A-110000 and
serial number GS4612C-10000)

6 - 49 6 - 50
January 2012 Section 6 Schematics

Electrical Schematic GS-3246


CE and AUS Models (from serial number GS4611A-110000 and
serial number GS-4612C-10000)

6 - 51 6 - 52
Section 6 Schematics January 2012

Electrical Schematic GS-3246


CE and AUS Models (from serial number GS4611A-110000 and serial number GS-4612C-10000)
A B C D E F G H I J K L M N

6 - 52 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 6 Schematics

Electrical Schematic GS-3246


CE and AUS Models (from serial number GS4611A-110000 and serial number GS4612C-10000)
N M L K J I H G F E D C B A

Part No. 228901 GS-30 GS-32 GS-46 GS-47 6 - 53


January 2012 Section 6 Schematics

Electrical Schematic GS-3246


CE and AUS Models (from serial number GS4611A-110000 and
serial number GS4612C-10000)

6 - 53 6 - 54
January 2012 Section 6 Schematics

Electrical Schematic GS-4047


CE and AUS Models (from serial number GS-4612C-101)

6 - 55 6 - 56
Section 6 Schematics January 2012

Electrical Schematic GS-4047


CE and AUS Models (from serial number GS-4612C-101)
A B C D E F G H I J K L M N

6 - 56 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 6 Schematics

Electrical Schematic GS-4047


CE and AUS Models (from serial number GS4612C-101)
N M L K J I H G F E D C B A

Part No. 228901 GS-30 GS-32 GS-46 GS-47 6 - 57


January 2012 Section 6 Schematics

Electrical Schematic GS-4047


CE and AUS Models (from serial number GS4612C-101)

This page left blank intentionally


T

6 - 57 6 - 58
January 2012 Section 6 Schematics

Component Reference and


Hydraulic Symbols Legend

Hydraulic cylinder
Variable speed Brake
motor

Shuttle valve
Fixed displacement pump
Relief valve

Solenoid operated
3 position 4 way
directional valve
Orifice
with size Bi-directional motor
Solenoid operated
2 position 4 way
directional valve Solenoid operated
2 position 2 way
directional valve
Pressure transducer normally closed

Priority flow regulator

Solenoid-operated Solenoid operated


2 position 2 way 3 position 5 way
blocking valve directional valve
Accumulator normally open
Filter

Check valve
Proportional solenoid-operated
2 position 2 way
Solenoid operated directional valve
2 position 2 way valve normally closed
normally closed Solenoid operated
2 position 4 way
directional valve

Part No. 228901 GS-30 GS-32 GS-46 GS-47 6 - 59


Section 6 Schematics January 2012

Component Reference and


Hydraulic Symbols Legend

Function manifold,
GS-1530, GS-1532,
GS-1930 and GS-1932

Function manifold,
GS-2032, GS-2632, GS-3232,
GS-2046, GS-2646 and GS-
3246

Lift pressure selector manifold,


GS-4047

Function manifold, Brake release manifold,


GS-4047 all models

Outrigger manifold,
Front outrigger cylinder, GS-3232
GS-3232 Rear outrigger cylinder,
GS-3232

6 - 60 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 6 Schematics

Hydraulic Schematic
GS-1530/1532/1930/1932 (from serial number GS3010A-110000)
GS-1530/1532/1930/1932 (from serial number GS3011C-10000)

ABBREVIATION LEGEND
Item Description
A Test port
B Check valve, steer circuit
C Relief valve, lift
D Check valve, brake circuit
E Drive forward/reverse
F Steer left/right
G Flow regulator/relief valve
H Platform up
I Relief valve, system
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 transducer
S Check valve, drive circuit

Part No. 228901 GS-30 GS-32 GS-46 GS-47 6 - 61


Section 6 Schematics January 2012

Hydraulic Schematic
GS-2032/2632/3232 (from serial number GS3211A-110000 and GS3212C-10000)
GS-2046/2646/3246 (from serial number GS4611A-110000 and GS4612C-10000)

6 - 62 GS-30 GS-32 GS-46 GS-47 Part No. 228901


January 2012 Section 6 Schematics

Hydraulic Schematic
GS-3232 (from serial number GS3211A-110000)
(from serial number GS3212C-10000)

Part No. 228901 GS-30 GS-32 GS-46 GS-47 6 - 63


Section 6 Schematics January 2012

Hydraulic Schematic
GS-4047 (from serial number GS4712C-101)

6 - 64 GS-30 GS-32 GS-46 GS-47 Part No. 228901


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