Professional Documents
Culture Documents
GS1930 Service Manual
GS1930 Service Manual
GS-2632
GS-3232 For detailed maintenance
GS-3246
GS-4047
Refer to the inside cover for a list of models Part No. 1272217
included in this manual.
Rev A3
September 2016
Service and Repair Manual September 2016
Introduction
Intr oducti on Intr oducti on
Important Inform ati on
Introduction
Introduction
Revision His tory
Revision History
Revision Date Section Procedure / Page / Description
A 3/2016 Initial Release
A1 5/2016 Repair Procedures 2-3, 2-4, 9-11
Diagnostics H067 fault
A2 5/2016 Repair Procedure 2-6
Diagnostics Type CXXX and UXXX fault codes
A3 9/2016 Introduction Serial Number Legend
Specifications Add drive speed stowed parameters
Reference Examples:
Section – Repair Procedure, 4-2 Electronic Version
Click on any content or procedure in the Table of Contents to view
Section – Fault Codes, All charts the update.
Section – Schematics, Legends and schematics
Introduction
Safety Rules
Gener al Safety R ules
Section 1 Safety R ules
Danger
Failure to obey the instructions and safety rules in
this manual and the appropriate Operator's Manual
on your machine will result in death or serious
injury.
Many of the hazards identified in the operator's
manual are also safety hazards when maintenance
and repair procedures are performed.
Safety Rules
Read each procedure thoroughly. This Be sure to keep sparks, flames and
manual and the decals on the machine, lighted tobacco away from flammable and
use signal words to identify the following: combustible materials like battery gases
and engine fuels. Always have an
Safety alert symbol—used to alert approved fire extinguisher within easy
personnel to potential personal reach.
injury hazards. Obey all safety
messages that follow this symbol Be sure that all tools and working areas
to avoid possible injury or death. are properly maintained and ready for
use. Keep work surfaces clean and free of
Indicates a imminently hazardous debris that could get into machine
situation which, if not avoided, will components and cause damage.
result in death or serious injury.
Be sure any forklift, overhead crane or
Indicates a potentially hazardous other lifting or supporting device is fully
situation which, if not avoided, capable of supporting and stabilizing the
could result in death or serious weight to be lifted. Use only chains or
injury. straps that are in good condition and of
ample capacity.
Indicates a potentially hazardous
situation which, if not avoided, Be sure that fasteners intended for one
may cause minor or moderate time use (i.e., cotter pins and self-locking
injury. nuts) are not reused. These components
may fail if they are used a second time.
Indicates a potentially hazardous
situation which, if not avoided, Be sure to properly dispose of old oil or
may result in property damage. other fluids. Use an approved container.
Please be environmentally safe.
Be sure to wear protective eye wear and
other protective clothing if the situation Be sure that your workshop or work area
warrants it. is properly ventilated and well lit.
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.
Table of Contents
Table of Contents
Table of Contents
Manifolds .............................................................................................................56
5-1 Function Manifold Components – GS-1530, GS-1532, GS-1930 and GS-1932
56
5-2 Function Manifold Components – GS-2032, GS-2632, GS-3232, GS-2046,
GS-2646 and GS-3246 .................................................................................58
5-3 Function Manifold Components – GS-4047 ...................................................60
5-4 Check Valve Manifold Components – GS-1530, GS-1532, GS-1930 and
GS-1932........................................................................................................62
5-5 Lift Pressure Selector Manifold Components – GS-4047 ..............................63
5-6 Outrigger Function Manifold Components – GS-3232 ...................................64
5-7 Outrigger Cylinder Manifold Components – GS-3232 ...................................65
5-8 Valve Adjustments – Function Manifold .........................................................66
5-9 Valve Coils......................................................................................................72
Table of Contents
Table of Contents
Table of Contents
Table of Contents
Table of Contents
Table of Contents
Specifications
Section 2 Specific ati ons
Machi ne Specific ations
Specifications
Specifications
Performanc e Specific ati ons (models without proportional lift functi on)
Specifications
Specifications
Performanc e Specific ati ons (models with pr oporti onal lift)
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 15 to 17 seconds GS-1930, GS-1932, 500 lbs
Platform down 18 to 25 seconds GS-2632 and GS-3232 227 kg
GS-1930, 1930PAR and GS-1932 GS-1930PAR 400 lbs
181 kg
Platform up 15 to 17 seconds
Platform down 18 to 25 seconds GS-2032 800 lbs
363 kg
GS-2032 and GS-2632
GS-2046 1200 lbs
Platform up 28 to 32 seconds 544 kg
Platform down 24 to 28 seconds
GS-2646 1000 lbs
GS-2046 and GS-2646 454 kg
Platform up 28 to 32 seconds GS-3246 700 lbs
Platform down 28 to 32 seconds 317 kg
GS-3232 and GS-3246 GS-4047 770 lbs
Platform up 55 to 59 seconds (CE and AS models) 350 kg
Platform down 28 to 32 seconds GS-4047 550lbs
GS-4047 (ANSI and CSA models) 250 kg
Platform up 71 to 76 seconds GS-3232 Outrigger leveling capacity, maximum
Platform down 41 to 46 seconds Side to side 5°
Front to rear 3°
Specifications
Hydraulic Specific ati on
Specifications
Specifications
Specifications
Hydraulic C omponent Speci fications
Specifications
Manifold Com ponent Specific ati ons
Specifications
Hydraulic H ose and Fitting T orque Specific ations
Specifications
Torque Pr ocedure
Specifications
Illustration 2
1 body hex fitting
2 reference mark
3 second mark
Repair Procedures
Section 3 Repair Pr oc edures
Intr oducti on
Machine Configuration:
Unless otherwise specified, perform each
repair procedure with the machine in the
following configuration:
• Machine parked on a firm, level surface
• Key switch in the off position with the key
Observe and Obey: removed
Repair procedures shall be completed by a • The red Emergency Stop button in the off
person trained and qualified on the repair of position at both the ground and platform
this machine. controls
Immediately tag and remove from service a • Wheels chocked
damaged or malfunctioning machine.
• All external AC power supply disconnected
Repair any machine damage or malfunction from the machine
before operating the machine.
• Platform in the stowed position
Repair Procedures
Platform Controls
Platform Contro ls
Platform Controls
Operational Indicator Codes Note: The Ld Operation Indicator Code will appear
when the outriggers are not fully retracted, the
These codes are generated by the electrical machine is not auto leveled, an outrigger has lost
system to indicate machine operating status. contact with the ground or either level sensor
During normal operation, a code will appear in the detects the machine is no longer level. When any
platform controls LED readout if a condition such of the above scenarios occur, the lift function is
as off-level, overload cutout, chassis mode disabled.
operation or pothole guard stuck occurs.
The lift function will also be disabled while
If the platform controls LED readout displays an extending or retracting the outriggers and during
operational indicator code such as LL, the fault the outrigger auto level procedure. While
condition must be repaired or removed before performing the above operations, the Ld Operation
resuming machine operation. Push in and pull out Indicator Code will appear.
the red Emergency Stop button to reset the
system. Note: A code and a description of a code can also
be viewed at the ground controls LCD display.
Code Condition
LL Off-level
OL Platform Overload (CE and Australia)
CH Chassis Mode Operation
PHS Pothole Guard Stuck
nd No Drive (option)
Ld Lifting Disabled (GS-3232 only)
Platform Controls
1-1 Circ uit Boar d
Platform Controls
1-2 Joys tick 1-3 Platfrom Contr ols Alarm
1-2 1-3
Joystick Platform Controls Alarm
Platform Controls
1-4 Platform Em ergency Stop Button
Ground Controls
Ground C ontrols
Ground Controls
2-1 Softw are Revisi on Lev el
Result: The display at the ground controls will a ground control LCD display
show the machine model and hour meter b ground control scroll down button
information. After 3 seconds, the machine
model will not show on the display. See
example below.
Ground Controls
2-2 M ac hine Setup
Ground Controls
2-3 Loading or U pdati ng Mac hi ne Softw are
Ground Controls
5 Locate the diagnostic port on the side of the 8 Launch a web browser such as Internet
GCON. Remove one of the fasteners securing Explorer ®, Chrome ® or Firefox ® on your PC
the cover and set aside. Loosen the other or laptop. Type the IP address from step 7 into
fastener. Do not remove it. the web browser address bar and press enter.
Result: The following screen will be displayed.
6 Connect one end of a CAT5 Ethernet cable Note: Verify it is the correct flash file.
into the diagnostic port. Connect the other end 10 Select the Load Flash File button to verify the
into a PC or laptop. file is a .gff file.
Result: The ground controls LCD display will Result: The following screen will be displayed.
show the following:
Ground Controls
Ground Controls
5 Read and record the IP address. 8 Select the Software tab at the header bar.
Note: The display wil only show the Result: The following screen will be displayed.
IP address for 3 seconds. Press the
scroll up button to display the IP
address for another 3 seconds.
Ground Controls
11 Select the Load Flash File button to verify the 15 Secure the diagnostic port cover using the
file is a .gff file. retaining fasteners removed in step 5. Do not
over tighten.
Result: The following screen will be displayed.
Note: Machines equipped with AGM batteries will
need to select the AGM battery type using the
GCON set parameters screen. Refer to the
Machine Setup procedure in the Service and
Repair manual that is appropriate for your machine.
12 Select the Reprogram Device(s) button to Perform drive speed test. Refer
start the ECM software update. to the Maintenance Manual that
is appropriate for your machine.
Result: The following screen will be displayed
after the software update is complete. 16 Perform a function test. Refer to the
Note: Do not turn off power while the ECM is being Operator's Manual on your machine.
reprogrammed. 17 Return the machine to service.
Ground Controls
2-4 U sing a Wi-Fi Router to C onnect to the Sm artLink Web Servic e T ool
Ground Controls
5 Read and record the IP address. 9 Enter the following username and password
then select OK.
Note: The display wil only show the
IP address for 3 seconds. Press the Username: smart.link
scroll up button to display the IP Password: SL1000
address for another 3 seconds. Note: The username and password are case
sensitive.
6 On a PC, laptop or mobile device, set up a Result: The following screen will be displayed.
wireless network for the portable router.
Note: Refer to the Operating System's procedure
for connecting to a wireless network.
8 Launch a web browser such as Internet 10 After using the Smart Link Service Tool web
Explorer ®, Chrome ® or Firefox ® on your site, push in the red Emergency Stop button
PC, laptop or mobile device. Type the IP and disconnect the CAT5 cable from the
address from step 5 into the web browser GCON.
address bar and press enter. 11 Secure the diagnostic port cover using the
Result: The following screen will be displayed. retaining fasteners removed in step 3. Do not
over tighten.
Note: Machines equipped with AGM batteries will
need to select the AGM battery type using the
GCON set parameters screen. Refer to the
Machine Setup procedure in the Service and
Repair manual that is appropriate for your machine.
Ground Controls
2-5 Service Ov erride Mode
Ground Controls
3 Pull out the red Emergency Stop button to the 6 Press the Enter button.
on position at the ground controls.
Result: The ground controls LCD display will
Result: The ground controls LCD display will show an alternating message every
show the following: 1.5 seconds.
Ground Controls
2-6 Level Sensors
2-6
Level Sensors
The Electronic Control Module (ECM) is
programmed to deactivate the lift and drive
functions and activate an alarm when a signal is
received from the level sensor.
The tilt alarm sounds when the incline of the
chassis exceeds 1.5° to the side and 3° to the front
or rear. Procedure 2
Use the illustrations to verify which type of level
sensor is installed and perform the procedure that
is appropriate for your machine.
Procedure 3
1 X axis
2 Y axis
Procedure 1
Ground Controls
How to Install and Calibrate the 7 Turn the key switch to the off position and
Level Sensor - Procedure 1 push in the red Emergency Stop button to the
off position at the ground controls.
Tip-over hazard. Failure to install 8 Tag and disconnect the level sensor wire
or calibrate the level sensor as harness from the chassis wire harness.
instructed will compromise
machine stability and cause the Note: The wire harness connection is located next
machine to tip over, resulting in to the level sensor, on top of the chassis at the
death or serious injury. Do not steer end of the machine.
install or calibrate the level
sensor other than specified in 9 Remove the level sensor retaining fasteners
this procedure. and remove the level sensor from the
machine.
1 Move the machine to an area that has a firm, 10 Tag and disconnect the level sensor wires
level surface and is free of obstructions. from the level sensor connector plug.
Note: The surface must be 0° +/- 0.5°. 11 Securely install the wires of the new level
sensor into the level sensor connector plug.
2 Remove the platform controls from the
platform.
3 Turn the key switch to platform controls and
pull out the red Emergency Stop button to the
on position at both ground and platform
controls.
4 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
5 Lift the safety arm, move it to the center of the
scissor arm and rotate down to a vertical
position.
6 Lower the platform onto the safety arm.
Crushing hazard. Keep hands
clear of the safety arm when
lowering the platform.
Ground Controls
12 Place the new level sensor onto the level 13 Install the level sensor retaining fasteners
sensor mount bracket with the "X" on the level through the level sensor and springs, and into
sensor base closest to the long side of the the mount bracket. Tighten the fasteners and
level sensor mount, and the "Y" on the level measure the distance between the level
sensor base closest to the short side of the sensor and the level sensor mount bracket.
level sensor mount.
Result: The measurement should be
Tip-over hazard. Failure to install approximately 0.375 inch / 10 mm.
the level sensor as instructed, 14 Connect the chassis wire harness to the level
could result in the machine sensor wire harness.
tipping over, causing death or
serious injury. 15 Turn the key switch to the ground control and
pull out the red Emergency Stop button to the
Steer End 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
the ground controls side of the machine.
21 Raise the machine approximately 2 inches /
5 cm. Place blocks under the chassis for
support.
Non-steer End
1 limit switch
2 level sensor mount bracket
3 level sensor S7
4 scissor chassis
5 alarm H5
Ground Controls
22 GS-1530 and GS-1930: Place a 0.64 x 6 x 29 Center a lifting jack under the drive chassis at
6 inch / 16.2 mm x 15 cm x 15 cm thick steel the battery pack side of the machine.
block under both wheels at the ground
30 Raise the machine approximately 2 inches /
controls side of the machine.
5 cm. Place blocks under the chassis for
GS-1532 and GS-1932: Place a 0.68 x 6 x support.
6 inch / 17.2 mm x 15 cm x 15 cm thick steel
block under both wheels at the ground 31 GS-1530 and GS-1930: Place a 0.77 x 6 x
controls side of the machine. 6 inch / 19.6 mm x 15 cm x 15 cm thick steel
block under both wheels at the battery pack
GS-2032, GS-2632 and GS-3232: Place a side of the machine.
0.66 x 6 x 6 inch / 16.8 mm x 15 cm x 15 cm
thick steel block under both wheels at the GS-1532 and GS-1932: Place a 0.83 x 6 x
ground controls side of the machine. 6 inch / 21.1 mm x 15 cm x 15 cm thick steel
block under both wheels at the battery pack
GS-2046, GS-2646, GS-3246 and GS-4047: side of the machine.
Place a 1 x 6 x 6 inch / 25.4 mm x 15 cm x
15 cm thick steel block under both wheels at GS-2032, GS-2632 and GS-3232: Place a
the ground controls side of the machine. 0.8 x 6 x 6 inch / 20.3 mm x 15 cm x 15 cm
thick steel block under both wheels at the
23 Lower the machine onto the blocks. battery pack side of the machine.
24 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. GS-2046, GS-2646, GS-3246 and GS-4047:
Place a 1.22 x 6 x 6 inch / 31 mm x 15 cm x
Result: The level sensor alarm should not
15 cm thick steel block under both wheels at
sound.
the battery pack side of the machine.
Result: The level sensor alarm does sound
32 Lower the machine onto the blocks.
and fault code LL appears in the diagnostic
display. Adjust the level sensor retaining 33 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
fasteners just until the level sensor alarm does
not sound. Result: The platform should stop, an alarm
should sound and fault code LL appears in the
25 Lower the platform to the stowed position. diagnostic display.
26 Raise the machine approximately 2 inches / Result: The platform does not stop or the level
5 cm. Place blocks under the chassis for sensor alarm does not sound. Adjust the level
support. sensor until the alarm just begins to sound OR
the down limit switch may need to be adjusted.
27 Remove the blocks from under both wheels.
34 Lower the platform to the stowed position.
28 Lower the machine and remove the blocks.
35 Raise the machine approximately 2 inches /
5 cm.
36 Remove the blocks from under both wheels.
37 Lower the machine and remove the jack.
Ground Controls
How to Install and Calibrate the 4 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
Level Sensor - Procedure 2 5 Lift the safety arm, move it to the center of the
scissor arm and rotate down to a vertical
Tip-over hazard. Failure to install position.
the level sensor as instructed will
compromise machine stability 6 Lower the platform onto the safety arm.
and cause the machine to tip
over, resulting in death or Crushing hazard. Keep hands
serious injury. Do not install the clear of the safety arm when
level sensor other than specified lowering the platform.
in this procedure.
7 Turn the key switch to the off position and
Note: If you are not installing a new level sensor, push in the red Emergency Stop button to the
proceed to step 14. off position at the ground controls.
1 Move the machine to an area that has a firm, 8 Tag and disconnect the level sensor wire
level surface and is free of obstructions. harness from the chassis wire harness.
Note: Use a digital level to verify the surface is Note: The wire harness connection is located on
level. the level sensor, on top of the chassis at the steer
end of the machine.
2 Remove the platform controls from the
platform. 9 Remove the level sensor retaining fasteners
and remove the level sensor from the
3 Turn the key switch to ground control and pull machine.
out the red Emergency Stop button to the on
position at both ground and platform controls. 10 Securely install the wires of the new level
sensor into the level sensor connector plug.
Ground Controls
11 Place the new level sensor on to the level 12 Install the level sensor retaining fasteners
sensor bracket with the "Y" on the level sensor through the level sensor and into the mount
closest to the ground controls of the machine bracket.
and the "X" on the level sensor closest to the
steer end of the machine. 13 Connect the chassis wire harness to the level
sensor.
Tip-over hazard. Failure to install
14 Turn the key switch to ground control and pull
the level sensor as instructed,
out the red Emergency Stop button to the on
could result in the machine
position at both ground and platform controls.
tipping over, causing death or
serious injury. Result: GCON will display a ‘C051:
SYSTEMFAULT, TILT:NoCal fault.
Steer End 15 Push in the red Emergency Stop button to the
off position at the ground controls.
16 Press and hold the ground control scroll up
and scroll down buttons.
Non-steer End
1 limit switch
2 level sensor mount bracket
3 level sensor S7
4 scissor chassis
5 alarm H5
Ground Controls
17 Pull out the red Emergency Stop button to the 23 Press and hold the Enter button to start
on position at the ground controls. calibration.
Result: The ground controls LCD display will Result: An audible alarm will sound when
show the following: calibration is complete.
Note: The machine will not calibrate if it is on a
slope of one degree or greater.
Note: If the level sensor has been replaced,
continue with step 24. If the level sensor was not
replaced skip to step 27.
18 Release the Scroll Up and Scroll Down
buttons after the ground controller powers up.
19 Use the Scroll Up or Scroll Down buttons to
scroll to Select Option.
Ground Controls
29 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. 35 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
Result: No audible alarm is heard. Result: No audible alarm is heard.
Result: The platform stops, an audible alarm is Result: The platform stops, an audible alarm is
heard and Fault LL is displayed. Repeat this heard and Fault LL is displayed. Repeat this
procedure starting at step 15 on a firm level procedure starting at step 15 on a firm level
surface. surface.
30 Lower the platform to the stowed position. 36 Lower the platform to the stowed position.
31 Continue driving the machine up the ramp until 37 Continue driving the machine up the ramp until
it is just over 3°. it is just over 3°.
32 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. 38 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
Result: The platform should stop, an alarm Result: The platform should stop, an alarm
should sound and fault code LL appears in the should sound and fault code LL appears in the
diagnostic display. diagnostic display.
Result: The platform does not stop or the level Result: The platform does not stop or the level
sensor alarm does not sound. Repeat this sensor alarm does not sound. Repeat this
procedure starting at step 15 on a firm level procedure starting at step 15 on a firm level
surface. surface.
33 Lower the platform to the stowed position. 39 Lower the platform to the stowed position.
34 Drive the non-steer end of the machine up a 40 Place a digital level on the steer end of the
ramp until it is just under 3°. drive chassis. Zero out the digital level.
41 Drive the ground control side of the machine
onto a ramp until it is just under 1.5°.
Ground Controls
42 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. 48 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
Result: No audible alarm is heard. Result: No audible alarm is heard.
Result: The platform stops, an audible alarm is Result: The platform stops, an audible alarm is
heard and Fault LL is displayed. Repeat this heard and Fault LL is displayed. Repeat this
procedure starting at step 15 on a firm level procedure starting at step 15 on a firm level
surface. surface.
43 Lower the platform to the stowed position. 49 Lower the platform to the stowed position.
44 Continue driving the machine onto the ramp 50 Continue driving the machine onto the ramp
until it is just over 1.5°. until it is just over 1.5°.
45 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. 51 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
Result: The platform should stop, an alarm Result: The platform should stop, an alarm
should sound and fault code LL appears in the should sound and fault code LL appears in the
diagnostic display. diagnostic display.
Result: The platform does not stop or the level Result: The platform does not stop or the level
sensor alarm does not sound. Repeat this sensor alarm does not sound. Repeat this
procedure starting at step 15 on a firm level procedure starting at step 15 on a firm level
surface. surface.
46 Lower the platform to the stowed position. 52 Lower the platform to the stowed position.
47 Drive the battery compartment side of the
machine onto a ramp until it is just under 1.5°.
Ground Controls
How to Install and Calibrate the 6 Lower the platform onto the safety arm.
Level Sensor - Procedure 3 Crushing hazard. Keep hands
clear of the safety arm when
Tip-over hazard. Failure to install
lowering the platform.
the level sensor as instructed will
compromise machine stability
7 Turn the key switch to the off position and
and cause the machine to tip
push in the red Emergency Stop button to the
over, resulting in death or
off position at the ground controls.
serious injury. Do not install the
level sensor other than specified 8 Tag and disconnect the level sensor wire
in this procedure. harness from the chassis wire harness.
Note: If you are not installing a new level sensor, Note: The wire harness connection is located on
proceed to step 14. the level sensor, on top of the chassis at the steer
end of the machine.
1 Move the machine to an area that has a firm,
level surface and is free of obstructions. 9 Remove the level sensor retaining fasteners
and remove the level sensor from the
Note: Use a digital level to verify the surface is machine.
level.
10 Securely install the wires of the new level
2 Remove the platform controls from the sensor into the level sensor connector plug.
platform.
3 Turn the key switch to ground control and pull
out the red Emergency Stop button to the on
position at both ground and platform controls.
4 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
5 Lift the safety arm, move it to the center of the
scissor arm and rotate down to a vertical
position.
Ground Controls
11 Place the new level sensor on to the level 12 Install the level sensor retaining fasteners
sensor bracket with the "Y" on the level sensor through the level sensor and into the mount
away from the ground controls of the machine bracket.
and the "X" on the level sensor closest to the
steer end of the machine. 13 Connect the chassis wire harness to the level
sensor.
Tip-over hazard. Failure to install
14 Turn the key switch to ground control and pull
the level sensor as instructed,
out the red Emergency Stop button to the on
could result in the machine
position at both ground and platform controls.
tipping over, causing death or
serious injury. Result: GCON will display a ‘C051:
SYSTEMFAULT, TILT:NoCal fault.
Steer End 15 Push in the red Emergency Stop button to the
off position at the ground controls.
16 Press and hold the ground control scroll up
and scroll down buttons.
Non-steer End
1 limit switch
2 level sensor mount bracket
3 level sensor S7
4 scissor chassis
5 alarm H5
Ground Controls
17 Pull out the red Emergency Stop button to the 23 Press and hold the Enter button to start
on position at the ground controls. calibration.
Result: The ground controls LCD display will Result: An audible alarm will sound when
show the following: calibration is complete.
Note: The machine will not calibrate if it is on a
slope of one degree or greater.
Note: If the level sensor has been replaced,
continue with step 24. If the level sensor was not
replaced skip to step 27.
18 Release the Scroll Up and Scroll Down
buttons after the ground controller powers up.
19 Use the Scroll Up or Scroll Down buttons to
scroll to Select Option.
Ground Controls
29 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. 35 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
Result: No audible alarm is heard. Result: No audible alarm is heard.
Result: The platform stops, an audible alarm is Result: The platform stops, an audible alarm is
heard and Fault LL is displayed. Repeat this heard and Fault LL is displayed. Repeat this
procedure starting at step 15 on a firm level procedure starting at step 15 on a firm level
surface. surface.
30 Lower the platform to the stowed position. 36 Lower the platform to the stowed position.
31 Continue driving the machine up the ramp until 37 Continue driving the machine up the ramp until
it is just over 3°. it is just over 3°.
32 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. 38 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
Result: The platform should stop, an alarm Result: The platform should stop, an alarm
should sound and fault code LL appears in the should sound and fault code LL appears in the
diagnostic display. diagnostic display.
Result: The platform does not stop or the level Result: The platform does not stop or the level
sensor alarm does not sound. Repeat this sensor alarm does not sound. Repeat this
procedure starting at step 15 on a firm level procedure starting at step 15 on a firm level
surface. surface.
33 Lower the platform to the stowed position. 39 Lower the platform to the stowed position.
34 Drive the non-steer end of the machine up a 40 Place a digital level on the steer end of the
ramp until it is just under 3°. drive chassis. Zero out the digital level.
41 Drive the ground control side of the machine
onto a ramp until it is just under 1.5°.
Ground Controls
42 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. 48 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
Result: No audible alarm is heard. Result: No audible alarm is heard.
Result: The platform stops, an audible alarm is Result: The platform stops, an audible alarm is
heard and Fault LL is displayed. Repeat this heard and Fault LL is displayed. Repeat this
procedure starting at step 15 on a firm level procedure starting at step 15 on a firm level
surface. surface.
43 Lower the platform to the stowed position. 49 Lower the platform to the stowed position.
44 Continue driving the machine onto the ramp 50 Continue driving the machine onto the ramp
until it is just over 1.5°. until it is just over 1.5°.
45 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. 51 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
Result: The platform should stop, an alarm Result: The platform should stop, an alarm
should sound and fault code LL appears in the should sound and fault code LL appears in the
diagnostic display. diagnostic display.
Result: The platform does not stop or the level Result: The platform does not stop or the level
sensor alarm does not sound. Repeat this sensor alarm does not sound. Repeat this
procedure starting at step 15 on a firm level procedure starting at step 15 on a firm level
surface. surface.
46 Lower the platform to the stowed position. 52 Lower the platform to the stowed position.
47 Drive the battery compartment side of the
machine onto a ramp until it is just under 1.5°.
Ground Controls
Outrigger Level Sensor - GS-3232 6 Place the new outrigger level sensor onto the
Models outrigger level sensor base with the flat side of
the outrigger level sensor closest to the
(from serial number GS3211A to GS3215A-141898) battery side access door. Refer to the
(from serial number GS3212C-10000) illustration below.
Tip-over hazard. Failure to install
the 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
level sensor other than specified
in this procedure.
Ground Controls
2-7 M anual Platform Loweri ng C able
Ground Controls
Ground Controls
2-8 Outrigger C alibr ati on
Hydraulic Tank
Hydr aulic T an k
3-1 H ydr aulic T ank
Hydraulic Pump
Hydr aulic Pump
4-1 H ydr aulic Pump
Hydraulic Pump
How to R emove the Hydr aulic Pump
How to Remove the Hydraulic 6 Tag, disconnect and plug the high pressure
hose from the pump. Cap the fitting on the
Pump pump.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose Bodily injury hazard. Spraying
end must be replaced. All connections must be hydraulic oil can penetrate and
torqued to specification during installation. Refer to burn skin. Loosen hydraulic
Specifications, Hydraulic Hose and Fitting Torque connections very slowly to allow
Specifications. the oil pressure to dissipate
gradually. Do not allow oil to
1 Disconnect the battery pack from the machine. squirt or spray.
Manifolds
Manifold s
5-1 F uncti on Manifold C om ponents – GS-1530, GS-1532, GS-1930 and GS-1932
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.
Manifolds
Manifolds
5-2 F uncti on Manifold C om ponents – GS-2032, GS-2632, GS-3232, GS-2046, GS-2646 and GS-3246
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, at the ground control side of the machine.
Manifolds
Manifolds
5-3 F uncti on Manifold C om ponents – GS-4047
5-3
Function Manifold Components – GS-4047
The function manifold is mounted behind an inspection door, at the ground control side of the machine.
Manifolds
Manifolds
5-4 C heck Val ve M anifol d C omponents – GS-1530, GS-1532, GS-1930 and GS-1932
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.
Manifolds
5-5 Lift Pr ess ure Selec tor M anifol d C omponents – GS-4047
5-5
Lift Pressure Selector Manifold Components – GS-4047
The lift pressure selector manifold is mounted behind an inspection door, at the ground control side of the
machine.
Manifolds
5-6 Outrigger Functi on Manifold Com ponents – GS-3232
5-6
Outrigger Function Manifold Components – GS-3232
The outrigger function manifold is mounted behind an inspection door, at the battery side of the machine.
Manifolds
5-7 Outrigger C ylinder M ani fol d C omponents – GS-3232
5-7
Outrigger Cylinder Manifold Components – GS-3232
The outrigger function manifold is mounted behind an inspection door, at the battery side of the machine.
Manifolds
5-8 Valve Adjus tments – Functi on Manifold
Manifolds
Manifolds
6 Move and hold the joystick fully in either 12 Turn the key switch to ground control and pull
direction while observing the pressure reading out the red Emergency Stop button to the on
on the pressure gauge. Note the pressure. position at both ground and platform controls.
Refer to Specifications, Hydraulic Component
Specifications. 13 Hold the lift relief valve with a wrench and
remove the cap (schematic item C, AJ or DJ).
7 Turn the machine off. Hold the system relief
14 While activating the platform up function,
valve with a wrench and remove the cap
(schematic item I, AB or DB). adjust the internal hex socket clockwise, just
until the platform fully rises.
8 Adjust the internal hex socket. Turn it
15 Fully lower the platform to the stowed position.
clockwise to increase the pressure or
counterclockwise to decrease the pressure. 16 Add an additional 50 pounds / 22.7 kg to the
platform. Secure the additional weight.
Tip-over hazard. Failure to adjust
the relief valves to specification 17 Attempt to raise the platform.
could result in the machine
Result: The power unit should not be able to
tipping over, causing death or
serious injury. Do not adjust the lift platform.
relief valve pressures higher Result: If the power unit lifts the platform,
than specifications. adjust the internal hex nut socket
counterclockwise until the platform will not
9 Install the relief valve cap. rise.
10 Repeat steps 5 and 6 to confirm the relief 18 Install the relief valve cap.
valve pressure.
19 Remove the weight from the platform.
11 Place maximum rated load into the platform.
Secure the load to the platform. Refer to 20 Bleed the hydraulic system by raising the
Specifications, Machine Specifications. 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.
Manifolds
GS-4047
1 lift pressure selector valve
2 solenoid valve
Manifolds
8 Adjust the internal hex socket. Turn it How to Adjust the Steer Relief
clockwise to increase the pressure or
counterclockwise to decrease the pressure.
Valve
Note: Perform this test from the ground with the
Tip-over hazard. Failure to adjust platform controls. Do not stand in the platform.
the relief valves to specification
could result in the machine Note: Verify the hydraulic oil level is at the FULL
tipping over, causing death or mark on the hydraulic tank.
serious injury. Do not adjust the
relief valve pressures higher 1 Locate the steer relief valve on the function
than specifications. manifold (schematic item G, AH or DH).
2 Connect a 0 to 5000 psi / 0 to 350 bar
9 Install the relief valve cap. pressure gauge to the test port on the function
10 Fully lower the platform to the stowed position. manifold (schematic item A, AA or DA).
11 Using a suitable lifting device, add and secure 3 Remove the platform controls from the
an additional 150 lbs / 68 kg to the platform platform.
deck. 4 Turn the key switch to platform controls and
12 Raise the platform. pull out the red Emergency Stop button to the
on position at both ground and platform
Result: The platform does not rise. Proceed to controls.
step 13.
Result: The platform rises. Perform steps
7 through 10 to decrease the pressure in small
increments until the platform does not rise.
13 Fully lower the platform to the stowed position.
14 Using a suitable lifting device, remove the
weight from the platform.
Manifolds
5 Activate the function enable switch and press 10 Repeat steps 5 and 6 to confirm the relief
and hold the steer thumb rocker switch to the valve pressure.
right. Allow the wheels to completely turn to
the right. Continue holding the switch while
observing the pressure reading on the
pressure gauge. Note the pressure. Refer to
Specifications, Hydraulic Component
Specifications..
6 Press and hold the steer thumb rocker switch
to the left. Allow the wheels to completely turn
to the left. Continue holding the switch while
observing the pressure reading on the
pressure gauge.
7 Turn the machine off. Hold the steer relief
valve with a wrench and remove the cap
(schematic item G, AH or DH).
GS-32, GS-46 and GS-47
8 Adjust the internal hex socket. Turn it
clockwise to increase the pressure or 1 test port
counterclockwise to decrease the pressure. 2 system relief valve
3 steer relief valve
Component damage hazard. Do
not adjust the relief valve 4 lift relief valve
pressures higher than
specifications.
Manifolds
5-9 Valve Coils
Manifolds
Note: If testing a single terminal coil, connect the
How to Test a Coil Diode negative lead to the internal metallic ring at either
Genie incorporates spike suppressing diodes in all end of the coil.
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 and other jewelry.
Note: Always replace the cotter pin with a new one 9 Remove the retaining fastener from the steer
when removing the castle nut. link at the yoke assembly.
Note: While removing the retaining fasteners, take
3 Loosen the wheel castle nut. Do not remove it.
note of the quantity and location of the spacers
4 Center a lifting jack under the drive chassis at when disconnecting the steer link from the yoke
the steer end of the machine. assembly.
5 Raise the machine approximately 6 inches / 10 Remove the retaining fastener from the top of
15 cm. Place blocks under the chassis for the yoke pivot shaft.
support.
Note: The pivot shaft retaining fastener is located
Crushing hazard. The chassis above the main deck.
will fall if not properly supported.
11 Lower the yoke assembly out of the chassis.
6 Remove the wheel castle nut. Remove the Bodily injury hazard. The
wheel. yoke/motor assembly may fall if
not properly supported when it is
removed from the chassis.
8-1
Brake Release Hand Pump Components
The brake release hand pump manifold is mounted behind the entry ladder.
Scissor Components
Scissor C ompon ents
Scissor Components
9-1 Sciss or Ass embly, GS-1530 and GS-1532
How to Disassemble the Scissor 5 At the ground controls, turn the key switch to
the off position and push in the red Emergency
Assembly Stop button to the off position.
Bodily injury hazard. The 6 Disconnect the battery pack from the machine.
procedures in this section
require specific repair skills, Electrocution/burn hazard.
lifting equipment and a suitable Contact with electrically charged
workshop. Attempting this circuits could result in death or
procedure without these skills serious injury. Remove all rings,
and tools could result in death or watches and other jewelry.
serious injury and significant
component damage. Dealer 7 Remove the fasteners securing the large
service is required. platform height sensor cover to the large
platform height sensor bracket.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose 8 Remove the platform height sensor cover.
end must be replaced. All connections must be 9 Tag and disconnect the platform height sensor
torqued to specification during installation. Refer to from the platform height sensor harness.
Specifications, Hydraulic Hose and Fitting Torque
Specifications. 10 Remove the fastener securing the platform
height sensor assembly to the number 1 inner
Note: Machines equipped with a Platform Height arm.
Sensor, begin the Scissor Disassembly procedure
at step 1. Machines without a Platform Height 11 Remove the platform height sensor assembly
Sensor, begin the Scissor Disassembly procedure from the number 1 pivot pin.
at step 24. 12 Remove the plastic nut securing the squeeze
connector to the large platform height sensor
1 Turn the key switch to ground controls and pull
bracket.
out the red Emergency Stop button to the on
position at both 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
scissor arm and rotate down to a vertical
1 inner arm pivot bracket.
position.
15 Remove the large platform height sensor
bracket from the number 1 inner arm pivot
bracket.
Scissor Components
16 Install the fasteners removed in 14 to the 24 Remove the platform. Refer to Repair
number 1 inner arm pivot bracket and chassis. Procedure, How to Remove the Platform.
17 Connect the battery pack to the machine. 25 Remove the cables from the number 3 outer
arm (index #11) at the ground controls side.
18 Turn the key switch to ground controls.
Component damage hazard.
19 Press and hold the ground control scroll up
Cables can be damaged if they
and scroll down buttons.
are kinked or pinched.
20 Pull out the red Emergency Stop button to the
on position at the ground controls. 26 Remove the cables from the number 3 cable
bridge and lay them off to the side.
21 Using the ground control menu buttons,
navigate to Service Override Mode. Select Component damage hazard.
Service Override Mode. Cables can be damaged if they
Note: The machine must be in Service Override are kinked or pinched.
Mode to raise the platform. While in Service
Override Mode, only the GCON will operate with 27 Attach a lifting strap from an overhead crane
limited functionality. The platform will raise a to the number 3 outer arm (index #11).
predetermined amount of time and stop. 28 Remove the external snap rings and retaining
fasteners from the number 3 center pivot pins
22 Raise the platform and rotate the safety arm to (index #2).
the stowed position.
29 Use a soft metal drift to remove the number
23 Fully lower the platform to the stowed position. 3 center pivot pins (index #2).
30 Remove the retaining fasteners from the
number 3 pivot pin (index #12) at the
non-steer end of the machine.
31 Use a soft metal drift to remove the number
3 pivot pin (index #12) from the non-steer end
of the machine. Remove the number 3 outer
arm (index #11) from the machine.
Crushing hazard. The number
3 outer arm may become
unbalanced and fall if not
properly supported when
removed from the machine.
Scissor Components
34 Remove the pin retaining fasteners from the 42 Attach a lifting strap from an overhead crane
lift cylinder rod-end pivot pin (index #3). Use a to the number 2 outer arm (index #14) at the
soft metal drift to remove the pin. ground controls side.
Bodily injury hazard. The 43 Use a soft metal drift to remove the number
cylinder may fall when the 2 center pivot pin (index #5) at the ground
rod-end pivot pin is removed if controls side.
not properly supported.
44 Remove the retaining fasteners from the
number 2 pivot pin (index #15) at the
35 Lower the cylinder onto the number 1 inner
non-steer end of the machine.
arm (index #8).
45 Use a soft metal drift to tap the number 2 pivot
Component damage hazard. pin (index #15) halfway out at the non-steer
Cables can be damaged if they end of the machine. Remove the number
are kinked or pinched. 2 outer arm (index #14) from the ground
controls side of the machine.
36 Attach a lifting strap from an overhead crane
to the number 3 inner arm (index #10). Bodily injury hazard. The number
2 outer arm at the ground
37 Remove the retaining fasteners from the
controls side may become
number 3 pivot pin (index #4) at the steer end.
unbalanced and fall if not
38 Use a soft metal drift to remove the number properly supported when
3 pivot pin (index #4). Remove the number removed from the machine.
3 inner arm (index #10) from the machine.
46 Attach a lifting strap from an overhead crane
Bodily injury hazard. The number to the number 2 outer arm (index #14) at the
3 inner arm may become battery pack side.
unbalanced and fall if not
properly supported when 47 Remove the external snap rings and retaining
removed from the machine. fasteners from the number 2 center pivot pin
(index #5) at the battery pack side.
39 Remove the cables from the number 2 cable 48 Use a soft metal drift to remove the number
bridge and lay them off to the side. 2 center pivot pin (index #5) at the battery
Component damage hazard. pack side.
Cables can be damaged if they Bodily injury hazard. The number
are kinked or pinched. 2 outer arm at the battery pack
side may become unbalanced
40 Remove the external snap rings and retaining and fall if not properly supported
fasteners from the number 2 center pivot pin when removed from the
(index #5) at the ground controls side. machine.
41 Remove the number 2 cable bridge mounting
fasteners and remove the cable bridge from
the machine.
Scissor Components
49 Use a soft metal drift to tap the number 2 pivot 56 Attach a lifting strap from an overhead crane
pin (index #15) in the other direction at the to the lug on the rod end of the lift cylinder
non-steer end. Remove the number 2 outer (index #3). Raise the lift cylinder
arm (index #14) from the battery pack side of approximately 3 ft / 1 m.
the machine.
57 Tag, disconnect and plug the hydraulic hoses
Bodily injury hazard. The number on the lift cylinder. Cap the fittings on the
2 outer arm at the battery pack cylinder.
side may become unbalanced
and fall if not properly supported Bodily injury hazard. Spraying
hydraulic oil can penetrate and
when removed from the
burn skin. Loosen hydraulic
machine.
connections very slowly to allow
the oil pressure to dissipate
50 Attach a lifting strap from an overhead crane
to the number 2 inner arm (index #13). gradually. Do not allow oil to
squirt or spray.
51 Remove the retaining fasteners from the
number 2 pivot pin (index #6) at the steer end 58 Tag and disconnect the wires and manual
of the machine. lowering cable from the solenoid valve on the
cylinder.
52 Use a soft metal drift to remove the number
2 pivot pin (index #6). Remove the number 59 Models with platform overload option: Tag
2 inner arm (index #13) from the machine. and disconnect the wire harness from the
platform overload pressure transducer.
Bodily injury hazard. The number
2 inner arm may become Note: After replacing the scissor assembly, the
unbalanced and fall if not platform overload system must be calibrated.
properly supported when Refer to Repair Procedure, How to Calibrate the
removed from the machine. Platform Overload System (if equipped).
Scissor Components
Scissor Components
Scissor Components
9-2 Sciss or Ass embly, GS-1930 and GS-1932
How to Disassemble the Scissor 5 At the ground controls, turn the key switch to
the off position and push in the red Emergency
Assembly Stop button to the off position.
Bodily injury hazard. The 6 Disconnect the battery pack from the machine.
procedures in this section
require specific repair skills, Electrocution/burn hazard.
lifting equipment and a suitable Contact with electrically charged
workshop. Attempting this circuits could result in death or
procedure without these skills serious injury. Remove all rings,
and tools could result in death or watches and other jewelry.
serious injury and significant
component damage. Dealer 7 Remove the fasteners securing the large
service is required. platform height sensor cover to the large
platform height sensor bracket.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose 8 Remove the platform height sensor cover.
end must be replaced. All connections must be 9 Tag and disconnect the platform height sensor
torqued to specification during installation. Refer to from the platform height sensor harness.
Specifications, Hydraulic Hose and Fitting Torque
Specifications. 10 Remove the fastener securing the platform
height sensor assembly to the number 1 inner
Note: Machines equipped with a Platform Height arm.
Sensor, begin the Scissor Disassembly procedure
at step 1. Machines without a Platform Height 11 Remove the platform height sensor assembly
Sensor, begin the Scissor Disassembly procedure from the number 1 pivot pin.
at step 24. 12 Remove the plastic nut securing the squeeze
connector to the large platform height sensor
1 Turn the key switch to ground controls and pull
bracket.
out the red Emergency Stop button to the on
position at both 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
scissor arm and rotate down to a vertical
1 inner arm pivot bracket.
position.
Scissor Components
15 Remove the large platform height sensor 23 Fully lower the platform to the stowed position.
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.
Scissor Components
28 Remove the external snap rings and retaining 35 Use a soft metal drift to remove the number
fasteners from the number 4 center pivot pins 4 pivot pin (index #3) at the steer end.
(index #2). Remove the number 4 inner arm (index #12)
29 Use a soft metal drift to remove the number from the machine.
4 center pivot pins (index #2).
Crushing hazard. The number
30 Remove the retaining fasteners from the 4 inner arm may become
number 4 pivot pin (index #14) at the unbalanced and fall if not
non-steer end of the machine. properly supported when
removed from the machine.
31 Use a soft metal drift to remove the number
4 pivot pin (index #14) from the non-steer end 36 Remove the cables from the number 3 cable
of the machine. Remove the number 4 outer bridge and lay them off to the side.
arm (index #13) from the machine.
Component damage hazard.
Crushing hazard. The number Cables can be damaged if they
4 outer arm may become are kinked or pinched.
unbalanced and fall if not
properly supported when 37 Remove the number 3 cable bridge mounting
removed from the machine. fasteners and remove the cable bridge from
the machine.
32 Remove the number 4 cable bridge mounting
fasteners and remove the cable bridge from 38 Attach a lifting strap from an overhead crane
the machine. to the number 3 outer arm (index #4) at the
ground controls side.
33 Attach a lifting strap from an overhead crane
to the number 4 inner arm (index #12). 39 Remove the external snap rings and retaining
fasteners from the number 3 center pivot pins
34 Remove the retaining fasteners from the (index #4).
number 4 pivot pin (index #3).
40 Use a soft metal drift to remove the number
3 center pivot pin (index #4) at the ground
control side.
41 Remove the retaining fasteners from the
number 3 pivot pin (index #17) at the
non-steer end of the machine.
Scissor Components
42 Use a soft metal drift to tap the number 3 pivot 48 Remove the pin retaining fasteners from the
pin (index #17) halfway out at the non-steer lift cylinder rod-end pivot pin (index #5). Use a
end of the machine. Remove the number soft metal drift to remove the pin.
3 outer arm (index #16) at the ground controls
side from the machine. Bodily injury hazard. The
cylinder may fall when the
Bodily injury hazard. The number rod-end pivot pin is removed if
3 outer arm at the ground not properly supported.
controls side may become
unbalanced and fall if not 49 Lower the cylinder onto the number 1 inner
properly supported when arm (index #9).
removed from the machine.
Component damage hazard.
43 Attach a lifting strap from an overhead crane Cables can be damaged if they
to the number 3 outer arm (index #16) at the are kinked or pinched.
battery pack side.
50 Attach a lifting strap from an overhead crane
44 Use a soft metal drift to remove the number to the number 3 inner arm (index #15).
3 center pivot pin (index #4) at the battery
pack side of the machine. 51 Remove the retaining fasteners from the
number 3 pivot pin (index #6) at the steer end.
45 Use a soft metal drift to tap the number 3 pivot
pin (index #17) in the other direction. Remove 52 Use a soft metal drift to remove the number
the number 3 outer arm (index #16) from the 3 pivot pin (index #6). Remove the number
battery pack side of the machine. 3 inner arm (index #15) from the machine.
Bodily injury hazard. The number Bodily injury hazard. The number
3 outer arm at the battery pack 3 inner arm may become
side may become unbalanced unbalanced and fall if not
and fall if not properly supported properly supported when
when removed from the removed from the machine.
machine.
53 Remove the cables from the number 2 cable
46 Remove the number 3 pivot pin (index #17) bridge and lay them off to the side.
from the non-steer end of the machine. Component damage hazard.
47 Attach a lifting strap from an overhead crane Cables can be damaged if they
to the lug on the rod end of the lift cylinder for are kinked or pinched.
support. Do not apply any lifting pressure.
54 Remove the external snap rings and retaining
fasteners from the number 2 center pivot pin
(index #7) at the ground controls side.
Scissor Components
55 Remove the number 2 cable bridge mounting 63 Use a soft metal drift to tap the number 2 pivot
fasteners and remove the cable bridge from pin (index #20) in the other direction at the
the machine. non-steer end. Remove the number 2 outer
arm (index #19) from the battery pack side of
56 Attach a lifting strap from an overhead crane the machine.
to the number 2 outer arm (index #19) at the
ground controls side. Bodily injury hazard. The number
2 outer arm at the battery pack
57 Use a soft metal drift to remove the number
side may become unbalanced
2 center pivot pin (index #7) at the ground
and fall if not properly supported
controls side.
when removed from the
58 Remove the retaining fasteners from the machine.
number 2 pivot pin (index #20) at the
non-steer end of the machine. 64 Remove the number 3 pivot pin (index #17)
from the non-steer end of the machine.
59 Use a soft metal drift to tap the number 2 pivot
pin (index #20) halfway out at the non-steer 65 Attach a lifting strap from an overhead crane
end of the machine. Remove the number to the number 2 inner arm (index #18).
2 outer arm (index #19) from the ground
66 Remove the retaining fasteners from the
controls side of the machine.
number 2 pivot pin (index #8) at the steer end
Bodily injury hazard. The number of the machine.
2 outer arm at the ground
67 Use a soft metal drift to remove the number
controls side may become 2 pivot pin (index #8). Remove the number
unbalanced and fall if not
2 inner arm (index #18) from the machine.
properly supported when
removed from the machine. Bodily injury hazard. The number
2 inner arm may become
60 Attach a lifting strap from an overhead crane unbalanced and fall if not
to the number 2 outer arm (index #19) at the properly supported when
battery pack side. removed from the machine.
61 Remove the external snap rings and retaining
68 Remove the safety arm from the number
fasteners from the number 2 center pivot pin
2 inner arm (index #18) that was just removed.
(index #7) at the battery pack side.
69 Attach a lifting strap from an overhead crane
62 Use a soft metal drift to remove the number
to the number 1 inner arm (index #10).
2 center pivot pin (index #7) at the battery
pack side.
Bodily injury hazard. The number
2 outer arm at the battery pack
side may become unbalanced
and fall if not properly supported
when removed from the
machine.
Scissor Components
70 Raise the number 1 inner arm (index #10) 76 Remove the pin retaining fasteners from the
approximately 2 feet / 60 cm and install the lift cylinder barrel-end pin (index #21). Use a
safety arm between the number 1 inner arm soft metal drift to remove the pin. Remove the
(index #10) and the number 1 outer arm (index lift cylinder from the machine.
#22) at the non-steer end of the machine.
Lower the scissor arms onto the safety arm. Crushing hazard. The lift cylinder
will become unbalanced and fall
Bodily injury hazard. Keep hands if not properly supported and
clear of moving parts when secured to the lifting device.
lowering the scissor arms onto
the safety arm. Component damage hazard. Be
careful not to damage the valve
71 Attach a lifting strap from an overhead crane or fittings on the cylinder while
to the lug on the rod end of the lift cylinder removing it from the machine.
(index #5). Raise the lift cylinder
approximately 3 ft / 1 m. 77 Place a 4 x 4 x 48 inch / 10 cm x 10 cm x
1.2 m long block across both sides of the
72 Tag, disconnect and plug the hydraulic hoses chassis under the number 1 center pivot pin
on the lift cylinder. Cap the fittings on the (index #11).
cylinder.
78 Attach a lifting strap from an overhead crane
Bodily injury hazard. Spraying to the number 1 inner arm (index #10) at the
hydraulic oil can penetrate and non-steer end. Raise the number 1 inner arm
burn skin. Loosen hydraulic and remove the safety arm. Lower the number
connections very slowly to allow 1 inner arm (index #10) onto the block that
the oil pressure to dissipate was placed across the chassis.
gradually. Do not allow oil to
squirt or spray. Bodily injury hazard. Keep hands
clear of moving parts when
73 Tag and disconnect the wires and manual lowering the scissor arms.
lowering cable from the solenoid valve on the
cylinder. 79 Remove the cables from the number 1 cable
bridge and lay them off to the side.
74 Models with platform overload option: Tag
and disconnect the wire harness from the Component damage hazard.
platform overload pressure transducer. Cables can be damaged if they
are kinked or pinched.
Note: After replacing the scissor assembly, the
platform overload system must be calibrated.
80 Support and secure the entry ladder to an
Refer to Repair Procedure, How to Calibrate the
appropriate lifting device.
Platform Overload System (if equipped).
Scissor Components
81 Remove the fasteners from the entry ladder 88 Remove the upper fasteners securing the
and remove the entry ladder from the number 1 inner arm pivot bracket to the end of
machine. the chassis. Loosen the lower fasteners.
Crushing hazard. The entry 89 Remove the number 1 inner arm (index #10)
ladder will fall if not properly from the machine.
supported and secured to the
lifting device. Bodily injury hazard. The number
1 inner arm may become
unbalanced and fall if not
82 Attach a lifting strap from an overhead crane
properly supported when
to the number 1 outer arm (index #22). Do not
removed from the machine.
apply any lifting pressure.
83 Remove the external snap rings and retaining Component damage hazard. Be
fasteners from the number 1 center pivot pins sure not to damage the limit
(index #11). switch or level sensor
components when the number
84 Remove the number 1 cable bridge from the 1 inner arm is removed from the
machine. machine.
85 Use a soft metal drift to remove the number
1 center pivot pins (index #9).
Bodily injury hazard. The number
1 outer arm may become
unbalanced and fall if not
properly supported when the pin
is removed.
Scissor Components
Scissor Components
9-3 Sciss or Ass embly, GS-2032 and GS-2046
How to Disassemble the Scissor 5 At the ground controls, turn the key switch to
the off position and push in the red Emergency
Assembly, GS-2032 and GS-2046 Stop button to the off position.
Bodily injury hazard. The 6 Disconnect the battery pack from the machine.
procedures in this section
require specific repair skills, Electrocution/burn hazard.
lifting equipment and a suitable Contact with electrically charged
workshop. Attempting this circuits could result in death or
procedure without these skills serious injury. Remove all rings,
and tools could result in death or watches and other jewelry.
serious injury and significant
component damage. Dealer 7 Remove the fasteners securing the large
service is required. platform height sensor cover to the large
platform height sensor bracket.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose 8 Remove the platform height sensor cover.
end must be replaced. All connections must be 9 Tag and disconnect the platform height sensor
torqued to specification during installation. Refer to from the platform height sensor harness.
Specifications, Hydraulic Hose and Fitting Torque
Specifications. 10 Remove the fastener securing the platform
height sensor assembly to the number 1 inner
Note: Machines equipped with a Platform Height arm.
Sensor, begin the Scissor Disassembly procedure
at step 1. Machines without a Platform Height 11 Remove the platform height sensor assembly
Sensor, begin the Scissor Disassembly procedure from the number 1 pivot pin.
at step 24. 12 Remove the plastic nut securing the squeeze
connector to the large platform height sensor
1 Turn the key switch to ground controls and pull
bracket.
out the red Emergency Stop button to the on
position at both 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
scissor arm and rotate down to a vertical
1 inner arm pivot bracket.
position.
15 Remove the large platform height sensor
bracket from the number 1 inner arm pivot
bracket.
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.
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.
Scissor Components
27 Remove the cables from the number 3 cable 36 Attach a lifting strap from an overhead crane
bridge and lay them off to the side. to the number 3 outer arm at the battery side
(index #11).
Component damage hazard.
Cables can be damaged if they 37 Remove the retaining fasteners from the
are kinked or pinched. number 3 center pivot pin (index #2) at the
battery side.
28 Disconnect the number 3 cable bridge from
38 Place a rod through the number 3 center pivot
the number 3 outer arm (index #11) and
pin at the battery side (index #2) and twist to
remove the cable bridge from the machine.
remove the pin.
29 Remove the retaining fasteners from the
39 Remove the number 3 outer arm (index #11)
number 4 pivot pin (index #1).
from the machine.
30 Use a soft metal drift to remove the number
Crushing hazard. The number
4 pivot pin (index #1). Remove the platform
3 outer arm (index #11) may
mount bracket from the machine.
become unbalanced and fall if
31 Attach a lifting strap from an overhead crane not properly supported when
to the number 3 outer arm at the ground removed from the machine.
control side (index #11).
40 Attach a lifting strap from an overhead crane
32 Remove the retaining fasteners from the
to the lug of the rod end of the lift cylinder.
number 3 center pivot pin (index #2) at the
ground control side. 41 Remove the retaining fasteners from the lift
cylinder rod end pivot pin (index #3).
33 Place a rod through the number 3 center pivot
pin at the ground control side (index #2) and 42 Use a soft metal drift to remove the lift cylinder
twist to remove the pin. rod end pivot pin (index #3) from the machine.
34 Remove the retaining fasteners from the Crushing hazard. The lift cylinder
number 3 pivot pin (index #12) at the will fall if not properly supported
non-steer end. when the pivot pin is removed.
35 Use a soft metal drift to remove the number
43 Place a 4 x 4 x 10 inch / 10 x 10 x 25 cm block
3 pivot pin (index #12) from the non-steer end
onto the number 1 inner arm cylinder plate
of the machine. Remove the number 3 outer
(index #8).
arm at the ground control side (index #11)
from the machine. 44 Lower the cylinder onto the block.
Crushing hazard. The number Bodily injury hazard. Keep hands
3 outer arm at the ground control clear of moving parts when
side (index #11) may become lowering the cylinder.
unbalanced and fall if not
properly supported when 45 Attach a lifting strap from an overhead crane
removed from the machine. to the number 3 inner arm (index #10). Raise
the arm to a vertical position.
Scissor Components
46 Remove the retaining fasteners from the 54 Use a soft metal drift to remove the number
number 3 pivot pin at the steer end of the 2 pivot pin (index #15) from the non-steer end
machine (index #4). of the machine. Remove the number 2 outer
arm at the ground control side (index #14)
47 Use a soft metal drift to remove the number from the machine.
3 pivot pin (index #4) from the steer end of the
machine. Remove the number 3 inner arm The number 2 outer arm at the
(index #10) from the machine. ground control side (index #14)
may become unbalanced and fall
Crushing hazard. The number if not properly supported when
3 inner arm (index #10) may
the pivot pin is removed.
become unbalanced and fall if
not properly supported when the
55 Attach a lifting strap from an overhead crane
pivot pin is removed.
to the number 2 outer arm at the battery side
(index #14).
48 Remove the cables from the number 2A and
2B cable bridges and lay them off to the side. 56 Remove the retaining fasteners from the
number 2 center pivot pin (index #5) at the
Component damage hazard. battery side.
Cables can be damaged if they
are kinked or pinched. 57 Place a rod through the number 2 center pivot
pin at the battery side (index #5) and twist to
49 Disconnect the number 2A and 2B cable remove the pin.
bridges from the scissor linkset and remove
Crushing hazard. The number
both cable bridges from the machine.
2 outer arm (index #14) may
50 Attach a lifting strap from an overhead crane become unbalanced and fall if
to the number 2 outer arm at the ground not properly supported when the
control side (index #14). pivot pin is removed.
51 Remove the retaining fasteners from the
58 Remove the number 2 outer arm (index #14)
number 2 center pivot pin (index #5) at the
from the machine.
ground control side.
Crushing hazard. The number
52 Place a rod through the number 2 center pivot
2 outer arm (index #14) may
pin at the ground control side (index #5) and
become unbalanced and fall if
twist to remove the pin.
not properly supported when
53 Remove the retaining fasteners from the removed from the machine.
number 2 pivot pin (index #15) at the
non-steer end. 59 Attach a lifting strap from an overhead crane
to the number 2 inner arm (index #13). Raise
the arm to a vertical position.
Scissor Components
60 Remove the retaining fasteners from the 67 Tag, disconnect and plug the hydraulic hose
number 2 pivot pin at the steer end of the on the lower lift cylinder. Cap the fittings on the
machine (index #6). cylinder.
61 Use a soft metal drift to remove the number Bodily injury hazard. Spraying
2 pivot pin (index #6) from the steer end of the hydraulic oil can penetrate and
machine. Remove the number 2 inner arm burn skin. Loosen hydraulic
(index #13) from the machine. connections very slowly to allow
the oil pressure to dissipate
Crushing hazard. The number gradually. Do not allow oil to
2 inner arm (index #13) may
squirt or spray.
become unbalanced and fall if
not properly supported when the
68 Tag and disconnect the wire harness from the
pivot pin is removed.
solenoid valve on the cylinder.
62 Attach a lifting strap from an overhead crane 69 Tag and disconnect the wires and manual
to the number 1 inner arm (index #8). lowering cable from the solenoid valve on the
cylinder.
63 Raise the number 1 inner arm (index #8)
approximately 2 feet / 60 cm. 70 Models with platform overload option: Tag
and disconnect the wire harness from the
64 Place a 4 x 4 x 48 inch / 10 cm x 10 cm x
platform overload pressure transducer.
1.2 m long block across both sides of the
chassis under the number 1 center pivot pin Note: After replacing the scissor assembly, the
(index #7). platform overload system must be calibrated.
Refer to Repair Procedure, How to Calibrate the
65 Lower the scissor arms onto the block that Platform Overload System (if equipped).
was placed across the chassis.
71 Raise the lift cylinder to a vertical position.
Bodily injury hazard. Keep hands
clear of moving parts when 72 Remove the pin retaining fasteners from the
lowering the scissor arms. lift cylinder barrel-end pin (index #16). Use a
soft metal drift to remove the pin. Remove the
66 Attach a lifting strap from an overhead crane lift cylinder from the machine.
to the lug of the rod end of the lower lift
cylinder. Crushing hazard. The lift cylinder
will fall if not properly supported
when the pivot pin is removed.
Scissor Components
Scissor Components
Scissor Components
9-4 Sciss or Ass embly, GS-2632 and GS-2646
How to Disassemble the Scissor 5 At the ground controls, turn the key switch to
the off position and push in the red Emergency
Assembly Stop button to the off position.
Bodily injury hazard. The 6 Disconnect the battery pack from the machine.
procedures in this section
require specific repair skills, Electrocution/burn hazard.
lifting equipment and a suitable Contact with electrically charged
workshop. Attempting this circuits could result in death or
procedure without these skills serious injury. Remove all rings,
and tools could result in death or watches and other jewelry.
serious injury and significant
component damage. Dealer 7 Remove the fasteners securing the large
service is required. platform height sensor cover to the large
platform height sensor bracket.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose 8 Remove the platform height sensor cover.
end must be replaced. All connections must be 9 Tag and disconnect the platform height sensor
torqued to specification during installation. Refer to from the platform height sensor harness.
Specifications, Hydraulic Hose and Fitting Torque
Specifications. 10 Remove the fastener securing the platform
height sensor assembly to the number 1 inner
Note: Machines equipped with a Platform Height arm.
Sensor, begin the Scissor Disassembly procedure
at step 1. Machines without a Platform Height 11 Remove the platform height sensor assembly
Sensor, begin the Scissor Disassembly procedure from the number 1 pivot pin.
at step 24. 12 Remove the plastic nut securing the squeeze
connector to the large platform height sensor
1 Turn the key switch to ground controls and pull
bracket.
out the red Emergency Stop button to the on
position at both 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
scissor arm and rotate down to a vertical
1 inner arm pivot bracket.
position.
15 Remove the large platform height sensor
bracket from the number 1 inner arm pivot
bracket.
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.
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.
Scissor Components
24 Remove the platform. Refer to Repair 34 Remove the retaining fasteners from the
Procedure, How to Remove the Platform. number 4 pivot pin (index #15) at the
non-steer end.
25 Support and secure the entry ladder to an
appropriate lifting device. 35 Use a soft metal drift to remove the number
4 pivot pin (index #14) from the non-steer end
26 Remove the fasteners from the entry ladder of the machine. Remove the number 4 outer
and remove the entry ladder from the
arm at the ground control side (index #13)
machine. from the machine.
Crushing hazard. The entry Crushing hazard. The number
ladder will fall if not properly 4 outer arm at the ground control
supported and secured to the
side (index #13) may become
lifting device. unbalanced and fall if not
properly supported when
27 Remove the cables from the number 4 cable removed from the machine.
bridge and lay them off to the side.
Component damage hazard. 36 Attach a lifting strap from an overhead crane
Cables can be damaged if they to the number 4 outer arm at the battery side
are kinked or pinched. (index #13).
37 Remove the retaining fasteners from the
28 Disconnect the number 4 cable bridge from number 4 center pivot pin (index #2) at the
the number 4 outer arm (index #13) and battery side.
remove the cable bridge from the machine.
38 Place a rod through the number 4 center pivot
29 Remove the retaining fasteners from the pin at the battery side (index #2) and twist to
number 5 pivot pin (index #1). remove the pin.
30 Use a soft metal drift to remove the number 39 Remove the number 4 outer arm (index #13)
5 pivot pin (index #1). Remove the platform from the machine.
mount bracket from the machine.
Crushing hazard. The number
31 Attach a lifting strap from an overhead crane 4 outer arm (index #13) may
to the number 4 outer arm at the ground become unbalanced and fall if
control side (index #13). not properly supported when
32 Remove the retaining fasteners from the removed 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
33 Place a rod through the number 4 center pivot the arm to a vertical position.
pin at the ground control side (index #2) and
twist to remove the pin.
Scissor Components
41 Remove the retaining fasteners from the 49 Use a soft metal drift to remove the number
number 4 pivot pin at the steer end of the 3 pivot pin (index #17) from the non-steer end
machine (index #3). of the machine. Remove the number 3 outer
arm at the ground control side (index #16)
42 Use a soft metal drift to remove the number from the machine.
4 pivot pin (index #3) from the steer end of the
machine. Remove the number 4 inner arm Crushing hazard. The number
(index #12) from the machine. 3 outer arm at the ground control
side (index #16) may become
Crushing hazard. The number unbalanced and fall if not
4 inner arm (index #12) may
properly supported when
become unbalanced and fall if
removed from the machine.
not properly supported when
removed from the machine.
50 Attach a lifting strap from an overhead crane
to the number 3 outer arm at the battery side
43 Remove the cables from the number 3A and
(index #16).
3B cable bridge and lay them off to the side.
51 Remove the retaining fasteners from the
Component damage hazard. number 3 center pivot pin (index #4) at the
Cables can be damaged if they battery side.
are kinked or pinched.
52 Place a rod through the number 3 center pivot
44 Disconnect the number 3A and 3B cable pin at the battery side (index #4) and twist to
bridges from the scissor linkset and remove remove the pin.
both cable bridges from the machine.
53 Remove the number 3 outer arm (index #16)
45 Attach a lifting strap from an overhead crane from the machine.
to the number 3 outer arm at the ground
Crushing hazard. The number
control side (index #16).
3 outer arm (index #16) may
46 Remove the retaining fasteners from the become unbalanced and fall if
number 3 center pivot pin (index #4) at the not properly supported when
ground control side. removed from the machine.
47 Place a rod through the number 3 center pivot
54 Attach a lifting strap from an overhead crane
pin at the ground control side (index #4) and
to the lug of the rod end of the lift cylinder.
twist to remove the pin.
55 Remove the retaining fasteners from the lift
48 Remove the retaining fasteners from the cylinder rod end pivot pin (index #5).
number 3 pivot pin (index #17) at the
non-steer end.
Scissor Components
56 Use a soft metal drift to remove the lift cylinder 63 Disconnect the number 2A and 2B cable
rod end pivot pin (index #5) from the machine. bridges from the scissor linkset and remove
both cable bridges from the machine.
Crushing hazard. The lift cylinder
will fall if not properly supported 64 Attach a lifting strap from an overhead crane
when the pivot pin is removed. to the number 2 outer arm at the ground
control side (index #19).
57 Place a 4 x 4 x 10 inch / 10 x 10 x 25 cm block
65 Remove the retaining fasteners from the
onto the number 1 inner arm cylinder plate
number 2 center pivot pin (index #7) at the
(index #10).
ground control side.
58 Lower the cylinder onto the block.
66 Place a rod through the number 2 center pivot
Bodily injury hazard. Keep hands pin at the ground control side (index #7) and
clear of moving parts when twist to remove the pin.
lowering the cylinder. 67 Remove the retaining fasteners from the
number 2 pivot pin (index #20) at the
59 Attach a lifting strap from an overhead crane non-steer end.
to the number 3 inner arm (index #15). Raise
the arm to a vertical position. 68 Use a soft metal drift to remove the number
2 pivot pin (index #20) from the non-steer end
60 Remove the retaining fasteners from the of the machine. Remove the number 2 outer
number 3 pivot pin at the steer end of the arm at the ground control side (index #19)
machine (index #6). from the machine.
61 61 Use a soft metal drift to remove the
The number 2 outer arm at the
number 3 pivot pin (index #6) from the steer
ground control side (index #19)
end of the machine. Remove the number
may become unbalanced and fall
3 inner arm (index #15) from the machine.
if not properly supported when
Crushing hazard. The number the pivot pin is removed.
3 inner arm (index #15) may
become unbalanced and fall if 69 Attach a lifting strap from an overhead crane
not properly supported when the to the number 2 outer arm at the battery side
pivot pin is removed. (index #19).
70 Remove the retaining fasteners from the
62 Remove the cables from the number 2A and number 2 center pivot pin (index #7) at the
2B cable bridge and lay them off to the side. battery side.
Component damage hazard.
Cables can be damaged if they
are kinked or pinched.
Scissor Components
Scissor Components
85 Raise the lift cylinder to a vertical position. 93 Secure the ends of the scissor arms together
at the non-steer end of the machine with a
86 Remove the pin retaining fasteners from the strap or other suitable device.
lift cylinder barrel-end pin (index #21). Use a
soft metal drift to remove the pin. Remove the 94 Remove the retaining fasteners securing the
lift cylinder from the machine. chassis mount bracket to the chassis.
Crushing hazard. The lift cylinder 95 Remove the linkset from the machine
will fall if not properly supported
when the pivot pin is removed. Bodily injury hazard. The number
1 inner and outer arms (index
Component damage hazard. Be #10 and #22) may become
careful not to damage the valve unbalanced and fall if not
or fittings on the cylinder while properly supported when
removing it from the machine. removed from the machine.
Scissor Components
Scissor Components
9-5 Sciss or Ass embly, GS-3232 and GS-3246
Bodily injury hazard. The 5 At the ground controls, turn the key switch to
procedures in this section the off position and push in the red Emergency
require specific repair skills, Stop button to the off position.
lifting equipment and a suitable
workshop. Attempting this 6 Disconnect the battery pack from the machine.
procedure without these skills
Electrocution/burn hazard.
and tools could result in death or
Contact with electrically charged
serious injury and significant
circuits could result in death or
component damage. Dealer
serious injury. Remove all rings,
service is required.
watches and other jewelry.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose 7 Remove the fasteners securing the large
end must be replaced. All connections must be platform height sensor cover to the large
torqued to specification during installation. Refer to platform height sensor bracket.
Specifications, Hydraulic Hose and Fitting Torque 8 Remove the platform height sensor cover.
Specifications.
9 Tag and disconnect the platform height sensor
Note: Machines equipped with a Platform Height from the platform height sensor harness.
Sensor, begin the Scissor Disassembly procedure
at step 1. Machines without a Platform Height 10 Remove the fastener securing the platform
Sensor, begin the Scissor Disassembly procedure height sensor assembly to the number 1 inner
at step 24. arm.
11 Remove the platform height sensor assembly
1 Turn the key switch to ground controls and pull
from the number 1 pivot pin.
out the red Emergency Stop button to the on
position at both ground and platform controls. 12 Remove the plastic nut securing the squeeze
connector to the large platform height sensor
2 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
bracket.
Scissor Components
13 Remove the squeeze connector from the large 22 Raise the platform and rotate the safety arm to
platform height sensor bracket. the stowed position.
14 Remove the fasteners securing the large 23 Fully lower the platform to the stowed position.
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.
Scissor Components
24 Remove the platform. Refer to Repair 35 Use a soft metal drift to remove the number
Procedure, How to Remove the Platform. 5 pivot pin (index #18) from the non-steer end
of the machine. Remove the number 5 outer
25 Support and secure the entry ladder to an
arm at the ground control side (index #17)
appropriate lifting device. from the machine.
26 Remove the fasteners from the entry ladder
Crushing hazard. The number
and remove the entry ladder from the
5 outer arm at the ground control
machine.
side (index #17) may become
Crushing hazard. The entry unbalanced and fall if not
ladder will fall if not properly properly supported when
supported and secured to the removed from the machine.
lifting device.
36 Attach a lifting strap from an overhead crane
27 Remove the cables from the number 5 cable to the number 5 outer arm at the battery side
bridge and lay them off to the side. (index #17).
28 Disconnect the number 4 cable bridge from 37 Remove the retaining fasteners from the
the number 5 outer arm (index #17) and number 5 center pivot pin (index #2) at the
remove the cable bridge from the machine. battery side.
29 Remove the retaining fasteners from the 38 Place a rod through the number 5 center pivot
number 6 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
6 pivot pin (index #1). Remove the platform 39 Remove the number 5 outer arm (index #17)
mount bracket from the machine. from the machine.
31 Attach a lifting strap from an overhead crane Crushing hazard. The number
to the number 5 outer arm at the ground 5 outer arm (index #17) may
control side (index #17). become unbalanced and fall if
not properly supported when
32 Remove the retaining fasteners from the removed from the machine.
number 5 center pivot pin (index #2) at the
ground control side. 40 Attach a lifting strap from an overhead crane
33 Place a rod through the number 5 center pivot to the number 5 inner arm (index #16). Raise
pin at the ground control side (index #2) and the arm to a vertical position.
twist to remove the pin. 41 Remove the retaining fasteners from the
34 Remove the retaining fasteners from the number 5 pivot pin at the steer end of the
number 5 pivot pin (index #18) at the machine (index #4).
non-steer end.
Scissor Components
42 Use a soft metal drift to remove the number 49 Use a soft metal drift to remove the upper lift
5 pivot pin (index #18) from the steer end of cylinder rod end pivot pin (index #3) from the
the machine. Remove the number 5 inner arm machine.
(index #16) from the machine.
Crushing hazard. The lift cylinder
Crushing hazard. The number will fall if not properly supported
5 inner arm (index #16) may when the pivot pin is removed.
become unbalanced and fall if
not properly supported when 50 Lower the cylinder onto the linkset.
removed from the machine.
51 Attach a lifting strap from an overhead crane
43 Tag, disconnect and plug the hydraulic hose to the number 4 outer arm at the ground
on the upper lift cylinder. Cap the fittings on control side (index #20).
the cylinder. 52 Remove the retaining fasteners from the
number 4 center pivot pin (index #5) at the
Bodily injury hazard. Spraying
ground control side.
hydraulic oil can penetrate and
burn skin. Loosen hydraulic 53 Place a rod through the number 4 center pivot
connections very slowly to allow pin at the ground control side (index #5) and
the oil pressure to dissipate twist to remove the pin.
gradually. Do not allow oil to
squirt or spray. 54 Remove the retaining fasteners from the
number 4 pivot pin (index #21) at the
44 Tag and disconnect the wire harness from the non-steer end.
solenoid valve on the cylinder. 55 Use a soft metal drift to remove the number
45 Remove the cables from the number 4A and 4 pivot pin (index #21) from the non-steer end
4B cable bridges and lay them off to the side. of the machine. Remove the number 4 outer
arm at the ground control side (index #20)
Component damage hazard. from the machine.
Cables can be damaged if they
are kinked or pinched. Crushing hazard. The number
4 outer arm at the ground control
46 Disconnect the number 4A and 4B cable side (index #20) may become
bridges from the scissor linkset and remove unbalanced and fall if not
both cable bridges from the machine. properly supported when
removed from the machine.
47 Attach a lifting strap from an overhead crane
to the lug of the rod end of the upper lift 56 Attach a lifting strap from an overhead crane
cylinder. to the number 4 outer arm at the battery side
(index #20).
48 Remove the retaining fasteners from the
upper lift cylinder rod end pivot pin (index #3). 57 Remove the retaining fasteners from the
number 4 center pivot pin (index #5) at the
battery side.
Scissor Components
58 Place a rod through the number 4 center pivot 66 Remove the retaining fasteners from the
pin at the battery side (index #5) and twist to number 3 center pivot pin (index #8) at the
remove the pin. ground control side.
59 Remove the number 4 outer arm (index #20) 67 Place a rod through the number 3 center pivot
from the machine. pin at the ground control side (index #8) and
twist to remove the pin.
Crushing hazard. The number
4 outer arm (index #20) may 68 Remove the retaining fasteners from the
become unbalanced and fall if number 3 pivot pin (index #24) at the
not properly supported when non-steer end.
removed from the machine.
69 Use a soft metal drift to remove the number
3 pivot pin (index #24) from the non-steer end
60 Attach a lifting strap from an overhead crane
of the machine. Remove the number 3 outer
to the number 4 inner arm (index #19). Raise
arm at the ground control side (index #7) from
the arm to a vertical position.
the machine.
61 Remove the retaining fasteners from the
Crushing hazard. The number
number 4 pivot pin at the steer end of the
3 outer arm at the ground control
machine (index #6).
side (index #7) may become
62 Use a soft metal drift to remove the number unbalanced and fall if not
4 pivot pin (index #6) from the steer end of the properly supported when
machine. Remove the number 4 inner arm removed from the machine.
(index #19) from the machine.
70 Attach a lifting strap from an overhead crane
Crushing hazard. The number to the number 3 outer arm at the battery side
4 inner arm (index #19) may (index #7).
become unbalanced and fall if
not properly supported when 71 Remove the retaining fasteners from the
removed from the machine. number 3 center pivot pin (index #8) at the
battery side.
63 Remove the cables from the number 3A and
72 Place a rod through the number 3 center pivot
3B cable bridges and lay them off to the side.
pin at the battery side (index #8) and twist to
Component damage hazard. remove the pin.
Cables can be damaged if they 73 Remove the number 3 outer arm (index #7)
are kinked or pinched. from the machine.
64 Disconnect the number 3A and 3B cable Crushing hazard. The number
bridges from the scissor linkset and remove 3 outer arm (index #7) may
both cable bridges from the machine. become unbalanced and fall if
not properly supported when
65 Attach a lifting strap from an overhead crane
removed from the machine.
to the number 3 outer arm at the ground
control side (index #7).
Scissor Components
74 Attach a lifting strap from an overhead crane 83 Remove the retaining fasteners from the
to the lug of the rod end of the upper lift number 3 pivot pin at the steer end of the
cylinder. machine (index #10).
75 Raise the lift cylinder to a vertical position. 84 Use a soft metal drift to remove the number
3 pivot pin (index #10) from the steer end of
76 Remove the pin retaining fasteners from the the machine. Remove the number 3 inner arm
lift cylinder barrel-end pivot pin (index #22).
(index #23) from the machine.
Remove the lift cylinder from the machine.
Crushing hazard. The number
Crushing hazard. The lift cylinder 3 inner arm (index #23) may
will fall if not properly supported become unbalanced and fall if
when the pivot pin is removed.
not properly supported when the
pivot pin is removed.
Component damage hazard. Be
careful not to damage the valve
85 Remove the cables from the number 2A and
or fittings on the cylinder while
2B cable bridges and lay them off to the side.
removing it from the machine.
Component damage hazard.
77 Attach a lifting strap from an overhead crane Cables can be damaged if they
to the lug of the rod end of the lower lift are kinked or pinched.
cylinder.
78 Remove the retaining fasteners from the lower 86 Disconnect the number 2A and 2B cable
lift cylinder rod end pivot pin (index #9). bridges from the scissor linkset and remove
both cable bridges from the machine.
79 Use a soft metal drift to remove the lower lift
cylinder rod end pivot pin (index #9) from the 87 Attach a lifting strap from an overhead crane
machine. to the number 2 outer arm at the ground
control side (index #26).
Crushing hazard. The lift cylinder
88 Remove the retaining fasteners from the
will fall if not properly supported
number 2 center pivot pin (index #11) at the
when the pivot pin is removed.
ground control side.
80 Place a 4 x 4 x 10 inch / 10 x 10 x 25 cm block 89 Place a rod through the number 2 center pivot
onto the number 1 inner arm cylinder plate pin at the ground control side (index #11) and
(index #14). twist to remove the pin.
81 Lower the cylinder onto the block. 90 Remove the retaining fasteners from the
number 2 pivot pin (index #27) at the
Bodily injury hazard. Keep hands
non-steer end.
clear of moving parts when
lowering the cylinder.
Scissor Components
91 Use a soft metal drift to remove the number 97 Remove the retaining fasteners from the
2 pivot pin (index #27) from the non-steer end number 2 pivot pin at the steer end of the
of the machine. Remove the number 2 outer machine (index #12).
arm at the ground control side (index #26)
from the machine. 98 Use a soft metal drift to remove the number
2 pivot pin (index #12) from the steer end of
The number 2 outer arm at the the machine. Remove the number 2 inner arm
ground control side (index #26) (index #25) from the machine.
may become unbalanced and fall
if not properly supported when Crushing hazard. The number
2 inner arm (index #25) may
the pivot pin is removed.
become unbalanced and fall if
not properly supported when the
92 Attach a lifting strap from an overhead crane
pivot pin is removed.
to the number 2 outer arm at the battery side
(index #26).
99 Attach a lifting strap from an overhead crane
93 Remove the retaining fasteners from the to the number 1 inner arm (index #14).
number 2 center pivot pin (index #11) at the
battery side. 100 Raise the number 1 inner arm (index #14)
approximately 2 feet / 60 cm.
94 Place a rod through the number 2 center pivot
101 Place a 4 x 4 x 48 inch / 10 cm x 10 cm x
pin at the battery side (index #11) and twist to
remove the pin. 1.2 m long block across both sides of the
chassis under the number 1 center pivot pin
Crushing hazard. The number (index #13).
2 outer arm (index #26) may
102 Lower the scissor arms onto the block that
become unbalanced and fall if
was placed across the chassis.
not properly supported when the
pivot pin is removed. Bodily injury hazard. Keep hands
clear of moving parts when
95 Remove the number 2 outer arm (index #26) lowering the scissor arms.
from the machine.
103 Attach a lifting strap from an overhead crane
Crushing hazard. The number
to the lug of the rod end of the lower lift
2 outer arm (index #26) may
cylinder.
become unbalanced and fall if
not properly supported when 104 Tag, disconnect and plug the hydraulic hose
removed from the machine. on the lower lift cylinder. Cap the fittings on the
cylinder.
96 Attach a lifting strap from an overhead crane
to the number 2 inner arm (index #25). Raise Bodily injury hazard. Spraying
the arm to a vertical position. 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.
Scissor Components
106 Models with platform overload option: Tag 113 Lower the arm to the stowed position.
and disconnect the wire harness from the
platform overload pressure transducer. Bodily injury hazard. Keep hands
clear of moving parts when
Note: After replacing the scissor assembly, the
lowering the scissor arms.
platform overload system must be calibrated.
Refer to Repair Procedure, How to Calibrate the
114 Secure the ends of the scissor arms together
Platform Overload System (if equipped).
at the steer end of the machine with a strap or
107 Raise the lift cylinder to a vertical position. other suitable device.
108 Remove the pin retaining fasteners from the 115 Secure the ends of the scissor arms together
lift cylinder barrel-end pin (index #28). Use a at the non-steer end of the machine with a
soft metal drift to remove the pin. Remove the strap or other suitable device.
lift cylinder from the machine. 116 Remove the retaining fasteners securing the
Crushing hazard. The lift cylinder chassis mount bracket to the chassis.
will fall if not properly supported 117 Remove the linkset from the machine.
when the pivot pin is removed.
Bodily injury hazard. The number
Component damage hazard. Be 1 inner and outer arms (index
careful not to damage the valve #14 and #29) may become
or fittings on the cylinder while unbalanced and fall if not
removing it from the machine. properly supported when
removed from the machine.
109 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
Component damage hazard. switch or level sensor
Cables can be damaged if they components when the number
are kinked or pinched. 1 inner and outer arms (index
#14 and #29) are removed from
110 Disconnect the number 1 cable bridge from the machine.
the number 1 outer arm (index #29) and
remove the cable bridge from the machine.
111 Attach a lifting strap from an overhead crane
to the number 1 inner arm (index #14).
112 Raise the arm slightly and remove the block.
Scissor Components
Scissor Components
9-6 Sciss or Ass embly, GS-4047
Bodily injury hazard. This 5 At the ground controls, turn the key switch to
procedure requires specific repair the off position and push in the red Emergency
skills, lifting equipment and a Stop button to the off position.
suitable workshop. Attempting
this procedure without these skills 6 Disconnect the battery pack from the machine.
and tools could result in death or
Electrocution/burn hazard.
serious injury and significant
Contact with electrically charged
component damage. Dealer
circuits could result in death or
service is strongly recommended.
serious injury. Remove all rings,
Note: When removing a hose assembly or fitting, watches and other jewelry.
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be 7 Remove the fasteners securing the large
torqued to specification during installation. Refer to platform height sensor cover to the large
Specifications, Hydraulic Hose and Fitting Torque platform height sensor bracket.
Specifications. 8 Remove the platform height sensor cover.
Note: Machines equipped with a Platform Height 9 Tag and disconnect the platform height sensor
Sensor, begin the Scissor Disassembly procedure from the platform height sensor harness.
at step 1. Machines without a Platform Height
Sensor, begin the Scissor Disassembly procedure 10 Remove the fastener securing the platform
at step 24. height sensor assembly to the number 1 inner
arm.
1 Turn the key switch to ground controls and pull
11 Remove the platform height sensor assembly
out the red Emergency Stop button to the on
from the number 1 pivot pin.
position at both ground and platform controls.
12 Remove the plastic nut securing the squeeze
2 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
connector to the large platform height sensor
bracket.
Scissor Components
13 Remove the squeeze connector from the large 23 Fully lower the platform to the stowed position.
platform height sensor bracket.
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.
Scissor Components
24 Remove the platform. Refer to Repair 35 Place a rod through the number 6 center pivot
Procedure, How to Remove the Platform. pin at the battery side (index #2) and twist to
remove the pin.
25 Remove the cables from cable bridges a, b, c,
d and e. 36 Remove the number 6 outer arm (index #19)
from the machine.
26 Remove the retaining fasteners from the
number 7 pivot pin (index #1). Crushing hazard. The number
6 outer arm (index #19) may
27 Use a soft metal drift to remove the number
become unbalanced and fall if
7 pivot pin (index #1). Remove the platform
not properly supported when
mount bracket from the machine.
removed from the machine.
28 Attach a lifting strap from an overhead crane
to the number 6 outer arm at the ground 37 Attach a lifting strap from an overhead crane
control side (index #19). to the number 6 inner arm (index #18). Raise
the arm to a vertical position.
29 Remove the retaining fasteners from the
number 6 center pivot pin (index #2) at the 38 Remove the retaining fasteners from the
ground control side. number 6 pivot pin at the steer end of the
machine (index #3).
30 Place a rod through the number 6 center pivot
pin at the ground control side (index #2) and 39 Use a soft metal drift to remove the number
twist to remove the pin. 6 pivot pin (index #3) from the steer end of the
machine. Remove the number 6 inner arm
31 Remove the retaining fasteners from the (index #18) from the machine.
number 6 pivot pin (index #20) at the
non-steer end. Crushing hazard. The number
5 inner arm (index #16) may
32 Use a soft metal drift to remove the number
become unbalanced and fall if
6 pivot pin (index #20) from the non-steer end
not properly supported when
of the machine. Remove the number 6 outer
removed from the machine.
arm at the ground control side (index #19)
from the machine.
40 Tag, disconnect and plug the hydraulic hose
Crushing hazard. The number on the upper lift cylinder. Cap the fittings on
6 outer arm at the ground control the cylinder.
side (index #19) may become
Bodily injury hazard. Spraying
unbalanced and fall if not
hydraulic oil can penetrate and
properly supported when
burn skin. Loosen hydraulic
removed from the machine.
connections very slowly to allow
the oil pressure to dissipate
33 Attach a lifting strap from an overhead crane
gradually. Do not allow oil to
to the number 6 outer arm at the battery side
squirt or spray.
(index #19).
34 Remove the retaining fasteners from the 41 Attach a lifting strap from an overhead crane
number 6 center pivot pin (index #2) at the to the number 5 outer arm at the ground
battery side. control side (index #22).
Scissor Components
42 Remove the retaining fasteners from the 49 Attach a lifting strap from an overhead crane
number 5 center pivot pin (index #4) at the to the lug of the rod end of the upper lift
ground control side. cylinder.
43 Place a rod through the number 5 center pivot 50 Remove the retaining fasteners from the
pin at the ground control side (index #4) and upper lift cylinder rod end pivot pin (index #5).
twist to remove the pin.
51 Use a soft metal drift to remove the upper lift
44 Remove the retaining fasteners from the cylinder rod end pivot pin (index #5) from the
number 5 pivot pin (index #23) at the machine.
non-steer end.
Crushing hazard. The lift cylinder
45 Use a soft metal drift to remove the number will fall if not properly supported
5 pivot pin (index #23) from the non-steer end when the pivot pin is removed.
of the machine. Remove the number 5 outer
arm at the ground control side (index #22) 52 Lower the cylinder onto the linkset.
from the machine.
53 Attach a lifting strap from an overhead crane
Crushing hazard. The number to the number 4 outer arm at the ground
5 outer arm at the ground control control side (index #25).
side (index #22) may become
unbalanced and fall if not 54 Remove the retaining fasteners from the
properly supported when number 4 center pivot pin (index #7) at the
removed from the machine. ground control side.
55 Place a rod through the number 4 center pivot
46 Attach a lifting strap from an overhead crane pin at the ground control side (index #7) and
to 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
from the machine. non-steer end.
Crushing hazard. The number 57 Use a soft metal drift to remove the number
5 outer arm at the battery side 4 pivot pin (index #26) from the non-steer end
(index #22) may become of the machine. Remove the number 4 outer
unbalanced and fall if not arm at the ground control side (index #25)
properly supported when from the machine.
removed from the machine.
Crushing hazard. The number
48 Tag and disconnect the wire harness from the 4 outer arm at the ground control
solenoid valve on the cylinder. side (index #25) may become
unbalanced and fall if not
Component damage hazard. properly supported when
Cables can be damaged if they removed from the machine.
are kinked or pinched.
Scissor Components
58 Attach a lifting strap from an overhead crane 66 Attach a lifting strap from an overhead crane
to the number 4 outer arm at the battery side to the number 3 outer arm at the ground
(index #25). control 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
become unbalanced and fall if 3 pivot pin (index #29) from the non-steer end
not properly supported when of the machine. Remove the number 3 outer
removed from the machine. arm at the ground control side (index #9) from
the machine.
62 Attach a lifting strap from an overhead crane
Crushing hazard. The number
to the number 4 inner arm (index #24). Raise
3 outer arm at the ground control
the arm to a vertical position.
side (index #9) may become
63 Remove the retaining fasteners from the unbalanced and fall if not
number 4 pivot pin at the steer end of the properly supported when
machine (index #8). removed from the machine.
64 Use a soft metal drift to remove the number
71 Attach a lifting strap from an overhead crane
4 pivot pin (index #8) from the steer end of the to 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 from the machine.
4 inner arm (index #24) may
become unbalanced and fall if Crushing hazard. The number
not properly supported when 3 outer arm (index #9) may
removed from the machine. become unbalanced and fall if
not properly supported when
65 Remove the cables from cable bridges f,h,i,j,k removed from the machine.
and l.
73 Attach a lifting strap from an overhead crane
Component damage hazard. to the number 3 inner arm (index #28). Raise
Cables can be damaged if they the number 3 inner arm and place a 4 x 4 x
are kinked or pinched. 48 inch / 10 cm x 10 cm x 1.2 m block across
the link stack to gain access to the barrel end
pivot pin (index 27).
Scissor Components
74 Attach a lifting strap from an overhead crane 83 Lower the cylinder onto the block.
to the lug of the rod end of the upper lift
cylinder. Bodily injury hazard. Keep hands
clear of moving parts when
75 Raise the lift cylinder to a vertical position. lowering the cylinder.
Crushing hazard. The lift cylinder 84 Attach a lifting strap from an overhead crane
will fall if not properly supported
to the number 3 inner arm (index #28). Raise
when the pivot pin is removed.
the arm to a vertical position.
Component damage hazard. Be 85 Remove the retaining fasteners from the
careful not to damage the valve number 3 pivot pin at the steer end of the
or fittings on the cylinder while machine (index #12).
removing it from the machine.
86 Use a soft metal drift to remove the number
76 Use a soft metal drift to remove the upper lift 3 pivot pin (index #12) from the steer end of
cylinder barrel end pivot pin (index #27) from the machine. Remove the number 3 inner arm
the machine. (index #28) from the machine.
77 Attach a lifting strap from an overhead crane Crushing hazard. The number
to the number 3 inner arm (index #28). Raise 3 inner arm (index #28) may
the number 3 inner arm and remove the 4 x become unbalanced and fall if
4 x 48 inch / 10 cm x 10 cm x 1.2 m block from not properly supported when the
the link stack. pivot pin is removed.
78 Lower the number 3 inner arm (index #28) and 87 Attach a lifting strap from an overhead crane
remove the lifting strap. to the number 2 outer arm at the ground
79 Attach a lifting strap from an overhead crane control side (index #31).
to the lug of the rod end of the lower lift 88 Remove the retaining fasteners from the
cylinder. number 2 center pivot pin (index #13) at the
80 Remove the retaining fasteners from the lower ground control side.
lift cylinder rod end pivot pin (index 11). 89 Place a rod through the number 2 center pivot
81 Use a soft metal drift to remove the lower lift pin at the ground control side (index #13) and
cylinder rod end pivot pin (index 11) from the twist to remove the pin.
machine. 90 Remove the retaining fasteners from the
number 2 pivot pin (index #32) at the
Crushing hazard. The lift cylinder
non-steer end.
will fall if not properly supported
when the pivot pin is removed.
Scissor Components
91 Use a soft metal drift to remove the number 97 Remove the retaining fasteners from the
2 pivot pin (index #32) from the non-steer end number 2 pivot pin at the steer end of the
of the machine. Remove the number 2 outer machine (index #14).
arm at the ground control side (index #31)
from the machine. 98 Use a soft metal drift to remove the number
2 pivot pin (index #14) from the steer end of
Crushing hazard. The number the machine. Remove the number 2 inner arm
2 outer arm at the ground control (index #30) from the machine.
side (index #31) may become
unbalanced and fall if not Crushing hazard. The number
2 inner arm (index #30) may
properly supported when the
become unbalanced and fall if
pivot pin is removed.
not properly supported when the
pivot pin is removed.
92 Attach a lifting strap from an overhead crane
to the number 2 outer arm at the battery side
99 Attach a lifting strap from an overhead crane
(index #31).
to the number 1 inner arm (index #16).
93 Remove the retaining fasteners from the
number 2 center pivot pin (index #13) at the 100 Raise the number 1 inner arm (index #16)
approximately 2 feet / 60 cm.
battery side.
101 Place a 4 x 4 x 48 inch / 10 cm x 10 cm x
94 Place a rod through the number 2 center pivot
pin at the battery side (index #13) and twist to 1.2 m long block across both sides of the
remove the pin. chassis under the number 1 center pivot pin
(index #15).
Crushing hazard. The number
102 Lower the scissor arms onto the block that
2 outer arm (index #31) may
was placed across the chassis.
become unbalanced and fall if
not properly supported when the Bodily injury hazard. Keep hands
pivot 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
cylinder.
2 outer arm (index #31) may
become unbalanced and fall if 104 Tag, disconnect and plug the hydraulic hose
not properly supported when on the lower lift cylinder. Cap the fittings on the
removed from the machine. cylinder.
96 Attach a lifting strap from an overhead crane Bodily injury hazard. Spraying
to the number 2 inner arm (index #30). Raise hydraulic oil can penetrate and
the 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.
Scissor Components
105 Tag and disconnect the wire harness from the 113 Attach a lifting strap from an overhead crane
solenoid valve on the cylinder. to the number 1 inner arm (index #16).
106 Tag and disconnect the wires and manual 114 Raise the arm slightly and remove the block.
lowering cable from the solenoid valve on the
cylinder. 115 Lower the arm to the stowed position.
107 Models with platform overload option: Tag Bodily injury hazard. Keep hands
and disconnect the wire harness from the clear of moving parts when
platform overload pressure transducer. lowering the scissor arms.
Note: After replacing the scissor assembly, the 116 Secure the ends of the scissor arms together
platform overload system must be calibrated. at the steer end of the machine with a strap or
Refer to Repair Procedure 9-10, How to Calibrate other suitable device.
the Platform Overload System (if equipped).
117 Secure the ends of the scissor arms together
108 Raise the lift cylinder to a vertical position. at the non-steer end of the machine with a
strap or other suitable device.
109 Remove the pin retaining fasteners from the
lift cylinder barrel-end pivot pin (index #28). 118 Remove the retaining fasteners securing the
Use a soft metal drift to remove the pin. chassis mount bracket to the chassis.
Remove the lift cylinder from the machine.
119 Remove the linkset from the machine.
Crushing hazard. The lift cylinder
will fall if not properly supported Bodily injury hazard. The number
1 inner and outer arms (index
when the pivot pin is removed.
#16 and #34) may become
Component damage hazard. Be unbalanced and fall if not
careful not to damage the valve properly supported when
or fittings on the cylinder while removed from the machine.
removing it from the machine.
Component damage hazard. Be
110 Remove the cables from the number 1 cable sure not to damage the limit
switch or level sensor
bridge and lay them off to the side.
components when the number
Component damage hazard. 1 inner and outer arms (index
Cables can be damaged if they #16 and 34) are removed from
are kinked or pinched. the machine.
Scissor Components
9-7 Sciss or Arm Wear Pads
Scissor Components
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
Override Mode, only the GCON will operate with pads.
limited functionality. The platform will raise a
predetermined amount of time and stop. Crushing hazard. The scissor
assembly will fall if not properly
22 Raise the platform and return the safety arm to supported when removed from
the stowed position. the drive chassis.
23 Fully lower the platform to the stowed position. Component damage hazard. Be
24 Remove the platform. Refer to Repair careful not to damage the level
Procedure, How to Remove the Platform. sensor or limit switch while
moving the scissor assembly.
25 Support and secure the entry ladder to an
appropriate lifting device. 33 Remove both old wear pads.
26 Remove the fasteners from the entry ladder 34 Install two new wear pads.
and remove the entry ladder from the
machine. 35 Slide the scissor assembly back into the drive
chassis.
Crushing hazard. The entry
ladder will fall if not properly 36 Lower the scissor assembly into position and
supported and secured to the install the chassis mount bracket onto the
lifting device. chassis. Securely install and tighten the
fasteners. Do not over tighten.
27 Secure the ends of the scissor arms together Component damage hazard. Be
at the steer end of the machine with a strap or careful not to damage the level
other suitable device. sensor or limit switch while
28 Secure the ends of the scissor arms together moving the scissor assembly.
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.
Scissor Components
9-8 Platform Hei ght Sens or
5 Disconnect the battery pack from the machine. 11 Remove the set screw securing the lever arm
to the platform height sensor.
Electrocution/burn hazard.
12 Remove the lever arm from the platform height
Contact with electrically charged
sensor assembly.
circuits could result in death or
serious injury. Remove all rings, 13 Working with the platform height sensor
watches and other jewelry. assembly, remove the Deustch connector
from the plastic clip.
6 Remove the fasteners securing the large
platform height sensor cover to the large 14 Remove the fasteners securing the platform
platform height sensor bracket. height sensor to the small platform height
sensor bracket.
Scissor Components
15 Remove the platform height sensor from the 18 Remove the fasteners securing the large
small angle sensor bracket. platform height bracket to the number 1 inner
arm pivot bracket.
16 Remove the plastic nut securing the squeeze
connector to the large platform height sensor 19 Remove the large platform height sensor
bracket. bracket from the number 1 inner arm pivot
bracket.
17 Remove the squeeze connector from the large
platform height sensor bracket. Tip-over hazard. Failure to install
the fasteners securing the large
platform height sensor bracket
and number 1 inner arm pivot
bracket to the chassis, could
result in the machine tipping
over, causing death or serious
injury.
Steer End
1 number 1 inner arm
2 fastener (platform height sensor assembly)
3 number 1 pivot pin
4 lever arm retaining screw
5 squeeze connector
6 lever arm
7 platform height sensor harness connection
8 platform height sensor
9 fastener (large platform height sensor
bracket)
10 fastener (platform height sensor)
11 platform height sensor assembly
Scissor Components
9-9 Lift Cylinder
Scissor Components
6 At the ground controls, turn the key switch to 13 Attach a lifting strap from an overhead crane
the off position and push in the red Emergency to the rod end of the lift cylinder for support.
Stop button to the off position.
14 Remove the fasteners from the lift cylinder
7 Disconnect the battery pack from the machine. rod-end pivot pin. Use a soft metal drift to
remove the pin.
Electrocution/burn hazard.
Contact with electrically charged Crushing hazard. The lift cylinder
circuits could result in death or will fall if not properly supported
serious injury. Remove all rings, when the pivot pin is removed.
watches and other jewelry.
15 Lower the cylinder onto the number 2 inner
8 Tag and disconnect the wiring from the arm.
solenoid valve coil at the barrel end of the lift
16 Attach a lifting strap from an overhead crane
cylinder.
or similar lifting device to the barrel end of the
9 If equipped, tag and disconnect the three-pin lift cylinder for support.
connector from the pressure transducer
17 Remove the fasteners from the lift cylinder
harness. To remove the pressure transducer
refer to Repair Procedure, How to Remove the barrel-end pivot pin. Use a soft metal drift to
Pressure Transducer (if equipped). remove the pin.
10 Loosen the adjustment nuts on the solenoid Crushing hazard. The lift cylinder
valve and disconnect the manual lowering will fall if not properly supported
cable from the valve. when the pivot 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.
Refer to Repair Procedure, 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. will 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
Bodily injury hazard. Spraying or fittings on the cylinder while
hydraulic oil can penetrate and removing it from the machine.
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
Scissor Components
20 Install new cylinder, fittings, hoses and GS-2032, GS-2632, GS-2046 and GS-2646
pressure transducer (if equipped).
Bodily injury hazard. The
Torque specifications procedures in this section
require specific repair skills,
Solenoid valve, 2 position 2 way, 20 ft-lbs
27 Nm
lifting equipment and a suitable
N.C. workshop. Attempting this
(schematic item N) procedure without these skills
Coil nut 5 ft-lbs
and tools could result in death or
7 Nm serious injury and significant
component damage. Dealer
Pressure transducer(if equipped) 27 ft-lbs
service is required.
(schematic item R) 37 Nm
Note: When removing a hose assembly or fitting,
21 Remove the lifting device supporting the link the O-ring (if equipped) on the fitting and/or hose
stack at the steer end of the machine. end must be replaced. All connections must be
torqued to specification during installation. Refer to
22 Connect the battery pack to the machine.
Specifications, Hydraulic Hose and Fitting Torque
23 Turn the key switch to ground control. Specifications.
Models without a pressure transducer Note: Models without a pressure transducer follow
continue at step 27. steps 1 through 23, 27 and 28.
Models equipped with a pressure transducer follow
Models with a pressure transducer
steps 1 through 28.
continue at step 24.
24 Press and hold the ground control scroll up 1 Turn the key switch to ground controls and pull
and scroll down buttons. out the red Emergency Stop button to the on
position at both ground and platform controls.
25 Pull out the red Emergency Stop button to the
on position at the ground controls. 2 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
Scissor Components
3 Lift the safety arm, move it to the center of the 6 At the ground controls, turn the key switch to
scissor arm and rotate down to a vertical the off position and push in the red Emergency
position. Stop button to the off position.
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.
Scissor Components
13 Attach a lifting strap from an overhead crane 20 Install new cylinder, fittings, hoses and
to the rod end of the lift cylinder for support. pressure transducer (if equipped).
14 Remove the fasteners from the lift cylinder Torque specifications
rod-end pivot pin. Use a soft metal drift to
Solenoid valve, 2 position 2 way, 20 ft-lbs
remove the pin. 27 Nm
N.C.
Crushing hazard. The lift cylinder (schematic item N)
will fall if not properly supported
when the pivot pin is removed. Coil nut 5 ft-lbs
7 Nm
15 Lower the cylinder onto the number 1 inner Pressure transducer(if equipped) 27 ft-lbs
arm cylinder plate. (schematic item R) 37 Nm
16 Attach a lifting strap from an overhead crane 21 Remove the lifting device supporting the link
or similar lifting device to the barrel end of the stack at the steer end of the machine.
lift cylinder for support.
22 Connect the battery pack to the machine.
17 Remove the fasteners from the lift cylinder
barrel-end pivot pin. Use a soft metal drift to 23 Turn the key switch to ground control.
remove the pin.
Models without a pressure transducer
Crushing hazard. The lift cylinder continue at step 27.
will fall if not properly supported Models with a pressure transducer
when the pivot pin is removed.
continue at step 24.
18 Support and secure the lift cylinder to an 24 Press and hold the ground control scroll up
appropriate lifting device. and scroll down buttons.
19 Remove the lift cylinder through the scissor 25 Pull out the red Emergency Stop button to the
arms at the steer end of the machine. on position at the ground controls.
Crushing hazard. The lift cylinder 26 Using the ground control menu buttons,
will become unbalanced and fall navigate to Service Override Mode. Select
if not properly supported and Service Override Mode.
secured to the lifting device. Note: The machine must be in Service Override
Mode to raise the platform. While in Service
Component damage hazard. Be
Override Mode, only the GCON will operate with
careful not to damage the valve
limited functionality. The platform will raise a
or fittings on the cylinder while
predetermined amount of time and stop.
removing it from the machine.
27 Raise the platform and rotate the safety arm to
the stowed position.
28 Fully lower the platform to the stowed position.
Note: Models with a pressure transducer, calibrate
the Platform Overload System. Refer to Repair
Procedure, How to Calibrate the Platform Overload
System (if equipped).
Scissor Components
GS-3232 and GS-3246 3 Lift the safety arm, move it to the center of the
scissor arm and rotate down to a vertical
Bodily injury hazard. The
position.
procedures in this section
require 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 required.
Scissor Components
4 Lower the platform onto the safety arm. 10 Loosen the adjustment nuts on the solenoid
valve and disconnect the manual lowering
Crushing hazard. Keep hands cable from the valve.
clear of the safety arm when
lowering the platform. Note: During assembly, the manual platform
lowering cable needs to be properly adjusted.
5 Using a suitable lifting device, support the link Refer to Repair Procedure, How to Adjust the
stack at the steer end of the machine. Manual Platform Lowering Cable.
6 At the ground controls, turn the key switch to 11 Remove the fasteners securing the manual
the off position and push in the red Emergency lowering cable mount bracket to the cylinder.
Stop button to the off position. Remove the bracket from the cylinder.
7 Disconnect the battery pack from the machine. 12 Tag, disconnect and plug the hydraulic hoses
on the lift cylinder. Cap the fittings on the
Electrocution/burn hazard. cylinder.
Contact with electrically charged
circuits could result in death or Bodily injury hazard. Spraying
serious injury. Remove all rings, hydraulic oil can penetrate and
watches and other jewelry. burn skin. Loosen hydraulic
connections very slowly to allow
Note: At the lower lift cylinder, install the orifice the oil pressure to dissipate
fitting with the small opening of the orifice fitting gradually. Do not allow oil to
closest to the supply hose. squirt or spray.
8 Tag and disconnect the wiring from the 13 Attach a lifting strap from an overhead crane
solenoid valve coil at the barrel end of the lift or similar lifting device to the barrel end of the
cylinder. lift cylinder for support.
Skip to step 13 if removing the upper 14 Remove the fasteners from the lift cylinder
cylinder. rod-end pivot pin. Use a soft metal drift to
remove the pin.
9 If equipped, tag and disconnect the three-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, How to Remove the when the pivot pin is removed.
Pressure Transducer (if equipped).
15 Lower the cylinder onto the number 1 inner
arm cylinder plate.
Scissor Components
16 Attach a lifting strap from an overhead crane 20 Install new cylinder, fittings, hoses and
or similar lifting device to the barrel end of the pressure transducer (if equipped).
lift cylinder for support.
17 Remove the fasteners from the lift cylinder
barrel-end pivot pin. Use a soft metal drift to
remove the pin.
Crushing hazard. The lift cylinder
will fall if not properly supported
when the pivot pin is removed.
Torque specifications
Solenoid valve, 2 position 2 way, 20 ft-lbs
N.C. 27 Nm
(schematic item N)
Scissor Components
Scissor Components
3 Lift the safety arm, move it to the center of the 4 Lower the platform onto the safety arm.
scissor arm and rotate down to a vertical
position. Crushing hazard. Keep hands
clear of the safety arm when
lowering the platform.
Scissor Components
12 Tag, disconnect and plug the hydraulic hoses 19 Remove the lift cylinder through the scissor
on the lift cylinder. Cap the fittings on the arms at the steer end of the machine.
cylinder.
Crushing hazard. The lift cylinder
Bodily injury hazard. Spraying will become unbalanced and fall
hydraulic oil can penetrate and if not properly supported and
burn skin. Loosen hydraulic secured to the lifting device.
connections very slowly to allow
the oil pressure to dissipate Component damage hazard. Be
gradually. Do not allow oil to careful not to damage the valve
squirt or spray. or fittings on the cylinder while
removing it from the machine.
13 Attach a lifting strap from an overhead crane
or similar lifting device to the barrel end of the 20 Install new cylinder, fittings, hoses and
lift cylinder for support. pressure transducer (if equipped).
14 Remove the fasteners from the lift cylinder
rod-end pivot pin. Use a soft metal drift to
remove the pin.
Crushing hazard. The lift cylinder
will fall if not properly supported
when the pivot pin is removed.
Scissor Components
9-10 Press ure Trans duc er
28 Fully lower the platform to the stowed position. 7 Pull the manual lowering cable and hold for
Note: Models with a pressure transducer, calibrate 3 seconds.
the Platform Overload System. Refer to Repair 8 Tag and disconnect the three-pin connector
Procedure, How to Calibrate the Platform Overload from the pressure transducer harness.
System (if equipped).
Scissor Components
Torque specifications
Pressure transducer(if equipped) 27 ft-lbs
(schematic item R) 37 Nm
Scissor Components
9-11 Platform Ov erload Sys tem
Personnel are not allowed in the platform while Note: If a new Ground Controller is installed on a
calibrating the platform overload system. machine, the Full Load Calibration procedure is
required to maintain rated load platform capacity.
Perform this procedure in an environment that If a No Load Calibration is performed, machine
allows the platform to be fully raised. Models rated lifting performance will be significantly reduced.
for indoor use only, should be calibrated inside a
facility with enough ceiling height to fully raise the Note: Ambient temperature must be above 32°F /
platform. If the facility height is not suitable to fully 0°C before calibrating the Platform Overload
raise the platform, then an indoor only rated model System.
may be calibrated outdoors if wind speeds are less Note: To calibrate the platform overload system,
then 28 mph / 12.5 m/s. Only use flat weights while follow the menu structure indicated on the ground
calibrating indoor only rated machines, outdoors. control LCD display.
Perform this procedure after confirming that the
platform height sensor is not damaged and
functions correctly.
Scissor Components
Full Load Calibration: Part 1 8 Release the Menu Up and Menu Down
1 Fully charge the batteries and check the buttons after the ground controller powers up.
hydraulic fluid level. 9 Use the Menu Up or Menu Down buttons to
Note: The hydraulic fluid level must be between the scroll to, Select Option. Press the Enter
FULL and ADD marks on the hydraulic tank. button.
10 Use the Menu Up or Menu Down buttons to
2 Apply a thin layer of dry film lubricant to the
scroll to Platform Overload.
area of the chassis and platform, where the
scissor arm wear pads make contact. 11 Press the Enter button to select Platform
Overload.
3 Chock both sides of the wheels at the steer
end of the machine. 12 Use the Menu Up or Menu Down buttons to
scroll to Platform Overload Calibrate.
4 Using a suitable lifting device, place a test
weight corresponding to the machine 13 Press the Enter button to select Platform
maximum load, in the center of the platform Overload Calibrate.
deck. Secure the weight to the platform. Refer
to the chart below. 14 Confirm the Platform Overload Calibrate
selection by pressing the Enter button again.
GS-1530 and GS-1532 272 kg
15 Use the Menu Up or Menu Down buttons to
GS-1930 and GS-1932 227 kg select Full Load calibration.
GS-2032 363 kg
16 Press the Enter button to select Full Load
GS-2632 227 kg calibration.
GS-3232 227 kg
17 Press the Enter button to confirm rated load is
Note: In the event of frequent nuisance trips in the platform.
occurring after calibrating a GS-3232 machine, it is
recommended to recalibrate the machine, full load 18 At the ground controls, press and hold the
and no load, with 250 kg of weight in the platform. Function Enable and Platform Up buttons until
the platform reaches maximum height.
GS-2046 544 kg
19 All Models except GS-4047: When the
GS-2646 454 kg platform reaches maximum height, press the
GS-3246 317 kg ground controls Enter button. Allow the ground
GS-4047 350 kg controls to gather data. GS-4047 only: Press
and hold the Menu Enter button to determine
5 Turn the key switch to ground control. the maximum height. The machine will lower
6 At the ground controls, press and hold the for 1.2 seconds and then raise in 1.2 second
Menu Up and Menu Down buttons. durations, until maximum height is reached.
When the platform reaches the maximum
7 While pressing both buttons down, pull out the height, a message will appear on the LCD
red Emergency Stop Button. screen to release the Menu Enter button.
Note: If at any point the Menu Enter button is
released before the message appears on the LCD
screen, the calibration procedure will restart at step
18.
Scissor Components
20 When prompted, press and hold the Function 23 When prompted, press and hold the Function
Enable and Platform Down buttons. The Enable and Platform Down buttons until the
platform will lower, then automatically stop at a platform is fully stowed. When the platform
predetermined point to gather data. Allow the reaches the stowed position, press the enter
ground controls to gather data. button.
21 Continue pressing the Function Enable and Note: If the Function Enable or Platform Down
Platform Down buttons throughout the buttons are released while the machine is
lowering and data gathering sequence. The collecting data, the GCON LCD will prompt the
machine will stop to gather data and lower user to raise the platform for 5 seconds before
several times before the machine reaches the prompting to lower the platform to the stowed
stowed position. When the platform reaches position again.
the stowed position, press the enter button.
Note: If the machine is switched to PCON mode to
Note: Software revision H or prior, and drive the machine to an area for weight removal,
GS-3032, GS-2646 and GS-4047 models, step 3 and steps 5 through 14 will have to be
continue to step 24. repeated before Full Load Calibration: Part 2 is
performed. Additionally, the CO25 fault will appear.
Note: All other models with software revision J This is expected and the data collected in Full Load
or higher, continue with step 22. Calibration: Part 1 has not been lost.
22 When prompted, press and hold the Function 24 Using a suitable lifting device, remove the test
Enable and Platform Up buttons until the weight from the platform deck.
platform reaches full height. When the
platform reaches full height, press the enter 25 After the weight is removed from the platform
button. deck, press the Enter button to confirm the
weight has been removed.
Note: If the Function Enable or Platform Up buttons
are released while the machine is collecting data,
the GCON LCD will prompt the user to lower the
platform for 5 seconds before prompting to raise
the platform to full height again.
Scissor Components
Scissor Components
8 At the ground controls, use the Menu Up 18 When prompted, press and hold the Function
or Menu Down buttons to scroll to Platform Enable and Platform Down buttons to lower
Overload. the platform. The platform will move down,
then automatically stop at a predetermined
9 Press the Enter button to select the Platform point to gather data. Allow the ground controls
Overload. to gather data.
10 Use the Menu Up or Menu Down buttons to 19 Continue pressing the Function Enable and
scroll to Platform Overload Calibrate. Platform Down buttons throughout the
lowering and data gathering sequence. The
11 Press the Enter button to select Platform
machine will stop to gather data and lower
Overload Calibrate.
several times before the machine reaches the
12 Confirm the Platform Overload Calibrate stowed position. When the platform reaches
selection by pressing the Enter button again. the stowed position, press the Enter button.
13 Use the Menu Up or Menu Down buttons to Note: Software revision H or prior, and
select No Load calibration. GS-2032, GS-2646 and GS-4047 models,
continue to step 22.
14 Press the Enter button to select No Load
calibration. Note: All other models with software revision J
or higher, continue with step 20.
Scissor Components
9-12 Platform Ov erload R ec ov ery
Scissor Components
3 Pull out the red Emergency Stop button at the 7 Press and hold the scroll down button for
ground controls. 5 seconds.
Result: The ground control LCD display will Result: The ground control LCD display will
show the following. show the following.
5 Press the enter button. 9 Press the buttons in the following sequence:
(down)(down)(up)(enter).
Result: The ground control LCD display will
show the following. Note: After each key press an asterisk (*) will
appear on the second line of the LCD display.
Result: The ground control LCD display will
show the following.
Platform Components
Platform Co mpon ents
10- 1 Platform
Platform Components
10- 2 Platform Extension D eck
5 Attach a strap from the platform extension 3 Install the new wear pads using new rivets.
railings to the carriage on the forklift to help When installing the new rivets, make sure the
support the platform extension. rivet heads are not above the surface of the
wear pad.
6 Remove the fasteners from each platform
extension roller bracket assembly. Remove
each assembly from the machine.
Note: Do not remove the platform roller bolt.
Diagnostics
Section 4 Diagnostics
Intr oducti on
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 Attempting short cuts may produce hazardous
be completed by a person trained and qualified conditions.
on 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 with electrically charged
• Machine parked on a firm, level surface
circuits could result in death or
• Platform in the stowed position serious injury. Remove all rings,
watches and other jewelry.
• Key switch in the off position with the key
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
connections very slowly to allow
• Wheels chocked the oil pressure to dissipate
gradually. Do not allow oil to
• All external AC power supply disconnected
squirt or spray.
from the machine
Diagnostics
Diagnostics
Diagnostics
GCON I/O Map without Load Sense (all m ac hines exc ept GS- 3232)
GCON I/O Map without Load Sense (all models except GS-3232)
GCON Pin Number Circuit Function I/O Type Wire Gauge and Color
J1 Connector – Gray
J1-01 ECM Power Power Input 14 RD
J1-02 PCON, E-Stop Power Power Output 18 RD
J1-03 PCON, E-Stop Return Power Input 18 WH
J1-04 Link to PCON — CANH Data Bus 18GR
J1-05 Link to PCON — CANL Data Bus 18 OR
J1-06 PCON — Ground Ground Output 18 BR
J1-07 GCON — Ground Ground Input 14 BR
J1-08 Key Switch — PCON Mode Digital Input 18 BK
J1-09 Key Switch — GCON Mode Digital Input 18 WH
J1-10 GCON — Emergency Mode Digital Input 18 WH/BK
J1-11 No Circuit N/A N/A
J1-12 Driver Power Power Input 14 RD
J-2 Connector – Black
J2-01 Platform Up Coil Digital Output 18 OR
J2-02 Platform Down Coil Digital Output 18 OR/BK
J2-03 Steer Left Coil Digital Output 18 BL/BK
J2-04 Steer Right Coil Digital Output 18 BL
J2-05 Parallel Coil (GS-32 & GS-46) Digital Output 18 RD/WH
J2-06 Drive Forward Coil Digital Output 18 WH
J2-07 No Circuit N/A N/A
J2-08 Motor Controller Enable Digital Output 18 GR/WH
J2-09 No Circuit N/A N/A
J2-10 Drive Reverse Coil Digital Output 18 WH/BK
J2-11 Motor Controller Throttle Analog Output 18 GR
J2-12 No Circuit N/A N/A
J-3 Connector – Green
J3-01 No Circuit N/A N/A
J3-02 GCON — Alarm Digital Output 18 BL
J3-03 Switch/Sensor Power Digital Output 14 RD
J3-04 Automotive Horn Digital Output 18 WH
J3-05 Pothole Limit Switch Digital Input 18 OR/RD
J3-06 Ground Ground Input 18 BR
J3-07 Down Limit Switch Digital Input 18 OR
J3-08 Level Sensor Digital Input 18 RD/BK
J3-09 Ground Ground Input 18 BK
J3-10 Ground Ground Input 18 BK
J3-11 No Circuit N/A N/A
J3-12 Load Sense — Ground Ground Input 18 BK
Diagnostics
GCON I/O Map with Load Sens e ( all mac hines ex cept GS-3232)
GCON I/O Map with Load Sense (all model except GS-3232)
GCON Pin Number Circuit Function I/O Type Wire Gauge and Color
J1 Connector – Gray
J1-01 ECM Power Power Input 14 RD
J1-02 PCON, E-Stop Power Power Output 18 RD
J1-03 PCON, E-Stop Return Power Input 18 WH
J1-04 Link to PCON — CANH Data Bus 18GR
J1-05 Link to PCON — CANL Data Bus 18 OR
J1-06 PCON — Ground Ground Output 18 BR
J1-07 GCON — Ground Ground Input 14 BR
J1-08 Key Switch — PCON Mode Digital Input 18 BK
J1-09 Key Switch — GCON Mode Digital Input 18 WH
J1-10 GCON — Emergency Mode Digital Input 18 WH/BK
J1-11 No Circuit N/A N/A
J1-12 Driver Power Power Input 14 RD
J-2 Connector – Black
J2-01 Platform Up Coil Digital Output 18 OR
J2-02 Platform Down Coil Digital Output 18 OR/BK
J2-03 Steer Left Coil Digital Output 18 BL/BK
J2-04 Steer Right Coil Digital Output 18 BL
J2-05 Parallel Coil (GS-32, GS-46 & GS-47) Digital Output 18 RD/WH
J2-06 Drive Forward Coil Digital Output 18 WH
J2-07 Ground (GS-4047) Ground Input 18 BR
J2-08 Motor Controller Enable Digital Output 18 GR/WH
J2-09 Lift Pressure Selector (GS-4047) N/A N/A
J2-10 Drive Reverse Coil Digital Output 18 WH/BK
J2-11 Motor Controller Throttle Analog Output 18 GR
J2-12 No Circuit N/A N/A
J-3 Connector – Green
J3-01 No Circuit N/A N/A
J3-02 GCON — Alarm Digital Output 18 BL
J3-03 Switch/Sensor Power Digital Output 14 RD
J3-04 Automotive Horn Digital Output 18 WH
J3-05 Pothole Limit Switch Digital Input 18 OR/RD
J3-06 Ground Ground Input 18 BR
J3-07 Down Limit Switch Digital Input 18 OR
J3-08 Level Sensor Digital Input 18 RD/BK
J3-09 Platform Overload Pressure Transducer Ground Input 18 BL/WH
J3-10 Platform Height Sensor Ground Input 18 OR/WH
J3-11 No Circuit N/A N/A
J3-12 Load Sense — Ground Ground Input 18 BK
Diagnostics
GCON I/O Map without Load Sense GS-3232 only)
Diagnostics
Diagnostics
GCON I/O Map with Load Sens e (GS-3232 only)
Diagnostics
Diagnostics
Operati on Indi cator C odes (OIC) Diagnostic Tr ouble Codes (DTC)
Diagnostic Chart
No
1 Check the faulted device for a short or open circuit. Good Replace faulted device.
Good
No
Check short or open circuit of the harness or
2 Good Repair or replace harness an/or connector.
connector between Ground Controls and faulted device.
Good
No
3 Check GCON Electronic Control Module (ECM). Good Replace ECM.
Wiring Diagram
The wiring diagram shown below illustrates how fault type "HXXX" and "PXXX" devices are typically wired.
The signal of these types of devices originates at the Ground Controls and terminates at system ground.
GCON
Electronic Control Module
(ECM) Signal Wire Signal Side Device Return Side Return Wire
In order to successfully troubleshoot "HXXX" or "PXXX" type faults, the entire faulted out circuit must be
investigated.
2 Check the harness between the ground controls and the faulted device
1 Disconnect the GCON ECM connectors, J1, J2 and J3.
2 Disconnect the faulted device connector.
3 Check the continuity between the GCON ECM connector
and the signal side of the faulted device.
Result: Resistance should be close to 0 Ω
4 Check the continuity between the return side of faulted
device and system ground.
Result: Resistance should be close to 0 Ω
5 Check resistance between return side and signal side of
the harness plug of faulted device.
Result: Resistance should be 1M Ω or higher.
Note: An error code C053 will be displayed if an updated PCON is installed on a machine that has not had
the GCON updated. The GCOn must be updated, or the original PCON must be installed back on the
machine.
Schematics
Section 5 Schem atics
Intr oducti on
Electrical Schematics
Electrocution/burn hazard.
Contact with electrically charged
Observe and Obey: circuits could result in death or
serious injury. Remove all rings,
Troubleshooting and repair procedures shall watches and other jewelry.
be completed by a person trained and qualified
on the repair of this machine
Hydraulic Schematics
Immediately tag and remove from service a
damaged or malfunctioning machine. Bodily injury hazard. Spraying
hydraulic oil can penetrate and
Repair any machine damage or malfunction
burn skin. Loosen hydraulic
before operating the machine.
connections very slowly to allow
the oil pressure to dissipate
Before Troubleshooting: gradually. Do not allow oil to
squirt or spray.
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.
Wire with description or color Limit Switch Motor controller Key switch
Circuits crossing no connection Emergency Stop button Motor Solenoid valve with diode
Fixed displacement Shuttle valve Solenoid operated 3 position Solenoid operated 3 position 4 way
pump 4 way directional valve directional valve
Hydraulic Schematics
Hydraulic C omponent R eferenc e Legend
Hydraulic Schematics
Hydraulic Schem atic, GS-1530, 1532, 1930, 1932 (from seri al num ber GS3010A- 110000, GS3011C- 10000, GS3014D- 101, GS3016P-142281)
Hydraulic Schematics
Hydraulic Schem atic, GS-2032, 2632, 3232, 2046, 2646, 3246 (fr om s erial num ber GS3211A-110000 to GS3214A-119070, GS3212C-10000 to GS3214C-11873, GS4612A-110000 to GS4614A-117177, GS4614C-10000 to GS4614C-12073)
Hydraulic Schematics
Hydraulic Schem atic, GS-2032, 2632, 3232, 2046, 2646, 3246 (fr om s erial num ber GS3214A-119071, GS3214C-11874, GS4614A- 117178, GS4614C-12074, GS4614D- 101)
Hydraulic Schematics
Hydraulic Schem atic, GS-3232 (fr om s erial num ber GS3211A-110000) (from serial number GS3212C-10000)
Hydraulic Schematics
Hydraulic Schem atic, GS-4047 (fr om s erial num ber GS4712C- 101 to GS4714C- 1459)
Hydraulic Schematics
Hydraulic Schem atic, GS-4047 (fr om s erial num ber GS4714C- 1460, GS4714D-101)
195
Service and Repair Manual September 2016
Elec trical Schem atic GS- 1530 / GS-1930, AN S / CSA (fr om s erial num ber GS3010A-110000 to GS3011A-110827)
198
September 2016 Service and Repair Manual
199
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Elec trical Schem atic, GS-1530 / GS-1930, AN SI / C SA (from seri al num ber GS3011A- 110828 to GS3014A-136972, GS3014D- 101 to GS3015D- 1113, GS3011C-10000 to GS3015C-18038)
202
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Elec trical Schem atic, GS-1530 / GS-1930 (from serial number GS3014A- 136973, GS3015D-1114, GS3016P- 142281)
206
September 2016 Service and Repair Manual
207
Service and Repair Manual September 2016
209
Service and Repair Manual September 2016
Elec trical Schem atic, GS-3232, AN SI / C SA ( from s erial number GS3211A- 110000 to GS3214A- 135714)
212
September 2016 Service and Repair Manual
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Service and Repair Manual September 2016
Elec trical Schem atic, GS-3232, AN SI / C SA ( from s erial number GS3214A- 135715 to GS3215A- 141898)
216
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Elec trical Schem atic, GS-3232, AN SI / C SA ( from s erial number GS3215A- 141899, GS3216P- 142677)
220
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224
September 2016 Service and Repair Manual
225
Service and Repair Manual September 2016
Elec trical Schem atic, GS-2032, 2632, 2046, 2646, ANSI / CSA (from seri al num ber GS3211A-110000 to GS3214A-135714, GS4612A- 110000 to GS4614A-135366, GS4613D- 101 to GS4615D- 1303)
228
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Elec trical Schem atic, GS-2032, 2632, 2046, 2646, ANSI/CSA (fr om s erial number GS3214A-1135715 to GS3215A-141898, GS4614A- 135367 to GS4615A-137959, GS4615D- 1304)
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Elec trical Schem atic, GS-3232, AS / CE (from s erial number GS3211A- 110000 to GS3214A-135714, GS3212C- 10000 to GS3215C- 14503)
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Elec trical Schem atic, GS-3246, AS / CE (from s erial number GS4616P- 139711, GS4616D-4433, GS4716D-3102)
Elec trical Schem atic, GS-4047, AS / CE (from s erial number GS4712C-101 to GS4715C-2130, GS4714D-101 to GS4715D-749)
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GS-30 • GS-32 • GS- 46 • GS-47 Part No. 1272217 Servic e and R epair M anual September 2016
WARNING
Operating, servicing and maintaining this
equipment, passenger vehicle or off-highway
motor vehicle can expose you to chemicals
including engine exhaust, carbon monoxide,
phthalates, and lead, which are known to the
State of California to cause cancer and birth
defects or other reproductive harm. These
chemicals can be emitted from or contained in
other various parts and systems, fluids and some
component wear by-products. To minimize
exposure, avoid breathing exhaust, do not idle
the engine except as necessary, service your
equipment and vehicle in a well-ventilated area
and wear gloves or wash your hands frequently
when servicing your equipment or vehicle and
after operation. For more information go to
Distributed By:
www.P65Warnings.ca.gov/passenger-vehicle.
www.genielift.com