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Manuels de pièces, d’entretien et d’utilisation | Genie
Genie Gs 1932 Fault Codes – Supa Stik Labels
1272217
Service and Repair Manual Serial Number Range GSTM-1530/1532 Refer to the inside cover GSTM-1930/1932 GSTM-2032/2632/3232 GSTM-2046/2646/3246 GSTM-4047 This manual includes: Repair procedures Fault Codes Electrical and Hydraulic Schematics For detailed maintenance procedures, refer to the appropriate Maintenance Manual for your machine. Part No. 1272217GT Rev E March 2021 Service and Repair Manual Introduction March 2021 Introduction Introduction Compliance Machine Classification Group A/Type 3 as defined by ISO 16368 Machine Design Life Unrestricted with proper operation, inspection and scheduled maintenance. Contact Us: Internet: www.genielift.com E-mail: awp.techpub@terex.com Find a Manual for this Model Go to http://www.genielift.com Service Manuals, Maintenance Manuals, Service and Repair Manuals, Parts Manuals and Operator's Manuals. Copyright © 2016 by Terex Corporation 1272215GT Rev E, March 2021 First Edition, Fifth Printing Genie is a registered trademark of Terex South Dakota, Inc. in the U.S.A. and many other countries. "GS" is a trademark of Terex South Dakota, Inc. Serial Number Range Use the following chart to identify the specific serial number for models included in this manual. GS-1530, GS-1532, GS-1930, GS-1932 from SN GS3010A-110000 to GS3016A-142280 from SN GS3011C-10000 to GS3016C-23999 from SN GS3014D-101 to GS3016D-6079 from SN GS3016P-151487 to GS3016P-160599 from SN GS30C-24000 from SN GS30D-6080 to GS30D-40100 from SN GS30P-160600 to GS30P-200100 GS-2032, GS-2632, GS-3232 from SN GS3211A-110000 to GS3216A-142675 from SN GS3212C-10000 to GS3216C-17299 from SN GS3216P-142676 to GS3216P-148699 from SN GS32C-17300 from GS32D-101 to GS32D-10100 from SN GS32P-148700 to GS32P-200100 GS-2046, GS-2646, GS-3246 from SN GS4612A-110000 to GS4616A-138361 from SN GS4612C-10000 to GS4616C-18099 from SN GS4614D-101 to GS4616D-5029 from SN GS4616P-138362 to GS4616P-141799 from SN GS46C-18100 from SN GS46D-5030 to GS46D-20100 from SN GS46P-141800 to GS46P-200100 GS-4047 from SN GS4712C-101 to GS4716C-4499 from SN GS4714D-101 to GS4716D-3959 from SN GS4716P-101 to GS4716P-999 from SN GS47C-4500 from SN GS47D-3960 from SN GS47P-1000 ii GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Revision History Revision A A1 Date 3/2016 5/2016 A2 5/2016 A3 9/2016 B 4/2017 B1 12/2017 C 1/2019 D 8/2019 E 3/2021 Section Repair Diagnostics Repair Diagnostics Introduction Specifications Repair Diagnostics Schematics All Sections All Sections All Sections Service and Repair Manual Introduction Procedure / Page / Description Initial Release Procedures 2-3, 2-4, 9-11 H067 fault Procedure 2-6 Type CXXX and UXXX fault codes Serial Number Legend Add drive speed stowed parameters Procedure 11-1 Battery charger and fault codes GS46, GS47 AS/CE Added GS-1330m Added GS-4655 Add ending serial break Remove GS-1330m, GS-4655 Reference Examples: Section Repair Procedure, 4-2 Section Fault Codes, All charts Section Schematics, Legends and schematics Electronic Version Click on any content or procedure in the Table of Contents to view the update. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 iii Service and Repair Manual Introduction Revision History(continued) Revision Date Section Procedure / Page / Description March 2021 Reference Examples: Section Repair Procedure, 4-2 Section Fault Codes, All charts Section Schematics, Legends and schematics Electronic Version Click on any content or procedure in the Table of Contents to view the update. iv GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Serial Number Legend To August 31, 2016 Service and Repair Manual Introduction 1. Model 2. Model year 3. Facility code From September 1, 2016 4. Sequence number 5. Serial label located on chassis 6. Serial number (stamped on chassis) 1. Model 2. Facility code 3. Sequence number Part No. 1272217GT 4. Serial label located on chassis 5. Serial number (stamped on chassis) GSTM-30 · 32 · 46 · 47 v Service and Repair Manual Safety Rules Section 1 Safety Rules March 2021 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. Do Not Perform Maintenance Unless: You are trained and qualified to perform maintenance on this machine. You read, understand and obey: · manufacturer's instructions and safety rules · employer's safety rules and worksite regulations · applicable governmental regulations You have the appropriate tools, lifting equipment and a suitable workshop. vi GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Safety Rules Personal Safety Any person working on or around a machine must be aware of all known safety hazards. Personal safety and the continued safe operation of the machine should be your top priority. Read each procedure thoroughly. This manual and the decals on the machine, use signal words to identify the following: Safety alert symbol--used to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Indicates a imminently hazardous situation which, if not avoided, will result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, may cause minor or moderate injury. Indicates a potentially hazardous situation which, if not avoided, may result in property damage. Be sure to wear protective eye wear and other protective clothing if the situation warrants it. Be aware of potential crushing hazards such as moving parts, free swinging or unsecured components when lifting or placing loads. Always wear approved steel-toed shoes. Workplace Safety Any person working on or around a machine must be aware of all known safety hazards. Personal safety and the continued safe operation of the machine should be your top priority. Be sure to keep sparks, flames and lighted tobacco away from flammable and combustible materials like battery gases and engine fuels. Always have an approved fire extinguisher within easy reach. Be sure that all tools and working areas are properly maintained and ready for use. Keep work surfaces clean and free of debris that could get into machine components and cause damage. Be sure any forklift, overhead crane or other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted. Use only chains or straps that are in good condition and of ample capacity. Be sure that fasteners intended for one time use (i.e., cotter pins and self-locking nuts) are not reused. These components may fail if they are used a second time. Be sure to properly dispose of old oil or other fluids. Use an approved container. Please be environmentally safe. Be sure that your workshop or work area is properly ventilated and well lit. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 vii Table of Contents March 2021 Introduction Section 1 Section 2 Introduction .......................................................................................................... ii Find a Manual for this Model...................................................................................ii Serial Number Range .............................................................................................ii Revision History .....................................................................................................iii Serial Number Legend ........................................................................................... v Safety Rules......................................................................................................... vi General Safety Rules.............................................................................................vi Specifications....................................................................................................... 1 Machine Specifications .......................................................................................... 1 Performance Specifications (models without proportional lift function) ................. 3 Performance Specifications (models with proportional lift) .................................... 5 Hydraulic Oil Specifications ................................................................................... 7 Hydraulic Component Specifications ................................................................... 10 Manifold Component Specifications..................................................................... 11 Hydraulic Hose and Fitting Torque Specifications ............................................... 12 Torque Procedure ................................................................................................ 13 viii GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Section 3 Table of Contents Repair Procedures .............................................................................................15 Introduction ........................................................................................................... 15 Platform Controls ...............................................................................................17 1-1 Circuit Board...................................................................................................19 1-2 Joystick...........................................................................................................20 1-3 Platfrom Controls Alarm .................................................................................20 1-4 Platform Emergency Stop Button...................................................................21 Ground Controls.................................................................................................22 2-1 Software Revision Level.................................................................................23 2-2 Machine Setup ...............................................................................................24 2-3 Loading or Updating Machine Software.........................................................25 2-4 Using a Wi-Fi Router to Connect to the SmartLink Web Service Tool ..........30 2-5 Service Override Mode ..................................................................................32 2-6 Level Sensors ................................................................................................34 2-7 Manual Platform Lowering Cable ...................................................................49 2-8 Outrigger Calibration ......................................................................................50 Hydraulic Tank....................................................................................................51 3-1 Hydraulic Tank ...............................................................................................51 Hydraulic Pump ..................................................................................................52 4-1 Hydraulic Pump..............................................................................................52 How to Remove the Hydraulic Pump ..............................................................53 Part No. 1272217GT GSTM-30 · 32 · 46 · 47 ix Table of Contents March 2021 Manifolds ............................................................................................................ 54 5-1 Function Manifold Components GS-1530, GS-1532, GS-1930 and GS-1932 ................................................................................ 54 5-2 Function Manifold Components GS-2032, GS-2632, GS-3232, GS-2046, GS-2646 and GS-3246 ................................................................ 56 5-3 Function Manifold Components GS-4047 .................................................. 58 5-4 Check Valve Manifold Components GS-1530, GS-1532, GS-1930 and GS-1932 ................................................................................ 60 5-5 Lift Pressure Selector Manifold Components GS-4047.............................. 61 5-6 Outrigger Function Manifold Components GS-3232 .................................. 62 5-7 Outrigger Cylinder Manifold Components GS-3232 ................................... 63 5-8 Valve Adjustments Function Manifold ........................................................ 64 5-9 Valve Coils ..................................................................................................... 70 Steer Axle Components .................................................................................... 72 6-1 Yoke and Drive Motor .................................................................................... 72 6-2 Steer Cylinder ................................................................................................ 73 6-3 Steer Bellcrank .............................................................................................. 74 Non-Steer Axle Components ............................................................................ 75 7-1 Drive Brake .................................................................................................... 75 Brake Release Hand Pump Components ........................................................ 76 8-1 Brake Release Hand Pump Components...................................................... 76 x GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Table of Contents Scissor Components .........................................................................................77 9-1 Scissor Assembly, GS-1530 and GS-1532....................................................78 9-2 Scissor Assembly, GS-1930 and GS-1932....................................................84 9-3 Scissor Assembly, GS-2032 and GS-2046....................................................92 9-4 Scissor Assembly, GS-2632 and GS-2646....................................................99 9-5 Scissor Assembly, GS-3232 and GS-3246..................................................107 9-6 Scissor Assembly, GS-4047 ........................................................................116 9-7 Scissor Arm Wear Pads ...............................................................................124 9-8 Platform Height Sensor ................................................................................126 9-9 Lift Cylinder ..................................................................................................128 9-10 Pressure Transducer..................................................................................139 9-11 Platform Overload System .........................................................................141 9-12 Platform Overload Recovery ......................................................................146 Platform Components......................................................................................148 10-1 Platform ......................................................................................................148 10-2 Platform Extension Deck............................................................................149 Battery Charger ................................................................................................150 11-1 Battery Charger..........................................................................................150 Selecting a Charge Profile ............................................................................151 Part No. 1272217GT GSTM-30 · 32 · 46 · 47 xi Table of Contents March 2021 Section 4 Diagnostics....................................................................................................... 152 Introduction ........................................................................................................ 152 GCON I/O Map without Load Sense (all machines except GS-3232) ............... 155 GCON I/O Map with Load Sense (all machines except GS-3232) .................... 156 GCON I/O Map without Load Sense GS-3232 only) ......................................... 157 GCON I/O Map with Load Sense (GS-3232 only) ............................................. 159 Operation Indicator Codes (OIC) ....................................................................... 161 Diagnostic Trouble Codes (DTC)....................................................................... 162 Troubleshooting "HXXX" and "PXXX" Faults..................................................... 163 Fault Inspection Procedure ................................................................................ 164 Type "HXXX" Faults ........................................................................................... 166 Type "PXXX" Faults ........................................................................................... 170 Type "UXXX" Faults ........................................................................................... 171 Type "FXXX" Faults ........................................................................................... 174 Type "CXXX" Faults ........................................................................................... 177 Battery Charger.................................................................................................. 179 Charger Fault Codes .................................................................................... 180 Charger Error Codes .................................................................................... 181 xii GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Section 5 Table of Contents Schematics ........................................................................................................ 185 Introduction ......................................................................................................... 185 Electrical Component and Wire Color Legends .................................................186 Wiring Diagram Ground and Platform Controls..................................................189 Limit Switch Legend ...........................................................................................190 Electrical Symbol Legend...................................................................................191 Hydraulic Symbols Legend.................................................................................192 Hydraulic Component Abbreviation Legend.......................................................193 Hydraulic Schematics ......................................................................................195 Hydraulic Schematic, GS-1530, 1532, 1930, 1932 (from serial number GS3010A- 110000, GS3011C-10000, GS3014D-101, GS3016P-142281) .................195 Hydraulic Schematic, GS-2032, 2632, 3232, 2046, 2646, 3246 (from serial number GS3211A-110000 to GS3214A-119070, GS3212C-10000 to GS3214C-11873, GS4612A-110000 to GS4614A-117177, GS4614C-10000 to GS4614C-12073) .......................................................196 Hydraulic Schematic, GS-2032, 2632, 3232, 2046, 2646, 3246 (from serial number GS3214A-119071, GS3214C-11874, GS4614A-117178, GS4614C-12074, GS4614D-101) ..............................................................197 Hydraulic Schematic, GS-3232 (from serial number GS3211A-110000, GS3212C-10000, GS3216P-142677) ........................................................198 Hydraulic Schematic, GS-4047 (from serial number GS4712C-101 to GS4714C-1459) .....................................................................................199 Hydraulic Schematic, GS-4047 (from serial number GS4714C-1460, GS4714D-101, GS4716P-101)...................................................................200 Part No. 1272217GT GSTM-30 · 32 · 46 · 47 xiii Table of Contents March 2021 Electrical Schematics ANSI / CSA Models ................................................. 201 Electrical Schematic GS-1530 / GS-1930, ANS / CSA (from serial number GS3010A-110000 to GS3011A-110827) ................................................... 202 Electrical Schematic, GS-1530 / GS-1930, ANSI / CSA (from serial number GS3011A-110828 to GS3014A-136972, GS3014D-101 to GS3015D-1113) ............................................................. 206 Electrical Schematic, GS-1530 / GS-1930, ANSI / CSA (from serial number GS3014A-136973, GS3015D-1114 to GS3016D-5426, GS3016P-142281 to GS3016P-158208) ................................................... 210 Electrical Schematic, GS-1530/1930, ANSI/CSA (from serial number GS3016D-5427, GS3016P-158209) .......................................................... 214 Electrical Schematic, GS-3232, ANSI / CSA (from serial number GS3211A-110000 to GS3214A-135714) ................................................... 216 Electrical Schematic, GS-3232, ANSI / CSA (from serial number GS3214A-135715 to GS3215A-141898) ................................................... 220 Electrical Schematic, GS-3232, ANSI / CSA (from serial number GS3215A-141899, GS3216P-142677 to GS3216P-146462) .................... 224 Electrical Schematic, GS-3232, ANSI / CSA (from serial number GS3216P-146463) ..................................................................................... 228 Electrical Schematic, GS-2032, 2632, 2046, 2646, ANSI / CSA (from serial number GS3211A-110000 to GS3214A-135714, GS4612A-110000 to GS4614A-135366, GS4613D-101 to GS4615D-1303) .............................. 232 Electrical Schematic, GS-2032, 2632, 2046, 2646, ANSI/CSA (from serial number GS3214A-1135715 to GS3215A-141898, GS4614A-135367 to GS4615A-137959, GS4615D-1304) .......................................................... 236 Electrical Schematic, GS-2032, 2632, 2046, 2646, ANSI / CSA (from serial number GS3215A-141899, GS3216P-142676 to GS3216P-146462, GS4615A-137960, GS4615D-1305 to GS4616D-4432, GS4616P-138362 to GS4616P-139710) ................................................... 240 xiv GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Table of Contents Electrical Schematic, GS-2032, 2632, 2046, 2646, ANSI / CSA (from serial number GS3216P-146463, GS4616D-4433, GS4616P-139711) ..............244 Electrical Schematic, GS-3246 / GS-4047, ANSI / CSA (from serial number GS4612A-110000 to GS4614A-135366, GS4614D-101 to GS4615D-1303, GS4714D-101 to GS4715D-749) ....................................246 Electrical Schematic, GS-3246 / GS-4047, ANSI / CSA (from serial number GS4614A-135367 to GS4615A-137959, GS4615D-1304 to GS4616D-4432, GS4616P-138362 to GS4616P-139710, GS4715D-750 to GS4716D-3101) .............................................................250 Electrical Schematic, GS-3246, GS4047 ANSI / CSA (from serial number GS4616D-4433, GS4616P-139711, GS4716D-3102, GS4716P-101) ......254 Electrical Schematics CE and Australia Models ........................................255 Electrical Schematic GS-1530, 1532, 1930, 1932, AS / CE (from serial number GS3010A-110000 to GS3011A-110827)....................................................256 Electrical Schematic, GS-1530/32_GS-1930/32, AS / CE (from serial number GS3011A-110828 to GS3014A-136972, GS3011C-10000 to GS3015C18038, GS3014D-101 to GS3015D-1113) .................................................260 Electrical Schematic, GS-1530, 1532, 1930, 1932, AS / CE (from serial number GS3014A-136973, GS3015C-18039, GS3015D-1114 to GS3016D-5426, GS3016P-142281 to GS3016P-158208)....................................................264 Electrical Schematic, GS-1530, 1532, 1930, 1932, AS / CE (from serial numbers GS3015D-5427, GS3016P-158209) ..........................................................268 Electrical Schematic, GS-3232, AS / CE (from serial number GS3211A-110000 to GS3214A-135714, GS3212C-10000 to GS3215C-14503) ........................270 Electrical Schematic, GS-3232, AS / CE (from serial number GS3214A-135715 to GS3215A-141898, GS3215C-14504) ........................................................274 Electrical Schematic, GS-3232, AS / CE (from serial number GS3215A-141899, GS3216P-142676 to GS3216P-146462)....................................................278 Electrical Schematic, GS-3232, AS / CE (from serial number GS3216P-146463) .....................................................282 Electrical Schematic, GS-2032, 2632, 2046, 2646, AS / CE (from serial number GS3211A-110000 to GS3214A-135714, GS3212C-10000 to GS3215C14377, GS4612A-110000 to GS4614A-135366, GS4612C-10000 to GS4615C-14503, GS4613D-101 to GS4615D-1303) ................................286 Part No. 1272217GT GSTM-30 · 32 · 46 · 47 xv Table of Contents March 2021 Electrical Schematic, GS-2032, 2632, 2046, 2646, AS / CE (from serial number GS3214A-135715 to GS3215A-141898, GS3215C-14378, GS4614A135367 to GS4615A-137959, GS4615C-14504, GS4615D-1304)............ 290 Electrical Schematic, GS-2032, 2632, 2046, 2646, AS / CE (from serial number GS3215A-141899, GS3216P-142676 to GS3216P-146462, GS4615A137960, GS4616P-138362 to GS4616P-139710) ..................................... 294 Electrical Schematic, GS-2032, 2632, 2046, 2646, AS / CE (from serial number GS3216P-146463, GS4616P-139711) ...................................................... 298 Electrical Schematic, GS-3246, AS / CE (from serial number GS4612A-110000 to GS4614A-135366, GS4612C-10000 to GS4615C-14503, GS4614D-101 to GS4615D-1303) ......................................................................................... 300 Electrical Schematic, GS-3246, AS / CE (from serial number GS4614A-135367 to GS4615A-137959, GS4615C-14504, GS4615D-1304) ............................. 304 Electrical Schematic, GS-3246, AS / CE (from serial number GS4615A-137960, GS4616P-138362, GS4616P to GS4616P-139710).................................. 308 Electrical Schematic, GS-3246, AS / CE (from serial number GS4616D-4433, GS4616P-139711) ..................................................................................... 312 Electrical Schematic, GS-4047, AS / CE (from serial number GS4712C-101 to GS4715C-2130, GS4714D-101 to GS4715D-749).................................... 314 Electrical Schematic, GS-4047, AS / CE (from serial number GS4715C-2131, GS4715D-750 to GS4716D-3101) ............................................................. 318 Electrical Schematic, GS-4047, AS / CE (from serial number GS4716D-3102)......................................................... 322 Electrical Schematic Foot Switch (option) All Models .............................. 323 Foot Switch (option) All Models ......................................................................... 324 xvi GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Specifications Section 2 Specifications Machine Specifications For operational specifications, refer to the Operator's Manual. Batteries, Standard All models except GS-4047 Voltage Group Type Quantity Battery capacity, maximum Reserve capacity @ 25A rate Weight, each Batteries, Standard, GS-4047 Voltage Group Type Quantity Battery capacity, maximum Reserve capacity @ 25A rate Weight, each Batteries, Maintenance-free (option) All models except GS-4047 Voltage Group Type Quantity Battery capacity, maximum Reserve capacity @ 25A rate Weight, each 6V DC GC2 T-105 4 C20 = 225AH 447 minutes 62 lbs 28 kg 12V DC GC2 T-1275 4 C20 = 150AH 280 minutes 82 lbs 37 kg 6V DC GC2 6V-AGM 4 200AH 380 minutes 62 lbs 28 kg Platform Overload Pressure Transducer (if equipped) All models except GS-3232, GS-4047 Input voltage 8 to 30 VDC Signal voltage 1 to 5 V Platform Overload Pressure Transducer (if equipped) GS-3232, GS-4047 Input voltage 8 to 30 VDC Signal voltage 0.25 to 6.25 V Angle Sensor (if equipped) Input voltage 8 to 30 VDC Signal voltage 3 to 4 V, PMW output Outrigger Pressure Transducer, GS-3232 only Input voltage 8 to 30 VDC Signal voltage 1 to 5 V Fluid capacities Hydraulic tank All models except GS-4047 3.4 gallons 12.9 liters Hydraulic tank, GS-4047 5.9 gallons 22.4 liters Hydraulic system (including tank) GS1530, GS-1532, GS-1930, GS-1932 3.8 gallons 14.2 liters Hydraulic system (including tank) GS2032, GS-2632, GS-2046, GS-2646 4.5 gallons 17 liters Hydraulic system (including tank) GS3232, GS-3246 5.5 gallons 20.8 liters Hydraulic system (including tank) GS4047 7.5 gallons 28.4 liters Part No. 1272217GT GSTM-30 · 32 · 46 · 47 1 Service and Repair Manual Specifications Tires and wheels GS-1530, GS-1532, GS-1930, GS-1932 Tire size (solid rubber) 12 x 4.5 in 30.5 x 11.4 cm Tire contact area 9 sq in 58 cm2 Castle nut torque, dry 300 ft-lbs 406.7 Nm Castle nut torque, lubricated 225 ft-lbs 305 Nm GS-2032, GS-2632, GS-3232, GS-2046, GS-2646, GS3246, GS-4047 Tire size (solid rubber) 15 x 5 in 38.1 x 12.7 cm Tire contact area 15 sq in 96.7 cm2 Castle nut torque, dry 300 ft-lbs 406.7 Nm Castle nut torque, lubricated 225 ft-lbs 305 Nm March 2021 2 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Specifications Performance Specifications (models without proportional lift) Drive speed, maximum GS-1530, GS-1532, GS-1930, GS-1932 Platform stowed, fast 2.5 mph 40 ft / 10.9 sec 4 km/h 12.2 m / 10.9 sec Platform raised 0.5 mph 40 ft / 55 sec 0.8 km/h 12.2 m / 55 sec GS-2032, GS-2632, GS-3232, GS-2046, GS-2646, GS3246 Platform stowed, fast to serial number: GS3216P-145830 GS4616P-139575 2.2 mph 40 ft / 12.4 sec 3.5 km/h 12.2 m / 12.4 sec Platform stowed, fast from serial number: GS3216P-145831 GS4616P-139576 2.0 mph 40 ft / 12.4 sec 3.2 km/h 12.2 m / 12.4 sec Platform raised 0.5 mph 40 ft / 55 sec 0.8 km/h 12.2 m / 55 sec GS-4047 Platform stowed, fast Platform raised Braking distance, maximum High range on paved surface Gradeability GS-1930, GS-1932, GS-2632,GS3232, GS-3246 and GS-4047 GS-1530, GS-1532, GS-2032, GS-2046 and GS-2646 Airborne noise emissions Sound pressure level at ground workstation Sound pressure level at platform workstation 2.0 mph 40 ft / 13.6 sec 3.2 km/h 12.2 m / 13.6 sec 0.5 mph 40 ft / 55 sec 0.8 km/h 12.2 m / 55 sec 1 - 3 ft 0.3 - 0.9 m 25% 30% < 70 dBA < 70 dBA Part No. 1272217GT GSTM-30 · 32 · 46 · 47 3 Service and Repair Manual Specifications March 2021 Performance Specifications (without proportional lift), continued Function speed, maximum from platform controls (with 1 person in platform) GS-1530 and GS-1532 Platform up (fast mode) Platform up (slow mode) Platform down 15 to 17 seconds 30 to 32 seconds 28 to 30 seconds GS-1930 and GS-1932 Platform up (fast mode) Platform up (slow mode) Platform down 15 to 17 seconds 30 to 32 seconds 28 to 30 seconds GS-2032 and GS-2632 Platform up (fast mode) Platform up (slow mode) Platform down 28 to 32 seconds 58 to 62 seconds 32 to 36 seconds GS-2046 and GS-2646 Platform up (fast mode) Platform up (slow mode) Platform down 28 to 32 seconds 58 to 62 seconds 32 to 36 seconds GS-3232 and GS-3246 Platform up (fast mode) Platform up (slow mode) Platform down 55 to 59 seconds 108 to 112 seconds 33 to 37 seconds GS-4047 Platform up (fast mode) Platform up (slow mode) Platform down 71 to 76 seconds 83 to 87 seconds 41 to 46 seconds Rated work load at full height, maximum GS-1530 and GS-1532 600 lbs 272 kg GS-1930, GS-1932, GS2632 and GS-3232 500 lbs 227 kg GS-2032 800 lbs 363 kg GS-2046 1200 lbs 544 kg GS-2646 1000 lbs 454 kg GS-3246 700 lbs 317 kg GS-4047 (CE and AS models) 770 lbs 350 kg GS-4047 (ANSI and CSA models) 550 lbs 250 kg GS-3232 Outrigger leveling capacity, maximum Side to side 5° Front to rear 3° 4 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Specifications Performance Specifications (models with proportional lift) Drive speed, maximum GS-1530, GS-1532, GS-1930, GS-1932 Platform stowed 2.5 mph 40 ft / 10.9 sec 4 km/h 12.2 m / 10,9 sec Platform raised 0.5 mph 40 ft / 55 sec 0,8 km/h 12.2 m / 55 sec GS-2032, GS-2632, GS-3232, GS-2046, GS-2646, GS3246 Platform stowed to serial number: GS3216P-145830 GS4616P-139575 2.2 mph 40 ft / 12.4 sec 3,5 km/h 12.2 m / 12,4 sec Platform stowed from serial number: GS3216P-145831 GS4616P-139576 2.0 mph 40 ft / 12.4 sec 3,2 km/h 12.2 m / 12,4 sec Platform raised 0.5 mph 40 ft / 55 sec 0,8 km/h 12.2 m / 55 sec GS-4047 Platform stowed Platform raised Braking distance, maximum High range on paved surface Gradeability GS-1930, GS-1932, GS-2632, GS-3232, GS-3246, GS-4047 GS-1530, GS-1532, GS-2032, GS2046, GS-2646 Airborne noise emissions Sound pressure level at ground workstation Sound pressure level at platform workstation 2.0 mph 40 ft / 13.6 sec 3,2 km/h 12.2 m / 13,6 sec 0.5 mph 40 ft / 55 sec 0,8 km/h 12.2 m / 55 sec 1 - 3 ft 0,3 - 0,9 m 25% 30% < 70 dBA < 70 dBA Part No. 1272217GT GSTM-30 · 32 · 46 · 47 5 Service and Repair Manual Specifications March 2021 Performance Specifications (with proportional lift), continued Function speed, maximum from platform controls (with 1 person in platform) GS-1530, GS-1532 Platform up Platform down 15 to 17 seconds 18 to 25 seconds GS-1930, 1930PAR, GS-1932 Platform up Platform down 15 to 17 seconds 18 to 25 seconds GS-2032, GS-2632 Platform up Platform down 28 to 32 seconds 24 to 28 seconds GS-2046, GS-2646 Platform up Platform down 28 to 32 seconds 28 to 32 seconds GS-3232, GS-3246 Platform up Platform down 55 to 59 seconds 28 to 32 seconds GS-4047 Platform up Platform down 71 to 76 seconds 41 to 46 seconds Rated work load at full height, maximum GS-1530, GS-1532 600 lbs 272 kg GS-1930, GS-1932, GS2632, GS-3232 500 lbs 227 kg GS-1930PAR 400 lbs 181 kg GS-2032 800 lbs 363 kg GS-2046 1200 lbs 544 kg GS-2646 1000 lbs 454 kg GS-3246 700 lbs 317 kg GS-4047 (CE and AS models) 770 lbs 350 kg GS-3232 Outrigger leveling capacity, maximum Side to side 5° Front to rear 3° 6 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Specifications Hydraulic Oil Specifications Hydraulic Fluid Specifications Genie specifications require hydraulic oils which are designed to give maximum protection to hydraulic systems, have the ability to perform over a wide temperature range, and the viscosity index should exceed 140. They should provide excellent antiwear, oxidation prevention, corrosion inhibition, seal conditioning, and foam and aeration suppression properties. Cleanliness level, minimum ISO 15/13 Water content, maximum 250 ppm Recommended Hydraulic Fluid Hydraulic oil type Chevron Rando HD Premium Viscosity grade 32 Viscosity index 200 Optional Hydraulic Fluids Mineral based Shell Tellus S2 V 32 Shell Tellus S2 V 46 Shell Tellus S4 VX 32 Shell Donax TG (Dexron III) Chevron 5606A Biodegradable Petro Canada Environ MV 46 Fire resistant UCON Hydrolube HP-5046 Note: Genie specifications require additional equipment and special installation instructions for the approved optional fluids. Consult Genie Product Support before use. Optional fluids may not have the same hydraulic lifespan and may result in component damage. Note: Extended machine operation can cause the hydraulic fluid temperature to increase beyond its maximum allowable range. If the hydraulic fluid temperature consistently exceeds 200°F / 90°C an optional oil cooler may be required. Do not top off with incompatible hydraulic fluids. Hydraulic fluids may be incompatible due to the differences in base additive chemistry. When incompatible fluids are mixed, insoluble materials may form and deposit in the hydraulic system, plugging hydraulic lines, filters, control valves and may result in component damage. Note: Do not operate the machine when the ambient air temperature is consistently above 120°F / 49°C. Hydraulic Fluid Temperature Range Ambient air temperature 1 Chevron hydraulic oil 5606A 2 Petro-Canada Environ MV 46 3 UCON Hydrolube HP-5046D 4 Chevron Rando HD premium oil MV Part No. 1272217GT GSTM-30 · 32 · 46 · 47 7 Service and Repair Manual Specifications March 2021 Chevron Rando HD Premium Oil MV Fluid Properties ISO Grade 32 Viscosity index 200 Kinematic Viscosity cSt @ 200°F / 100°C 7.5 cSt @ 104°F / 40°C 33.5 Brookfield Viscosity cP @ -4°F / -20°C cP @ -22°F / -30°C 1040 3310 Flash point 375°F / 190°C Pour point -58°F / -50°C Maximum continuous operating temperature 171°F / 77°C Note: A hydraulic oil heating system is recommended when the ambient temperature is consistently below 0°F / -18°C. Note: Do not operate the machine when the ambient temperature is below -20°F / -29°C with Rando HD Premium MV. Chevron 5606A Hydraulic Oil Fluid Properties ISO Grade 15 Viscosity index 300 Kinematic Viscosity cSt @ 200°F / 100°C 5.5 cSt @ 104°F / 40°C 15.0 cSt @ -40°F / -40°C 510 Flash point 180°F / 82°C Pour point -81°F / -63°C Maximum continuous operating temperature 124°F / 51°C Note: Use of Chevron 5606A hydraulic fluid, or equivalent, is required when ambient temperatures are consistently below 0°F / -17°C unless an oil heating system is used. Continued use of Chevron 5606A hydraulic fluid, or equivalent, when ambient temperatures are consistently above 32°F / 0°C may result in component damage 8 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Specifications Petro-Canada Environ MV 46 Fluid Properties ISO Grade Viscosity index Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 104°F / 40°C Flash point Pour point Maximum continuous operating temperature Shell Tellus S4 VX Fluid Properties 46 154 8.0 44.4 482°F / 250°C -49°F / -45°C 180°F / 82°C ISO Grade Viscosity index Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 104°F / 40°C Brookfield Viscosity cSt @ -4°F / -20°C cSt @ -13°F / -25°C cSt @ -40°F / -40°C Flash point Pour point Maximum continuous operating temperature 32 300 9 33.8 481 702.4 2624 >100 -76°F / -60°C 103°F / 75°C UCON Hydrolube HP-5046 Fluid Properties ISO Grade Viscosity index Kinematic Viscosity cSt @ 149°F / 65°C cSt @ 104°F / 40°C cSt @ 0°F / -18°C Flash point Pour point Maximum continuous operating temperature 46 192 22 46 1300 None -81°F / -63°C 189°F / 87°C Part No. 1272217GT GSTM-30 · 32 · 46 · 47 9 Service and Repair Manual Specifications March 2021 Hydraulic Component Specifications Function Pump GS-1530, GS1532, GS-1930, GS1932 Type Gear Displacement per revolution 0.244 cu in 4 cc Flow rate @ 2500 psi / 172 bar 3 gpm 11,3 L/min Hydraulic tank return filter 10 micron 25 psi / 1.7 bar bypass Function Pump GS-2032, GS-2632, GS-3232, GS2046, GS-2646, GS-3246, GS-4047 Type Gear Displacement per revolution 0.355 cu in 5,5 cc Flow rate @ 2500 psi / 172 bar 4 gpm 15 L/min Hydraulic tank return filter 10 micron 25 psi / 1,7 bar bypass Function manifold All models except GS-4047 System relief valve pressure, maximum 3700 psi 255 bar Lift relief valve pressure 1800 to 3700 psi 142 to 241 bar Steer relief valve pressure 1500 psi 103 bar Function manifold GS-4047 System relief valve pressure, maximum 3500 psi 241 bar Platform relief valve pressure 3000 psi 206 bar Steer relief valve pressure 1500 psi 103 bar Outrigger manifold Relief valve pressure, maximum Check valve manifold GS-1530, GS-1532, GS-1930. GS-1932 Check valve pressure, maximum Lift pressure selector manifold - GS-4047 Platform relief valve pressure, maximum 3500 psi 241 bar 200 psi 13,8 bar 2000 psi 138 bar 10 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Specifications Manifold Component Specifications Plug torque SAE No. 2 SAE No. 4 SAE No. 6 SAE No. 8 SAE No. 10 SAE No. 12 50 in-lbs / 6 Nm 13 ft-lbs / 18 Nm 18 ft-lbs / 24 Nm 50 ft-lbs / 68 Nm 55 ft-lbs / 75 Nm 75 ft-lbs / 102 Nm Valve coil resistance Note: The following coil resistance specifications are at an ambient temperature of 68°F / 20°C. As valve coil resistance is sensitive to change in air temperature, the coil resistance will typically increase or decrease by 4% of each 18°F / -7.7°C that your air temperature increases or decreases from 68°F / 20°C. Description Specification Solenoid valve, 3 position 4 way, 20V DC with diode (schematic items F, AC or DC) 27.2 Solenoid valve, 3 position 4 way, 19 20V DC with diode (schematic item E) Solenoid valve, 2 position 4 way, 19 20V DC with diode (schematic items H, AI or DI) Solenoid valve, 2 position 2 way, 25 N.C. 20V DC with diode (schematic item N) Solenoid valve, 2 position 4 way, 19 20V DC with diode (schematic item AE or DE) Solenoid valve, 3 position 5 way, 19 20V DC with diode (schematic item AG or DG) Solenoid valve, 2 position 2 way, 20V DC with diode (schematic items CA, CB, CC and CD) 27.2 Solenoid valve, 3 position 4 way, 19 20V DC with diode (schematic item BA) Solenoid valve, 2 position 2 way, 20V DC with diode (schematic item DN) 23.9 Solenoid valve, 3 position 4 way 24V DC with diode (schematic item EA) 33.75 Solenoid valve, 2 position 4 way 24V DC with diode (schematic item EC) 33.75 Solenoid valve, 2 position 4 way, 24 20V DC with diode (schematic item GC) Solenoid valve, 3 position 4 way, 24 20V DC with diode (schematic item GA) Part No. 1272217GT GSTM-30 · 32 · 46 · 47 11 Service and Repair Manual Specifications March 2021 Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with Parker Seal-LokTM ORFS or 37° JIC fittings and hose ends. Genie specifications require that fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed. Seal-LokTM Fittings (hose end - ORFS) SAE Dash Size Torque -4 18 ft-lbs / 25 Nm -6 30 ft-lbs / 41 Nm -8 40 ft-lbs / 55 Nm -10 60 ft-lbs / 81 Nm -12 85 ft-lbs / 115 Nm -16 110 ft-lbs / 150 Nm -20 150 ft-lbs / 205 Nm -24 230 ft-lbs / 315 Nm JIC 37° Fittings (swivel nut or hose connection) SAE Dash Size Thread Size -4 7/16-20 -6 9/16-18 -8 3/4-16 -10 7/8-14 -12 1 1/16-12 -16 1 5/16-12 -20 1 5/8-12 -24 1 7/8-12 Flats 2 1 1/2 1 1/2 1 1/2 1 1/4 1 1 1 SAE O-ring Boss Port (tube fitting - installed into Aluminum) (all types) SAE Dash Size Torque -4 14 ft-lbs / 19 Nm -6 23 ft-lbs / 31,2 Nm -8 36 ft-lbs / 49 Nm -10 62 ft-lbs / 84 Nm -12 84 ft-lbs / 114 Nm -16 125 ft-lbs / 169,5 Nm -20 151 ft-lbs / 204,7 Nm -24 184 ft-lbs / 249,5 Nm Adjustable Fitting 1 jam nut Non-adjustable fitting SAE O-ring Boss Port (tube fitting - installed into Steel) SAE Dash Size Torque -4 ORFS / 37° (Adj) ORFS (Non-adj) 37° (Non-adj) 15 ft-lbs / 20,3 Nm 26 ft-lbs / 35,3 Nm 22 ft-lbs / 30 Nm -6 ORFS (Adj / Non-adj) 37° (Adj / Non-adj) 35 ft-lbs / 47,5 Nm 29 ft-lbs / 39,3 Nm -8 ORFS (Adj / Non-adj) 37° (Adj / Non-adj) 60 ft-lbs / 81,3 Nm 52 ft-lbs / 70,5 Nm -10 ORFS (Adj / Non-adj) 37° (Adj / Non-adj) 100 ft-lbs / 135,6 Nm 85 ft-lbs / 115,3 Nm -12 (All types) 135 ft-lbs / 183 Nm -16 (All types) 200 ft-lbs / 271,2 Nm -20 (All types) 250 ft-lbs / 339 Nm -24 (All types) 305 ft-lbs / 413,5 Nm 12 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Specifications Torque Procedure Seal-LokTM fittings 1 Replace the O-ring. The O-ring must be replaced anytime the seal has been broken. The O-ring cannot be re-used if the fitting or hose end has been tightened beyond finger tight. Note: The O-ring in Parker Seal LokTM fittings and hose end are custom-size O-rings. They are not standard size O-rings. They are available in the Oring field service kit (Genie part number 49612). 2 Lubricate the O-ring before installation. 3 Be sure the O-ring face seal is seated and retained properly. 4 Position the tube and nut squarely on the face seal end of the fitting, and tighten the nut finger tight. 5 Tighten the nut or fitting to the appropriate torque. Refer to the appropriate torque chart in this section. 6 Operate all machine functions and inspect the hose, fittings and related components to confirm there are no leaks. JIC 37° fittings 1 Align the tube flare (hex nut) against the nose of the fitting body (body hex fitting) and tighten the hex nut to the body hex fitting to hand tight, approximately 30 in-lbs / 3.4 Nm. 2 Using a permanent ink marker, make a reference mark on one the flats of the hex nut and continue the mark onto the body of the hex fitting. Refer to Illustration 1. Illustration 1 1 hex nut 2 reference mark 3 body hex fitting Part No. 1272217GT GSTM-30 · 32 · 46 · 47 13 Service and Repair Manual Specifications 3 Working clockwise on the body hex fitting, make a second mark with a permanent ink marker to indicate the proper tightening position. Refer to Illustration 2. Note: Use the JIC 37° Fitting table in this section to determine the correct number of flats, for the proper tightening position. Note: The marks indicate the correct tightening positions have been determined. Use the second mark on the body hex fitting to properly tighten the joint after it has been loosened. Illustration 2 1 body hex fitting 2 reference mark 3 second mark 4 Tighten the hex nut until the mark on the hex nut is aligned with the second mark on the body hex fitting. 5 Operate all machine functions and inspect the hose, fittings and related components to confirm there are no leaks. March 2021 14 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Repair Procedures Section 3 Repair Procedures Observe and Obey: Repair procedures shall be completed by a person trained and qualified on the repair of this machine. Immediately tag and remove from service a damaged or malfunctioning machine. Repair any machine damage or malfunction before operating the machine. Before Repairs Start: 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 parts are available and ready for use. Use only Genie approved replacement parts. Read each procedure completely and adhere to the instructions. Attempting shortcuts may produce hazardous conditions. 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 removed · The red Emergency Stop button in the off position at both the ground and platform controls · Wheels chocked · All external AC power supply disconnected from the machine · Platform in the stowed position Part No. 1272217GT GSTM-30 · 32 · 46 · 47 15 Service and Repair Manual Repair Procedures March 2021 About This Section Most of the procedures in this section should only be performed by trained service professional in a suitably equipped workshop. Select the appropriate repair procedure after troubleshooting the problem. Perform disassembly procedures to the point where repairs can be completed. Then to reassemble, perform the disassembly steps in reverse order. Symbols Legend Safety alert symbol--used to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Indicates a imminently hazardous situation which, if not avoided, will result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, may cause minor or moderate injury. Indicates a potentially hazardous situation which, if not avoided, may result in property damage. Indicates that a specific result is expected after performing a series of steps. Indicates that an incorrect result has occurred after performing a series of steps. 16 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 The platform controls are used to operate the machine from the platform. Activating a function button sends a signal to the Electronic Control Module (ECM). When the ECM is in the function mode, the platform controls are used to operate the various machine functions. The platform controls consist of an Emergency Stop button, electronic circuit board, proportional control handle, drive/steer enable switch, alarm, function buttons and LED display. For further information or assistance, contact Genie Product Support. Service and Repair Manual Platform Controls a red Emergency Stop button P2 b platform controls circuit board U3 c proportional control handle and drive/steer enable switch JC9 d alarm H1 Part No. 1272217GT GSTM-30 · 32 · 46 · 47 17 Service and Repair Manual Platform Controls March 2021 Operational Indicator Codes These codes are generated by the electrical system to indicate machine operating status. During normal operation, a code will appear in the platform controls LED readout if a condition such as off-level, overload cutout, chassis mode operation or pothole guard stuck occurs. If the platform controls LED readout displays an operational indicator code such as LL, the fault condition must be repaired or removed before resuming machine operation. Push in and pull out the red Emergency Stop button to reset the system. Note: The Ld Operation Indicator Code will appear when the outriggers are not fully retracted, the machine is not auto leveled, an outrigger has lost contact with the ground or either level sensor detects the machine is no longer level. When any of the above scenarios occur, the lift function is disabled. The lift function will also be disabled while extending or retracting the outriggers and during the outrigger auto level procedure. While performing the above operations, the Ld Operation Indicator Code will appear. Note: A code and a description of a code can also be viewed at the ground controls LCD display. Platform Controls LED Readout Code LL OL CH PHS nd Ld br OHL Condition Off-level Platform Overload (CE and Australia) Chassis Mode Operation Pothole Guard Stuck No Drive (option) Lifting Disabled Brake Release Outdoor Height Restriction 18 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Platform Controls 1-1 Circuit Board How to Remove the Platform Controls Circuit Board 1 Push in the red Emergency Stop button to the off position at both the ground and platform controls. 2 Disconnect the platform controls from the control cable at the platform. 3 Remove the fasteners securing the platform control box to the platform control bracket. 4 Remove the fasteners securing the bottom cover to the platform control box. Open the control box. 5 Remove the ties securing the wire harness. 6 Disconnect the red and black wires from the alarm. 7 Carefully remove the alarm from the platform control box. 8 Carefully disconnect all wire harness connectors from the platform controls circuit board. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Component damage hazard. Electrostatic discharge (ESD) can damage printed circuit board components. Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap. 9 Carefully remove the platform controls circuit board fasteners. 10 Carefully remove the platform controls circuit board from the platform control box. 11 Remove the transparent caps from the platform controls circuit board and save. Circuit board fastener torque specifications Hand tighten until screws seat < 5 in-lbs < 0.6 Nm Note: Before installing a circuit board, place the transparent caps removed in step 11, over the circuit board buttons. Note: After installing the circuit board, check for proper button operation. Excessive torque of the circuit board fasteners will cause the buttons to bind. Moderate torque of the circuit board fasteners will not allow the buttons to engage. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 19 Service and Repair Manual Platform Controls March 2021 1-2 Joystick 1-3 Platform Controls Alarm How to Remove the Joystick 1 Push in the red Emergency Stop button to the off position at both the ground and platform controls. 2 Disconnect the platform controls from the control cable at the platform. 3 Remove the fasteners securing the platform control box to the platform control bracket. 4 Remove the fasteners securing the bottom cover to the platform control box. Open the control box. 5 Remove the ties securing the joystick wire harness. 6 Carefully disconnect the joystick wire harness from the platform controls circuit board. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Component damage hazard. Electrostatic discharge (ESD) can damage printed circuit board components. Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap. 7 Carefully remove the joystick fasteners. 8 Carefully remove the joystick from the platform control box. Torque specifications Joystick fasteners 9 in-lbs 1 Nm How to Remove the Platform Controls Alarm 1 Push in the red Emergency Stop button to the off position at both the ground and platform controls. 2 Disconnect the platform controls from the control cable at the platform. 3 Remove the fasteners securing the platform control box to the platform control bracket. 4 Remove the fasteners securing the bottom cover to the platform control box. Open the control box. 5 Disconnect the red and black wires from the alarm. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Component damage hazard. Electrostatic discharge (ESD) can damage printed circuit board components. Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap. 6 Carefully remove the alarm from the platform control box. 20 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Platform Controls 1-4 Platform Emergency Stop Button How to Remove the Platform Controls Emergency Stop Button 1 Push in the red Emergency Stop button to the off position at both the ground and platform controls. 2 Disconnect the platform controls from the control cable at the platform. 3 Remove the fasteners securing the platform control box to the platform control bracket. 4 Remove the fasteners securing the bottom cover to the platform control box. Open the control box. 5 Disconnect the white wires from the Emergency Stop base. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Component damage hazard. Electrostatic discharge (ESD) can damage printed circuit board components. Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap. 6 Carefully remove the Emergency Stop base from the Emergency Stop button. 7 Carefully remove the retaining ring from the Emergency Stop button. 8 Carefully remove the Emergency Stop button from the platform control box. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 21 Service and Repair Manual Ground Controls The ground controls, used to operate the machine from the ground, can also be used to tune the performance of the machine. The ground controls consist of an Electronic Control Module (ECM), emergency stop button, key switch and circuit breaker. Activating the function enable button and the up or down at the same time, sends a signal to the (ECM). This allows the platform to be raised or lowered at the ground controls. Note: Steer and drive functions are not available at the ground controls. When the ECM is in the set up mode, the ground controls are used to adjust the function speed parameters, machine models, or machine options. For further information or assistance, contact Genie Product Support. March 2021 1 machine setup escape button 2 machine setup scroll up button 3 LCD readout 4 machine setup scroll down button 5 machine setup enter button 6 Key switch KS1 7 red Emergency Stop P1 8 circuit breaker CB2 9 Diagnostic port (if equipped) 10 platform down button 11 lift function enable button 12 platform up button 22 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Ground Controls 2-1 Software Revision Level How to Determine the Revision Level The machine software revision level is displayed at the ground controls LCD display. 1 Turn the key switch to the ground controls or platform controls position. Pull out the red Emergency Stop button to the on position at both ground and platform controls. Result: The display at the platform controls will show "CH". See example below. 2 Press the ground control scroll down button. Result: The ground control LCD display will indicate the software revision and hour meter information. After 5 seconds, the ground controls LCD display will display machine model and hour meter information again. 3 Push in the red Emergency Stop button to the off position at both the ground and platform controls and turn the key switch to the off position. Result: The display at the ground controls will show the machine model and hour meter information. After 3 seconds, the machine model will not show on the display. See example below. a ground control LCD display b ground control scroll down button Part No. 1272217GT GSTM-30 · 32 · 46 · 47 23 Service and Repair Manual Ground Controls March 2021 2-2 Machine Setup 2 Press and hold the ground control scroll up and scroll down buttons. How to Setup the Machine from Ground Controls The ground controls can be used to setup the machine parameters from the ground. Features that can be adjusted from the ground controls include machine Model, Options and Speed setup. This menu can only be entered from ground controls with the key switch in the ground controls position. Tip-over hazard. Do not adjust function speeds higher than specified in this procedure. Setting the function speeds greater than specifications could cause the machine to tip over resulting in death or serious injury. Tip-over hazard. This procedure must only be performed by a trained service professional. Attempting this procedure without the necessary skills could result in death or serious injury. Note: Select a test area that is firm, level and free of obstructions. 1 Turn the key switch to ground controls. Ground Control Menu Buttons 1 scroll down button 2 enter button 3 scroll up button 4 escape button 5 LCD display 3 Pull out the red Emergency Stop button to the on position at the ground controls. Result: The ground controls LCD display will show the following: 4 Use the ground control menu buttons to select machine Model, Options and Speed Setup parameters. Follow the menu structure indicated on the ground control LCD display. 24 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Ground Controls 2-3 Loading or Updating Machine Software Note: Before updating the machine software, open a web browser and navigate to the following location for the Genie Machine Software Download portal, http://firmware.genielift.com. Perform a search by applying the appropriate filters and download the machine software. Note: There are two procedures available to update the machine software. These are Bootloader Mode and Machine Application Mode. Bootloader Mode: The Bootloader mode is only available with the key switch in the GCON position. It allows the user to update or reinstall the machine software by directing the system into the Bootloader. Choose this mode if the GCON ECM is not opertaing correctly. Machine Application Mode: The machine Application mode is available with the key switch in the GCON or PCON position. This mode of machine software update requires the user to enter the Machine Service Tool. Choose this mode if the machine is operating correctly and you are updating the machine software. Bootloader Mode 1 Open the GCON compartment. Note: Some models will require opening the ground control box to access the GCON. 2 Turn the key switch to the ground controls position and pull out the red Emergency Stop button to the on position at the platform controls. 3 At the ground controls, press and hold the Enter and Escape buttons. a LCD display b enter button c escape button 4 Pull out the red Emergency Stop button to the on position at the ground controls. Result: The ground controls LCD display will show the following: Part No. 1272217GT GSTM-30 · 32 · 46 · 47 25 Service and Repair Manual Ground Controls March 2021 5 Locate the diagnostic port on the side of the GCON. Remove one of the fasteners securing the cover and set aside. Loosen the other fastener. Do not remove it. 8 Launch a web browser such as Internet Explorer ®, Chrome ® or Firefox ® on your PC or laptop. Type the IP address from step 7 into the web browser address bar and press enter. Result: The following screen will be displayed. a diagnostic port 6 Connect one end of a CAT5 Ethernet cable into the diagnostic port. Connect the other end into a PC or laptop. Result: The ground controls LCD display will show the following: 9 Select the Choose File button and navigate to the downloaded Genie Flash file (.gff). Note: Verify it is the correct flash file. 10 Select the Load Flash File button to verify the file is a .gff file. Result: The following screen will be displayed. 7 Read and record the IP address. 26 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Ground Controls 11 Select the Reprogram Device(s) button to start the ECM software update. Result: The following screen will be displayed after the software update is complete. Note: Do not turn off power while the ECM is being reprogrammed. Machine Application Mode 1 Open the GCON compartment. Note: Some models will require opening the ground control box to access the GCON. 2 Turn the key switch to ground controls or platform controls and pull out the red Emergency Stop button to the on position at both ground and platform controls. 3 Locate the diagnostic port on the side of the GCON. Remove one of the fasteners securing the cover and set aside. Loosen the other fastener. Do not remove it. 12 Select the Run Application button to exit the software update mode. 13 Push in the red Emergency Stop button and disconnect the CAT5 cable from the GCON. 14 Secure the diagnostic port cover using the retaining fasteners removed in step 5. 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. Tip over hazard. Updating the SmartLink software may have impacted the machines default drive speeds. Tipping over the machine will result in death or serious injury. Perform drive speed test. Refer to the Maintenance Manual that is appropriate for your machine. 15 Perform a function test. Refer to the Operator's Manual on your machine. 16 Return the machine to service. a diagnostic port 4 Connect one end of a CAT5 Ethernet cable into the diagnostic port. Connect the other end into a PC or laptop. Result: The ground controls LCD display will show the following: Part No. 1272217GT GSTM-30 · 32 · 46 · 47 27 Service and Repair Manual Ground Controls March 2021 5 Read and record the IP address. Note: The display will only show the IP address for 3 seconds. Press the scroll up button to display the IP address for another 3 seconds. 6 Launch a web browser such as Internet Explorer ®, Chrome ® or Firefox ® on your PC or laptop. Type the IP address from step 5 into the web browser address bar and press enter. Result: The following screen will be displayed. 8 Select the Software tab at the header bar. Result: The following screen will be displayed. 9 Select the Update Machine Software button. Result: The following screen will be displayed. 7 Enter the following username and password then select OK. Username: smart.link Password: SL1000 Note: The username and password are case sensitive. Result: The following screen will be displayed. 10 Select the Choose File button and navigate to the downloaded Genie Flash file (.gff). Note: Verify it is the correct flash file. 28 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Ground Controls 11 Select the Load Flash File button to verify the file is a .gff file. Result: The following screen will be displayed. 12 Select the Reprogram Device(s) button to start the ECM software update. Result: The following screen will be displayed after the software update is complete. Note: Do not turn off power while the ECM is being reprogrammed. 15 Secure the diagnostic port cover using the retaining fasteners removed in step 5. 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. Tip over hazard. Updating the SmartLink software may have impacted the machines default drive speeds. Tipping over the machine will result in death or serious injury. Perform drive speed test. Refer to the Maintenance Manual that is appropriate for your machine. 16 Perform a function test. Refer to the Operator's Manual on your machine. 17 Return the machine to service. 13 Select the Run Application button to exit the software update mode. 14 Push in the red Emergency Stop button and disconnect the CAT5 cable from the GCON. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 29 Service and Repair Manual Ground Controls March 2021 2-4 Using a Wi-Fi Router to Connect to the SmartLink Web Service Tool Note: Before using a portable wireless router to connect to the Smart Link Service Tool web site, the router must be configured to the type of connection desired. Refer to the portable wireless router users manual for set-up and configuration instructions. 1 Open the GCON compartment. Note: Some models will require opening the ground control box to access the GCON. 2 Turn the key switch to ground controls or platform controls and pull out the red Emergency Stop button to the on position at both ground and platform controls. Result: The display at the platform controls will show "CH". See example below. 3 Locate the diagnostic port on the side of the GCON. Remove one of the fasteners securing the cover and set aside. Loosen the other fastener. Do not remove it. a diagnostic port 4 Connect one end of a CAT5 Ethernet cable into the diagnostic port. Connect the other end into the ethernet port of the portable wireless router. Result: The ground controls LCD display will show the following: 30 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Ground Controls 5 Read and record the IP address. Note: The display will only show the IP address for 3 seconds. Press the scroll up button to display the IP address for another 3 seconds. 6 On a PC, laptop or mobile device, set up a wireless network for the portable router. Note: Refer to the Operating System's procedure for connecting to a wireless network. 7 After establishing a new wireless network, select the appropriate network your portable wireless router. Note: Refer to the Operating System's procedure for connecting to a wireless network. 8 Launch a web browser such as Internet Explorer ®, Chrome ® or Firefox ® on your PC, laptop or mobile device. Type the IP address from step 5 into the web browser address bar and press enter. Result: The following screen will be displayed. 9 Enter the following username and password then select OK. Username: smart.link Password: SL1000 Note: The username and password are case sensitive. Result: The following screen will be displayed. 10 After using the Smart Link Service Tool web site, push in the red Emergency Stop button and disconnect the CAT5 cable from the GCON. 11 Secure the diagnostic port cover using the 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. Tip over hazard. Updating the SmartLink software may have impacted the machines default drive speeds. Tipping over the machine will result in death or serious injury. Perform drive speed test. Refer to the Maintenance Manual that is appropriate for your machine. 12 Perform a function test. Refer to the Operator's Manual on your machine. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 31 Service and Repair Manual Ground Controls March 2021 2-5 Service Override Mode The Electronic Control Module (ECM) is programmed with a Service Override mode. Service Override mode is only indented for certain circumstances and is not part of the normal machine operation. Service Override mode should only be accessed by trained personal to repair faults and/ or a malfunctioning machine. Note: Service Override mode can only be entered at the ground controls and is intended to allow the platform to be raised or lowered. Once the platform has reached the maximum allowable height, the system will exit Service Override mode. Repeat this procedure to lower the platform. Note: When in Service Override mode, an audible alarm will sound. Note: Before entering Service Override mode, fault codes or the malfunction affecting the operation of the machine should be fully understood to ensure Service Override mode is required. Note: Perform this operation on a firm, level surface and if equipped, with the outriggers auto leveled or fully retracted. Tip-over hazard. Operating the machine on a surface that is not level while in Service Override mode will result in death or serious injury. Follow proper operating procedures and safety precautions. Do not use Service Override mode if you are not trained and familiar with the operation of the machine. 1 Turn the key switch to the ground controls position and pull out the red Emergency Stop button to the on position at the platform controls. 2 Press and hold the ground control scroll up and scroll down buttons. Ground Control Menu Buttons a scroll down button b enter button c scroll up button d escape button e LCD display 32 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Ground Controls 3 Pull out the red Emergency Stop button to the on position at the ground controls. Result: The ground controls LCD display will show the following: 6 Press the enter button. Result: The ground controls LCD display will show an alternating message every 1.5 seconds. 4 Release the Scroll Up and Scroll Down buttons after the ground controller powers up. 5 At the ground controls, use the Scroll Down button to scroll to SVC Override. Result: The ground controls LCD display will show the following: 7 Press the enter button. Result: The ground controls LCD display will show the following: 8 Press the enter button. Result: The ground controls LCD display will show the following: Part No. 1272217GT GSTM-30 · 32 · 46 · 47 33 Service and Repair Manual Ground Controls 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. Use the illustrations to verify which type of level sensor is installed and perform the procedure that is appropriate for your machine. March 2021 Procedure 2 Procedure 1 Procedure 3 1 X axis 2 Y axis 34 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Ground Controls How to Install and Calibrate the Level Sensor - Procedure 1 Procedure 1 1 X axis 2 Y axis Tip-over hazard. Failure to install or calibrate 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 or calibrate the level sensor other than specified in this procedure. Note: If you are not installing a new level sensor, proceed to step 15. 1 Move the machine to an area that has a firm, level surface and is free of obstructions. Note: The surface must be 0° +/- 0.5°. 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. 7 Turn the key switch to the off position and push in the red Emergency Stop button to the off position at the ground controls. 8 Tag and disconnect the level sensor wire harness from the chassis wire harness. Note: The wire harness connection is located next to the level sensor, on top of the chassis at the steer end of the machine. 9 Remove the level sensor retaining fasteners and remove the level sensor from the machine. 10 Tag and disconnect the level sensor wires from the level sensor connector plug. 11 Securely install the wires of the new level sensor into the level sensor connector plug. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 35 Service and Repair Manual Ground Controls March 2021 12 Place the new level sensor onto the level sensor mount bracket with the "X" on the level sensor base closest to the long side of the level sensor mount, and the "Y" on the level sensor base closest to the short side of the level sensor mount. Tip-over hazard. Failure to install the level sensor as instructed, could result in the machine tipping over, causing death or serious injury. Steer End Non-steer End 1 limit switch 2 level sensor mount bracket 3 level sensor S7 4 scissor chassis 5 alarm H5 13 Install the level sensor retaining fasteners through the level sensor and springs, and into the mount bracket. Tighten the fasteners and measure the distance between the level sensor and the level sensor mount bracket. Result: The measurement should be approximately 0.375 inch / 10 mm. 14 Connect the chassis wire harness to the level sensor wire harness. 15 Turn the key switch to the ground control and pull out the red Emergency Stop button to the on position at the ground controls. 16 Adjust the level 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. 36 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Ground Controls 22 GS-1530 and GS-1930: Place a 0.64 x 6 x 6 inch / 16.2 mm x 15 cm x 15 cm thick steel block under both wheels at the ground controls side of the machine. GS-1532 and GS-1932: Place a 0.68 x 6 x 6 inch / 17.2 mm x 15 cm x 15 cm thick steel block under both wheels at the ground controls side of the machine. GS-2032, GS-2632 and GS-3232: Place a 0.66 x 6 x 6 inch / 16.8 mm x 15 cm x 15 cm thick steel block under both wheels at the ground controls side of the machine. GS-2046, GS-2646, GS-3246 and GS-4047: Place a 1 x 6 x 6 inch / 25.4 mm x 15 cm x 15 cm thick steel block under both wheels at the ground controls side of the machine. 23 Lower the machine onto the blocks. 24 Raise the platform 7 to 8 feet / 2,1 to 2,4 m. Result: The level sensor alarm should not sound. Result: The level sensor alarm does sound and fault code LL appears in the diagnostic display. Adjust the level sensor retaining fasteners just until the level sensor alarm does not sound. 25 Lower the platform to the stowed position. 26 Raise the machine approximately 2 inches / 5 cm. Place blocks under the chassis for support. 27 Remove the blocks from under both wheels. 28 Lower the machine and remove the jack. 29 Center a lifting jack under the drive chassis at the battery pack side of the machine. 30 Raise the machine approximately 2 inches / 5 cm. Place blocks under the chassis for support. 31 GS-1530 and GS-1930: Place a 0.77 x 6 x 6 inch / 19.6 mm x 15 cm x 15 cm thick steel block under both wheels at the battery pack side of the machine. GS-1532 and GS-1932: Place a 0.83 x 6 x 6 inch / 21.1 mm x 15 cm x 15 cm thick steel block under both wheels at the battery pack side of the machine. GS-2032, GS-2632 and GS-3232: Place a 0.8 x 6 x 6 inch / 20.3 mm x 15 cm x 15 cm thick steel block under both wheels at the battery pack side of the machine. GS-2046, GS-2646, GS-3246 and GS-4047: Place a 1.22 x 6 x 6 inch / 31 mm x 15 cm x 15 cm thick steel block under both wheels at the battery pack side of the machine. 32 Lower the machine onto the blocks. 33 Raise the platform 7 to 8 feet / 2,1 to 2,4 m. Result: The platform should stop, an alarm should sound and fault code LL appears in the diagnostic display. Result: The platform does not stop or the level sensor alarm does not sound. Adjust the level sensor until the alarm just begins to sound OR the down limit switch may need to be adjusted. 34 Lower the platform to the stowed position. 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. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 37 Service and Repair Manual Ground Controls March 2021 How to Install and Calibrate the Level Sensor - Procedure 2 Procedure 2 1 X axis 2 Y axis 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. Note: If you are not installing a new level sensor, proceed to step 14. 1 Move the machine to an area that has a firm, level surface and is free of obstructions. Note: Use a digital level to verify the surface is level. 2 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. 3 Raise the platform 7 to 8 feet / 2,1 to 2,4 m. 4 Lift the safety arm, move it to the center of the scissor arm and rotate down to a vertical position. 5 Lower the platform onto the safety arm. Crushing hazard. Keep hands clear of the safety arm when lowering the platform. 6 Turn the key switch to the off position and push in the red Emergency Stop button to the off position at the ground controls. 7 Tag and disconnect the level sensor wire harness from the chassis wire harness. Note: The wire harness connection is located on the level sensor, on top of the chassis at the steer end of the machine. 8 Remove the level sensor retaining fasteners and remove the level sensor from the machine. 9 Securely install the wires of the new level sensor into the level sensor connector plug. 38 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Ground Controls 10 Place the new level sensor on to the level sensor bracket with the "Y" on the level sensor closest to the ground controls of the machine and the "X" on the level sensor closest to the steer end of the machine. Tip-over hazard. Failure to install the level sensor as instructed, could result in the machine tipping over, causing death or serious injury. Steer End 11 Install the level sensor retaining fasteners through the level sensor and into the mount bracket. 12 Connect the chassis wire harness to the level sensor. 13 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. Result: GCON will display a `C051: SYSTEMFAULT, TILT:NoCal fault. 14 Push in the red Emergency Stop button to the off position at the ground controls. 15 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 Control Menu Buttons 1 scroll down button 2 enter button 3 scroll up button 4 escape button 5 LCD display Part No. 1272217GT GSTM-30 · 32 · 46 · 47 39 Service and Repair Manual Ground Controls March 2021 16 Pull out the red Emergency Stop button to the on position at the ground controls. Result: The ground controls LCD display will show the following: 17 Release the Scroll Up and Scroll Down buttons after the ground controller powers up. 18 Use the Scroll Up or Scroll Down buttons to scroll to Select Option. 22 Press and hold the Enter button to start calibration. Result: An audible alarm will sound when 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 23. If the level sensor was not replaced skip to step 26. 19 Press the enter button. 20 Use the Scroll Up or Scroll Down buttons to scroll to Tilt Sensor. 21 Press the enter button. 23 Raise the platform 7 to 8 feet / 2,1 to 2,4 m. 24 Return the safety arm to the stowed position. 25 Lower the platform to the stowed position. 26 Place a digital level on the ground control side of the drive chassis. Zero out the digital level. 27 Drive the steer end of the machine up a ramp until it is just under 3°. 40 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Ground Controls 28 Raise the platform 7 to 8 feet / 2,1 to 2,4 m. Result: No audible alarm is heard. Result: The platform stops, an audible alarm is heard and Fault LL is displayed. Repeat this procedure starting at step 15 on a firm level surface. 29 Lower the platform to the stowed position. 30 Continue driving the machine up the ramp until it is just over 3°. 31 Raise the platform 7 to 8 feet / 2,1 to 2,4 m. Result: The platform should stop, an alarm should sound and fault code LL appears in the diagnostic display. Result: The platform does not stop or the level sensor alarm does not sound. Repeat this procedure starting at step 15 on a firm level surface. 32 Lower the platform to the stowed position. 33 Drive the non-steer end of the machine up a ramp until it is just under 3°. 34 Raise the platform 7 to 8 feet / 2,1 to 2,4 m. Result: No audible alarm is heard. Result: The platform stops, an audible alarm is heard and Fault LL is displayed. Repeat this procedure starting at step 15 on a firm level surface. 35 Lower the platform to the stowed position. 36 Continue driving the machine up the ramp until it is just over 3°. 37 Raise the platform 7 to 8 feet / 2,1 to 2,4 m. Result: The platform should stop, an alarm should sound and fault code LL appears in the diagnostic display. Result: The platform does not stop or the level sensor alarm does not sound. Repeat this procedure starting at step 15 on a firm level surface. 38 Lower the platform to the stowed position. 39 Place a digital level on the steer end of the drive chassis. Zero out the digital level. 40 Drive the ground control side of the machine onto a ramp until it is just under 1.5°. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 41 Service and Repair Manual Ground Controls March 2021 41 Raise the platform 7 to 8 feet / 2,1 to 2,4 m. Result: No audible alarm is heard. Result: The platform stops, an audible alarm is heard and Fault LL is displayed. Repeat this procedure starting at step 15 on a firm level surface. 42 Lower the platform to the stowed position. 43 Continue driving the machine onto the ramp until it is just over 1.5°. 44 Raise the platform 7 to 8 feet / 2,1 to 2,4 m. Result: The platform should stop, an alarm should sound and fault code LL appears in the diagnostic display. Result: The platform does not stop or the level sensor alarm does not sound. Repeat this procedure starting at step 15 on a firm level surface. 45 Lower the platform to the stowed position. 46 Drive the battery compartment side of the machine onto a ramp until it is just under 1.5°. 47 Raise the platform 7 to 8 feet / 2,1 to 2,4 m. Result: No audible alarm is heard. Result: The platform stops, an audible alarm is heard and Fault LL is displayed. Repeat this procedure starting at step 15 on a firm level surface. 48 Lower the platform to the stowed position. 49 Continue driving the machine onto the ramp until it is just over 1.5°. 50 Raise the platform 7 to 8 feet / 2,1 to 2,4 m. Result: The platform should stop, an alarm should sound and fault code LL appears in the diagnostic display. Result: The platform does not stop or the level sensor alarm does not sound. Repeat this procedure starting at step 15 on a firm level surface. 51 Lower the platform to the stowed position. 42 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Ground Controls How to Install and Calibrate the Level Sensor - Procedure 3 Procedure 3 1 X axis 2 Y axis 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. Note: If you are not installing a new level sensor, proceed to step 14. 1 Move the machine to an area that has a firm, level surface and is free of obstructions. Note: Use a digital level to verify the surface is level. 2 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. 3 Raise the platform 7 to 8 feet / 2,1 to 2,4 m. 4 Lift the safety arm, move it to the center of the scissor arm and rotate down to a vertical position. 5 Lower the platform onto the safety arm. Crushing hazard. Keep hands clear of the safety arm when lowering the platform. 6 Turn the key switch to the off position and push in the red Emergency Stop button to the off position at the ground controls. 7 Tag and disconnect the level sensor wire harness from the chassis wire harness. Note: The wire harness connection is located on the level sensor, on top of the chassis at the steer end of the machine. 8 Remove the level sensor retaining fasteners and remove the level sensor from the machine. 9 Securely install the wires of the new level sensor into the level sensor connector plug. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 43 Service and Repair Manual Ground Controls March 2021 10 Place the new level sensor on to the level sensor bracket with the "Y" on the level sensor away from the ground controls of the machine and the "X" on the level sensor closest to the steer end of the machine. Tip-over hazard. Failure to install the level sensor as instructed, could result in the machine tipping over, causing death or serious injury. Steer End 11 Install the level sensor retaining fasteners through the level sensor and into the mount bracket. 12 Connect the chassis wire harness to the level sensor. 13 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. Result: GCON will display a `C051: SYSTEMFAULT, TILT:NoCal fault. 14 Push in the red Emergency Stop button to the off position at the ground controls. 15 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 Control Menu Buttons 1 scroll down button 2 enter button 3 scroll up button 4 escape button 5 LCD display 44 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Ground Controls 16 Pull out the red Emergency Stop button to the on position at the ground controls. Result: The ground controls LCD display will show the following: 17 Release the Scroll Up and Scroll Down buttons after the ground controller powers up. 18 Use the Scroll Up or Scroll Down buttons to scroll to Select Option. 22 Press and hold the Enter button to start calibration. Result: An audible alarm will sound when 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 23. If the level sensor was not replaced skip to step 26. 19 Press the enter button. 20 Use the Scroll Up or Scroll Down buttons to scroll to Tilt Sensor. 21 Press the enter button. 23 Raise the platform 7 to 8 feet / 2,1 to 2,4 m. 24 Return the safety arm to the stowed position. 25 Lower the platform to the stowed position. 26 Place a digital level on the ground control side of the drive chassis. Zero out the digital level. 27 Drive the steer end of the machine up a ramp until it is just under 3° Part No. 1272217GT GSTM-30 · 32 · 46 · 47 45 Service and Repair Manual Ground Controls March 2021 28 Raise the platform 7 to 8 feet / 2,1 to 2,4 m. Result: No audible alarm is heard. Result: The platform stops, an audible alarm is heard and Fault LL is displayed. Repeat this procedure starting at step 15 on a firm level surface. 29 Lower the platform to the stowed position. 30 Drive the steer end of the machine up a ramp until it is just over 3°. 31 Raise the platform 7 to 8 feet / 2,1 to 2,4 m. Result: The platform should stop, an alarm should sound and fault code LL appears in the diagnostic display. Result: The platform does not stop or the level sensor alarm does not sound. Repeat this procedure starting at step 15 on a firm level surface. 32 Lower the platform to the stowed position. 33 Drive the non-steer end of the machine up a ramp until it is just under 3°. 34 Raise the platform 7 to 8 feet / 2,1 to 2,4 m. Result: No audible alarm is heard. Result: The platform stops, an audible alarm is heard and Fault LL is displayed. Repeat this procedure starting at step 15 on a firm level surface. 35 Lower the platform to the stowed position. Drive the non-steer end of the machine up a ramp until it is just over 3°. 36 Raise the platform 7 to 8 feet / 2,1 to 2,4 m. Result: The platform should stop, an alarm should sound and fault code LL appears in the diagnostic display. Result: The platform does not stop or the level sensor alarm does not sound. Repeat this procedure starting at step 15 on a firm level surface. 37 Lower the platform to the stowed position. 38 Place a digital level on the steer end of the drive chassis. Zero out the digital level. 39 Drive the ground control side of the machine onto a ramp until it is just under 1.5°. 46 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Ground Controls 40 Raise the platform 7 to 8 feet / 2,1 to 2,4 m. Result: No audible alarm is heard. Result: The platform stops, an audible alarm is heard and Fault LL is displayed. Repeat this procedure starting at step 15 on a firm level surface. 41 Lower the platform to the stowed position. 42 Continue driving the machine onto the ramp until it is just over 1.5°. 43 Raise the platform 7 to 8 feet / 2,1 to 2,4 m. Result: The platform should stop, an alarm should sound and fault code LL appears in the diagnostic display. Result: The platform does not stop or the level sensor alarm does not sound. Repeat this procedure starting at step 15 on a firm level surface. 44 Lower the platform to the stowed position. 45 Drive the battery compartment side of the machine onto a ramp until it is just under 1.5°. 46 Raise the platform 7 to 8 feet / 2,1 to 2,4 m. Result: No audible alarm is heard. Result: The platform stops, an audible alarm is heard and Fault LL is displayed. Repeat this procedure starting at step 15 on a firm level surface. 47 Lower the platform to the stowed position. 48 Continue driving the machine onto the ramp until it is just over 1.5°. 49 Raise the platform 7 to 8 feet / 2,1 to 2,4 m. Result: The platform should stop, an alarm should sound and fault code LL appears in the diagnostic display. Result: The platform does not stop or the level sensor alarm does not sound. Repeat this procedure starting at step 15 on a firm level surface. 50 Lower the platform to the stowed position. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 47 Service and Repair Manual Ground Controls March 2021 Outrigger Level Sensor - GS-3232 Models (from serial number GS3211A to GS3215A-141898) (from serial number GS3212C-10000) 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. 1 Move the machine to an area that has a firm, level surface and is free of obstructions. 2 Turn the key switch to the off position and push in the red Emergency Stop button to the off position at both the ground and platform controls. 3 Open the access door at the battery side of the machine. 4 Tag and disconnect the outrigger level sensor wire harness from the outrigger level sensor. 5 Remove the outrigger level sensor retaining fasteners and remove the outrigger level sensor from the machine. 6 Place the new outrigger level sensor onto the outrigger level sensor base with the flat side of the outrigger level sensor closest to the battery side access door. Refer to the illustration below. 1 outrigger level sensor (GS-3232) 7 Secure the outrigger level sensor onto the base with the retaining fasteners removed in step 5. 8 Adjust the outrigger level sensor retaining fasteners until the bubble at the top of the level sensor is centered in the circles. 9 Connect the outrigger level sensor wire harness to the new outrigger level sensor. 10 Close the access door at the battery side of the machine. 11 Calibrate the outrigger level sensor. Refer to Repair Procedure, How to Calibrate the Outrigger System. 48 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Ground Controls 2-7 Manual Platform Lowering Cable The manual platform lowering cable lowers the platform in the event of a main power failure. The manual platform lowering cable is attached to the barrel end of the lift cylinder and is activated next to the ground controls. How to Adjust the Manual Platform Lowering Cable 1 Raise the platform 7 to 8 feet / 2,1 to 2,4 m.: 2 Lift the safety arm, move it to the center of the scissor arm and rotate down to a vertical position. 3 Lower the platform onto the safety arm. Crushing hazard. Keep hands clear of the safety arm when lowering the platform. 4 Pull the handle of the manual platform lowering cable out until considerable resistance is felt. Release the handle. 5 Measure the distance between the base of the handle and cable mounting nut. Result: The measurement should be no greater than 0.125 inch / 3 mm. Note: Proceed to step 8 if measurement is correct. Platform manual lowering cable specification Gap, lowering handle to mounting nut 0 to 0.125 inch 0 to 3 mm 6 To adjust, loosen the upper lock nut on the cable mounting bracket at the cylinder. Turn the lower lock nut clockwise to decrease the distance or counterclockwise to increase the distance. Tighten the upper lock nut. 1 manual lowering cable sheath 2 upper lock nut 3 cable mounting bracket 4 lower lock nut 5 cable mounting nut 6 end of lowering cable 7 manual lowering valve (hydraulic schematic item N) 7 Repeat this procedure beginning with step 4. 8 Raise the platform and rotate the safety arm to the stowed position. 9 Pull the manual lowering handle at the ground controls 2 to 3 times to ensure it is functioning correctly. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 49 Service and Repair Manual Ground Controls March 2021 2-8 Outrigger Calibration The Electronic Control Module (ECM) is programmed to deactivate the drive and steer functions while the outriggers are deployed and activate an alarm when a signal is received from the outrigger level sensor, indicating the outriggers are not deployed or the machine is out of level. The ECM is also used to calibrate the outrigger level sensor to achieve a levelness of 0° +/- 0.5° front to back and side to side, while the outriggers are deployed. For further information or assistance, contact Genie Product Support. How to Calibrate the Outrigger System (GS-3232 - facility code C) (GS-3232 - facility code A, to GS3215A-141898) 1 Move the machine to an area that has a firm, level surface and is free of obstructions. Use digital level to confirm. 2 Turn the key switch to ground controls. 3 At the ground controls, press and hold the Menu Up and Menu Down buttons. 4 While pressing both buttons down, pull out the red Emergency Stop Button. 5 Release the Menu Up and Menu Down buttons after the ground controller powers up. 6 Use the Menu Up or Menu Down buttons to scroll to Machine Options. 7 Press the Enter button to select Machine Options. 8 Use the Menu Up or Menu Down buttons to scroll to Outriggers. 9 Press the Enter button to select Outriggers. 10 Use the Menu Up or Menu Down buttons to scroll to Calibrate Outriggers. 11 Press the Enter button to select Calibrate Outriggers. 12 Press and hold the Enter button while the system gathers data to calibrate the outrigger level sensor. Crushing hazard. Keep body parts away from outriggers during outrigger movement. 13 Continue holding the Enter button after the outrigger level sensor is calibrated. The outriggers will retract while the outrigger system gathers and saves data. 14 Continue holding the Enter button after the outriggers retract. The outriggers will now extend and the system will gather and save data to calibrate the outriggers. 15 Continue holding the Enter button after the outriggers extend. The outriggers will now retract while the outrigger system gathers and saves data. Result: The alarms at the ground and platform controls should sound for 1 second. The outrigger system is calibrated. Note: After installing a new outrigger level sensor, the new outrigger level sensor must be calibrated following this procedure. 50 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Hydraulic Tank 3-1 Hydraulic Tank The primary functions of the hydraulic tank are to cool and deaerate the hydraulic fluid during operation. It utilizes internal suction strainers for the pump supply lines and has an external return line filter. How to Remove the Hydraulic Tank Component damage hazard. The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system. Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications. Perform this procedure with the platform in the stowed position. 1 Disconnect the battery pack from the machine. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 2 Tag and disconnect the hydraulic tank return hard line from the filter. Remove the hard line from the machine. Cap the fitting on the filter head. 3 Tag and disconnect the hydraulic tank hard line from the pump. Remove the hard line from the machine. Cap the fitting on the pump. 4 Remove the hydraulic tank retaining fasteners and remove the hydraulic tank from the machine. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 5 Remove the hydraulic tank cap and drain the tank into a suitable container. Torque specifications Hydraulic retaining fasteners, dry Hydraulic tank retaining fasteners, lubricated 35 in-lbs 4 Nm 26 in-lbs 2,9 Nm Part No. 1272217GT GSTM-30 · 32 · 46 · 47 51 Service and Repair Manual Hydraulic Pump March 2021 4-1 Function Pump The hydraulic pump is attached to the motor which makes up the hydraulic power unit. How to Test the Hydraulic Pump Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications. Component damage hazard. The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system. 1 Tag, disconnect and plug the high pressure hydraulic hose from the hydraulic pump. 2 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to the high pressure port on the pump. 3 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both ground and platform controls. 4 Activate the platform up function from the ground controls. Result: If the pressure gauge reads 3200 psi / 221 bar, immediately stop. The pump is good. Result: If the pressure gauge fails to reach 3200 psi / 221 bar, the pump is bad and will need to be serviced or replaced. Component damage hazard. There is no relief valve in the hydraulic pump and the pump can be damaged if the pressure is allowed to exceed 3200 psi / 221 bar. When testing the pump, activate the pump in one second intervals until 3200 psi / 221 bar is confirmed. Do not over-pressurize the pump. 5 Remove the pressure gauge and reconnect the hydraulic hose. Torque to specifications. 52 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Hydraulic Pump How to Remove the Hydraulic Pump How to Remove the Hydraulic Pump Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications. 1 Disconnect the battery pack from the machine. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 2 Tag and disconnect the hydraulic power unit cables at the motor controller. 3 Disconnect the filter head from the filter head mounting bracket. Rotate the filter out and away from the hydraulic power unit. 4 Remove the hydraulic power unit retaining fasteners. 5 Tag, disconnect and plug the hydraulic tank hard line from the pump. Cap the fitting on the pump. 6 Tag, disconnect and plug the high pressure hose from the pump. Cap the fitting on the pump. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 7 Remove the hydraulic power unit from the machine. 8 Remove the pump mounting bolts. Carefully remove the pump. Tip-over hazard. After replacing the hydraulic pump, it is critical to return the function speed settings to original factory specifications. Failure to restore the machine to original factory specifications could cause the machine to tip over resulting in death or serious injury. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 53 Service and Repair Manual Manifolds March 2021 5-1 Function Manifold Components GS-1530, GS-1532, GS-1930 and GS-1932 The function manifold is mounted under the machine, between the module trays. Index No. Description -- Coil nut (item F) -- Coil nut (items E and H) 1 Diagnostic port 2 Check disc 3 Relief valve, 1800 to 3700 psi / 124 to 255 bar 4 Check valve, 10 psi / 0.7 bar 5 Solenoid valve, 3 position 4 way 6 Solenoid valve, 3 position 4 way 7 Flow regulator and relief valve, 0.75 gpm / 2.8 L/min 1500 psi / 130 bar 8 Solenoid valve, 2 position 4 way 9 Relief valve, 3700 psi / 255 bar maximum Schematic Item -- -- A B C D E F G H I Function -- -- Test port Steer circuit Lift relief Drive circuit Drive forward/reverse Steer left/right Steer circuit Platform up System relief Torque 4-5 ft-lbs / 5-7 Nm 5-7 ft-lbs / 7-9 Nm -- 18 ft-lbs / 24 Nm 20 ft-lbs / 27 Nm 20 ft-lbs / 27 Nm 25 ft-lbs / 34 Nm 25 ft-lbs / 34 Nm 26 ft-lbs / 35 Nm 25 ft-lbs / 34 Nm 20 ft-lbs / 27 Nm How to Install a Valve Cartridge 1 Dip the cartridge in clean oil to lube the O-rings. 2 Screw the cartridge in by hand until the top O-ring is met, then torque to specifications. 3 If required, install the valve coil(s) onto the valve stem. Install the coil nut onto the valve stem and torque to specifications. 54 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Manifolds Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic. Note: 'alpha-numeric' callouts refer to corresponding notes on the electrical schematic. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 55 Service and Repair Manual Manifolds March 2021 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. Index No. Description -- Coil nut (item AC) -- Coil nut (items AE, AG and AI) 1 Diagnostic port 2 Relief valve, 3700 psi / 255 bar maximum 3 Solenoid valve, 3 position 4 way 4 Check valve, (GS-3232 and GS-3246 with load sense installed) 5 Check disc 6 Solenoid valve, 2 position 4 way 7 Relief valve, 50 psi / 3.4 bar 8 Solenoid valve, 3 position 5 way 9 Flow regulator and relief valve, 0.75 gpm / 2.8 L/min, 1500 psi / 103 bar 10 Solenoid valve, 2 position 4 way 11 Relief valve, 1800 to 3700 psi / 124 to 255 bar Schematic Item -- -- AA AB AC Function -- -- Test port System relief Steer left/right Torque 4-5 ft-lbs / 5-7 Nm 5-7 ft-lbs / 7-9 Nm -- 20 ft-lbs / 27 Nm 25 ft-lbs / 34 Nm AK Lift circuit 23 ft-lbs / 31 Nm AD Steer circuit 18 ft-lbs / 24 Nm AE Drive speed select 25 ft-lbs / 34 Nm circuit AF Brake release 20 ft-lbs / 27 Nm AG Drive forward/reverse 25 ft-lbs / 34 Nm AH Steer circuit 26 ft-lbs / 35 Nm AI Platform up 25 ft-lbs / 34 Nm AJ Lift relief 20 ft-lbs / 27 Nm How to Install a Valve Cartridge 1 Dip the cartridge in clean oil to lube the O-rings. 2 Screw the cartridge in by hand until the top O-ring is met, then torque to specifications. 3 If required, install the valve coil(s) onto the valve stem. Install the coil nut onto the valve stem and torque to specifications. 56 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Manifolds Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic. Note: 'alpha-numeric' callouts refer to corresponding notes on the electrical schematic. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 57 Service and Repair Manual Manifolds March 2021 5-3 Function Manifold Components GS-4047 The function manifold is mounted behind an inspection door, at the ground control side of the machine. Index No. Description -- Coil nut (item DC) -- Coil nut (items DE, DG and DI) 1 Diagnostic port 2 Relief valve, 3500 psi / 241 bar maximum 3 Solenoid valve, 3 position 4 way 4 Check disc 5 Solenoid valve, 2 position 4 way 6 Relief valve, 50 psi / 3.4 bar 7 Solenoid valve, 3 position 5 way 8 Flow regulator and relief valve, 0.75 gpm / 2.8 L/min, 1500 psi / 103 bar 9 Solenoid valve, 2 position 4 way 10 Relief valve, 3000 psi / 207 bar Schematic Item -- -- DA DB DC DD DE DF DG DH Function -- -- Test port System relief Steer left/right Steer circuit Drive speed select circuit Brake release Drive forward/reverse Steer circuit Torque 4-5 ft-lbs / 5-7 Nm 5-7 ft-lbs / 7-9 Nm -- 20 ft-lbs / 27 Nm 25 ft-lbs / 34 Nm 18 ft-lbs / 24 Nm 25 ft-lbs / 34 Nm 20 ft-lbs / 27 Nm 25 ft-lbs / 34 Nm 26 ft-lbs / 35 Nm DI Platform up 25 ft-lbs / 34 Nm DJ Lift relief 20 ft-lbs / 27 Nm How to Install a Valve Cartridge 1 Dip the cartridge in clean oil to lube the O-rings. 2 Screw the cartridge in by hand until the top O-ring is met, then torque to specifications. 3 If required, install the valve coil(s) onto the valve stem. Install the coil nut onto the valve stem and torque to specifications. 58 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Manifolds Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic. Note: 'alpha-numeric' callouts refer to corresponding notes on the electrical schematic. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 59 Service and Repair Manual Manifolds 5-4 Check Valve Manifold Components GS-1530, GS-1532, GS-1930 and GS-1932 The check valve manifold is mounted on the function manifold. Index No. Description 1 Check valve, 200 psi / 13.8 bar Schematic Item S Function Drive circuit March 2021 Torque 20 ft-lbs / 27 Nm Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic. How to Install a Valve Cartridge 1 Dip the cartridge in clean oil to lube the O-rings. 2 Screw the cartridge in by hand until the top O-ring is met, then torque to specifications. 3 If required, install the valve coil(s) onto the valve stem. Install the coil nut onto the valve stem and torque to specifications. 60 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Manifolds 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. Index No. Description -- Coil nut (item DN) -- Plug 1 Lift pressure selector valve, 200 psi / 138 bar 2 Solenoid valve, 2 position 2 way Schematic Item -- -- DM DN Function -- -- Lift relief Lift circuit Torque 4-5 ft-lbs / 5-7 Nm 13 ft-lbs / 18 Nm 20 ft-lbs / 27 Nm 20 ft-lbs / 27 Nm Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic. Note: 'alpha-numeric' callouts refer to corresponding notes on the electrical schematic. How to Install a Valve Cartridge 1 Dip the cartridge in clean oil to lube the O-rings. 2 Screw the cartridge in by hand until the top O-ring is met, then torque to specifications. 3 If required, install the valve coil(s) onto the valve stem. Install the coil nut onto the valve stem and torque to specifications. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 61 Service and Repair Manual Manifolds March 2021 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. Index No. Description -- Coil nut (item BA) 1 Solenoid valve, 3 position 4 way 2 Relief valve, 3500 psi / 241 bar maximum Schematic Item -- BA BB Function -- Outriggers extend / retract Outrigger circuit Torque 4-5 ft-lbs / 5-7 Nm 25 ft-lbs / 34 Nm 20 ft-lbs / 27 Nm Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic. Note: 'alpha-numeric' callouts refer to corresponding notes on the electrical schematic. How to Install a Valve Cartridge 1 Dip the cartridge in clean oil to lube the O-rings. 2 Screw the cartridge in by hand until the top O-ring is met, then torque to specifications. 3 If required, install the valve coil(s) onto the valve stem. Install the coil nut onto the valve stem and torque to specifications. 62 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Manifolds 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. Index No. Description -- Coil nut (item CA, CB. CC, CD) 1 Solenoid valve, 2 position 2 way 2 Orifice Plug, 0.037 inch / 0.94 mm 3 Check Valve, pilot operated 4 Pressure transducer Schematic Item -- CA, CB, CC, CD CE CF CG Function -- Outriggers extend / retract Outrigger retract Retract flow control Outrigger auto level Torque 4-5 ft-lbs / 5-7 Nm 25 ft-lbs / 34 Nm -- 20 ft-lbs / 27.1 Nm 16 ft-lbs / 21.7 Nm Front Outriggers Rear Outriggers Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic. Note: 'alpha-numeric' callouts refer to corresponding notes on the electrical schematic. How to Install a Valve Cartridge 1 Dip the cartridge in clean oil to lube the O-rings. 2 Screw the cartridge in by hand until the top O-ring is met, then torque to specifications. 3 If required, install the valve coil(s) onto the valve stem. Install the coil nut onto the valve stem and torque to specifications. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 63 Service and Repair Manual Manifolds March 2021 5-8 Valve Adjustments - Function Manifold Note: Perform this test from the ground with the platform controls. Do not stand in the platform. Note: Verify the hydraulic oil level is at the FULL mark on the hydraulic tank. 5 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. How to Adjust the System Relief Valve 1 Locate the system relief valve on the function manifold (schematic item I, AB or DB). 2 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to the test port on the function manifold. (schematic item A, AA or DA). 3 Chock both sides of the wheels at the steer end of the machine. 4 Remove the platform controls from the platform. GS-1530/32 and GS-1930/32 1 test port 2 system relief valve 6 Move and hold the joystick fully in either direction while observing the pressure reading on the pressure gauge. Note the pressure. Refer to Specifications, Hydraulic Component Specifications. 7 Turn the machine off. Hold the system relief valve with a wrench and remove the cap. I, AB or DB). 64 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Manifolds 8 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Tip-over hazard. Failure to adjust the relief valves to specification could result in the machine tipping over, causing death or serious injury. Do not adjust the relief valve pressures higher than specifications. 9 Install the relief valve cap. 10 Repeat steps 5 and 6 to confirm the relief valve pressure. How to Adjust the Platform Lift Relief Valve Note: Perform this test from the ground with the platform controls. Do not stand in the platform. Note: Verify the hydraulic oil level is at the FULL mark on the hydraulic tank. 1 Locate the system relief valve on the function manifold (schematic item I, AB or DB). 2 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to the test port on the function manifold. (schematic item A, AA or DA). 3 Chock both sides of the wheels at the steer end of the machine. 4 Remove the platform controls from the platform. 5 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. GS-32, GS-46 and GS-47 1 test port 2 system relief valve 3 steer relief valve 4 lift relief valve GS-1530/32 and GS-1930/32 1 test port 2 system relief valve 3 lift relief valve Part No. 1272217GT GSTM-30 · 32 · 46 · 47 65 Service and Repair Manual Manifolds March 2021 6 Move and hold the joystick fully in either direction while observing the pressure reading on the pressure gauge. Note the pressure. Refer to Specifications, Hydraulic Component Specifications. 7 Turn the machine off. Hold the system relief valve with a wrench and remove the cap. I, AB or DB). 8 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Tip-over hazard. Failure to adjust the relief valves to specification could result in the machine tipping over, causing death or serious injury. Do not adjust the relief valve pressures higher than specifications. 9 Install the relief valve cap. 10 Repeat steps 5 and 6 to confirm the relief valve pressure. 11 Place maximum rated load into the platform. Secure the load to the platform. Refer to Specifications, Machine Specifications. 12 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. 13 Hold the lift relief valve with a wrench and remove the cap (schematic item C, AJ or DJ). 14 While activating the platform up function, adjust the internal hex socket clockwise, just until the platform fully rises. 15 Fully lower the platform to the stowed position. 16 Add an additional 50 pounds / 22,7 kg to the platform. Secure the additional weight. 17 Attempt to raise the platform. Result: The power unit should not be able to lift platform. Result: If the power unit lifts the platform, adjust the internal hex nut socket counterclockwise until the platform will not rise. 18 Install the relief valve cap. 19 Remove the weight from the platform. 20 Bleed the hydraulic system by raising the platform to full height. If the pump cavitates or the platform fails to reach full height, add hydraulic oil until the pump is functioning correctly. Do not overfill the hydraulic tank. GS-32, GS-46 and GS-47 1 test port 2 system relief valve 3 steer relief valve 4 lift relief valve 66 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Manifolds How to Adjust the Lift Pressure Selector Valve (GS-4047 only) Note: The System Relief Valve and Platform Lift Relief Valve must be adjusted before making an adjustment to the Lift Pressure Selector Valve. Refer to Repair Procedures, How to Adjust the System Relief Valve and How to Adjust the Platform Lift Relief Valve. Note: Perform this test from the ground with the platform controls. Do not stand in the platform. Note: Verify the hydraulic oil level is at the FULL mark on the hydraulic tank. 1 Locate the pressure selector relief valve on the pressure selector manifold (schematic item DM). 2 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to the test port on the function manifold. (schematic item DA). 3 Using a suitable lifting device, place and secure the maximum rated load in the center of the platform deck. Maximum load, GS-4047 GS-4047 (CE and AS models) 770 lbs 350 kg GS-4047 (ANSI and CSA models) 550 lbs 250 kg 4 Remove the platform controls from the platform. 5 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. 6 Press and hold the lift function enable button and the press the platform up button to raise the platform 4 ft / 1.2 m above the stowed position. Result: The platform does not rise. Perform steps 7 through 10 to increase the pressure in small increments until the platform rises. Then proceed to step 12. Result: The platform rises. Perform steps 7 through 10 to decrease the pressure in small increments until the platform does not rise. Then follow steps 7 through 10 again to increase the pressure in small increments until the platform is able to rise. 7 Turn the machine off. Hold the lift pressure selector valve with a wrench and remove the cap (schematic item DM). GS-32, GS-46 and GS-47 1 test port 2 system relief valve 3 steer relief valve 4 lift relief valve GS-4047 1 lift pressure selector valve 2 solenoid valve Part No. 1272217GT GSTM-30 · 32 · 46 · 47 67 Service and Repair Manual Manifolds March 2021 8 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Tip-over hazard. Failure to adjust the relief valves to specification could result in the machine tipping over, causing death or serious injury. Do not adjust the relief valve pressures higher than specifications. 9 Install the relief valve cap. 10 Fully lower the platform to the stowed position. 11 Using a suitable lifting device, add and secure an additional 150 lbs / 68 kg to the platform deck. 12 Raise the platform. Result: The platform does not rise. Proceed to 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. How to Adjust the Steer Relief Valve Note: Perform this test from the ground with the platform controls. Do not stand in the platform. Note: Verify the hydraulic oil level is at the FULL mark on the hydraulic tank. 1 Locate the steer relief valve on the function manifold (schematic item G, AH or DH). 2 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to the test port on the function manifold. (schematic item A, AA or DA). 3 Remove the platform controls from the platform. 4 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. GS-1530/32 and GS-1930/32 1 test port 2 steer relief valve 68 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Manifolds 5 Activate the function enable switch and press and hold the steer thumb rocker switch to the right. Allow the wheels to completely turn to the right. Continue holding the switch while observing the pressure reading on the pressure gauge. Note the pressure. Refer to 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. G, AH or DH). 8 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Component damage hazard. Do not adjust the relief valve pressures higher than specifications. 9 Install the relief valve cap. 10 Repeat steps 5 and 6 to confirm the relief valve pressure. GS-32, GS-46 and GS-47 1 test port 2 system relief valve 3 steer relief valve 4 lift relief valve Part No. 1272217GT GSTM-30 · 32 · 46 · 47 69 Service and Repair Manual Manifolds March 2021 5-9 Valve Coils How to Test a Coil A properly functioning coil provides an electromagnetic force which operates the solenoid valve. Critical to normal operation is continuity within the coil. Zero resistance or infinite resistance indicates the coil has failed. Since coil resistance is sensitive to temperature, resistance values outside specification can produce erratic operation. When coil resistance decreases below specification, amperage increases. As resistance rises above specification, voltage increases. While valves may operate when coil resistance is outside specification, maintaining coils within specification will help ensure proper valve function over a wide range of operating temperatures. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Note: If the machine has been in operation, allow the coil to cool at least 3 hours before performing this test. 1 Tag and disconnect the wiring from the coil to be tested. 2 Test the coil resistance using a multimeter set to resistance (W). Refer to the Valve Coil Resistance Specification table. Result: If the resistance is not within the adjusted specification, plus or minus 10%, replace the coil. Valve Coil Resistance Specification Note: The following coil resistance specifications are at an ambient temperature of 68°F / 20°C. As valve coil resistance is sensitive to changes in air temperature, the coil resistance will typically increase or decrease by 4% for each 18°F / 10°C that your air temperature increases or decreases from 68°F / 20°C. Description Specification Solenoid valve, 3 position 4 way, 20V DC with diode (schematic item F, AC or DC) 27.2 Solenoid valve, 3 position 4 way, 20V DC with diode (schematic item E) Solenoid valve, 2 position 4 way, 20V DC with diode (schematic item H, AI or DI) Solenoid valve, 2 position 2 way, N.C. 20V DC with diode (schematic item N) Solenoid valve, 2 position 4 way, 20V DC with diode (schematic item AE or DE) Solenoid valve, 3 position 5 way, 20V DC with diode (schematic item AG or DG) Solenoid valve, 2 position 2 way, 20V DC with diode (schematic item CA, CB, CC and CD Solenoid valve, 3 position 4 way, 20V DC with diode (schematic item BA) Proportional solenoid valve, 2 position 2 way, 20V DC with diode (schematic item DN) 19 19 25 19 19 27.2 19 23.9 70 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Manifolds How to Test a Coil Diode Genie incorporates spike suppressing diodes in all of its coils. Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes. Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil. Faulty diodes can fail to protect the electrical system, resulting in a tripped circuit breaker or component damage. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 1 Test the coil resistance. Refer to Repair Procedure, How to Test a Coil. 2 Connect a 10 resistor to the negative terminal of a known good 9V DC battery. Connect the other end of the resistor to a terminal on the coil. Note: The battery should read 9V DC or more when measured across the terminals. Resistor, 10 Genie part number 27287 3 Set a multimeter to read DC amperage. Note: The multimeter, when set to read DC amperage, should be capable of reading up to 800 mA. 4 Connect the negative lead to the other terminal on the coil. Note: If testing a single terminal coil, connect the negative lead to the internal metallic ring at either end of the coil. 1 multimeter 2 9V DC battery 3 10 resistor 4 coil Note: Dotted lines in illustration indicate a reversed connection as specified in step 6. 5 Momentarily connect the positive lead from the multimeter to the positive terminal on the 9V battery. Note and record the reading. 6 At the battery or coil terminals, reverse the connections. Note and record the current reading. Result: Both current readings are greater than 0 mA and are different by a minimum of 20%. The coil is good. Result: if one or both current readings are greater than 0 mA, or if the two current readings do not differ by a minimum of 20%, the coil and/or its internal diode are faulty and the coil should be replaced. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 71 Service and Repair Manual Steer Axle Components March 2021 6-1 Yoke and Drive Motor How to Remove the Yoke and Drive Motor Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications. 1 Block the non-steer tires. 2 Remove the cotter pin from the wheel castle nut. Note: Always replace the cotter pin with a new one when removing the castle nut. 3 Loosen the wheel castle nut. Do not remove it. 4 Center a lifting jack under the drive chassis at the steer end of the machine. 5 Raise the machine approximately 6 inches / 15 cm. Place blocks under the chassis for support. Crushing hazard. The chassis will fall if not properly supported. 6 Remove the wheel castle nut. Remove the wheel. 7 Tag, disconnect and plug the hydraulic hoses on the drive motor. Cap the fittings on the drive motor. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Component damage hazard. Hoses can be damaged if they are kinked or pinched. 8 Support and secure the yoke assembly to an appropriate lifting device. 9 Remove the retaining fastener from the steer link at the yoke assembly. Note: While removing the retaining fasteners, take note of the quantity and location of the spacers when disconnecting the steer link from the yoke assembly. 10 Remove the retaining fastener from the top of the yoke pivot shaft. Note: The pivot shaft retaining fastener is located above the main deck. 11 Lower the yoke assembly out of the chassis. Bodily injury hazard. The yoke/motor assembly may fall if not properly supported when it is removed from the chassis. 72 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Steer Axle Components How to Remove a Drive Motor 1 Block the non-steer tires. 2 Remove the cotter pin from the wheel castle nut of the motor to be removed. 3 Note: Always replace the cotter pin with a new one when removing the castle nut. 4 Loosen the wheel castle nut. Do not remove it. 5 Raise the machine approximately 2 inches / 5 cm. Place blocks under the chassis for support. Crushing hazard. The chassis will fall if not properly supported. 6 Remove the wheel castle nut. Remove the wheel. 7 Tag, disconnect and plug the hydraulic hoses on the drive motor. Cap the fittings on the drive motor. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Component damage hazard. Hoses can be damaged if they are kinked or pinched. 8 Remove the drive motor mounting fasteners. Remove the motor. Torque specifications Drive motor mounting fasteners, dry Drive motor mounting fasteners, lubricated 75 ft-lbs 101.7 Nm 56 ft-lbs 76.3 Nm 6-2 Steer Cylinder How to Remove the Steer Cylinder Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications. 1 Block the non-steer tires. 2 Remove the pin retaining fasteners from the rod-end pivot pin. Remove the pivot pin. Note: While removing the pin retaining fasteners, take note of the quantity and location of the spacers when removing the pivot pin. 3 Remove the pin retaining fasteners from the barrel-end pivot pin. Remove the pin. Note: While removing the pin retaining fasteners, take note of the quantity and location of the spacers when removing the pivot pin. 4 Remove the steer cylinder from the machine. 5 Tag, disconnect and plug the hydraulic hoses from the steer cylinder. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Component damage hazard. Hoses can be damaged if they are kinked or pinched. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 73 Service and Repair Manual Steer Axle Components March 2021 6-3 Steer Bellcrank 6 Remove the bellcrank from the machine. How to Remove the Steer Bellcrank 1 Remove the steer cylinder. Refer to Repair Procedure, How to Remove the Steer Cylinder. 2 Remove the retaining fasteners from the steer links at each end of the bellcrank. Note: While removing the retaining fasteners, take note of the quantity and location of the spacers between the bellcrank and the steer links. 3 Center a lifting jack under the drive chassis at the steer end of the machine. 4 Raise the machine approximately 14 inches / 36 cm. Place blocks under the chassis for support. Crushing hazard. The chassis will fall if not properly supported. 5 Turn the yokes to the side so the bellcrank can be removed. 1 apply removable thread lock to fastener threads Note: While removing the bellcrank from the machine, take note of the quantity and location of the spacers between the bellcrank and the steer links. Note: Before re-installing the steer bellcrank onto the machine, apply a small amount of removable thread lock onto the threads of the fasteners. Torque the fasteners to 31 ft-lbs / 42 Nm. 74 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Non-Steer Axle Components 7-1 Drive Brake How to Remove the Drive Brake Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications. 1 Support and secure the entry ladder to an appropriate lifting device. 2 Remove the entry ladder mounting fasteners. Remove the entry ladder from the machine. Crushing hazard. The entry ladder will fall if not properly supported and secured to the lifting device. 3 Block the steer wheels. 4 Remove the cotter pin from the wheel castle nut. Note: Always replace the cotter pin with a new one when removing the castle nut. 5 Loosen the wheel castle nut. Do not remove it. 6 Center a lifting jack under the drive chassis at the non-steer end of the machine. 7 Raise the machine approximately 2 inches / 5 cm. Place blocks under the chassis for support. Crushing hazard. The chassis will fall if not properly supported. 8 Remove the wheel castle nut. Remove the wheel. 9 Tag, disconnect and plug the hydraulic hose from the brake. Cap the fitting on the brake. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 10 Place a lifting jack under the brake for support. 11 Remove the fasteners that attach the brake to the drive chassis. Remove the brake. Crushing hazard. The brake will fall if not properly supported when the mounting fasteners are removed. Torque specifications Brake mounting fasteners, dry Brake mounting fasteners, lubricated 75 ft-lbs 102 Nm 56 ft-lbs 76 Nm Part No. 1272217GT GSTM-30 · 32 · 46 · 47 75 Service and Repair Manual Brake Release Hand Pump Components 8-1 Brake Release Hand Pump Components The brake release hand pump manifold is mounted behind the entry ladder. Index No. Description 1 Hand pump 2 Needle valve Schematic Item L M Function Manual brake release Manual brake release enable March 2021 Torque 30 ft-lbs / 41 Nm 45-50 in-lbs / 5 Nm Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic. 76 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Scissor Components Steer End 1 - Number 4 pivot pin 2 - Number 3 center pivot pin (Qty. 2) 3 - Lift cylinder rod-end pivot pin 4 - Number 3 pivot pin (steer end) 5 - Number 2 center pivot pin (Qty. 2) 6 - Number 2 pivot pin (steer end) 7 - Number 1 center pivot pin (Qty. 2) 8 - Number 1 inner arm 9 - Number 1 pivot pin Non-steer End 10 - Number 3 inner arm 11 - Number 3 outer arm 12 - Number 3 pivot pin (non-steer end) 13 - Number 2 inner arm 14 - Number 2 outer arm 15 - Number 2 pivot pin (non-steer end) 16 - Lift cylinder barrel-end pivot pin 17 - Number 1 outer arm Part No. 1272217GT GSTM-30 · 32 · 46 · 47 77 Service and Repair Manual Scissor Components March 2021 9-1 Scissor Assembly, GS-1530 and GS-1532 How to Disassemble the Scissor Assembly Bodily injury hazard. The 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. Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications. Note: Machines equipped with a Platform Height Sensor, begin the Scissor Disassembly procedure at step 1. Machines without a Platform Height Sensor, begin the Scissor Disassembly procedure at step 24. 1 Turn the key switch to ground controls and pull out the red Emergency Stop button to the on position at both ground and platform controls. 2 Raise the platform 7 to 8 feet / 2,1 to 2,4 m. 3 Lift the safety arm, move it to the center of the scissor arm and rotate down to a vertical position. 4 Lower the platform onto the safety arm. Crushing hazard. Keep hands clear of the safety arm when lowering the platform. 5 At the ground controls, turn the key switch to the off position and push in the red Emergency Stop button to the off position. 6 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. 7 Remove the fasteners securing the large platform height sensor cover to the large platform height sensor bracket. 8 Remove the platform height sensor cover. 9 Tag and disconnect the platform height sensor from the platform height sensor harness. 10 Remove the fastener securing the platform height sensor assembly to the number 1 inner arm. 11 Remove the platform height sensor assembly from the number 1 pivot pin. 12 Remove the plastic nut securing the squeeze connector to the large platform height sensor bracket. 13 Remove the squeeze connector from the large 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. 78 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Scissor Components 16 Install the fasteners removed in 14 to the number 1 inner arm pivot bracket and chassis. 17 Connect the battery pack to the machine. 18 Turn the key switch to ground controls. 19 Press and hold the ground control scroll up and scroll down buttons. 20 Pull out the red Emergency Stop button to the on position at the ground controls. 21 Using the ground control menu buttons, navigate to Service Override Mode. Select Service Override Mode. Note: The machine must be in Service Override Mode to raise the platform. While in Service Override Mode, only the GCON will operate with limited functionality. The platform will raise a predetermined amount of time and stop. 22 Raise the platform and rotate the safety arm to the stowed position. 23 Fully lower the platform to the stowed position. Cable bridge and platform height sensor 1 cable bridge 3 2 cable bridge 2 3 cable bridge 1 4 platform height sensor 24 Remove the platform. Refer to Repair Procedure, How to Remove the Platform. 25 Remove the cables from the number 3 outer arm (index #11) at the ground controls side. Component damage hazard. Cables can be damaged if they are kinked or pinched. 26 Remove the cables from the number 3 cable bridge and lay them off to the side. Component damage hazard. Cables can be damaged if they are kinked or pinched. 27 Attach a lifting strap from an overhead crane to the number 3 outer arm (index #11). 28 Remove the external snap rings and retaining fasteners from the number 3 center pivot pins (index #2). 29 Use a soft metal drift to remove the number 3 center pivot pins (index #2). 30 Remove the retaining fasteners from the number 3 pivot pin (index #12) at the nonsteer 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. 32 Remove the number 3 cable bridge mounting fasteners and remove the cable bridge from the machine. 33 Attach a lifting strap from an overhead crane to the lug on the rod end of the lift cylinder for support. Do not apply any lifting pressure. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 79 Service and Repair Manual Scissor Components March 2021 34 Remove the pin retaining fasteners from the lift cylinder rod-end pivot pin (index #3). Use a soft metal drift to remove the pin. Bodily injury hazard. The cylinder may fall when the rodend pivot pin is removed if not properly supported. 35 Lower the cylinder onto the number 1 inner arm (index #8). Component damage hazard. Cables can be damaged if they are kinked or pinched. 36 Attach a lifting strap from an overhead crane to the number 3 inner arm (index #10). 37 Remove the retaining fasteners from the number 3 pivot pin (index #4) at the steer end. 38 Use a soft metal drift to remove the number 3 pivot pin (index #4). Remove the number 3 inner arm (index #10) from the machine. Bodily injury hazard. The number 3 inner arm may become unbalanced and fall if not properly supported when removed from the machine. 39 Remove the cables from the number 2 cable bridge and lay them off to the side. Component damage hazard. Cables can be damaged if they are kinked or pinched. 40 Remove the external snap rings and retaining fasteners from the number 2 center pivot pin (index #5) at the ground controls side. 41 Remove the number 2 cable bridge mounting fasteners and remove the cable bridge from the machine. 42 Attach a lifting strap from an overhead crane to the number 2 outer arm (index #14) at the ground controls side. 43 Use a soft metal drift to remove the number 2 center pivot pin (index #5) at the ground controls side. 44 Remove the retaining fasteners from the number 2 pivot pin (index #15) at the nonsteer end of the machine. 45 Use a soft metal drift to tap the number 2 pivot pin (index #15) halfway out at the nonsteer end of the machine. Remove the number 2 outer arm (index #14) from the ground controls side of the machine. Bodily injury hazard. The number 2 outer arm at the ground controls side may become unbalanced and fall if not properly supported when removed from the machine. 46 Attach a lifting strap from an overhead crane to the number 2 outer arm (index #14) at the battery pack side. 47 Remove the external snap rings and retaining fasteners from the number 2 center pivot pin (index #5) at the battery pack side. 48 Use a soft metal drift to remove the number 2 center pivot pin (index #5) 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. 80 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Scissor Components 49 Use a soft metal drift to tap the number 2 pivot pin (index #15) in the other direction at the non-steer end. Remove the number 2 outer arm (index #14) from the battery pack side of the machine. Bodily injury hazard. The number 2 outer arm at the battery pack side may become unbalanced and fall if not properly supported when removed from the machine. 50 Attach a lifting strap from an overhead crane to the number 2 inner arm (index #13). 51 Remove the retaining fasteners from the number 2 pivot pin (index #6) at the steer end of the machine. 52 Use a soft metal drift to remove the number 2 pivot pin (index #6). Remove the number 2 inner arm (index #13) from the machine. Bodily injury hazard. The number 2 inner arm may become unbalanced and fall if not properly supported when removed from the machine. 53 Remove the safety arm from the number 2 inner arm (index #13) that was just removed. 54 Attach a lifting strap from an overhead crane to the number 1 inner arm (index #8). 55 Raise the number 1 inner arm (index #8) approximately 2 feet / 60 cm and install the safety arm between the number 1 inner arm (index #8) and the number 1 outer arm (index #17). Lower the scissor arms onto the safety arm. Bodily injury hazard. Keep hands clear of moving parts when lowering the scissor arms onto the safety arm. 56 Attach a lifting strap from an overhead crane to the lug on the rod end of the lift cylinder (index #3). Raise the lift cylinder approximately 3 ft / 1 m. 57 Tag, disconnect and plug the hydraulic hoses on the lift cylinder. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 58 Tag and disconnect the wires and manual lowering cable from the solenoid valve on the cylinder. 59 Models with platform overload option: Tag and disconnect the wire harness from the platform overload pressure transducer. Note: After replacing the scissor assembly, the platform overload system must be calibrated. Refer to Repair Procedure, How to Calibrate the Platform Overload System (if equipped). 60 Raise the lift cylinder to a vertical position. 61 Remove the pin retaining fasteners from the lift cylinder barrel-end pin (index #16). Use a soft metal drift to remove the pin. Remove the lift cylinder from the machine. Crushing hazard. The lift cylinder will become unbalanced and fall if not properly supported and secured to the lifting device. Component damage hazard. Be careful not to damage the valve or fittings on the cylinder while removing it from the machine. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 81 Service and Repair Manual Scissor Components March 2021 62 Place a 4 x 4 x 48 inch / 10 cm x 10 cm x 1.2 m long block across both sides of the chassis under the number 1 center pivot pin (index #7). 63 Attach a lifting strap from an overhead crane to the number 1 inner arm (index #8) at the non-steer end. Raise the number 1 inner arm and remove the safety arm. Lower the number 1 inner arm (index #8) onto the block that was placed across the chassis. Bodily injury hazard. Keep hands clear of moving parts when lowering the scissor arms. 64 Remove the cables from the number 1 cable bridge and lay them off to the side. Component damage hazard. Cables can be damaged if they are kinked or pinched. 65 Support and secure the entry ladder to an appropriate lifting device. 66 Remove the fasteners from the entry ladder and remove the entry ladder from the machine. Crushing hazard. The entry ladder will fall if not properly supported and secured to the lifting device. 67 Attach a lifting strap from an overhead crane to the number 1 outer arm (index #17). Do not apply any lifting pressure. 68 Remove the external snap rings and retaining fasteners from the number 1 center pivot pins (index #7). 69 Remove the number 1 cable bridge from the machine. 70 Use a soft metal drift to remove the number 1 center pivot pins (index #7). Bodily injury hazard. The number 1 outer arm may become unbalanced and fall if not properly supported when the pin is removed. 71 Slide the number 1 outer arm (index #17) to the non-steer end and remove it from the machine. Bodily injury hazard. The number 1 outer arm may become unbalanced and fall if not properly supported when removed from the machine. 72 Attach the strap from an overhead crane to the number 1 inner arm (index #8). Do not lift it. 73 Remove the upper fasteners securing the number 1 inner arm pivot bracket to the end of the chassis. Loosen the lower fasteners. 74 Remove the number 1 inner arm (index #8) from the machine. Bodily injury hazard. The number 1 inner arm may become unbalanced and fall if not properly supported when removed from the machine. Component damage hazard. Be sure not to damage the limit switch or level sensor components when the number 1 inner arm is removed from the machine. 82 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Scissor Components Steer End 1 - Number 5 pivot pin 2 - Number 4 center pivot pin (Qty. 2) 3 - Number 4 pivot pin (steer end) 4 - Number 3 center pivot pin (Qty. 2) 5 - Lower lift cylinder rod-end pivot pin 6 - Number 3 pivot pin (steer end) 7 - Number 2 center pivot pin (Qty. 2) 8 - Number 2 pivot pin (steer end) 9 - Number 1 center pivot pin (Qty. 2) 10 - Number 1 inner arm 11 - Number 1 pivot pin Non-steer End 12 - Number 4 inner arm 13 - Number 4 outer arm 14 - Number 4 pivot pin (non-steer end) 15 - Number 3 inner arm 16 - Number 3 outer arm 17 - Number 3 pivot pin (non-steer end) 18 - Number 2 inner arm 19 - Number 2 outer arm 20 - Number 2 pivot pin (non-steer end) 21 - Lower lift cylinder barrel-end pivot pin 22 - Number 1 outer arm Part No. 1272217GT GSTM-30 · 32 · 46 · 47 83 Service and Repair Manual Scissor Components March 2021 9-2 Scissor Assembly, GS-1930 and GS-1932 How to Disassemble the Scissor Assembly Bodily injury hazard. The 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. Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications. Note: Machines equipped with a Platform Height Sensor, begin the Scissor Disassembly procedure at step 1. Machines without a Platform Height Sensor, begin the Scissor Disassembly procedure at step 24. 1 Turn the key switch to ground controls and pull out the red Emergency Stop button to the on position at both ground and platform controls. 2 Raise the platform 7 to 8 feet / 2,1 to 2,4 m. 3 Lift the safety arm, move it to the center of the scissor arm and rotate down to a vertical position. 4 Lower the platform onto the safety arm. Crushing hazard. Keep hands clear of the safety arm when lowering the platform. 5 At the ground controls, turn the key switch to the off position and push in the red Emergency Stop button to the off position. 6 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. 7 Remove the fasteners securing the large platform height sensor cover to the large platform height sensor bracket. 8 Remove the platform height sensor cover. 9 Tag and disconnect the platform height sensor from the platform height sensor harness. 10 Remove the fastener securing the platform height sensor assembly to the number 1 inner arm. 11 Remove the platform height sensor assembly from the number 1 pivot pin. 12 Remove the plastic nut securing the squeeze connector to the large platform height sensor bracket. 13 Remove the squeeze connector from the large platform height sensor bracket. 14 Remove the fasteners securing the large platform height sensor bracket to the number 1 inner arm pivot bracket. 84 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Scissor Components 15 Remove the large platform height sensor bracket from the number 1 inner arm pivot bracket. 16 Install the fasteners removed in 14 to the number 1 inner arm pivot bracket and chassis. Tip-over hazard. Failure to install the fasteners securing the number 1 inner arm pivot bracket to the chassis, could result in the machine tipping over, causing death or serious injury. 17 Connect the battery pack to the machine. 18 Turn the key switch to ground controls. 19 Press and hold the ground control scroll up and scroll down buttons. 20 Pull out the red Emergency Stop button to the on position at the ground controls. 21 Using the ground control menu buttons, navigate to Service Override Mode. Select Service Override Mode. Note: The machine must be in Service Override Mode to raise the platform. While in Service Override Mode, only the GCON will operate with limited functionality. The platform will raise a predetermined amount of time and stop. 22 Raise the platform and rotate the safety arm to the stowed position. 23 Fully lower the platform to the stowed position. Cable bridge and platform height sensor 1 cable bridge 4 2 cable bridge 3 3 cable bridge 2 4 cable bridge 1 5 platform height sensor 24 Remove the platform. Refer to Repair Procedure, How to Remove the Platform. 25 Remove the cables from the number 4 outer arm (index #13) at the ground controls side. Component damage hazard. Cables can be damaged if they are kinked or pinched. 26 Remove the cables from the number 4 cable bridge and lay them off to the side. Component damage hazard. Cables can be damaged if they are kinked or pinched. 27 Attach a lifting strap from an overhead crane to the number 4 outer arm (index #13). Part No. 1272217GT GSTM-30 · 32 · 46 · 47 85 Service and Repair Manual Scissor Components March 2021 28 Remove the external snap rings and retaining fasteners from the number 4 center pivot pins (index #2). 29 Use a soft metal drift to remove the number 4 center pivot pins (index #2). 30 Remove the retaining fasteners from the number 4 pivot pin (index #14) at the nonsteer end of the machine. 31 Use a soft metal drift to remove the number 4 pivot pin (index #14) from the non-steer end of the machine. Remove the number 4 outer arm (index #13) from the machine. Crushing hazard. The number 4 outer arm may become unbalanced and fall if not properly supported when removed from the machine. 32 Remove the number 4 cable bridge mounting fasteners and remove the cable bridge from the machine. 33 Attach a lifting strap from an overhead crane to the number 4 inner arm (index #12). 34 Remove the retaining fasteners from the number 4 pivot pin (index #3). 35 Use a soft metal drift to remove the number 4 pivot pin (index #3) at the steer end. Remove the number 4 inner arm (index #12) from the machine. Crushing hazard. The number 4 inner arm may become unbalanced and fall if not properly supported when removed from the machine. 36 Remove the cables from the number 3 cable bridge and lay them off to the side. Component damage hazard. Cables can be damaged if they are kinked or pinched. 37 Remove the number 3 cable bridge mounting fasteners and remove the cable bridge from the machine. 38 Attach a lifting strap from an overhead crane to the number 3 outer arm (index #4) at the ground controls side. 39 Remove the external snap rings and retaining fasteners from the number 3 center pivot pins (index #4). 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 nonsteer end of the machine. 86 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Scissor Components 42 Use a soft metal drift to tap the number 3 pivot pin (index #17) halfway out at the nonsteer end of the machine. Remove the number 3 outer arm (index #16) at the ground controls side from the machine. Bodily injury hazard. The number 3 outer arm at the ground controls side may become unbalanced and fall if not properly supported when removed from the machine. 43 Attach a lifting strap from an overhead crane to the number 3 outer arm (index #16) at the battery pack side. 44 Use a soft metal drift to remove the number 3 center pivot pin (index #4) at the battery pack side of the machine. 45 Use a soft metal drift to tap the number 3 pivot pin (index #17) in the other direction. Remove the number 3 outer arm (index #16) from the battery pack side of the machine. Bodily injury hazard. The number 3 outer arm at the battery pack side may become unbalanced and fall if not properly supported when removed from the machine. 46 Remove the number 3 pivot pin (index #17) from the non-steer end of the machine. 47 Attach a lifting strap from an overhead crane to the lug on the rod end of the lift cylinder for support. Do not apply any lifting pressure. 48 Remove the pin retaining fasteners from the lift cylinder rod-end pivot pin (index #5). Use a soft metal drift to remove the pin. Bodily injury hazard. The cylinder may fall when the rodend pivot pin is removed if not properly supported. 49 Lower the cylinder onto the number 1 inner arm (index #9). Component damage hazard. Cables can be damaged if they are kinked or pinched. 50 Attach a lifting strap from an overhead crane to the number 3 inner arm (index #15). 51 Remove the retaining fasteners from the number 3 pivot pin (index #6) at the steer end. 52 Use a soft metal drift to remove the number 3 pivot pin (index #6). Remove the number 3 inner arm (index #15) from the machine. Bodily injury hazard. The number 3 inner arm may become unbalanced and fall if not properly supported when removed from the machine. 53 Remove the cables from the number 2 cable bridge and lay them off to the side. Component damage hazard. Cables can be damaged if they are kinked or pinched. 54 Remove the external snap rings and retaining fasteners from the number 2 center pivot pin (index #7) at the ground controls side. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 87 Service and Repair Manual Scissor Components March 2021 55 Remove the number 2 cable bridge mounting fasteners and remove the cable bridge from the machine. 56 Attach a lifting strap from an overhead crane to the number 2 outer arm (index #19) at the ground controls side. 57 Use a soft metal drift to remove the number 2 center pivot pin (index #7) at the ground controls side. 58 Remove the retaining fasteners from the number 2 pivot pin (index #20) at the nonsteer end of the machine. 59 Use a soft metal drift to tap the number 2 pivot pin (index #20) halfway out at the nonsteer end of the machine. Remove the number 2 outer arm (index #19) from the ground controls side of the machine. Bodily injury hazard. The number 2 outer arm at the ground controls side may become unbalanced and fall if not properly supported when removed from the machine. 60 Attach a lifting strap from an overhead crane to the number 2 outer arm (index #19) at the battery pack side. 61 Remove the external snap rings and retaining fasteners from the number 2 center pivot pin (index #7) at the battery pack side. 62 Use a soft metal drift to remove the number 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. 63 Use a soft metal drift to tap the number 2 pivot pin (index #20) in the other direction at the non-steer end. Remove the number 2 outer arm (index #19) from the battery pack side of the machine. Bodily injury hazard. The number 2 outer arm at the battery pack side may become unbalanced and fall if not properly supported when removed from the machine. 64 Remove the number 3 pivot pin (index #17) from the non-steer end of the machine. 65 Attach a lifting strap from an overhead crane to the number 2 inner arm (index #18). 66 Remove the retaining fasteners from the number 2 pivot pin (index #8) at the steer end of the machine. 67 Use a soft metal drift to remove the number 2 pivot pin (index #8). Remove the number 2 inner arm (index #18) from the machine. Bodily injury hazard. The number 2 inner arm may become unbalanced and fall if not properly supported when removed from the machine. 68 Remove the safety arm from the number 2 inner arm (index #18) that was just removed. 69 Attach a lifting strap from an overhead crane to the number 1 inner arm (index #10). 88 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Scissor Components 70 Raise the number 1 inner arm (index #10) approximately 2 feet / 60 cm and install the safety arm between the number 1 inner arm (index #10) and the number 1 outer arm (index #22) at the non-steer end of the machine. Lower the scissor arms onto the safety arm. Bodily injury hazard. Keep hands clear of moving parts when lowering the scissor arms onto the safety arm. 71 Attach a lifting strap from an overhead crane to the lug on the rod end of the lift cylinder (index #5). Raise the lift cylinder approximately 3 ft / 1 m. 72 Tag, disconnect and plug the hydraulic hoses on the lift cylinder. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 73 Tag and disconnect the wires and manual lowering cable from the solenoid valve on the cylinder. 74 Models with platform overload option: Tag and disconnect the wire harness from the platform overload pressure transducer. Note: After replacing the scissor assembly, the platform overload system must be calibrated. Refer to Repair Procedure, How to Calibrate the Platform Overload System (if equipped). 75 Raise the lift cylinder to a vertical position. 76 Remove the pin retaining fasteners from the lift cylinder barrel-end pin (index #21). Use a soft metal drift to remove the pin. Remove the lift cylinder from the machine. Crushing hazard. The lift cylinder will become unbalanced and fall if not properly supported and secured to the lifting device. Component damage hazard. Be careful not to damage the valve or fittings on the cylinder while removing it from the machine. 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 chassis under the number 1 center pivot pin (index #11). 78 Attach a lifting strap from an overhead crane to the number 1 inner arm (index #10) at the non-steer end. Raise the number 1 inner arm and remove the safety arm. Lower the number 1 inner arm (index #10) onto the block that was placed across the chassis. Bodily injury hazard. Keep hands clear of moving parts when lowering the scissor arms. 79 Remove the cables from the number 1 cable bridge and lay them off to the side. Component damage hazard. Cables can be damaged if they are kinked or pinched. 80 Support and secure the entry ladder to an appropriate lifting device. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 89 Service and Repair Manual Scissor Components March 2021 81 Remove the fasteners from the entry ladder and remove the entry ladder from the machine. Crushing hazard. The entry ladder will fall if not properly supported and secured to the lifting device. 82 Attach a lifting strap from an overhead crane to the number 1 outer arm (index #22). Do not apply any lifting pressure. 83 Remove the external snap rings and retaining fasteners from the number 1 center pivot pins (index #11). 84 Remove the number 1 cable bridge from the 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. 86 Slide the number 1 outer arm (index #22) to the non-steer end and remove it from the machine. Bodily injury hazard. The number 1 outer arm may become unbalanced and fall if not properly supported when removed from the machine. 87 Attach the strap from an overhead crane to the number 1 inner arm (index #10). Do not lift it. 88 Remove the upper fasteners securing the number 1 inner arm pivot bracket to the end of the chassis. Loosen the lower fasteners. 89 Remove the number 1 inner arm (index #10) from the machine. Bodily injury hazard. The number 1 inner arm may become unbalanced and fall if not properly supported when removed from the machine. Component damage hazard. Be sure not to damage the limit switch or level sensor components when the number 1 inner arm is removed from the machine. 90 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Scissor Components Steer End 1 - Number 4 pivot pin 2 - Number 3 center pivot pin (Qty. 2) 3 - Lift cylinder rod-end pivot pin 4 - Number 3 pivot pin (steer end) 5 - Number 2 center pivot pin (Qty. 2) 6 - Number 2 pivot pin (steer end) 7 - Number 1 center pivot pin (Qty. 2) 8 - Number 1 inner arm 9 - Number 1 pivot pin Non-steer End 10 - Number 3 inner arm 11 - Number 3 outer arm 12 - Number 3 pivot pin (non-steer end) 13 - Number 2 inner arm 14 - Number 2 outer arm 15 - Number 2 pivot pin (non-steer end) 16 - Lift cylinder barrel-end pivot pin 17 - Number 1 outer arm Part No. 1272217GT GSTM-30 · 32 · 46 · 47 91 Service and Repair Manual Scissor Components March 2021 9-3 Scissor Assembly, GS-2032 and GS-2046 How to Disassemble the Scissor Assembly, GS-2032 and GS-2046 Bodily injury hazard. The 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. Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications. Note: Machines equipped with a Platform Height Sensor, begin the Scissor Disassembly procedure at step 1. Machines without a Platform Height Sensor, begin the Scissor Disassembly procedure at step 24. 1 Turn the key switch to ground controls and pull out the red Emergency Stop button to the on position at both ground and platform controls. 2 Raise the platform 7 to 8 feet / 2,1 to 2,4 m. 3 Lift the safety arm, move it to the center of the scissor arm and rotate down to a vertical position. 4 Lower the platform onto the safety arm. Crushing hazard. Keep hands clear of the safety arm when lowering the platform. 5 At the ground controls, turn the key switch to the off position and push in the red Emergency Stop button to the off position. 6 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. 7 Remove the fasteners securing the large platform height sensor cover to the large platform height sensor bracket. 8 Remove the platform height sensor cover. 9 Tag and disconnect the platform height sensor from the platform height sensor harness. 10 Remove the fastener securing the platform height sensor assembly to the number 1 inner arm. 11 Remove the platform height sensor assembly from the number 1 pivot pin. 12 Remove the plastic nut securing the squeeze connector to the large platform height sensor bracket. 13 Remove the squeeze connector from the large 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. 92 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Scissor Components 16 Install the fasteners removed in 14 to the number 1 inner arm pivot bracket and chassis. Tip-over hazard. Failure to install the fasteners securing the number 1 inner arm pivot bracket to the chassis, could result in the machine tipping over, causing death or serious injury. 17 Connect the battery pack to the machine. 18 Turn the key switch to ground controls. 19 Press and hold the ground control scroll up and scroll down buttons. 20 Pull out the red Emergency Stop button to the on position at the ground controls. 21 Using the ground control menu buttons, navigate to Service Override Mode. Select Service Override Mode. Note: The machine must be in Service Override Mode to raise the platform. While in Service Override Mode, only the GCON will operate with limited functionality. The platform will raise a predetermined amount of time and stop. 22 Raise the platform and rotate the safety arm to the stowed position. 23 Fully lower the platform to the stowed position. Cable bridge and platform height sensor 1 cable bridge 3 2 cable bridge 2A 3 cable bridge 2B 4 cable bridge 1 5 platform height sensor 24 Remove the platform. Refer to Repair Procedure, How to Remove the Platform. 25 Support and secure the entry ladder to an appropriate lifting device. 26 Remove the fasteners from the entry ladder and remove the entry ladder from the machine. Crushing hazard. The entry ladder will fall if not properly supported and secured to the lifting device. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 93 Service and Repair Manual Scissor Components March 2021 27 Remove the cables from the number 3 cable bridge and lay them off to the side. Component damage hazard. Cables can be damaged if they are kinked or pinched. 28 Disconnect the number 3 cable bridge from the number 3 outer arm (index #11) and remove the cable bridge from the machine. 29 Remove the retaining fasteners from the number 4 pivot pin (index #1). 30 Use a soft metal drift to remove the number 4 pivot pin (index #1). Remove the platform mount bracket from the machine. 31 Attach a lifting strap from an overhead crane to the number 3 outer arm at the ground control side (index #11). 32 Remove the retaining fasteners from the number 3 center pivot pin (index #2) at the ground control side. 33 Place a rod through the number 3 center pivot pin at the ground control side (index #2) and twist to remove the pin. 34 Remove the retaining fasteners from the number 3 pivot pin (index #12) at the nonsteer end. 35 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 at the ground control side (index #11) from the machine. Crushing hazard. The number 3 outer arm at the ground control side (index #11) may become unbalanced and fall if not properly supported when removed from the machine. 36 Attach a lifting strap from an overhead crane to the number 3 outer arm at the battery side (index #11). 37 Remove the retaining fasteners from the number 3 center pivot pin (index #2) at the battery side. 38 Place a rod through the number 3 center pivot pin at the battery side (index #2) and twist to remove the pin. 39 Remove the number 3 outer arm (index #11) from the machine. Crushing hazard. The number 3 outer arm (index #11) may become unbalanced and fall if not properly supported when removed from the machine. 40 Attach a lifting strap from an overhead crane to the lug of the rod end of the lift cylinder. 41 Remove the retaining fasteners from the lift cylinder rod end pivot pin (index #3). 42 Use a soft metal drift to remove the lift cylinder rod end pivot pin (index #3) from the machine. Crushing hazard. The lift cylinder will fall if not properly supported when the pivot pin is removed. 43 Place a 4 x 4 x 10 inch / 10 x 10 x 25 cm block onto the number 1 inner arm cylinder plate (index #8). 44 Lower the cylinder onto the block. Bodily injury hazard. Keep hands clear of moving parts when lowering the cylinder. 45 Attach a lifting strap from an overhead crane to the number 3 inner arm (index #10). Raise the arm to a vertical position. 94 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Scissor Components 46 Remove the retaining fasteners from the number 3 pivot pin at the steer end of the machine (index #4). 47 Use a soft metal drift to remove the number 3 pivot pin (index #4) from the steer end of the machine. Remove the number 3 inner arm (index #10) from the machine. Crushing hazard. The number 3 inner arm (index #10) may become unbalanced and fall if not properly supported when the pivot pin is removed. 48 Remove the cables from the number 2A and 2B cable bridges and lay them off to the side. Component damage hazard. Cables can be damaged if they are kinked or pinched. 49 Disconnect the number 2A and 2B cable bridges from the scissor linkset and remove both cable bridges from the machine. 50 Attach a lifting strap from an overhead crane to the number 2 outer arm at the ground control side (index #14). 51 Remove the retaining fasteners from the number 2 center pivot pin (index #5) at the ground control side. 52 Place a rod through the number 2 center pivot pin at the ground control side (index #5) and twist to remove the pin. 53 Remove the retaining fasteners from the number 2 pivot pin (index #15) at the nonsteer end. 54 Use a soft metal drift to remove the number 2 pivot pin (index #15) from the non-steer end of the machine. Remove the number 2 outer arm at the ground control side (index #14) from the machine. The number 2 outer arm at the ground control side (index #14) may become unbalanced and fall if not properly supported when the pivot pin is removed. 55 Attach a lifting strap from an overhead crane to the number 2 outer arm at the battery side (index #14). 56 Remove the retaining fasteners from the number 2 center pivot pin (index #5) at the battery side. 57 Place a rod through the number 2 center pivot pin at the battery side (index #5) and twist to remove the pin. Crushing hazard. The number 2 outer arm (index #14) may become unbalanced and fall if not properly supported when the pivot pin is removed. 58 Remove the number 2 outer arm (index #14) from the machine. Crushing hazard. The number 2 outer arm (index #14) may become unbalanced and fall if not properly supported when removed from the machine. 59 Attach a lifting strap from an overhead crane to the number 2 inner arm (index #13). Raise the arm to a vertical position. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 95 Service and Repair Manual Scissor Components March 2021 60 Remove the retaining fasteners from the number 2 pivot pin at the steer end of the machine (index #6). 61 Use a soft metal drift to remove the number 2 pivot pin (index #6) from the steer end of the machine. Remove the number 2 inner arm (index #13) from the machine. Crushing hazard. The number 2 inner arm (index #13) may become unbalanced and fall if not properly supported when the pivot pin is removed. 62 Attach a lifting strap from an overhead crane to the number 1 inner arm (index #8). 63 Raise the number 1 inner arm (index #8) approximately 2 feet / 60 cm. 64 Place a 4 x 4 x 48 inch / 10 cm x 10 cm x 1.2 m long block across both sides of the chassis under the number 1 center pivot pin (index #7). 65 Lower the scissor arms onto the block that was placed across the chassis. Bodily injury hazard. Keep hands clear of moving parts when lowering the scissor arms. 66 Attach a lifting strap from an overhead crane to the lug of the rod end of the lower lift cylinder. 67 Tag, disconnect and plug the hydraulic hose on the lower lift cylinder. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 68 Tag and disconnect the wire harness from the solenoid valve on the cylinder. 69 Tag and disconnect the wires and manual lowering cable from the solenoid valve on the cylinder. 70 Models with platform overload option: Tag and disconnect the wire harness from the platform overload pressure transducer. Note: After replacing the scissor assembly, the platform overload system must be calibrated. Refer to Repair Procedure, How to Calibrate the Platform Overload System (if equipped). 71 Raise the lift cylinder to a vertical position. 72 Remove the pin retaining fasteners from the lift cylinder barrel-end pin (index #16). Use a soft metal drift to remove the pin. Remove the lift cylinder from the machine. Crushing hazard. The lift cylinder will fall if not properly supported when the pivot pin is removed. Component damage hazard. Be careful not to damage the valve or fittings on the cylinder while removing it from the machine. 96 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 73 Remove the cables from the number 1 cable bridge and lay them off to the side. Component damage hazard. Cables can be damaged if they are kinked or pinched. 74 Disconnect the number 1 cable bridge from the number 1 outer arm (index #17) and remove the cable bridge from the machine. 75 Attach a lifting strap from an overhead crane to the number 1 inner arm (index #8). 76 Raise the arm slightly and remove the block. 77 Lower the arm to the stowed position. Bodily injury hazard. Keep hands clear of moving parts when lowering the scissor arms. 78 Secure the ends of the scissor arms together at the steer end of the machine with a strap or other suitable device. 79 Secure the ends of the scissor arms together at the non-steer end of the machine with a strap or other suitable device. 80 Remove the retaining fasteners securing the chassis mount bracket to the chassis. 81 Remove the linkset from the machine Bodily injury hazard. The number 1 inner and outer arms (index #8 and #17) may become unbalanced and fall if not properly supported when removed from the machine. Component damage hazard. Be sure not to damage the limit switch or level sensor components when the number 1 inner and outer arms (index #8 and #17) are removed from the machine. Service and Repair Manual Scissor Components Part No. 1272217GT GSTM-30 · 32 · 46 · 47 97 Service and Repair Manual Scissor Components March 2021 Steer End 1 - Number 5 pivot pin 2 - Number 4 center pivot pin (Qty. 2) 3 - Number 4 pivot pin (steer end) 4 - Number 3 center pivot pin (Qty. 2) 5 - Lift cylinder rod-end pivot pin 6 - Number 3 pivot pin (steer end) 7 - Number 2 center pivot pin (Qty. 2) 8 - Number 2 pivot pin (steer end) 9 - Number 1 center pivot pin (Qty. 2) 10 - Number 1 inner arm 11 - Number 1 pivot pin Non-steer End 12 - Number 4 inner arm 13 - Number 4 outer arm 14 - Number 4 pivot pin (non-steer end) 15 - Number 3 inner arm 16 - Number 3 outer arm 17 - Number 3 pivot pin (non-steer end) 18 - Number 2 inner arm 19 - Number 2 outer arm 20 - Number 2 pivot pin (non-steer end) 21 - Lift cylinder barrel-end pivot pin 22 - Number 1 outer arm 98 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Scissor Components 9-4 Scissor Assembly, GS-2632 and GS-2646 How to Disassemble the Scissor Assembly Bodily injury hazard. The 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. Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications. Note: Machines equipped with a Platform Height Sensor, begin the Scissor Disassembly procedure at step 1. Machines without a Platform Height Sensor, begin the Scissor Disassembly procedure at step 24. 1 Turn the key switch to ground controls and pull out the red Emergency Stop button to the on position at both ground and platform controls. 2 Raise the platform 7 to 8 feet / 2,1 to 2,4 m. 3 Lift the safety arm, move it to the center of the scissor arm and rotate down to a vertical position. 4 Lower the platform onto the safety arm. Crushing hazard. Keep hands clear of the safety arm when lowering the platform. 5 At the ground controls, turn the key switch to the off position and push in the red Emergency Stop button to the off position. 6 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. 7 Remove the fasteners securing the large platform height sensor cover to the large platform height sensor bracket. 8 Remove the platform height sensor cover. 9 Tag and disconnect the platform height sensor from the platform height sensor harness. 10 Remove the fastener securing the platform height sensor assembly to the number 1 inner arm. 11 Remove the platform height sensor assembly from the number 1 pivot pin. 12 Remove the plastic nut securing the squeeze connector to the large platform height sensor bracket. 13 Remove the squeeze connector from the large 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. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 99 Service and Repair Manual Scissor Components March 2021 16 Install the fasteners removed in 14 to the number 1 inner arm pivot bracket and chassis. Tip-over hazard. Failure to install the fasteners securing the number 1 inner arm pivot bracket to the chassis, could result in the machine tipping over, causing death or serious injury. 17 Connect the battery pack to the machine. 18 Turn the key switch to ground controls. 19 Press and hold the ground control scroll up and scroll down buttons. 20 Pull out the red Emergency Stop button to the on position at the ground controls. 21 Using the ground control menu buttons, navigate to Service Override Mode. Select Service Override Mode. Note: The machine must be in Service Override Mode to raise the platform. While in Service Override Mode, only the GCON will operate with limited functionality. The platform will raise a predetermined amount of time and stop. 22 Raise the platform and rotate the safety arm to the stowed position. 23 Fully lower the platform to the stowed position. Cable bridge and platform height sensor 1 cable bridge 4 2 cable bridge 3A 3 cable bridge 3B 4 cable bridge 2A 5 cable bridge 2B 6 cable bridge 1 7 platform height sensor 100 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Scissor Components 24 Remove the platform. Refer to Repair Procedure, How to Remove the Platform. 25 Support and secure the entry ladder to an appropriate lifting device. 26 Remove the fasteners from the entry ladder and remove the entry ladder from the machine. Crushing hazard. The entry ladder will fall if not properly supported and secured to the lifting device. 27 Remove the cables from the number 4 cable bridge and lay them off to the side. Component damage hazard. Cables can be damaged if they are kinked or pinched. 28 Disconnect the number 4 cable bridge from the number 4 outer arm (index #13) and remove the cable bridge from the machine. 29 Remove the retaining fasteners from the number 5 pivot pin (index #1). 30 Use a soft metal drift to remove the number 5 pivot pin (index #1). Remove the platform mount bracket from the machine. 31 Attach a lifting strap from an overhead crane to the number 4 outer arm at the ground control side (index #13). 32 Remove the retaining fasteners from the number 4 center pivot pin (index #2) at the ground control side. 33 Place a rod through the number 4 center pivot pin at the ground control side (index #2) and twist to remove the pin. 34 Remove the retaining fasteners from the number 4 pivot pin (index #15) at the nonsteer end. 35 Use a soft metal drift to remove the number 4 pivot pin (index #14) from the non-steer end of the machine. Remove the number 4 outer arm at the ground control side (index #13) from the machine. Crushing hazard. The number 4 outer arm at the ground control side (index #13) may become unbalanced and fall if not properly supported when removed from the machine. 36 Attach a lifting strap from an overhead crane to the number 4 outer arm at the battery side (index #13). 37 Remove the retaining fasteners from the number 4 center pivot pin (index #2) at the battery side. 38 Place a rod through the number 4 center pivot pin at the battery side (index #2) and twist to remove the pin. 39 Remove the number 4 outer arm (index #13) from the machine. Crushing hazard. The number 4 outer arm (index #13) may become unbalanced and fall if not properly supported when removed from the machine. 40 Attach a lifting strap from an overhead crane to the number 4 inner arm (index #12). Raise the arm to a vertical position. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 101 Service and Repair Manual Scissor Components March 2021 41 Remove the retaining fasteners from the number 4 pivot pin at the steer end of the machine (index #3). 42 Use a soft metal drift to remove the number 4 pivot pin (index #3) from the steer end of the machine. Remove the number 4 inner arm (index #12) from the machine. Crushing hazard. The number 4 inner arm (index #12) may become unbalanced and fall if not properly supported when removed from the machine. 43 Remove the cables from the number 3A and 3B cable bridge and lay them off to the side. Component damage hazard. Cables can be damaged if they are kinked or pinched. 44 Disconnect the number 3A and 3B cable bridges from the scissor linkset and remove both cable bridges from the machine. 45 Attach a lifting strap from an overhead crane to the number 3 outer arm at the ground control side (index #16). 46 Remove the retaining fasteners from the number 3 center pivot pin (index #4) at the ground control side. 47 Place a rod through the number 3 center pivot pin at the ground control side (index #4) and twist to remove the pin. 48 Remove the retaining fasteners from the number 3 pivot pin (index #17) at the nonsteer end. 49 Use a soft metal drift to remove the number 3 pivot pin (index #17) from the non-steer end of the machine. Remove the number 3 outer arm at the ground control side (index #16) from the machine. Crushing hazard. The number 3 outer arm at the ground control side (index #16) may become unbalanced and fall if 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 (index #16). 51 Remove the retaining fasteners from the number 3 center pivot pin (index #4) at the battery side. 52 Place a rod through the number 3 center pivot pin at the battery side (index #4) and twist to remove the pin. 53 Remove the number 3 outer arm (index #16) from the machine. Crushing hazard. The number 3 outer arm (index #16) may become unbalanced and fall if not properly supported when removed from the machine. 54 Attach a lifting strap from an overhead crane to the lug of the rod end of the lift cylinder. 55 Remove the retaining fasteners from the lift cylinder rod end pivot pin (index #5). 102 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Scissor Components 56 Use a soft metal drift to remove the lift cylinder rod end pivot pin (index #5) from the machine. Crushing hazard. The lift cylinder will fall if not properly supported when the pivot pin is removed. 57 Place a 4 x 4 x 10 inch / 10 x 10 x 25 cm block onto the number 1 inner arm cylinder plate (index #10). 58 Lower the cylinder onto the block. Bodily injury hazard. Keep hands clear of moving parts when lowering the cylinder. 59 Attach a lifting strap from an overhead crane to the number 3 inner arm (index #15). Raise the arm to a vertical position. 60 Remove the retaining fasteners from the number 3 pivot pin at the steer end of the machine (index #6). 61 61 Use a soft metal drift to remove the number 3 pivot pin (index #6) from the steer end of the machine. Remove the number 3 inner arm (index #15) from the machine. Crushing hazard. The number 3 inner arm (index #15) may become unbalanced and fall if not properly supported when the pivot pin is removed. 62 Remove the cables from the number 2A and 2B cable bridge and lay them off to the side. Component damage hazard. Cables can be damaged if they are kinked or pinched. 63 Disconnect the number 2A and 2B cable bridges from the scissor linkset and remove both cable bridges from the machine. 64 Attach a lifting strap from an overhead crane to the number 2 outer arm at the ground control side (index #19). 65 Remove the retaining fasteners from the number 2 center pivot pin (index #7) at the ground control side. 66 Place a rod through the number 2 center pivot pin at the ground control side (index #7) and twist to remove the pin. 67 Remove the retaining fasteners from the number 2 pivot pin (index #20) at the nonsteer end. 68 Use a soft metal drift to remove the number 2 pivot pin (index #20) from the non-steer end of the machine. Remove the number 2 outer arm at the ground control side (index #19) from the machine. The number 2 outer arm at the ground control side (index #19) may become unbalanced and fall if not properly supported when the pivot pin is removed. 69 Attach a lifting strap from an overhead crane to the number 2 outer arm at the battery side (index #19). 70 Remove the retaining fasteners from the number 2 center pivot pin (index #7) at the battery side. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 103 Service and Repair Manual Scissor Components March 2021 71 Place a rod through the number 2 center pivot pin at the battery side (index #7) and twist to remove the pin. Crushing hazard. The number 2 outer arm (index #19) may become unbalanced and fall if not properly supported when the pivot pin is removed. 72 Remove the number 2 outer arm (index #19) from the machine. Crushing hazard. The number 2 outer arm (index #19) may become unbalanced and fall if not properly supported when removed from the machine. 73 Attach a lifting strap from an overhead crane to the number 2 inner arm (index #18). Raise the arm to a vertical position. 74 Remove the retaining fasteners from the number 2 pivot pin at the steer end of the machine (index #8). 75 Use a soft metal drift to remove the number 2 pivot pin (index #8) from the steer end of the machine. Remove the number 2 inner arm (index #18) from the machine. Crushing hazard. The number 2 inner arm (index #18) may become unbalanced and fall if not properly supported when the pivot pin is removed. 76 Attach a lifting strap from an overhead crane to the number 1 inner arm (index #10). 77 Raise the number 1 inner arm (index #10) approximately 2 feet / 60 cm. 78 Place a 4 x 4 x 48 inch / 10 cm x 10 cm x 1.2 m long block across both sides of the chassis under the number 1 center pivot pin (index #9). 79 Lower the scissor arms onto the block that was placed across the chassis. Bodily injury hazard. Keep hands clear of moving parts when lowering the scissor arms. 80 Attach a lifting strap from an overhead crane to the lug of the rod end of the lower lift cylinder. 81 Tag, disconnect and plug the hydraulic hose on the lower lift cylinder. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 82 Tag and disconnect the wire harness from the solenoid valve on the cylinder. 83 Tag and disconnect the wires and manual lowering cable from the solenoid valve on the cylinder. 84 Models with platform overload option: Tag and disconnect the wire harness from the platform overload pressure transducer. Note: After replacing the scissor assembly, the platform overload system must be calibrated. Refer to Repair Procedure, How to Calibrate the Platform Overload System (if equipped). 104 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Scissor Components 85 Raise the lift cylinder to a vertical position. 86 Remove the pin retaining fasteners from the lift cylinder barrel-end pin (index #21). Use a soft metal drift to remove the pin. Remove the lift cylinder from the machine. Crushing hazard. The lift cylinder will fall if not properly supported when the pivot pin is removed. Component damage hazard. Be careful not to damage the valve or fittings on the cylinder while removing it from the machine. 87 Remove the cables from the number 1 cable bridge and lay them off to the side. Component damage hazard. Cables can be damaged if they are kinked or pinched. 88 Disconnect the number 1 cable bridge from the number 1 outer arm (index #22) and remove the cable bridge from the machine. 89 Attach a lifting strap from an overhead crane to the number 1 inner arm (index #10). 90 Raise the arm slightly and remove the block. 91 Lower the arm to the stowed position. Bodily injury hazard. Keep hands clear of moving parts when lowering the scissor arms. 92 Secure the ends of the scissor arms together at the steer end of the machine with a strap or other suitable device. 93 Secure the ends of the scissor arms together at the non-steer end of the machine with a strap or other suitable device. 94 Remove the retaining fasteners securing the chassis mount bracket to the chassis. 95 Remove the linkset from the machine Bodily injury hazard. The number 1 inner and outer arms (index #10 and #22) may become unbalanced and fall if not properly supported when removed from the machine. Component damage hazard. Be sure not to damage the limit switch or level sensor components when the number 1 inner and outer arms (index #10 and #22) are removed from the machine. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 105 Service and Repair Manual Scissor Components March 2021 Steer End 1 - Number 6 pivot pin 2 - Number 5 center pivot pin (Qty. 2) 3 - Upper lift cylinder rod-end pivot pin 4 - Number 5 pivot pin (steer end) 5 - Number 4 center pivot pin (Qty. 2) 6 - Number 4 pivot pin (steer end) 7 - Number 3 outer arm 8 - Number 3 center pivot pin (Qty. 2) 9 - Lift cylinder rod-end pivot pin 10 - Number 3 pivot pin (steer end) 11 - Number 2 center pivot pin (Qty. 2) 12 - Number 2 pivot pin (steer end) 13 - Number 1 center pivot pin (Qty. 2) 14 - Number 1 inner arm 15 - Number 1 pivot pin (steer end) (Qty. 2) Non-steer End 16 - Number 5 inner arm 17 - Number 5 outer arm 18 - Number 5 pivot pin (non-steer end) 19 - Number 4 inner arm 20 - Number 4 outer arm 21 - Number 4 pivot pin (non-steer end) 22 - Upper lift cylinder barrel-end pivot pin 23 - Number 3 inner arm 24 - Number 3 pivot pin (non-steer end) 25 - Number 2 inner arm 26 - Number 2 outer arm 27 - Number 2 pivot pin (non-steer end) 28 - Lift cylinder barrel-end pivot pin 29 - Number 1 outer arm 106 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Scissor Components 9-5 Scissor Assembly, GS-3232 and GS-3246 How to Disassemble the Scissor Assembly Bodily injury hazard. The 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. Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications. Note: Machines equipped with a Platform Height Sensor, begin the Scissor Disassembly procedure at step 1. Machines without a Platform Height Sensor, begin the Scissor Disassembly procedure at step 24. 1 Turn the key switch to ground controls and pull out the red Emergency Stop button to the on position at both ground and platform controls. 2 Raise the platform 7 to 8 feet / 2,1 to 2,4 m. 3 Lift the safety arm, move it to the center of the scissor arm and rotate down to a vertical position. 4 Lower the platform onto the safety arm. Crushing hazard. Keep hands clear of the safety arm when lowering the platform. 5 At the ground controls, turn the key switch to the off position and push in the red Emergency Stop button to the off position. 6 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. 7 Remove the fasteners securing the large platform height sensor cover to the large platform height sensor bracket. 8 Remove the platform height sensor cover. 9 Tag and disconnect the platform height sensor from the platform height sensor harness. 10 Remove the fastener securing the platform height sensor assembly to the number 1 inner arm. 11 Remove the platform height sensor assembly from the number 1 pivot pin. 12 Remove the plastic nut securing the squeeze connector to the large platform height sensor bracket. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 107 Service and Repair Manual Scissor Components March 2021 13 Remove the squeeze connector from the large 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. 17 Connect the battery pack to the machine. 18 Turn the key switch to ground controls. 19 Press and hold the ground control scroll up and scroll down buttons. 20 Pull out the red Emergency Stop button to the on position at the ground controls. 21 Using the ground control menu buttons, navigate to Service Override Mode. Select Service Override Mode. Note: The machine must be in Service Override Mode to raise the platform. While in Service Override Mode, only the GCON will operate with limited functionality. The platform will raise a predetermined amount of time and stop. 22 Raise the platform and rotate the safety arm to the stowed position. 23 Fully lower the platform to the stowed position. Cable bridge and platform height sensor 1 cable bridge 5 2 cable bridge 4A 3 cable bridge 4B 4 cable bridge 3A 5 cable bridge 3B 6 cable bridge 2A 7 cable bridge 2B 8 cable bridge 1 9 platform height sensor 108 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Scissor Components 24 Remove the platform. Refer to Repair Procedure, How to Remove the Platform. 25 Support and secure the entry ladder to an appropriate lifting device. 26 Remove the fasteners from the entry ladder and remove the entry ladder from the machine. Crushing hazard. The entry ladder will fall if not properly supported and secured to the lifting device. 27 Remove the cables from the number 5 cable bridge and lay them off to the side. 28 Disconnect the number 4 cable bridge from the number 5 outer arm (index #17) and remove the cable bridge from the machine. 29 Remove the retaining fasteners from the number 6 pivot pin (index #1). 30 Use a soft metal drift to remove the number 6 pivot pin (index #1). Remove the platform mount bracket from the machine. 31 Attach a lifting strap from an overhead crane to the number 5 outer arm at the ground control side (index #17). 32 Remove the retaining fasteners from the number 5 center pivot pin (index #2) at the ground control side. 33 Place a rod through the number 5 center pivot pin at the ground control side (index #2) and twist to remove the pin. 34 Remove the retaining fasteners from the number 5 pivot pin (index #18) at the nonsteer end. 35 Use a soft metal drift to remove the number 5 pivot pin (index #18) from the non-steer end of the machine. Remove the number 5 outer arm at the ground control side (index #17) from the machine. Crushing hazard. The number 5 outer arm at the ground control side (index #17) may become unbalanced and fall if not properly supported when removed from the machine. 36 Attach a lifting strap from an overhead crane to the number 5 outer arm at the battery side (index #17). 37 Remove the retaining fasteners from the number 5 center pivot pin (index #2) at the battery side. 38 Place a rod through the number 5 center pivot pin at the battery side (index #2) and twist to remove the pin. 39 Remove the number 5 outer arm (index #17) from the machine. Crushing hazard. The number 5 outer arm (index #17) may become unbalanced and fall if not properly supported when removed from the machine. 40 Attach a lifting strap from an overhead crane to the number 5 inner arm (index #16). Raise the arm to a vertical position. 41 Remove the retaining fasteners from the number 5 pivot pin at the steer end of the machine (index #4). Part No. 1272217GT GSTM-30 · 32 · 46 · 47 109 Service and Repair Manual Scissor Components March 2021 42 Use a soft metal drift to remove the number 5 pivot pin (index #18) from the steer end of the machine. Remove the number 5 inner arm (index #16) from the machine. Crushing hazard. The number 5 inner arm (index #16) may become unbalanced and fall if not properly supported when removed from the machine. 43 Tag, disconnect and plug the hydraulic hose on the upper lift cylinder. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 44 Tag and disconnect the wire harness from the solenoid valve on the cylinder. 45 Remove the cables from the number 4A and 4B cable bridges and lay them off to the side. Component damage hazard. Cables can be damaged if they are kinked or pinched. 46 Disconnect the number 4A and 4B cable bridges from the scissor linkset and remove both cable bridges from the machine. 47 Attach a lifting strap from an overhead crane to the lug of the rod end of the upper lift cylinder. 48 Remove the retaining fasteners from the upper lift cylinder rod end pivot pin (index #3). 49 Use a soft metal drift to remove the upper lift cylinder rod end pivot pin (index #3) from the machine. Crushing hazard. The lift cylinder will fall if not properly supported when the pivot pin is removed. 50 Lower the cylinder onto the linkset. 51 Attach a lifting strap from an overhead crane to the number 4 outer arm at the ground control side (index #20). 52 Remove the retaining fasteners from the number 4 center pivot pin (index #5) at the ground control side. 53 Place a rod through the number 4 center pivot pin at the ground control side (index #5) and twist to remove the pin. 54 Remove the retaining fasteners from the number 4 pivot pin (index #21) at the nonsteer end. 55 Use a soft metal drift to remove the number 4 pivot pin (index #21) from the non-steer end of the machine. Remove the number 4 outer arm at the ground control side (index #20) from the machine. Crushing hazard. The number 4 outer arm at the ground control side (index #20) may become unbalanced and fall if not properly supported when removed from the machine. 56 Attach a lifting strap from an overhead crane to the number 4 outer arm at the battery side (index #20). 57 Remove the retaining fasteners from the number 4 center pivot pin (index #5) at the battery side. 110 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Scissor Components 58 Place a rod through the number 4 center pivot pin at the battery side (index #5) and twist to remove the pin. 59 Remove the number 4 outer arm (index #20) from the machine. Crushing hazard. The number 4 outer arm (index #20) may become unbalanced and fall if not properly supported when removed from the machine. 60 Attach a lifting strap from an overhead crane to the number 4 inner arm (index #19). Raise the arm to a vertical position. 61 Remove the retaining fasteners from the number 4 pivot pin at the steer end of the machine (index #6). 62 Use a soft metal drift to remove the number 4 pivot pin (index #6) from the steer end of the machine. Remove the number 4 inner arm (index #19) from the machine. Crushing hazard. The number 4 inner arm (index #19) may become unbalanced and fall if not properly supported when removed from the machine. 63 Remove the cables from the number 3A and 3B cable bridges and lay them off to the side. Component damage hazard. Cables can be damaged if they are kinked or pinched. 64 Disconnect the number 3A and 3B cable bridges from the scissor linkset and remove both cable bridges from the machine. 65 Attach a lifting strap from an overhead crane to the number 3 outer arm at the ground control side (index #7). 66 Remove the retaining fasteners from the number 3 center pivot pin (index #8) at the ground control side. 67 Place a rod through the number 3 center pivot pin at the ground control side (index #8) and twist to remove the pin. 68 Remove the retaining fasteners from the number 3 pivot pin (index #24) at the nonsteer end. 69 Use a soft metal drift to remove the number 3 pivot pin (index #24) from the non-steer end of the machine. Remove the number 3 outer arm at the ground control side (index #7) from the machine. Crushing hazard. The number 3 outer arm at the ground control side (index #7) may become unbalanced and fall if not properly supported when removed from the machine. 70 Attach a lifting strap from an overhead crane to the number 3 outer arm at the battery side (index #7). 71 Remove the retaining fasteners from the number 3 center pivot pin (index #8) at the battery side. 72 Place a rod through the number 3 center pivot pin at the battery side (index #8) and twist to remove the pin. 73 Remove the number 3 outer arm (index #7) from the machine. Crushing hazard. The number 3 outer arm (index #7) may become unbalanced and fall if not properly supported when removed from the machine. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 111 Service and Repair Manual Scissor Components March 2021 74 Attach a lifting strap from an overhead crane to the lug of the rod end of the upper lift cylinder. 75 Raise the lift cylinder to a vertical position. 76 Remove the pin retaining fasteners from the lift cylinder barrel-end pivot pin (index #22). Remove the lift cylinder from the machine. Crushing hazard. The lift cylinder will fall if not properly supported when the pivot pin is removed. Component damage hazard. Be careful not to damage the valve or fittings on the cylinder while removing it from the machine. 77 Attach a lifting strap from an overhead crane to the lug of the rod end of the lower lift cylinder. 78 Remove the retaining fasteners from the lower lift cylinder rod end pivot pin (index #9). 79 Use a soft metal drift to remove the lower lift cylinder rod end pivot pin (index #9) from the machine. Crushing hazard. The lift cylinder will fall if not properly supported when the pivot pin is removed. 80 Place a 4 x 4 x 10 inch / 10 x 10 x 25 cm block onto the number 1 inner arm cylinder plate (index #14). 81 Lower the cylinder onto the block. Bodily injury hazard. Keep hands clear of moving parts when lowering the cylinder. 82 Attach a lifting strap from an overhead crane to the number 3 inner arm (index #23). Raise the arm to a vertical position. 83 Remove the retaining fasteners from the number 3 pivot pin at the steer end of the machine (index #10). 84 Use a soft metal drift to remove the number 3 pivot pin (index #10) from the steer end of the machine. Remove the number 3 inner arm (index #23) from the machine. Crushing hazard. The number 3 inner arm (index #23) may become unbalanced and fall if not properly supported when the pivot pin is removed. 85 Remove the cables from the number 2A and 2B cable bridges and lay them off to the side. Component damage hazard. Cables can be damaged if they are kinked or pinched. 86 Disconnect the number 2A and 2B cable bridges from the scissor linkset and remove both cable bridges from the machine. 87 Attach a lifting strap from an overhead crane to the number 2 outer arm at the ground control side (index #26). 88 Remove the retaining fasteners from the number 2 center pivot pin (index #11) at the ground control side. 89 Place a rod through the number 2 center pivot pin at the ground control side (index #11) and twist to remove the pin. 90 Remove the retaining fasteners from the number 2 pivot pin (index #27) at the nonsteer end. 112 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Scissor Components 91 Use a soft metal drift to remove the number 2 pivot pin (index #27) from the non-steer end of the machine. Remove the number 2 outer arm at the ground control side (index #26) from the machine. The number 2 outer arm at the ground control side (index #26) may become unbalanced and fall if 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 (index #26). 93 Remove the retaining fasteners from the number 2 center pivot pin (index #11) at the battery side. 94 Place a rod through the number 2 center pivot pin at the battery side (index #11) and twist to remove the pin. Crushing hazard. The number 2 outer arm (index #26) may become unbalanced and fall if not properly supported when the pivot pin is removed. 95 Remove the number 2 outer arm (index #26) from the machine. Crushing hazard. The number 2 outer arm (index #26) may become unbalanced and fall if not properly supported when removed from the machine. 96 Attach a lifting strap from an overhead crane to the number 2 inner arm (index #25). Raise the arm to a vertical position. 97 Remove the retaining fasteners from the number 2 pivot pin at the steer end of the machine (index #12). 98 Use a soft metal drift to remove the number 2 pivot pin (index #12) from the steer end of the machine. Remove the number 2 inner arm (index #25) from the machine. Crushing hazard. The number 2 inner arm (index #25) may become unbalanced and fall if not properly supported when the pivot pin is removed. 99 Attach a lifting strap from an overhead crane to the number 1 inner arm (index #14). 100 Raise the number 1 inner arm (index #14) approximately 2 feet / 60 cm. 101 Place a 4 x 4 x 48 inch / 10 cm x 10 cm x 1.2 m long block across both sides of the chassis under the number 1 center pivot pin (index #13). 102 Lower the scissor arms onto the block that was placed across the chassis. Bodily injury hazard. Keep hands clear of moving parts when lowering the scissor arms. 103 Attach a lifting strap from an overhead crane to the lug of the rod end of the lower lift cylinder. 104 Tag, disconnect and plug the hydraulic hose on the lower lift cylinder. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 113 Service and Repair Manual Scissor Components March 2021 105 Tag and disconnect the wire harness from the solenoid valve on the cylinder. 106 Models with platform overload option: Tag and disconnect the wire harness from the platform overload pressure transducer. Note: After replacing the scissor assembly, the platform overload system must be calibrated. Refer to Repair Procedure, How to Calibrate the Platform Overload System (if equipped). 107 Raise the lift cylinder to a vertical position. 108 Remove the pin retaining fasteners from the lift cylinder barrel-end pin (index #28). Use a soft metal drift to remove the pin. Remove the lift cylinder from the machine. Crushing hazard. The lift cylinder will fall if not properly supported when the pivot pin is removed. Component damage hazard. Be careful not to damage the valve or fittings on the cylinder while removing it from the machine. 109 Remove the cables from the number 1 cable bridge and lay them off to the side. Component damage hazard. Cables can be damaged if they are kinked or pinched. 110 Disconnect the number 1 cable bridge from 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. 113 Lower the arm to the stowed position. Bodily injury hazard. Keep hands clear of moving parts when lowering the scissor arms. 114 Secure the ends of the scissor arms together at the steer end of the machine with a strap or other suitable device. 115 Secure the ends of the scissor arms together at the non-steer end of the machine with a strap or other suitable device. 116 Remove the retaining fasteners securing the chassis mount bracket to the chassis. 117 Remove the linkset from the machine. Bodily injury hazard. The number 1 inner and outer arms (index #14 and #29) may become unbalanced and fall if not properly supported when removed from the machine. Component damage hazard. Be sure not to damage the limit switch or level sensor components when the number 1 inner and outer arms (index #14 and #29) are removed from the machine. 114 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Scissor Components Steer End 1 - Number 7 pivot pin 2 - Number 6 center pivot pin (Qty. 2) 3 - Number 6 pivot pin (steer end) 4 - Number 5 center pivot pin 5 - Upper lift cylinder rod-end pivot pin 6 - Number 5 pivot pin (steer end) 7 - Number 4 center pivot pin (Qty. 2) 8 - Number 4 pivot pin (steer end) 9 - Number 3 outer arm 10 - Number 3 center pivot pin (Qty. 2) 11 - Lower lift cylinder rod-end pivot pin 12 - Number 3 pivot pin (steer end) 13 - Number 2 center pivot pin (Qty. 2) 14 - Number 2 pivot pin (steer end) 15 - Number 1 center pivot pin (Qty. 2) 16 - Number 1 inner arm 17 - Number 1 pivot pin (steer end) (Qty. 2) 18 - Number 6 inner arm 19 - Number 6 outer arm 20 - Number 6 pivot pin (non-steer end) 21 - Number 5 inner arm 22 - Number 5 outer arm 23 - Number 5 pivot pin (non-steer end) 24 - Number 4 inner arm Non-steer End 25 - Number 4 outer arm 26 - Number 4 pivot pin (non-steer end) 27 - Upper lift cylinder barrel-end pivot pin 28 - Number 3 inner arm 29 - Number 3 pivot pin (non-steer end) 30 - Number 2 inner arm 31 - Number 2 inner arm 32 - Number 2 pivot pin (non-steer end) 33 - Lower lift cylinder barrel-end pivot pin 34 - Number 1 outer arm Part No. 1272217GT GSTM-30 · 32 · 46 · 47 115 Service and Repair Manual Scissor Components March 2021 9-6 Scissor Assembly, GS-4047 How to Disassemble the Scissor Assembly Bodily injury hazard. This procedure requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. Dealer service is strongly recommended. Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications. Note: Machines equipped with a Platform Height Sensor, begin the Scissor Disassembly procedure at step 1. Machines without a Platform Height Sensor, begin the Scissor Disassembly procedure at step 24. 1 Turn the key switch to ground controls and pull out the red Emergency Stop button to the on position at both ground and platform controls. 2 Raise the platform 7 to 8 feet / 2,1 to 2,4 m. 3 Lift the safety arm, move it to the center of the scissor arm and rotate down to a vertical position. 4 Lower the platform onto the safety arm. Crushing hazard. Keep hands clear of the safety arm when lowering the platform. 5 At the ground controls, turn the key switch to the off position and push in the red Emergency Stop button to the off position. 6 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. 7 Remove the fasteners securing the large platform height sensor cover to the large platform height sensor bracket. 8 Remove the platform height sensor cover. 9 Tag and disconnect the platform height sensor from the platform height sensor harness. 10 Remove the fastener securing the platform height sensor assembly to the number 1 inner arm. 11 Remove the platform height sensor assembly from the number 1 pivot pin. 12 Remove the plastic nut securing the squeeze connector to the large platform height sensor bracket. 116 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Scissor Components 13 Remove the squeeze connector from the large 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. 17 Connect the battery pack to the machine. 18 Turn the key switch to ground controls. 19 Press and hold the ground control scroll up and scroll down buttons. 20 Pull out the red Emergency Stop button to the on position at the ground controls. 21 Using the ground control menu buttons, navigate to Service Override Mode. Select Service Override Mode. Note: The machine must be in Service Override Mode to raise the platform. While in Service Override Mode, only the GCON will operate with limited functionality. The platform will raise a predetermined amount of time and stop. 22 Raise the platform and rotate the safety arm to the stowed position. 23 Fully lower the platform to the stowed position. Cable bridge and platform height sensor 1 cable bridge 6 2 cable bridge 5B 3 cable bridge 5A 4 cable bridge 4B 5 cable bridge 4A 6 cable bridge 1A 7 platform height sensor 8 cable bridge 1B 9 cable bridge 2A 10 cable bridge 2B 11 cable bridge 2C 12 cable bridge 2D Part No. 1272217GT GSTM-30 · 32 · 46 · 47 117 Service and Repair Manual Scissor Components March 2021 24 Remove the platform. Refer to Repair Procedure, How to Remove the Platform. 25 Remove the cables from cable bridges a, b, c, d and e. 26 Remove the retaining fasteners from the number 7 pivot pin (index #1). 27 Use a soft metal drift to remove the number 7 pivot pin (index #1). Remove the platform mount bracket from the machine. 28 Attach a lifting strap from an overhead crane to the number 6 outer arm at the ground control side (index #19). 29 Remove the retaining fasteners from the number 6 center pivot pin (index #2) at the ground control side. 30 Place a rod through the number 6 center pivot pin at the ground control side (index #2) and twist to remove the pin. 31 Remove the retaining fasteners from the number 6 pivot pin (index #20) at the nonsteer end. 32 Use a soft metal drift to remove the number 6 pivot pin (index #20) from the non-steer end of the machine. Remove the number 6 outer arm at the ground control side (index #19) from the machine. Crushing hazard. The number 6 outer arm at the ground control side (index #19) may become unbalanced and fall if not properly supported when removed from the machine. 33 Attach a lifting strap from an overhead crane to the number 6 outer arm at the battery side (index #19). 34 Remove the retaining fasteners from the number 6 center pivot pin (index #2) at the battery side. 35 Place a rod through the number 6 center pivot pin at the battery side (index #2) and twist to remove the pin. 36 Remove the number 6 outer arm (index #19) from the machine. Crushing hazard. The number 6 outer arm (index #19) may become unbalanced and fall if not properly supported when removed from the machine. 37 Attach a lifting strap from an overhead crane to the number 6 inner arm (index #18). Raise the arm to a vertical position. 38 Remove the retaining fasteners from the number 6 pivot pin at the steer end of the machine (index #3). 39 Use a soft metal drift to remove the number 6 pivot pin (index #3) from the steer end of the machine. Remove the number 6 inner arm (index #18) from the machine. Crushing hazard. The number 5 inner arm (index #16) may become unbalanced and fall if not properly supported when removed from the machine. 40 Tag, disconnect and plug the hydraulic hose on the upper lift cylinder. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 41 Attach a lifting strap from an overhead crane to the number 5 outer arm at the ground control side (index #22). 118 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Scissor Components 42 Remove the retaining fasteners from the number 5 center pivot pin (index #4) at the ground control side. 43 Place a rod through the number 5 center pivot pin at the ground control side (index #4) and twist to remove the pin. 44 Remove the retaining fasteners from the number 5 pivot pin (index #23) at the nonsteer end. 45 Use a soft metal drift to remove the number 5 pivot pin (index #23) from the non-steer end of the machine. Remove the number 5 outer arm at the ground control side (index #22) from the machine. Crushing hazard. The number 5 outer arm at the ground control side (index #22) may become unbalanced and fall if not properly supported when removed from the machine. 46 Attach a lifting strap from an overhead crane to the number 5 outer arm at the battery side (index #22). 47 Remove the number 5 outer arm (index #22) from the machine. Crushing hazard. The number 5 outer arm at the battery side (index #22) may become unbalanced and fall if not properly supported when removed from the machine. 48 Tag and disconnect the wire harness from the solenoid valve on the cylinder. Component damage hazard. Cables can be damaged if they are kinked or pinched. 49 Attach a lifting strap from an overhead crane to the lug of the rod end of the upper lift cylinder. 50 Remove the retaining fasteners from the upper lift cylinder rod end pivot pin (index #5). 51 Use a soft metal drift to remove the upper lift cylinder rod end pivot pin (index #5) from the machine. Crushing hazard. The lift cylinder will fall if not properly supported when the pivot pin is removed. 52 Lower the cylinder onto the linkset. 53 Attach a lifting strap from an overhead crane to the number 4 outer arm at the ground control side (index #25). 54 Remove the retaining fasteners from the number 4 center pivot pin (index #7) at the ground control side. 55 Place a rod through the number 4 center pivot pin at the ground control side (index #7) and twist to remove the pin. 56 Remove the retaining fasteners from the number 4 pivot pin (index #26) at the nonsteer end. 57 Use a soft metal drift to remove the number 4 pivot pin (index #26) from the non-steer end of the machine. Remove the number 4 outer arm at the ground control side (index #25) from the machine. Crushing hazard. The number 4 outer arm at the ground control side (index #25) may become unbalanced and fall if not properly supported when removed from the machine. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 119 Service and Repair Manual Scissor Components March 2021 58 Attach a lifting strap from an overhead crane to the number 4 outer arm at the battery side (index #25). 59 Remove the retaining fasteners from the number 4 center pivot pin (index #7) at the battery side. 60 Place a rod through the number 4 center pivot pin at the battery side (index #7) and twist to remove the pin. 61 Remove the number 4 outer arm (index #25) from the machine. Crushing hazard. The number 4 outer arm (index #25) may become unbalanced and fall if not properly supported when removed from the machine. 62 Attach a lifting strap from an overhead crane to the number 4 inner arm (index #24). Raise the arm to a vertical position. 63 Remove the retaining fasteners from the number 4 pivot pin at the steer end of the machine (index #8). 64 Use a soft metal drift to remove the number 4 pivot pin (index #8) from the steer end of the machine. Remove the number 4 inner arm (index #24) from the machine. Crushing hazard. The number 4 inner arm (index #24) may become unbalanced and fall if not properly supported when removed from the machine. 65 Remove the cables from cable bridges f,h,i,j,k and l. Component damage hazard. Cables can be damaged if they are kinked or pinched. 66 Attach a lifting strap from an overhead crane to the number 3 outer arm at the ground control side (index #9). 67 Remove the retaining fasteners from the number 3 center pivot pin (index #10) at the ground control side. 68 Place a rod through the number 3 center pivot pin at the ground control side (index #10) and twist to remove the pin. 69 Remove the retaining fasteners from the number 3 pivot pin (index #29) at the nonsteer end. 70 Use a soft metal drift to remove the number 3 pivot pin (index #29) from the non-steer end of the machine. Remove the number 3 outer arm at the ground control side (index #9) from the machine. Crushing hazard. The number 3 outer arm at the ground control side (index #9) may become unbalanced and fall if not properly supported when removed from the machine. 71 Attach a lifting strap from an overhead crane to the number 3 outer arm at the battery side (index #9). 72 Remove the number 3 outer arm (index #9) from the machine. Crushing hazard. The number 3 outer arm (index #9) may become unbalanced and fall if not properly supported when removed from the machine. 73 Attach a lifting strap from an overhead crane to the number 3 inner arm (index #28). Raise the number 3 inner arm and place a 4 x 4 x 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). 120 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Scissor Components 74 Attach a lifting strap from an overhead crane to the lug of the rod end of the upper lift cylinder. 75 Raise the lift cylinder to a vertical position. Crushing hazard. The lift cylinder will fall if not properly supported when the pivot pin is removed. Component damage hazard. Be careful not to damage the valve or fittings on the cylinder while removing it from the machine. 76 Use a soft metal drift to remove the upper lift cylinder barrel end pivot pin (index #27) from the machine. 77 Attach a lifting strap from an overhead crane to the number 3 inner arm (index #28). Raise the number 3 inner arm and remove the 4 x 4 x 48 inch / 10 cm x 10 cm x 1.2 m block from the link stack. 78 Lower the number 3 inner arm (index #28) and remove the lifting strap. 79 Attach a lifting strap from an overhead crane to the lug of the rod end of the lower lift cylinder. 80 Remove the retaining fasteners from the lower lift cylinder rod end pivot pin (index 11). 81 Use a soft metal drift to remove the lower lift cylinder rod end pivot pin (index 11) from the machine. Crushing hazard. The lift cylinder will fall if not properly supported when the pivot pin is removed. 82 Place a 4 x 4 x 10 inch / 10 x 10 x 25 cm block onto the number 1 inner arm cylinder plate (index #16). 83 Lower the cylinder onto the block. Bodily injury hazard. Keep hands clear of moving parts when lowering the cylinder. 84 Attach a lifting strap from an overhead crane to the number 3 inner arm (index #28). Raise the arm to a vertical position. 85 Remove the retaining fasteners from the number 3 pivot pin at the steer end of the machine (index #12). 86 Use a soft metal drift to remove the number 3 pivot pin (index #12) from the steer end of the machine. Remove the number 3 inner arm (index #28) from the machine. Crushing hazard. The number 3 inner arm (index #28) may become unbalanced and fall if not properly supported when the pivot pin is removed. 87 Attach a lifting strap from an overhead crane to the number 2 outer arm at the ground control side (index #31). 88 Remove the retaining fasteners from the number 2 center pivot pin (index #13) at the ground control side. 89 Place a rod through the number 2 center pivot pin at the ground control side (index #13) and twist to remove the pin. 90 Remove the retaining fasteners from the number 2 pivot pin (index #32) at the nonsteer end. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 121 Service and Repair Manual Scissor Components March 2021 91 Use a soft metal drift to remove the number 2 pivot pin (index #32) from the non-steer end of the machine. Remove the number 2 outer arm at the ground control side (index #31) from the machine. Crushing hazard. The number 2 outer arm at the ground control side (index #31) may become unbalanced and fall if 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 (index #31). 93 Remove the retaining fasteners from the number 2 center pivot pin (index #13) at the battery side. 94 Place a rod through the number 2 center pivot pin at the battery side (index #13) and twist to remove the pin. Crushing hazard. The number 2 outer arm (index #31) may become unbalanced and fall if not properly supported when the pivot pin is removed. 95 Remove the number 2 outer arm (index #31) from the machine. Crushing hazard. The number 2 outer arm (index #31) may become unbalanced and fall if not properly supported when removed from the machine. 96 Attach a lifting strap from an overhead crane to the number 2 inner arm (index #30). Raise the arm to a vertical position. 97 Remove the retaining fasteners from the number 2 pivot pin at the steer end of the machine (index #14). 98 Use a soft metal drift to remove the number 2 pivot pin (index #14) from the steer end of the machine. Remove the number 2 inner arm (index #30) from the machine. Crushing hazard. The number 2 inner arm (index #30) may become unbalanced and fall if not properly supported when the pivot pin is removed. 99 Attach a lifting strap from an overhead crane to the number 1 inner arm (index #16). 100 Raise the number 1 inner arm (index #16) approximately 2 feet / 60 cm. 101 Place a 4 x 4 x 48 inch / 10 cm x 10 cm x 1.2 m long block across both sides of the chassis under the number 1 center pivot pin (index #15). 102 Lower the scissor arms onto the block that was placed across the chassis. Bodily injury hazard. Keep hands clear of moving parts when lowering the scissor arms. 103 Attach a lifting strap from an overhead crane to the lug of the rod end of the lower lift cylinder. 104 Tag, disconnect and plug the hydraulic hose on the lower lift cylinder. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 122 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Scissor Components 105 Tag and disconnect the wire harness from the solenoid valve on the cylinder. 106 Tag and disconnect the wires and manual lowering cable from the solenoid valve on the cylinder. 107 Models with platform overload option: Tag and disconnect the wire harness from the platform overload pressure transducer. Note: After replacing the scissor assembly, the platform overload system must be calibrated. Refer to Repair Procedure 9-10, How to Calibrate the Platform Overload System (if equipped). 108 Raise the lift cylinder to a vertical position. 109 Remove the pin retaining fasteners from the lift cylinder barrel-end pivot pin (index #28). Use a soft metal drift to remove the pin. Remove the lift cylinder from the machine. Crushing hazard. The lift cylinder will fall if not properly supported when the pivot pin is removed. Component damage hazard. Be careful not to damage the valve or fittings on the cylinder while removing it from the machine. 110 Remove the cables from the number 1 cable bridge and lay them off to the side. Component damage hazard. Cables can be damaged if they are kinked or pinched. 111 Remove the cables from the number 1 cable bridge and lay them off to the side. 112 Disconnect the number 1 cable bridge from the number 1 outer arm (index #34) and remove the cable bridge from the machine. 113 Attach a lifting strap from an overhead crane to the number 1 inner arm (index #16). 114 Raise the arm slightly and remove the block. 115 Lower the arm to the stowed position. Bodily injury hazard. Keep hands clear of moving parts when lowering the scissor arms. 116 Secure the ends of the scissor arms together at the steer end of the machine with a strap or other suitable device. 117 Secure the ends of the scissor arms together at the non-steer end of the machine with a strap or other suitable device. 118 Remove the retaining fasteners securing the chassis mount bracket to the chassis. 119 Remove the linkset from the machine. Bodily injury hazard. The number 1 inner and outer arms (index #16 and #34) may become unbalanced and fall if not properly supported when removed from the machine. Component damage hazard. Be sure not to damage the limit switch or level sensor components when the number 1 inner and outer arms (index #16 and 34) are removed from the machine. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 123 Service and Repair Manual Scissor Components March 2021 9-7 Scissor Arm Wear Pads How to Replace the Scissor Arm Wear Pads Note: Machines equipped with a Platform Height Sensor, begin at step 1. Machines without a Platform Height Sensor, begin at step 24. 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls. 2 GS-4655: Raise the platform approximately 13 feet / 4 m. All other models: Raise the platform 7 to 8 feet / 2,1 to 2,4 m. 3 Lift the safety arm, move it to the center of the scissor arm and rotate down to a vertical position. 4 Lower the platform onto the safety arm. Crushing hazard. Keep hands clear of the safety arm when lowering the platform. 5 At the ground control, turn the key switch to the off position and push in the red Emergency Stop button to the off position. 6 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. 7 Remove the fasteners securing the platform height sensor cover to the large platform height sensor bracket. 8 Remove the platform height sensor cover. 9 Tag and disconnect the platform height sensor from the platform height sensor harness. 10 Remove the fastener securing the platform height sensor assembly to the number 1 inner arm. 11 Remove the platform height sensor assembly from the number 1 pivot pin. 12 Remove the plastic nut securing the squeeze connector to the large platform height sensor bracket. 13 Remove the squeeze connector from the large 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. 17 Connect the battery pack to the machine. 18 Turn the key switch to the ground control position. 19 Press and hold the ground control scroll up and scroll down buttons. 20 Pull out the red Emergency Stop button to the on position at the ground controls. 124 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Scissor Components 21 Using the ground control menu buttons, navigate to Service Override Mode. Select Service Override Mode. Note: The machine must be in Service Override Mode to raise the platform. While in Service Override Mode, only the GCON will operate with limited functionality. The platform will raise a predetermined amount of time and stop. 22 Raise the platform and return the safety arm to the stowed position. 23 Fully lower the platform to the stowed position. 24 Remove the platform. Refer to Repair Procedure, How to Remove the Platform. 25 Support and secure the entry ladder to an appropriate lifting device. 26 Remove the fasteners from the entry ladder and remove the entry ladder from the machine. Crushing hazard. The entry ladder will fall if not properly supported and secured to the lifting device. 27 Secure the ends of the scissor arms together at the steer end of the machine with a strap or other suitable device. 28 Secure the ends of the scissor arms together at the non-steer end of the machine with a strap or other suitable device. 29 Remove the retaining fasteners securing the chassis mount bracket to the chassis at the steer end of the machine. 30 Attach a lifting strap from an overhead crane to the scissor arm assembly. 31 Raise the scissor arm assembly at the steer end with the overhead crane until the chassis mount bracket will clear the level sensor. 32 Remove the scissor assembly from the machine just enough to access both wear pads. Crushing hazard. The scissor assembly will fall if not properly supported when removed from the drive chassis. Component damage hazard. Be careful not to damage the level sensor or limit switch while moving the scissor assembly. 33 Remove both old wear pads. 34 Install two new wear pads. 35 Slide the scissor assembly back into the drive chassis. 36 Lower the scissor assembly into position and install the chassis mount bracket onto the chassis. Securely install and tighten the fasteners. Do not over tighten. Component damage hazard. Be careful not to damage the level sensor or limit switch while moving the scissor assembly. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 125 Service and Repair Manual Scissor Components March 2021 9-8 Platform Height Sensor 7 Remove the platform height sensor cover. How to Disassemble the Platform Height Sensor Assembly (if equipped) Note: When a Platform Height Sensor Assembly is removed or replaced, the platform overload system must be calibrated. Refer to Repair Procedure, How to Calibrate the Platform Overload System (if equipped) and follow the no load calibration procedure. 1 Raise the platform 7 to 8 feet / 2,1 to 2,4 m. 2 Lift the safety arm, move it to the center of the scissor arm and rotate down to a vertical position. 3 Lower the platform onto the safety arm. Crushing hazard. Keep hands clear of the safety arm when lowering the platform. 4 Turn the key switch to the off position. 5 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. 6 Remove the fasteners securing the large platform height sensor cover to the large platform height sensor bracket. Steer End 1 fasteners (platform height sensor cover) 2 platform height sensor cover 8 Tag and disconnect the platform height sensor from the platform height sensor harness. 9 Remove the fastener securing the platform height sensor assembly to the number 1 inner arm. 10 Remove the platform height sensor assembly from the number 1 pivot pin. 11 Remove the set screw securing the lever arm to the platform height sensor. 12 Remove the lever arm from the platform height sensor assembly. 13 Working with the platform height sensor assembly, remove the Deustch connector from the plastic clip. 14 Remove the fasteners securing the platform height sensor to the small platform height sensor bracket. 126 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Scissor Components 15 Remove the platform height sensor from the small angle sensor bracket. 16 Remove the plastic nut securing the squeeze connector to the large platform height sensor bracket. 17 Remove the squeeze connector from the large platform height sensor bracket. 18 Remove the fasteners securing the large platform height bracket to the number 1 inner arm pivot bracket. 19 Remove the large platform height sensor bracket from the number 1 inner arm pivot 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 Part No. 1272217GT GSTM-30 · 32 · 46 · 47 127 Service and Repair Manual Scissor Components March 2021 9-9 Lift Cylinders How to Remove the Lift Cylinder Bodily injury hazard. The 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. Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications. GS-1330m, GS-1530, GS-1532, GS1930 and GS-1932: Note: Models without a pressure transducer follow steps 1 through 23, 27 and 28. Models equipped with a pressure transducer follow steps 1 through 28. 1 Turn the key switch to ground controls and pull out the red Emergency Stop button to the on position at both ground and platform controls. 2 Raise the platform 7 to 8 feet / 2,1 to 2,4 m. 3 Lift the safety arm, move it to the center of the scissor arm and rotate down to a vertical position. 1 lift cylinder 2 orifice(schematic item O) 3 connector fitting 4 hydraulic hose 5 pressure transducer(schematic item R)(if equipped) 6 manual lowering cable 7 solenoid valve(schematic item N) 8 cable mount bracket 4 Lower the platform onto the safety arm. Crushing hazard. Keep hands clear of the safety arm when lowering the platform. 5 Using a suitable lifting device, support the link stack at the steer end of the machine. 128 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Scissor Components 6 At the ground controls, turn the key switch to the off position and push in the red Emergency 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. 8 Tag and disconnect the wiring from the solenoid valve coil at the barrel end of the lift cylinder. 9 If equipped, tag and disconnect the three-pin connector from the pressure transducer harness. To remove the pressure transducer refer to Repair Procedure, How to Remove the Pressure Transducer (if equipped). 10 Loosen the adjustment nuts on the solenoid valve and disconnect the manual lowering cable from the valve. Note: During assembly, the manual platform lowering cable needs to be properly adjusted. Refer to Repair Procedure, How to Adjust the Manual Platform Lowering Cable. 11 Remove the fasteners securing the manual lowering cable mount bracket to the cylinder. Remove the bracket from the cylinder. 12 Tag, disconnect and plug the hydraulic hoses on the lift cylinder. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 13 Attach a lifting strap from an overhead crane to the rod end of the lift cylinder for support. 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. 15 Lower the cylinder onto the number 2 inner arm. 16 Attach a lifting strap from an overhead crane or similar lifting device to the barrel end of the 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. 18 Support and secure the lift cylinder to an appropriate lifting device. 19 Remove the lift cylinder through the scissor arms at the steer end of the machine. Crushing hazard. The lift cylinder will become unbalanced and fall if not properly supported and secured to the lifting device. Component damage hazard. Be careful not to damage the valve or fittings on the cylinder while removing it from the machine. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 129 Service and Repair Manual Scissor Components March 2021 20 Install new cylinder, fittings, hoses and pressure transducer (if equipped). Torque specifications Solenoid valve, 2 position 2 way, N.C. (schematic item N) 20 ft-lbs 27 Nm Coil nut Pressure transducer(if equipped) (schematic item R) 5 ft-lbs 7 Nm 27 ft-lbs 37 Nm 21 Remove the lifting device supporting the link stack at the steer end of the machine. 22 Connect the battery pack to the machine. 23 Turn the key switch to ground control. Models without a pressure transducer continue at step 27. Models with a pressure transducer continue at step 24. 24 Press and hold the ground control scroll up and scroll down buttons. 25 Pull out the red Emergency Stop button to the on position at the ground controls. 26 Using the ground control menu buttons, navigate to Service Override Mode. Select Service Override Mode. Note: The machine must be in Service Override Mode to raise the platform. While in Service Override Mode, only the GCON will operate with limited functionality. The platform will raise a predetermined amount of time and stop. 27 Raise the platform and 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). GS-2032, GS-2632, GS-2046 and GS-2646 Bodily injury hazard. The 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. Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications. Note: Models without a pressure transducer follow steps 1 through 23, 27 and 28. Models equipped with a pressure transducer follow steps 1 through 28. 1 Turn the key switch to ground controls and pull out the red Emergency Stop button to the on position at both ground and platform controls. 2 Raise the platform 7 to 8 feet / 2,1 to 2,4 m. 130 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Scissor Components 3 Lift the safety arm, move it to the center of the scissor arm and rotate down to a vertical position. 1 lift cylinder 2 orifice(schematic item O) 3 connector fitting 4 hydraulic hose 5 pressure transducer(schematic item R)(if equipped) 6 manual lowering cable 7 solenoid valve(schematic item N) 8 cable mount bracket 4 Lower the platform onto the safety arm. Crushing hazard. Keep hands clear of the safety arm when lowering the platform. 5 Using a suitable lifting device, support the link stack at the steer end of the machine. 6 At the ground controls, turn the key switch to the off position and push in the red Emergency 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. 8 Tag and disconnect the wiring from the solenoid valve coil at the barrel end of the lift cylinder. 9 If equipped, tag and disconnect the three-pin connector from the pressure transducer harness. To remove the pressure transducer refer to Repair Procedure, How to Remove the Pressure Transducer (if equipped). 10 Loosen the adjustment nuts on the solenoid valve and disconnect the manual lowering cable from the valve. Note: During assembly, the manual platform lowering cable needs to be properly adjusted. Refer to Repair Procedure, How to Adjust the Manual Platform Lowering Cable. 11 Remove the fasteners securing the manual lowering cable mount bracket to the cylinder. Remove the bracket from the cylinder. 12 Tag, disconnect and plug the hydraulic hoses on the lift cylinder. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 131 Service and Repair Manual Scissor Components March 2021 13 Attach a lifting strap from an overhead crane to the rod end of the lift cylinder for support. 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. 15 Lower the cylinder onto the number 1 inner arm cylinder plate. 16 Attach a lifting strap from an overhead crane or similar lifting device to the barrel end of the 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. 18 Support and secure the lift cylinder to an appropriate lifting device. 19 Remove the lift cylinder through the scissor arms at the steer end of the machine. Crushing hazard. The lift cylinder will become unbalanced and fall if not properly supported and secured to the lifting device. Component damage hazard. Be careful not to damage the valve or fittings on the cylinder while removing it from the machine. 20 Install new cylinder, fittings, hoses and pressure transducer (if equipped). Torque specifications Solenoid valve, 2 position 2 way, N.C. (schematic item N) 20 ft-lbs 27 Nm Coil nut Pressure transducer(if equipped) (schematic item R) 5 ft-lbs 7 Nm 27 ft-lbs 37 Nm 21 Remove the lifting device supporting the link stack at the steer end of the machine. 22 Connect the battery pack to the machine. 23 Turn the key switch to ground control. Models without a pressure transducer continue at step 27. Models with a pressure transducer continue at step 24. 24 Press and hold the ground control scroll up and scroll down buttons. 25 Pull out the red Emergency Stop button to the on position at the ground controls. 26 Using the ground control menu buttons, navigate to Service Override Mode. Select Service Override Mode. Note: The machine must be in Service Override Mode to raise the platform. While in Service Override Mode, only the GCON will operate with limited functionality. The platform will raise a predetermined amount of time and stop. 27 Raise the platform and 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). 132 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Scissor Components GS-3232 and GS-3246 Bodily injury hazard. The 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. Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications. Note: Models without a pressure transducer follow steps 1 through 21, 25 and 26. Models equipped with a pressure transducer follow steps 1 through 26. 1 Turn the key switch to ground controls and pull out the red Emergency Stop button to the on position at both ground and platform controls. 2 Raise the platform 7 to 8 feet / 2,1 to 2,4 m. 3 Lift the safety arm, move it to the center of the scissor arm and rotate down to a vertical position. 1 lift cylinder 2 orifice(schematic item O) 3 connector fitting 4 hydraulic hose 5 pressure transducer(schematic item R)(if equipped) 6 manual lowering cable 7 solenoid valve(schematic item N) 8 cable mount bracket Part No. 1272217GT GSTM-30 · 32 · 46 · 47 133 Service and Repair Manual Scissor Components March 2021 4 Lower the platform onto the safety arm. Crushing hazard. Keep hands clear of the safety arm when lowering the platform. 5 Using a suitable lifting device, support the link stack at the steer end of the machine. 6 At the ground controls, turn the key switch to the off position and push in the red Emergency 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. Note: At the lower lift cylinder, install the orifice fitting with the small opening of the orifice fitting closest to the supply hose. 8 Tag and disconnect the wiring from the solenoid valve coil at the barrel end of the lift cylinder. Skip to step 13 if removing the upper cylinder. 9 If equipped, tag and disconnect the three-pin connector from the pressure transducer harness. To remove the pressure transducer refer to Repair Procedure, How to Remove the Pressure Transducer (if equipped). 10 Loosen the adjustment nuts on the solenoid valve and disconnect the manual lowering cable from the valve. Note: During assembly, the manual platform lowering cable needs to be properly adjusted. Refer to Repair Procedure, How to Adjust the Manual Platform Lowering Cable. 11 Remove the fasteners securing the manual lowering cable mount bracket to the cylinder. Remove the bracket from the cylinder. 12 Tag, disconnect and plug the hydraulic hoses on the lift cylinder. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 13 Attach a lifting strap from an overhead crane or similar lifting device to the barrel end of the lift cylinder for support. 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. 15 Lower the cylinder onto the number 1 inner arm cylinder plate. 134 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Scissor Components 16 Attach a lifting strap from an overhead crane or similar lifting device to the barrel end of the 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. 18 Support and secure the lift cylinder to an appropriate lifting device. 19 Remove the lift cylinder through the scissor arms at the steer end of the machine. Crushing hazard. The lift cylinder will become unbalanced and fall if not properly supported and secured to the lifting device. Component damage hazard. Be careful not to damage the valve or fittings on the cylinder while removing it from the machine. 20 Install new cylinder, fittings, hoses and pressure transducer (if equipped). Upper Lift Cylinder 1 lift cylinder 2 connector fitting 3 hydraulic hose 4 solenoid valve (schematic item N) 5 orifice (schematic item O) 6 relief valve (schematic item Q) Note: At the upper lift cylinder, install the orifice fitting with the small opening of the orifice fitting closest to the supply hose. Torque specifications Solenoid valve, 2 position 2 way, N.C. (schematic item N) 20 ft-lbs 27 Nm Relief valve (schematic item Q) 20 ft-lbs 27 Nm Coil nut 5 ft-lbs 7 Nm Part No. 1272217GT GSTM-30 · 32 · 46 · 47 135 Service and Repair Manual Scissor Components March 2021 21 Remove the lifting device supporting the link stack at the steer end of the machine. 22 Connect the battery pack to the machine. 23 Turn the key switch to ground control. Models without a pressure transducer continue at step 27. Models with a pressure transducer continue at step 24. 24 Press and hold the ground control scroll up and scroll down buttons. 25 Pull out the red Emergency Stop button to the on position at the ground controls. 26 Using the ground control menu buttons, navigate to Service Override Mode. Select Service Override Mode. Note: The machine must be in Service Override Mode to raise the platform. While in Service Override Mode, only the GCON will operate with limited functionality. The platform will raise a predetermined amount of time and stop. 27 Raise the platform and 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). GS-4047 Bodily injury hazard. The 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. Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications. 1 Turn the key switch to ground controls and pull out the red Emergency Stop button to the on position at both ground and platform controls. 2 Raise the platform 7 to 8 feet / 2,1 to 2,4 m. 136 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Scissor Components 3 Lift the safety arm, move it to the center of the scissor arm and rotate down to a vertical position. 1 relief valve(schematic item Q) 2 lift cylinder 3 connector fitting 4 hydraulic hose 5 pressure transducer(schematic item R)(if equipped) 6 manual lowering cable 7 solenoid valve(schematic item DO) 8 cable mount bracket 4 Lower the platform onto the safety arm. Crushing hazard. Keep hands clear of the safety arm when lowering the platform. 5 Using a suitable lifting device, support the link stack at the steer end of the machine. 6 At the ground controls, turn the key switch to the off position and push in the red Emergency 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. 8 Tag and disconnect the wiring from the solenoid valve coil at the barrel end of the lift cylinder. Skip to step 13 if removing the upper cylinder. 9 If equipped, tag and disconnect the three-pin connector from the pressure transducer harness. To remove the pressure transducer refer to Repair Procedure, How to Remove the Pressure Transducer (if equipped). 10 Loosen the adjustment nuts on the solenoid valve and disconnect the manual lowering cable from the valve. Note: During assembly, the manual platform lowering cable needs to be properly adjusted. Refer to Repair Procedure, How to Adjust the Manual Platform Lowering Cable. 11 Remove the fasteners securing the manual lowering cable mount bracket to the cylinder. Remove the bracket from the cylinder. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 137 Service and Repair Manual Scissor Components March 2021 12 Tag, disconnect and plug the hydraulic hoses on the lift cylinder. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 13 Attach a lifting strap from an overhead crane or similar lifting device to the barrel end of the lift cylinder for support. 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. 15 Lower the cylinder onto the number 1 inner arm cylinder plate. 16 Attach a lifting strap from an overhead crane or similar lifting device to the barrel end of the 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. 18 Support and secure the lift cylinder to an appropriate lifting device. 19 Remove the lift cylinder through the scissor arms at the steer end of the machine. Crushing hazard. The lift cylinder will become unbalanced and fall if not properly supported and secured to the lifting device. Component damage hazard. Be careful not to damage the valve or fittings on the cylinder while removing it from the machine. 20 Install new cylinder, fittings, hoses and pressure transducer (if equipped). Upper Lift Cylinder 1 relief valve(schematic item Q) 2 lift cylinder 3 connector fitting 4 hydraulic hose 5 check valve(schematic item DK) 138 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Scissor Components Torque specifications Solenoid valve, 2 position 2 way, N.C. (schematic item N) 20 ft-lbs 27 Nm Relief valve (schematic item Q) 20 ft-lbs 27 Nm Coil nut Pressure transducer(if equipped) (schematic item R) 5 ft-lbs 7 Nm 27 ft-lbs 37 Nm Check valve (schematic item DK) 20 ft-lbs 27 Nm 21 Remove the lifting device supporting the link stack at the steer end of the machine. 22 Connect the battery pack to the machine. 23 Turn the key switch to ground controls. 24 Press and hold the ground control scroll up and scroll down buttons. 25 Pull out the red Emergency Stop button to the on position at the ground controls. 26 Using the ground control menu buttons, navigate to Service Override Mode. Select Service Override Mode. Note: The machine must be in Service Override Mode to raise the platform. While in Service Override Mode, only the GCON will operate with limited functionality. The platform will raise a predetermined amount of time and stop. 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). 9-10 Pressure Transducer How to Remove the Pressure Transducer (if equipped) Note: Calibrating the platform overload system is not required if the pressure transducer is the only component replaced on the machine lift structure. In the event of frequent nuisance trips occurring after a pressure transducer is replaced, a no load calibration is recommended. Refer to Repair Procedure, How to Calibrate the Platform Overload System (if equipped) 1 Turn the key switch to ground controls and pull out the red Emergency Stop button to the on position at both ground and platform controls. 2 Raise the platform 7 to 8 feet / 2,1 to 2,4 m. 3 Lift the safety arm, move it to the center of the scissor arm and rotate down to a vertical position. 4 Lower the platform onto the safety arm. 5 At the ground controls, turn the key switch to the off position and push in the red Emergency Stop button to the off position. 6 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. 7 Pull the manual lowering cable and hold for 3 seconds. 8 Tag and disconnect the three-pin connector from the pressure transducer harness. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 139 Service and Repair Manual Scissor Components 9 Slowly loosen the pressure transducer from the lift cylinder and remove. Discard the pressure transducer. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 10 Connect the battery pack to the machine. 11 Turn the key switch to ground controls. 12 Press and hold the ground control scroll up and scroll down buttons. 13 Pull out the red Emergency Stop button to the on position at the ground controls. 14 Using the ground control menu buttons, navigate to Service Override Mode. Select Service Override Mode. Note: The machine must be in Service Override Mode to raise the platform. While in Service Override Mode, only the GCON will operate with limited functionality. The platform will raise a predetermined amount of time and stop. 15 Raise the platform and rotate the safety arm to the stowed position. 16 Fully lower the platform to the stowed position. Note: After replacing the pressure transducer, calibrating the platform overload system is not required. If the machine begins to nuisance trip frequently, a no load calibration is recommended. Refer to Repair Procedure, How to Calibrate the Platform Overload System (if equipped). Torque specifications Pressure transducer(if equipped) (schematic item R) 27 ft-lbs 37 Nm March 2021 140 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Scissor Components 9-11 Platform Overload System (if equipped) How to Calibrate the Platform Overload System Perform this procedure with the machine in the stowed position and on a firm, level surface that is free of obstructions. Personnel are not allowed in the platform while calibrating the platform overload system. Perform this procedure in an environment that allows the platform to be fully raised. Models rated for indoor use only, should be calibrated inside a facility with enough ceiling height to fully raise the platform. If the facility height is not suitable to fully raise the platform, then an indoor only rated model may be calibrated outdoors if wind speeds are less then 28 mph / 12.5 m/s. Only use flat weights while calibrating indoor only rated machines, outdoors. Perform this procedure after confirming that the platform height sensor is not damaged and functions correctly. There are two options to the platform overload calibration procedure in this section, Full Load Calibration and No Load Calibration. Full Load Calibration has two steps requiring calibration with and without rated load in the platform. No Load Calibration does not require rated load in the platform. Note: No Load Calibration can be completed stand alone to fulfill the C-2 overload calibration requirements, if the machine has completed the Full Load Calibration procedure. Note: If a new Ground Controller is installed on a machine, the Full Load Calibration procedure is required to maintain rated load platform capacity. If a No Load Calibration is performed, machine lifting performance will be significantly reduced. Note: Ambient temperature must be above 32°F / 0°C before calibrating the Platform Overload System. Note: To calibrate the platform overload system, follow the menu structure indicated on the ground control LCD display. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 141 Service and Repair Manual Scissor Components March 2021 Full Load Calibration: Part 1 1 Fully charge the batteries and check the hydraulic fluid level. Note: The hydraulic fluid level must be between the FULL and ADD marks on the hydraulic tank. 2 Apply a thin layer of dry film lubricant to the area of the chassis and platform, where the scissor arm wear pads make contact. 3 Chock both sides of the wheels at the steer end of the machine. 4 Using a suitable lifting device, place a test weight corresponding to the machine maximum load, in the center of the platform deck. Secure the weight to the platform. Refer to the chart below. GS-1530, GS-1532 600 lbs / 272 kg GS-1930, GS-1932 500 lbs / 227 kg GS-2032 800 lbs / 363 kg GS-2632 500 lbs / 227 kg GS-3232 500 lbs / 227 kg Note: In the event of frequent nuisance trips occurring after calibrating a GS-3232 machine, it is recommended to recalibrate the machine, full load and no load, with 250 kg of weight in the platform. GS-2046 1200 lbs / 544 kg GS-2646 1000 lbs / 454 kg GS-3246 700 lbs / 317 kg GS-4047 770 lbs / 350 kg 5 Turn the key switch to ground control. 6 At the ground controls, press and hold the Menu Up and Menu Down buttons. 7 While pressing both buttons down, pull out the red Emergency Stop Button. 8 Release the Menu Up and Menu Down buttons after the ground controller powers up. 9 Use the Menu Up or Menu Down buttons to scroll to, Select Option. Press the Enter button. 10 Use the Menu Up or Menu Down buttons to scroll to Platform Overload. 11 Press the Enter button to select Platform Overload. 12 Use the Menu Up or Menu Down buttons to scroll to Platform Overload Calibrate. 13 Press the Enter button to select Platform Overload Calibrate. 14 Confirm the Platform Overload Calibrate selection by pressing the Enter button again. 15 Use the Menu Up or Menu Down buttons to select Full Load calibration. 16 Press the Enter button to select Full Load calibration. 17 Press the Enter button to confirm rated load is in the platform. 18 At the ground controls, press and hold the Function Enable and Platform Up buttons until the platform reaches maximum height. 19 All Models except GS-4047: When the platform reaches maximum height, press the ground controls Enter button. Allow the ground controls to gather data. GS4047 only: Press and hold the Menu Enter button to determine the maximum height. The machine will lower for 1.2 seconds and then raise in 1.2 second durations, until maximum height is reached. When the platform reaches the maximum height, a message will appear on the LCD 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. 142 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Scissor Components 20 When prompted, press and hold the Function Enable and Platform Down buttons. The platform will lower, then automatically stop at a predetermined point to gather data. Allow the ground controls to gather data. 21 Continue pressing the Function Enable and Platform Down buttons throughout the lowering and data gathering sequence. The machine will stop to gather data and lower several times before the machine reaches the stowed position. When the platform reaches the stowed position, press the enter button. Note: Software revision H or prior, and GS3032, GS-2646 and GS-4047 models, continue to step 24. Note: All other models with software revision J or higher, continue with step 22. 22 When prompted, press and hold the Function Enable and Platform Up buttons until the platform reaches full height. When the platform reaches full height, press the enter button. 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. 23 When prompted, press and hold the Function Enable and Platform Down buttons until the platform is fully stowed. When the platform reaches the stowed position, press the enter button. Note: If the Function Enable or Platform Down buttons are released while the machine is collecting data, the GCON LCD will prompt the user to raise the platform for 5 seconds before prompting to lower the platform to the stowed position again. Note: If the machine is switched to PCON mode to drive the machine to an area for weight removal, step 3 and steps 5 through 14 will have to be repeated before Full Load Calibration: Part 2 is performed. Additionally, the CO25 fault will appear. This is expected and the data collected in Full Load Calibration: Part 1 has not been lost. 24 Using a suitable lifting device, remove the test weight from the platform deck. 25 After the weight is removed from the platform deck, press the Enter button to confirm the weight has been removed. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 143 Service and Repair Manual Scissor Components March 2021 Full Load Calibration: Part 2 26 At the ground controls, press and hold the Function Enable and Platform Up buttons until the platform reaches maximum height. 27 All Models except GS-4047: When the platform reaches maximum height, press the Enter button. Allow the ground controls to gather data. GS-4047 only: Press and hold the Menu Enter button to determine the maximum height. The machine will lower for 1.2 seconds and then raise in 1.2 second durations, until maximum height is reached. When the platform reaches the maximum height, a message will appear on the LCD 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 26. 28 When prompted, press and hold the Function Enable and Platform Down buttons to lower the platform. The platform will move down, then automatically stop at a predetermined point to gather data. Allow the ground controls to gather data. 29 Continue pressing the Function Enable and Platform Down buttons throughout the lowering and data gathering sequence. The machine will stop to gather data and lower several times before the machine reaches the stowed position. When the platform reaches the stowed position, press the Enter button. Note: Software revision H or prior, and GS2032, GS-2646 and GS-4047 models, continue to step 32. Note: All other models with software revision J or higher, continue with step 30. 30 When prompted, press and hold the Function Enable and Platform Up buttons until the platform reaches full height. When the platform reaches full height, press the enter button. 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. 31 When prompted, press and hold the Function Enable and Platform Down buttons until the platform is fully stowed. When the platform reaches the stowed position, press the enter button. Note: If the Function Enable or Platform Down buttons are released while the machine is collecting data, the GCON LCD will prompt the user to raise the platform for 5 seconds before prompting to lower the platform to the stowed position again. 32 When prompted, push the red Emergency Stop button in to complete the Platform Overload Calibration procedure. 144 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Scissor Components No Load Calibration 1 Fully charge the batteries and check the hydraulic fluid level. Note: The hydraulic fluid level must be between the FULL and ADD marks on the hydraulic tank. 2 Apply a thin layer of dry film lubricant to the area of the chassis where the scissor arm wear pads make contact. 3 Chock both sides of the wheels at the steer end of the machine. 4 Turn the key switch to ground control. 5 At the ground controls, press and hold the Menu Up and Menu Down buttons. 6 While pressing both buttons down, pull out the red Emergency Stop Button. 7 Release the Menu Up and Menu Down buttons after the ground controller powers up. 8 At the ground controls, use the Menu Up or Menu Down buttons to scroll to Platform Overload. 9 Press the Enter button to select the Platform Overload. 10 Use the Menu Up or Menu Down buttons to scroll to Platform Overload Calibrate. 11 Press the Enter button to select Platform Overload Calibrate. 12 Confirm the Platform Overload Calibrate selection by pressing the Enter button again. 13 Use the Menu Up or Menu Down buttons to select No Load calibration. 14 Press the Enter button to select No Load calibration. 15 Press the Enter button to confirm no load is in the platform. 16 At the ground controls, press and hold the Function Enable and Platform Up buttons until the platform reaches maximum height. 17 All Models except GS-4047: When the platform reaches maximum height, press the ground controls Enter button. Allow the ground controls to gather data. GS4047 only: Press and hold the Menu Enter button to determine the maximum height. The machine will lower for 1.2 seconds and then raise in 1.2 second durations, until maximum height is reached. When the platform reaches the maximum height, a message will appear on the LCD screen to release the Menu Enter button. 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 16. 18 When prompted, press and hold the Function Enable and Platform Down buttons to lower the platform. The platform will move down, then automatically stop at a predetermined point to gather data. Allow the ground controls to gather data. 19 Continue pressing the Function Enable and Platform Down buttons throughout the lowering and data gathering sequence. The machine will stop to gather data and lower several times before the machine reaches the stowed position. When the platform reaches the stowed position, press the Enter button. Note: Software revision H or prior, and GS2032, GS-2646 and GS-4047 models, continue to step 22. Note: All other models with software revision J or higher, continue with step 20. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 145 Service and Repair Manual Scissor Components March 2021 20 When prompted, press and hold the Function Enable and Platform Up buttons until the platform reaches full height. When the platform reaches full height, press the enter button. 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. 21 When prompted, press and hold the Function Enable and Platform Down buttons until the platform is fully stowed. When the platform reaches the stowed position, press the enter button. Note: If the Function Enable or Platform Down buttons are released while the machine is collecting data, the GCON LCD will prompt the user to raise the platform for 5 seconds before prompting to lower the platform to the stowed position again. 22 When prompted, push the red Emergency Stop button in to complete the No Load Calibration procedure. 9-12 Platform Overload Recovery Message If the ground controls LCD screen displays OL: PLATFORM OVERLOADED, the emergency lowering system has been used while the platform was overloaded. How to Clear the Platform Overload Recovery Message Note: This message shall be cleared by a person trained and qualified on the troubleshooting and repair of this machine. Note: Use the following chart to identify the description of each LCD screen control button used in this procedure. Escape Scroll up Scroll down Enter 1 Turn the key switch to the ground controls position and pull out the red Emergency Stop button to the on position at the platform controls. 2 Press and hold the ground control scroll up and scroll down buttons. 146 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Scissor Components 3 Pull out the red Emergency Stop button at the ground controls. Result: The ground control LCD display will show the following. 7 Press and hold the scroll down button for 5 seconds. Result: The ground control LCD display will show the following. 4 Press the scroll down button. Result: The ground control LCD display will show the following. 8 Press the enter button. Result: The ground control LCD display will show the following. 5 Press the enter button. Result: The ground control LCD display will show the following. 6 Press the enter button. Result: The ground control LCD display will show the following. 9 Press the buttons in the following sequence: (down)(down)(up)(enter). 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. Note: After 3 seconds the LCD display will return to SELECT OPTION PLAT. OVERLOAD. 10 Push in the red Emergency stop button. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 147 Service and Repair Manual Platform Components March 2021 10-1 Platform How to Remove the Platform Perform this procedure with the platform extension fully retracted and locked in position. 1 Raise the platform to approximately 3 ft / 1 m. 2 Remove the retaining fasteners securing the platform to the platform mount at the steer end of the machine. 3 Lower the platform to the stowed position. 4 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. 5 Disconnect the platform controls from the control cable at the platform. 6 Remove the cover from the AC outlet. Tag and disconnect the wiring from the outlet. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 7 Disconnect the wiring from the platform and pull the wiring free of the platform. 8 Models with air line to platform option: Disconnect the air line from the platform. Pull the air line free of the platform. 9 Support the platform with a forklift at the nonsteer end. Do not apply any lifting pressure. 10 Attach a strap from the lanyard anchorage point on the platform railings to the carriage on the forklift to help support the platform. 11 GS-1530/32 and GS-1930/32: Lift the steer end of the platform slightly to clear the platform mount and slide the platform towards the non-steer end of the machine until the platform slide blocks at the non-steer end of the machine are visible through the access holes in the bottom of the platform. All other models: Lift the steer end of the platform slightly to clear the platform mount and slide the platform towards the steer end of the machine until the platform slide blocks at the non-steer end of the machine are visible through the access holes in the bottom of the platform. Crushing hazard. The platform will fall if not properly supported. 12 Carefully lift the platform off of the machine and place it on a structure capable of supporting it. Note: Take notice of the wear pad position before the platform is removed. Correct wear pad position is essential for proper platform functionality. 148 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Platform Components 10-2 Platform Extension Deck How to Remove the Platform Extension Deck 1 Lower the platform to the stowed position. 2 Extend the platform approximately 3 ft / 1 m. 3 Remove the platform controls from the platform. 4 Support the platform extension with a forklift at the steer end of the machine. Do not apply any lifting pressure. 5 Attach a strap from the platform extension railings to the carriage on the forklift to help support the platform extension. 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. 7 Remove the platform roller wheels from the machine. 8 Carefully slide the platform extension out from the platform and place it on a structure capable of supporting it. How to Replace the Platform Extension Deck Wear Pads 1 Remove the Platform Extension Deck. Refer to Repair Procedure, How to Remove the Platform Extension. 2 Drill out the rivets which hold the wear pads in place. 3 Install the new wear pads using new rivets. When installing the new rivets, make sure the rivet heads are not above the surface of the wear pad. 1 roller bracket assembly 2 assembly retaining fastener 3 platform roller bolt Part No. 1272217GT GSTM-30 · 32 · 46 · 47 149 Service and Repair Manual Battery Charger 11-1 Battery Charger The charger contains selectable charging profiles stored in its internal memory to charge batteries. These profiles are specific to each battery type. The charging profile must be programmed to match the specific battery type on the machine. Charger status indicators 1 Error / Fault / USB indicator 2 AC power indicator 3 Battery charging indicator 4 USB port 5 Charging output indicator 6 Charger profile / Error display 7 Charge profile selection button March 2021 Remote charger status indicators 1 Error / Fault / USB indicator 2 Error / Fault 3 Charge complete 4 Charging, high state of charge 5 Charging, low state of charge 150 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Battery Charger Selecting a Charge Profile Selecting a Charge Profile Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 1 At the ground controls, turn the key switch to the off position and push in the red Emergency Stop button to the off position. 2 Open the battery compartment. 3 Press and hold the charge profile selection button and plug the battery charger into an AC power source. Continue to hold the button until the amber error indicator is on and the green charging indicator light is flashing. Release the button. 4 Press and release the charge profile selection button to navigate to the charge profile appropriate for your machine and battery type. Refer to the chart below. Profile Description P001 Scissor, GR, GRC, QS (does not include GS-4047) - Flooded lead acid batteries Temperature compensated * P003 Scissor, GR, GRC, QS (does not include GS-4047) - Flooded lead acid batteries Not temperature compensated ** P007 GS-4047 - Flooded lead acid batteries Not temperature compensated ** P043 All Scissors, GR, GRC, QS - AGM batteries - Temperature compensated * * Temperature compensated: Battery temperature sensor has been installed on the machine. ** Not temperature compensated: Battery temperature sensor has not been installed on the machine. 5 Press and hold the charge profile selection button until the error indicator and charging indicator lights turn off and the AC status indicator light turns on to confirm selection and exit charge profile mode. Release the button. Note: Charge profile mode will time out and exit if there is 15 seconds of inactivity, the charge profile number has been displayed three times or the AC power source had been disconnected. 6 Press and release the charge profile selection button to confirm the correct charge profile has been selected. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 151 Service and Repair Manual Diagnostics March 2021 Section 4 Diagnostics Observe and Obey: Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service a damaged or malfunctioning machine. Repair any machine damage or malfunction before operating the machine. Unless otherwise specified, perform each repair procedure with the machine in the following configuration: · Machine parked on a firm, level surface · Platform in the stowed position · Key switch in the off position with the key removed · The red Emergency Stop button in the off position at both ground and platform controls · Wheels chocked · All external AC power supply disconnected from the machine 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. Read each appropriate fault code thoroughly. Attempting short cuts may produce hazardous conditions. Be aware of the following hazards and follow generally accepted safe workshop practices. Crushing hazard. When testing or replacing any hydraulic component, always support the structure and secure it from movement Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. About This Section When a malfunction is discovered, the fault code charts in this section will help a service professional pinpoint the cause of the problem. To use this section, basic hand tools and certain pieces of test equipment are required -- voltmeter, ohmmeter, pressure gauges. 152 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Definitions GSDS Genie SmartLinkTM Diagnostic System ECM Electronic Control Module GCON Ground Controls PCON Platform Controls OIC Operational Indicator Codes DTC Diagnostic Trouble Codes Service and Repair Manual Diagnostics GCON LCD Diagnostic Readout The diagnostic readout displays alpha numeric codes that provide information about the machine operating status and about malfunctions. The codes listed in the Diagnostic Trouble Code Charts describe malfunctions and can aid in troubleshooting the machine by pinpointing the area or component affected. Models are listed below each code to assist in the troubleshooting codes for a specific model. Genie® SmartLinkTM Diagnostic System This machine is equipped with the Genie SmartLinkTM Diagnostic System (GSDS). The GSDS indicates a machine malfunction has happened by displaying Operational Indicator Codes (OIC) and Diagnostic Trouble Codes (DTC). These codes are displayed at the Platform Controls and the Ground Controls. The Ground Controls will display a brief description of the code at the LCD display as well. Refer to the GCON I/O Maps, Operational Indicator Codes (OIC) and Diagnostic Trouble Codes (DTC) in this section, to assist in troubleshooting faults. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 153 Service and Repair Manual Diagnostics GCON ECM Connector Layout Rear of Ground Controls ECM (models without outriggers) Rear of Ground Controls ECM (models with outriggers) March 2021 154 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Diagnostics GCON Pin Number J1-01 J1-02 J1-03 J1-04 J1-05 J1-06 J1-07 J1-08 J1-09 J1-10 J1-11 J1-12 J2-01 J2-02 J2-03 J2-04 J2-05 J2-06 J2-07 J2-08 J2-09 J2-10 J2-11 J2-12 J3-01 J3-02 J3-03 J3-04 J3-05 J3-06 J3-07 J3-08 J3-09 J3-10 J3-11 J3-12 GCON I/O Map without Load Sense (all models except GS-3232) Circuit Function I/O Type J1 Connector Gray ECM Power Power Input PCON, E-Stop Power Power Output PCON, E-Stop Return Power Input Link to PCON -- CANH Data Bus Link to PCON -- CANL Data Bus PCON -- Ground Ground Output GCON -- Ground Ground Input Key Switch -- PCON Mode Digital Input Key Switch -- GCON Mode Digital Input GCON -- Emergency Mode Digital Input No Circuit N/A Driver Power Power Input J-2 Connector Black Platform Up Coil Digital Output Platform Down Coil Digital Output Steer Left Coil Digital Output Steer Right Coil Digital Output Parallel Coil (GS-32 & GS-46) Digital Output Drive Forward Coil Digital Output No Circuit N/A Motor Controller Enable Digital Output No Circuit N/A Drive Reverse Coil Digital Output Motor Controller Throttle Analog Output No Circuit N/A J-3 Connector Green No Circuit N/A GCON -- Alarm Digital Output Switch/Sensor Power Digital Output Automotive Horn Digital Output Pothole Limit Switch Digital Input Ground Ground Input Down Limit Switch Digital Input Level Sensor Digital Input Ground Ground Input Ground Ground Input No Circuit N/A Load Sense -- Ground Ground Input Wire Gauge and Color 14 RD 18 RD 18 WH 18GR 18 OR 18 BR 14 BR 18 BK 18 WH 18 WH/BK N/A 14 RD 18 OR 18 OR/BK 18 BL/BK 18 BL 18 RD/WH 18 WH N/A 18 GR/WH N/A 18 WH/BK 18 GR N/A N/A 18 BL 14 RD 18 WH 18 OR/RD 18 BR 18 OR 18 RD/BK 18 BK 18 BK N/A 18 BK Part No. 1272217GT GSTM-30 · 32 · 46 · 47 155 Service and Repair Manual Diagnostics March 2021 GCON Pin Number J1-01 J1-02 J1-03 J1-04 J1-05 J1-06 J1-07 J1-08 J1-09 J1-10 J1-11 J1-12 J2-01 J2-02 J2-03 J2-04 J2-05 J2-06 J2-07 J2-08 J2-09 J2-10 J2-11 J2-12 J3-01 J3-02 J3-03 J3-04 J3-05 J3-06 J3-07 J3-08 J3-08 J3-09 J3-10 J3-11 J3-12 GCON I/O Map with Load Sense (all model except GS-3232) Circuit Function I/O Type J1 Connector Gray ECM Power Power Input PCON, E-Stop Power Power Output PCON, E-Stop Return Power Input Link to PCON -- CANH Data Bus Link to PCON -- CANL Data Bus PCON -- Ground Ground Output GCON -- Ground Ground Input Key Switch -- PCON Mode Digital Input Key Switch -- GCON Mode Digital Input GCON -- Emergency Mode Digital Input No Circuit N/A Driver Power Power Input J-2 Connector Black Platform Up Coil Digital Output Platform Down Coil Digital Output Steer Left Coil Digital Output Steer Right Coil Digital Output Parallel Coil (GS-32, GS-46 & GS-47) Digital Output Drive Forward Coil Digital Output Ground (GS-4047) Ground Input Motor Controller Enable Digital Output Lift Pressure Selector (GS-4047) N/A Drive Reverse Coil Digital Output Motor Controller Throttle Analog Output No Circuit N/A J-3 Connector Green No Circuit N/A GCON -- Alarm Digital Output Switch/Sensor Power Digital Output Automotive Horn Digital Output Pothole Limit Switch Digital Input Ground Ground Input Down Limit Switch Digital Input Level Sensor (all models except GS-4655) Digital Input Brake Release (GS-4655) Digital Input Platform Overload Pressure Transducer Ground Input Platform Height Sensor Ground Input No Circuit N/A Load Sense -- Ground Ground Input Wire Gauge and Color 14 RD 18 RD 18 WH 18GR 18 OR 18 BR 14 BR 18 BK 18 WH 18 WH/BK N/A 14 RD 18 OR 18 OR/BK 18 BL/BK 18 BL 18 RD/WH 18 WH 18 BR 18 GR/WH N/A 18 WH/BK 18 GR N/A N/A 18 BL 14 RD 18 WH 18 OR/RD 18 BR 18 OR 18 RD/BK 18 RD/BK 18 BL/WH 18 OR/WH N/A 18 BK 156 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Diagnostics GCON Pin Number J1-01 J1-02 J1-03 J1-04 J1-05 J1-06 J1-07 J1-08 J1-09 J1-10 J1-11 J1-12 J2-01 J2-02 J2-03 J2-04 J2-05 J2-06 J2-07 J2-08 J2-09 J2-10 J2-11 J2-12 GCON I/O Map without Load Sense (GS-3232 only) Circuit Function I/O Type J1 Connector Gray ECM Power Power Input PCON, E-Stop Power Power Output PCON, E-Stop Return Power Input Link to PCON -- CANH Data Bus Link to PCON -- CANL Data Bus PCON -- Ground Ground Output GCON -- Ground Ground Input Key Switch -- PCON Mode Digital Input Key Switch -- GCON Mode Digital Input GCON -- Emergency Mode Digital Input No Circuit N/A Driver Power Power Input J-2 Connector Black Platform Up Coil Digital Output Platform Down Coil Digital Output Steer Left Coil Digital Output Steer Right Coil Digital Output Parallel Coil (GS-32 & GS-46) Digital Output Drive Forward Coil Digital Output No Circuit N/A Motor Controller Enable Digital Output No Circuit N/A Drive Reverse Coil Digital Output Motor Controller Throttle Analog Output No Circuit N/A Wire Gauge and Color 14 RD 18 RD 18 WH 18GR 18 OR 18 BR 14 BR 18 BK 18 WH 18 WH/BK N/A 14 RD 18 OR 18 OR/BK 18 BL/BK 18 BL 18 RD/WH 18 WH N/A 18 GR/WH N/A 18 WH/BK 18 GR N/A Part No. 1272217GT GSTM-30 · 32 · 46 · 47 157 Service and Repair Manual Diagnostics March 2021 GCON Pin Number J3-01 J3-02 J3-03 J3-04 J3-05 J3-06 J3-07 J3-08 J3-09 J3-10 J3-11 J3-12 J4-01 J4-02 J4-03 J4-04 J4-05 J4-06 J4-07 J4-08 J4-09 J4-10 J4-11 J4-12 GCON I/O Map without Load Sense (GS-3232 only) continued Circuit Function I/O Type J-3 Connector Green No Circuit N/A GCON -- Alarm Digital Output Switch/Sensor Power Digital Output Automotive Horn Digital Output Pothole Limit Switch Digital Input Ground Ground Input Down Limit Switch Digital Input Level Sensor Digital Input Ground Ground Input Ground Ground Input No Circuit N/A Load Sense -- Ground Ground Input J-4 Connector Brown Left Front Pressure Transducer Analog Input Right Front Pressure Transducer Analog Input Left Rear Pressure Transducer Analog Input Right Rear Pressure Transducer Analog Input Lever Sensor -- X Axis Analog Input Lever Sensor -- Y Axis Analog Input Left Front Outrigger Coil Digital Output Right Front Outrigger Coil Digital Output Left Rear Outrigger Coil Digital Output Right Rear Outrigger Coil Digital Output Outrigger Extend Coil Digital Output Outrigger Retract Coil Digital Output Wire Gauge and Color N/A 18 BL 14 RD 18 WH 18 OR/RD 18 GR 18 OR 18 RD/BK 18 BK 18 BK N/A 18 BK 18 WH 18 OR 18 BL 18 GR 18 OR 18 BR 18 RD/WH 18 OR/WH 18 BL/WH 18 GR/WH 18 GR 18 GR/BK 158 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Diagnostics GCON Pin Number J1-01 J1-02 J1-03 J1-04 J1-05 J1-06 J1-07 J1-08 J1-09 J1-10 J1-11 J1-12 J2-01 J2-02 J2-03 J2-04 J2-05 J2-06 J2-07 J2-08 J2-09 J2-10 J2-11 J2-12 GCON I/O Map with Load Sense (GS-3232 only) Circuit Function I/O Type J1 Connector Gray ECM Power Power Input PCON, E-Stop Power Power Output PCON, E-Stop Return Power Input Link to PCON -- CANH Data Bus Link to PCON -- CANL Data Bus PCON -- Ground Ground Output GCON -- Ground Ground Input Key Switch -- PCON Mode Digital Input Key Switch -- GCON Mode Digital Input GCON -- Emergency Mode Digital Input No Circuit N/A Driver Power Power Input J-2 Connector Black Platform Up Coil Digital Output Platform Down Coil Digital Output Steer Left Coil Digital Output Steer Right Coil Digital Output Parallel Coil (GS-32, GS-46 & GS-47) Digital Output Drive Forward Coil Digital Output Ground (GS-4047) Ground Input Motor Controller Enable Digital Output Lift Pressure Selector (GS-4047) N/A Drive Reverse Coil Digital Output Motor Controller Throttle Analog Output No Circuit N/A Wire Gauge and Color 14 RD 18 RD 18 WH 18GR 18 OR 18 BR 14 BR 18 BK 18 WH 18 WH/BK N/A 14 RD 18 OR 18 OR/BK 18 BL/BK 18 BL 18 RD/WH 18 WH 18 BR 18 GR/WH N/A 18 WH/BK 18 GR N/A Part No. 1272217GT GSTM-30 · 32 · 46 · 47 159 Service and Repair Manual Diagnostics March 2021 GCON Pin Number J3-01 J3-02 J3-03 J3-04 J3-05 J3-06 J3-07 J3-08 J3-09 J3-10 J3-11 J3-12 J4-01 J4-02 J4-03 J4-04 J4-05 J4-06 J4-07 J4-08 J4-09 J4-10 J4-11 J4-12 GCON I/O Map with Load Sense (GS-3232 only) continued Circuit Function I/O Type J-3 Connector Green No Circuit N/A GCON -- Alarm Digital Output Switch/Sensor Power Digital Output Automotive Horn Digital Output Pothole Limit Switch Digital Input Ground Ground Input Down Limit Switch Digital Input Level Sensor Digital Input Platform Overload Pressure Transducer Ground Input Platform Height Sensor Ground Input No Circuit N/A Load Sense -- Ground Ground Input J-4 Connector Brown Left Front Pressure Transducer Analog Input Right Front Pressure Transducer Analog Input Left Rear Pressure Transducer Analog Input Right Rear Pressure Transducer Analog Input Lever Sensor -- X Axis Analog Input Lever Sensor -- Y Axis Analog Input Left Front Outrigger Coil Digital Output Right Front Outrigger Coil Digital Output Left Rear Outrigger Coil Digital Output Right Rear Outrigger Coil Digital Output Outrigger Extend Coil Digital Output Outrigger Retract Coil Digital Output Wire Gauge and Color N/A 18 BL 14 RD 18 WH 18 OR/RD 18 GR 18 OR 18 RD/BK 18 BL/WH 18 OR/WH N/A 18 BK 18 WH 18 OR 18 BL 18 GR 18 OR 18 BR 18 RD/WH 18 OR/WH 18 BL/WH 18 GR/WH 18 GR 18 GR/BK 160 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Diagnostics Operational Indicator Codes (OIC) These codes are generated by the electrical system to indicate machine operating status. During normal operation a code will appear in the platform controls LED readout if a condition such as off-level, overload cutout, chassis mode operation or pothole guards stuck occurs. These codes are not indicators of a device malfunction in the electrical system. Code Condition LL Off-Level OL Platform Overload (CE / AS models) CH Chassis Mode Operation PHS Pothole Guard Stuck nd No Drive (option) Ld Lifting Disabled (GS-3232 only) CHrg Charger Interlock (option) LoHt Lift Height Limited (CE / AS models) FLHt Limited Lift Height Cleared ObS Obstruction (option) OHL Outdoor Height Restriction Note: The Ld Operation Indicator Code will appear when the outriggers are not fully retracted, the machine is not auto leveled, an outrigger has lost contact with the ground or either level sensor detects the machine is no longer level. When any of the above scenarios occur, the lift function is disabled. The lift function will also be disabled while extending or retracting the outriggers and during the outrigger auto level procedure. While performing the above operations, the Ld Operation Indicator Code will appear. Note: The CHrgr code indicates the charger is connected to an AC power source and functionality is limited. To clear the code, disconnect the charger from the AC power source. Note: The LoHt code indicates the platform has reached the maximum working height or a maximum working height has been activated by the operator. Note: The FLHt code indicates the operator has deactivated the maximum working height LoHt code. Note: The ObS code indicates the contact alarm has been actuated by an obstruction. Move the machine away from the obstruction to clear the code. Note: The br operation indicator code will appear when the drive brake was release by manual. When the code appears, drive and lift functions are disabled. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 161 Service and Repair Manual Diagnostics Diagnostic Trouble Codes (DTC) These codes are generated by the system to indicate that a device or circuit malfunction has been detected in the electrical system. The types of Diagnostic Trouble Codes that may occur are explained below. Type "HXXX" Indicate a malfunction associated with devices that control hydraulic functions in the electrical system. The "HXXX" faults are divided into short circuit battery negative, short circuit to battery positive, open circuit and generic shorts. Examples of these devices are solenoid controlled hydraulic valves and motor controller. Type "PXXX" Indicate a malfunction associated with power type devices in the electrical system. The "PXXX" faults are divided into short circuit to battery negative, short circuit to battery positive, open circuit and generic shorts. Examples of these devices are horns, sensor power and alarms. Type "UXXX" Indicate a malfunction associated with user interface devices in the electrical system. The "UXXX" faults are divided into short circuit to battery negative, short circuit to battery positive, open circuit and generic shorts. Examples of these devices are GCON up and down switches and PCON drive joystick. Type "FXXX" Indicate a malfunction associated with machine feedback devices in the electrical system. The "FXXX" faults are divided into short circuit to battery negative, short circuit to battery positive, open circuit and generic shorts. Examples of these devices are limit switches, height sensors and pressure transducers. Type "CXXX" Indicate a malfunction associated with controls devices in the electrical system. Examples of these devices are platform controls and ground controls ECM. March 2021 162 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Troubleshooting "HXXX" and "PXXX" Faults Troubleshooting "HXXX" and "PXXX" Faults The procedure below illustrates typical steps for diagnosing and fixing faults of type "HXXX" and "PXXX". Diagnostic Chart 1 Check the faulted device for a short or open circuit. Good 2 Check short or open circuit of the harness or connector between Ground Controls and faulted device. Good 3 Check GCON Electronic Control Module (ECM). No Good Replace faulted device. No Good Repair or replace harness an/or connector. No 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. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 163 Service and Repair Manual Fault Inspection Procedure March 2021 Fault Inspection Procedure 1 Check the device associated with the faulted circuit 1 Disconnect the faulted device connector. 2 Using a multi-meter, measure resistance between the two terminals of the faulted device. 3 Resistance should be as follows. Device Solenoid Valve, Drive Typical Resistance 27.2 Solenoid Valve, Steer Solenoid Valve, Platform Up 19 25 Solenoid Valve, Platform Down GCON and PCON Alarm 6.25 >1M Automotive Horn Motor Controller Enable 1.0 5.7k Motor Controller Throttle Contactor Coil 5.7k 47 OK Go to step 2 No Good Replace faulted device 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 4 Check the continuity between the return side of faulted device and system ground. Result: Resistance should be close to 0 5 Check resistance between return side and signal side of the harness plug of faulted device. Result: Resistance should be 1M or higher. OK Go to step 3 No Good Replace or repair harness 164 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 3 Service and Repair Manual Fault Inspection Procedure Check the GCON ECM 1 Disconnect the GCON ECM connectors, J1, J2 and J3. 2 For short to B- type faults, measure resistance between pins J1-7 (ground) and the GCON pin associated with the fault code. Refer to the GCON I/O Map in this section to identify the faulted out circuit pin. 3 Short to ground resistance should be greater than 5k . 4 For short to B+ type faults, measure resistance between pins J1-12 (driver power) and the GCON pin associated with the fault code. Refer to the GCON I/O Map in this section to identify the faulted out circuit pin. 5 Short to power resistance should be greater than 50k . No Good Replace GCON ECM Part No. 1272217GT GSTM-30 · 32 · 46 · 47 165 Service and Repair Manual Type "HXXX" Faults March 2021 Type "HXXX" Faults DTC Number H001: GS30, GS32, GS46 & GS47 H002: GS30, GS32, GS46 & GS47 H003: GS30, GS32, GS46 & GS47 H009: GS30, GS32, GS46 & GS47 H013: GS30, GS32, GS46 & GS47 H014: GS30, GS32, GS46 & GS47 H015: GS30, GS32, GS46 & GS47 H019: GS30, GS32, GS46 & GS47 H020: GS30, GS32, GS46 & GS47 H021: GS30, GS32, GS46 & GS47 H027: GS30, GS32, GS46 & GS47 H030: GS30, GS32, GS46 & GS47 H033: GS30, GS32, GS46 & GS47 Message on GCON LCD H001:COILFAULT PLAT UP1:BAT- H002:COILFAULT PLAT UP1:OPEN H003:COILFAULT PLAT UP1:BAT+ H009:COILFAULT PLAT DOWN1:BAT+ H013:COILFAULT DRIVE FWD1:BAT- H014:COILFAULT DRIVE FWD1:OPEN H015:COILFAULT DRIVE FWD1:BAT+ H019:COILFAULT DRIVE REV1:BAT- H020:COILFAULT DRIVE REV1:OPEN H021:COILFAULT DRIVE REV1:BAT+ H027:COILFAULT DRIVE STEER RIGHT:BAT+ H030:COILFAULT DRIVE STEER LEFT:BAT+ H033:COILFAULT HI/LO SPEED:BAT+ Description Possible Causes Short circuit of the platform up #1 circuit to battery negative. · Short circuit in platform up #1 harness. · Platform up #1 coil short circuit. · GCON ECM. Open circuit in the platform up #1 circuit. · Short circuit in platform up #1 harness. · Platform up #1 coil open circuit. · GCON ECM. Short circuit of the platform up #1 circuit to battery positive. · Short circuit in platform up #1 harness. · Platform up #1 coil short circuit. · GCON ECM. Short circuit of the platform down #1 circuit to battery positive. · Short circuit in platform down #1 harness. · Platform down #1 coil short circuit. · GCON ECM. Short circuit of the drive forward #1 circuit to battery negative. · Short circuit in drive forward #1 harness. · Drive forward #1 coil short circuit. · GCON ECM. Open circuit in the drive forward #1 circuit. · Open circuit in drive forward #1 harness. · Drive forward #1 coil open circuit. · GCON ECM. Short circuit of the drive forward #1 circuit to battery positive. · Short circuit in drive forward #1 harness. · Drive forward #1 coil short circuit. · GCON ECM. Short circuit of the drive reverse #1 circuit to battery negative. · Short circuit in drive reverse #1 harness. · Drive reverse #1 coil short circuit. · GCON ECM. Open circuit in the drive reverse #1 circuit. · Open circuit in drive reverse #1 harness. · Drive reverse #1 coil open circuit. · GCON ECM. Short circuit of the drive reverse #1 circuit to battery positive. · Short circuit in drive reverse #1 harness. · Drive reverse #1 coil short circuit. · GCON ECM. Short circuit of the steer right circuit to battery positive. · Short circuit in steer right harness. · Steer right coil short circuit. · GCON ECM. Short circuit of the steer left circuit to battery positive. · Short circuit in steer left harness. · Steer left coil short circuit. · GCON ECM. Short circuit of the hi/lo speed coil to battery positive. · Short circuit in Hi/Lo speed coil harness. · Hi/Lo speed coil short circuit. · GCON ECM. Failure Mode Platform up function inhibited. Platform up function inhibited. All functions inhibited except platform down. All functions inhibited. Drive forward function inhibited. Drive forward function inhibited. All functions inhibited except platform down. Drive reverse function inhibited. Drive reverse function inhibited. All functions inhibited except platform down. All functions inhibited except platform down. All functions inhibited except platform down. Hi/Lo speed coil disabled. Machine will operate in low speed mode. 166 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Type "HXXX" Faults Type "HXXX" Faults, continued DTC Number H049: GS-3232 Message on GCON LCD H049:COILFAULT O/R EXTEND:BAT- H050: GS-3232 H050:COILFAULT O/R EXTEND:OPEN H051: GS-3232 H051:COILFAULT O/R EXTEND:BAT+ H052: GS-3232 H052:COILFAULT O/R RETRACT:BAT- H053: GS-3232 H053:COILFAULT O/R RETRACT:OPEN H054: GS-3232 H054:COILFAULT O/R RETRACT:BAT+ H057: GS-3232 H057:COILFAULT LF RIGGER:BAT+ H060: GS-3232 H060:COILFAULT LR RIGGER:BAT+ H063: GS-3232 H063:COILFAULT RF RIGGER:BAT+ H066: GS-3232 H067: GS30, GS32, GS46 & GS47 H069: GS30, GS32, GS46 & GS47 H070: GS30, GS32, GS46 & GS47 H066:COILFAULT RR RIGGER:BAT+ H067:FAULT MC ENABLE:BAT- H069:FAULT MC ENABLE:BAT+ H070:FAULT MC THROTTLE:BAT- Description Possible Causes Short circuit of the outrigger extend coil to battery negative. Open circuit in the outrigger extend coil circuit. Short circuit of the outrigger extend coil to battery positive. Short circuit of the outrigger retract coil to battery negative. Open circuit in the outrigger retract coil circuit. Short circuit of the outrigger retract coil to battery positive. Short circuit of the left front outrigger coil to battery positive. Short circuit of the left rear outrigger coil to battery positive. Short circuit of the right front outrigger coil to battery positive. Short circuit of the right rear outrigger coil to battery positive. · Short circuit in outrigger extend coil harness. · Outrigger extend coil short circuit. · GCON ECM. · Short circuit in outrigger extend coil harness. · Outrigger extend coil open circuit. · GCON ECM. · Short circuit in outrigger extend coil harness. · Outrigger extend coil short circuit. · GCON ECM. · Short circuit in outrigger retract coil harness. · Outrigger retract coil short circuit. · GCON ECM. · Short circuit in outrigger retract coil harness. · Outrigger retract coil open circuit. · GCON ECM. · Short circuit in outrigger retract coil harness. · Outrigger retract coil short circuit. · GCON ECM. · Short circuit in left front outrigger coil harness. · Left front outrigger coil short circuit. · GCON ECM. · Short circuit in left rear outrigger coil harness. · Left rear outrigger coil short circuit. · GCON ECM. · Short circuit in right front outrigger coil harness. · Right front outrigger coil short circuit. · GCON ECM. · Short circuit in right rear outrigger coil harness. · Right rear outrigger coil short circuit. · GCON ECM. Short circuit of the motor controller circuit to battery negative. · Short circuit in motor controller enable wire. · Motor Controller. · Contactor coil shorted to battery negative. · GCON ECM. Failure Mode Only outrigger extend function disabled. Only outrigger extend function disabled. All functions inhibited except platform down. Only outrigger retract function disabled. Only outrigger retract function disabled. All functions inhibited except platform down. All functions inhibited except platform down. All functions inhibited except platform down. All functions inhibited except platform down. All functions inhibited except platform down. All functions inhibited except platform down. Short circuit of the motor controller circuit to battery positive. · Short circuit in motor controller enable wire. · Motor Controller. · Contactor Coil. · GCON ECM. All functions inhibited except platform down. Short circuit of the motor controller throttle circuit to battery negative. · Short circuit in motor controller throttle wire. · Motor Controller. · GCON ECM. All functions inhibited except platform down. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 167 Service and Repair Manual Type "HXXX" Faults March 2021 Type "HXXX" Faults, continued DTC Number H072: GS30, GS32, GS46 & GS47 Message on GCON LCD H072:FAULT MC THROTTLE:BAT+ H074: GS-3232 H074:COILFAULT LF RIGGER H075: GS-3232 H075:COILFAULT LR RIGGER H076: GS-3232 H076:COILFAULT RF RIGGER H077: GS-3232 H077:COILFAULT RR RIGGER H078: GS30, GS32, GS46 & GS47 H078:COILFAULT PLAT DOWN1 Description Possible Causes Short circuit of the motor controller throttle circuit to battery positive. · Short circuit in motor controller throttle wire. · Motor Controller. · GCON ECM. Short circuit of the left front outrigger circuit to battery positive/negative or open circuit. · Short or open circuit in left front outrigger harness. · Left front outrigger coil short or open circuit. · GCON ECM. Short circuit of the left rear outrigger circuit to battery positive/negative or open circuit. · Short or open circuit in left rear outrigger harness. · Left rear outrigger coil short or open circuit. · GCON ECM. Short circuit of the right front outrigger circuit to battery positive/negative or open circuit. · Short or open circuit in right front outrigger harness. · Right front outrigger coil short or open circuit. · GCON ECM. Short circuit of the right rear outrigger circuit to battery positive/negative or open circuit. · Short or open circuit in right rear outrigger harness. · Right rear outrigger coil short or open circuit. · GCON ECM. Short circuit of the platform down #1 circuit to battery positive/negative or open circuit. · Short or open circuit in platform down #1 harness. · Platform down #1 coil short or open circuit. · GCON ECM. H079: GS32, GS46 & GS47 H079:COILFAULT HI/LO SPEED Short circuit of the HI/LO speed circuit to battery positive/negative or open circuit. · Short circuit in HI/LO speed harness. · HI/LO speed coil short or open circuit. · GCON ECM. H080: GS30, GS32, GS46 & GS47 H081: GS30, GS32, GS46 & GS47 H080:COILFAULT STEER LEFT H081:COILFAULT STEER RIGHT H102: GS-4047 H102:COILFAULT RELIEF VALVE:BAT+ H103: GS-4047 H103:COILFAULT RELIEF VALVE:BAT- H104: GS-4047 H104:COILFAULT RELIEF VALVE:OPEN Short circuit of the steer left circuit to battery negative or open circuit. · Short or open circuit in steer left harness. · Steer left coil short or open circuit. · GCON ECM. Short circuit of the steer right circuit to battery negative or open circuit. Short circuit of the relief valve circuit to battery positive. Short circuit of the relief valve circuit to battery negative. Relief valve circuit open. · Short or open circuit in steer right harness. · Steer right coil short or open circuit. · GCON ECM. · Short circuit in relief valve harness. · Relief valve coil short circuit. · GCON ECM. · Short circuit in relief valve harness. · Relief valve coil short circuit. · GCON ECM. · Open circuit in relief valve harness. · Relief valve coil open circuit. · GCON ECM. Failure Mode All functions inhibited except platform down. Left front outrigger function inhibited. Left rear outrigger function inhibited. Right front outrigger function inhibited. Right rear outrigger function inhibited. Platform down function inhibited. Hi/Lo speed coil disabled. Machine will operate in high speed mode if open circuit or short with battery negative. Machine will operate in low speed mode if short with battery positive. Steer left function inhibited. Steer right function inhibited. All functions inhibited except platform down while above limit switch. All functions inhibited except platform down while above limit switch. All functions inhibited except platform down while above limit switch. 168 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Type "HXXX" Faults Type "HXXX" Faults, continued DTC Number Message on GCON LCD H106: H106:COILFAULT GS-2646AV DECK EXTEND:BAT- H107: H107:COILFAULT GS-2646AV DECK EXTEND:OPEN H108: H108:COILFAULT GS-2646AV DECK EXTEND:BAT+ H109: H109:COILFAULT GS-2646AV DECK RETRACT:BAT- H110: H110:COILFAULT GS-2646AV DECK RETRACT:OPEN H111: H111:COILFAULT GS-2646AV DECK RETRACT:BAT+ H114: H114:COILFAULT GS-2646AV DECK ENABLE:BAT+ H115: H115:COILFAULT GS-2646AV DECK ENABLE Description Possible Causes Short circuit of the platform extend circuit to battery negative. Open circuit in the platform extend circuit. Short circuit of the platform extend circuit to battery positive. Short circuit of the platform retract circuit to battery negative. Open circuit in the platform retract circuit. Short circuit of the platform retract circuit to battery positive. Short circuit of the platform enable circuit to battery positive. Short circuit of the platform enable circuit. · Short circuit in PED harness. · PED extend valve coil short circuit. · GCON ECM. · Open circuit in PED harness. · PED extend valve coil open circuit. · GCON ECM. · Short circuit in PED harness. · PED extend valve coil short circuit. · GCON ECM. · Short circuit in PED harness. · PED retract valve coil short circuit. · GCON ECM. · Open circuit in PED harness. · PED retract valve coil open circuit. · GCON ECM. · Short circuit in PED harness. · PED retract valve coil short circuit. · GCON ECM. · Short circuit in PED harness. · PED enable valve coil short circuit. · GCON ECM. · Short circuit in PED harness. · GCON ECM. Failure Mode All functions inhibited. All functions inhibited. All functions inhibited. All functions inhibited. All functions inhibited. All functions inhibited. All functions inhibited. All functions inhibited. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 169 Service and Repair Manual Type "PXXX" Faults March 2021 Type "PXXX" Faults DTC Number P001: GS30, GS32, GS46 & GS47 P003: GS30, GS32, GS46 & GS47 P004: GS30, GS32, GS46 & GS47 P005: GS30, GS32, GS46 & GS47 P006: GS30, GS32, GS46 & GS47 P007: GS30, GS32, GS46 & GS47 P009: GS30, GS32, GS46 & GS47 P013: GS30, GS32, GS46 & GS47 P015: GS30, GS32, GS46 & GS47 P018: GS30, GS32, GS46 & GS47 P019: GS30, GS32, GS46 & GS47 Message on GCON LCD P001:PWR FAULT SW PWR1:BAT- P003:PWR FAULT SW PWR1:BAT+ P004:DEVICEFAULT HORN:BAT- P005:DEVICEFAULT HORN:OPEN P006:DEVICEFAULT HORN:BAT+ P007:DEVICEFAULT GCON ALARM:BAT- P009:DEVICEFAULT GCON ALARM:BAT+ P013:PWR FAULT PCON PWRET:BAT- P015:PWR FAULT PCON PWRET:BAT+ 018:PWR FAULT PCON POWER:BAT- 018:PWR FAULT PCON POWER:BAT+ Description Short circuit of the switched power #1 circuit to battery negative. Short circuit of the switched power #1 circuit to battery positive. Possible Causes · Short circuit in switched power #1, down limit switch, pothole limit switch, digital tilt switch harness. · GCON ECM. · Short circuit in switched power #1, down limit switch, pothole limit switch, digital tilt switch harness. · GCON ECM. Short circuit of the automotive horn circuit to battery negative. · Short circuit in automotive horn harness. · Automotive horn short circuit. · GCON ECM. Open circuit of the automotive horn circuit. · Open circuit in automotive horn harness. · Automotive horn open circuit. · GCON ECM. Short circuit of the automotive horn circuit to battery positive. · Short circuit in automotive horn harness. · Automotive horn short circuit. · GCON ECM. Short circuit of the GCON alarm circuit to battery negative. · Short circuit in GCON alarm harness. · GCON alarm short circuit. · GCON ECM. Short circuit of the GCON alarm circuit to battery positive. · Short circuit in GCON alarm harness. · GCON alarm short circuit. · GCON ECM. Short circuit of the PCON power return circuit to battery negative. · Short circuit in PCON power return harness. · GCON ECM. Short circuit of the PCON power return circuit to battery positive. · Short circuit in PCON power return harness. · GCON ECM. Short circuit of the PCON power circuit to battery negative. · Short circuit in PCON power harness. · GCON ECM. Short circuit of the PCON power circuit to battery positive. · Short circuit in PCON power harness. · GCON ECM. Failure Mode All functions inhibited. All functions inhibited. Automotive horn inhibited. Automotive horn inhibited. Automotive horn inhibited. GCON alarm inhibited. GCON alarm inhibited. All functions inhibited. All functions inhibited. All functions inhibited. All functions inhibited. 170 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Type "UXXX" Faults Type "UXXX" Faults DTC Number U001: GS30, GS32, GS46 & GS47 U002: GS30, GS32, GS46 & GS47 U003: GS30, GS32, GS46 & GS47 U004: GS30, GS32, GS46 & GS47 U005: GS30, GS32, GS46 & GS47 U006: GS30, GS32, GS46 & GS47 U007: GS30, GS32, GS46 & GS47 U014: GS30, GS32, GS46 & GS47 U015: GS30, GS32, GS46 & GS47 U016: GS30, GS32, GS46 & GS47 U017: GS30, GS32, GS46 & GS47 U018: GS30, GS32, GS46 & GS47 U019: GS30, GS32, GS46 & GS47 Message on GCON LCD U001:SWITCHFAULT GCON MAIN FTN EN U002:SWITCHFAULT GCON PLAT UP U003:SWITCHFAULT GCON PLAT DOWN U004:SWITCHFAULT GCON LCD UP U005:SWITCHFAULT GCON LCD DOWN U006:SWITCHFAULT GCON LCD ENTER U007:SWITCHFAULT GCON LCD ESCAPE U014:SWITCHFAULT PCON DRIVE EN U015:SWITCHFAULT PCON STEER LEFT U016:SWITCHFAULT PCON STEER RIGHT U017:SWITCHFAULT PCON HORN U018:SWITCHFAULT PCON LO DRIV SPD U019:SWITCHFAULT PCON LO LIFT SPD Description Possible Causes Failure Mode Short circuit of the GCON main function enable switch at system startup. · Short circuit of the GCON main function enable switch. · GCON ECM. All GCON functions inhibited. Short circuit of the GCON up directional switch at system startup. · Short circuit of the GCON up directional switch. · GCON ECM. All GCON functions inhibited except platform down. Short circuit of the GCON down directional switch at system startup. · Short circuit of the GCON down directional switch. · GCON ECM. All GCON functions inhibited except platform up. Short circuit of the GCON LCD scroll up switch at system startup. · Short circuit of the GCON LCD scroll up switch. · GCON ECM. All GCON LCD menu functions inhibited. Short circuit of the GCON LCD scroll down switch at system startup. · Short circuit of the GCON LCD scroll down switch. · GCON ECM. All GCON LCD menu functions inhibited. Short circuit of the GCON LCD enter switch · Short circuit of the GCON LCD enter switch. at system startup. · GCON ECM. All GCON LCD menu functions inhibited. Short circuit of the GCON LCD escape switch at system startup. · Short circuit of the GCON LCD escape switch. · GCON ECM. All GCON LCD menu functions inhibited. Short circuit of the PCON drive enable switch at system startup. · Short circuit of the PCON drive enable switch. · GCON ECM. All PCON drive and steer functions inhibited. Short circuit of the PCON steer left switch at · Short circuit of the PCON steer left switch. system startup. · GCON ECM. All PCON drive and steer functions inhibited. Short circuit of the PCON steer right switch at system startup. · Short circuit of the PCON steer right switch. · GCON ECM. All PCON drive and steer functions inhibited. Short circuit of the PCON horn switch at system startup. · Short circuit of the PCON horn switch. · GCON ECM. PCON horn switch function inhibited. Short circuit of the PCON low drive speed switch at system startup. · Short circuit of the PCON low drive speed switch. · GCON ECM. The machine is limited to low drive speed. Short circuit of the PCON low lift speed switch at system startup. · Short circuit of the PCON low lift speed switch. · GCON ECM. PCON platform up and down functions inhibited. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 171 Service and Repair Manual Type "UXXX" Faults March 2021 Type "UXXX" Faults, continued DTC Number U020: GS30, GS32, GS46 & GS47 U021: GS30, GS32, GS46 & GS47 U022: GS30, GS32, GS46 & GS47 Message on GCON LCD U020:SWITCHFAULT PCON HI LIFT SPD U021:SWITCHFAULT PCON UP U022:SWITCHFAULT PCON DOWN U023: GS-3232 U023:SWITCHFAULT PCON O/R ENABLE U033: GS30, GS32, GS46 & GS47 U034: GS30, GS32, GS46 & GS47 U035: GS30, GS32, GS46 & GS47 U036: GS30, GS32, GS46 & GS47 U037: GS30, GS32, GS46 & GS47 U038: GS30, GS32, GS46 & GS47 U039: GS30, GS32, GS46 & GS47 U040: GS30, GS32, GS46 & GS47 (GS3232 excluded) U033:JSTICKFAULT OUT OF CAL RANGE U034:JSTICKFAULT OUT OF RANGE:HI U035:JSTICKFAULT OUT OF RANGE:LO U036:SWITCHFAULT GCON + PCON:ON U037:SWITCHFAULT FOOTSW PRESSED U038:SWITCHFAULT FOOTSWITCH:BAT+ U039:SWITCHFAULT FOOTSW:OPEN/BAT- U040:SWITCHFAULT FOOTSW:TIMEOUT Description Short circuit of the PCON high lift speed switch at system startup. Possible Causes · Short circuit of the PCON hi lift speed switch. · GCON ECM. Failure Mode PCON platform up and down functions inhibited. Short circuit of the PCON up directional switch at system startup. · Short circuit of the PCON up directional switch. · GCON ECM. PCON platform up function inhibited. Short circuit of the PCON down directional switch at system startup. · Short circuit of the PCON down directional switch. · GCON ECM. PCON platform down functions inhibited. Short circuit of the PCON outrigger enable switch at system startup. PCON drive joystick signal is outside acceptable calibration range at system startup. · Short circuit of the PCON outrigger enable switch. · GCON ECM. · PCON drive joystick is not in neutral position at startup. · PCON joystick. · GCON ECM. All outrigger functions inhibited. All PCON drive and steer functions inhibited. Short circuit of the PCON drive joystick signal to battery positive at system startup. · Short circuit of the PCON drive joystick signal circuit. · PCON joystick. · GCON ECM. All PCON drive and steer functions inhibited. Short circuit of the PCON drive joystick signal to battery negative at system startup. · Short circuit of the PCON drive joystick signal circuit. · PCON joystick. · GCON ECM. All PCON drive and steer functions inhibited. Mis-wiring or short circuit of GCON key switch. · GCON key switch. · GCON ECM. All functions inhibited. Foot switch pressed at machine startup. · Short circuit in the foot switch harness. · Foot switch. · GCON ECM. Mis-wiring or short circuit of foot switch to battery positive. · Short circuit in the foot switch harness. · Foot switch. · GCON ECM. Mis-wiring, open or short circuit of foot switch to battery negative. · Short circuit in the foot switch harness. · Foot switch. · GCON ECM. All functions inhibited. All functions inhibited. All functions inhibited. PCON deck switch pressed at machine startup. · Short circuit in the foot switch harness. · Foot switch. · GCON ECM. All functions inhibited. 172 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Type "UXXX" Faults Type "UXXX" Faults, continued DTC Number U041: GS30, GS32, GS46 & GS47 U042: GS30, GS32, GS46 & GS47 Message on GCON LCD U041:SWITCHFAULT GCON DECK ENABLE U042:SWITCHFAULT PCON DRIVE MODE U043: GS-3232 U043:SWITCHFAULT PCON OR MODE U045: GS30, GS32, GS46 & GS47 U046: GS30, GS32, GS46 & GS47 U045:SWITCHFAULT PCON FUNCTION EN U046:SWITCHFAULT PCON LIFT MODE Description Possible Causes GCON deck enable switch stuck closed, or depressed at system startup. · GCON deck enable switch stuck closed. · GCON deck enable switch depressed at system startup. · GCON ECM. PCON drive mode switch stuck closed, or depressed at system startup. PCON outrigger mode switch stuck closed, or depressed at system startup. PCON function enable switch stuck closed, or depressed at system startup. · PCON drive mode switch stuck closed. · PCON drive mode switch depressed at system startup. · PCON ECM. · PCON outrigger mode switch stuck closed. · PCON outrigger mode switch depressed at system startup. · PCON ECM. · PCON function enable switch stuck closed. · PCON function enable switch depressed at system startup. · PCON ECM. PCON Lift mode switch stuck closed, or depressed at system startup. · PCON lift mode switch stuck closed. · PCON lift mode switch depressed at system startup. · PCON ECM. Failure Mode All functions inhibited. Drive functions inhibited. Outrigger extend/retract functions inhibited. All drive and steer functions inhibited. All functions operate except platform up/down. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 173 Service and Repair Manual Type "FXXX" Faults March 2021 Type "FXXX" Faults DTC Number F001: GS-3232 F003: GS30, GS32, GS46 & GS47 Message on GCON LCD F001:SWITCHFAULT UP LIMIT1:BAT+ F003:SWITCHFAULT DOWN LIMIT1:BAT+ Description Short circuit of the up limit #1 switch at system startup. Short circuit of the down limit #1 switch at system startup. Possible Causes · Short circuit of the up limit switch circuit. · Up limit #1 switch short circuit. · GCON ECM. · Short circuit of the down limit switch circuit. · Down limit #1 switch short circuit. · GCON ECM. F005: GS30, GS32, GS46 & GS47 F005:SWITCHFAULT POTHOLE:BAT+ Short circuit of the pothole limit #1 switch at system startup. · Short circuit of the pothole switch circuit. · Pothole limit #1 switch short circuit. · GCON ECM. F007: GS30, GS32, GS46 & GS47 F007:SWITCHFAULT CHASSISTILT:BAT+ F008: GS30, GS32, GS46 & GS47 F009: GS30, GS32, GS46 & GS47 F008:SENSORFAULT OVLD XDUCER:BAT+ F009:SENSORFAULT OVLD XDUCER:BAT- F010: GS30, GS32, GS46 & GS47 F010:SENSORFAULT PLAT HEIGHT:BAT+ Short circuit of the chassis digital tilt switch at system startup. · Short circuit of the chassis digital tilt switch circuit. · Chassis digital tilt switch short circuit. · GCON ECM. Short circuit of the Platform Overload Transducer circuit to battery positive. Short circuit of the Platform Overload Transducer circuit to battery negative. · Short circuit in the transducer circuit. · Faulty pressure transducer. · GCON ECM. · Short circuit in the transducer circuit. · Faulty pressure transducer. · GCON ECM. Short circuit of the Platform Height Sensor circuit to battery positive. · Short circuit in the platform height circuit. · Faulty platform height sensor. · GCON ECM. F011: GS30, GS32, GS46 & GS47 F011:SENSORFAULT PLAT HEIGHT:BAT- Short circuit of the Platform Height Sensor circuit to battery negative. · Short circuit in the platform height circuit. · Faulty platform height sensor. · GCON ECM. Failure Mode Platform up function inhibited. All functions inhibited except platform down. All functions inhibited except platform down as long as machine is in the elevated position. If machine is in stowed position, all functionality is resumed. All functions inhibited except platform down as long as machine is in the elevated position. If machine is in stowed position, all functionality is resumed. All functions inhibited. All functions inhibited. All functions inhibited except platform down as long as machine is in the elevated position. If machine is in stowed position, all functionality is resumed. All functions inhibited except platform down as long as machine is in the elevated position. If machine is in stowed position, all functionality is resumed. 174 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Type "FXXX" Faults Type "FXXX" Faults, continued DTC Number F012: GS-3232 Message on GCON LCD F012:SENSORFAULT LEVEL PITCH:BAT+ F013: GS-3232 F013:SENSORFAULT LEVEL PITCH:BAT- F014: GS-3232 F014:SENSORFAULT LEVEL ROLL:BAT+ F015: GS-3232 F015:SENSORFAULT LEVEL ROLL:BAT- F016: GS-3232 F016:SENSORFAULT LF RIGGER:BAT+ Description Possible Causes Short circuit of the Level Pitch Sensor circuit to battery positive. Short circuit of the Level Pitch Sensor circuit to battery negative. Short circuit of the Level Roll Sensor circuit to battery positive. Short circuit of the Level Roll Sensor circuit to battery negative. · Short circuit in the level pitch sensor circuit. · Faulty level sensor. · GCON ECM. · Short circuit in the level pitch sensor circuit. · Faulty level sensor. · GCON ECM. · Short circuit in the level roll sensor circuit. · Faulty level sensor. · GCON ECM. · Short circuit in the level roll sensor circuit. · Faulty level sensor. · GCON ECM. Short circuit of the Left Front Outrigger Sensor circuit to battery positive. · Short circuit in the left front outrigger sensor circuit. · Faulty pressure transducer. · GCON ECM. F017: GS-3232 F017:SENSORFAULT LF RIGGER:BAT- Short circuit of the Left Front Outrigger Sensor circuit to battery negative. · Short circuit in the left front outrigger sensor circuit. · Faulty pressure transducer. · GCON ECM. F018: GS-3232 F018:SENSORFAULT RF RIGGER:BAT+ Short circuit of the Right Front Outrigger Sensor circuit to battery positive. · Short circuit in the right front outrigger sensor circuit. · Faulty pressure transducer. · GCON ECM. F019: GS-3232 F019:SENSORFAULT RF RIGGER:BAT- Short circuit of the Right Front Outrigger Sensor circuit to battery negative. · Short circuit in the right front outrigger sensor circuit. · Faulty pressure transducer. · GCON ECM. F020: GS-3232 F020:SENSORFAULT LR RIGGER:BAT+ Short circuit of the Left Rear Outrigger Sensor circuit to battery positive. · Short circuit in the left rear outrigger sensor circuit. · Faulty pressure transducer. · GCON ECM. F021: GS-3232 F021:SENSORFAULT LR RIGGER:BAT- Short circuit of the Left Rear Outrigger Sensor circuit to battery negative. · Short circuit in the left rear outrigger sensor circuit. · Faulty pressure transducer. · GCON ECM. F022: GS-3232 F022:SENSORFAULT RR RIGGER:BAT+ Short circuit of the Right Rear Outrigger Sensor circuit to battery positive. · Short circuit in the right rear outrigger sensor circuit. · Faulty pressure transducer. · GCON ECM. Failure Mode All functions inhibited. All functions inhibited. All functions inhibited. All functions inhibited. Left front outrigger inhibited if outrigger extend is activated. Outrigger can still be retracted. Left front outrigger inhibited if outrigger extend is activated. Outrigger can still be retracted. Right front outrigger inhibited if outrigger extend is activated. Outrigger can still be retracted. Right front outrigger inhibited if outrigger extend is activated. Outrigger can still be retracted. Left rear outrigger inhibited if outrigger extend is activated. Outrigger can still be retracted. Left rear outrigger inhibited if outrigger extend is activated. Outrigger can still be retracted. Right rear outrigger inhibited if outrigger extend is activated. Outrigger can still be retracted. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 175 Service and Repair Manual Type "FXXX" Faults March 2021 Type "FXXX" Faults, continued DTC Number Message on GCON LCD Description F023: GS-3232 F023:SENSORFAULT RR RIGGER:BAT- Short circuit of the Right Rear Outrigger Sensor circuit to battery negative. F034: GS30, GS32, GS46 & GS47 F035: GS30, GS32, GS46 & GS47 F036: GS30, GS32, GS46 & GS47 F034:SENSORFAULT OVLD:PLAT HEIGHT F035:SENSORFAULT OVLD RANGE:LOW F036:SENSORFAULT OVLD RANGE:HI F072: F072:SENSORFAULT GS-2646AV FUNCTION CUT B+ F073: GS-2646AV F129: GS30, GS32, GS46 & GS47 F073:SENSORFAULT DECK SENSOR B+ F129:TILT SENSOR FAULT Height Sensor settings are not calibrated correctly. Height Sensor setting is lower than calibrated stowed height. Height Sensor setting is higher than calibrated maximum height. Function Cutout sensor B+ fault. Power Deck sensor B+ fault. UTS mismatch fault. Two accelerometers inside UTS mismatch.(universal tilt sensor) Possible Causes · Short circuit in the right rear outrigger sensor circuit. · Faulty pressure transducer. · GCON ECM. · Height sensor needs calibration for stowed height and maximum height settings. · GCON or PCON ECM. · Height sensor not calibrated for stowed height correctly. · GCON or PCON ECM. · Height sensor not calibrated for maximum height correctly. · GCON or PCON ECM. · Faulty extension deck limit switch. · Faulty gate proximity switch. · GCON ECM. · Short circuit in deck sensor input circuit. · GCON ECM. · Faulty UTS. Failure Mode Right rear outrigger inhibited if outrigger extend is activated. Outrigger can still be retracted. All functions inhibited. All functions inhibited. All functions inhibited. All functions inhibited. All functions inhibited. All functions inhibited. 176 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Type "CXXX" Faults Type "CXXX" Faults DTC Number C001: GS30, GS32, GS46 & GS47 C004: GS30, GS32, GS46 & GS47 C005: GS30, GS32, GS46 & GS47 C006: GS30, GS32, GS46 & GS47 C007: GS30, GS32, GS46 & GS47 C009: GS30; GS32' GS46 & GS47 C010: GS30, GS32, GS46 & GS47 C021: GS30, GS32, GS46 & GS47 C023: GS30, GS32, GS46 & GS47 C025: GS30, GS32, GS46 & GS47 Message on GCON LCD C001:GCON ECM FAULT TYPE 1 C004:GCON ECM FAULT TYPE 4 C005:GCOM ECM FAULT TYPE 5 C006:GCON ECM FAULT TYPE 6 C007:GCON ECM FAULT TYPE 7 C009:GCON ECM FAULT FAULT TYPE 9 C010:SECONDARY NOT PROGRAMMED C021:PCON NOT DETECTED C023:MACHINE MODEL FAULT C025:SYSTEMFAULT PLAT OVLD:NOCAL Description GCON ECM CRC check error. Possible Causes · Incorrect software file. · GCON ECM internal failure. GCON ECM master switch error. · Short circuit in the master switch circuit. · GCON ECM. GCON ECM safety switch error. · Short circuit in the safety switch circuit. · GCON ECM. GCON input redundancy error. · Input conditioning circuit failure. · GCON ECM. GCON ECM inter-processor communication error. · Incorrectly programmed device. · Error in loading software on device. · GCON ECM. GCON ECM fault type 9. · Contact Genie support. GCON secondary processor not programmed. PCON not detected error. · Incorrectly programmed device. · Error in loading software on device. · GCON ECM. · PCON disconnected. · CAN communication failure. · GCON or PCON ECM. Discrepancy between model detected and model programmed. · Incorrect machine model programmed. · GCON or PCON ECM. Platform overload system not calibrated. · Platform overload system not calibrated. · GCON or PCON ECM. Failure Mode All functions inhibited. All functions inhibited. All functions inhibited. All functions inhibited. All functions inhibited. All functions inhibited. All functions inhibited. All functions inhibited. All functions inhibited. All functions inhibited. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 177 Service and Repair Manual Type "CXXX" Faults March 2021 Type "CXXX" Faults DTC Number Message on GCON LCD Description Possible Causes Failure Mode C028: GS30, GS32, GS46 & GS47 C028:SERVICE OVERRIDE MODE ON Machine is in service override mode. · Machine programmed for use in service override mode. All functions inhibited except for down function and up function. Platform can be elevated only once with the maximum elevate time of XX seconds. Elevate time XX depends on machine model. C029: GS-3232 C053: GS30, GS32, GS46 & GS47 C055 C029:SYSTEMFAULT O/R SENSOR:NOCAL C053:PCON-GCOM SOFTWARE MISMATCH C055 DCON ECM Fault Type 01 Outrigger not calibrated. · Outrigger not calibrated. · GCON ECM. Software revisions do not match between the · Short circuit in the safety switch circuit. PCON and GCON. · GCON ECM. Hardware failur of drive controller DCON ECM All functions operate. Will not lift above the down limit switch. All functions inhibited. Performance reduced or all functions inhibited. C056 C056 DCON ECM Fault Type 02 Setup initialization failure of the drive controller at system startup · Drive input active at system startup · Faulty drive joystick · Incorrect software D14 · DCON ECM Performance reduced or all functions inhibited. C058 C058 DCON ECM Fault Type 04 Drive controller voltage out of range · Battery charger connected · Batteries too low · DCON ECM All functions inhibited. C059 C059 DCON ECM Fault Type 05 Capacitor charge failure of the drive controller · Open on B+ or B- to the drive contoller · DCON ECM All functions inhibited. C061 C061 DCON ECM Fault Type 07 Open circuit of the key switch circuit or battery positive / negative of the drive controller · Open circuit of the motor controller harness · Open circuit to the B+ and/or B· Key switch relay power not closed · DCON or GCON ECM All functions inhibited. C063 C063 DCON ECM Fault Type 09 Communication error of the CAN circuit · Open circuit of the motor controller harness between the GCON and the motor controller · DCON or GCON ECM All functions inhibited. C064 C064 DCON ECM Fault Type 10 Output error of the thermal sensor circuit of the motor controller DCON ECM All functions inhibited. 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. 178 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Battery Charger Battery Charger The charger continuously monitors internal and external conditions. Fault and Error codes are generated by the charger to indicate that an internal or external malfunction has been detected in the electrical system. The types of Diagnostic Trouble Codes that may occur are explained below. Type "F" codes Indicate an internal fault condition has occurred and caused charging to stop. Type "E" codes - Indicate an external fault condition has occurred and caused charging to stop. Type "P" code - Indicates charger programming mode is active. This will occur when the charger profile is being configured. Type "USB" code - Indicates the USB interface is active, and the USB should not be removed. This will occur when the charger firmware is being updated. Solid red - Internal fault condition. Type "F" fault code. Flashing amber - External fault condition. Type "E" error code. Flashing green - USB interface is active. Solid green - Firmware update is complete. Remove USB from charger. Codes are displayed as F, E or P and followed by three numbers and a period (example: E-0-0-4). The charger can display multiple codes. If the batteries are changed from one type to another, (example: flooded lead acid to AGM), the charger profile must be programmed. Refer to Repair Procedure, Programming the Charger Profile. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 179 Service and Repair Manual Battery Charger March 2021 Charger status indicators Remote charger status indicators 1 Error / Fault / USB indicator 2 Charger profile / Error display Charger Fault Codes 3 Error / Fault Charger Fault Codes Fault Code F-0-0-1 F-0-0-2 F-0-0-3 F-0-0-4 F-0-0-5 Description DC-DC failure: LLC excessive leakage fault. PFC failure: PFC excessive leakage fault. PFC taken too long to boost. Charger unable to calibrate current offset. Output relay voltage too high when closed. Possible Causes Internal charger fault. Solution Disconnect AC input and battery pack for 30 seconds. If fault does not clear, contact Genie Product Support. 180 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Battery Charger Charger Error Codes Charger Error Codes Error Code Description E-0-0-1 High battery voltage E-0-0-2 Low battery voltage detected prior to starting charge cycle E-0-0-3 Charge timeout E-0-0-4 Defective battery E-0-0-7 Amp hour limit exceeded Condition Possible Causes Battery voltage too high to charge. Check battery voltage and cable connections. Self clearing when condition has been corrected. Battery voltage too low to charge. Check battery voltage and cable connections. Check battery condition. Self clearing when condition has been corrected. Charge timeout caused by battery pack not reaching required voltage within safe time limit. Charge output reduced due to high temperature. Charge at lower temperature. Check battery condition. Replace damaged battery. Check battery connections. Battery pack deep discharge. Disconnect battery pack for 30 seconds to clear fault when condition has been corrected. Battery pack could not be trickle charged up to the minimum voltage. Check battery condition. Replace damaged battery. Check battery connections. Disconnect battery pack for 30 seconds to clear fault when condition has been corrected. Safety limit exceeded. Check battery condition. Replace damaged battery. Check battery connections. Battery pack deep discharge. High parasitic loads on battery pack while charging. Disconnect parasitic loads. Disconnect battery pack for 30 seconds to clear fault when condition has been corrected. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 181 Service and Repair Manual Battery Charger March 2021 Charger Error Codes Error Code Description E-0-0-8 Battery temperature out of range E-0-1-1 Charger disabled by external command E-0-1-2 Reverse polarity E-0-1-3 Battery does not take current E-0-1-6 Software update failed E-0-1-7 USB error E-0-1-8 Slot CRC error E-0-1-9 Hardware does not support software E-0-2-0 No algorithm selected Condition Possible Causes Battery temperature sensor. Check temperature sensor and electrical connections. Rest charger. Disconnect AC power for 30 seconds. Self clearing when condition has been corrected. Battery pack not being charged.. Power outage. AC power disconnected before charging complete. Battery connected incorrectly. Check battery connections. Self clearing when condition has been corrected. Battery voltage is detected, but charger is unable to charge the battery pack.. Incorrect profile for battery type. Installed from a different machine with different battery type. Disconnect battery pack for 30 seconds to clear fault when condition has been corrected. Software update failed. Confirm USB Flash Drive is formatted with correct software. If software update continues to fail, contact Genie Product support. USB not connected correctly. Remove and re-insert USB Flash Drive. Disconnect AC input and battery pack for 30 seconds. Software update failed. Confirm USB Flash Drive is formatted with correct software. If software update continues to fail, contact Genie Product support. Charger hardware does not support software version being programmed. Confirm USB Flash Drive is formatted with correct software. If software update continues to fail, contact Genie Product support. Charger profile not programmed. Program the charger for the proper battery profile. 182 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Charger Error Codes Error Code E-0-2-1 Description High battery voltage detected while charging E-0-2-2 Low battery voltage detected while charging E-0-2-3 High AC voltage E-0-2-4 Failure to initialize E-0-2-5 Low AC voltage oscillation E-0-2-6 Script failure E-0-2-7 USB over current fault E-0-2-8 Charge profile incompatibility Service and Repair Manual Battery Charger Condition Battery voltage too high as detected by charger profile. Battery voltage too low as detected by charger profile. AC voltage greater than 270 VAC. Charger failed to turn on correctly. AC voltage unstable. Software update failed. USB over current protection has been tripped. Selected charger profile is not compatible with charger software. Possible Causes Check battery voltage and cable connections. Confirm charger profile is programmed for correct battery type. Self clearing when condition has been corrected. Check battery voltage and cable connections. Confirm charger profile is programmed for correct battery type. Self clearing when condition has been corrected. Connect to a stable AC source between 85 - 270 VAC / 45 - 65 Hz. Self clearing when condition has been corrected. Disconnect AC input and battery pack for 30 seconds. Contact Genie Product Support. Connect to a stable AC source between 85 - 270 VAC / 45 - 65 Hz. Using an undersized generator. Self clearing when condition has been corrected. Confirm USB Flash Drive is formatted with correct software. If software update continues to fail, contact Genie Product support. Remove and re-insert USB Flash Drive. Use different USB Flash drive. Update charger software. Confirm charger profile is programmed for correctly. Updating current firmware and error occurs, contact Genie Product Support. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 183 Service and Repair Manual Battery Charger March 2021 Charger Error Codes Error Code Description E-0-2-9 CAN Bus error E-0-3-0 COMM battery module error E-0-3-1 Vref for ADC measurements triggered alarm E-0-3-2 CAN Bus heartbeat error E-0-3-6 Battery temperature sensor charge profile E-0-3-8 CAN Open Error Condition Possible Causes CAN Bus network error. Check CAN Bus connections. CAN modules not functioning correctly. Termination resistance is ~60 ohms. CAN Bus battery module error. CAN Buss battery module not functioning correctly. Internal charger error. Disconnect AC input and battery pack for 30 seconds. Contact Genie Product Support. CAN Bus heartbeat error. CAN Bus devices not functioning correctly. Battery temperature sensor is required by charger profile but is not installed. Check battery temperature sensor connections. Check charger profile and confirm battery temperature sensor is installed. CAN Open reprogramming failed. Download CAN Open software. Reprogram charger using USB Flash Drive. 184 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Section 5 Schematics Observe and Obey: Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service a damaged or malfunctioning machine. Repair any machine damage or malfunction before operating the machine. 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. Service and Repair Manual Schematics About This Section There are two groups of schematics in this section. Electrical Schematics Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Hydraulic Schematics Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Part No. 1272217GT GSTM-30 · 32 · 46 · 47 185 Service and Repair Manual Electrical Component and Wire Color Legends March 2021 Item B5 C ELECTRICAL COMPONENT LEGEND Description Batteries B5 = Battery Pack 24V DC, 4 each @ 6V DC (all machines except GS-4047) B10 = Battery Pack 24 V DC Wired in Parallel, 4 each @ 12 V DC (GS-4047) Connector C1 = Anderson Connector C2 = PCON Cable Connector C3 = PCON Coil Cord Connector C4 = Power Control (J1) C5 = Sensors & Switches (J3) C6 = Function Manifold (J2) C7 = Sensor Power Bus C8 = Sensor Ground Bus C9 = Pot Hole Limit Switch C10 = Down Limit Switch C11 = Level Sensor C12 = Function Manifold Ground Bus C13 = Drive Reverse Coil C14 = Drive Forward Coil C15 = Steer Right Coil C16 = Steer Left Coil C17 = Platform Up Coil C18 = Platform Down Coil C19 = Load Sense Cable C20 = Platform Height Cable C21 = Load Sense Ground Cable C22 = Parallel Coil C23 = Platform Height Sensor C24 = Platform Overload Transducer C25 = Outrigger (J4) (GS-3232) C26 = Outrigger Retract Coil (GS-3232) C27 = Outrigger Extend Coil (GS-3232) C28 = Right Rear Outrigger Coil (GS-3232) C29 = Left Rear Outrigger Coil (GS-3232) C30 = Right Front Outrigger Coil (GS-3232) C31 = Left Front Outrigger Coil (GS-3232) C32 = Outrigger Manifold Ground Bus (GS-332) C33 = Outrigger Sensor Power Bus (GS-3232) C34 = Outrigger Level Sensor Ground Bus (GS3232) C35 = Left Front Outrigger Pressure Transducer (GS-3232) C36 = Right Front Outrigger Pressure Transducer (GS-3232) ELECTRICAL COMPONENT LEGEND cont. Item Description C Connector C37 = Left Rear Outrigger Pressure Transducer (GS-3232) C38 = Right Rear Outrigger Pressure Transducer (GS-3232) C39 = Outrigger Sensor Power (GS-3232) C40 = Up Limit Switch (GS-3232) C41 = Platform Control Bus C43 = Key Switch, Platform Mode C44 = Key Switch, Emergency Stop C45 = Automotive Style Horn + C46 = Emergency Stop C47 = GCON Alarm + C48 = Circuit Breaker, MTR V+ C49 = Emergency Stop, ECM Driver V+ C50 = Circuit Breaker, ECM Driver V+ C51 = Key Switch, Ground Mode C52 = GCON Alarm C53 = Automotive Style Horn C70 = Platform Down Coil + (GS-3232 & GS3246) C71 = Platform Down Coil - (GS-3232 & GS3246) C84 = Lift Pressure Selector Coil (GS-4047) CB2 Circuit Breaker, 7A E Enclosure EN1 = Platform Control Box EN4 = AC Outlet Box FB Flashing Beacon (option) FS1 Foot Switch (option) GND Ground Stud H Horn or Alarm H1 = Horn or Alarm H2 = Automotive Style Horn (option) H5 = Multifunction Alarm J Connector Plug J1 = Power Control (U5) J2 = Function Manifold (U5) J3 = Sensors & Switches (U5) J4 = Outriggers (U5) GS-3232) J5 = PCON Coil Cord to Platform Controls PC Board J6 = PCON Emergency Stop & Alarm to Platform Controls PC Board J7 = Joystick to Platform Controls PC Board 186 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Electrical Component and Wire Color Legends ELECTRICAL COMPONENT LEGEND cont. Item Description JC9 Joystick Controller K1 Contactor, Motor Controller Power, N.O.H.C. KS1 Key Switch LS Limit Switch LS1 = Maximum Drive Height (GS-3232) LS6 = Platform Down LS7 = Pothole LS8 = Pothole LS10 = Maximum Drive Height (GS-3232) M5 Hydraulic Power Unit N.C. Normally Closed N.C.H.O Normally Closed Held Open N.O.H.C. Normally Open Held Closed P Power Switch P1 = Emergency Stop Button at Ground Controls P2 = Emergency Stop Button at Platform Controls PT Pressure Transducer PT1 = Left Front Outrigger (GS-3232) PT2 = Right Front Outrigger (GS-3232) PT3 = Left Rear Outrigger (GS-3232) PT4 = Right Rear Outrigger (GS-3232) PT15 = Platform Overload (option) R30 Resistor, 20 Ohm, 10W S Sensor S7 = Level Sensor S8 = Outrigger Level Sensor (GS-3232) S14 = Platform Height Sensor U Electronic Component U3 = PCON Printed Circuit Board U5 = Electronic Control Module U6 = Motor Controller U9 = Battery Charger U13 = Voltage Inverter (option) Y Valve Coil Y1 = Parallel (GS-32, GS-46 & GS47 models) Y2 = Lift Pressure Selector (GS-4047) Y3 = Steer Right Y4 = Steer Left Y5 = Drive Reverse Y6 = Drive Forward Y7 = Platform Down Y8 = Platform Up Y9 = Platform Down GS-3232 & GS-3246) Y33 = Left Rear Outrigger (GS-3232) Y34 = Right Rear Outrigger (GS-3232) Y35 = Left Front Outrigger (GS-3232) Y36 = Right Front Outrigger (GS-3232) Y39 = Outrigger Retract (GS-3232) Y40 = Outrigger Extend (GS-3232) Part No. 1272217GT GSTM-30 · 32 · 46 · 47 187 Service and Repair Manual Electrical Component and Wire Color Legends Color BK BK/RD BL BL/BK BL/OR BL/WH BR GR GR/BK GR/WH GR/YL LB OR OR/BK OR/RD OR/WH RD RD/BK RD/WH WH WH/BK YL WIRE COLOR LEGEND Description Black Black/Red Blue Blue/Black Blue/Orange Blue/White Brown Green Green/Black Green/White Green/Yellow Light Blue Orange Orange/Black Orange/Red Orange/White Red Red/Black Red/White White White/Black Yellow March 2021 188 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Wiring Diagram Ground and Platform Controls Part No. 1272217GT GSTM-30 · 32 · 46 · 47 189 Service and Repair Manual Limit Switch Legend March 2021 Limit Switch Legend 1 down limit switch LS6 2 pothole limit switches LS7, LS8 3 22ft / 6,7 m maximum drive height when outriggers are not deployed (LS1, LS10 GS-3232) 190 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Electrical Symbol Legend Wire with description or color Limit switch Motor controller Key switch Circuits crossing no connection Emergency Stop button Motor Solenoid valve with diode Diode Circuit breaker Battery charger Level sensor Circuit connection Fuse 6V or 12V DC battery Deutsch connector Resistor Contactor Horn or alarm Flashing beacon Platform height sensor Pressure transducer Part No. 1272217GT GSTM-30 · 32 · 46 · 47 191 Service and Repair Manual Hydraulic Symbols Legend March 2021 Hydraulic cylinder Variable speed motor Pressure transducer Solenoid operated 2 position 4 way directional valve Relief valve Bi-directional motor Solenoid operated 2 position 2 way blocking valve normally open Solenoid operated 2 position 4 way directional valve Priority flow regulator Brake Solenoid operated 2 position 2 way valve normally closed Proportional solenoid operated 2 position 2 way directional valve normally closed Accumulator Check valve Solenoid operated 2 position 2 way directional valve normally closed Solenoid operated 3 position 5 way directional valve Fixed displacement pump Shuttle valve Solenoid operated 3 position 4 way directional valve Solenoid operated 3 position 4 way directional valve Filter Orifice with size 192 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Hydraulic Component Abbreviation Legend Item A B C D E F G H I L M N O P Q R S AA AB AC AD AE AF AG AH AI AJ AK Description Test port Check valve, steer circuit Relief valve, lift Check valve, drive circuit Drive forward/reverse Steer left/right Flow regulator/relief valve Platform up Relief valve, system Hand pump, manual brake release Needle valve, manual brake release Platform lowering valve Orifice, platform down circuit Accumulator Relief valve, platform down Pressure transducer, platform overload (CE only) Check valve, drive circuit Test Port Relief valve, system Steer left/right Check dics, steer circuit Drive speed Relief valve, brake circuit Drive forward/reverse Flow regulator/relive valve Platform up Relief valve, lift Check valve, lift (GS-3232 and GS-3246 equipped with load sense only) Part No. 1272217GT GSTM-30 · 32 · 46 · 47 193 Service and Repair Manual Hydraulic Component Abbreviation Legend Item BA BB CA CB CC CD CE CF CG DA DB DC DD DE DF DG DH DI DJ DK DL DM DN DO EA EB EC ED EE GA GB GC Description 3 position, 4 way directional valve outrigger cylinder extend/retract Relief valve, outrigger circuit Right front outrigger extend/retract Left front outrigger extend/retract Right rear outrigger extend/retract Left rear outrigger extend/retract Orifice plug outrigger retract Check valve, pilot operated Pressure transducer Test port Relief valve, system Steer left/right Check valve steer circuit Drive speed Relief valve, brake release Drive forward/reverse Flow regulator/relief valve Platform up Relief valve, lift Check valve, upper cylinder Check valve, lower cylinder Relief valve, lift Lift circuit Platform lowering valve Steer left/right Relief valve steer Platform up Relief valve system Test port Steer left/right Relief valve system Platform up March 2021 194 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Hydraulic Schematics Hydraulic Schematic, GS-1530 / 1532 / 1930 / 1932 (from serial number GS3010A-110000, GS3011C-10000, GS3014D-101, GS3016P-142281) Part No. 1272217GT GSTM-30 · 32 · 46 · 47 195 Service and Repair Manual Hydraulic Schematics March 2021 Hydraulic Schematic, GS-2032 / 2632 / 3232 (from serial number GS3211A-110000 to GS3214A-119070, GS3212C-10000 to GS3214C-11873) GS-2046 / 2646 / 3246 (from serial number GS4612A-110000 to GS4614A-117177, GS4614C-10000 to GS4614C-12073) 196 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Hydraulic Schematics Hydraulic Schematic, GS-2032 / 2632 / 3232 (from serial number GS3214A-119071, GS3214C-11874) GS-2046 / 2646 / 3246 (from serial number GS4614A-117178, GS4614C-12074, GS4614D-101) Part No. 1272217GT GSTM-30 · 32 · 46 · 47 197 Service and Repair Manual Hydraulic Schematics Hydraulic Schematic, GS-3232 (from serial number GS3211A-110000, GS3212C-10000, GS3216P-142677) March 2021 198 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Hydraulic Schematics Hydraulic Schematic, GS-4047 (from serial number GS4712C-101 to GS4714C-1459) Part No. 1272217GT GSTM-30 · 32 · 46 · 47 199 Service and Repair Manual Hydraulic Schematics Hydraulic Schematic, GS-4047 (from serial number GS4714C-1460, GS4714D-101, GS4716P-101) March 2021 200 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Electrical Schematic, GS-1530 / GS-1930, ANSI / CSA (from serial number GS3010A-110000 to GS3011A-110827) 201 Service and Repair Manual Electrical Schematic, GS-1530 / GS-1930, ANSI / CSA (from serial number GS3010A-110000 to GS3011A-110827) March 2021 202 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Electrical Schematic, GS-1530 / GS-1930, ANSI / CSA (from serial number GS3010A-110000 to GS3011A-110827) Part No. 1272217GT GSTM-30 · 32 · 46 · 47 203 Service and Repair Manual Electrical Schematic, GS-1530 / GS-1930, ANSI / CSA (from serial number GS3010A-110000 to GS3011A-110827) March 2021 204 March 2021 Service and Repair Manual Electrical Schematic, GS-1530 / GS-1930, ANSI / CSA (from serial numbers GS3011A-110828 to GS3014A-136972, GS3014D-101 to GS3015D-1113) 205 Service and Repair Manual March 2021 Electrical Schematic, GS-1530 / GS-1930, ANSI / CSA (from serial numbers GS3011A-110828 to GS3014A-136972, GS3014D-101 to GS3015D-1113) 206 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Electrical Schematic, GS-1530 / GS-1930, ANSI / CSA (from serial numbers GS3011A-110828 to GS3014A-136972, GS3014D-101 to GS3015D-1113) Part No. 1272217GT GSTM-30 · 32 · 46 · 47 207 Service and Repair Manual March 2021 Electrical Schematic, GS-1530 / GS-1930, ANSI / CSA (from serial numbers GS3011A-110828 to GS3014A-136972, GS3014D-101 to GS3015D-1113) 208 March 2021 Service and Repair Manual Electrical Schematic, GS-1530 / GS-1930, ANSI / CSA (from serial numbers GS3014A-136973, GS3015D-1114 to GS3016D-5426, GS3016P-142281 to GS3016P-158208) 209 Service and Repair Manual Electrical Schematic, GS-1530 / GS-1930, ANSI / CSA (from serial numbers GS3014A-136973, GS3015D-1114 to GS3016D-5426, GS3016P-142281 to GS3016P-158208) March 2021 210 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Electrical Schematic, GS-1530 / GS-1930, ANSI / CSA (from serial numbers GS3014A-136973, GS3015D-1114 to GS3016D-5426, GS3016P-142281 to GS3016P-158208) Part No. 1272217GT GSTM-30 · 32 · 46 · 47 211 Service and Repair Manual Electrical Schematic, GS-1530 / GS-1930, ANSI / CSA (from serial numbers GS3014A-136973, GS3015D-1114 to GS3016D-5426, GS3016P-142281 to GS3016P-158208) March 2021 212 March 2021 Service and Repair Manual Electrical Schematic, GS-1530, GS-1930 ANSI / CSA (from serial numbers GS3016D-5427, GS301P-158209) 213 Service and Repair Manual Electrical Schematic, GS-1530 / GS-1930, ANSI / CSA (from serial numbers GS3016D-5427, GS3016P-158209) March 2021 214 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Electrical Schematic, GS-3232, ANSI / CSA (from serial number GS3211A-110000 to GS3214A-135714) 215 Service and Repair Manual Electrical Schematic, GS-3232, ANSI / CSA (from serial number GS3211A-110000 to GS3214A-135714) March 2021 216 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Electrical Schematic, GS-3232, ANSI / CSA (from serial number GS3211A-110000 to GS3214A-135714) Part No. 1272217GT GSTM-30 · 32 · 46 · 47 217 Service and Repair Manual Electrical Schematic, GS-3232, ANSI / CSA (from serial number GS3211A-110000 to GS3214A-135714) March 2021 218 March 2021 Service and Repair Manual Electrical Schematic, GS-3232, ANSI / CSA (from serial number GS3214A-135715 to GS3215A-141898) 219 Service and Repair Manual Electrical Schematic, GS-3232, ANSI / CSA (from serial number GS3214A-135715 to GS3215A-141898) March 2021 220 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Electrical Schematic, GS-3232, ANSI / CSA (from serial number GS3214A-135715 to GS3215A-141898) Part No. 1272217GT GSTM-30 · 32 · 46 · 47 221 Service and Repair Manual Electrical Schematic, GS-3232, ANSI / CSA (from serial number GS3214A-135715 to GS3215A-141898) March 2021 222 March 2021 Service and Repair Manual Electrical Schematic, GS-3232, ANSI / CSA (from serial numbers GS3215A-141899, GS3216P-142677 to GS3216P-146462) 223 Service and Repair Manual March 2021 Electrical Schematic, GS-3232, ANSI / CSA (from serial numbers GS3215A-141899, GS3216P-142677 to GS3216P-146462) 224 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Electrical Schematic, GS-3232, ANSI / CSA (from serial numbers GS3215A-141899, GS3216P-142677 to GS3216P-146462) Part No. 1272217GT GSTM-30 · 32 · 46 · 47 225 Service and Repair Manual March 2021 Electrical Schematic, GS-3232, ANSI / CSA (from serial numbers GS3215A-141899, GS3216P-142677 to GS3216P-146462) 226 March 2021 Service and Repair Manual Electrical Schematic, GS-3232, ANSI / CSA (from serial number GS3216P-146463) 227 Service and Repair Manual Electrical Schematic, GS-3232, ANSI / CSA (from serial numbers GS3216P-146463) March 2021 228 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Electrical Schematic, GS-3232, ANSI / CSA (from serial number GS3216P-146463) Part No. 1272217GT GSTM-30 · 32 · 46 · 47 229 Service and Repair Manual Electrical Schematic, GS-3232, ANSI / CSA (from serial number GS3216P-146463) March 2021 230 March 2021 Service and Repair Manual Electrical Schematic, GS-2032, 2632, 2046, 2646, ANSI / CSA (from serial numbers GS3211A-110000 to GS3214A-135714, GS4612A-110000 to GS4614A-135366, GS4613D-101 to GS4615D-1303) 231 Service and Repair Manual March 2021 Electrical Schematic, GS-2032, 2632, 2046, 2646, ANSI / CSA (from serial numbers GS3211A-110000 to GS3214A-135714, GS4612A-110000 to GS4614A-135366, GS4613D-101 to GS4615D-1303) 232 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Electrical Schematic, GS-2032, 2632, 2046, 2646, ANSI / CSA (from serial numbers GS3211-110000 to GS3214A-135714, GS4612A-110000 to GS4614A-135366, GS4613D-101 to GS4615D-1303) Part No. 1272217GT GSTM-30 · 32 · 46 · 47 233 Service and Repair Manual March 2021 Electrical Schematic, GS-2032, 2632, 2046, 2646, ANSI / CSA (from serial numbers GS3211A-110000 to GS3214A-135714, GS4612A-110000 to GS4614A-135366, GS4613D-101 to GS4615D-1303) 234 March 2021 Service and Repair Manual Electrical Schematic, GS-2032, 2632, 2046, 2646, ANSI / CSA (from serial numbers GS3214A-135715 to GS3215A-141898, GS4614A-135367 to GS4615A-137959, GS4615D-1304) 235 Service and Repair Manual March 2021 Electrical Schematic, GS-2032, GS-2632, 2046, 2646, ANSI / CSA (from serial numbers GS3214A-135715 to GS3215A-141898, GS4614A-135367 to GS4615A-137959, GS4615D-1304) 236 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Electrical Schematic, GS-2032, 2632, 2046, 2646, ANSI / CSA (from serial numbers GS3214A-1135715 to GS3215A-1141898, GS4614A-135367 to GS4615A-137959, GS4615D-1304) Part No. 1272217GT GSTM-30 · 32 · 46 · 47 237 Service and Repair Manual March 2021 Electrical Schematic, GS-2032, 2632, 2046, 2646, ANSI / CSA (from serial numbers GS3214A-135715 to GS3215A-141898, GS4614A-135367 to GS4615A-137959, GS4615D-1304) 238 March 2021 Service and Repair Manual Electrical Schematic, GS-2032, 2632, 2046, 2646, ANSI / CSA (from serial numbers GS3215A-141899, GS3216P-142676 to GS3216P-146462, GS4615A-137960, GS4615D-1305 to GS4616D-4432, GS4616P-138362 to GS4616P-139710) 239 Service and Repair Manual March 2021 Electrical Schematic, GS-2032, 2632, 2046, 2646, ANSI / CSA (from serial numbers GS3215A-141899, GS3216P-142676 to GS3216P-146462, GS4615A-137960, GS4615D-1305 to GS4616D-4432, GS4616P-138362 to GS4616P-139710) 240 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Electrical Schematic, GS-2032, 2632, 2046, 2646, ANSI / CSA (from serial numbers GS3215A-141899, GS3216P-142676 to GS3216P-146462, GS4615A-137960, GS4615D-1305 to GS4616D-4432, GS4616P-138362 to GS4616P-139710) Part No. 1272217GT GSTM-30 · 32 · 46 · 47 241 Service and Repair Manual March 2021 Electrical Schematic, GS-2032, 2632, 2046, 2646, ANSI / CSA (from serial numbers GS3215A-14189, GS3216P-142676 to GS3216P-146462, GS4615A-137960, GS4615D-1305 to GS4616D-4432, GS4616P-138362 to GS4616P-139710) 242 March 2021 Service and Repair Manual Electrical Schematic, GS-2032, 2632, 2046, 2646, ANSI / CSA (from serial numbers, GS3216P-146463, GS4616D-4433, GS4616P-139711) 243 Service and Repair Manual March 2021 Electrical Schematic, GS-2032, 2632, 2046, 2646, ANSI / CSA (from serial numbers GS3216P-146463, GS4616D-4433, GS4616P-139711) 244 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Electrical Schematic, GS-3246 / GS-4047, ANSI / CSA (from serial numbers GS4612A-110000 to GS4614A-135366, GS4614D-101 to GS4615D-1303, GS4714D-101 to GS4715D-749) 245 Service and Repair Manual March 2021 Electrical Schematic, GS-3246 / GS-4047, ANSI / CSA (from serial numbers GS4612A-110000 to GS4614A-135366, GS4614D-101 to GS4615D-1303, GS4714D-101 to GS4715D-749) 246 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Electrical Schematic, GS-3246 / GS-4047, ANSI / CSA (from serial numbers GS4621A-110000 to GS4614A-135366, GS4614D-101 to GS4615D-1303, GS4714D-101 to GS4715D-749) Part No. 1272217GT GSTM-30 · 32 · 46 · 47 247 Service and Repair Manual March 2021 Electrical Schematic, GS-3246 / GS-4047, ANSI / CSA (from serial numbers GS4612A-110000 to GS4614A-135366, GS4614D-101 to GS4615D-1303, GS4714D-101 to GS4715D-749) 248 March 2021 Service and Repair Manual Electrical Schematic, GS-3246 / GS-4047, ANSI / CSA (from serial numbers GS4614A-135367 to GS4615A-137959, GS4615D-1304 to GS4616D-4432, GS4616P-138362 to GS4616P-139710, GS4715D-750 to GS4716D-3101) 249 Service and Repair Manual March 2021 Electrical Schematic, GS-3246 / GS-4047, ANSI / CSA (from serial numbers GS4614A-135367 to GS4615A-137959, GS4615D-1304 to GS4616D-4432, GS4616P-138362 to GS4616P-139710, GS4715D-750 to GS4716D-3101) 250 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Electrical Schematic, GS-3246 / GS-4047, ANSI / CSA (from serial numbers GS4614A-135367 to GS4615A-137959, GS4615D-1304 to GS4616D-4432, GS4616P-138362 to GS4616P-139710, GS4715D-750 to GS4716D-3101) Part No. 1272217GT GSTM-30 · 32 · 46 · 47 251 Service and Repair Manual March 2021 Electrical Schematic, GS-3246 / GS-4047, ANSI / CSA (from serial numbers GS4614A-135367 to GS4615A-137959, GS4615D-1304 to GS4616D-4432, GS4616P-138362 to GS4616P-139710, GS4715D-750 to GS4716D-3101) 252 March 2021 Service and Repair Manual Electrical Schematic, GS-3246, GS-4047 ANSI / CSA (from serial numbers GS4616D-4433, GS4616P-139711, GS4716D-3102, GS4716P-101) 253 Service and Repair Manual March 2021 Electrical Schematic, GS-3246, GS-4047 ANSI / CSA (from serial numbers GS4616D-4433, GS4616P-139711, GS4716D-3102, GS4716P-101) 254 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Electrical Schematic, GS-1530, 1532, 1930, 1932, AS / CE (from serial number GS3010A-110000 to GS3011A-110827) 255 Service and Repair Manual Electrical Schematic, GS-1530, 1532, 1930, 1932, AS / CE (from serial number GS3010A-110000 to GS3011A-110827) March 2021 256 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Electrical Schematic, GS-1530, 1532, 1930, 1932, AS / CE (from serial number GS3010A-110000 to GS3011A-110827) Part No. 1272217GT GSTM-30 · 32 · 46 · 47 257 Service and Repair Manual Electrical Schematic, GS-1530, 1532, 1930, 1932, AS / CE (from serial number GS3010A-110000 to GS3011A-110827) March 2021 258 March 2021 Service and Repair Manual Electrical Schematic, GS-1530, 1530, 1930, 1932, AS / CE (from serial numbers GS3011A-110828 to GS3014A-136972, GS3011C-10000 to GS3015C-18038, GS3014D-101 to GS3015D-1113) 259 Service and Repair Manual Electrical Schematic, GS-1530, 1532, 1930, 1932, AS / CE (from serial numbers GS3011A-110828 to GS3014A-136972, GS3011C-10000 to GS3015C-18038, GS3014D-101 to GS3015D-1113) March 2021 260 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Electrical Schematic, GS-1530, 1532, 1930, 1932, AS / CE (from serial numbers GS3011A-110828 to GS3014A-136972, GS3011C-10000 to GS3015C-18038, GS3014D-101 to GS3015D-1113) Part No. 1272217GT GSTM-30 · 32 · 46 · 47 261 Service and Repair Manual Electrical Schematic, GS-1530, 1532, 1930, 1932, AS / CE (from serial numbers GS3011A-110828 to GS3014A-136972, GS3011C-10000 to GS3015C-18038, GS3014D-101 to GS3015D-1113) March 2021 262 March 2021 Service and Repair Manual Electrical Schematic, GS-1530, 1532, 1930, 1932, AS / CE (from serial numbers GS3014A-136973, GS3015C-18039, GS3015D-1114 to GS3016D-5426, GS3016P-142281 to GS3016P-158208) 263 Service and Repair Manual March 2021 Electrical Schematic, GS-1530, 1532, 1930, 1932, AS / CE (from serial numbers GS3014A-136973, GS3015C-18039, GS3015D-1114 to GS3016D-5426, GS3016P-142281 to GS3016P-158208) 264 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Electrical Schematic, GS-1530, 1532, 1930, 1932, AS / CE (from serial numbers GS3014A-136973, GS3015C-18039, GS3015D-1114 to GS3016D-5426, GS3016P-142281 to GS3016P-158208) Part No. 1272217GT GSTM-30 · 32 · 46 · 47 265 Service and Repair Manual March 2021 Electrical Schematic, GS-1530, 1532, 1930, 1932, AS / CE (from serial numbers GS3014A-136973, GS3015C-18039, GS3015D-1114 to GS3016D-5426, GS3016P-142281 to GS3016P-158208) 266 March 2021 Service and Repair Manual Electrical Schematic, GS-1530, 1532, 1930 1932, AS / CE (from serial number GS3016D-5427, GS3016P-158209) 267 Service and Repair Manual Electrical Schematic, GS-1530, 1532, 1930, 1932, AS / CE (from serial numbers GS3016D-5427, GS3016P-158209) March 2021 268 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Electrical Schematic, GS-3232, AS / CE (from serial number GS3211A-110000 to GS3214A-135714, GS3212C-10000 to GS3215C-14503) 269 Service and Repair Manual Electrical Schematic, GS-3232, AS / CE (from serial number GS3211A-110000 to GS3214A-135714, GS3212C-10000 to GS3215C-14503) March 2021 270 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Electrical Schematic, GS-3232, AS / CE (from serial number GS3211A-110000 to GS3214A-135714, GS3212C-10000 to GS3215C-14503) Part No. 1272217GT GSTM-30 · 32 · 46 · 47 271 Service and Repair Manual Electrical Schematic, GS-3232, AS / CE (from serial number GS3211A-110000 to GS3214A-135714, GS3212C-10000 to GS3215C-14503) March 2021 272 March 2021 Service and Repair Manual Electrical Schematic, GS-3232, AS / CE (from serial number GS3214A-135715 to GS3215A-141898, GS3215C-14504) 273 Service and Repair Manual March 2021 Electrical Schematic, GS-3232, AS / CE (from serial number GS3214A-135715 to GS3215A-141898, GS3215C-14504) 274 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Electrical Schematic, GS-3232, AS / CE (from serial number GS3214A-135715 to GS3215A-141898, GS3215C-14504) Part No. 1272217GT GSTM-30 · 32 · 46 · 47 275 Service and Repair Manual March 2021 Electrical Schematic, GS-3232, AS / CE (from serial number GS3214A-135715 to GS3215A-141898, GS32115C-14504) 276 March 2021 Service and Repair Manual Electrical Schematic, GS-3232, AS / CE (from serial numbers GS3215A-141899, GS3216P-142676 to GS3216P-146462) 277 Service and Repair Manual March 2021 Electrical Schematic, GS-3232, AS / CE (from serial number GS3215A-141899, GS3216P-142676 to GS3216P-146462) 278 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Electrical Schematic, GS-3232, AS / CE (from serial numbers GS3215A-141899, GS3216P-142676 to GS3216P-146462) Part No. 1272217GT GSTM-30 · 32 · 46 · 47 279 Service and Repair Manual March 2021 Electrical Schematic, GS-3232, AS / CE (from serial numbers GS3215A-141899, GS3216P-142676 to GS3216P-146462) 280 March 2021 Service and Repair Manual Electrical Schematic, GS-3232, AS / CE (from serial number GS3216P-146463) 281 Service and Repair Manual Electrical Schematic, GS-3232, AS / CE (from serial number GS3216P-146463) March 2021 282 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Electrical Schematic, GS-3232, AS / CE (from serial number GS3216P-146463) Part No. 1272217GT GSTM-30 · 32 · 46 · 47 283 Service and Repair Manual Electrical Schematic, GS-3232, AS / CE (from serial number GS3216P-143463) March 2021 284 March 2021 Service and Repair Manual Electrical Schematic, GS-2032, 2632, 2046, 2646, AS / CE (from serial number GS3211A-110000 to GS3214A-135715, GS3212C-10000 to GS3215C-14377, GS4612A-110000 to GS4614A-135366, GS4612C-10000 to GS4615C-14503, GS4613D-101 to GS4615D-1303) 285 Service and Repair Manual March 2021 Electrical Schematic, GS-2032, 2632, 2046, 2646, AS / CE (from serial number GS3211A-110000 to GS3214A-1135714, GS3212C-10000 to GS3215C-14377, GS4612A-110000 to GS4614A-135366, GS4612C-10000 to GS4615C-14503, GS4613D-101 to GS4615D-1303) 286 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Electrical Schematic, GS-2032, 2632, 2046, 2646, AS / CE (from serial number GS3211A-110000 to GS3214A-135714, GS3212C-10000 to GS3215C-14377, GS4612A-110000 to GS4614A-135366, GS4612C-10000 to GS4615C-14503, GS4613D-101 to GS4615D-1303) Part No. 1272217GT GSTM-30 · 32 · 46 · 47 287 Service and Repair Manual March 2021 Electrical Schematic, GS-2032, 2632, 2046, 2646, AS / CE (from serial number GS3211A-110000 to GS3214A-1135714, GS3215C-10000 to GS3215C-14377, GS4612A-110000 to GS4614A-135366, GS4612C-10000 to GS4615C-14503, GS4613D-101 to GS4615D-1303) 288 March 2021 Service and Repair Manual Electrical Schematic, GS-2032, 2632, 2046, 2646, AS / CE (from serial numbers GS3214A-135715 to GS3215A-141898, GS3215C-14378, GS4614A-135367 to GS4615A-137959, GS46C-14504, GS4615D-1304) 289 Service and Repair Manual March 2021 Electrical Schematic, GS-2032, 2632, 2046, 2646, AS / CE (from serial numbers GS3214A-135715 to GS3215A-141898, GS3215C-14378, GS4614A-135367 to GS4615A-137959, GS4615C-14504, GS4615D-1304) 290 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Electrical Schematic, GS-2032, 2632, 2046, 2646, AS / CE (from serial numbers GS3214A-1135715 to GS3215A-1141898, GS3215C-14378, GS4614A-135367 to GS4615A-137959, GS4615C-14504, GS4615D-1304) Part No. 1272217GT GSTM-30 · 32 · 46 · 47 291 Service and Repair Manual March 2021 Electrical Schematic, GS-2032, 2632, 2046, 2646, AS / CE (from serial numbers GS3214A-135715 to GS3215A-141898, GS3215C-14378, GS4614A-135367 to GS4615A-137959, GS4615C-14504, GS4615D-1304) 292 March 2021 Service and Repair Manual Electrical Schematic, GS-2032, 2632, 2046, 2646, AS / CE (from serial numbers GS3215A-141899, GS3216P-142676 to GS3216P-146462, GS4615A-137960, GS4616P-138362 to GS4616P-139710) 293 Service and Repair Manual March 2021 Electrical Schematic, GS-2032, 2632, 2046, 2646, AS / CE (from serial numbers GS3215A-141899, GS3216P-142676 to GS3216P-146462, GS4615A-137960, GS4616P-138362 to GS4616P-139710) 294 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Electrical Schematic, GS-2032, 2632, 2046, 2646, AS / CE (from serial numbers GS3215A-141899, GS3216P-142676 to GS3216P-146462, GS4615A-137960, GS4616P-138362 to GS4616P-139710) Part No. 1272217GT GSTM-30 · 32 · 46 · 47 295 Service and Repair Manual March 2021 Electrical Schematic, GS-2032, 2632, 2046, 2646, AS / CE (from serial numbers GS3215A-141899, GS3216P-142676 to GS3216P-146462, GS4615A-137960, GS4616P-138362 to GS4616P-139710) 296 March 2021 Service and Repair Manual Electrical Schematic, GS-2032, 2632, 2046, 2646, AS / CE (from serial numbers GS3216P-146463, GS4616P-139711) 297 Service and Repair Manual Electrical Schematic, GS-2032, 2632, 2046, 2646, AS / CE (from serial numbers GS3216P-146463, GS4616P-139711) March 2021 298 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Electrical Schematic, GS-3246, AS / CE (from serial numbers GS4612A-110000 to GS4614A-135366, GS4612C-10000 to GS4615C-14503, GS4614D-101 to GS4615D-1303) 299 Service and Repair Manual Electrical Schematic, GS-3246, AS / CE (from serial numbers GS4612A-110000 to GS4614A-135366, GS4612C-10000 to GS4615C-14503, GS4614D-101 to GS4615D-1303) March 2021 300 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Electrical Schematic, GS-3246, AS / CE (from serial numbers GS4621A-110000 to GS4614A-135366, GS4612C-10000 to GS4615C-14503, GS4614D-101 to GS4615D-1303) Part No. 1272217GT GSTM-30 · 32 · 46 · 47 301 Service and Repair Manual Electrical Schematic, GS-3246, AS / CE (from serial numbers GS4612A-110000 to GS4614A-135366, GS4612C-10000 to GS4615C-14503, GS4614D-101 to GS4615D-1303) March 2021 302 March 2021 Service and Repair Manual Electrical Schematic, GS-3246, AS / CE (from serial numbers GS4614A-135367 to GS4615A-137959, GS4615C-14504, GS4615D-1304 to GS4616D-4432) 303 Service and Repair Manual Electrical Schematic, GS-3246, AS / CE (from serial numbers GS4614A-135367 to GS4615A-137959, GS4615C-14504, GS4615D-1304 to GS4616D-4432) March 2021 304 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Electrical Schematic, GS-3246, AS / CE (from serial numbers GS4614A-135367 to GS4615A-137959, GS4615C-14504, GS4615D-1304 to GS4616D-4432) Part No. 1272217GT GSTM-30 · 32 · 46 · 47 305 Service and Repair Manual Electrical Schematic, GS-3246, AS / CE (from serial numbers GS4614A-135368 to GS4615A-137959, GS4615C-14504, GS4615D-1304 to GS4616D-4432) March 2021 306 March 2021 Service and Repair Manual Electrical Schematic, GS-3246, AS / CE (from serial number GS4615A-137960, GS4616P-138362 to GS4616P-139710) 307 Service and Repair Manual March 2021 Electrical Schematic, GS-3246, AS / CE (from serial number GS4615A-137960, GS4616P-138362 to GS4616P-139710) 308 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Electrical Schematic, GS-3246, AS / CE (from serial number GS4615A-137960, GS4616P-138362 to GS4616P-139710) Part No. 1272217GT GSTM-30 · 32 · 46 · 47 309 Service and Repair Manual March 2021 Electrical Schematic, GS-3246, AS / CE (from serial number GS4615A-137960, GS4616P-138362 to GS4616P-139710) 310 March 2021 Service and Repair Manual Electrical Schematic, GS-3246, AS / CE (from serial number GS4616D-4433, GS4616P-139711) 311 Service and Repair Manual Electrical Schematic, GS-3246, AS / CE (from serial number GS4616D-4433, GS4616P-139711) March 2021 312 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Electrical Schematic, GS-4047, AS / CE (from serial numbers GS4712C-101 to GS4715C-2130, GS4714D-101 to GS4715D-749) 313 Service and Repair Manual Electrical Schematic, GS-4047, AS / CE (from serial numbers GS4712C-101 to GS4715C-2130, GS4714D-101 to GS4715D-749) March 2021 314 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Electrical Schematic, GS-4047, AS / CE (from serial numbers GS4712C-101 to GS4715C-2130, GS4714D-101 to GS4715D-749) Part No. 1272217GT GSTM-30 · 32 · 46 · 47 315 Service and Repair Manual Electrical Schematic, GS-4047, AS / CE (from serial numbers GS4712C-101 to GS4715C-2130, GS4714D-101 to GS4715D-749) March 2021 316 March 2021 Service and Repair Manual Electrical Schematic, GS-4047, AS / CE (from serial number GS4715C-2131, GS4715D-750 to GS4716D-3101) 317 Service and Repair Manual Electrical Schematic, GS-4047, AS / CE (from serial number GS4715C-2131, GS4715D-750 to GS4716D-3101) March 2021 318 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Electrical Schematic, GS-4047, AS / CE (from serial number GS4715C-2131, GS4715D-750 to GS4716D-3101) Part No. 1272217GT GSTM-30 · 32 · 46 · 47 319 Service and Repair Manual Electrical Schematic, GS-4047, AS / CE (from serial numbers GS4715C-2131, GS4715D-750 to GS4716D-3101) March 2021 320 March 2021 Service and Repair Manual Electrical Schematic, GS-4047, AS / CE (from serial number GS4716D-3102) 321 Service and Repair Manual Electrical Schematic, GS-4047, AS / CE (from serial number GS4716D-3102) March 2021 322 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT March 2021 Service and Repair Manual Electrical Schematic · Foot Switch (option) All Models 323 Service and Repair Manual Electrical Schematic · Foot Switch (option) All Models March 2021 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT Service and Repair Manual March 2021 324 GSTM-30 · 32 · 46 · 47 Part No. 1272217GT
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