genie gs-2632 service manual - rentalex€¦ · genie gs-2032 service manual, first edition (before...

Service Manual Part No. 72963

September 2006

Rev C2Refer to inside cover for serial number information

Genie GS-2032 and GS-2632 Part No. 72963

June 2004

ii

Important

Read, understand and obey the safety rules andoperating instructions in the appropriate Operator'sManual on your machine before attempting anymaintenance procedure.

Basic mechanical, hydraulic and electricalskills are required to perform most procedures.However, several procedures require specializedskills, tools, lifting equipment and a suitableworkshop. In these instances, we stronglyrecommend that maintenance and repair beperformed at an authorized Genie dealerservice center.

Technical Publications

Genie Industries has endeavored to deliver thehighest degree of accuracy possible. However,continuous improvement of our products is a Geniepolicy. Therefore, product specificationsare subject to change without notice.

Readers are encouraged to notify Genie of errorsand send in suggestions for improvement. Allcommunications will be carefully considered forfuture printings of this and all other manuals.

Copyright © 1997 by Genie Industries

72963 Rev C June 2004Second Edition, Third Printing

"Genie" is a registered trademark of GenieIndustries in the USA and many other countries."GS" is a trademark of Genie Industries.

Printed on recycled paper

Printed in U.S.A.

Contact Us:

www.genieindustries.come-mail: [email protected]

Serial Number Information

Genie Industries offers the following ServiceManuals for these models:

Title Part No.

Genie GS-2032 Service Manual,First Edition(before serial number 17408) .............................. 46326

Part No. 72963 Genie GS-2032 and GS-2632

June 2004

iii

DangerFailure to obey the instructions and safety rulesin this manual and the appropriate Operator'sManual on your machine will result in death orserious injury.

Many of the hazards identified in theoperator’s manual are also safety hazardswhen maintenance and repair proceduresare performed.

Do Not Perform MaintenanceUnless:

You are trained and qualified to performmaintenance 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, liftingequipment and a suitable workshop.

Safety Rules


June 2004

SAFETY RULES

Personal SafetyAny person working on or around a machine mustbe aware of all known safety hazards. Personalsafety and the continued safe operation of themachine should be your top priority.

Read each procedure thoroughly. Thismanual and the decals on the machine,use signal words to identify the following:

Safety alert symbol—used to alertpersonnel to potential personalinjury hazards. Obey all safetymessages that follow this symbolto avoid possible injury or death.

Red—used to indicate thepresence of an imminentlyhazardous situation which, if notavoided, will result in death orserious injury.

Orange—used to indicate thepresence of a potentiallyhazardous situation which, if notavoided, could result in death orserious injury.

Yellow with safety alert symbol—used to indicate the presence of apotentially hazardous situationwhich, if not avoided, may causeminor or moderate injury.

Yellow without safety alertsymbol—used to indicate thepresence of a potentiallyhazardous situation which, if notavoided, may result in propertydamage.

Green—used to indicate operationor maintenance information.

iv

Be sure to wear protective eye wear andother protective clothing if the situationwarrants it.

Be aware of potential crushing hazardssuch as moving parts, free swinging orunsecured components when lifting or

placing loads. Always wear approved steel-toedshoes.

Workplace SafetyBe sure to keep sparks, flames andlighted tobacco away from flammable andcombustible materials like battery gases

and engine fuels. Always have an approved fireextinguisher within easy reach.

Be sure that all tools and working areasare properly maintained and ready for use.Keep work surfaces clean and free of

debris that could get into machine components andcause damage.

Be sure that your workshop or work area isproperly ventilated and well lit.

Be sure any forklift, overhead crane orother lifting or supporting device is fullycapable of supporting and stabilizing the

weight to be lifted. Use only chains or straps thatare in good condition and of ample capacity.

Be sure that fasteners intended for onetime use (i.e., cotter pins and self-lockingnuts) are not reused. These components

may fail if they are used a second time.

Be sure to properly dispose of old oil orother fluids. Use an approved container.Please be environmentally safe .


June 2004

Table of Contents

Introduction

Important Information ......................................................................................... ii

Section 1 Safety Rules

General Safety Rules ........................................................................................ iii

Section 2 Rev Specifications

A Machine Specifications ................................................................................ 2 - 1

A Performance Specifications ......................................................................... 2 - 1

A Hydraulic Specifications ............................................................................... 2 - 2

A Manifold Component Specifications ............................................................. 2 - 3

A Hydraulic Hose and Fitting Torque Specifications......................................... 2 - 4

Section 3 Rev Scheduled Maintenance Procedures

Introduction .................................................................................................. 3 - 1

Pre-delivery Preparation Report .................................................................... 3 - 3

Maintenance Inspection Report .................................................................... 3 - 5

B Checklist A Procedures

A-1 Perform Pre-operation Inspection ........................................................ 3 - 6

A-2 Perform Function Tests ...................................................................... 3 - 6

A-3 Perform 30 Day Service ...................................................................... 3 - 7

A-4 Grease the Steer Yokes ...................................................................... 3 - 7

v


September 2006

TABLE OF CONTENTS

Section 3 Rev Scheduled Maintenance Procedures, continued

D Checklist B Procedures

B-1 Inspect the Batteries ........................................................................... 3 - 8

B-2 Inspect the Electrical Wiring ............................................................... 3 - 9

B-3 Inspect the Tires and Wheels (including castle nut torque) ................ 3 - 10

B-4 Test the Emergency Stop ................................................................. 3 - 10

B-5 Test the Key Switch ......................................................................... 3 - 11

B-6 Test the Automotive-style Horn (if equipped) ..................................... 3 - 11

B-7 Test the Drive Brakes ....................................................................... 3 - 12

B-8 Test the Drive Speed - Stowed Position ............................................ 3 - 15

B-9 Test the Drive Speed - Raised Position ............................................. 3 - 16

B-10 Perform Hydraulic Oil Analysis ......................................................... 3 - 17

B-11 Replace the Hydraulic Tank Return Filter .......................................... 3 - 17

B-12 Check the Module Tray Latch Components ....................................... 3 - 18

C Checklist C Procedure

C-1 Test the Platform Overload System (if equipped) .............................. 3 - 19

D Checklist D Procedures

D-1 Check the Scissor Arm Wear Pads ................................................... 3 - 21

A Checklist E Procedure

E-1 Test or Replace the Hydraulic Oil ...................................................... 3 - 22

vi


June 2006

TABLE OF CONTENTS

Section 4 Rev Repair Procedures

Introduction .................................................................................................. 4 - 1

B Platform Controls

1-1 Circuit Boards ..................................................................................... 4 - 2

1-2 Joystick Controller .............................................................................. 4 - 3

1-3 Controller Adjustments ....................................................................... 4 - 5

1-4 Software Configuration ...................................................................... 4 - 13

B Platform Components

2-1 Platform............................................................................................ 4 - 16

2-2 Platform Extension ........................................................................... 4 - 17

D Scissor Components

3-1 Scissor Assembly, GS-2032............................................................. 4 - 18

3-2 Scissor Assembly, GS-2632............................................................. 4 - 24

3-3 Lift Cylinder ...................................................................................... 4 - 32

3-4 Platform Overload System ............................................................... 4 - 34

C Ground Controls

4-1 Manual Platform Lowering Cable ....................................................... 4 - 36

4-2 Control Relays .................................................................................. 4 - 37

4-3 Level Sensor (before serial number 47665) ....................................... 4 - 38

4-4 Level Sensor (after serial number 47664) .......................................... 4 - 44

A Hydraulic Pump

5-1 Function Pump ................................................................................. 4 - 50

vii


June 2006

Section 4 Rev Repair Procedures, continued

C Function Manifold

6-1 Function Manifold Components(from serial number 17408 to 17481) ................................................. 4 - 52




6-5 Function Manifold Components -Models with Traction Control ............................................................. 4 - 60

6-6 Valve Adjustments - Function Manifold ............................................ 4 - 62

6-7 Valve Coils ....................................................................................... 4 - 70

A Hydraulic Tank

7-1 Hydraulic Tank ................................................................................. 4 - 72

A Steer Axle Components

8-1 Yoke and Drive Motor ....................................................................... 4 - 73

8-2 Steer Cylinder ................................................................................... 4 - 75

8-3 Steer Bellcrank ................................................................................. 4 - 76

A Non-steer Axle Components

9-1 Drive Brake ...................................................................................... 4 - 77

A Brake Release Hand Pump Components

10-1 Brake Release Hand Pump Components .......................................... 4 - 78

TABLE OF CONTENTS

viii


June 2004

Section 5 Rev Fault Codes

Introduction .................................................................................................. 5 - 1

A Fault Code Chart (after serial number 17407) ................................................ 5 - 3

ChartNumber Chart Title

1 A All Functions Will Not Operate ..................................................................... 5 - 4

2 A Pump Motor Will Not Operate ....................................................................... 5 - 6

3 A All Functions Inoperative, Power Unit Starts and Runs................................. 5 - 8

4 A Ground Controls Inoperative,Platform Controls Operate Normally ............................................................. 5 - 9

5 A Platform Controls Inoperative,Ground Controls Operate Normally ............................................................. 5 - 10

6 A Platform Up Function Inoperative ............................................................... 5 - 11

7 A Platform Down Function Inoperative ........................................................... 5 - 12

8 A Steer Left Function Inoperative .................................................................. 5 - 14

9 A Steer Right Function Inoperative ................................................................ 5 - 16

10 A All Drive Functions Inoperative,All Other Functions Operate Normally ........................................................ 5 - 18

10A A Brake Release Function Inoperative ........................................................... 5 - 19

11 A Drive Forward Function Inoperative ............................................................ 5 - 20

12 A Drive Reverse Function Inoperative ............................................................ 5 - 21

13 A Machine Will Not Drive At Full Speed ......................................................... 5 - 22

14 A Machine Drives At Full Speed With Platform Raised .................................. 5 - 23

15 A Limit Switch Function Inoperative ............................................................... 5 - 24

16 A Fault Code 02 - ECM / Platform Communication Error ................................ 5 - 26

17 B Fault Code 59 - Parallel/Series Coil Fault ................................................... 5 - 29

ix


June 2004

Section 6 Rev Schematics

Introduction .................................................................................................. 6 - 1

B Control Relay Layout, GS-2032 (ANSI, CSA and Australia models) ............. 6 - 2

B Control Relay Layout, GS-2032 (CE models) and GS-2632 (all models) ....... 6 - 3

B ECM Pin-out Legend .................................................................................... 6 - 4

B Platform Controls Wiring Diagram(models with potentiometer-equipped joystick) ............................................. 6 - 6

A Platform Controls Wiring Diagram(models with hall-effect joystick) .................................................................. 6 - 7

B Ground Controls Wiring Diagram................................................................... 6 - 8

B Level Sensor Box Wiring Diagram ................................................................ 6 - 9

B Electrical Symbols Legend ......................................................................... 6 - 10

B Electrical Schematic -(from serial number 17408 to 21064) .......................................................... 6 - 11





A Electrical Schematic -(from serial number 48104 to 49299) .......................................................... 6 - 21

A Electrical Schematic -(from serial number 49300 to 59999) .......................................................... 6 - 23

B Component Reference and Hydraulic Symbols Legend............................... 6 - 25

B Hydraulic Schematic -(from serial number 17408 to 36100) .......................................................... 6 - 26

B Hydraulic Schematic -(from serial number 36101 to 52788) .......................................................... 6 - 27

A Hydraulic Schematic -(from serial number 52789 to 59999) .......................................................... 6 - 28

B Hydraulic Schematic -Models with Traction Control ...................................................................... 6 - 29

x

Part No. 72963 Genie GS-2032 and GS-2632 2 - 1

Section 2 • Specifications

REV A

June 2004

Machine Specifications

Batteries

Type 6V DC

Group T-105

Quantity 4

Battery capacity, maximum 225AH

Reserve capacity @ 25A rate 447 minutes

Fluid capacities

Hydraulic tank 5 gallons18.9 liters

Hydraulic system (including tank) 5.5 gallons20.8 liters

Tires and wheels

Tire size (solid rubber) 15 x 5 in38.1 x 12.7 cm

Tire contact area 10 sq in 64.5 cm2

Castle nut torque, dry 300 ft-lbs 406.7 Nm

Castle nut torque, lubricated 225 ft-lbs 305 Nm

For operational specifications, refer to theOperator's Manual.

Performance Specifications

Drive speed, maximum

Platform stowed 2.2 mph40 ft / 12.4 sec

3.5 km/h12.2 m / 12.4 sec

Platform raised 0.5 mph40 ft / 55 sec

0.8 km/h12.2 m / 55 sec

Braking distance, maximum

High range on paved surface 2 ft61 cm

Function speed, maximum from platform controls(with 1 person in platform)

Platform up 29 to 31 secondsPlatform down 25 to 27 seconds

Gradeability

GS-2032 30%GS-2632 25%

Airborne noise emissions >70 dBMaximum sound level at normal operation workstations(A-weighted)

Continuous improvement of our products is aGenie policy. Product specifications are subjectto change without notice.

Specifications

2 - 2 Genie GS-2032 and GS-2632 Part No. 72963


REV A

June 2004

Hydraulic Specifications

Hydraulic Oil Specifications

Hydraulic oil type Chevron Rykon MV equivalentApproximate SAE grade 5W-20Viscosity index rating 200

Chevron Rykon MV oil is fully compatible andmixable with Shell Donax TG (Dexron III) oils.Genie specifications require hydraulic oils which aredesigned to give maximum protection to hydraulicsystems, have the ability to perform over a widetemperature range, and have a minimum viscosity indexrating of 150. They should provide excellent antiwear,oxidation, corrosion inhibition, seal conditioning, andfoam and aeration suppression properties.

Optional fluids

Biodegradable Petro Canada Premium ECO 46Statoil Hydra Way Bio Pa 32

BP Biohyd SE-S

Fire resistant UCON Hydrolube HP-5046Quintolubric 822

Mineral based Shell Tellus T32Shell Tellus T46

Chevron Aviation A

Genie specifications requireadditional equipment and specialinstallation instructions for theapproved optional fluids. Consultthe Genie Industries ServiceDepartment before use.

SPECIFICATIONS

Function pump

Type Gear

Displacement per revolution 0.244 cu in 4 cc

Flow rate @ 2500 psi / 172 bar 4 gpm15 L/min

Hydraulic tank return filter 10 micron with25 psi / 1.7 bar bypass

Function manifold

System relief valve pressure, maximum 3500 psi241 bar

Lift relief valve pressure 3000 to 3200 psi207 to 221 bar

Steer relief valve pressure 1500 psi103 bar




REV A

June 2004

SPECIFICATIONS

Manifold ComponentSpecifications

Plug torque

SAE No. 2 50 in-lbs / 6 Nm

SAE No. 4 13 ft-lbs / 18 Nm





Valve Coil Resistance

Description Specification

Solenoid valve, N.C. 23 - 252 position 2 way 20V DC(schematic item D, before serial number 28937)

Solenoid valve, N.C. 23 - 252 position 2 way 20V DC with diode(schematic item D, after serial number 28936)

Solenoid valve, 2 position 2 way N.O. 25 to 27Ω20V DC with diode(schematic items AI, BK, CI and CL)

Solenoid valve, 2 position 4 way 18 to 20Ω20V DC with diode(schematic items AH, AJ, BI, BL, CJ and CN)

Solenoid valve, 3 position 4 way 18 to 20Ω20V DC with diode(schematic items AK, BJ and CK)

Solenoid valve, 3 position 4 way 25 to 27Ω20V DC with diode(schematic items AG, BH and CH)




REV A

June 2004

Hydraulic Hose and FittingTorque SpecificationsYour machine is equipped with JIC 37° flaredfittings and hose ends. Genie specifications requirethat fittings and hose ends be torqued tospecification when they are removed and installedor when new hoses or fittings are installed.

JIC 37° Fittings(swivel nut or hose connection)

SAE Dash size Thread Size Flats

-4 7/16-20 2

-6 9/16-18 1 1/4

-8 3/4-16 1

-10 7/8-14 1

-12 1 1/16-12 1

-16 1 5/16-12 1

-20 1 5/8-12 1

-24 1 7/8-12 1

SAE O-ring Boss Port(tube fitting - installed into Aluminum)

SAE Dash size Torque

-4 11 ft-lbs / 14.9 Nm

-6 23 ft-lbs / 31.2 Nm

-8 40 ft-lbs / 54.2 Nm

-10 69 ft-lbs / 93.6 Nm

-12 93 ft-lbs / 126.1 Nm

-16 139 ft-lbs / 188.5 Nm

-20 172 ft-lbs / 233.2 Nm

-24 208 ft-lbs / 282 Nm

SAE O-ring Boss Port(tube fitting - installed into Steel)

SAE Dash size Torque

-4 16 ft-lbs / 21.7 Nm

-6 35 ft-lbs / 47.5 Nm

-8 60 ft-lbs / 81.3 Nm

-10 105 ft-lbs / 142.4 Nm

-12 140 ft-lbs / 190 Nm

-16 210 ft-lbs / 284.7 Nm

-20 260 ft-lbs / 352.5 Nm

-24 315 ft-lbs / 427.1 Nm

SPECIFICATIONS



REV A

June 2004

a

b

c

b

3 Working clockwise on the body hex fitting, makea second mark with a permanent ink marker toindicate the proper tightening position. Refer toFigure 2.

Use the JIC 37° Fittings table onthe previous page to determine thecorrect number of flats for theproper tightening position.

The marks indicate that the correcttightening positions have beendetermined. Use the second markon the body hex fitting to properlytighten the joint after it has beenloosened.

Figure 1a hydraulic hoseb hex nutc reference markd body hex fitting

b

c

a

d

Torque ProcedureJIC 37° fittings

1 Align the tube flare (hex nut) against the nose ofthe fitting body (body hex fitting) and tighten thehex nut to the body hex fitting to hand-tight,approximately 30 in-lbs / 3.4 Nm.

2 Make a reference mark on one of the flats of thehex nut, and continue it on to the body hexfitting with a permanent ink marker. Refer toFigure 1.

Figure 2a body hex fittingb reference markc second mark

4 Tighten the hex nut until the mark on the hex nutis aligned with the second mark on the body hexfitting.

5 Operate all machine functions and inspect thehoses and fittings and related components toconfirm that there are no leaks.

SPECIFICATIONS



REV A

June 2004

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June 2004 Section 3 • Scheduled Maintenance Procedures

About This Section

This section contains detailed procedures for eachscheduled maintenance inspection.

Each procedure includes a description, safetywarnings and step-by-step instructions.

Symbols Legend







Indicates that a specific result is expected afterperforming a series of steps.

Indicates that an incorrect result has occurredafter performing a series of steps.

Scheduled Maintenance Procedures

Observe and Obey:

Maintenance inspections shall be completed bya person trained and qualified on themaintenance of this machine.

Scheduled maintenance inspections shall becompleted daily, quarterly, annually and every 2years as specified on the MaintenanceInspection Report.

Failure to properly complete eachinspection when required maycause death, serious injury orsubstantial machine damage.

Immediately tag and remove from service adamaged or malfunctioning machine.

Repair any machine damage or malfunctionbefore operating the machine.

Keep records on all inspections for three years.

Unless otherwise specified, perform eachprocedure with the machine in the followingconfiguration:

· Machine parked on a firm, level surface

· Platform in the stowed position

· Key switch in the off position with the keyremoved

· Wheels chocked

· All external AC power supply disconnectedfrom the machine


June 2004Section 3 • Scheduled Maintenance Procedures

Maintenance Symbols Legend

The following symbols have beenused in this manual to helpcommunicate the intent of theinstructions. When one or more ofthe symbols appears at thebeginning of a maintenanceprocedure, it conveys the meaningbelow.

Indicates that tools will be required toperform this procedure.

Indicates that new parts will be requiredto perform this procedure.

Indicates that a cold motor or pump willbe required to perform this procedure.

Indicates that dealer service will berequired to perform this procedure.

Pre-delivery Preparation Report

The pre-delivery preparation report containschecklists for each type of scheduled inspection.

Make copies of the Pre-delivery Preparation reportto use for each inspection. Store completed formsas required.

Maintenance Schedule

There are five types of maintenance inspectionsthat must be performed according to a schedule—daily, quarterly, semi-annually, annually, andtwo year. The Scheduled Maintenance ProceduresSection and the Maintenance Inspection Reporthave been divided into five subsections—A, B, C,D, and E. Use the following chart to determinewhich group(s) of procedures are required toperform a scheduled inspection.

Inspection Checklist

Daily or every 8 hours A

Quarterly or every 250 hours A + B

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

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

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

Maintenance Inspection Report

The maintenance inspection report containschecklists for each type of scheduled inspection.

Make copies of the Maintenance Inspection Reportto use for each inspection. Store completed formsfor three years.

SCHEDULED MAINTENANCE PROCEDURES



Genie Industries USA18340 NE 76th StreetPO Box 97030Redmond, WA 98073-9730(425) 881-1800

Copyright © 2002 by Genie Industries. Genie® is a registered trademark of GenieIndustries. Rev A

Genie UKThe Maltings, Wharf Road

Grantham, LincolnshireNG31- 6BH England

(44) 1476-584333

Pre-Delivery PreparationPre-Delivery PreparationPre-Delivery PreparationPre-Delivery PreparationPre-Delivery Preparation

Pre-Delivery Preparation Y N R

Pre-operation inspectioncompleted

Maintenance items completed

Function tests completed

Model

Serial number

Date

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

Instructions

Use the operator’s manual on your machine.

The Pre-delivery Preparation consists of completingthe Pre-operation Inspection, the Maintenance itemsand the Function Tests.

Use this form to record the results. Place a check inthe appropriate box after each part is completed.Follow the instructions in the operator’s manual.

If any inspection receives an N, remove the machinefrom service, repair and re-inspect it. After repair,place a check in the R box.

LegendY = yes, completedN = no, unable to completeR = repaired

Comments

Fundamentals

It is the responsibility of the dealer to perform thePre-delivery Preparation.

The Pre-delivery Preparation is performed prior toeach delivery. The inspection is designed to discover ifanything is apparently wrong with a machine before itis put into service.

A damaged or modified machine must never be used.If damage or any variation from factory deliveredcondition is discovered, the machine must be taggedand removed from service.

Repairs to the machine may only be made by aqualified service technician, according to themanufacturer's specifications.

Scheduled maintenance inspections shall beperformed by qualified service technicians, accordingto the manufacturer's specifications and therequirements listed in the responsibilities manual.



Maintenance Inspection Report

Checklist B - Rev D Y N R

B-1 Batteries

B-2 Electrical wiring

B-3 Tires and wheels

B-4 Emergency stop

B-5 Key switch

B-6 Horn (if equipped)

B-7 Drive brakes

B-8 Drive speed - stowed

B-9 Drive speed - raised

B-10 Hydraulic oil analysis

B-11 Hydraulic filter

B-12 Latch components

Checklist C - Rev C Y N R

C-1 Platform overload(if equipped)

Checklist D - Rev D Y N R

D-1 Scissor arm wear pads

Checklist E - Rev A Y N R

E-1 Hydraulic oil

Comments

Checklist A - Rev B Y N R

A-1 Pre-operationinspection

A-2 Function tests

Perform after 40 hours:

A-3 30 day service

Perform every 100 hours:

A-4 Grease steer yokes

Instructions· Make copies of this report to use for

each inspection.

· Select the appropriate checklist(s) forthe type of inspection to beperformed.

Daily or 8 hoursInspection: A

Quarterly or 250 hoursInspection: A+B

Semi-annually or500 hoursInspection: A+B+C

Annually or1000 hoursInspection: A+B+C+D

Two year or2000 hoursInspection: A+B+C+D+E

· Place a check in the appropriate boxafter each inspection procedure iscompleted.

· Use the step-by-step procedures inthis section to learn how to performthese inspections.

· If any inspection receives an “N”, tagand remove the machine from service,repair and re-inspect it. After repair,place a check in the “R” box.

LegendY = yes, acceptableN = no, remove from service

R = repaired

Model

Serial number

Date

Hour meter

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

REV B



Checklist A Procedures

A-1Perform Pre-operation InspectionCompleting a Pre-operation Inspection is essentialto safe machine operation. The Pre-operationInspection is a visual inspection performed by theoperator prior to each work shift. The inspection isdesigned to discover if anything is apparentlywrong with a machine before the operator performsthe function tests. The Pre-operation Inspectionalso serves to determine if routine maintenanceprocedures are required.

Complete information to perform this procedure isavailable in the appropriate operator's manual.Refer to the Operator's Manual on your machine.

A-2Perform Function TestsCompleting the function tests is essential to safemachine operation. Function tests are designed todiscover any malfunctions before the machine isput into service. A malfunctioning machine mustnever be used. If malfunctions are discovered, themachine must be tagged and removed fromservice.

Complete information to perform this procedure isavailable in the appropriate operator's manual.Refer to the Operator's Manual on your machine.

REV B



CHECKLIST A PROCEDURES

A-3Perform 30 Day Service

The 30 day maintenance procedure is a onetimeprocedure to be performed after the first 30 days or40 hours of usage. After this interval, refer to themaintenance tables for continued scheduledmaintenance.

1 Perform the following maintenance procedures:

· B-3 Inspect the Tires and Wheels(including castle nut torque)

· B-10 Replace the Hydraulic TankReturn Filter

A-4Grease the Steer Yokes

Genie specifications require thatthis procedure be performed every100 hours of operation.

Regular application of lubrication to the steer yokesis essential to good machine performance andservice life. Continued use of an insufficientlygreased steer yoke will result in componentdamage.

1 Locate the grease fitting on the top of the steeryoke.

2 Pump multipurpose grease into the steer yokeuntil the steer yoke is full and grease is beingforced past the bearings. Repeat this step forthe other steer yoke.

Grease type Multipurpose grease

REV D


September 2006Section 3 • Scheduled Maintenance Procedures

B-1Inspect the Batteries

Proper battery condition is essential to goodmachine performance and operational safety.Improper fluid levels or damaged cables andconnections can result in component damage andhazardous conditions.

Bodily injury hazard. Batteriescontain acid. Avoid spilling orcontacting battery acid. Neutralizebattery acid spills with baking sodaand water.

Electrocution hazard. Contactwith hot or live circuits couldresult in death or serious injury.Remove all rings, watches andother jewelry.

Perform this test after fullycharging the batteries.

For a more accurate determinationof battery condition, fully chargethe batteries and allow thebatteries to rest 24 hours beforeperforming this procedure to allowthe battery cells to equalize.

1 Put on protective clothing and eye wear.

2 Disconnect the battery pack from the machine.

3 Be sure that the battery cable connections arefree of corrosion.

4 Be sure that the battery hold downs and cableconnections are tight.

Models without maintenance-free or sealedbatteries:

5 Remove the battery vent caps and check thespecific gravity of each battery cell with ahydrometer.

Result: If any battery cell displays a specificgravity of less than 1.026, the battery must bereplaced.

6 Check the battery acid level of each battery. Ifneeded, replenish with distilled water to thebottom of the battery fill tube. Do not overfill.

7 Install the battery vent caps.

8 Check each battery pack and verify that thebatteries are wired correctly.

Checklist B Procedures

F6

QD1

275A Fuse

+

-

+

-

-

+

+

- +

-

b ca

a batteries B5b quick disconnect QD1c 275A fuse F6

REV D


September 2006 Section 3 • Scheduled Maintenance Procedures

CHECKLIST B PROCEDURES

B-2Inspect the Electrical Wiring

Maintaining electrical wiring in good condition isessential to safe operation and good machineperformance. Failure to find and replace burnt,chafed, corroded or pinched wires could result inunsafe operating conditions and may causecomponent damage.

Electrocution hazard. Contact withhot or live circuits could result indeath or serious injury. Remove allrings, watches and other jewelry.

1 Inspect the underside of the chassis fordamaged or missing ground strap(s).

2 Inspect the following areas for burnt, chafed,corroded and loose wires:

· Ground control panel

· Hydraulic power unit module tray

· Battery pack module tray

· Scissor arms

· Platform controls

3 Inspect for a liberal coating of dielectric greasein all connections between the ECM and theplatform controls.

4 Turn the key switch to ground control and pullout the Emergency Stop button to the onposition at both the ground and platformcontrols.

5 Raise the platform approximately 8 feet / 2.4 mfrom the ground.

6 Rotate the safety arm away from the machineand let it hang down.

7 Lower the platform onto the safety arm.

Crushing hazard. Keep handsclear of the safety arm whenlowering the platform.

8 Inspect the center chassis area and scissorarms for burnt, chafed and pinched cables.

9 Inspect the following areas for burnt, chafed,corroded, pinched and loose wires:

· Scissor arms

· ECM to platform controls

· Power to platform wiring

10 Inspect for a liberal coating of dielectric greasein all connections between the ECM and theplatform controls.

11 Raise the platform and return the safety arm tothe stowed position.

12 Lower the platform to the stowed position andturn the machine off.

REV D



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

Maintaining the tires and wheels in goodcondition is essential to safe operation and goodperformance. Tire and/or wheel failure could resultin a machine tip-over. Component damage mayalso result if problems are not discovered andrepaired in a timely fashion.

1 Check the tire surface and sidewalls for cuts,cracks or unusual wear.

2 Check each wheel for damage, bends andcracks.

3 Remove the cotter pin and check each castlenut for proper torque. Refer to Section 2,Specifications.

Always replace the cotter pin witha new one when removing thecastle nut or when checking thetorque of the castle nut.

4 Install a new cotter pin. Bend the cotter pin tolock it in place.


B-4Test the Emergency StopA properly functioning Emergency Stop is essentialfor safe machine operation. An improperlyoperating red Emergency Stop button will fail toshut off power and stop all machine functions,resulting in a hazardous situation.

As a safety feature, selectingand operating the ground controlswill override the platform controls,except the platform redEmergency Stop button.

1 Turn the key switch to ground control and pullout the red Emergency Stop button to the onposition at both the ground and platformcontrols.

2 Push in the red Emergency Stop button at theground controls to the off position.

Result: No machine functions should operate.

3 Turn the key switch to platform control and pullout the red Emergency Stop button to the onposition at both the ground and platformcontrols.

4 Push down the red Emergency Stop button atthe platform controls to the off position.


The red Emergency Stop button atthe ground controls will stop allmachine operation, even if the keyswitch is switched to platformcontrol.

REV D



B-5Test the Key SwitchProper key switch action and response is essentialto safe machine operation. The machine can beoperated from the ground or platform controls andthe activation of one or the other is accomplishedwith the key switch. Failure of the key switch toactivate the appropriate control panel could causea hazardous operating situation.

Perform this procedure from theground using the platform controls.Do not stand in the platform.

1 Pull out the Emergency Stop button to the onposition at both the ground and platformcontrols.

2 Turn the key switch to platform control.

3 Check the platform up/down function from theground controls.

Result: The machine functions should notoperate.

4 Turn the key switch to ground control.

5 Check the machine functions from the platformcontrols.

Result: The machine functions should notoperate.

6 Turn the key switch to the off position.



B-6Test the Automotive-style Horn(if equipped)A functioning horn is essential to safe machineoperation. The horn is activated at the platformcontrols and sounds at the ground as a warning toground personnel. An improperly functioning hornwill prevent the operator from alerting groundpersonnel of hazards or unsafe conditions.

1 Turn the key switch to platform control andpull out the Emergency Stop button to theon position at both the ground andplatform controls.

2 Push down the horn button at the platformcontrols.

Result: The horn should sound.

REV D



B-7Test the Drive Brakes

Proper brake action is essential to safe machineoperation. The drive brake function should operatesmoothly, free of hesitation, jerking and unusualnoise. Hydraulically-released individual wheelbrakes can appear to operate normally when notfully operational.

Perform this procedure with themachine on a flat, level surfacethat is free of obstructions.

Be sure the platform extensiondeck is fully retracted and theplatform is in the stowed position.

1 Mark a test line on the ground for reference.

2 Turn the key switch to platform control and pullout the Emergency Stop button to the onposition at both the ground and platformcontrols.

2 Lower the platform to the stowed position.

3 Models with drive function select button:Press the drive function select button. Refer toIllustration 1.

®

Stop

a

Illustration 1

a drive function select button BN8

5 Choose a point on the machine; i.e., contactpatch of a tire, as a visual reference for usewhen crossing the test line.

6 Bring the machine to full drive speed beforereaching the test line. Release the functionenable switch or the joystick on the platformcontrols when your reference point on themachine crosses the test line.

7 Measure the distance between the test lineand your machine reference point. Refer toSection 2, Specifications.

Result: The machine stops within the specifiedbraking distance. No action required.

Result: The machine does not stop within thespecified braking distance. Proceed to step 8and determine if the machine is equipped witha dynamic braking valve.

The brakes must be able to holdthe machine on any slope it isable to climb.


Electrocution hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.

9 Locate the drive forward/reverse valve on thefunction manifold. Refer to Illustrations 2.


a

Illustration 2

a drive forward/reserve valve

REV D



10 Tag the forward and the reverse valve coils.Remove the coils from the valve.

The forward valve coil has whiteand brown wires attached.

The reverse valve coil haswhite/black and brown wiresattached.

For reassembly, it will be helpfulto leave the wire harnessattached to the valve coils.

For GS-2032 and GS-2632 before serial numberGS3204-51608 proceed to step 11.

For GS-2032 and GS-2632 after serial numberGS3204-51607 proceed to step 20.

11 Remove the drive forward/reverse valve fromthe function manifold. Cap the open port of themanifold.

12 Carefully inspect the hex portion of the valvefor an identification stamp.

Result: SV10-4727 is stamped on the hexportion of the drive forward/reverse valve. Thisindicates the machine is equipped with adynamic brake valve. Proceed to step 13.

Result: SV10-4727 is not stamped on the hexportion of the drive forward/reverse valve. Thisindicates the machine is not equipped with adynamic brake valve. Proceed to step 18.

13 Install the drive forward/reverse valve removedin step 11 into the function manifold andsecurely tighten. Torque to 25 ft-lbs / 34 Nm.

14 In order, install the reverse valve coil (withwhite/black and brown wires), spacer washerand the forward valve coil (with white andbrown wires) onto the valve.

For the machine to functioncorrectly, the reverse valve coilmust be closest to the manifold.

15 Install the coil nut onto the valve and tighten.Torque to 60 in-lbs / 7 Nm.

16 Connect the battery pack to the machine.

17 Replace the brakes and repeat this procedurebeginning with step 1. Refer to RepairProcedure 9-1, How to Remove a Drive Brake.

18 Contact the Genie Industries Service PartsDepartment and order kit part number 105457.

19 Install the new valve received in the kit andmark the new valve with a white paint pen toidentify new valve installation.

20 Repeat this procedure beginning with step 1.

If the machine fails to stop within the specifiedstopping distance after installing new brakes,please contact the Genie Industries ScissorsService Department, 1-800-536-1800 Ext. 8710.


REV D




21 Remove the drive forward/reverse valve fromthe function manifold. Cap the open port of themanifold.

22 Carefully inspect the hex portion of the valvefor an identification stamp.

Result: SV10-5905 is stamped on the hexportion of the drive forward/reverse valve.This indicates the machine is equipped with a dynamic brake valve. Proceed to step 22.

Result: SV10-5905 is not stamped on the hexportion of the drive forward/reverse valve. Thisindicates the machine is not equipped with adynamic brake valve. Proceed to step 27.

23 Install the drive forward/reverse valve removedin step 20 into the function manifold andsecurely tighten. Torque to 25 ft-lbs / 34 Nm.

24 In order, install the reverse valve coil (withwhite/black and brown wires), spacer washerand the forward valve coil (with white andbrown wires) onto the valve.

For the machine to functioncorrectly, the reverse valve coilmust be closest to the manifold.

25 Install the coil nut onto the valve and tighten.Torque to 60 in-lbs 7 Nm.

26 Connect the battery pack to the machine.

27 Replace the brakes and repeat this procedurebeginning with step 1. Refer to RepairProcedure 9-1, How to Remove a Drive Brake.

28 Contact the Genie Industries Service PartsDepartment and order kit part number 105458.

29 Install the new valve received in the kit andmark the new valve with a white paint pen toidentify new valve installation.

30 Repeat this procedure beginning with step 1.

If the machine fails to stop within the specifiedstopping distance after installing new brakes,please contact the Genie Industries ScissorsService Department, 1-800-536-1800 Ext. 8710.

REV D




B-8Test the Drive Speed -Stowed Position

Proper drive functions are essential to safemachine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free ofhesitation, jerking and unusual noise over theentire proportionally controlled speed range.

Perform this procedure with themachine on a firm, level surfacethat is free of obstructions.

1 Create start and finish lines by marking twolines on the ground 40 feet / 12.2 m apart.



4 Models with drive function select button:Press the drive function select button.

®

Stop

a

a drive function select button BN8

5 Choose a point on the machine; i.e., contactpatch of a tire, as a visual reference for usewhen crossing the start and finish lines.

6 Bring the machine to maximum drive speedbefore reaching the start line. Begin timingwhen your reference point on the machinecrosses the start line.

7 Continue at full speed and note the time whenthe machine reference point passes over thefinish line. Refer to Section 2, Specifications.

REV D



B-9Test the Drive Speed -Raised Position

Proper drive functions are essential to safemachine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free ofhesitation, jerking and unusual noise over theentire proportionally controlled speed range.


1 Create start and finish lines by marking twolines on the ground 40 feet / 12.2 m apart.


3 Models with lift function enable button:Press and hold the lift function enable button.Models with drive function select button:Press the lift function select button.

4 Press and hold the function enable switch onthe joystick.

5 Raise the platform approximately 4 feet / 1.2 mfrom the ground.

6 Models with lift function enable button:Release the lift function enable button.Models with drive function select button:Press the drive function select button.

7 Choose a point on the machine; i.e., contactpatch of a tire, as a visual reference for usewhen crossing the start and finish lines.

8 Bring the machine to maximum drive speedbefore reaching the start line. Begin timingwhen your reference point on the machinecrosses the start line.

9 Continue at full speed and note the time whenthe machine reference point passes over thefinish line. Refer to Section 2, Specifications.


®

Stop

®

Stop

a

b

c

a lift function enable button BN9b lift function select button BN9c drive function select button BN8

REV D



B-10Perform Hydraulic Oil Analysis

Replacement or testing of the hydraulic oil isessential for good machine performance andservice life. Dirty oil and a clogged suction strainermay cause the machine to perform poorly andcontinued use may cause component damage.Extremely dirty conditions may require oil changesto be performed more often.

Before replacing the hydraulic oil,the oil may be tested by an oildistributor for specific levels ofcontamination to verify thatchanging the oil is necessary. Ifthe hydraulic oil is not replacedat the two year inspection, testthe oil quarterly. Replace the oilwhen it fails the test. See D-1,Test or Replace the Hydraulic Oil.

B-11Replace the Hydraulic TankReturn Filter

Replacement of the hydraulic tank return filter isessential for good machine performance andservice life. A dirty or clogged filter may cause themachine to perform poorly and continued use maycause component damage. Extremely dirtyconditions may require that the filter be replacedmore often.

Beware of hot oil. Contact withhot oil may cause severe burns.

The hydraulic filter is mounted onthe function manifold next to thehydraulic power unit.

1 Clean the area around the oil filter. Remove thefilter with an oil filter wrench.

2 Apply a thin layer of oil to the new oil filtergasket.

3 Install the new filter and tighten it securely byhand.

4 Use a permanent ink marker to write the dateand number of hours from the hour meter(if equipped) on the filter.


6 Activate and hold the platform up toggle switch.

7 Inspect the filter and related components tobe sure that there are no leaks.

8 Clean up any oil that may have spilled duringthe replacement procedure. Properly dispose ofthe used filter.


REV D



B-12Check the Module Tray LatchComponents

Maintaining the module tray latch components ingood condition is essential to good performanceand service life. Failure to detect worn out latchcomponents may result in module trays openingunexpectedly, creating an unsafe operatingcondition.

Models before serial number 35800:

1 Open both module trays and lubricate eachmodule tray latch. Using light oil, apply a fewdrops to the side of the latch pin.

2 Inspect each module tray latch pad(if equipped). Replace any worn pad before thelatch fails to securely hold the module trayclosed.

The module tray latch pad isattached to the drive chassis andlocated above the module traylatch when the module tray isclosed.

Models after serial number 35799:

1 Lubricate each module tray rotary latch. Usinglight oil, apply a few drops to each of thesprings and to the sides of the rotary latchmechanism.

a rotary latch springsb module tray rotary latch

2 Inspect each module tray latch U-bolt. Tightenany loose U-bolt retaining fastener before thelatch fails to securely hold the module trayclosed.


b

a

REV C



C-1Test thePlatform Overload System(if equipped)

Genie specifications require thatthis procedure be performed every500 hours or six months,whichever comes first OR whenthe machine fails to lift themaximum rated load.

Testing the platform overload system regularly isessential to safe machine operation. Continueduse of an improperly operating platform overloadsystem could result in the system not sensing anoverloaded platform condition. Machine stabilitycould be compromised resulting in the machinetipping over.

The platform overload system is designed toprevent machine operation in the event themachine is overloaded. Models equipped with theplatform overload option are provided with twoadditional machine control components: theoverload pressure switch and a maximum heightlimit switch.

The overload pressure switch, which is adjustableand located at the barrel-end of the lift cylinder, isused to determine when the hydraulic lift cylinderrequires too much pressure to support the loadinside the platform. When this occurs, the pressureswitch will send a signal to the ECM, which will notallow the machine to function until the extra weightis removed from the platform.

The maximum height limit switch, located in themiddle of the drive chassis under the scissor arms,is used to disable the lift valve coil when theplatform is near maximum height. When activated,the limit switch keeps the lift cylinder from goingover lift relief which would cause the pressureswitch to falsely indicate an overload condition.

Checklist C Procedure

a overload pressure switchb maximum height limit switch

1 Locate the lift valve coil on the functionmanifold.

a test portb lift valve coil

2 Tag and disconnect the black and white wires ofthe up limit switch wire harness from theblue/black wires of the manifold wire harness atthe lift valve coil on the manifold.

b

a

a

b

REV C



3 Securely connect together the terminals of thetwo blue/black wires of the manifold wireharness, disconnected from the limit switch wireharness in step 2.


5 Fully raise the platform. Release the toggleswitch.

Result: The alarm should sound.

Result: The alarm does not sound. Calibrate theplatform overload system. See MaintenanceProcedure D-2, Calibrate the Platform OverloadSystem (if equipped).

6 Using the manual lowering knob, lower theplatform to the stowed position.

7 Disconnect the two blue/black wires of themanifold wire harness at the lift valve coil on themanifold.

8 Securely connect the black and white wires ofthe up limit switch wire harness to the twoblue/black wires of the manifold wire harness atthe lift valve coil on the manifold.

9 Fully raise the platform. Release the toggleswitch.

Result - models with software revision A0 andA1: The alarm should not sound and fault code54 should be present in the diagnostic display.The system is functioning correctly.

Result - models with software revision A2 andhigher: The alarm should not sound. Thesystem is functioning correctly.

Result - all models: The alarm sounds. Thesystem is not functioning correctly.Troubleshoot the limit switch, limit switch wireharness or limit switch mount bracket OR theplatform overload system needs to becalibrated. See Maintenance Procedure D-2,Calibrate the Platform Overload System (ifequipped).

To determine the software revisionlevel, refer to Repair Procedure1-2, How to Determine theRevision Level.


CHECKLIST C PROCEDURES

REV D



D-1Check the Scissor Arm WearPads

Maintaining the scissor arm wear pads in goodcondition is essential to safe machine operation.Continued use of worn out wear pads may result incomponent damage and unsafe operatingconditions.

Perform this procedure with theplatform in the stowed position.

1 Measure the thickness of the wear pad at theground controls side of the non-steer end of themachine.

Result: The measurement is 0.21 inch / 5.3 mmor more. Proceed to step 2.

Result: The measurement is less than0.21 inch / 5.3 mm. Replace both wear pads.Refer to Repair Procedure 3-1 or 3-2, How toReplace the Scissor Arm Wear Pads.

Checklist D Procedure

2 Measure the thickness of the wear pad at thebattery pack side of the non-steer end of themachine.

Result: The measurement is 0.21 inch / 5.3 mmor more. Proceed to step 2.

Result: The measurement is less than0.21 inch / 5.3 mm. Replace both wear pads.Refer to Repair Procedure 3-1 or 3-2, How toReplace the Scissor Arm Wear Pads.

3 Apply a thin layer of dry film lubricant to thearea of the chassis where the scissor arm wearpads make contact.

Wear pad specification

Thickness, minimum 0.21 inch5.3 mm

0.21 inches / 5.3 mm

REV A



E-1Test or Replace the Hydraulic Oil

Replacement or testing of the hydraulic oil isessential for good machine performance andservice life. Dirty oil and a clogged suction strainermay cause the machine to perform poorly andcontinued use may cause component damage.Extremely dirty conditions may require oil changesto be performed more often.

Before replacing the hydraulic oil,the oil may be tested by an oildistributor for specific levels ofcontamination to verify thatchanging the oil is necessary. Ifthe hydraulic oil is not replacedat the two year inspection, testthe oil quarterly. Replace the oilwhen it fails the test.



2 Open the power unit module tray. Remove thedrain plug from the hydraulic tank and allow allof the oil to drain into a suitable container. Referto Section 2, Specifications, for capacityinformation.

Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.

3 Tag, disconnect and cap the hydraulic hosesfrom the hydraulic tank.

4 Remove the hydraulic tank mounting fasteners.Remove the hydraulic tank from the machine.

Checklist E Procedure

5 Remove the suction strainer and clean it usinga mild solvent.

6 Clean the inside of the hydraulic tank using amild solvent.

7 Install the suction strainer using thread sealeron the threads.

8 Install the drain plug using thread sealer on thethreads. Torque to specification.

Torque specifications

Hydraulic tank drain plug, dry 75 in-lbs8.5 Nm

Hydraulic tank drain plug, lubricated 56 in-lbs6.3 Nm

9 Install the hydraulic tank and install and tightenthe hydraulic tank retaining fasteners. Torque tospecification.


Hydraulic tank retaining fasteners, dry 35 in-lbs4 Nm

Hydraulic tank retaining fasteners, lubricated 26 in-lbs2.9 Nm

10 Connect the hydraulic hoses to the hydraulictank.

11 Fill the tank with hydraulic oil until the fluid iswithin the FULL and ADD marks on the oil levelindicator decal. Do not overfill.

12 Activate the pump to fill the hydraulic systemwith oil and bleed the system of air and checkfor leaks.

13 Repeat steps 11 and 12 until the hydraulic tankand system are both full.

14 Clean up any oil that may have spilled. Properlydiscard the used oil.


June 2004 Section 4 • Repair Procedures

Repair Procedures

Observe and Obey:

Repair procedures shall be completed by aperson trained and qualified on the repair of thismachine.



Before Repairs Start:

Read, understand and obey the safety rulesand operating instructions in the appropriateoperator's manual on your machine.

Be sure that all necessary tools and parts areavailable and ready for use.

Read each procedure completely and adhere tothe instructions. Attempting shortcuts mayproduce hazardous conditions.

Unless otherwise specified, perform each repairprocedure with the machine in the followingconfiguration:




· The red Emergency Stop button in the offposition at both ground and platform controls

· Wheels chocked


About This Section

Most of the procedures in this section should onlybe performed by a trained service professionalin a suitably equipped workshop. Select theappropriate repair procedure after troubleshootingthe problem. Perform disassembly procedures tothe point where repairs can be completed. Tore-assemble, perform the disassembly steps inreverse order.

Symbols Legend







Indicates that a specific result is expected afterperforming a series of steps.

Indicates that an incorrect result has occurredafter performing a series of steps.

REV B


June 2004Section 4 • Repair Procedures

Platform Controls

The platform controls, used to operate the machinefrom the platform or while standing on the ground,can also be used to tune the performance of themachine.

Moving the joystick or activating a button or toggleswitch sends a signal to the Electronic ControlModule (ECM). When the ECM is in the functionmode, the platform controls are used to operatethe various machine functions. When the ECM is inthe programming mode (PS is shown in thediagnostic display window), the platform controlsare used to adjust the function speed parameters.

The platform controls contains an electronic circuitboard, joystick, membrane decal, buttons, switchesand LEDs. Potentiometer-equipped joysticks canbe adjusted to maintain performance.

For further information or assistance, consult theGenie Industries Service Department.

P2EMERGENCY STOPBUTTON

JC1JOYSTICK

CONTROLLER

H1ALARM

21

U3PLATFORMCONTROLS

CIRCUITBOARD

h

g

f

e

a

b

c

d

19

F2

34

56

78

ON

AL

CO

AD

F0

85


H1ALARM

U3PLATFORM CONTROLSCIRCUIT BOARD

14.25.

2

1 NC

19

F2

34

56

78

ON

AL

CO

AD

F0

85

P/N

00

00

00

Da

te0

00

0S

/NA

l0

00

00

00

0

JC1JOYSTICKCONTROLLER

h

a

c

e

f

b

Platform controls withhall-effect joystick

a Emergency Stop button P2b platform controls circuit board U3c circuit board retaining fastenerd circuit board voltage regulatore alarm H1f joystick controller JC1g potentiometerh DIP switch SW25

Platform controls withpotentiometer-equipped joystick

REV B



1-1Circuit Boards

How to Remove the PlatformControls Circuit Board1 Push in the Emergency Stop button to the off

position at both the ground and platformcontrols.

2 Loosen the platform control box lid retainingfasteners. Open the control box lid.

3 Locate the circuit board mounted to the insideof the platform control box lid.

Electrocution hazard. Contact withelectrically charged circuits couldresult in death or serious injury.Remove all rings, watches andother jewelry.

Component damage hazard.Electrostatic discharge (ESD) candamage printed circuit boardcomponents. Maintain firm contactwith a metal part of the machinethat is grounded at all times whenhandling printed circuit boards ORuse a grounded wrist strap.

4 Carefully disconnect the three wire harnessconnectors from the platform controls circuitboard.

5 Carefully remove the platform controls circuitboard retaining fasteners.

6 Carefully remove the platform controls circuitboard from the platform control box lid.

1-2Joystick Controller

Maintaining the joystick at the proper setting isessential to safe machine operation. The joystickshould operate smoothly over its entire range ofmotion.

Platform controls equipped with Hall-effectjoysticks do not require any calibration.

How to Calibrate thePotentiometer-equipped Joystick1 Turn the key switch to platform controls and pull

out the Emergency Stop button to the onposition at both the ground and platformcontrols.

2 Remove the platform control box lid retainingfasteners. Open the control box lid.


PLATFORM CONTROLS

REV B



PLATFORM CONTROLS

3 Locate the potentiometer on the base of thejoystick.

a joystick controller JC1b potentiometer shaft slotc potentiometer shaft set screwd platform controls circuit board U3e potentiometerf brown wireg purple wire

4 With a volt meter set to read DC voltage, placethe volt meter negative lead on the purple wire.Place the volt meter positive lead on the brownwire.


5 Loosen the set screw on the potentiometershaft just enough to let the shaft rotate.

6 With the joystick in the neutral position, adjustthe potentiometer to 2.05V DC at thepotentiometer shaft. Tighten the set screw.

7 Move the joystick full stroke in both directionsseveral times. Return the joystick to the neutralposition.

Result: The volt meter should read 2.05V DC.

Result: If the volt meter does not read 2.05VDC, repeat steps 5 through 7.


9 Wait a few seconds and then turn the keyswitch to platform controls.

Result: The error light on the top of the platformcontrol box should go out and Code 47 shouldnot be present on the diagnostic display at thebattery module side of the machine.

Result: If the error indicator light is still on or ifcode 47 is present on the diagnostic display,repeat steps 5 through 9.


11 Close the lid and install the fasteners.

REV B



PLATFORM CONTROLS

4 Press and hold the lift function enable buttonOR press the lift function select button.

a yellow arrowb joystick controller JC1c lift function select button BN9d Emergency Stop button P2e lift function enable button BN9

5 Slowly move the joystick in the directionindicated by the yellow arrow.

Result: The software revision level will appearin the diagnostic display.

Result: If the software revision level does notappear in the diagnostic display, turn the keyswitch to ground control and repeat steps 4 and5. The software revision level will appear in thediagnostic display.

6 Push in the Emergency Stop button to the offposition at both the ground and platformcontrols and turn the key switch to the offposition.

1-3Controller Adjustments

Platform lift speed, stowed drive speed, raiseddrive speed and high torque drive speed are areadjustable to compensate for wear in the hydraulicpump and drive motors.

The function speeds are determined by thepercentage of total controller output.

For further information or assistance, consult theGenie Industries Service Department.

Tip-over hazard. Do not adjust thelift and/or drive speed higher thanspecified in this procedure. Settingthe function speeds greater thanspecifications could cause themachine to tip over resulting indeath or serious injury.

Tip-over hazard. This proceduremust only be performed by atrained service professional.Attempting this procedure withoutthe necessary skills will result indeath or serious injury.

Select a test area that is firm, leveland free of obstructions.

How to Determine the RevisionLevel1 Remove the platform controls from the platform.

2 Place the platform controls close to thediagnostic display on the ground controls sideof the machine.

3 Turn the key switch to platform control and pullout the Emergency Stop buttons to the onposition at both the ground and platformcontrols.

REV B



PLATFORM CONTROLS

How to Adjust the Lift SpeedTip-over hazard. Do not adjust thelift and/or drive speed higher thanspecified in this procedure. Settingthe drive speed greater thanspecifications will cause death orserious injury.


Software revision A0 and B0:

1 Push in the Emergency Stop button to the offposition at the ground and platform controls.Turn the key switch to the off position.

2 Pull out the Emergency Stop button to the onposition at the ground and platform controls.

3 Press and hold the lift function enable and hornbuttons, and turn the key switch to platformcontrols.

Result: The diagnostic display will show "PS."

a function enable switch SW5b joystick controller JC1 with thumb

steering rocker SW6c horn button BN5d machine on incline button BN6e lift function enable button BN9f red Emergency Stop button P2

4 Release the lift function enable and hornbuttons.

5 Press and hold the lift function enable button.

Result: The diagnostic display will show themaximum lift speed percentage.

6 Use the steering thumb rocker switch on thejoystick to increase or decrease the maximumlift speed percentage. Refer to Section 2,Specifications.


Any change in software settingswill not take effect until the keyswitch is turned to the off position.

REV B



PLATFORM CONTROLS

Software revision C0 and higher:

1 Push in the red Emergency Stop button to theoff position at the ground and platform controls.Turn the key switch to the off position.

2 Pull out the red Emergency Stop button to theon position at the ground and platform controls.

3 At the platform controls, press and hold the liftfunction select and horn buttons and turn thekey switch to platform controls.



steering rocker SW6c horn button BN5d machine on incline buttone lift function select button BN9f drive function select BN8g red Emergency Stop button P2

4 Release the lift function select and hornbuttons.


5 Press the lift function select button.




REV B



PLATFORM CONTROLS

How to Adjust the Stowed DriveSpeed



Software revision D0 and higher:



3 Press and hold the lift function select and hornbuttons and turn the key switch to platformcontrols.




5 Press the drive function select button.

Result: The diagnostic display will show thestowed drive speed percentage.


steering rocker SW6c horn button BN5d machine on incline button BN6e lift function select button BN9f drive function select BN8g red Emergency Stop button P2

6 Use the steering thumb rocker switch on thejoystick to increase or decrease the stoweddrive speed percentage. Refer to Section 2,Specifications.



REV B



PLATFORM CONTROLS

How to Adjust the High TorqueDrive Speed

Tip-over hazard. Do not adjust thelift and/or drive speed higher thanspecified in this procedure. Settingthe drive speed greater thanspecifications could cause themachine to tip over resulting indeath or serious injury.





3 Press and hold the lift function select and hornbuttons and turn the key switch to platformcontrols.





Result: The diagnostic display will show thestowed drive speed percentage.


rocker switch SW6c horn button BN5d machine on incline button BN6e lift function select button BN9f drive function select BN8g red Emergency Stop button P2

6 Press and hold the machine on incline button.

Result: The diagnostic display will show thestowed high torque drive speed percentage.

7 Use the steering thumb rocker switch on thejoystick to increase or decrease the stowedhigh torque drive speed percentage. Refer toSection 2, Specifications.



REV B



PLATFORM CONTROLS

How to Adjust the Raised DriveSpeed



Software revision A0 and B0:



3 Press and hold the lift function enable and hornbuttons, and turn the key switch to platformcontrols.



steering rocker SW6c horn button BN5d machine on incline buttone lift function enable button BN9f red Emergency Stop button P2

4 Release the lift function enable and hornbuttons.

5 Press and hold the horn button.

Result: The diagnostic display will show theraised drive speed percentage.

6 Use the steering thumb rocker switch on thejoystick to increase or decrease the maximumraised drive speed percentage. Refer to Section2, Specifications.



REV B



Software revision C0:



3 Press and hold the lift function select and hornbuttons, and turn the key switch to platformcontrols.

Result: The diagnostic display will show "PS".












PLATFORM CONTROLS

REV B






3 Press and hold the lift function select and hornbuttons, and turn the key switch to platformcontrols.











PLATFORM CONTROLS

REV B



1-4Software Configuration

The ECM (Electronic Control Module) containsprogramming for all configurations of the GenieGS-2032 and GS-2632. The machine can beadjusted to a different configuration by changingthe toggle settings on the DIP switch. The DIPswitch is located on the circuit board inside theplatform control box.

Each of the eight toggles of the DIP switch havetwo positions: on or off. When reading the DIPswitch code in the DIP Switch Code Chart, the onand off are represented by the numbers 1 (on) and0 (off).

PLATFORM CONTROLS

a platform controls circuit board U3b enlarged view of DIP switch SW25c joystick controller JC1d DIP switch SW25

P2EMERGENCYSTOPBUTTON

H1ALARM

21

bON (1)

OFF (0)

SW25DIPSWITCH

U3PLATFORMCONTROLSCIRCUITBOARD

JC1JOYSTICK

CONTROLLER

c

d

a

19F 2 3 4 5 6 7 8

ON ALCO ADF085


H1ALARM


14.25.

2

1 NC

19

F2

34

56

78

ON

AL

CO

AD

F0

85

P/N

00

00

00

Da

te0

00

0S

/NA

l0

00

00

00

0


c

a

d

before serial number 48055

after serial number 48054

How to Determine the DIP SwitchConfiguration1 Remove the platform controls from the platform.

2 Place the platform controls close to thediagnostic display on the hydraulic module sideof the machine.

3 Turn the key switch to platform control and pullout the red Emergency Stop buttons to the onposition at both the ground and platformcontrols.

4 Press and hold the lift function enable buttonOR press the lift function select button.

5 Slowly move the joystick in the directionindicated by the blue arrow.

Result: The DIP switch configuration will appearin the diagnostic display.

a yellow arrowb joystick controller JC1c lift function select button BN9d red Emergency Stop button P2e lift function enable button BN9

REV B



How to Set the DIP Switch CodesTip-over hazard. Do not adjust theDIP switch settings to other thanwhat is specified in this procedure.Exceeding specifications couldcause the machine to tip overresulting in death or serious injury.

If replacing the circuit board, notethe toggle positions on the DIPswitch. Set the DIP switch on thenew circuit board to the sameconfiguration as the old board.


2 Remove the fasteners securing the top of theplatform controls and open the platform controlbox.

3 Rotate the platform control box to the positionshown to correctly identify the configuration ofthe DIP switch settings.

4 Locate the DIP switch on the circuit board.Move the DIP switch settings to correspondwith the configuration of the machine options,indicated in the DIP Switch Code Chart.

a platform controls circuit board U3b enlarged view of DIP switch SW25c joystick controller JC1d DIP switch SW25

5 Close the lid and install the fasteners.

6 Confirm the settings. See 1-3, How toDetermine the DIP Switch Configuration.

7 Push in the red Emergency Stop button to theoff position at both the ground and platformcontrols and turn the key switch to the offposition.

Any change in DIP settings will nottake effect until the key switch isturned to the off position.

PLATFORM CONTROLS

P2EMERGENCYSTOPBUTTON

H1ALARM

21

bON (1)

OFF (0)

SW25DIPSWITCH

U3PLATFORMCONTROLSCIRCUITBOARD

JC1JOYSTICK

CONTROLLER

c

d

a

19F 2 3 4 5 6 7 8

ON ALCO ADF085


H1ALARM


14.25.

2

1 NC

19

F2

34

56

78

ON

AL

CO

AD

F0

85

P/N

00

00

00

Da

te0

00

0S

/NA

l0

00

00

00

0


c

a

d

before serial number 48055

after serial number 48054

REV B



PLATFORM CONTROLS

DIP Switch Code ChartA mark in the column indicates that the machineconfiguration includes this option.

DIP Switch Function DefinitionsIf replacing the circuit board, notethe toggle positions of the DIPswitch before removal. Set the DIPswitch toggle positions on the newcircuit board to the sameconfiguration of the old board.

If replacing the circuit board, usedielectric grease on all plug-inconnectors.

Motion Beacon: The motion beacon option flashesonly when operating a function.

Motion Alarm: The motion alarm will sound whenoperating any function.

Lift/Drive Cut Out: This cuts out lift and drivefunctions when the machine exceeds the rating onthe serial plate. Required for Europe and Australiabefore serial number 47055. Configured on allmachines after serial number 47054.

Platform Overload: This cuts out all functions whenthe pressure sensor is overloaded. The additionalweight must be removed from the platform and theEmergency Stop button must be cycled before anyfunction can be resumed. Required for France.

Descent Delay: This option halts descent atapproximately 7 feet / 2.1 m. All controls must bereleased for 4 to 6 seconds before descent isre-enabled. Required for CE models.

Battery Drain Alarm: When the machine is turnedon and no function is activated for 10 minutes, thealarm will sound once every 3 seconds. This optioncan be activated by moving DIP switch 7 toposition 1.When this option is configured, the flashing dot inthe diagnostic display window will remainilluminated when the lift mode is selected andactivated.

Diagnostic Display Code

DIP Switch Code

ON

fo

r 20

32 a

nd

263

2

Mo

tio

n B

eaco

n

Mo

tio

n A

larm

Lif

t D

rive

Cu

t O

ut

Ove

rlo

ad C

ut

Ou

t

Des

cen

t D

elay

Bat

tery

Dra

in A

larm

OF

F f

or

all m

od

els

32 10000000 •33 10000100 • •34 10001000 • •35 10010000 • •36 10100000 • •37 11000000 • •38 10001100 • • •39 10010100 • • •40 10100100 • • •41 11000100 • • •42 10011100 • • • •43 10101100 • • • •44 11001100 • • • •45 10110100 • • • •46 11010100 • • • •47 11100100 • • • •48 10111100 • • • • •49 11011100 • • • • •50 11101100 • • • • •51 11110100 • • • • •52 11111100 • • • • • •53 10011000 • • •54 10101000 • • •55 11001000 • • •56 10111000 • • • •57 11011000 • • • •58 11101000 • • • •59 11111000 • • • • •60 10110000 • • •61 11010000 • • •62 11110000 • • • •63 11100000 • • •

REV B



2-1Platform

How to Remove the PlatformPerform this procedure with theplatform extension fully retractedand locked in position.

1 Machines with voltage inverter: Disconnectthe battery pack from the machine.

Electrocution hazard. Contact withelectrically charged circuits couldresult in death or serious injury.Disconnect the battery pack fromthe machine before removing theplatform.


3 Remove the retaining fastener that holds theplatform controls quick disconnect plug to thebottom of the platform.

4 Disconnect the plug from the platform controls.

5 Remove the cover from the AC outlet. Labeland disconnect the wiring from the outlet.

6 Pull the wiring through the platform tube.

If your machine is equipped withan air line to platform option, theair line must be disconnected fromthe platform before removal.

7 Support the platform with a forklift at thenon-steer end. Do not lift it.

Platform Components

8 Attach a strap from the platform railings to thecarriage on the forklift to help support theplatform.

9 Remove the platform pivot pin retainingfasteners from the platform pivot pins at thesteer end of the machine.

10 Use a slide hammer to remove the pins.

Crushing hazard. The platform willfall if it is not properly supported.

11 Remove the plugs from the access holes in theside of the platform.

12 Lift the steer end of the platform slightly to clearthe scissor arms and slide the platform towardsthe non-steer end of the machine until the non-steer end platform pivot pins are visible throughthe access holes in the side of the platform.

13 Remove the platform pivot pin retainingfasteners from the platform pivot pins at thenon-steer end of the machine.

14 Use a slide hammer to remove the pins.

Crushing hazard. The platform willfall if it is not properly supported.

15 Carefully lift the platform off of the machine andplace it on a structure capable of supporting it.

Note the position of the wear padsbefore the platform is removed sowhen the platform is installed theywill be in the correct position.

REV B



PLATFORM COMPONENTS

2-2Platform Extension

How to Remove thePlatform Extension1 Lower the platform to the stowed position.

2 Extend the platform approximately 3 feet / 1 m.

3 Remove the platform controls from the platformand lay them off to the side of the machine.

4 Support the platform extension with a forklift atthe steer end. Do not lift it.

5 Attach a strap from the platform extensionrailings to the carriage on the forklift to helpsupport the platform extension.

6 Remove the two retaining fasteners from eachplatform extension roller bracket assembly.Remove each assembly from the machine.

Do not remove the platform rollerbolt.

a roller bracket assemblyb assembly retaining fastenerc platform roller bolt

7 Remove the platform roller wheels from themachine.

8 Carefully slide the platform extension out fromthe platform and place it on a structure capableof supporting it.

Crushing hazard. The platformextension could becomeunbalanced and fall if not properlysupported and secured to theforklift.

How to Replace the PlatformExtension Wear Pads1 Remove the Platform Extension. See 2-2, How

to Remove the Platform Extension.

2 Drill out the rivets which hold the wear pads inplace.

3 Install the new wear pads using new rivets.

When installing new rivets, makesure the rivet heads are not abovethe surface of the wear pad.

REV B



Scissor Components

1 Number 4 pivot pin (steer end)2 Number 3 center pivot pin3 Lift cylinder rod-end pivot pin4 Number 3 pivot pin (steer end)5 Number 2 center pivot pin (2pins)6 Number 2 inner arm7 Number 2 pivot pin (steer end)8 Number 1 center pivot pin9 Number 1 inner arm10 Number 1 pivot pin (steer end) (2pins)

11 Number 4 pivot pin (non-steer end)12 Number 3 inner arm13 Number 3 outer arm14 Number 3 pivot pin (non-steer end)15 Lift cylinder16 Number 2 outer arm17 Number 2 pivot pin (non-steer end)18 Lift cylinder barrel-end pivot pin19 Number 1 outer arm

Non-steer EndSteer End

GS-2032

14

19

17

18

7

3

4

6

13

12

15

9

5

11

10

16

2

1

8

REV B



SCISSOR COMPONENTS

3-1Scissor Assembly, GS-2032

How to Disassemble theScissor Assembly, GS-2032

Bodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is required.

When removing a hose assemblyor fitting, the O-ring on the fittingand/or hose end must be replacedand then torqued to specificationduring installation. Refer toSection Two, Hydraulic Hose andFitting Torque Specifications.

1 Remove the platform. See 2-1, How to Removethe Platform.

2 Remove the cables from the side of the number3 outer arm (index #13) at the ground controlsside.

Component damage hazard.Cables can be damaged if theyare kinked or pinched.

3 Attach a lifting strap from an overhead crane tothe number 3 outer arm (index #13).

4 Remove the external snap rings from thenumber 3 center pivot pin (index #2).

5 Use a soft metal drift to remove the number 3center pivot pin (index #2).

6 Remove the external snap rings from thenumber 3 pivot pin (index #14).

7 Use a soft metal drift to remove the number 3pivot pin (index #14). Remove the number 3outer arm (index #13) from the machine.

Bodily injury hazard. The number3 outer arm (index #13) maybecome unbalanced and fall if notproperly supported when it isremoved from the machine.

8 Remove the cable clamps from the number 3inner arm (index #12).

9 Remove the mounting fasteners from the cabletray support at the steer end.

10 Remove the external snap rings from thenumber 2 center pivot pin (index #5) at theground controls side. Do not remove the pin.

11 Slide the cable tray towards the battery packside of the machine. Remove it from themachine and lay it off to the side.


12 Attach a lifting strap from an overhead crane tothe lug on the rod end of the liftcylinder (index #15).

REV B



SCISSOR COMPONENTS

13 Remove the pin retaining fasteners from thecylinder rod-end pivot pin (index #3). Use a softmetal drift to remove the pin.

Bodily injury hazard. The cylindermay fall if not properly supportedwhen the pin is removed.

14 Lower the lift cylinder (index #15) onto thenumber 1 center pivot pin (index #8).

15 Attach a lifting strap from an overhead crane tothe number 3 inner arm (index #12).


17 Use a soft metal drift to remove the number 3pivot pin (index #4). Remove the number 3inner arm (index #12) from the machine.

Bodily injury hazard. The number3 inner arm (index #12) maybecome unbalanced and fall if notproperly supported when it isremoved from the machine.


19 Remove the external snap rings from thenumber 2 center pivot pin (index #5) at thebattery pack side of the machine.

20 Use a soft metal drift to remove both of thenumber 2 center pivot pins (index #5).

21 Remove the external snap rings from thenumber 2 pivot pin (index #17) at the non-steerend.

22 Use a soft metal drift to remove the number 2pivot pin (index #17). Remove the number 2outer arm (index #16) from the machine.






26 Remove the safety arm from the number 2 innerarm (index #6) that was just removed.


28 Raise the number 1 inner arm (index #9)approximately 2 feet / 0.6 m and insert thesafety arm between the number 1 inner arm(index #9) and the number 1 outer arm(index #19).

Bodily injury hazard. Keep handsclear of moving parts whenlowering the scissor arms onto thesafety arm.

REV B



SCISSOR COMPONENTS

29 Tag, disconnect and plug the hydraulic hose onthe lift cylinder (index #15). Cap the fitting onthe cylinder.


30 Tag and disconnect the wires from the solenoidvalve on the cylinder.

31 Attach a lifting strap from an overhead crane tothe lug on the rod end of the lift cylinder(index #15). Raise the lift cylinder to a verticalposition.

32 Remove the pin retaining fasteners from the liftcylinder barrel-end pin (index #18). Use a softmetal drift to remove the pin. Remove the liftcylinder (index #15) from the machine.

Crushing hazard. The lift cylinder(index #15 )may becomeunbalanced and fall when it isremoved from the machine if it isnot properly attached to theoverhead crane.

Component damage hazard. Becareful not to damage the valve orfittings on the cylinder whileremoving it from the machine.

33 Place a 4 x 4 x 32 inch / 10 x 10 x 80 cm longblock across both sides of the chassis underthe number 1 center pivot pin (index #8).

34 Attach a lifting strap from an overhead crane tothe number 1 inner arm (index #9). Raise theinner arm slightly and remove the safety arm.Lower the arms onto the block.

Bodily injury hazard. Keep handsclear of moving parts whenlowering the arms onto the block.

35 Remove the cables from the number 1 innerarm (index #9) and lay them off to the side.


36 Attach a lifting strap from an overhead crane tothe number 1 outer arm (index #19).Do not lift it.



Bodily injury hazard. The number1 outer arm (index #19) maybecome unbalanced and fall if notproperly supported when the pin isremoved.

REV B



SCISSOR COMPONENTS

39 Slide the number 1 outer arm (index #19) to thenon-steer end and remove it from the machine.


Note the position of the wear padsbefore the arm is removed sowhen the scissor assembly isinstalled they will be in the correctposition.

40 Attach a lifting strap from an overhead crane tothe number 1 inner arm (index #9).Do not lift it.

41 Remove the pin retaining fasteners from both ofthe number 1 pivot pins (index #10) at the steerend of the machine. Use a slide hammer toremove the pins.

42 Remove the number 1 inner arm (index #9)from the machine.

Bodily injury hazard. The number1 inner arm (index #9) maybecome unbalanced and fall if notproperly supported when removedfrom the machine.

How to Replace the Scissor ArmWear Pads1 Remove the platform. See 2-1, How to Remove

the Platform.

2 Remove the mounting fasteners from thestationary wear pads on the platform.

Note the position of the wear padsbefore they are removed so whenthe new ones are installed theywill be in the correct position.

3 Support and secure the entry ladder to anappropriate lifting device.

4 Remove the entry ladder mounting fasteners.Remove the entry ladder from the machine.

Crushing hazard. The entry laddermay become unbalanced and fallif not properly supported andsecured to the lifting device.

5 Raise the platform 6 to 7 feet / 1.8 to 2.1 m.

6 Lift the safety arm, move it to the center of thescissor arm and rotate down to a verticalposition.

7 Lower the scissor arms onto the safety arm.


8 Mark the mounting position of the level sensorbox on the drive chassis.

9 Remove the level sensor box cover.

10 Mark the mounting position of the level sensoron the level sensor box.

REV B



SCISSOR COMPONENTS

11 Remove the level sensor box mountingfasteners and slide the box towards the non-steer end of the machine as far as it can go.

Component damage hazard. Becareful not to damage the levelsensor box, limit switch, levelsensor or wiring while moving thelevel sensor box.

12 Secure the ends of the scissor arms together atboth ends of the machine with a tie down strapor other appropriate device.

13 Remove the pin retaining fasteners from thenumber 1 inner arm pivot pins (item #11) at thesteer end of the machine. Use a slide hammerto remove the pins.

14 Attach a lifting strap from an overhead crane tothe steer end of the scissor arms.

15 Slide the forks from a forklift under the scissorarms at the non-steer end of the machine.

16 Raise the scissor arms up with the overheadcrane until the number 1 inner arm will clear thelevel sensor box.

Component damage hazard. Becareful not to damage the levelsensor box, limit switch or levelsensor while moving the scissorassembly.

17 Move the scissor assembly towards the non-steer end of the machine slightly and to oneside of the machine until one of the scissor armwear pads is accessible. Do not allow bothwear pads to slide out of the drive chassis.

Crushing hazard. The scissorassembly will fall if both wear padsare allowed to slide out of the drivechassis.

18 Remove the old wear pad.

Note the position of the wear padbefore it is removed so when thenew one is installed it will be in thecorrect position.

19 Install the new wear pad.

20 Move the scissor assembly towards the otherside of the machine until the other scissor armwear pad is accessible.





23 Slide the scissor assembly back into the drivechassis.

24 Lower the scissor assembly into position andinstall the pivot pins.

Component damage hazard. Becareful not to damage the levelsensor box, limit switch or levelsensor while installing the scissorassembly.

REV B



SCISSOR COMPONENTS

1 Number 5 pivot pin (steer end)2 Number 4 center pivot pin3 Number 4 pivot pin (steer end)4 Number 3 outer arm5 Lift cylinder rod-end pivot pin6 Number 3 pivot pin (steer end)7 Number 2 center pivot pin (2 pins)8 Lift cylinder9 Number 2 pivot pin (steer end)10 Number 1 center pivot pin11 Number 1 inner arm12 Number 1 pivot pin (steer end) (2 pins)

13 Number 5 pivot pin (non-steer end)14 Number 4 inner arm15 Number 4 outer arm16 Number 4 pivot pin (non-steer end)17 Number 3 inner arm18 Number 3 center pivot pin19 Number 3 pivot pin (non-steer end)20 Number 2 inner arm21 Number 2 outer arm22 Number 2 pivot pin (non-steer end)23 Lift cylinder barrel-end pivot pin24 Number 1 outer arm

Non-steer EndSteer End

GS-2632

19

22

23

18

15

21

17

14

20

13

24

16

10

4

5

6

2

11

1

3

12

9

7

8

REV B



SCISSOR COMPONENTS

3-2Scissor Assembly, GS-2632

How to Disassemble theScissor Assembly, GS-2632

Bodily injury hazard. Theprocedures in this section requirespecific repair skills, liftingequipment and a suitableworkshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is required.


1 Remove the platform. See 2-1, How to Removethe Platform.

2 Remove the cables from the side of the number4 outer arm (index #15) at the ground controlsside.





6 Remove the external snap ring from the number4 pivot pin (index #16) at the non-steer end ofthe machine.

7 Use a soft metal drift to remove the number 4pivot pin (index #16) from the non-steer end ofthe machine. Remove the number 4 outer arm(index #15) from the machine.

Crushing hazard. The number 4outer arm (index #15) maybecome unbalanced and fall if notproperly supported when it isremoved from the machine.

8 Remove the cables from the upper cable trayand lay them off to the side.


9 Remove the mounting fasteners from the uppercable tray supports.

10 Remove the upper cable tray from the scissorassembly.



REV B



SCISSOR COMPONENTS

13 Use a soft metal drift to remove the number 4pivot pin (index #3) at the steer end. Removethe number 4 inner arm (index #14) from themachine.

Crushing hazard. The number 4inner arm (index #14) maybecome unbalanced and fall if notproperly supported when it isremoved.

14 Attach a lifting strap from an overhead crane tothe number 3 outer arm (index #4) at theground controls side.



17 Remove the external snap rings from thenumber 3 pivot pin (index #19) at the non-steerend of the machine. Do not remove the pin.

18 Use a soft metal drift to tap the number 3 pivotpin (index #19) halfway out at the non-steer endof the machine. Remove the number 3 outerarm (index #4) at the ground controls side fromthe machine.

Bodily injury hazard. The number3 outer arm (index #4) at theground controls side may becomeunbalanced and fall if not properlysupported when it is removed fromthe machine.

19 Attach a lifting strap from an overhead crane tothe number 3 outer arm (index #4) at thebattery pack side.

20 Use a soft metal drift to tap the number 3 pivotpin (index #19) in the other direction. Removethe number 3 outer arm (index #4) from thebattery pack side of the machine.

Bodily injury hazard. The number3 outer arm (index #4) at thebattery pack side may becomeunbalanced and fall if not properlysupported when it is removed fromthe machine.

21 Remove the number 3 pivot pin (index #19)from the non-steer end of the machine.

22 Attach a lifting strap from an overhead crane tothe lug on the rod end of the lift cylinder forsupport. Do not lift it.

23 Remove the pin retaining fasteners from the liftcylinder rod-end pivot pin (index #5). Use a softmetal drift to remove the pin.

Bodily injury hazard. The cylindermay fall when the rod-end pivotpin is removed if it is not properlysupported.

24 Lower the cylinder onto the number 1 centerpivot pin (index #10).

25 Remove the cables from the number 3 innerarm (index #17) and lay them to the side.


27 Remove the external snap rings from thenumber 3 pivot pin (index #6) at the steer end.

REV B



SCISSOR COMPONENTS



29 Remove the cable clamps from the lower cabletray. Lay the cables to the side.


30 Remove the mounting fasteners from the lowercable tray supports.

31 Remove the mounting fasteners from the lowercable tray mounting bracket on the number 2center pivot pin (index #7) at the groundcontrols side of the machine.

32 Slide the cable tray towards the battery packside of the machine and remove it from themachine.

33 Attach a lifting strap from an overhead crane tothe number 2 outer arm (index #21) at theground controls side.

34 Remove the external snap rings from thenumber 2 center pivot pin (index #7) at theground controls side.

35 Use a soft metal drift to remove the number 2center pivot pin (index #7) at the groundcontrols side.

36 Use a soft metal drift to tap the number 2 pivotpin (index #22) halfway out at the non-steer endof the machine. Remove the number 2 outerarm (index #21) from the ground controls sideof the machine.

Bodily injury hazard. The number2 outer arm (index #21) at theground controls side may becomeunbalanced and fall if not properlysupported when it is removed fromthe machine.

37 Attach a lifting strap from an overhead crane tothe number 2 outer arm (index #21) at thebattery pack side.

38 Remove the external snap rings from thenumber 2 center pivot pin (index #7) at thebattery pack side.

39 Use a soft metal drift to remove the number 2center pivot pin (index #7) at the battery packside.


40 Use a soft metal drift to tap the number 2 pivotpin (index #22) in the other direction at the non-steer end. Remove the number 2 outer arm(index #21) from the battery pack side of themachine.


REV B



SCISSOR COMPONENTS


42 Remove the external snap rings from thenumber 2 pivot pin (index #9) at the steer endof the machine.



44 Remove the safety arm from the number 2 innerarm (index #20) that was just removed.


46 Raise the number 1 inner arm (index #11)approximately 2 feet / 60 cm and install thesafety arm between the number 1 inner arm(index #11) and the number 1 outer arm(index #24). Lower the scissor arms onto thesafety arm.

Bodily injury hazard. Keep handsclear of moving parts whenlowering the scissor arms onto thesafety arm.

47 Tag, disconnect and plug the hydraulic hose onthe lift cylinder. Cap the fitting on the cylinder.


48 Tag and disconnect the wires from the solenoidvalve on the cylinder.

49 Attach a lifting strap from an overhead crane tothe lug on the rod end of the lift cylinder(index #8). Raise the lift cylinder to a verticalposition.

50 Remove the pin retaining fasteners from the liftcylinder barrel-end pin (index #23). Use a softmetal drift to remove the pin. Remove the liftcylinder (index #8) from the machine.

Crushing hazard. The lift cylinder(index #8 )may becomeunbalanced and fall when it isremoved from the machine if it isnot properly attached to theoverhead crane.


51 Place a 4 x 4 x 48 inch / 10 cm x 10 cm x 1.2 mlong block across both sides of the chassisunder the number 1 center pivot pin(index #10).

52 Attach a lifting strap from an overhead crane tothe number 1 inner arm (index #11) at the non-steer end. Raise the number 1 inner arm andremove the safety arm. Lower the number 1inner arm (index #11) onto the block that wasplaced across the chassis.

Bodily injury hazard. Keep handsclear of moving parts whenlowering the arms onto the block.

REV B



SCISSOR COMPONENTS

53 Remove the cables and hydraulic hoses fromthe number 1 inner arm (index #11) and laythem to the side.

Component damage hazard.Cables and hoses can bedamaged if they are kinked orpinched.




56 Attach a lifting strap from an overhead crane tothe number 1 outer arm (index #24). Do notlift it.



Bodily injury hazard. The number1 outer arm (index #24) maybecome unbalanced and fall if notproperly supported when the pin isremoved.

59 Slide the number 1 outer arm (index #24) to thenon-steer end and remove it from the machine.


Note the position of the wear padsbefore the arm is removed sowhen the scissor is assembledthey will be in the correct position.

60 Attach the strap from an overhead crane to thenumber 1 inner arm (index #11). Do not lift it.

61 Remove the pin retaining fasteners from both ofthe number 1 pivot pins (index #12) at the steerend of the machine. Use a slide hammer toremove the pins.

62 Remove the number 1 inner arm (index #11)from the machine.


Component damage hazard. Besure not to damage the limit switchor level sensor box componentswhen the number 1 inner arm(index #11) is removed from themachine.

REV B



SCISSOR COMPONENTS

How to Replace the Scissor ArmWear Pads1 Remove the platform. See 2-1, How to Remove

the Platform.

2 Remove the mounting fasteners from thestationary wear pads on the platform.

Note the position of the wear padsbefore they are removed so whenthe new ones are installed theywill be in the correct position.








8 Mark the mounting position of the level sensorbox on the drive chassis.

9 Remove the level sensor box cover.

10 Mark the mounting position of the level sensoron the level sensor box.

11 Remove the level sensor box mountingfasteners and slide the box towards the non-steer end of the machine as far as it can go.

Component damage hazard. Becareful not to damage the levelsensor box, limit switch, levelsensor or wiring while moving thelevel sensor box.

12 Secure the ends of the scissor arms together atboth ends of the machine with a tie down strapor other appropriate device.

13 Remove the pin retaining fasteners from thenumber 1 inner arm pivot pins (item #11) at thesteer end of the machine. Use a slide hammerto remove the pins.

14 Attach a lifting strap from an overhead crane tothe steer end of the scissor arms.

15 Slide the forks from a forklift under the scissorarms at the non-steer end of the machine.

16 Raise the scissor arms up with the overheadcrane until the number 1 inner arm will clear thelevel sensor box.

Component damage hazard. Becareful not to damage the levelsensor box, limit switch or levelsensor while moving the scissorassembly.

17 Move the scissor assembly towards the non-steer end of the machine slightly and to oneside of the machine until one of the scissor armwear pads is accessible. Do not allow bothwear pads to slide out of the drive chassis.


REV B



SCISSOR COMPONENTS




20 Move the scissor assembly towards the otherside of the machine until the other scissor armwear pad is accessible.





23 Slide the scissor assembly back into the drivechassis.

24 Lower the scissor assembly into position andinstall the pivot pins.

Component damage hazard. Becareful not to damage the levelsensor box, limit switch or levelsensor while installing the scissorassembly.

REV A



3-3Lift Cylinder

How to Remove the Lift CylinderBodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.



2 Lift the safety arm, move it to the center of thescissor arm and rotate down to a verticalposition

SCISSOR COMPONENTS

GS-2032 models beforeserial number 23568

D

E

Y7

d

b

c

h

g

a

f

D

Y7

E

g

h

f

e

i

b

d

a

c

a lift cylinderb lowering cablec solenoid valve (schematic item D)d cable mounting brackete springf orifice (schematic item E)g connector fittingh hydraulic hosei hard line assembly

GS-2632 models &GS-2032 models after serial number 23567

REV A





4 Tag and disconnect the wiring from the solenoidat the barrel end of the lift cylinder.

5 Loosen the adjustment nuts on the solenoid,then disconnect the manual lowering cable fromthe solenoid.

During assembly, the manualplatform lowering cable needs tobe properly adjusted. Refer to 4-1,How to Adjust the Manual PlatformLowering Cable.

6 Remove the mounting fasteners from themanual lowering cable mounting bracket.Remove the bracket from the cylinder.

7 Before serial number 23568: Tag, disconnectand plug the hydraulic hardline from the liftcylinder. Cap the fitting on the cylinder.After serial number 23567: Tag, disconnectand plug the hydraulic hose from the liftcylinder. Cap the fitting on the cylinder.


8 Before serial number 23568: Remove thehardline retaining strap from the cylinder.

9 Attach a lifting strap from an overhead crane orsimilar lifting device to the rod end of the liftcylinder for support.

10 Remove the external snap ring from the liftcylinder rod-end pivot pin. Use a soft metal driftto remove the pin.

Crushing hazard. The lift cylinderwill fall if not properly supportedwhen the pin is removed.

11 Lower the cylinder.

Component damage hazard. Becareful not to damage the levelsensor box, limit switch or levelsensor while lowering the cylinder.




14 Attach a lifting strap from an overhead crane orsimilar lifting device to the barrel end of the liftcylinder for support.

15 Remove the external snap ring from the liftcylinder barrel-end pivot pin. Use a soft metaldrift to remove the pin.

Crushing hazard. The lift cylinderwill fall if not properly supportedwhen the pin is removed.

16 Support and secure the lift cylinder to anappropriate lifting device.

Crushing hazard. The lift cylindermay become unbalanced and fallif not properly supported andsecured to the lifting device.

17 Remove the lift cylinder through the scissorarms at the non-steer end of the machine.


SCISSOR COMPONENTS



REV D

3-4Platform Overload System

Calibrate thePlatform Overload System(if equipped)On machines with platform overload systems,proper calibration is essential to safe machineoperation. An improperly calibrated platformoverload system could result in the system failingto sense an overloaded platform. The stability ofthe machine is compromised and it could tip over.

Perform this procedure after fullycharging the batteries.

Perform this procedure with toggleposition 4 and 5 of DIP switchSW25, located in the platformcontrol box, set to the on position.

Perform this procedure afterconfirming that the maximumheight limit switch and the limitswitch bracket are not damagedand are functioning correctly.

Be sure the hydraulic oil level isbetween the FULL and ADD markson the hydraulic tank.

1 Apply a thin layer of dry film lubricant to thearea of the chassis where the scissor arm wearpads make contact.

2 Chock both sides of the wheels at the steer endof the machine.

3 Using a suitable lifting device, place a testweight, corresponding to the maximum load asindicated on the capacity indicator decal, in thecenter of the platform floor. Secure the weightto the platform. Refer to the chart below.

GS-2032 677 kg

GS-2632 508 kg


5 Apply a piece of tape onto the side of theplatform at a point which corresponds to themaximum load position of the capacity indicatordecal on the side of the platform.

6 Raise the platform until the position indicatorcorresponds to the maximum load position ofthe capacity indicator decal on the platform.Release the toggle switch.

Tip-over hazard. Raising theplatform with maximum loadabove the maximum load position,as shown on the capacity indicatordecal on the side of the platform,could result in the machine tippingover, resulting in death or seriousinjury. Do not raise the platformabove the maximum load positionof the capacity indicator decal onthe side of the platform.

To perform this step, the lift reliefvalve will need to be adjusted.


8 Remove the cover from the platform overloadpressure switch box. Using a wrench, turn thenut of the platform overload pressure switchinto the hydraulic line in 90° increments until theoverload alarm does not sound.

To allow the platform overloadsystem to reset, the redEmergency Stop button must becycled after each quarter turn ofthe nut.

Turning the nut into the hydraulicline will deactivate the alarm;turning the nut out of the hydraulicline will activate the alarm.

SCISSOR COMPONENTS



REV D

9 Slowly turn the nut of the platform overloadpressure switch out of the hydraulic line justuntil the overload alarm sounds.

To allow for the platform overloadsystem delay, wait 3 secondsbetween each quarter turn of thenut.

10 Turn the nut one quarter turn into the hydraulicline.

11 Return the safety arm to the stowed position.

12 Using the manual lowering knob, lower theplatform to the stowed position and remove alltest weight from the platform.

13 Using a suitable lifting device, place a testweight in the center of the platform floor.Secure the weight to the platform. Refer to thechart below.

GS-2032 363 kg

GS-2632 227 kg

14 Raise the platform to 25 cm less than full height.


16 Raise the platform in 5 cm increments until theoverload alarm sounds. Adjust the up limitswitch until it actuates just before this point wasreached.

17 Install the cover onto the platform overloadpressure switch box and install and tighten thecover retaining fasteners. Do not over tighten.

18 Apply Sentry Seal to one of the fastenerssecuring the cover onto the platform overloadpressure switch box.


20 Using the machine controls, lower the platformto the stowed position and remove all testweight from the platform.

21 Calibrate the lift relief valve. See 6-3, How toAdjust the Platform Lift Relief Valve.

CONDITION POSSIBLE CAUSE SOLUTIONCANNOT LIFT RATED LOAD RELIEF VALVE SETTING INCREASE RELIEF VALVE PRESSURE

AT MAX HEIGHT THE PRESSURE SWITCH ALARM CONTINUES TO SOUND AFTER ADJUSTMENT

SYSTEM NEEDS TO BE RESETTURN OFF RED EMERGENCY STOP BUTTON, WAIT THREE SECONDS AND TURN BACK ON

UP LIMIT SWITCH OUT OF ADJUSTMENT LOWER THE UP LIMIT SWITCH SLIGHTLYWRONG RATED LOAD FOR HEIGHT BEING TESTED

PUT CORRECT RATED LOAD IN PLATFORM

PRESSURE SWITCH OUT OF ADJUSTMENTTURN THE PRESSURE SWITCH NUT INTO THE HYDRAULIC LINE 1/4 TURN

BATTERIES ARE NOT FULLY CHARGED CHARGE BATTERIESOVERLOAD SYSTEM NOT ADJUSTED PROPERLY

REPEAT CALIBRATION PROCEDURE

SLIDER CHANNEL NOT LUBRICATED LUBRICATE SLIDER CHANNELS

AT DOWN LIMIT THE PRESSURE SWITCH ALARM CONTINUES TO SOUND AFTER ADJUSTMENT

SYSTEM NEEDS TO BE RESETTURN OFF RED EMERGENCY STOP BUTTON, WAIT THREE SECONDS AND TURN BACK ON

DOWN LIMIT SWITCH OUT OF ADJUSTMENT RAISE THE DOWN LIMIT SWITCHWRONG RATED LOAD FOR HEIGHT BEING TESTED

PUT CORRECT RATED LOAD IN PLATFORM

OVERLOAD SYSTEM NOT ADJUSTED PROPERLY

TURN THE PRESSURE SWITCH NUT INTO THE HYDRAULIC LINE 1/4 TURN OR REPEAT CALIBRATION PROCEDURE

TROUBLESHOOTING THE PLATFORM OVERLOAD SYSTEM

SCISSOR COMPONENTS



REV CGround Controls

4-1Manual Platform Lowering Cable

The manual platform lowering cable lowers theplatform in the event of a main power failure. Themanual platform lowering cable is attached to thebarrel end of the lift cylinder and is activated nextto the ground controls.

How to Adjust the ManualPlatform Lowering Cable1 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.

2 Lift the safety arm, move it to the center of thescissor arm and rotate to a vertical position.



4 Push the handle on the manual platformlowering cable all the way in.

5 Disconnect the cable mounting nut from thelowering valve at the barrel end of the liftcylinder.

6 Pull the cable tight and measure the distancebetween the end of the lowering cable and theend of the lowering valve.

Result: The measurement should be 3/16 to1/4 inch / 4.7 to 6.4 mm.

Platform manual lowering cable specification

Gap, lowering cable to valve 3/16 to 1/4 inch4.7 to 6.4 mm

a Manual lowering cablesheath

b Upper lock nutc cable mounting

bracketd Lower lock nute Cable mounting nutf End of the lowering

cableg Manual lowering valve

(schematic item D)

c

a

b

g

d

e

f

D

Skip to step 10 if the measurement is correct.

7 To adjust, loosen the upper lock nut on thecable mounting bracket. Turn the lower lock nutclockwise to decrease the distance orcounterclockwise to increase the distance.

8 Tighten the upper lock nut.

9 Measure the distance between the end of thelowering cable and the end of the loweringvalve. Adjust if needed.

10 Install the cable mounting nut onto the loweringvalve.

11 Raise the platform and return the safety arm tothe stowed position.

12 Pull the manual lowering handle at the groundcontrols 2 to 3 times to ensure it is functioningcorrectly.



REV C GROUND CONTROLS

4-2Control Relays

Relays used for single function switching are singlepole double throw (SPDT) relays.

How to Test a Single Pole DoubleThrow Relay


1 Label and then disconnect all the wiring fromthe relay to be tested.

2 Connect the leads from an ohmmeter orcontinuity tester to each terminal combinationand check for continuity. Terminals 85 and 86represent the coil and should not be tested inany other combination.

Test Desired result

terminal 85 to 86 with resistor 280 to 330Ω

terminal 87 to 87a and 30 no continuity(infinite Ω)

terminal 87a to 30 continuity(zero Ω)

3 Connect 24V DC and a ground wire to terminals85 and 86, then test the following terminalcombinations.

Test Desired result

terminal 87a to 87 and 30 no continuity(infinite Ω)

terminal 87 to 30 continuity(zero Ω)

Relay schematic - deactivated

Relay schematic - activated

Terminal Number Legendterminal no. 87a - N.C.terminal no. 85 - groundterminal no. 30 - commonterminal no. 86 - coilterminal no. 87 - N.O.

85

87

8687a

30

30

87a87

86

85

30

87a87

86

85



REV CGROUND CONTROLS

4-3Level Sensor(before serial number 47665)

The tilt sensor sounds when the incline of thechassis exceeds the rating on the serial plate.

How to Install and Calibrate the1.5° Level SensorThis procedure is for the following models:

• GS-2032 (ANSI and CSA models)

Tip-over hazard. Failure to installor calibrate the tilt level sensor asinstructed will compromisemachine stability and cause themachine to tip over, resulting indeath or serious injury. Do notinstall or calibrate the level sensorother than specified in thisprocedure.


1 Remove the platform controls from the platform.

2 Turn the key switch to platform control and pullout the red Emergency Stop buttons to the ON


3 Block the wheels at the non-steer end of themachine.

4 Center a lifting jack under the drive chassis atthe steer end of the machine.

5 Raise the machine approximately2 inches / 5 cm.

6 Place a 1.27 x 6 x 6 inch / 32.3 mm x15 cm x 15 cm thick steel block under bothwheels at the steer end of the machine.

7 Lower the machine onto the blocks.





11 Remove the tilt level sensor box cover retainingfasteners. Remove the cover.

The tilt level sensor box is locatedon top of the chassis at the steerend of the machine.

If you are not installing a new level sensor,proceed to step 18.

12 Tag and disconnect the wiring harness from thelevel sensor, limit switch and alarm.

13 Remove the tilt level sensor box retainingfasteners. Remove the tilt level sensor box fromthe machine.

14 Remove the tilt level sensor retaining fasteners.Remove the tilt level sensor from the levelsensor box.




X

Y

f

e

a

b

d

c

15 Place the new tilt level sensor in the tilt levelsensor box with the "X" on the level sensorbase closest to the long side of the tilt levelsensor box and the "Y" on the level sensorbase closest to the short side of the tilt levelsensor box. Install the level sensor retainingfasteners.

Tip-over hazard. The tilt levelsensor must be installed with the"X" on the level sensor baseclosest to the long side of the tiltlevel sensor box and the "Y" onthe level sensor base closest tothe short side of the tilt levelsensor box. Failure to install the tiltlevel sensor as instructed couldresult in death or serious injury.

16 Install the level sensor box onto the machine.Install the level sensor box retaining fasteners.

17 Connect the wiring harness to the level sensor,limit switch and alarm.

18 Tighten the level sensor adjusting fastenersuntil the bubble in the top of the level sensor iscentered in the circles.

Be sure there are threads showingthrough the top of the adjustingfasteners.

Result: The tilt sensor alarm should not sound.

19 Raise the platform slightly.



Steer end

Non-steer end

a scissor chassisb tilt level sensorc level sensor boxd alarme box retaining fastenerf level sensor retaining fastener


23 Remove the blocks from under both wheels.

24 Lower the machine and remove the jack.

25 Remove the blocks from the wheels at thenon-steer end of the machine.




26 Block the wheels at the steer end of themachine.

27 Center a lifting jack under the drive chassis atthe non-steer end of the machine.


29 Place a 4.07 x 6 x 6 inch / 103.4 mm x15 cm x 15 cm thick steel block under bothwheels at the non-steer end of the machine.



Result: The tilt sensor alarm should sound.

CE models: When the platform israised 7 to 8 feet / 2.1 to 2.4 mfrom the ground, an alarm shouldsound and the lift and drivefunctions should not operate.





36 Remove the blocks from the wheels at the steerend of the machine.

37 Center a lifting jack under the drive chassis atthe ground controls side of the machine.


39 Place a 0.78 x 6 x 6 inch / 20 mm x15 cm x 15 cm thick steel block under bothwheels at the ground controls side of themachine.



42 Adjust the tilt level sensor retaining fastenersjust until the tilt sensor alarm does not sound.





47 Center a lifting jack under the drive chassis atthe battery pack side of the machine.


49 Place a 0.95 x 6 x 6 inch / 24 mm x15 cm x 15 cm thick steel block under bothwheels at the battery pack side of the machine.




Result: If the tilt sensor alarm does not sound,adjust the tilt level sensor until the alarm justbegins to sound OR the down limit switch mayneed to be adjusted.








54 Install the tilt level sensor box cover.

55 Raise the platform approximately 7 to 8 feet /2.1 to 2.4 m.






How to Install and Calibrate the2° Level SensorThis procedure is for the following models:

• GS-2032 (CE and Australia models)• GS-2632

Tip-over hazard. Failure to installor calibrate the tilt level sensor asinstructed will cause death orserious injury. Do not install orcalibrate the level sensor otherthan specified in this procedure.


The degree of level sensor is listedunder "maximum inclination of thechassis" on the serial plate.


2 Turn the key switch to platform control and pullout the red Emergency Stop buttons to the ON


3 Block the wheels at the non-steer end of themachine.



6 Place a 1.27 x 6 x 6 inch / 32.3 mm x15 cm x 15 cm thick steel block under bothwheels at the steer end of the machine.









11 Remove the tilt level sensor box cover retainingfasteners. Remove the cover.

The tilt level sensor box is locatedon top of the chassis at the steerend of the machine.


12 Tag and disconnect the wiring harness from thelevel sensor, limit switch and alarm.

13 Remove the tilt level sensor box retainingfasteners. Remove the tilt level sensor box fromthe machine.

14 Remove the tilt level sensor retaining fasteners.Remove the tilt level sensor from the levelsensor box.

15 Place the new tilt level sensor in the tilt levelsensor box with the "X" on the level sensorbase closest to the long side of the tilt levelsensor box and the "Y" on the level sensorbase closest to the short side of the tilt levelsensor box.

Tip-over hazard. The tilt levelsensor must be installed with the"X" on the level sensor baseclosest to the long side of the tiltlevel sensor box and the "Y" onthe level sensor base closest tothe short side of the tilt levelsensor box. Failure to install the tiltlevel sensor as instructed couldresult in death or serious injury.

Steer end

Non-steer end

a scissor chassisb tilt level sensorc level sensor boxd alarme box retaining fastenerf level sensor retaining fastener

16 Install the level sensor box onto the machine.Install the level sensor box retaining fasteners.

17 Connect the wiring harness to the level sensor,limit switch and alarm.

X

Y

f

e

a

b

d

c




18 Tighten the level sensor adjusting fastenersuntil the bubble in the top of the level sensor iscentered in the circles.

Be sure there are threads showingthrough the top of the adjustingfasteners.








25 Remove the blocks from the wheels at thenon-steer end of the machine.

26 Block the wheels at the steer end of themachine.

27 Center a lifting jack under the drive chassis atthe non-steer end of the machine.


29 Place a 4.07 x 6 x 6 inch / 103.4 mm x15 cm x 15 cm thick steel block under bothwheels at the non-steer end of the machine.









36 Remove the blocks from the wheels at the steerend of the machine.



39 Place a 1.06 x 6 x 6 inch / 27 mm x15 cm x 15 cm thick steel block under bothwheels at the ground controls side of themachine.



42 Adjust the tilt level sensor retaining fastenersjust until the tilt sensor alarm does not sound.










49 Place a 1.23 x 6 x 6 inch / 31 mm x15 cm x 15 cm thick steel block under bothwheels at the battery pack side of the machine.




Result: If the tilt sensor alarm does not sound,adjust the tilt level sensor until the alarm justbegins to sound OR the down limit switch mayneed to be adjusted.





54 Install the tilt level sensor box cover.







4-4Level Sensor(after serial number 47664)

The tilt sensor sounds when the incline of thechassis exceeds the rating on the serial plate.

How to Install and Calibrate the1.5° Level SensorThis procedure is for the following models:

• GS-2032 (ANSI and CSA models)• GS-2032 (CE models after serial number GS3204-51682)• GS-2632 (CE models after serial number GS3204-51682)








REV C





6 Turn the key switch to the off position and pushin the red Emergency Stop button to the offposition at the ground controls.

7 Tag and disconnect the level sensor wireharness from the chassis wire harness.

The wire harness connection islocated next to the level sensor,on top of the chassis at the steerend of the machine.

8 Remove the level sensor retaining fasteners.Remove the level sensor from the machine.

9 Tag and disconnect the level sensor wires fromthe level sensor connector plug.

10 Securely install the wires of the new levelsensor into the level sensor connector plug.

11 Place the new level sensor onto the levelsensor mount bracket with the "X" on the levelsensor base closest to the long side of the levelsensor mount and the "Y" on the level sensorbase closest to the short side of the levelsensor mount.

Tip-over hazard. The level sensormust be installed with the "X" onthe level sensor base closest tothe long side of the tilt level sensorbox and the "Y" on the levelsensor base closest to the shortside of the tilt level sensor box.Failure to install the tilt levelsensor as instructed could result inthe machine tipping over, causingdeath or serious injury.

Steer end

Non-steer end

a limit switchb level sensor mount bracketc level sensor S7d alarm H5e level sensor retaining fastenerf scissor chassis

12 Install the level sensor retaining fastenersthrough the level sensor and springs, and intothe mount bracket. Tighten the fasteners andmeasure the distance between the level sensorand the level sensor mount bracket.

Result: The measurement should beapproximately 3/8 inch / 10 mm.

X

Y

f

e

a

b

d

c

GROUND CONTROLS



REV C

13 Connect the chassis wire harness to the levelsensor wire harness.

14 Turn the key switch to the ground control andpull out the red Emergency Stop button to theon position at the ground controls.

15 Adjust the level sensor retaining fasteners untilthe bubble in the top of the level sensor iscentered in the circles.







21 Place a 0.66 x 6 x 6 inch / 16.8 mm x 15 cm x15 cm thick steel block under both wheels atthe ground controls side of the machine.



Result: The level sensor alarm should notsound.

Result: The level sensor alarm does sound.Adjust the level sensor retaining fasteners justuntil the level sensor alarm does not sound.







30 Place a 0.8 x 6 x 6 inch / 20.3 mm x 15 cm x 15cm thick steel block under both wheels at thebattery pack side of the machine.



Result: The platform should stop and an alarmshould sound.

Result: The platform does not stop or the levelsensor alarm does not sound. Adjust the levelsensor until the alarm just begins to sound ORthe down limit switch may need to be adjusted.










GROUND CONTROLS



REV C

How to Install and Calibrate the2° Level SensorThis procedure is for the following models:

• GS-2032 (Australia models)• GS-2032 (CE models before serial number GS3204-51683)• GS-2632 (ANSI, CSA and Australia models)• GS-2632 (CE models before serial number GS3204-51683)










6 Turn the key switch to the off position and pushin the red Emergency Stop button to the offposition at the ground controls.

7 Tag and disconnect the level sensor wireharness from the chassis wire harness.

The wire harness connection islocated next to the level sensor,on top of the chassis at the steerend of the machine.

8 Remove the level sensor retaining fasteners.Remove the level sensor from the machine.

9 Tag and disconnect the level sensor wires fromthe level sensor connector plug.

10 Securely install the wires of the new levelsensor into the level sensor connector plug.

GROUND CONTROLS



REV C

11 Place the new level sensor onto the levelsensor mount bracket with the "X" on the levelsensor base closest to the long side of the levelsensor mount and the "Y" on the level sensorbase closest to the short side of the levelsensor mount.

Tip-over hazard. The level sensormust be installed with the "X" onthe level sensor base closest tothe long side of the tilt level sensorbox and the "Y" on the levelsensor base closest to the shortside of the tilt level sensor box.Failure to install the tilt levelsensor as instructed could result inthe machine tipping over, causingdeath or serious injury.

12 Install the level sensor retaining fastenersthrough the level sensor and springs, and intothe mount bracket. Tighten the fasteners andmeasure the distance between the level sensorand the level sensor mount bracket.

Result: The measurement should beapproximately 3/8 inch / 10 mm.

13 Connect the chassis wire harness to the levelsensor wire harness.

14 Turn the key switch to the ground control andpull out the red Emergency Stop button to theon position at the ground controls.

15 Adjust the level sensor retaining fasteners untilthe bubble in the top of the level sensor iscentered in the circles.


Steer end

GROUND CONTROLS

Non-steer end

a limit switchb level sensor mount bracketc level sensor S7d alarm H5e level sensor retaining fastenerf scissor chassis





X

Y

f

e

a

b

d

c





21 Place a 0.9 x 6 x 6 inch / 22.9 mm x 15 cm x 15cm thick steel block under both wheels at theground controls side of the machine.



Result: The level sensor alarm should notsound.

Result: The level sensor alarm does sound.Adjust the level sensor retaining fasteners justuntil the level sensor alarm does not sound.







30 Place a 1.04 x 6 x 6 inch / 26.4 mm x 15 cm x15 cm thick steel block under both wheels atthe battery pack side of the machine.



Result: The platform should stop and an alarmshould sound.

Result: The platform does not stop or the levelsensor alarm does not sound. Adjust the levelsensor until the alarm just begins to sound ORthe down limit switch may need to be adjusted.










REV A



Hydraulic Pump

5-1Function Pump

The hydraulic pump is attached to an electricmotor which makes up the Hydraulic Power Unit.

How to Test the Hydraulic PumpWhen removing a hose assemblyor fitting, the O-ring on the fittingand/or hose end must be replacedand then torqued to specificationduring installation. Refer toSection Two, Hydraulic Hose andFitting Torque Specifications.

1 Disconnect and plug the high pressurehydraulic hose from the hydraulic pump.


2 Connect a 0 to 5000 psi / 0 to 350 bar pressuregauge to the high pressure port on the pump.

3 Turn the key switch to ground control and pullout the Emergency Stop button to the ON


4 Activate the platform up function from theground controls.

Result: If the pressure gauge reads3200 psi / 221 bar, immediately stop. The pumpis good.

Result: If pressure fails to reach3200 psi / 221 bar, the pump is bad and willneed to be serviced or replaced.

Component damage hazard.There is no relief valve in thehydraulic pump and the pump canbe damaged if the pressure isallowed to exceed 3200 psi / 221bar. When testing the pump,activate the pump in one secondintervals until 3200 psi / 221 bar isconfirmed. Do not over-pressurizethe pump.

5 Remove the pressure gauge and reconnect thehydraulic hose.


REV A



How to Remove theHydraulic Pump


1 Remove the mounting fasteners from thehydraulic filter bracket at the function manifold.Move the filter off to the side.

2 Tag, disconnect and plug the hydraulic hoseson the pump. Cap the fittings on the pump.


3 Remove the pump mounting bolts. Carefullyremove the pump.

HYDRAULIC PUMP



REV C

6-1Function Manifold Components (from serial number 17408 to 17481)

Manifolds

Index SchematicNo. Description Item Function Torque

1 Check valve, 30 psi / 2 bar ........................ AA ...............Steer circuit .................................... 20 ft-lbs / 27 Nm

2 Diagnostic nipple ....................................... AB ...............Testing ........................................... 10 ft-lbs / 14 Nm

3 Flow regulator, 0.75 gpm / 2.8 L/min ......... AC ...............Steer circuit .................................... 35 ft-lbs / 47 Nm

4 Orifice - washer, 0.040 in / 1 mm............... AD ...............Steer circuit

5 Relief valve, 1500 psi / 103.4 bar .............. AE ...............Steering relief ................................ 20 ft-lbs / 27 Nm

6 Relief valve, 3500 psi / 241.3 bar .............. AF ................System relief .................................. 20 ft-lbs / 27 Nm

7 Solenoid valve, 3 position 4 way ............... AG ...............Steer left/right ................................ 20 ft-lbs / 27 Nm

8 Solenoid valve, 2 position 4 way ............... AH ...............Platform up .................................... 25 ft-lbs / 34 Nm

9 Solenoid valve,2 position 2 way, N.O. ............................... AI .................Brake circuit ................................... 20 ft-lbs / 27 Nm

10 Solenoid valve, 2 position 4 way ............... AJ ................Drive speed select circuit ............... 25 ft-lbs / 34 Nm

11 Solenoid valve, 3 position 4 way ............... AK ...............Drive forward/reverse .................... 25 ft-lbs / 27 Nm

12 Check valve, 200 psi / 13.8 bar ................. AL ................Brake circuit ................................... 25 ft-lbs / 34 Nm

The function manifold is mounted inside the hydraulic power unit module tray.



REV C MANIFOLDS



REV CMANIFOLDS


1 Check valve, 30 psi / 2 bar ........................ AA ...............Steer circuit .................................... 20 ft-lbs / 27 Nm

2 Diagnostic nipple ....................................... AB ...............Testing ........................................... 10 ft-lbs / 14 Nm

3 Flow regulator, 0.75 gpm / 2.8 L/min ......... AC ...............Steer circuit .................................... 35 ft-lbs / 47 Nm

4 Orifice - washer, 0.040 in / 1 mm............... AD ...............Steer circuit

5 Relief valve, 1500 psi / 103.4 bar .............. AE ...............Steering relief ................................ 20 ft-lbs / 27 Nm

6 Relief valve, 3500 psi / 241.3 bar .............. AF ................System relief .................................. 20 ft-lbs / 27 Nm

7 Solenoid valve, 3 position 4 way ............... AG ...............Steer left/right ............................... 20 ft-lbs / 27 Nm

8 Solenoid valve, 2 position 4 way ............... AH ...............Platform up .................................... 25 ft-lbs / 34 Nm

9 Solenoid valve,2 position 2 way, N.O. ............................... AI .................Brake circuit ................................... 20 ft-lbs / 27 Nm

10 Solenoid valve, 2 position 4 way ............... AJ ................Drive speed select circuit ............... 25 ft-lbs / 34 Nm

11 Solenoid valve, 3 position 4 way ............... AK ...............Drive forward/reverse .................... 25 ft-lbs / 34 Nm

12 Relief valve, 130 psi / 9 bar ....................... AL ................Brake circuit ................................... 20 ft-lbs / 27 Nm





REV C MANIFOLDS



REV C


1 Diagnostic nipple ....................................... BA ...............Testing ........................................... 10 ft-lbs / 14 Nm

2 Flow regulator valve,0.75 gpm / 2.8 L/min .................................. BB ...............Steer circuit .................................... 35 ft-lbs / 47 Nm

3 Relief valve,3000 to 3200 psi / 207 to 221 bar .............. BC ...............Platform up .................................... 20 ft-lbs / 27 Nm

4 Relief valve, 3500 psi / 241.3 bar .............. BD ...............System relief .................................. 20 ft-lbs / 27 Nm

5 Orifice - washer, 0.040 in / 1 mm............... BE ...............Steer circuit

6 Relief valve, 1500 psi / 103.4 bar .............. BF ................Steering relief ................................ 20 ft-lbs / 27 Nm

7 Relief valve, 130 psi / 9 bar ....................... BG ...............Brake relief .................................... 20 ft-lbs / 27 Nm

8 Solenoid valve, 3 position 4 way ............... BH ...............Steer left/right ................................ 20 ft-lbs / 27 Nm

9 Solenoid valve, 2 position 4 way ............... BI .................Drive speed select circuit ............... 25 ft-lbs / 34 Nm

10 Solenoid valve, 3 position 4 way ............... BJ ................Drive forward/reverse .................... 25 ft-lbs / 34 Nm

11 Solenoid valve,2 position 2 way, N.O. ............................... BK ...............Brake circuit ................................... 20 ft-lbs / 27 Nm

12 Solenoid valve, 2 position 4 way ............... BL ................Platform up .................................... 25 ft-lbs / 34 Nm

13 Check valve, 5 psi / 0.3 bar ....................... BM ...............Steer circuit .................................... 20 ft-lbs / 27 Nm



MANIFOLDS



REV C MANIFOLDS



REV C


1 Diagnostic nipple ....................................... BA ...............Testing ........................................... 10 ft-lbs / 14 Nm

2 Flow regulator valve,0.75 gpm / 2.8 L/min .................................. BB ...............Steer circuit .................................... 35 ft-lbs / 47 Nm

3 Relief valve,3000 to 3200 psi / 207 to 221 bar .............. BC ...............Platform up .................................... 20 ft-lbs / 27 Nm

4 Relief valve, 3500 psi / 241.3 bar .............. BD ...............System relief .................................. 20 ft-lbs / 27 Nm

5 Orifice - washer, 0.040 in / 1 mm............... BE ...............Steer circuit

6 Relief valve, 1500 psi / 103.4 bar .............. BF ................Steering relief ................................ 20 ft-lbs / 27 Nm

7 Relief valve, 130 psi / 9 bar ....................... BG ...............Brake relief .................................... 20 ft-lbs / 27 Nm

8 Solenoid valve, 3 position 4 way ............... BH ...............Steer left/right ................................ 20 ft-lbs / 27 Nm

9 Solenoid valve, 2 position 4 way ............... BI .................Drive speed select circuit ............... 25 ft-lbs / 34 Nm

10 Solenoid valve, 3 position 4 way ............... BJ ................Drive forward/reverse .................... 25 ft-lbs / 34 Nm

11 Solenoid valve,2 position 2 way, N.O. ............................... BK ...............Brake circuit ................................... 20 ft-lbs / 27 Nm

12 Solenoid valve, 2 position 4 way ............... BL ................Platform up .................................... 25 ft-lbs / 34 Nm

13 Check valve, 5 psi / 0.3 bar ....................... BM ...............Steer circuit .................................... 20 ft-lbs / 27 Nm



MANIFOLDS



REV C

3

4

7

8

6

5

1 2

BA

BB

BE

9

111213

BF

BC

BD

BG

BH

BJBKBL

BM

BI

Y3

Y2Y2Y8

Y1

Y6Y6

Y5Y5

Y4

10

MANIFOLDS



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1 Diagnostic nipple ....................................... CA ...............Testing ........................................... 10 ft-lbs / 14 Nm

2 Flow regulator valve,0.75 gpm / 2.8 L/min .................................. CB ...............Steer circuit .................................... 35 ft-lbs / 47 Nm

3 Relief valve,3000 to 3200 psi / 207 to 221 bar .............. CC ...............Platform up .................................... 20 ft-lbs / 27 Nm

4 Relief valve, 3500 psi / 241.3 bar .............. CD ...............System relief .................................. 20 ft-lbs / 27 Nm

5 Orifice - washer, 0.040 in / 1 mm............... CE ...............Steer circuit

6 Relief valve, 1500 psi / 103.4 bar .............. CF ...............Steering relief ................................ 20 ft-lbs / 27 Nm

7 Check valve, 30 psi / 2 bar ........................ CG ...............Brake circuit ................................... 20 ft-lbs / 27 Nm

8 Solenoid valve, 3 position 4 way ............... CH ...............Steer left/right ................................ 20 ft-lbs / 27 Nm

9 Solenoid valve,2 position 2 way, N.O. ............................... CI .................Brake circuit ................................... 20 ft-lbs / 27 Nm

10 Solenoid valve, 2 position 4 way ............... CJ ................Drive speed select circuit ............... 25 ft-lbs / 34 Nm

11 Solenoid valve, 3 position 4 way ............... CK ...............Drive forward/reverse .................... 25 ft-lbs / 34 Nm

12 Solenoid valve, 2 position 2 way ............... CL ................High speed bypass ........................ 20 ft-lbs / 27 Nm

13 Flow divider/combiner valve ...................... CM ...............Drive slip limit ................................ 25 ft-lbs / 34 Nm

14 Solenoid valve, 2 position 4 way ............... CN ...............Platform up .................................... 25 ft-lbs / 34 Nm

15 Check valve, 10 psi / 0.7 bar ..................... CO ...............Steer circuit .................................... 20 ft-lbs / 27 Nm

6-5Function Manifold Components - Models with Traction Control


MANIFOLDS



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6-6Valve Adjustments -Function Manifold

How to Adjust theSystem Relief Valve(before serial number 36101)1 Open the hydraulic power unit module tray and

locate the system relief valve on the functionmanifold (item AF).

2 Place maximum rated load into the platform.Secure the load to the platform.

Load capacity, maximum

GS-2032 800 lbs363 kg

GS-2632 500 lbs227 kg

MANIFOLDS

3 Turn the key switch to ground control and pullout the red Emergency Stop button to the ON


4 Hold the system relief valve with a wrench andremove the cap (item AF).

5 While activating the platform up function, adjustthe internal hex socket clockwise to increase liftcapacity or counterclockwise to decrease liftcapacity. Adjust the relief valve until theplatform just begins to raise.

6 Fully lower the platform.

7 Add an additional 50 pounds / 22.7 kg to theplatform. Secure the additional weight.

8 Activate the platform up function.

Result: The power unit should not be able to liftthe platform.

Result: If the power unit lifts the platform, adjustthe internal hex socket counterclockwise untilthe platform will not raise.

Tip-over hazard. Do not adjust therelief valve to allow the power unitto lift more than maximum ratedload.

9 Install the relief valve cap.

10 Remove the weight from the platform.

11 Bleed the hydraulic system. Raise the platformto full height, and then lower it to the stowedposition through two complete cycles.

Result: If the pump cavitates or platform fails toreach full height, add hydraulic oil until thepump is functioning correctly and the platformreaches full height. Do not overfill the hydraulictank.

Component damage hazard. Donot continue to operate themachine if the hydraulic pump iscavitating. If the pump is stillcavitating, see 5-1, How to Testthe Hydraulic Pump.

AC

AD

AA

AB

AF

AE

AG

AH

AJ

AK

AL

AI

a

b

Y3

Y8

Y2

Y1

Y6

Y5

Y4

a system relief valveb function manifold



REV C

How to Adjust theSystem Relief Valve(after serial number 36100)

Be sure that the hydraulic oil levelis between the FULL and ADD markson the oil level indicator decal.

1 Open the hydraulic power unit module tray andlocate the system relief valve on the functionmanifold (item BD or CD).

2 Connect a 0 to 5000 psi / 0 to 350 bar pressuregauge to the test port on the function manifold(item BA or CA).

Models with traction control

a system relief valveb function manifoldc test port

Y3

Y8 Y1A

Y2

Y1

Y6

Y5

Y4

CA

CB

CC

CD

CF

CG

CH

CJ

CK

CLCN

CO

CM

C I

CEa

b

c

BA

BB

BC

BD

BF

BG

BH

BJ

BKBL

BM

B I

BE

a

b

c

Y3

Y8Y2

Y1

Y6

Y5

Y4

MANIFOLDS


Models without traction control(from serial number 49426 to 59999)


BA

BB

BC

BD

BE

BF

BG

BH

BI

BJBKBL

BM

a

b

c



REV C



Perform this test from the groundwith the platform controls. Do notstand in the platform.


6 Press and hold the function enable switch.

7 Move and hold the joystick controller fully ineither direction while observing the pressurereading on the pressure gauge. Note thepressure. Refer to Section 2, Specifications.

8 Turn the machine off. Hold the system reliefvalve with a wrench and remove the cap(item BD or CD).

9 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counterclockwise todecrease the pressure.

Tip-over hazard. Failure to adjustthe relief valves to specificationcould cause the machine to tipover resulting in death or seriousinjury. Do not adjust the reliefvalve pressures higher thanspecifications.


11 Repeat steps 5 through 7 to confirm the reliefvalve pressure.

MANIFOLDS



REV C

How to Adjust theSteering Relief Valve(before serial number 36101)1 Connect a 0 to 5000 psi / 0 to 350 bar pressure

gauge to the test port (item AB) on the functionmanifold.

a steer relief valveb function manifoldc test port


3 Press and hold the steer thumb rocker switch tothe right. Allow the wheels to completely turn tothe right, then continue holding the switch whileobserving the pressure reading on the pressuregauge. Note the pressure.

4 Press and hold the steer thumb rocker switch tothe left. Allow the wheels to completely turn tothe left, then continue holding the switch whileobserving the pressure reading on the pressuregauge. Note the pressure. Refer to Section 2,Specifications.

5 Turn the machine off. Hold the steering reliefvalve with a wrench and remove the cap(item AE).

6 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counterclockwise todecrease the pressure. Install the relief valvecap.


7 Repeat steps 3 and 4 to confirm the relief valvepressure.

AC

AD

AA

AB

AF

AE

AG

AH

AJ

AK

AL

AI

a

b

c

Y3

Y8

Y2

Y1

Y6

Y5

Y4

MANIFOLDS



REV C

How to Adjust theSteering Relief Valve(after serial number 36100)1 Connect a 0 to 5000 psi / 0 to 350 bar pressure

gauge to the test port (item BA or CA) on thefunction manifold.

Models with traction control

a steer relief valveb function manifoldc test port

BA

BB

BC

BD

BF

BG

BH

BJ

BKBL

BM

B I

BE

a

b

c

Y3

Y8Y2

Y1

Y6

Y5

Y4

Y3

Y8 Y1A

Y2

Y1

Y6

Y5

Y4

CA

CB

CC

CD

CF

CG

CH

CJ

CK

CLCN

CO

CM

C I

CE

ab

c

MANIFOLDS




BA

BB

BC

BD

BE

BF

BG

BH

BI

BJBKBL

BM

a

b

c



REV C


3 Press and hold the steer thumb rocker switch tothe right. Allow the wheels to completely turn tothe right, then continue holding the switch whileobserving the pressure reading on the pressuregauge. Note the pressure.

4 Press and hold the steer thumb rocker switch tothe left. Allow the wheels to completely turn tothe left, then continue holding the switch whileobserving the pressure reading on the pressuregauge. Note the pressure. Refer to Section 2,Specifications.

5 Turn the machine off. Hold the steering reliefvalve with a wrench and remove the cap(item BF or CF).

6 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counterclockwise todecrease the pressure. Install the relief valvecap.


7 Repeat steps 3 and 4 to confirm the relief valvepressure.

MANIFOLDS



REV C

How to Adjust thePlatform Lift Relief Valve(after serial number 36100)

Be sure that the hydraulic oil levelis between the FULL and ADD markson the oil level indicator decal.

1 Open the hydraulic power unit module tray andlocate the system relief valve on the functionmanifold (item BD or CD).

Models without traction control

a lift relief valveb system relief valvec function manifoldd test port

MANIFOLDS

a lift relief valveb system relief valvec function manifoldd test port



BA

BB

BC

BD

BF

BG

BH

BJ

BKBL

BM

B I

BE

b

a

c

d

Y3

Y8Y2

Y1

Y6

Y5

Y4

BA

BB

BC

BD

BF

BG

BH

BJ

BKBL

BM

B I

BE

b

a

c

d

Y3

Y8Y2

Y1

Y6

Y5

Y4

BA

BB

BC

BDBE

BF

BG

BH

BI

BJBKBL

BM

a

b

c

d



REV C MANIFOLDS

2 Connect a 0 to 5000 psi / 0 to 350 bar pressuregauge to the test port on the function manifold(item BA or CA).



Perform this test from the groundwith the platform controls. Do notstand in the platform.

Confirm the System Relief Valve Pressure:

5 Turn the key switch to platform control and pullout the Emergency Stop button to the ON


6 Press and hold the function enable switch.

7 Move and hold the joystick controller fully ineither direction while observing the pressurereading on the pressure gauge. Note thepressure. Refer to Section 2, Specifications.

8 Turn the machine off. Hold the system reliefvalve with a wrench and remove the cap(item BD or CD).

9 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counterclockwise todecrease the pressure.



11 Repeat steps 5 through 7 to confirm the reliefvalve pressure.

Confirm the Lift Relief Valve Pressure:

12 Place the maximum rated load in the platform.Secure the load to the platform. Refer toSection 2, Specifications.

13 Turn the key switch to ground control and pullout the Emergency Stop button to the ON


14 Hold the lift relief valve with a wrench andremove the cap (item BC or CC).

15 While activating the platform up function, adjustthe internal hex socket clockwise, just until theplatform begins to raise.

16 Fully lower the platform.

17 Add an additional 100 pounds / 45.4 kg to theplatform. Secure the additional weight.


Result: The power unit should not be able to liftthe platform.

Result: If the power unit lifts the platform, adjustthe internal hex socket counterclockwise untilthe adjustment is correct.


20 Remove the weight from the platform.

21 Bleed the hydraulic system by raising theplatform to full height. If the pump cavitates orthe platform fails to reach full height, addhydraulic oil until the pump is functioningcorrectly. Do not overfill the hydraulic reservoir.

Component damage hazard. Donot continue to operate themachine if the hydraulic pump iscavitating.



REV CMANIFOLDS

6-7Valve Coils

How to Test a CoilA properly functioning coil provides anelectromotive force which operates the solenoidvalve. Critical to normal operation is continuitywithin the coil that provides this force field.


1 Tag and disconnect the wire harness from thecoil to be tested.

2 Test the coil resistance.

Result: The resistance should be withinspecification, plus or minus 30%.

Result: If the resistance is not withinspecification, plus or minus 30%, replace thecoil.

Valve Coil Resistance Specifications

Description Specification

Solenoid valve, 3 position 4 way 25 to 27Ω20V DC with diode(schematic items AG, BH and CH)

Solenoid valve, 2 position 4 way 18 to 20Ω20V DC with diode(schematic items AH, AJ, BI, BL, CJ and CN)

Solenoid valve, 2 position 2 way N.O. 25 to 27Ω20V DC with diode(schematic items AI, BK, CI and CL)

Solenoid valve, 3 position 4 way 18 to 20Ω20V DC with diode(schematic items AK, BJ and CK)

Solenoid valve, N.C. 23 to 25Ω2 position 2 way 20V DC with diode(schematic item D, after serial number 28936)



REV C MANIFOLDS

How to Test a Coil DiodeGenie incorporates spike suppressing diodes in allof its coils. Properly functioning coil diodes protectthe electrical circuit by suppressing voltage spikes.Voltage spikes naturally occur within a functioncircuit following the interruption of electrical currentto a coil. Faulty diodes can fail to protect theelectrical system, resulting in a tripped circuitbreaker or component damage.


1 Test the coil for resistance. See 6-8 How toTest a Coil.

2 Connect a 10Ω resistor to the negative terminalof a known good 9V DC battery. Connect theother end of the resistor to a terminal on thecoil.

The battery should read 9V DC ormore when measured across theterminals.

Resistor, 10ΩΩΩΩΩGenie part number 27287

a multimeterb 9V DC batteryc 10Ω resistord coil

3 Set a multimeter to read DC amperage.

The multimeter, when set to readDC amperage, should be capableof reading up to 800 mA.

4 Connect the negative lead to the other terminalon the coil.

If testing a single-terminal coil,connect the negative lead to theinternal metallic ring at either endof the coil.

5 Momentarily connect the positive lead from themultimeter to the positive terminal on the 9Vbattery. Note and record the current reading.

6 At the battery or coil terminals, reverse theconnections. Note and record the currentreading.

Result: Both current readings are greater than0 mA and are different by a minimum of 20%.The coil is good.

Result: If one or both of the current readings are0 mA, or if the two current readings do not differby a minimum of 20%, the coil and/or itsinternal diode are faulty and the coil should bereplaced.

9VBATTERY

10

RESISTOR

�

AMMETER

COIL

+

-

+

-

d

b

b

a

c

c

Note: Dotted lines in illustration indicate areversed connection as specified in step 6

REV A



7-1Hydraulic Tank

The primary functions of the hydraulic tank are tocool, clean and deaerate the hydraulic fluid duringoperation. It utilizes internal suction strainers forthe pump supply lines and has an external returnline filter.

How to Remove theHydraulic Tank

Component damage hazard. Thework area and surfaces where thisprocedure will be performed mustbe clean and free of debris thatcould get into the hydraulicsystem.





2 Open the power unit module tray.

3 Remove the drain plug from the hydraulic tankand allow all of the oil from the tank to drain intoa suitable container. Refer to Section 2,Specifications.


4 Tag, disconnect and plug the hydraulic tankreturn hose at the top of the hydraulic tank.

5 Remove the motor controller mounting bracketretaining fasteners and move the motorcontroller to the side.

6 Remove the return filter mounting bracketfasteners from the manifold. Push the filter andaccumulator out of the way.

7 Tag, disconnect and plug the hydraulic pumpinlet hose at the side of the hydraulic tank.

8 Remove the hydraulic tank retaining fastenersand remove the hydraulic tank from themachine.

Hydraulic Tank

REV A



Steer Axle Components

8-1Yoke and Drive Motor

How to Remove the Yokeand Drive Motor


1 Block the non-steer wheels.


3 Remove the cotter pin from the wheel castlenut.

Always replace the cotter pin witha new one when removing thecastle nut.

4 Loosen the wheel castle nut. Do not remove it.

5 Raise the machine approximately14 inches / 36 cm. Place blocks under thechassis for support.

Crushing hazard. The chassis willfall if it is not properly supported.

6 Remove the wheel castle nut. Remove thewheel.

7 Tag, disconnect and plug the hydraulic hoseson the drive motor. Cap the fittings.

Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly toallow the oil pressure todissipate gradually. Do notallow oil to squirt or spray.

Component damage hazard.Hoses can be damaged if they arekinked or pinched.

8 Support and secure the yoke assembly to anappropriate lifting device.

9 Remove the retaining fastener from the steerlink at the yoke assembly.

Note the quantity and location ofthe spacers when disconnectingthe steer link from the yokeassembly.

10 Remove the retaining fastener from the top ofthe yoke pivot shaft.

11 Lower the yoke assembly out of the chassis.

Bodily injury hazard. The yoke/motor assembly may fall if notproperly supported when it isremoved from the chassis.

During re-assembly, be sure thatthe spacers are installed onto thesteer link.

REV A



STEER AXLE COMPONENTS

How to Remove a Drive Motor1 Block the non-steer wheels.


3 Remove the cotter pin on the wheel lug nut ofthe motor to be removed.



5 Raise the machine approximately2 inches / 5 cm. Place blocks under the chassisfor support.



7 Tag, disconnect and plug the hydraulic hoseson the drive motor. Cap the fittings.



8 Remove the drive motor mounting fasteners.Remove the drive motor.


Drive motor mounting fasteners, dry 75 ft-lbs101.7 Nm

Drive motor mounting fasteners, lubricated 56 ft-lbs76.3 Nm

REV A




8-2Steer Cylinder

How to Remove theSteer Cylinder


1 Block the non-steer wheels.

2 Tag, disconnect and plug the hydraulic hosesfrom the steering cylinder. Cap the fittings onthe cylinder.

Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.


3 Remove the pin retaining fasteners from thebarrel-end pivot pin. Remove the pivot pin.

Note the quantity and location ofthe spacers when removing thebarrel-end pivot pin.

4 Remove the pin retaining fasteners from therod-end pivot pin. Remove the pin.

Note the quantity and location ofthe spacers when removing therod-end pivot pin.

5 Remove the steering cylinder from the machine.

REV A




8-3Steer Bellcrank

How to Remove theSteer Bellcrank

Perform this procedure with themachine on a flat, level surface.

1 Remove the steering cylinder. See 8-2, How toRemove the Steering Cylinder.

2 From serial number 17408 to 43000: Removethe retaining fastener from the center pivot pinof the bellcrank.After serial number 43000: Remove theretaining fastener from the center pivot pin ofthe bellcrank. Remove the pin.

Note the quantity and the locationof the spacers on the bellcrank.

3 Remove the retaining fasteners from the steerlinks at each end of the bellcrank.

Note the quantity and the locationof the spacers in between thebellcrank and the steer links.

4 Raise the machine approximately14 inches / 36 cm. Place blocks under thechassis for support.


4 Turn the yokes to the side so the bellcrank canbe removed.

5 Remove the bellcrank from the machine.

Note the quantity and the locationof the spacers in between thebellcrank and the steer links.

REV A



Non-steer Axle Components

9-1Drive Brake

How to Remove a Drive BrakeWhen removing a hose assemblyor fitting, the O-ring on the fittingand/or hose end must be replacedand then torqued to specificationduring installation. Refer toSection Two, Hydraulic Hose andFitting Torque Specifications.



Crushing hazard. The entry laddermay become unbalanced and fallif it is not properly supported andsecured to the lifting device.

3 Block the steer wheels.

4 Center a lifting jack under the drive chassis atthe non-steer end.

5 Remove the cotter pin from the wheel castlenut.



7 Raise the machine approximately2 inches / 5 cm. Place blocks under the chassisfor support.



9 Disconnect and plug the hydraulic hose fromthe brake. Cap the fittings on the brake.


10 Place a lifting jack under the brake for support.

11 Remove the fasteners that attach the brake tothe drive chassis. Remove the brake.

Crushing hazard. The brake willfall if it is not properly supportedwhen the mounting fasteners areremoved.


Brake mounting fasteners, dry 75 ft-lbs101.7 Nm

Brake mounting fasteners, lubricated 56 ft-lbs76.3 Nm

REV B




1 Shuttle valve ..................................... J ................ Brake release circuit ............................ 45-50 in-lbs / 5 Nm

2 Check valve, pilot operated .............. K ............... Manual brake release circuit ............65-70 in-lbs / 7-8 Nm

3 Hand pump ....................................... L ............... Manual brake release .............................. 30 ft-lbs / 41 Nm

4 Needle valve ..................................... M............... Manual brake release enable .............. 45-50 in-lbs / 5 Nm

10-1Brake Release Hand Pump Components

The brake release hand pump manifold is mounted behind the entry ladder, next to the battery charger.

Brake Release Hand Pump Components

GS-2032, GS-2632

(after serial number GS-3204-52788)

J

K

L

M

L

M

GS-2032, GS-2632

(before serial number GS-3204-52789)

Note: 'alpha' callouts referto corresponding notes onthe hydraulic schematic

1

2

3

4

4

3


June 2004 Section 5 • Troubleshooting Flow Charts

Before Troubleshooting:

Read, understand and obey the safety rules andoperating instructions in the appropriateoperator's manual on your machine.

Be sure that all necessary tools and testequipment are available and ready for use.

Read each appropriate flow chart thoroughly.Attempting shortcuts may produce hazardousconditions.

Be aware of the following hazards and followgenerally accepted safe workshop practices.

Crushing hazard. When testingor replacing any hydrauliccomponent, always supportthe structure and secure itfrom movement.

Electrocution hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.

Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.

Two persons will be required tosafely perform sometroubleshooting procedures.

Troubleshooting Flow Charts

Observe and Obey:

Troubleshooting and repair procedures shall becompleted by a person trained and qualified onthe repair of this machine.



Unless otherwise specified, perform eachrepair procedure with the machine in thefollowing configuration:




· The red Emergency Stop button in the offposition at both ground and platform controls

· Wheels chocked



June 2004Section 5 • Troubleshooting Flow Charts

General Repair Process

TROUBLESHOOTING FLOW CHARTS

About This SectionWhen a malfunction is discovered, the flow chartsin this section will help a service professionalpinpoint the cause of the problem. To use thissection, basic hand tools and certain pieces of testequipment are required—voltmeter, ohmmeter,pressure gauges.

The location of terminals mentioned in this sectioncan be found on the appropriate electrical orhydraulic schematics provided in Section 6,Schematics.

Since various degrees of a particular functionloss may occur, selecting the appropriate flowchart may be troublesome. When a function will notoperate with the same speed or power as amachine in good working condition, refer to theflow chart which most closely describes theproblem.

Malfunctiondiscovered

Identifysymptoms

Troubleshoot

Performrepair

Return toservice problem

solved

problemstill exists

Inspectand test

LED Diagnostic ReadoutThe diagnostic readout displays numerical codesthat provide information about the machineoperating status and about malfunctions. The dotto the right of the numbers will blink duringnormal operation codes and remain on with faultcodes.

The codes listed in the Fault Code Chartdescribe malfunctions and can aid introubleshooting the machine by pinpointing thearea or component affected.

REV A



Fault Code Chart(after serial number 17407)

Fault Code Problem Possible Causes Solution

01 Internal ECM error. EPROM not programmed. Replace ECM.

02(See Chart 16)

ECM/Platformcommunication error.

Malfunctioning control cableOR malfunctioning platformcontrols.

Troubleshoot control cableOR troubleshoot platformcontrols.

03 Undefined platform DIPswitch settings.

DIP switch settingsincorrect.

Correct DIP switch settings.

12(See Chart 4)

Chassis up/down toggleclosed at start up.

Malfunctioning up/downswitch.

Troubleshoot up/downswitch.

18(See Charts 10,

13 or 14)

Pothole guard failure. Malfunctioning potholeswitch OR obstruction inpothole guard linkage.

Troubleshoot pothole switchOR remove obstruction.

19(See Chart 15)

Limit switch failure. Malfunctioning limit switchOR wire disconnected fromlimit switch.

Troubleshoot limit switchOR inspect wire connection.

42(See Chart 5 or

Chart 8)

Platform left turn switchfault.

Malfunctioning steer leftmicroswitch.

Troubleshoot steer leftmicroswitch.

43(See Chart 5 or

Chart 9)

Platform right turn switchfault.

Malfunctioning steer rightmicroswitch.

Troubleshoot steer rightmicroswitch.

46(See Chart 5)

Platform drive enableswitch fault.

Malfunctioning drive enableswitch.

Troubleshoot drive enableswitch.

47 Platform joystick fault. Joystick potentiometer notcentered.

Verify potentiometer setting.

52(See Chart 11)

Forward coil fault. Malfunctioning coil OR wiredisconnected from coil.

Troubleshoot coil ORinspect wire connection.

53(See Chart 12)

Reverse coil fault. Malfunctioning coil OR wiredisconnected from coil.


54(See Chart 6)

Up coil fault. Malfunctioning coil OR wiredisconnected from coil.


55(See Chart 7)

Down coil fault. Malfunctioning coil OR wiredisconnected from coil.


56(See Chart 9)

Right coil fault. Malfunctioning coil OR wiredisconnected from coil.


57(See Chart 8)

Left coil fault. Malfunctioning coil OR wiredisconnected from coil.


58(See Chart 10 or

Chart 10A)

Brake coil fault. Malfunctioning coil OR wiredisconnected from coil.


59(See Chart 17)

Series/parallel coil fault. DIP switch settings areincorrect.

Troubleshoot and correctDIP switch settings.

68 Low battery voltage. Batteries discharged. Charge batteries.

88 ECM has been erased. Static strap may be missingfrom the machine.

Replace static strap.

REV A



All FunctionsWill NotOperate

Be sure the circuitbreaker and fuse arenot tripped or blown.

Be sure bothEmergency Stopswitches are pulled outto the ON position.

Be sure the batteriesare fully charged andproperly connected.

Be sure the hydraulictank is filled to thecorrect level.

Chart 1

Replace F6 OR checkfor short circuits ORcheck battery cables ORcheck for open innegative battery cablefrom batteries to groundpoint on module tray.20V or more

Continued on the nextpage.

Check voltage on theoutput side of the 275Afuse F6.

less than20V

Check voltage atterminal D1 at the pumpmotor M6.

Repair open in the 24Vcable circuit from F6 toQD1 OR replace orrepair QD1 OR repairopen in 24V cable circuitfrom QD1 throughterminal B+ at U6 toterminal D1 at M6.

20V or more

Check continuity fromthe B- terminal on themotor controller U6 tothe negative batterycable at QD1.

nocontinuity

continuity

Repair open in thenegative battery cablefrom the B- terminal atmotor controller U6 toQD1.

With the key switchturned to platformcontrol and bothEmergency Stop buttonspulled out to the ONposition, press and holdthe function enableswitch. Visually inspectthe power-on LED.

light is on

light is not on

Troubleshoot groundand platform controlsystems separately ORconsult the GenieIndustries ServiceDepartment.

0V

After serial number25141: Troubleshoot theCR48 power relay to U5

good

bad Repair or replace thewire circuit from theplatform controls toCR48 OR repair orreplace the CR48 socketOR replace CR48.

REV A



CHART 1

Continued from theprevious page.

Check voltage at theinput side of eachcontact at key switchKS1.

Repair open in the wirefrom P1 to KS1 ORrepair open in the wirejumper to each contactOR replace contact onP1 OR replace P1.

20V or more

Check the output side ofthe platform controlcontact at KS1.

Check the cam on KS1. bad Repair or replace KS1.

good

Replace contact ORrefer to Ground ControlsInoperative, Chart 5 ORconsult the GenieIndustries ServiceDepartment.

20V or more

0V

0V

Turn KS1 to the groundcontrol position andcheck output side ofeach contact.

Replace contact ORrefer to PlatformControls Inoperative,Chart 6 OR consult theGenie Industries ServiceDepartment.

20V or more

Refer to Chart 2, PumpMotor Will Not OperateOR repair open in whtwire (C2 estop chassis)OR consult the GenieIndustries ServiceDepartment.

0V Check the cam on KS1. bad Repair or replace KS1.

good

Check voltage at inputside of Emergency Stopbutton P1.

0V

20V or more

Repair open in wire fromthe input side of P1 toCB2 OR reset or replaceCB2 OR repair open inthe wire from CB2 toQD1.

REV A



Chart 2

Pump MotorWill NotOperate



With the key switchturned to groundcontrols and bothEmergency Stop buttonspulled out to the ONposition, activate the liftfunction and check forvoltage on the positiveterminal D1 at pumpmotor M5.

20V ormore

Check for continuity inthe ground cable circuitfrom terminal A1 atpump motor M5 to theM- terminal at motorcontroller U6.

nocontinuity

continuity

Replace ground cablefrom A1 at M5 to M- atU6.

0V


Check voltage on the B+terminal at motorcontroller U6.

20V ormore Replace positive battery

cable from the B+terminal at U6 to D1 atM5.

0V

Replace the cable fromthe B+ terminal at U6 toQD1 OR repair orreplace QD1 OR replacethe cable from QD1 toF6 OR replace F6 ORreplace the cable fromF6 to B5.

Check for continuity inthe positive cable circuitfrom the B+ terminal atU6 through battery quickdisconnect QD1 throughthe 275A fuse F6 to thebattery B5.

continuity

nocontinuity

0V

20V or more

Activate the lift functionand check voltage onterminal M- at U6.

Repair open in theground cable circuit fromterminal A1 at M5 toterminal M- at U6 ORreplace M5 OR consultthe Genie IndustriesService Department.

Replace U6 OR consultthe Genie IndustriesService Department.

After serial number25141: Troubleshoot theCR48 power relay to U5

good

bad Repair or replace thewire circuit from theplatform controls toCR48 OR repair orreplace the CR48 socketOR replace CR48.

REV A



CHART 2


Activate the lift functionand check voltage onterminal 1 at U6.

20V or more

Replace ground cablefrom the B- terminal atU6 to QD1 OR repair orreplace QD1 OR replacethe cable from QD1 toB5.

Check for continuity inthe ground cable circuitfrom the B- terminal atU6 through QD1 to thebattery B5.

nocontinuity

Repair open in the WHA8 motor contr enablewire from terminal 1 atU6 to pin A8 of the AMPconnector at ECM U5.

Activate the lift functionand check voltage onterminal 3 at U6.

Repair open in the WHA9-motor cont enablewire from pin A9 at U5to terminal 3 at U6 ORreplace U5 OR consultthe Genie IndustriesService Department.

0V

5V

Replace M5 OR consultthe Genie IndustriesService Department.

0V

continuity

REV A



Chart 3

All FunctionsInoperative,Power UnitStarts and Runs

Be sure, if the ErrorIndicator light is on atthe platform controls,you refer to the specificchart that relates to theerror code that isdisplayed on the ECM.



Be sure the hydraulictank is filled to thecorrect level.

Check for a positiveconnection betweenelectric motor andpump by removingpump from motor M5,leaving all hosesconnected. Visuallycheck the couplingconnection.

bad Replace pump couplingOR replace the pumpOR replace the motor.

good

Test the hydraulic pump.See Repair section.

Consult the GenieIndustries ServiceDepartment.

bad Replace the pump.

good

REV A



GroundControlsInoperative,PlatformControlsOperateNormally



Be sure the batteriesare properly connected.

Be sure the batteriesare fully charged.

Chart 4

With key switch turnedto ground controls andboth Emergency Stopbuttons pulled out to theON position, checkvoltage on the groundcontrol contact at theinput side of the keyswitch KS1.

0V

Repair open in WH wirefrom KS1 to EmergencyStop button P1 ORrepair or replace P1 ORrepair open in WH wirefrom P1 to circuitbreaker CB2.

20V or more

Check voltage on outputside of ground controlcontact at KS1.

Check if internal cam atKS1 is activating theground control contact.

yes Replace contact forground controls at KS1.

no

Replace KS1.20V or more

Repair open in WH wirejumper from KS1 to thecenter terminal at TS66.

Check voltage on thecenter terminal of theplatform up/down toggleswitch TS66 at theground controls.

0V

20V or more

Test or replace TS66(See Repair Section)OR repair open in theWH B12 UP/DWN SWITCHUP wire from TS66 to theECM U5 OR repair openin the WH A12 UP/DWNSWITCH DWN wire fromTS66 to U5 OR consultthe Genie IndustriesService Department.

0V

REV A



Chart 5

PlatformControlsInoperative,GroundControlsOperateNormally




With the key switchturned to platformcontrol and bothEmergency Stop buttonspulled out to the ONposition, check voltageon the input side of theplatform control contacton key switch KS1.

0V

Repair open in WH wirefrom KS1 to EmergencyStop button P1 ORrepair open in the WHwire from P1 to circuitbreaker CB2.

20V or more

Check voltage on outputside of platform controlcontact at KS1.

0V Check if internal cam atKS1 is activatingplatform control contact.

yes Replace contact forplatform controls at KS1.

no

Replace KS1.20V or more

Repair or replace P2 ORreplace control cablefrom U5 to the platformcontrols.

Check voltage at theoutput side of theEmergency Stop buttonP2.

0V

20V or more

Check voltage onterminal B2 at U5.

0V Replace U5.

Check voltage onterminal A11 at the ECMU5.

0V Repair open in WH A11-keyswitch wire from KS1to terminal A11 at U5.

20V or more

20V or more

20V or more

Check voltage onterminal A4 at U5.

0V Replace control cablefrom U5 to the platformcontrols.

Replace control cablefrom U5 to the platformcontrols OR replace theplatform controls ORconsult the GenieIndustries ServiceDepartment.

REV A



Platform UpFunctionInoperative

Be sure all otherfunctions operatenormally.



Chart 6

From serial number17408 to 21262: Withthe key switch turned toplatform controls andboth Emergency Stopbuttons pulled out to theON position, press andhold the lift functionenable button andactivate the controller inthe UP direction andcheck to see if the errorindicator light at theplatform controls is on.After serial number21262: With the keyswitch turned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition, press the liftfunction select buttonand activate thecontroller in the UPdirection and check tosee if the error indicatorlight at the platformcontrols is on.

light ison

light is not on

Connect the positivelead from a volt meter tothe coil on the platformup directional valve(item AG or BG) wireterminal withoutdisconnecting the wireand the negative lead ofthe volt meter to theground point on themanifold. Activate thecontroller in the UPdirection and check thevoltage.

Disconnect the wirefrom the platform updirectional valve coil onthe function manifold(item AG or BG) andcheck the resistance.See Repair Section.

0V

Repair open in the WHA6-up coil wire from theplatform up directionalvalve coil (item AG orBG) to the ECM U5 (seeRepair Section) ORreplace U5 OR consultthe Genie IndustriesService Department.

20V or more0 orinfiniteohms

18-20 ohms

Replace the platform updirectional valve coil(item AG or BG).

Repair or replace theplatform up directionalvalve cartridge (item AGor BG) OR consult theGenie Industries ServiceDepartment.

Install a 0 to 5000 PSI(345 bar) pressuregauge at the quickdisconnect coupling(item AA or BA) on thefunction manifold andactivate the platform upfunction.

3000PSI ormore

less than3000 PSI

Adjust the system reliefvalve (item AC or BC)OR repair or replace theplatform lift cylinder ORthe platform loweringvalve (item D) may bestuck open OR thefunction manifold couldhave an internal defect.Consult the GenieIndustries ServiceDepartment.

Are there mechanicalrestrictions keepingplatform up functionfrom moving?

Remove the mechanicalrestrictions keepingplatform up functionfrom moving.

Repair or replace theplatform lift cylinder ORconsult the GenieIndustries ServiceDepartment.

yes

no

REV A



Chart 7

Platform DownFunctionInoperative




With the key switchturned to platformcontrols and bothEmergency Stop buttonspulled out to the onposition and the platformraised slightly,From serial number17408 to 21262: pressand hold the lift functionenable button andactivate the controller inthe DOWN direction andcheck to see if the errorindicator light is on.After serial number21262: press the liftfunction select buttonand activate thecontroller in the DOWNdirection and check tosee if the error indicatorlight is on.

light ison

light is not on

Label and disconnectthe wires from the coilon the platform loweringvalve (item D) at theplatform lift cylinder andcheck the resistance(See Repair Section).

0V

Repair open in the WHB6-down coil wire fromthe platform loweringvalve coil (item D) to theECM U5 OR repair openin the brown ground wirecircuit from the coil tothe battery module trayOR replace U5 ORconsult the GenieIndustries ServiceDepartment.

20V or more

0 orinfiniteohms

23 to 25 ohms

Replace platformlowering valve coil(item D).

Repair or replace theplatform lowering valvecartridge (item D).

Are there mechanicalrestrictions keeping theplatform from lowering?

With the platform raisedand the safety armremoved, pull themanual platformlowering handle at theground controls.

platform doesnot lower

platformlowers

With the platform raisedand the safety arminstalled, connect theleads of a volt meter tothe wires on the platformlowering coil (item D) onthe cylinder withoutremoving the wires.From serial number17408 to 21262:Press and hold the liftfunction enable buttonand activate thecontroller in the DOWNdirection and check thevoltage.After serial number21262: Press the liftfunction select buttonand activate thecontroller in the DOWNdirection and check thevoltage.

Repair or replace theplatform lowering valvecartridge (item D) ORrepair or replace the liftcylinder OR replace theorifice or orifice washer(item E) OR consult theGenie Industries ServiceDepartment.

Remove mechanicalrestrictions keeping theplatform from lowering.

yes

no

Replace the platformcontrols OR replace theECM U5 OR consult theGenie Industries ServiceDepartment.

REV A




REV A



Chart 8

Steer LeftFunctionInoperative




no

With the key switchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition,From serial number17408 to 21262:activate the functionenable switch andactivate the steer rockerswitch in the LEFTdirection and check tosee if the error indicatorlight at the platformcontrols is on.After serial number21262: press the drivefunction select buttonand activate the functionenable switch andactivate the steer rockerswitch in the LEFTdirection and check tosee if the error indicatorlight at the platformcontrols is on.

light ison

light is not on

Disconnect the wiresfrom the coil on thesteer left directionalvalve on the functionmanifold (item AF or BI)and check theresistance of the valvecoil (See RepairSection).

0V

Repair open in the WHB7-left coil wire from thecoil on the steer leftdirectional valve (itemAF or BI) to the ECM U5OR repair open in thebrown ground wirecircuit from the coil tothe wire harness ORreplace U5 OR consultthe Genie IndustriesService Department.

20V or more

25 to 27ohms

0 or infiniteohms

Replace the steer leftdirectional valve coil(item AF or BI).

Repair or replace thesteer directional valvecartridge (item AF or BI)OR consult the GenieIndustries ServiceDepartment.

Activate the functionenable switch andactivate the steer leftfunction. Does the motorturn on?

Replace SW6.bad

yes


Check continuity of thesteer left/rightmicroswitch SW6 insidethe joystick controllerhandle JC1.

good

Repair or replace thewire circuit from SW6 tothe platform controlscircuit board U3 ORreplace U3 OR consultthe Genie IndustriesService Department.

Connect the positivelead from a volt meter tothe WH C7-rt coil wireterminal at the steerright directional valvecoil (item AF or BI)without disconnectingthe wire, and thenegative lead of the voltmeter to the brownground wire at the valvecoil. Activate the steerrocker switch in theRIGHT direction andcheck the voltage.

REV A



CHART 8


Install a 0 to 2000 psi(138 bar) pressuregauge at the quickdisconnect coupling onthe function manifoldand activate the steerleft function.

1500 PSI

less than1500 PSI

Repair or replace thesteer cylinder ORreplace the steer left/right valve cartridge(item AF or BI) OR thefunction manifold couldhave an internal defect.Consult the GenieIndustries ServiceDepartment.

Are there mechanicalrestrictions keeping thesteer left function frommoving?

Reset the steer reliefvalve pressure(item AE or BF)(See Repair Section).

less than1500 PSI

Remove the mechanicalrestrictions.

Repair or replace thesteer cylinder ORconsult the GenieIndustries ServiceDepartment.

yes

no

1500 PSI

Replace the steer reliefvalve (item AE or BF).

REV A



Steer RightFunctionInoperative




Chart 9

light is not on

With the key switchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition,From serial number17408 to 21262:activate the functionenable switch andactivate the steer rockerswitch in the RIGHTdirection and check tosee if the error indicatorlight at the platformcontrols is on.After serial number21262: press the drivefunction select buttonand activate the functionenable switch andactivate the steer rockerswitch in the RIGHTdirection and check tosee if the error indicatorlight at the platformcontrols is on.

light ison

Disconnect the wiresfrom the coil on thesteer right directionalvalve on the functionmanifold (item AF or BI)and check theresistance of the valvecoil (See RepairSection).

0V

Repair open in the WHC7-rt coil wire from thecoil on the steer rightdirectional valve (itemAF or BI) to the ECM U5OR repair open in thebrown ground wirecircuit from the coil tothe wire harness ORreplace U5 OR consultthe Genie IndustriesService Department.

20V or more

25 to 27ohms

Repair or replace thesteer directional valvecartridge (item AF or BI)OR consult the GenieIndustries ServiceDepartment.

Activate the functionenable switch andactivate the steer rightfunction. Does the motorturn on?

Replace SW6.

yes


no

badCheck continuity of thesteer left/rightmicroswitch SW6 insidethe joystick controllerhandle JC1.

good

Repair or replace thewire circuit from SW6 tothe platform controlscircuit board U3 ORreplace U3 OR consultthe Genie IndustriesService Department.

Replace the steer rightdirectional valve coil(item AF or BI).

Connect the positivelead from a volt meter tothe WH B7-left coil wireterminal at the steer leftdirectional valve coil(item AF or BI) withoutdisconnecting the wire,and the negative lead ofthe volt meter to thebrown ground wire atthe valve coil. Activatethe steer rocker switchin the LEFT direction andcheck the voltage.

0 or infiniteohms

REV A



CHART 9


Install a 0 to 2000 psi(138 bar) pressuregauge at the quickdisconnect coupling onthe function manifoldand activate the steerright function.

Repair or replace thesteer cylinder ORreplace the steer left/right valve cartridge(item AF or BI) OR thefunction manifold couldhave an internal defect.Consult the GenieIndustries ServiceDepartment.

Are there mechanicalrestrictions keeping thesteer left function frommoving?

Reset the steer reliefvalve pressure(item AE or BF)(See Repair Section).

Remove the mechanicalrestrictions.

Repair or replace thesteer cylinder ORconsult the GenieIndustries ServiceDepartment.

yes

no

Replace the steer reliefvalve (item AE or BF).

1500 PSI

less than1500 PSI

less than1500 PSI

1500 PSI

REV A



All DriveFunctionsInoperative, AllOtherFunctionsOperateNormally




Chart 10

With the key switchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition, activate driveforward and drivereverse functions.Check to see if the errorindicator light is on atthe platform controls.

light ison

light isnot on

Reset the ECM U5 bypushing in EmergencyStop button P2 to theOFF position. Pull theEmergency Stop buttonP2 up to the ON position.Check to see if the errorindicator light is on atthe platform controls.

Refer to the chart(s) thatare related to the errorcode that is displayedon U5 OR consult theGenie Industries ServiceDepartment.

Replace the ECM U5OR consult the GenieIndustries ServiceDepartment.

light ison

light isnot on

Replace the platformcontrols OR consult theGenie Industries ServiceDepartment.

Replace the platformcontrols with knownoperating platformcontrols. Activate thedrive function. Does thedrive function operate?

Replace the platformcontrols.

yes

no

REV A



Brake ReleaseFunctionInoperative




Chart 10A

wheelsturn

Turn the brake releasevalve (item A) clockwiseall the way and try torotate the wheels.

Chock the wheels at thesteer end of themachine. Jack the non-steer end of themachine upapproximately 4 inches(10 cm) and place jackstands under themachine for support.Turn the brake releaseknob (item A)counterclockwise all theway and pump the handpump (item C) fully13-15 times or untilmuch resistance is felt.Turn each wheel byhand. Each wheelshould turn freelywithout much effort.

wheelsturn

wheelsdo notturn

Rebuild or replace thebrakes OR replace thebrake release valve(item A) OR consult theGenie Industries ServiceDepartment.

Attempt to drive themachine in eitherdirection and have anassistant try to rotate thenon steer wheels. Thiswill require 2 people.

wheelsturn

If machine still does notdrive at full speed withthe platform in thestowed position, replacethe platform controls ORreplace the platformcontrols circuit board U3OR replace the ECM U5OR consult the GenieIndustries ServiceDepartment.

wheelsdo notturn

Plumb a 0 to 500 psi (35bar) gauge into the hosefrom the functionmanifold to the brake.Attempt to drive themachine in eitherdirection and read thepressure on the gauge.

less than200 psi

Pressure is good.Replace the brakes ORconsult the GenieIndustries ServiceDepartment.

200 to300 psi

Replace the shuttlevalve (item B) ORreplace the brakerelease valve (item A)OR the functionmanifold or brakerelease manifold mayhave an internal defectOR consult the GenieIndustries ServiceDepartment.

Plumb a 0 to 500 psi (35bar) gauge into the hosefrom the functionmanifold to the brake.Attempt to drive themachine in eitherdirection and read thepressure on the gauge.

less than200 psi

Pressure is good.Replace the brakes ORconsult the GenieIndustries ServiceDepartment.

200 to300 psi

Replace the shuttlevalve (item B) ORreplace the brakerelease valve (item A)OR the functionmanifold or brakerelease manifold mayhave an internal defectOR consult the GenieIndustries ServiceDepartment.

wheelsdo notturn

REV A



Drive ForwardFunctionInoperative




Chart 11

With the key switchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition, activate drivecontroller in the forwarddirection and check tosee if the error indicatorlight at the platformcontrols is on.

light ison

light is not on

Connect the positivelead from a volt meter tothe drive forwarddirectional valve coil(item AI or BJ) wireterminal withoutdisconnecting the wire,and the negative lead ofthe volt meter to thebrown ground wire onthe coil. Activate drive inthe forward directionand check the voltage.

Disconnect the wiresfrom the drive forwarddirectional valve coil(item AI or BJ) andcheck resistance of thecoil. See Repair Section.

0V

Repair open in the WHC6-fwd coil wire fromthe drive forwarddirectional valve coil(item AI or BJ) to theECM U5 OR repair openin the brown ground wirecircuit from the coil tothe wire harness ORreplace U5 OR consultthe Genie IndustriesService Department.

20V or more

0 orinfiniteohms

18 to 20 ohms

Replace the driveforward directional valvecoil (item AI or BJ).

Repair or replace thedrive forward directionalvalve (item AI or BJ)OR consult the GenieIndustries ServiceDepartment.

Check the connection atthe ECM U5 OR replacethe drive forward/reverse valve cartridge(item AI or BJ) ORconsult the GenieIndustries ServiceDepartment.

REV A



Chart 12

Drive ReverseFunctionInoperative




With the key switchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition, activate drivecontroller in the reversedirection and check tosee if the error indicatorlight at the platformcontrols is on.

light ison

light is not on

Connect the positivelead from a volt meter tothe drive reversedirectional valve coil(item AI or BJ) wireterminal withoutdisconnecting the wire,and the negative lead ofthe volt meter to thebrown ground wire onthe coil. Activate drive inthe REVERSE directionand check the voltage.

Disconnect the wiresfrom the drive reversedirectional valve coil(item AI or BJ) andcheck resistance of thecoil. See Repair Section.

0V

Repair open in the WHA7-rev coil wire from thedrive reverse directionalvalve coil (item AI or BJ)to the ECM U5 ORrepair open in the brownground wire circuit fromthe coil to the wireharness OR replace U5OR consult the GenieIndustries ServiceDepartment.

20V or more

0 orinfiniteohms

18 to 20 ohms

Replace the drivereverse directional valvecoil (item AI or BJ).

Repair or replace thedrive reverse directionalvalve (item AI or BJ)OR consult the GenieIndustries ServiceDepartment.

Check the connection atthe ECM U5 OR replacethe drive forward/reverse valve cartridge(item AI or BJ) ORconsult the GenieIndustries ServiceDepartment.

REV A



Machine WillNot Drive AtFull Speed



Chart 13

With the key switchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition and the platformin the stowed position,drive the machine ineither direction. Is theerror indicator light on atthe platform controls?

light isnot on

Check voltage at theWH 39C-pothole swwire at pothole limitswitch LS7.

lightis on

0V

20V or more

Raise the platformapproximately 3 feet(0.9 m) and drive themachine.Does the machine driveat a reduced speed?

Repair open in the WH39C-pothole sw wirefrom LS7 to the multi-function alarm H5.

Check voltage at theWH 21B-pothole sw wireon the input side of limitswitch LS8.

Repair open in the WH21B-pothole jumper wirefrom the output side ofLS7 to the input side ofLS8.

Check voltage on theoutput side of LS8.

Adjust LS8 so thepothole arm activatesthe switch OR replacethe limit switch contactOR replace the LS8.

no

yes

Raise the platform tomore than 6 feet (1.8 m)and drive the machine. Ifthe machine does notdrive and an alarmsounds, the machine isoperating normally.Check the potholeguards for obstructionsOR test the potholeguard limit switches(See Repair section).


Raise the platformapproximately 3 feet(0.9 m) and check thevoltage at the outputside of LS7.

Adjust LS7 so thepothole arm activatesthe switch OR replacethe limit switch contactOR replace LS7.

20V or more

0V

0V

20V or more

0V

20V or more

Repair open in the WHB10-pothole sw wirefrom the output side ofLS8 to the ECM U5 ORreplace U5 OR see Chart10A, Brake ReleaseFunction Inoperative.

REV A



Chart 14

MachineDrives At FullSpeed WithPlatformRaised



light isnot on

lightis on

See Chart 13 ORremove the obstructionfrom the pothole guardOR consult the GenieIndustries ServiceDepartment.

Check limit switch LS7and LS8 for correctadjustment.

With the key switchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition and the platformin the stowed position,drive the machine ineither direction. Is theerror indicator light on atthe platform controls?

Check the controlleradjustments (SeeRepair Section) ORreplace the platformcontrols OR replace theECM U5 OR consult theGenie Industries ServiceDepartment.Adjust LS7 or LS8 (See

Repair Section) ORrepair or replace limitswitch wire circuit.

good

bad

REV A



Limit SwitchFunctionInoperative


Be sure the limitswitches are clear ofdebris.

Be sure the potholeguards are deploying.


Chart 15

20V ormore

0V

Adjust the pothole limitswitch LS7 OR adjustpothole limit switch LS8.

With the key switchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition and the platformin the stowed position,check voltage on theWH B10 pothole sw wireat the ECM U5.

20V or more

0V Check voltage on theother terminal at LS6.

With the platform raisedto 6 feet (1.8 m), checkfor 20V or more on oneside of LS8.

0V

0V Adjust LS6 OR replacethe LS6 contacts.

20V or more

Repair or replace the44D wire from alarm H5to LS6.

Repair or replace thewire circuit between LS7and the positive terminalat alarm H5

20V or more

Repair or replace thewire circuit betweenterminal B10 at ECM U5and LS8 OR replace U5

Check voltage at downlimit switch LS6. Is there20V or more on one sideof LS6?

Check LS8 for correctadjustment.

Adjust LS8.

good

bad

Check for 20V or moreon both sides of LS7.

0V

20V or more

Replace the LS8contacts OR repair orreplace the wire circuitbetween LS8 and LS7OR replace the LS7contacts.

Check LS7 for correctadjustment.

Adjust LS7.

good

bad

REV A




REV A



Chart 16

Fault Code 02 -ECM / PlatformCommunicationError



Open the platformcontrol box. With the keyswitch turned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition, check forvoltage on the positiveterminal 1 of theEmergency Stop buttonP2 at the platformcontrols.

0V

20V or more

Continued onpage 28.

0V

20V or more

Before serial number25142: Check forvoltage on terminal B2at the ECM U5.After serial number25141: Check forvoltage on terminal 30 atrelay CR48.

Disconnect the controlcable quick disconnectplug at the ECM andcheck for voltage atterminal C of the quickdisconnect plug.

20V or more

Connect the controlcable quick disconnectplug at the ECM.Disconnect the controlcable quick disconnectplug at the platform andcheck for voltage atterminal C of the quickdisconnect plug.

0VRepair or replace thequick disconnect plugOR replace the harnesspigtail.

0VRepair or replace thequick disconnect plugOR replace the controlcable.

20V or more

Replace the coil cordassembly OR replacethe platform controls.

20V or more

With the negative lead ofan ohmmeter connectedto the negative terminalof the battery B5, checkfor voltage at terminal 1of the voltage regulatoron the platform controlscircuit board U3.

0V Repair or replace thewire between P2 andU3.

Before serial number25142: Replace U5.After serial number25141: TroubleshootCR48.

REV A



CHART 16

a Platform controls circuit boardb voltage regulator terminal 2c voltage regulator terminal 1d circuit board voltage regulatore voltage regulator terminal 3

REV A



CHART 16

Continued frompage 26.

5V

Check for voltage atterminal 3 of the voltageregulator on U3.

0V Replace U3.

Check for continuity inthe blue data (+) linefrom pin D of theplatform controls quickdisconnect to terminalB1 at U5.

no continuity

continuity

Replace the coil cordassembly OR replacethe control cable fromthe platform to U5.

Check for continuity inthe green data (-) line orthe yellow data (-) linefrom pin E of theplatform controls quickdisconnect to terminalC1 at U5.

continuity Consult the GenieIndustries ServiceDepartment.

no continuity

Replace the coil cordassembly OR replacethe control cable fromthe platform to U5.

REV B



Chart 17

Fault Code 59 -Parallel/SeriesCoil Fault




With the key switchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition and themachine on incline LEDactivated, check forvoltage on the positiveterminal at the Drivespeed select valve coil(item AJ or BI or CJ).

0VCheck for continuity inthe WH C-8 prll coil wirefrom the ECM U5 to thedrive speed select coil(item AJ or BI or CJ).

20V or more

Check for continuity inthe brown ground wirecircuit from the drivespeed select valve coil(item AJ or BI or CJ) toground.

nocontinuity

0 or infiniteohms

Repair or replace theground wire circuit fromthe drive speed selectcoil to ground.


Disconnect the wiresfrom the drive speedselect valve coil (item AJor BI or CJ) and checkresistance of the coil.See Repair Section.

18 to 20ohms

Replace the drive speedselect valve coil (item AJor BI or CJ).

continuity

Repair or replace theWH C-8 prll coil wirefrom the ECM U5 to thedrive speed select coil.

Replace U5 OR consultthe Genie IndustriesService Department.

nocontinuity

continuity

REV A




Section 6 • SchematicsJune 2004


Schematics

Observe and Obey:

Troubleshooting and repair procedures shall becompleted by a person trained and qualified onthe repair of this machine.



Before Troubleshooting:

Read, understand and obey the safety rulesand operating instructions in the appropriateoperator's manual on your machine.

Be sure that all necessary tools and testequipment are available and ready for use.

About This SectionThere are two groups of schematics in this section.An illustration legend precedes each group ofdrawings.

Electrical Schematics


Hydraulic Schematics


General Repair Process

Malfunctiondiscovered

Identifysymptoms

Troubleshoot

Performrepair

Return toservice problem

solved

problemstill exists

Inspectand test

REV B

Section 6 • Schematics June 2004


Control Relay Layout -GS-2032 (ANSI, CSA and Australia models)

a electronic control module (ECM) U5b CR48 power relay to U5 (not used

before serial number 25142)c hydraulic tankd motor controller U6e function manifoldf hydraulic pumpg 24V DC motorh automotive-style horn H2 (option)i multifunction alarm H5j CR5 horn relayk tilt level sensor S7

d

-LHA-

h

e f

j k

g

i

a cb

REV B



Control Relay Layout -GS-2032 (CE models) and

GS-2632 (all models)

h j k

e f

i

a b c d

g

a batteries B5b electronic control module (ECM) U5c CR48 power relay to U5d ECM box lide module tray rotary latchf battery quick disconnect QD1g 275A fuse F6h automotive-style horn H2 (option)i multifunction alarm H5j CR5 horn relayk tilt level sensor S7

REV B



ECM Pin-out Legend

A 12

B

C

1

1

1

12

1212

ECM PIN-OUT LEGEND From serial number 21065 to 25141

Item Description A1 Flashing beacon A2 Platform ground from joystick

(White wire at platform) A3 Spare A4 Emergency Stop from platform

(Red wire at platform) A5 Level sensor power A6 Platform up valve coil A7 Drive reverse valve coil A8 Motor controller terminal 1 A9 Motor controller terminal 3 A10 Overload sensor A11 Key switch to platform A12 Platform down from ground controls B1 Platform data link +

(Blue wire at platform) B2 Emergency Stop to platform

(Black wire at platform) B3 Ground for electronic control module B4 Spare B5 Spare B6 Platform down valve coil B7 Steer left valve coil B8 Automotive-style horn (option) B9 Multifunction alarm B10 Pothole limit switch B11 Spare B12 Platform up from ground controls C1 Platform data link —

(Yellow wire at platform) C2 Emergency Stop at ground controls (main power) C3 Spare C4 Spare C5 Spare C6 Drive forward valve coil C7 Steer right valve coil C8 Parallel coil C9 Brake release valve coil C10 Spare C11 Level sensor signal C12 Down limit switch

ECM PIN-OUT LEGEND From serial number 17408 to 21064

Item Description A1 Spare A2 Platform ground from joystick

(White wire at platform) A3 Spare A4 Emergency Stop from platform

(Red wire at platform) A5 Level sensor power A6 Platform up valve coil A7 Drive reverse valve coil A8 Motor controller terminal 1 A9 Motor controller terminal 3 A10 Overload sensor A11 Key switch to platform A12 Platform down at ground controls B1 Platform data link +

(Blue wire at platform) B2 Emergency Stop to platform

(Black wire at platform) B3 Ground for electronic control module B4 Spare B5 Spare B6 Platform down valve coil B7 Steer left valve coil B8 Automotive-style horn (option) B9 Multifunction alarm B10 Pothole limit switch B11 Spare B12 Platform up at ground controls C1 Platform data link —

(yellow wire at platform) C2 Emergency Stop at ground controls (main power) C3 Spare C4 Spare C5 Spare C6 Drive forward valve coil C7 Steer right valve coil C8 Parallel coil C9 Brake release valve coil C10 Spare C11 Level sensor signal C12 Down limit switch

REV B



ECM PIN-OUT LEGEND

A 12

B

C

1

1

1

12

1212

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8cT\� 3TbRaX_cX^]�1!� 6\QcXY^W�RUQS_^�

1"� @\QdV_b]�Wb_e^T�Vb_]�Z_icdYS[��2\eU�gYbU�Qd�`\QdV_b]��

1#� C`QbU�

1$� 5]UbWU^Si�Cd_`�Vb_]�`\QdV_b]��GXYdU�gYbU�Qd�`\QdV_b]��

1%� <UfU\�cU^c_b�`_gUb�

1&� @\QdV_b]�e`�fQ\fU�S_Y\�

1'� 4bYfU�bUfUbcU�fQ\fU�S_Y\�

1(� =_d_b�S_^db_\\Ub�dUb]Y^Q\�!�

1)� =_d_b�S_^db_\\Ub�dUb]Y^Q\�#�

1! � ?fUb\_QT�cU^c_b�

1!!� ;Ui�cgYdSX�d_�`\QdV_b]�

1!"� @\QdV_b]�T_g^�Vb_]�Wb_e^T�S_^db_\c�

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2!� @\QdV_b]�TQdQ�\Y^[��2\QS[�gYbU�Qd�`\QdV_b]��

2"� C`QbU�

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2$� C`QbU�

2%� C`QbU�

2&� @\QdV_b]�T_g^�fQ\fU�S_Y\�

2'� CdUUb�\UVd�fQ\fU�S_Y\�

2(� 1ed_]_dYfU�cdi\U�X_b^��_`dY_^��

2)� =e\dYVe^SdY_^�Q\Qb]�

2! � @_dX_\U�\Y]Yd�cgYdSX�

2!!� C`QbU�

2!"� @\QdV_b]�e`�Vb_]�Wb_e^T�S_^db_\c�

� �

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3#� C`QbU�

3$� C`QbU�

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3(� @QbQ\\U\�S_Y\�

3)� 2bQ[U�bU\UQcU�fQ\fU�S_Y\�

3! � C`QbU�

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1!!� ;Ui�cgYdSX�d_�`\QdV_b]�

1!"� @\QdV_b]�T_g^�Vb_]�Wb_e^T�S_^db_\c�

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2!� @\QdV_b]�TQdQ�\Y^[��2\QS[�gYbU�Qd�`\QdV_b]��

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2#� 7b_e^T�V_b�U\USdb_^YS�S_^db_\�]_Te\U�

2$� C`QbU�

2%� C`QbU�

2&� @\QdV_b]�T_g^�fQ\fU�S_Y\�

2'� CdUUb�\UVd�fQ\fU�S_Y\�

2(� 1ed_]_dYfU�cdi\U�X_b^��_`dY_^��

2)� =e\dYVe^SdY_^�Q\Qb]�

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2!"� @\QdV_b]�e`�Vb_]�Wb_e^T�S_^db_\c�

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3!� @\QdV_b]�TQdQ�\Y^[�°��IU\\_g�gYbU�Qd�`\QdV_b]��

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3!!� <UfU\�cU^c_b�cYW^Q\�

3!"� 4_g^�\Y]Yd�cgYdSX�

REV B



WIRE COLOR LEGEND

Color Description BL Blue BK Black BN Brown GN Green GY Gray OR Orange PP Purple RD Red WH White YL Yellow

ABBREVIATION LEGEND Item Description H1 Alarm JC1 Joystick controller P2 Emergency Stop button at platform controls SW25 DIP switch U3 Platform controls circuit board

Platform Controls Wiring Diagram(models with potentiometer-equipped joystick)


JC1JOYSTICK

CONTROLLER

H1ALARM

21

BK

RD

RD

BK

RD

RD YL

OR

BK

BL

WH

TOCOILCORDASSEMBLY

WH

BN

WH/BK

WH/RD

WH/BL

SW25DIP SWITCH

OR

PP

U3PLATFORMCONTROLS

CIRCUITBOARD

12

34

56

78

ON

AL

CO

AD

FO

8S

OE

REV A



Platform Controls Wiring Diagram(models with hall-effect joystick)

8*3&�$0-03�

-&(&/%�

$PMPS� %FTDSJQUJPO�%/� %OXH�

%.� %ODFN�

%1� %URZQ�

*1� *UHHQ�

*<� *UD\�

25� 2UDQJH�

33� 3XUSOH�

5'� 5HG�

:+� :KLWH�

</� <HOORZ�

011A4E80C8>=�;464=3�

8cT\� 3TbRaX_cX^]�

8!� 1\Qb]�

:3!� :_icdYS[�S_^db_\\Ub�

@"� 5]UbWU^Si�Cd_`�Redd_^�Qd�`\QdV_b]�S_^db_\c�

CG"%� 49@�cgYdSX�

E#� @\QdV_b]�S_^db_\c�SYbSeYd�R_QbT�

P2EMERGENCY STOP

BUTTON

H1ALARM

BL

WH

OR

RD

BK

TO

COIL

CORD

ASSEMBLY

RD

RD

BK

SW25DIP SWITCH

U3PLATFORM CONTROLS

CIRCUIT BOARD

14.25.

2

1 NC

19

F2

34

56

78

ON

AL

CO

AD

F0

85

P/N

00

00

00

Da

te0

00

0

S/N

Al0

00

00

00

0

BN

YL BL BKWH RD

JC1JOYSTICK

CONTROLLER

RD

BK

OR

WH

GN

PP

BL

GY

BN

REV B



Ground Controls Wiring Diagram

(from serial number 49012 to 59999)



(before serial number 21065)

-

G6

+

NC

P1

N.O.N.O.

TS66CB2

N.O. N.O.

KS1(PLATFORM)

KS1(GROUND) 25F

29F41F

24FA12

(UP)

B12

(DOWN)

76F

53F 51F

45F

50F 49F

48F

A11

52F

A11 KEY SWITCH

G6

NC

P1

NONO

TS66CB2

NO NO

KS1(PLATFORM)

KS1(GROUND) 25F

3

2

129F

41F

24FA12

(UP)

B12

(DOWN)

76F

53F 51F

54F

45F

50F 49F

48F

A11

52F

A11 KEY SWITCH

NC

P1

NONO

TS66CB2

NO NO

KS1(PLATFORM)

KS1(GROUND)

A12

(UP)

B12

(DOWN)

76F

-

G6+25F

29F41F

53F 51F

45F

50F 49F

23F

A11

52F

A11 KEY SWITCH

42F

24F

-

G6

+

NC

P1TS66CB2

25F

29F41F

24FA12

(UP)

B12

(DOWN) 53F 51F

A11 KEY SWITCH

KS1 51F

76F

A11

B

B1

3 1

4 2

52F

REV B



Level Sensor Box Wiring Diagram

(after serial number 21064)

(before serial number 21065)

ABBREVIATION LEGENDItem DescriptionH5 Multi-function alarmLS6 Down limit switchS7 Level sensor

WIRE COLOR LEGENDColor DescriptionBK BlackRD RedWH White

S7

S7

N.C.

N.C.

N.O.

N.O.

LS6

LS6

H5

H5

-

-

+

+

B11

B11

B9

B9

BK

BK

WH

WH

RD

RD

44D

44D

44D

44D

23F

75D23D

C12

C12

C11

C11

70D

70D

27D

27D

29F75D

29F

A5

A5

39C

39C

REV B



Electrical Symbols Legend

Wire withdescription

Circuits crossingno connection

Diode

Connectionno terminal

Connector

Hour meterG6

Flashing beaconsFB1

Pressure switchnormally open

Limit switch

Switch

Toggle switch

Emergency Stop buttonNormally closed

Circuit breaker

Relay

Fuse

Motor controller

Motor

Battery charger

6V battery

Horn or alarm

Key switch

Level sensor

Solenoid valve

Solenoid valvewith diode

Joystick controller

LED

Inductor,noise suppression

-

+

U6

U9

CB2

13

2

FB

PLATFORMCONTROL

T

B

B

T

GROUNDCONTROL

KS1KEY SWITCH

A8

-MO

TO

RC

ON

TR

.E

NA

BL

E

N.C.H.O.N.C.

B+

A2

M- B-

3

1

87A 85

8630

87

M5

N.O.

S7LEVEL

SENSOR

OR

BR

PP

WH/BK

5KPOTENTIOMETER

JC1 JOYSTICK CONTROLLER

SW6STEER LEFT/ RIGHT

LE

FT

RIG

HTSW5

FUNCTIONENABLE

WH/YL

1

2

3

4

5

6

7

8

A B C D E F G H I J K L M N

Electrical Schematic(from serial number 17408 to 21064)

REV B



CB27A

CIRCUITBREAKER

P1EMERGENCYSTOP

A1

2-U

P/D

WN

SW

DW

N

B1

2-U

P/D

WN

SW

UP

C2

-EM

ER

GS

TO

P

A11

-KE

YS

WIT

CH

A9

-CU

RT

IST

ER

M3

B8

-OP

TS

ER

VIC

EH

OR

N

CR5HORN RELAY(H2 OPTION)

LS7POTHOLE

GUARDSWITCH

LS8POTHOLE

GUARDSWITCH

TS66PLATFORM UP/DOWN

SWITCH

H5MULTI-

FUNCTIONALARM

H2AUTOMOTIVE-STYLE

HORN(OPTION)

B8

OUT OUT OUT IN IN IN IN IN

B3 C9 C7 B7 A7 C6 B6

OUT

A12 B12 B10 A11

OUT OUT OUT OUT OUT OUT OUT

B9A8 A9 C2

C9

-BR

KC

OIL

C7

-RT

CO

IL

B7

-LE

FT

CO

IL

A7

-RE

VC

OIL

C6

-FW

DC

OIL

B6

-DW

NC

OIL

A6

-UP

CO

IL

GN

D

Y2BRAKE

RELEASE

Y3STEERRIGHT

Y4STEER

LEFT

Y5DRIVE

REVERSE

Y6DRIVE

FORWARD

Y7PLATFORM

DOWN

Y8PLATFORM

UP

A6

OUT

GND

B9

-MU

LT

IFU

NC

TA

LM

B1

0-P

OT

HO

LE

SW

FB

(OPTION)

FLASHINGBEACONS

FB

FB

G6HOUR

METER(OPTION)

C8

OUT

C8

-PR

LL

CO

IL

Y1PARALLEL

DA

TA

LIN

K-

DA

TA

LIN

K+

GN

DF

RO

MJO

YS

TIC

K

ES

TO

PT

OJO

YS

TIC

K

IN IN INOUT

ES

TO

PF

RO

MJO

YS

TIC

K

IN

A4 A2 B1 C1B2

PLATFORMCONTROL

T

B

B

T

GROUNDCONTROL

KS1KEY SWITCH

C11

-LV

LS

NS

R-W

HT

A5

-LV

LS

NS

R-R

ED

BR

RD

WH

IN OUT

C11 A5

LS6DOWN

LIMIT SWITCH

IN

C12

C1

2-D

WN

LIM

IT

IN

A10

OV

ER

LO

AD

SE

NS

OR

OP

TIO

N

PS2PLATFORMOVERLOADPRESSURE

SWITCH(OPTION)

U5ELECTRONIC CONTROL MODULE

A8

-MO

TO

RC

ON

TR

.E

NA

BL

E

39C

21B

U2747 mH

INDUCTOR,NOISE

SUPPRESSION

U6 MOTOR

CONTROLLER

AWH A

CWH C

BBL B

DBK D

EOR E

8587

8630

+

-

N.C.H.O.N.C.

N.C.H.O.

N.O.

S7LEVEL

SENSOR

UP

LIM

IT

IN

B11

F6275A FUSE

U6 MOTOR

CONTROLLER

B+

3A2

M-T2

B- 1

M5MOTOR

QD1 +( )

A1

D1

M5

B54-6V

BATTERY

GND

U13DC/AC INVERTER(OPTION)

QD1 -( )

+

-

-

+

+-

-+

F850A FUSE

AC INPUT

1

2

3

4

5

6

7

8

N M L K J I H G F E D C B A


REV B


June 2004 Section 6 • Schematics

ABBREVIATION LEGENDItem Description

BatteryB B5 = Main power B7 = Auxiliary down (GS-3246 only)ButtonBN BN5 = Horn BN6 = High torque BN9 = Lift enable BN23 = Auxiliary down (GS-3246 only)

CB2 Circuit breaker, 7AControl relayCR CR5 = Horn (with H2 option) CR48 = Power to U5

D7 Voltage regulatorFuseF F6 = 275A F8 = 50A (with U13 option)

FB Flashing beacons (option)GaugeG G6 = Hour meter G7 = Battery charge indicator

GND GroundHorn or alarmH H1 = Horn H2 = Automotive-style horn (option) H5 = Multifunction alarm

JC1 Joystick controllerKS1 Key switch

LED or lightL L16 = Lift L17 = Drive L19 = Power L21 = High Torque L25 = FaultLimit switchLS LS2 = Platform up (GS-3246 only) LS6 = Platform down LS7 = Pothole LS8 = Pothole

M5 Hydraulic power unit

ABBREVIATION LEGENDItem DescriptionN.C. Normally closedN.C.H.O. Normally closed held openN.O. Normally open

Power switchP P1 = Emergency Stop button at ground controls P2 = Emergency Stop button at platform controls

PS2 Platform overload pressure switch (option)QD Quick disconnect

QD1 = Battery quick disconnect QD3 = Control cable to ground QD4 = Control cable to platformResistorR R15 = 5000 ohm potentiometer R21 = 75 ohm resistor

S7 Tilt level sensorSwitchSW SW5 = Function enable SW6 = Steer left/right SW25 = DIP switch

TS66 Platform up/down toggle switchElectronic componentU U3 = Encoder printed circuit board U5 = Electronic control module U6 = Motor controller U9 = Battery charger U13 = Voltage inverter (option) U27 = 0.034 ohm inductor, noise suppressionValve coilY Y1 = Parallel Y1A = High speed bypass (option) Y2 = Brake release Y3 = Steer right Y4 = Steer left Y5 = Drive reverse Y6 = Drive forward Y7 = Platform down Y8 = Platform up Y9 = Platform down (GS-3246 only) Y10 = Auxiliary down (GS-3246 only) Y11 = Auxiliary down (GS-3246 only)

WIRE COLOR LEGENDColor Description Color Description

BL Blue RD RedBK Black WH WhiteBN Brown YL YellowGN Green WH/BL White/BlueGY Gray WH/BK White/BlackOR Orange WH/RD White/RedPP Purple WH/YL White/Yellow

1

2

3

4

8

5

7

6

PLATFORM CONTROLLER

SW25DIP SWITCHES

HORN BN5

DRIVE ENABLE BN8

HIGH TORQUE BN6

U3PLATFORM CONTROLSPRINTED CIRCUIT BOARD

PIN1

PIN2

PIN3

PIN8

PIN10

PIN9

LIFT ENABLE BN9PIN4

POWER LED L19

DRIVE LED L17

LIFT LED L16

POUT4

POUT2

POUT3

FAULT LED L25

POUT5

POUT6

POUT7

POUT9

POUT8

POUT10

HIGH TORQUE LED L21

POUT1

BATTERY LEVEL 1

BATTERY LEVEL 2

BATTERY LEVEL 3

BATTERY LEVEL 4

BATTERY LEVEL 5

G7

PLATFORM CONTROLSMEMBRANE DECAL PANEL

H1 ALARM

POUT11

PIN11

RD+

-BK

OR

BR

PP

WH/BK

WH/BL

BK

WH/RD

WH

PIO2

PIO3

PIO5

PIO4

DATA LINK (LOW)

DATA LINK (HIGH)

GROUND

POWER TO GROUND CONTROLS

POWER TO PLATFORM CONTROLSBK

AA RD

CC

WHBB

BLDD

ORYL

EE

5V DC24V DC

P2EMERGENCY STOP

BK

RD

D7VOLTAGE

REGULATOR

QD3


SW6STEER

LE

FT

RIG

HTSW5

FUNCTIONENABLE

WH/YL

R155000 OHMPOTENTIOMETER

Electrical Schematic (from serial number 17408 to 21064)


1

2

3

4

5

6

7

8



REV B



P1EMERGENCYSTOP

DA

TA

LIN

K-

DA

TA

LIN

K+

GN

DF

RO

MJO

YS

TIC

K

LS6DOWN

LIMIT SWITCH

IN IN IN IN

A6

C12 A2 B1 C1

OUT

A6

-UP

CO

IL

C1

2-D

WN

LIM

IT

IN

A10

OV

ER

LO

AD

SE

NS

OR

OP

TIO

N

LS7POTHOLE

GUARDSWITCH

LS8POTHOLE

GUARDSWITCH

IN

B10

B1

0-P

OT

HO

LE

SW

A11

-KE

YS

WIT

CH

IN

A11

A1

2-U

P/D

WN

SW

DW

N

B1

2-U

P/D

WN

SW

UP

C2

-EM

ER

GS

TO

P

A9

-CU

RT

IST

ER

M3

B8

-OP

TS

ER

VIC

EH

OR

N

TS66UP/DOWN

SWITCH

B8

OUT OUT OUT IN IN IN

A12 B12A8 A9 C2

H5MULTI-

FUNCTIONALARM

OUT

B9

B9

-MU

LT

IFU

NC

TA

LM

CB27A

CIRCUITBREAKER PLATFORM

CONTROL

T

B

B

T

GROUNDCONTROL

KS1KEY SWITCH


Y8PLATFORM

UP

A8

-MO

TO

RC

ON

TR

.E

NA

BL

E

39C

21B


A1 OUT

H2

HORN(OPTION)

AUTOMOTIVE-STYLE

13

2G6HOUR

METER(OPTION)

ES

TO

PT

OJO

YS

TIC

K

OUT

ES

TO

PF

RO

MJO

YS

TIC

K

IN

A4B2

FB

FB

FB

(OPTION)

FLASHINGBEACONS

B3 C9 C7 B7 A7 C6 B6


C9

-BR

KC

OIL

C7

-RT

CO

IL

B7

-LE

FT

CO

IL

A7

-RE

VC

OIL

C6

-FW

DC

OIL

B6

-DW

NC

OIL

GN

D

Y2BRAKE

RELEASE

Y3STEERRIGHT

Y4STEER

LEFT

Y5DRIVE

REVERSE

Y6DRIVE

FORWARD

Y7PLATFORM

DOWN

C8

OUT

Y1PARALLEL

C8

-PR

LL

CO

IL

C11

-LV

LS

NS

R-W

HT

A5

-LV

LS

NS

R-R

ED

BR

RD

WH

IN OUT

C11 A5


SWITCH(OPTION)

U2747 mH

INDUCTOR,NOISE

SUPPRESSION

AWH A

CWH C

BBL B

DBK D

EOR E

8587

8630

+

-

N.C.H.O.N.C.

N.C.H.O.

N.O.

S7LEVEL

SENSOR

UP

LIM

IT

IN

B11

F6275A FUSE

U6 MOTOR

CONTROLLER

B+

3A2

M-T2

B- 1

M5MOTOR

QD1 +( )

A1

D1

M5

B54-6V

BATTERY

GND


QD1 -( )

+

-

-

+

+-

-+

F850A FUSE

AC INPUT

1

2

3

4

5

6

7

8



REV B




















1

2

3

4

8

5

7

6

PLATFORM CONTROLLER

SW25DIP SWITCHES

HORN BN5

DRIVE ENABLE BN8

HIGH TORQUE BN6


PIN1

PIN2

PIN3

PIN8

PIN10

PIN9

LIFT ENABLE BN9PIN4

POWER LED L19

DRIVE LED L17

LIFT LED L16

POUT4

POUT2

POUT3

FAULT LED L25

POUT5

POUT6

POUT7

POUT9

POUT8

POUT10

HIGH TORQUE LED L21

POUT1

BATTERY LEVEL 1

BATTERY LEVEL 2

BATTERY LEVEL 3

BATTERY LEVEL 4

BATTERY LEVEL 5

G7


H1 ALARM

POUT11

PIN11

RD+

-BK

OR

BR

PP

WH/BK

WH/BL

BK

WH/RD

WH

PIO2

PIO3

PIO5

PIO4

DATA LINK (LOW)

DATA LINK (HIGH)

GROUND



AA RD

CC

WHBB

BLDD

ORYL

EE

5V DC24V DC

P2EMERGENCY STOP

BK

RD

D7VOLTAGE

REGULATOR

QD3


SW6STEER

LE

FT

RIG

HTSW5

FUNCTIONENABLE

WH/YL


Electrical Schematic (from serial number 21065 to 25141)



1

2

3

4

5

6

7

8




REV B

DA

TA

LIN

K-

DA

TA

LIN

K+

GN

DF

RO

MJO

YS

TIC

K

ES

TO

PF

RO

MJO

YS

TIC

K

EM

ER

GS

TO

P

LS6DOWN

LIMITSWITCH

IN IN IN IN IN IN

C12 C2 A2 B1 C1A4

C1

2-D

WN

LIM

IT

IN

A10

OV

ER

LO

AD

SE

NS

OR

OP

TIO

N

LS7POTHOLE

GUARDSWITCH

LS8POTHOLE

GUARDSWITCH

IN

B10

B1

0-P

OT

HO

LE

SW


SWITCH(OPTION)

A11

-KE

YS

WIT

CH

IN

A11

A8

-MO

TO

RC

ON

TR

.E

NA

BL

E

A1

2-U

P/D

WN

SW

DW

N

B1

2-U

P/D

WN

SW

UP

A9

-MO

TO

RC

ON

TR

OL

LE

R

B8

-HO

RN

OP

TIO

N

TS66UP/DOWN

SWITCH

B8

OUT OUT OUT IN IN

A12 B12A8 A9

39C

76F

23D

78F

77F

21B

A6

OUT

A6

-UP

CO

IL

H5ALARM

OUT

B9

B9

-MU

LT

IFU

NC

TA

LM

C11

-LV

LS

NS

R-W

HT

A5

-LV

LS

NS

R-R

ED

BR

RD

WH

IN OUT

C11 A5

P1EMERGENCYSTOP

CB27A


CONTROL

T

B

B

T

GROUNDCONTROL

KS1KEY SWITCH CR48

POWERRELAYTO U5

Y8PLATFORM

UP

U5ELECTRONIC CONTROL MODULEA1 OUT


H2

HORN(OPTION)

AUTOMOTIVE-STYLE

13

2G6HOUR

METER(OPTION)

B3 C9 C7 B7 A7 C6 B6


C9

-BR

KC

OIL

C7

-RT

CO

IL

B7

-LE

FT

CO

IL

A7

-RE

VC

OIL

C6

-FW

DC

OIL

B6

-DW

NC

OIL

GN

D

Y2BRAKE

RELEASE

Y3STEERRIGHT

Y4STEER

LEFT

Y5DRIVE

REVERSE

Y6DRIVE

FORWARD

Y7PLATFORM

DOWN

C8

OUT

Y1PARALLEL

C8

-PR

LL

CO

IL

FB

FB

FB

(OPTION)

FLASHINGBEACONS

U2747 mH

INDUCTOR,NOISE

SUPPRESSION

WH A A

WH C C

BL B B

BK D D

OR E E

8587

8630

8587

8630

+

-

N.C.H.O.N.C.

N.C.H.O.

N.O.

S7LEVEL

SENSOR

UP

LIM

IT

IN

B11

F6275A FUSE

U6 MOTOR

CONTROLLER

B+

3A2

M-T2

B- 1

M5MOTOR

QD1 +( )

A1

D1

M5

B54-6V

BATTERY

GND


QD1 -( )

+

-

-

+

+-

-+

F850A FUSE

AC INPUT


1

2

3

4

5

6

7

8





















REV B

1

2

3

4

8

5

7

6

PLATFORM CONTROLLER

SW25DIP SWITCHES

HORN BN5

DRIVE ENABLE BN8

HIGH TORQUE BN6


PIN1

PIN2

PIN3

PIN8

PIN10

PIN9

LIFT ENABLE BN9PIN4

POWER LED L19

DRIVE LED L17

LIFT LED L16

POUT4

POUT2

POUT3

FAULT LED L25

POUT5

POUT6

POUT7

POUT9

POUT8

POUT10

HIGH TORQUE LED L21

POUT1

BATTERY LEVEL 1

BATTERY LEVEL 2

BATTERY LEVEL 3

BATTERY LEVEL 4

BATTERY LEVEL 5

G7


H1 ALARM

POUT11

PIN11

RD+

-BK

OR

BR

PP

WH/BK

WH/BL

BK

WH/RD

WH

PIO2

PIO3

PIO5

PIO4

DATA LINK (LOW)

DATA LINK (HIGH)

GROUND



AA RD

CC

WHBB

BLDD

ORYL

EE

5V DC24V DC

P2EMERGENCY STOP

BK

RD

D7VOLTAGE

REGULATOR

QD3


SW6STEER

LE

FT

RIG

HTSW5

FUNCTIONENABLE

WH/YL



1

2

3

4

5

6

7

8




REV B

DA

TA

LIN

K-

DA

TA

LIN

K+

GN

DF

RO

MJO

YS

TIC

K

IN IN IN

A2 B1 C1

A8

-MO

TO

RC

ON

TR

.E

NA

BL

E

A1

2-U

P/D

WN

SW

DW

N

B1

2-U

P/D

WN

SW

UP

A9

-MO

TO

RC

ON

TR

OL

LE

R

B8

-HO

RN

OP

TIO

N

TS66UP/DOWN

SWITCH

B8

OUT OUT OUT IN IN

A12 B12A8 A9

A6

OUT

A6

-UP

CO

IL

C11

-LV

LS

NS

R-W

HT

A5

-LV

LS

NS

R-R

ED

BR

RD

WH

IN OUT

C11 A5

P1EMERGENCYSTOP

CB27A

CIRCUITBREAKER

Y8PLATFORM

UP


ES

TO

PF

RO

MJO

YS

TIC

K

EM

ER

GS

TO

P

LS6DOWN

LIMITSWITCH

IN IN IN

C12 C2 A4

C1

2-D

WN

LIM

IT

IN

A10

OV

ER

LO

AD

SE

NS

OR

OP

TIO

N

LS7POTHOLE

GUARDSWITCH

LS8POTHOLE

GUARDSWITCH

IN

B10B

10

-PO

TH

OL

ES

W


SWITCH(OPTION)

39C

21B

H5ALARM

OUT

B9

B9

-MU

LT

IFU

NC

TA

LM


H2

HORN(OPTION)

AUTOMOTIVE-STYLE

13

2G6HOUR

METER(OPTION)

76F

23D

78F

77F

CR48POWERRELAYTO U5

A1 OUT

B3 C9 C7 B7 A7 C6 B6


C9

-BR

KC

OIL

C7

-RT

CO

IL

B7

-LE

FT

CO

IL

A7

-RE

VC

OIL

C6

-FW

DC

OIL

B6

-DW

NC

OIL

GN

D

Y2BRAKE

RELEASE

Y3STEERRIGHT

Y4STEER

LEFT

Y5DRIVE

REVERSE

Y6DRIVE

FORWARD

Y7PLATFORM

DOWN

C8

OUT

Y1PARALLEL

C8

-PR

LL

CO

IL

FB

FB

FB

(OPTION)

FLASHINGBEACONS

U2747 mH

INDUCTOR,NOISE

SUPPRESSION

A11

-KE

YS

WIT

CH

IN

A11

PLATFORMCONTROL

T

B

B

T

GROUNDCONTROL

KS1KEY SWITCH

WH A A

WH C C

BL B B

BK D D

OR E E

8587

8630

8587

8630

+

-

N.C.H.O.N.C.

N.C.H.O.

N.O.

S7LEVEL

SENSOR

UP

LIM

IT

IN

B11

F6275A FUSE

U6 MOTOR

CONTROLLER

B+

3A2

M-T2

B- 1

M5MOTOR

QD1 +( )

A1

D1

M5

B54-6V

BATTERY

GND


QD1 -( )

+

-

-

+

+-

-+

F850A FUSE

AC INPUT


1

2

3

4

5

6

7

8





















REV B

1

2

3

4

8

5

7

6

PLATFORM CONTROLLER

SW25DIP SWITCHES

HORN BN5

DRIVE ENABLE BN8

HIGH TORQUE BN6


PIN1

PIN2

PIN3

PIN8

PIN10

PIN9

LIFT ENABLE BN9PIN4

POWER LED L19

DRIVE LED L17

LIFT LED L16

POUT4

POUT2

POUT3

FAULT LED L25

POUT5

POUT6

POUT7

POUT9

POUT8

POUT10

HIGH TORQUE LED L21

POUT1

BATTERY LEVEL 1

BATTERY LEVEL 2

BATTERY LEVEL 3

BATTERY LEVEL 4

BATTERY LEVEL 5

G7


H1 ALARM

POUT11

PIN11

RD+

-BK

OR

BR

PP

WH/BK

WH/BL

BK

WH/RD

WH

PIO2

PIO3

PIO5

PIO4

DATA LINK (LOW)

DATA LINK (HIGH)

GROUND



AA RD

CC

WHBB

BLDD

ORYL

EE

5V DC24V DC

P2EMERGENCY STOP

BK

RD

D7VOLTAGE

REGULATOR

QD3


SW6STEER

LE

FT

RIG

HTSW5

FUNCTIONENABLE

WH/YL



1

2

3

4

5

6

7

8




REV B

P1EMERGENCYSTOP

A6

-UP

CO

IL

B8

-OP

TS

ER

VIC

EH

OR

N

CB27A


CONTROL

T

B

B

T

GROUNDCONTROL

KS1KEY SWITCH

Y8PLATFORM

UP

GND

U270.034 OHM

INDUCTOR,NOISE

SUPPRESSION

(HARD-WIREDAFTER SERIAL

NUMBER 46645)

(CE MODELS ONLYAFTER SERIAL

NUMBER 47940)

G6HOUR

METER

C9

-BR

KC

OIL

C7

-RT

CO

IL

B7

-LE

FT

CO

IL

A7

-RE

VC

OIL

C6

-FW

DC

OIL

Y2BRAKE

RELEASE

Y3STEERRIGHT

Y4STEER

LEFT

Y5DRIVE

REVERSE

Y6DRIVE

FORWARD

Y1PARALLEL

Y1AHIGH SPEED

BYPASS(OPTION)

C8

-PR

LL

CO

IL

LS7POTHOLE

GUARDSWITCH

LS8POTHOLE

GUARDSWITCH

H5MULTI-

FUNCTIONALARM

B9

-MU

LT

IFU

NC

TA

LM

B1

0-P

OT

HO

LE

SW

C1

2-D

WN

LIM

IT

OV

ER

LO

AD

SE

NS

OR

OP

TIO

N

N.C.H.O.

N.C.H.O.

LS6DOWN

LIMITSWITCH

N.C.

A6

OUT

A11

-KE

YS

WIT

CH

IN

A11B8

OUT

A8

-MO

TO

RC

ON

TR

.E

NA

BL

E

OUT OUT IN IN

A8

A1

2-U

P/D

WN

SW

DW

N

B1

2-U

P/D

WN

SW

UP

A9

-CU

RT

IST

ER

M3

TS66UP/DOWN

SWITCH

A12 B12A9


DA

TA

LIN

K-

DA

TA

LIN

K+

GN

DF

RO

MJO

YS

TIC

K

IN IN IN

A2 B1 C1

C9 C7 B7 A7 C6

OUT OUT OUT OUT OUT

GN

D

B3

OUT

C8

OUT

INOUT

B10B9

IN

C12

IN

A10

IN

C2

-EM

ER

GS

TO

P

C2

ES

TO

PF

RO

MJO

YS

TIC

K

IN

A4

IN

B11

B11

-UP

LIM

IT

39C

21B

A1 OUT

FB

FB

FB

(OPTION)

FLASHINGBEACONS

B6

-DW

NC

OIL

Y7PLATFORM

DOWN

B6

OUT

WH RD

QD4

A AWH

C C

BL B B

BK D D

OR E E

N.O.


SWITCH(OPTION)

C11

-LV

LS

NS

R-W

HT

A5

-LV

LS

NS

R-R

ED

IN OUT

C11 A5

RD

WH

BN

N.O.

S7LEVEL

SENSOR

LEVELSENSORCIRCUITBOARD

R2175 OHM

CR5HORN RELAY(H2 OPTION)8587

8630

H2AUTOMOTIVE-STYLEHORN(OPTION)

F6275A FUSE

U6 MOTOR

CONTROLLER

B+

3A2

M-T2

B- 1

M5MOTOR

QD1 +( )

A1

D1

M5

B54-6V

BATTERY

GND


QD1 -( )

+

-

-

+

+-

-+

F850A FUSE

AC INPUT

U9BATTERY

CHARGER

87A 85

8630

87

76F

23D

78F

77F

CR48POWERRELAYTO U5


1

2

3

4

5

6

7

8





















REV B

1

2

3

4

8

5

7

6

PLATFORM CONTROLLER

SW25DIP SWITCHES

HORN BN5

DRIVE ENABLE BN8

HIGH TORQUE BN6


PIN1

PIN2

PIN3

PIN8

PIN10

PIN9

LIFT ENABLE BN9PIN4

POWER LED L19

DRIVE LED L17

LIFT LED L16

POUT4

POUT2

POUT3

FAULT LED L25

POUT5

POUT6

POUT7

POUT9

POUT8

POUT10

HIGH TORQUE LED L21

POUT1

BATTERY LEVEL 1

BATTERY LEVEL 2

BATTERY LEVEL 3

BATTERY LEVEL 4

BATTERY LEVEL 5

G7


H1 ALARM

POUT11

PIN11

RD+

-BK

OR

BR

PP

WH/BK

WH/BL

BK

WH/RD

WH

PIO2

PIO3

PIO5

PIO4

DATA LINK (LOW)

DATA LINK (HIGH)

GROUND



AA RD

CC

WHBB

BLDD

ORYL

EE

5V DC24V DC

P2EMERGENCY STOP

BK

RD

D7VOLTAGE

REGULATOR

QD3


SW6STEER

LE

FT

RIG

HTSW5

FUNCTIONENABLE

WH/YL



1

2

3

4

5

6

7

8




REV A

A6

-UP

CO

IL

B8

-OP

TS

ER

VIC

EH

OR

N

Y8PLATFORM

UP

GND

U270.034 OHM

INDUCTOR,NOISE

SUPPRESSION(CE MODELS ONLY)

G6HOUR

METER

C9

-BR

KC

OIL

C7

-RT

CO

IL

B7

-LE

FT

CO

IL

A7

-RE

VC

OIL

C6

-FW

DC

OIL

Y2BRAKE

RELEASE

Y3STEERRIGHT

Y4STEER

LEFT

Y5DRIVE

REVERSE

Y6DRIVE

FORWARD

Y1PARALLEL

Y1AHIGH SPEED

BYPASS(OPTION)

C8

-PR

LL

CO

IL

LS7POTHOLE

GUARDSWITCH

LS8POTHOLE

GUARDSWITCH

H5MULTI-

FUNCTIONALARM

B9

-MU

LT

IFU

NC

TA

LM

B1

0-P

OT

HO

LE

SW

C1

2-D

WN

LIM

IT

OV

ER

LO

AD

SE

NS

OR

OP

TIO

N

N.C.H.O.

N.C.H.O.

LS6DOWN

LIMITSWITCH

N.C.

A6

OUT

A11

-KE

YS

WIT

CH

IN

A11B8

OUT

A8

-MO

TO

RC

ON

TR

.E

NA

BL

E

OUT OUT IN IN

A8

A1

2-U

P/D

WN

SW

DW

N

B1

2-U

P/D

WN

SW

UP

A9

-CU

RT

IST

ER

M3

TS66UP/DOWN

SWITCH

A12 B12A9


DA

TA

LIN

K-

DA

TA

LIN

K+

GN

DF

RO

MJO

YS

TIC

K

IN IN IN

A2 B1 C1

C9 C7 B7 A7 C6

OUT OUT OUT OUT OUT

GN

D

B3

OUT

C8

OUT

INOUT

B10B9

IN

C12

IN

A10

IN

C2

-EM

ER

GS

TO

P

C2

ES

TO

PF

RO

MJO

YS

TIC

K

IN

A4

IN

B11

B11

-UP

LIM

IT

39C

21B

A1 OUT

FB

FB

FB

(OPTION)

FLASHINGBEACONS

B6

-DW

NC

OIL

Y7PLATFORM

DOWN

B6

OUT

WH RD

QD4

A AWH

C C

BL B B

BK D D

OR E E

N.O.


SWITCH(OPTION)

C11

-LV

LS

NS

R-W

HT

A5

-LV

LS

NS

R-R

ED

IN OUT

C11 A5

RD

WH

BN

N.O.

S7LEVEL

SENSOR


R2175 OHM


8630


F6275A FUSE

U6 MOTOR

CONTROLLER

B+

3A2

M-T2

B- 1

M5MOTOR

QD1 +( )

A1

D1

M5

B54-6V

BATTERY

GND


QD1 -( )

+

-

-

+

+-

-+

F850A FUSE

AC INPUT

U9BATTERY

CHARGER

87A 85

8630

87

76F

23D

78F

77F

CR48POWERRELAYTO U5

P1EMERGENCYSTOP

KS1KEY SWITCH

CB27A

CIRCUITBREAKER

PLATFORMCONTROL

GROUNDCONTROL

B

B1

3

4

2

1


1

2

3

4

5

6

7

8





















REV A

PLATFORMCONTROLLER

HORN BN5

DRIVE ENABLE BN8

HIGH TORQUE BN6


PIN1

PIN2

PIN3

PIN8

PIN10

PIN9

LIFT ENABLE BN9PIN4

POWER LED L19

DRIVE LED L17

LIFT LED L16

POUT4

POUT2

POUT3

FAULT LED L25

POUT5

POUT6

POUT7

POUT9

POUT8

POUT10

HIGH TORQUE LED L21

POUT1

BATTERY LEVEL 1

BATTERY LEVEL 2

BATTERY LEVEL 3

BATTERY LEVEL 4

BATTERY LEVEL 5

G7


H1 ALARM

POUT11

PIN11

RD+

-BK

GY

GN

BN

WH

BL

PP

JC1JOYSTICK

CONTROLLER

HALLGENERATOR


LE

FT

RIG

HTSW5

FUNCTIONENABLE

OR

BK

BK

RD

DATA LINK -

DATA LINK +

GROUND



AA RD

CC

WHBB

BLDD

OREE

P2EMERGENCY STOP

BK

WH

RD

BL

YL

1

2

3

4

8

5

7

6

SW25DIP SWITCHES

PIO3 PIO2

PIO5

PIO4 5V DC24V DC

D7VOLTAGE

REGULATORQD3


1

2

3

4

5

6

7

8




REV A

A6

-UP

CO

IL

B8

-OP

TS

ER

VIC

EH

OR

N

Y8PLATFORM

UP

GND

U270.034 OHM

INDUCTOR,NOISE

SUPPRESSION(CE MODELS ONLY)

G6HOUR

METER

C9

-BR

KC

OIL

C7

-RT

CO

IL

B7

-LE

FT

CO

IL

A7

-RE

VC

OIL

C6

-FW

DC

OIL

Y2BRAKE

RELEASE

Y3STEERRIGHT

Y4STEER

LEFT

Y5DRIVE

REVERSE

Y6DRIVE

FORWARD

Y1PARALLEL

C8

-PR

LL

CO

IL

LS7POTHOLE

GUARDSWITCH

LS8POTHOLE

GUARDSWITCH

H5MULTI-

FUNCTIONALARM

B9

-MU

LT

IFU

NC

TA

LM

B1

0-P

OT

HO

LE

SW

C1

2-D

WN

LIM

IT

OV

ER

LO

AD

SE

NS

OR

OP

TIO

N

N.C.H.O.

N.C.H.O.

LS6DOWN

LIMITSWITCH

N.C.

A6

OUT

A11

-KE

YS

WIT

CH

IN

A11B8

OUT

A8

-MO

TO

RC

ON

TR

.E

NA

BL

E

OUT OUT IN IN

A8

A1

2-U

P/D

WN

SW

DW

N

B1

2-U

P/D

WN

SW

UP

A9

-CU

RT

IST

ER

M3

TS66UP/DOWN

SWITCH

A12 B12A9


DA

TA

LIN

K-

DA

TA

LIN

K+

GN

DF

RO

MJO

YS

TIC

K

IN IN IN

A2 B1 C1

C9 C7 B7 A7 C6

OUT OUT OUT OUT OUT

GN

D

B3

OUT

C8

OUT

INOUT

B10B9

IN

C12

IN

A10

IN

C2

-EM

ER

GS

TO

P

C2

ES

TO

PF

RO

MJO

YS

TIC

K

IN

A4

IN

B11

B11

-UP

LIM

IT

39C

21B

A1 OUT

FB

FB

FB

(OPTION)

FLASHINGBEACONS

B6

-DW

NC

OIL

Y7PLATFORM

DOWN

B6

OUT

WH WH RD

3WH WH

4

WH BL 1

WH BK 2

WH OR 5

N.O.


SWITCH(OPTION)

C11

-LV

LS

NS

R-W

HT

A5

-LV

LS

NS

R-R

ED

IN OUT

C11 A5

RD

WH

BN

N.O.

S7LEVEL

SENSOR


R2175 OHM


8630


F6275A FUSE

U6 MOTOR

CONTROLLER

B+

3A2

M-T2

B- 1

M5MOTOR

QD1 +( )

A1

D1

M5

B54-6V

BATTERY

GND


QD1 -( )

+

-

-

+

+-

-+

F850A FUSE

AC INPUT

U9BATTERY

CHARGER

87A 85

8630

87

76F

23D

78F

77F

CR48POWERRELAYTO U5

P1EMERGENCYSTOP

CB27A

CIRCUITBREAKER

KS1KEY SWITCH

PLATFORMCONTROL

GROUNDCONTROL

B

B1

3

4

2

1


1

2

3

4

5

6

7

8





















REV A

PLATFORMCONTROLLER

HORN BN5

DRIVE ENABLE BN8

HIGH TORQUE BN6


PIN1

PIN2

PIN3

PIN8

PIN10

PIN9

LIFT ENABLE BN9PIN4

POWER LED L19

DRIVE LED L17

LIFT LED L16

POUT4

POUT2

POUT3

FAULT LED L25

POUT5

POUT6

POUT7

POUT9

POUT8

POUT10

HIGH TORQUE LED L21

POUT1

BATTERY LEVEL 1

BATTERY LEVEL 2

BATTERY LEVEL 3

BATTERY LEVEL 4

BATTERY LEVEL 5

G7


H1 ALARM

POUT11

PIN11

RD+

-BK

GY

GN

BN

WH

BL

PP

JC1JOYSTICK

CONTROLLER

HALLGENERATOR


LE

FT

RIG

HTSW5

FUNCTIONENABLE

OR

BK

BK

RD

DATA LINK (LOW)

DATA LINK (HIGH)

GROUND



33 RD

44

WH11

BL22

OR55

P2EMERGENCY STOP

BK

WH

RD

BL

OR

1

2

3

4

8

5

7

6

SW25DIP SWITCHES

PIO3 PIO2

PIO5

PIO4 5V DC24V DC

D7VOLTAGE

REGULATORQD3

Hydraulic Symbols Legend andComponent Reference


Y7

Y7

D

E

0.040 in1 mm

M 1.03 CU. IN.

(16.9 cc)

DE

Y7

Y8

Y2

Y4

Y8 Y1A

Y2

Y1

Y6

Y5

Y3

CA

CB

CC

CD

CF

CG

CH

CJ

CK

CLCN

CO

CM

C I

CE

BA

BB

BC

BD

BF

BG

BH

BJ

BKBL

BM

B I

BE

Y4

Y8Y2

Y1

Y6

Y5

Y3

AC

AD

AA

AB

AF

AE

AG

AH

AJ

AK

AL

AI

Y4

Y8

Y2

Y1

Y6

Y5

Y3

AL

Check valve (AL) wasreplaced by relief valve (AL)at serial number 17482

BA

BB

BC

BD

BF

BG

BH

BJBKBL

BM

B I

BE

Hydraulic Symbols Legend andComponent Reference


Function manifold components(from serial number 17408 to 36100)


Function manifold componentsModels with Traction Control



Lift cylinder components(before serial number 23568)

Filter

Fixed displacementpump

Bi-directional motor

Variable speed motor

Check valve

Orifice with size

Relief valve

REV B

Priorityflow regulator

Platform overloadpressure switch

Check valve,pilot to open

Accumulator

Dual acting cylinder

Solenoid operated2 position 2 way valve,normally closed with

manual over-ride

Solenoid operated2 position 4 waydirectional valve

Shuttle valve

Brake

Hand pump

Single acting cylinder



Lift cylinder components(after serial number 23567)

Hydraulic Schematic(from serial number 17408 to 36100)

1

2

3

4

5

6

7

8




IMPORTANT NOTESItem DescriptionAL Changed to 130 psi / 9 bar relief valve after serial number 17481

ABBREVIATION LEGENDItem DescriptionAA Check valve, steer circuitAB Test portAC Flow regulator, steer circuitAD Orifice washer, steer circuitAE Relief valve, steerAF Relief valve, systemAG Steer left/rightAH Platform upAI Brake circuitAJ Drive speed selectAK Drive forward/reverseAL Check valve OR relief valve, brake circuit

REV B

DRIVE MOTOR DRIVE MOTOR

Y2

Y5Y6

200 psi13.8 bar

M1 M4

RIGHTLEFT

AJ

AL

AI

Y1

AK

AHY8

M

0.75 gpm2.8 L/min

3500 psi241.3 bar

10 MICRON WITH25 psi / 1.7 bar

BYPASS

100 MESH

PRESSURE

POWERUNIT

TANK

TP

0.040 in1 mm

AD

AF

AC

AB

AA 30 psi2 bar

AG

AE

1500 psi103.4 bar

STEERLEFT

STEERRIGHT

S1 S2

Y3Y4

LIFTCYLINDER

Y7D

E

LIFT

COM

PLATFORMOVERLOAD(OPTION)

N.O.

N.C.

0.046 in1.17 mm

SEE NOTE

R

BRAKE

L

M

F

BRAKERELEASE

MANIFOLD

MANUALRELEASE

RIGHTBRAKE

HANDPUMP

HP

HP

LEFTBRAKE

1.03 CU. IN.

16.9 cc

B1

BRAKE

J

K

ABBREVIATION LEGEND Item Description

D Platform lowering valve E Orifice, platform down circuit F Accumulator J Shuttle valve, brake release K Check valve, manual brake release circuit L Hand pump, manual brake release circuit M Platform lowering valve R Platform overload pressure switch


1

2

3

4

5

6

7

8




ABBREVIATION LEGENDItem DescriptonBA Test portBB Flow regulator, steer circuitBC Relief valve, liftBD Relief valve, systemBE Orifice washer, steer circuitBF Relief valve, steerBG Relief valve, brake circuitBH Steer left/rightBI Drive speed selectBJ Drive forward/reverseBK Brake circuitBL Platform upBM Check valve, steer circuit

IMPORTANT NOTESItem DescriptionBM Changed to 10 psi (0,7 bar) after serial number 43739

REV B

M

PRESSURE

POWERUNIT

STEERLEFT

STEERRIGHT

S1 S2

0.046 in1.17 mm

LIFTCYLINDER

TP

E


BYPASS

100 MESH

TANK

Y7

D

0.040 in1 mm


M1 M3 M2 M4

RIGHTLEFT

Y5Y6

Y2

Y3Y4

0.75 gpm2.8 L/min

Y1

BI

BK

130 psi9 bar

BG

BJ

5 psi0.3 bar

BMBH

BE BF

1500 psi103.4 bar

BBBL

BC

BA

3000 to 3200 psi207 to 221 bar

LIFT

COM


N.O.

N.C.

BD

3500 psi241.3 bar

SEE NOTE

BRAKE

L

M

F

BRAKERELEASE

MANIFOLD

MANUALRELEASE

RIGHTBRAKE

HANDPUMP

HP

HP

LEFTBRAKE

1.03 CU. IN.

16.9 cc

B1

BRAKE

J

K

R

Y8




1

2

3

4

5

6

7

8




ABBREVIATION LEGENDItem DescriptonBA Test portBB Flow regulator, steer circuitBC Relief valve, liftBD Relief valve, systemBE Orifice washer, steer circuitBF Relief valve, steerBG Relief valve, brake circuitBH Steer left/rightBI Drive speed selectBJ Drive forward/reverseBK Brake circuitBL Platform upBM Check valve, steer circuit

REV A

M

PRESSURE

POWERUNIT

3500 psi maximum241 bar maximum

0.046” / 1.17 mm

LIFT

LIFT CYLINDER

PS2

The lift cylinder orifice is

located underneath the

fitting on the lift cylinder.

TP


BYPASS

TANK

1800 to 3500 psi124 to 241 bar

AA

E

AJ

AI

AB

V

Y7R

D

FUNCTION MANIFOLD

PLATFORMOVERLOAD

(CE MODELS)

FUNCTION MANIFOLD

F

130 psi9 bar

AF

STEERLEFT

STEERRIGHT

0.040”1 mm

S1 S2

Y3Y4

0.75 gpm2.8 L/min

1500 psi103 bar

AD

AH

AC

M1

LEFTDRIVE

MOTOR

M4

RIGHTDRIVE

MOTOR

HP

1.03 CU. IN.

16.9 cc

B

Y1

AE

Y5Y6

AG

AC

BRAKE

RIGHTBRAKE

LEFTBRAKE

L

BRAKERELEASEMANIFOLD

M

HANDPUMP

B1

MANUALRELEASE

Y8



Hydraulic SchematicModels with Traction Control

1

2

3

4

5

6

7

8




ABBREVIATION LEGENDItem DescriptionCA Test portCB Flow regulator, steer circuitCC Relief valve, liftCD Relief valve, systemCE Orifice washer, steer circuitCF Relief valve, steerCG Check valve, brake circuitCH Steer left/rightCI Brake circuitCJ Drive speed selectCK Drive forward/reverseCL High speed bypassCM Flow divider/combinerCN Platform upCO Check valve, steer circuit

REV B



M

PRESSURE

POWERUNIT

STEERLEFT

STEERRIGHT

S1 S2

LIFTCYLINDER

TP

E

100 MESH

TANK

CA

CN

CH

Y7

D

10 psi0.7 bar

CE

CO


M1 M3 M2 M4

RIGHTLEFT

Y5Y6

CJ

30 psi2 bar

CG

CK

CM

CLY1A

Y1

CF

Y3Y4

CB

Y2

C I

LIFT

COM


N.O.

N.C.

CD

3500 psi241.3 bar

0.040 in1 mm0.75 gpm

2.8 L/min

1500 psi103.4 bar

3000 to 3200 psi207 to 221 bar


BYPASS

0.046 in1.17 mm

R

CC

BRAKE

L

M

F

BRAKERELEASE

MANIFOLD

MANUALRELEASE

RIGHTBRAKE

HANDPUMP

HP

HP

LEFTBRAKE

1.03 CU. IN.

16.9 cc

B1

BRAKE

J

K

Y8

Hydraulic SchematicModels with Traction Control


Se

rvic

eM

an

ua

lG

S-2

03

2&

GS

-26

32

Rev C2

Part No.72963

Dis

trib

ute

d B

y:

Genie North America

Genie Australia Pty Ltd.

Genie China

Genie Malaysia

Genie Japan

Genie Korea

Genie Brasil

Genie Holland

Phone 425.881.1800

Toll Free USA and Canada

800.536.1800

Fax 425.883.3475

Phone +61 7 3375 1660

Fax +61 7 3375 1002

Phone +86 21 53852570

Fax +86 21 53852569

Phone +65 98 480 775

Fax +65 67 533 544

Phone +81 3 3453 6082

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Phone +82 25 587 267

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Phone +55 11 41 665 755

Fax +55 11 41 665 754

Phone +31 183 581 102

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Phone +46 31 575100

Fax +

Phone +33 (0)2 37 26 09 99

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Phone +34 93 579 5042

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Fax +44 (0)1476 584334

Phone +52 55 5666 5242

Fax +52 55 5666 3241

46 31 579020

Phone +49 422 149 1818

genie gs-2632 service manual - rentalex€¦ · genie gs-2032 service manual, first edition (before...

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