GS2X46

Technical
Publications
GS-2046
GS-2646
GS-3246
Service
Manual
(before serial number 17408)
First Edition, Third Printing

Rev C2
Part No. 48339
Introduction Service Manual - First Edition
GS-2046
GS-2646 Genie North America
Telephone (425) 881-1800
GS-3246 Toll Free 800 536-1800 in U.S.A.
Toll Free 800 426-8089 in Canada
Fax (425) 882-9260
Important http://www.genielift.com
E-mail: techpub@genieind.com
Read, understand and obey the safety rules and
operating instructions in the Genie GS-2032 &
Genie GS-2046 & Genie GS-2646 & Genie Genie Europe
GS-3246 Operator's Manual before attempting any Telephone (44) 01636-605030
maintenance or repair procedure. Fax (44) 01636-611090
http://www.genielift.com
This manual provides detailed scheduled E-mail: techpub@genieind.com
maintenance information for the machine owner
and user. It also provides troubleshooting and
repair procedures for qualified service
professionals.
Basic mechanical, hydraulic and electrical

skills are required to perform most procedures.
However, several procedures require specialized
skills, tools, lifting equipment and a suitable
workshop. In these instances, we strongly

recommend that maintenance and repair be
performed at an authorized Genie dealer Copyright 1997 by Genie Industries
service center. First Edition: First Printing, December 1997
Second Printing, April 1999
Genie Industries has endeavored to deliver the Third Printing,October 1999
highest degree of accuracy possible. However,
continuous improvement of our products is a "Genie" is a Registered Trademark
of Genie Industries in the USA and many other
Genie policy. Therefore, product specifications countries. "GS" is a Trademark of
are subject to change without notice. Genie Industries.
Readers are encouraged to notify Genie of errors Printed on recycled paper

and send in suggestions for improvement. All Printed in U.S.A.
communications will be carefully considered for
future printings of this and other manuals. Please
write to the technical publications team in care of
Genie Industries, PO Box 97030, Redmond WA
98073-9730 USA.
If you have any questions, please call Genie

Industries.
ii Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339
Service Manual - First Edition
Safety Rules
Danger
Failure to obey the instructions and safety rules
in this manual and the Genie GS-2032 & Genie
GS-2046 & Genie GS-2646 & Genie GS-3246
Operator's Manual will result in death or serious
injury.
Many of the hazards identified in the
operators manual are also safety hazards
when maintenance and repair procedures
are performed.
Do Not Perform Maintenance

Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
- manufacturers instructions and safety rules
- employers safety rules and worksite
regulations
- applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.
Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 iii
SAFETY RULES
Personal Safety Be sure to wear protective eye wear and

other protective clothing if the situation
Any person working on or around a machine must warrants it.
be aware of all known safety hazards. Personal
safety and the continued safe operation of the Be aware of potential crushing hazards
machine should be your top priority. such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved steel-toed
shoes.
Read each procedure thoroughly. This
manual and the decals on the machine
use signal words to identify the following:
Safety alert symbolused to alert
Workplace Safety
personnel to potential personal Be sure to keep sparks, flames and
injury hazards. Obey all safety lighted tobacco away from flammable and
messages that follow this symbol combustible materials like battery gases
to avoid possible injury or death. and engine fuels. Always have an approved fire
extinguisher within easy reach.
Redused to indicate the
presence of an imminently
hazardous situation which, if not
avoided, will result in death or Be sure that all tools and working areas
serious injury. are properly maintained and ready for
use. Keep work surfaces clean and free
Orangeused to indicate the of debris that could get into machine components
presence of a potentially and cause damage.
avoided, could result in death or
serious injury.
Be sure that your workshop or work area
Yellow with safety alert symbol is properly ventilated and well lit.
used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause Be sure any forklift, overhead crane or
minor or moderate injury. other lifting or supporting device is fully
Yellow without safety alert capable of supporting and stabilizing the
symbolused to indicate the weight to be lifted. Use only chains or straps that
presence of a potentially are in good condition and of ample capacity.
avoided, may result in property
damage. Be sure that fasteners intended for one
time use (i.e., cotter pins and self-locking
Greenused to indicate operation nuts) are not reused. These components
or maintenance information. may fail if they are used a second time.
Be sure to properly dispose of old oil or

other fluids. Use an approved container.
Please be environmentally safe.
iv Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339
Theory of Operation
Power Source to the default settings in the ECM software.
The Genie GS-2046 & Genie GS-2646 & Genie Machine Controls
GS-3246 machines are powered by four six-volt
(225 AH) batteries. The four batteries are wired in The GS-2046 & GS-2646 & GS-3246 machines
series to produce 24 volts. are equipped with operational controls which are
found in two locations: the ground controls,
Hydraulic System located on the hydraulic tank side of the machine,
and the platform controls, located in the platform.
All machine functions are performed by the All lift and drive functions are available at the
hydraulic system. The hydraulic system is platform controls. Only platform up/down functions
powered by a single-section gear pump. When the are available at the ground controls.
pump is activated, it supplies hydraulic fluid under The ECM uses input from the ground or platform
pressure to the function manifold, where the controls to activate the various machine functions.
control valves are located. To protect from over- The ECM has predetermined settings for the
pressurization of the hydraulic system, the pump various machine functions.
is provided with a pressure relief valve.
The joystick is fitted with a 5000 ohm
Activating a machine function is accomplished by potentiometer. With the joystick in the neutral
actuating or moving a switch and/or control position, the potentiometer will measure 2730
handle, which sends voltage to the ECM. The ohms. These signals are sent to the multiplex
ECM then sends the signal to the appropriate card, then down to the ECM to control the voltage
directional control valve. The directional valve supplied to the proportional valve. Two
determines which direction the hydraulic fluid will microswitches mounted on the joystick tell the
travel. Computer software determines the volume ECM the drive direction desired. A thumb rocker
of fluid in relation to the proportional valve input switch on the top of the joystick is used for
voltage. steering.
Electrical System Mounted on the platform control box lid of

machines before serial number 17408 are buttons
Limit switches are found in various locations on and a switch that, when activated, sends a signal
the machine. The function of a limit switch is to to the ECM through the multiplex card. On
communicate the operating position of the machines after serial number 17407, the platform
machine to the ECM (Electronic Control Module). control box lid has a decal/membrane pad. This is
When a change in signal is received from a limit a touch-activated pad incorporating wiring,
switch, the ECM responds by limiting the drive switches and LEDs that are resistant to the
speed to 0.5 miles per hour (0.8 km/h), according environment. Activating any of the buttons on the
Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 v
THEORY OF OPERATION
pad will send a signal to the ECM through the

multiplex card.
A diagnostic display is located at the battery pack
side of the machine to aid in troubleshooting. If the
machine malfunctions, a fault code will be shown
in the display window.
Washing electronic components is not suggested.

Instead, use compressed air to remove debris
from these components.
Component damage hazard.

Avoid shock or impact to the
ECM. Internal damage may not be
visible from the outside.
vi Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339
Table of Contents
Introduction
Important Information ..................................................................................................... ii
Section One Safety Rules

General Safety Rules .................................................................................................... iii
Section Two Specifications

Machine Specifications, GS-2046 ............................................................................ 2 - 1
Performance Specifications, All Models ................................................................... 2 - 4
Hydraulic Specifications, All Models ......................................................................... 2 - 4
Hydraulic Hose and Fitting Torque Specifications .................................................... 2 - 5
Section Three Scheduled Maintenance Inspections

Introduction ............................................................................................................... 3 - 1
Table A ..................................................................................................................... 3 - 2
Table B ..................................................................................................................... 3 - 2
Table C ..................................................................................................................... 3 - 3
Table D ..................................................................................................................... 3 - 3
Maintenance Inspection Report ................................................................................ 3 - 4
Section Four Scheduled Maintenance Procedures

Introduction ............................................................................................................... 4 - 1
A-1 Inspect the Operators and Safety Manuals .................................................... 4 - 2
A-2 Inspect the Decals and Placards .................................................................... 4 - 2
A-3 Inspect for Damage, and Loose or Missing Parts ........................................... 4 - 3
A-4 Check the Hydraulic Oil Level ......................................................................... 4 - 4
A-5 Check for Hydraulic Leaks .............................................................................. 4 - 4
Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 vii
TABLE OF CONTENTS
Section Four Scheduled Maintenance Procedures, continued

A-6 Test the Platform and Ground Controls .......................................................... 4 - 5
A-7 Test the Manual Platform Lowering Operation ............................................... 4 - 6
A-8 Test the Tilt Sensor ........................................................................................ 4 - 6
A-9 Test the Pothole Guards ................................................................................. 4 - 7
A-10 Test the Lift/Drive Select Switch ..................................................................... 4 - 7
A-11 Perform 30 Day Service .................................................................................. 4 - 8
B-1 Check the Batteries ........................................................................................ 4 - 9
B-2 Inspect the Electrical Wiring .......................................................................... 4 - 10
B-3 Inspect the Tires and Wheels (including castle nut torque) ............................ 4 - 11
B-4 Test the Key Switch ...................................................................................... 4 - 11
B-5 Test the Emergency Stop Buttons ................................................................. 4 - 12
B-6 Test the Service Horn .................................................................................... 4 - 12
B-7 Test the Drive Brakes .................................................................................... 4 - 13
B-8 Test the Drive Speed - Stowed Position ........................................................ 4 - 15
B-9 Test the Drive Speed - Raised Position ......................................................... 4 - 15
B-10 Perform Hydraulic Oil Analysis ...................................................................... 4 - 16
B-11 Check the Electrical Contactor ...................................................................... 4 - 16
B-12 Replace the Hydraulic Return Filter ............................................................... 4 - 17
C-1 Check the Module Tray Latch Components ................................................... 4 - 18
D-1 Test or Replace the Hydraulic Oil .................................................................. 4 - 19
viii Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339
TABLE OF CONTENTS
Section Five Troubleshooting Flow Charts and Fault Codes

Chart
Number Chart Title Page
Fault Code Chart (Before Serial Number 17408) ..................................................... 5 - 3
Normal Operation Code Chart (Before Serial Number 17408) ................................. 5 - 6
Fault Code Chart (After Serial Number 17407) ........................................................ 5 - 8
1 All Functions Will Not Operate ................................................................................. 5 - 9
2 Pump Motor Will Not Operate ................................................................................ 5 - 12
3 Pump Motor Will Not Operate
After serial number 6900 ........................................................................................ 5 - 14
4 All Functions Inoperative, Power Unit Starts and Runs
(No applicable code) ............................................................................................... 5 - 16
5 Ground Controls Inoperative, Platform Controls Operate Normally
6 Platform Controls Inoperative, Ground Controls Operate Normally
7 Platform Up Function Inoperative ........................................................................... 5 - 20
8 Platform Down Function Inoperative
GS-2046 & GS-2646 Models .................................................................................. 5 - 21
9 Platform Down Function Inoperative
GS-3246 Models .................................................................................................... 5 - 23
10 Steer Left Function Inoperative .............................................................................. 5 - 25
11 Steer Right Function Inoperative ............................................................................ 5 - 27
12 All Drive Functions Inoperative, All Other Functions Operate Normally ................. 5 - 29
13 Brake Release Function Inoperative ...................................................................... 5 - 31
14 Drive Forward Function Inoperatmive .................................................................... 5 - 32
Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 ix
TABLE OF CONTENTS
Section Five Troubleshooting Flow Charts and Fault Codes, continued

15 Drive Reverse Function Inoperative ....................................................................... 5 - 33
16 Machine Will Not Drive At Full Speed ..................................................................... 5 - 34
17 Machine Drives At Full Speed With Platform Raised ............................................. 5 - 36
18 Manual Platform Lowering Function Inoperative
GS-2046 & GS-2646 (No applicable code) ............................................................ 5 - 37
19 Manual Platform Lowering Function Inoperative
GS-3246 (No applicable code) ............................................................................... 5 - 38
20 Drive Function Overspeeds While Driving Down an Incline
GS-3246 Models (No applicable code) ................................................................... 5 - 39
21 Drive Function Hesitates While Steering
GS-3246 Models (No applicable code) ................................................................... 5 - 40
Section Six Schematics

Introduction ............................................................................................................... 6 - 1
Electrical Components .............................................................................................. 6 - 2
Module Tray Legend (Before serial number 6901) ................................................... 6 - 4
Module Tray Legend (After serial number 6900) ...................................................... 6 - 5
Electrical Symbols Legend ....................................................................................... 6 - 6
Electrical Schematic (Before serial number 6901) .................................................... 6 - 7
Electrical Schematic (From serial number 6901 to 8931) ......................................... 6 - 9
Electrical Schematic (From serial number 8932 to 17407) ..................................... 6 - 11
Electrical Schematic (After serial number 17407)................................................... 6 - 13
Ground Controls and Level Sensor Box Legend .................................................... 6 - 15
Platform Controls Legend (Before serial number 17408) ....................................... 6 - 16
Platform Controls Legend (After serial number 17407) .......................................... 6 - 17
Hydraulic Symbols Legend ..................................................................................... 6 - 18
Hydraulic Schematic (Before serial number 17482) ............................................... 6 - 19
Hydraulic Schematic (After serial number 17481) .................................................. 6 - 20
x Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339
TABLE OF CONTENTS
Section Seven Repair Procedures

Introduction ............................................................................................................... 7 - 1
Platform Controls
1-1 Joystick Controller .......................................................................................... 7 - 2
1-2 Software Configuration ................................................................................... 7 - 3
1-3 How to Set the Dip Switch Codes .................................................................. 7 - 4
1-4 Toggle Switches ............................................................................................. 7 - 6
Platform Components
2-1 Platform .......................................................................................................... 7 - 7
2-2 Platform Extension .......................................................................................... 7 - 8
Scissor Components
3-1 Scissor Assembly, GS-2046 ......................................................................... 7 - 11
3-4 Lift Cylinder ................................................................................................... 7 - 32
Ground Controls
4-1 Manual Platform Lowering Cable, GS-2046 & GS-2646 ............................... 7 - 35
4-2 Manual Platfrom Lowering, GS-3246 ............................................................ 7 - 36
4-3 Toggle Switches, See 1-2, Toggle Switches ................................................. 7 - 36
Hydraulic Pump
5-1 Hydraulic Pump ............................................................................................ 7 - 36
Manifolds
6-1 Function Manifold Components (Before serial number 11501) ..................... 7 - 38
6-2 Function Manifold Components (After serial number 11500) ........................ 7 - 40
6-3 Valve Adjustments - Function Manifold......................................................... 7 - 42
6-4 Valve Adjustments - Lift Relief Valve, GS-3246 ........................................... 7 - 44
6-5 Valve Adjustments - Back Pressure Relief Valve ......................................... 7 - 45
Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 xi
Section Seven Repair Procedures, continued

Steering Axle Components
7-1 Yoke and Drive Motor ................................................................................... 7 - 46
7-2 Steering Cylinder .......................................................................................... 7 - 48
7-3 Steering Bellcrank ......................................................................................... 7 - 48
Non-steering Axle Components
8-1 Drive Brake ................................................................................................... 7 - 49
Brake Release Hand Pump Components
9-1 Brake Release Hand Pump .......................................................................... 7 - 50
xii Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339
Service Manual - First Edition Section 2 - Specifications
Specifications
Machine Specifications - Platform dimensions
GS-2046 Length 89 in 226 cm
Stowed dimensions Width 453/4 in 116 cm
Length 96 in 243.8 cm Extension length 39 in 99 cm
Length, platform extended 1351/2 in 344.1 cm Maximum load capacity 1200 lbs 544 kg
Width 46 in 116.8 cm All Models
Models with sliding rails Weight 4324 lbs 1961 kg
Height, stowed maximun 781/2 in 199.4 cm Ground clearance 4 in 10.2 cm

Rails up - ANSI & CSA 7/8
Pothole guards deployed in 2.2 cm
Height, stowed maximum 827/8 in 210.4 cm
Rails up - CE Tires and wheels
Height, stowed maximum 713/4 in 182.25 cm Tire size (solid rubber) 15 x 5 x 11 1/4 in
Rails lowered 38.1 x 12.7 x 28.6 cm
Height, stowed maximum 391/4 in 99.7 cm Load range 2,400 lbs 1,089 kg
Rails removed Tire contact area 9 sq in 58 sq cm
Height, guard rails - ANSI & CSA 39 in 99.1 cm Overall tire diameter 15 in 38.1 cm
Height, guard rails - CE 42 1 /2 in 110.2 cm Wheel diameter 111/4 in 28.6 cm
Models with folding rails Wheel width 5 in 12.7 cm
Height, stowed maximum 861/8 in 219 cm Castle nut torque 300 ft-lbs 406.7 Nm
Height stowed maximum 643/4 in 164 cm Fluid Capacities
Rails folded
Hydraulic tank capacity 51/2 gallons 20.8 liters
Platform height, 423/8 in 107.6 cm
Stowed maximum Hydraulic system capacity 6 gallons 22.7 liters
(including tank)
Operational dimensions
Continuous improvement of our products is a
Maximum platform height 26 ft 7.9 m Genie policy. Product specifications are subject to
change without notice.
Maximum platform working height 20 ft 6.1 m
Maximum platform extension 39 in 99 cm
Wheelbase 72 7/8 in 185.1 cm
Turning radius, outside 91 3/4 in 233.1 cm
Turning radius, inside 0 in 0 cm
Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 2-1
Section 2 - Specifications Service Manual - First Edition
SPECIFICATIONS

Stowed dimensions Width 45 3/4 in 116 cm
Length, platform extended 135 1/2 in 344.1 cm Maximum load capacity 1000 lbs 454 kg
Height - stowed maximum 85 1/2 in 217.2 cm Ground clearance 4 in 10.2 cm

Height - stowed maximum 897/8 in 228.3 cm
Height - stowed maximum 851/2 in 217.2 cm Tire size (solid rubber) 15 x 5 x 11 1/4 in
Height , stowed maximum 46 1/8 in 117.2 cm Load range 2,400 lbs 1,089 kg
Rails removed Tire contact area 10 sq in 64.5 sq cm
Height, guard rails - CE 431/2 in 110.2 cm Wheel diameter 11 1/4 in 28.6 cm
Height, stowed maximum 897/8 in 228 cm Castle nut torque 300 ft-lbs 406.7 Nm
Height, stowed maximum 681/8 in 173 cm Fluid Capacities
Rails folded
Platform height, 46 1/8 in 117.2 cm
(including tank)
Continuous improvement of our products is a
Maximum platform height 26 ft 7.9 m Genie policy. Product specifications are subject to
Maximum platform working height 32 ft 9.8 m change without notice.
Turning radius, inside 0 in 0 cm
2-2 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339
SPECIFICATIONS

Stowed dimensions Width 45 3/4 in 116 cm
Length, platform extended 135 1/2 in 344.2 cm Maximum load capacity 1000 lbs 454 kg
Height - stowed maximum 90 1/2 in 229.9 cm Ground clearance 4 in 10.2 cm

Height - stowed maximum 95 in 241 cm
Height, stowed maximum 833/4 in 212.7 cm Tire size (solid rubber) 15 x 5 x 11 1/4 in
Height - stowed maximum 511/4 in 130.2 cm Load range 2,400 lbs 1,089 kg
Rails removed Tire contact area 10 sq in 64.5 sq cm
Height, guard rails - CE 431/2 in 110.2 cm Wheel diameter 11 1/4 in 28.6 cm
Height, stowed maximum 95 in 241 cm Castle nut torque 300 ft-lbs 406.7 Nm
Height, stowed maximum 733/8 in 186 cm Fluid Capacities
Rails folded
Platform height 511/4 in 130.2 cm
(including tank)
Maximum platform height 32 ft 11.75 m
Maximum platform working height 38 ft 11.6 m
Turning radius, inside 0 in 0 cm Continuous improvement of our products is a

Genie policy. Product specifications are subject to
change without notice.
SPECIFICATIONS
Performance Specifications - Hydraulic Specifications -

All Models All Models
Drive speeds (maximum) Hydraulic fluid Dexron equivalent
Stowed, maximum 2.2 mph 3.5 km/h Lift pump

40 ft/12.4 sec 12.2 m/12.4 sec
Type: gear
Platform raised 0.5 mph 0.8 km/h
40 ft/54.5 sec 12.2 m/54.5 sec Displacement
per revolution 0.244 cu in 4 cc
Gradability
GS-2046, GS-2646 30% Displacement 4 gallons per minute
GS-3246 25% 15.1 liters per minute
(2500 psi/172 bar)
Function speeds, maximum
from platform controls Hydraulic tank 10 micron with 25 psi
return line filter (1.7 bar) bypass
GS-2046
Function manifold
Platform up 28 to 32 seconds
System relief valve pressure
Platform down 26 to 30 seconds (GS-2046 & GS-2646 models) 3700 psi 205.1 bar
GS-2646 Drive relief valve pressure

(GS-3246 models) 3700 psi 205.1 bar
Lift relief valve pressure
Platform down 26 to 30 seconds (GS-3246 models) 2000 psi 137.9 bar
GS-3246 Steer relief valve pressure 1500 psi 103.4 bar
Platform down 38 to 40 seconds
SPECIFICATIONS
Hydraulic Hose and Fitting Torque Specifications

Your machine is equipped with either 37 flared fittings and hose ends OR Parker Seal-Lok fittings and
hose ends. Machines that utilize Parker Seal-Lok hoses and fittings require that the fittings and hose
ends be torqued to specification when they are removed and installed or when new hoses or fittings are
installed. Machines equipped with 37 flared fittings and hose ends do not need to be torqued to these
specifications.
Hydraulic Hose and Fitting Torque Specifications

SAE O-ring Boss Port - tube fitting Seal-Lok - hose end
SAE Dash Installing SAE Dash
Size into... ft. lbs. Nm Size ft. lbs. Nm
-4 Aluminum 11 14.9 -4 18 24.4
Steel 16 21.7 -6 27 36.6
-6 Aluminum 23 31.2 -8 40 54.2
Steel 35 47.5 -10 63 85.4
-8 Aluminum 40 54.2 -12 90 122
Steel 60 81.3 -16 120 162.7
-10 Aluminum 69 93.6 -20 140 190
Steel 105 142.4 -24 165 223.7
-12 Aluminum 93 126.1
Steel 140 190
-16 Aluminum 139 188.5
Steel 210 284.7
-20 Aluminum 172 233.2
Steel 260 352.5
-24 Aluminum 208 282
Steel 315 427.1
Torque Procedure
2 Lubricate the O-ring before installation.
1 Replace the O-ring. The O-ring must be
replaced anytime the seal has been broken. 3 Be sure that the face seal O-ring is seated and
The O-ring cannot be re-used if the fitting or retained properly.
hose end has been tightened beyond finger
4 Position the tube and nut squarely on the face
tight.
seal end of the fitting and tighten the nut finger
The O-rings used in the Parker tight.
Seal Lok fittings and hose ends
are a custom-size O-ring. They 5 Tighten the nut or fitting to the appropriate
are not a standard SAE size O- torque per given size as shown in the table
ring. They are available in the O- above.
ring field service kit (Genie pn. 6 Operate all machine functions and inspect the
49612). hoses and fittings and related components to
be sure that there are no leaks.
This page intentionally left blank.
Service Manual - First Edition Section 3 - Scheduled Maintenance Inspections
Scheduled Maintenance Inspections
About
Tools ThisNew
Section
Dealer
are parts service
Therequired
Schedulerequired suggested
There are four types of maintenance inspections

that must be performed according to a schedule
daily, quarterly, annual and every two years. To
account for repeated procedures, the Maintenance
Observe and Obey: Tables and the Maintenance Inspection Report
have been divided into four subsectionsA, B, C,
Maintenance inspections shall be completed by D. Use the following chart to determine which
a person trained and qualified on the group(s) of procedures are required to perform a
maintenance of this machine. scheduled inspection.
Scheduled maintenance inspections shall be
completed daily, quarterly, annually and every Inspection Table or Checklist
2 years as specified on the Maintenance
Inspection Report. Daily A
Failure to properly complete each Quarterly A+B

inspection when required may
cause death, serious injury or Annual A+B+C
substantial machine damage.
Two year A+B+C+D
Immediately tag and remove from service a
damaged or malfunctioning machine.
Maintenance Tables
Repair any machine damage or malfunction
before operating machine. The maintenance tables contained in this section
provide summary information on the specific
Keep records on all inspections for three years.
physical requirements for each inspection.
A quarterly inspection must be completed for
machines that have been out of service for a Complete step-by-step instructions for each
period longer than 3 months. scheduled maintenance procedure are provided in
section 4, Scheduled Maintenance Procedures.
Maintenance Inspection Report

The maintenance inspection report contains
checklists for each type of scheduled inspection.
Make copies of the Maintenance Inspection

Report to use for each inspection. Store
completed forms for three years.
Section 3 - Scheduled Maintenance Inspections Service Manual - First Edition
Maintenance Tables
Tools New Dealer

Table A are parts service
required required suggested
A-1 Inspect the Operator's and Safety Manuals
A-2 Inspect the Decals and Placards
A-3 Inspect for Damage, Loose or Missing Parts
A-4 Check the Hydraulic Oil Level
A-5 Check for Hydraulic Leaks
A-6 Test the Platform and Ground Controls
A-7 Test the Manual Platform Lowering Operation
A-8 Test the Tilt Sensor
A-9 Test the Pothole Guards
A-10 Test the Lift/Drive Select Switch
A-11 Perform 30 Day Service
Table B
B-1 Check the Batteries
B-2 Inspect the Electrical Wiring
B-3 Inspect the Tires and Wheels

(including castle nut torque)
B-4 Test the Key Switch
Service Manual - First Edition Section 3 - Scheduled Maintenance Inspections
MAINTENANCE TABLES
Tools New Dealer

Table B, continued are parts service
required required suggested
B-5 Test the Emergency Stop Buttons
B-6 Test the Horn
B-7 Test the Drive Brakes
B-8 Test the Drive Speed - Stowed Position
B-9 Test the Drive Speed - Raised Position
B-10 Perform Hydraulic Oil Analysis

See D-1 Test or Replace the Hydraulic Oil
B-11 Check the Electrical Contactor
Every 250 hours, perform the following engine

maintenance procedure.
B-12 Replace the Hydraulic Return Filter
Table C
C-1 Check the Module Tray latch Components
Table D
D-1 Test or Replace the Hydraulic Oil
Section 3 - Scheduled Maintenance Inspections Service Manual - First Edition
Maintenance Inspection Report

Model Checklist A Y N R NewChecklistDealer
Tools C Y N R
Refer to Table A are partsRefer to Table
service
C
Serial number required required suggested
A-1 Operator's and C-1 Latch Components
Date Safety manuals
A-2 Decals and Placards Checklist D Y N R
Hour meter A-3 Damage and loose or Refer to Table D
Missing Parts
Machine owner D-1 Hydraulic oil
A-4 Hydraulic Oil Level
Inspected by (print) A-5 Hydraulic Leaks
A-6 Platform and
Inspector signature Ground Controls
A-7 Manual Platform Lowering
Inspector title
A-8 Tilt Sensor
Inspector company A-9 Pothole Guards
A-10 Lift/drive Select Switch
Instructions
Make copies of this page to use for A-11 30 Day Service
each inspection.
Select the appropriate checklist(s) for Checklist B Y N R
the type of inspection to be performed.
Refer to Table B
Daily Inspection: A B-1 Batteries
Quarterly Inspection: A+B B-2 Electrical Wiring
Annual Inspection: A+B+C B-3 Tires and Wheels
2 Year Inspection: A+B+C+D B-4 Key Switch
B-5 Emergency Stop
Place a check in the appropriate box
after each inspection procedure is B-6 Horn
completed. B-7 Drive Brakes
Use the maintenance tables in this B-8 Drive Speed - stowed
section and the step-by-step
procedures in section 4 to learn how to B-9 Drive Speed - raised
perform these inspections. B-10 Hydraulic Oil Analysis
If any inspection receives an N, tag B-11 Electrical Contactor
and remove the machine from service, (before serialnumber 6901)
repair and re-inspect it. After repair, Perform every 250 hours
place a check in the R box.
B-12 Hydraulic Return Filter
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
Comments
Service Manual - First Edition Section 4 - Scheduled Maintenance Procedures
Scheduled Maintenance Procedures

About This Section
This section contains detailed procedures for each
scheduled maintenance inspection.
Each procedure includes a description, safety

warnings and step-by-step instructions.
Observe and Obey: Symbols Legend
Maintenance inspections shall be completed by Safety alert symbolused to alert

a person trained and qualified on the personnel to potential personal
maintenance of this machine. injury hazards. Obey all safety
messages that follow this symbol
Scheduled maintenance inspections shall be to avoid possible injury or death.
completed daily, quarterly, annually and every
2 years as specified on the Maintenance Redused to indicate the
Inspection Report. presence of an imminently
Failure to properly complete each avoided, will result in death or
inspection when required may serious injury.
cause death, serious injury or
substantial machine damage. Orangeused to indicate the
presence of a potentially
Immediately tag and remove from service a hazardous situation which, if not
damaged or malfunctioning machine. avoided, could result in death or
serious injury.
before operating machine. Yellow with safety alert symbol
Keep records on all inspections for three years. potentially hazardous situation
Unless otherwise specified, perform each which, if not avoided, may cause
procedure with the machine in the following minor or moderate injury.
configuration: Yellow without safety alert
Machine parked on a flat level surface symbolused to indicate the
presence of a potentially
Platform in the stowed position hazardous situation which, if not
Key switch in the OFF position with the key avoided, may result in property
removed damage.
Wheels chocked Greenused to indicate operation

or maintenance information.
Indicates that a specific result is expected after
performing a series of steps.
Section 4 - Scheduled Maintenance Procedures Service Manual - First Edition
Table A Procedures
A-1 A-2
Inspect the Operators and Inspect the
Safety Manuals Decals and Placards
Maintaining the operators and safety manuals in Maintaining all of the safety and instructional
good condition is essential to safe machine decals and placards in good condition is
operation. Manuals are included with each mandatory for safe machine operation. Decals
machine and should be stored in the container alert operators and personnel to the many
provided in the platform. An illegible or missing possible hazards associated with using this
manual will not provide safety and operational machine. They also provide users with operation
information necessary for a safe operating and maintenance information. An illegible decal
condition. will fail to alert personnel of a procedure or hazard
and could result in unsafe operating conditions.
1 Check to be sure the storage container is
present and in good condition. 1 Refer to the Decals section in the appropriate
Genie GS-2032 & Genie GS-2046 & Genie
2 Check to make sure that the operators,
GS-2646 & Genie GS-3246 Operator's Manual
responsibilities and safety manuals are present
and use the decal list and illustrations to
and complete in the storage container in the
determine that all decals and placards are in
platform.
place.
3 Examine the pages of each manual to be sure
2 Inspect all decals for legibility and damage.
that they are legible and in good condition.
Replace any damaged or illegible decal
4 Always return the manuals to the storage immediately.
container after use.
Contact your authorized Genie
Contact your authorized Genie distributor or Genie Industries if
distributor or Genie Industries if replacement decals are needed.
replacement manuals are needed.
TABLE A PROCEDURES
A-3 Check the entire machine for:

Inspect for Damage and Loose or Cracks in welds or structural components
Missing Parts Dents or damage to machine

Be sure that all structural and other critical
Daily machine condition inspections are essential components are present and all associated
to safe machine operation and good machine fasteners and pins are in place and properly
performance. Failure to locate and repair damage, tightened
and discover loose or missing parts may result in
an unsafe operating condition. Side rails installed and bolts are fastened
Be sure that the chassis trays are in place,
1 Inspect the entire machine for damage and latched and properly connected
improperly installed or missing parts including:
Electrical components, wiring and electrical
cables
Hydraulic power unit, tank, hoses, fittings,
cylinders and manifolds
Battery pack and connections
Drive motors
Wear pads
Tires and wheels
Limit switches, alarms and horn
Nut, bolts and other fasteners
Platform entry chain or gate
Beacons and alarms (if equipped)
Brake release components
Safety arm
Pothole guards
Platform extension
Scissor pins and retaining fasteners
Platform control joystick
Inverter (if equipped)
TABLE A PROCEDURES
A-4 A-5
Check the Hydraulic Oil Level Check for Hydraulic Leaks
Maintaining the hydraulic oil at the proper level is Detecting hydraulic fluid leaks is essential to
essential to machine operation. Improper hydraulic operational safety and good machine
oil levels can damage hydraulic components. Daily performance. Undiscovered leaks can develop into
checks allow the inspector to identify changes in hazardous situations, impair machine functions
the oil level that might indicate the presence of and damage machine components.
hydraulic system problems.
1 Inspect for hydraulic oil puddles, dripping or
Perform this procedure with the residue on or around the following areas:
platform in the stowed position.
Hydraulic tank, return filter, fittings and hoses
1 Visually inspect the oil level in the hydraulic Hydraulic power unit, fittings and hoses
tank through the sight gauge in the side of the
power unit module. Hydraulic lift cylinder(s) and manual
lowering valve(s)
Result: The hydraulic oil level should be within
Function manifold
the FULL and ADD marks on the oil level indicator
decal. The underside of the drive chassis
Drive motors
2 Add oil if necessary. Do not overfill.
Drive brakes
Hydraulic Oil Specifications Ground area under the machine
All Models Before Serial Number 21920
Hydraulic oil type Dexron equivalent
Hydraulic tank capacity 5.5 gallons

20.8 liters
Hydraulic system 6 gallons

(including tank) 22.7 liters
Hydraulic Oil Specifications

GS-3246 After Serial Number 21919
Hydrailic tank capacity 7 gallons

26.5 liters

TABLE A PROCEDURES
A-6 7 Press and hold the function enable switch on

the control handle.
Test the Platform and
Result: The green power light should come on,
Ground Controls
OR the light below the lift selector button
Testing the machine functions and the Emergency should come on.
Stop buttons for malfunctions is essential for safe
8 Slowly move the control handle in the direction
machine operation. An unsafe working condition
indicated by the blue arrow.
exists if any function fails to operate properly or
either Emergency Stop button fails to stop all the Result: The platform should raise. The pothole
machine functions. Each function should operate guards should deploy.
smoothly and be free of hesitation, jerking and
unusual noise. 9 Release the control handle.
1 Turn the key switch to ground control and pull Result: The platform should stop raising.
out the Emergency Stop button to the ON 10 Press and hold the function enable switch.
position at both the platform and ground Slowly move the control handle in the direction
controls. indicated by the yellow arrow.
2 Activate the platform up function.
Result: The platform should lower. The descent
Result: The platform should raise. alarm should sound while the platform is
lowering.
3 Activate the platform down function.
CE models: When lowering the
Result: The platform should lower. The descent platform, the platform should stop
alarm should sound while the platform is when it is 6 feet (1.8 m) from the
lowering. ground. Be sure the area below
the platform is clear of personnel
4 Push in the ground controls Emergency Stop
and obstructions before
button to the OFF position.
continuing. To continue lowering,
Result: No function should operate. release the control handle, wait
4-6 seconds, then move the
5 Turn the key switch to platform control and pull control handle again.
out the Emergency Stop button to the ON
position at both the ground and the platform 11 Push in the Emergency Stop button to the OFF
controls. position.
6 Press and hold the lift function enable button Result: No function should operate. The
OR move the lift/drive selector switch to the lift machine should stop.
position, OR press the lift function selector
As a safety feature, selecting
button.
and operating the ground
controls will override the
platform controls, except the
Emergency Stop button.
TABLE A PROCEDURES
A-7 A-8
Test the Manual Platform Test the Tilt Sensor
Lowering Operation Perform this test from the ground
Detection of manual platform lowering system with the platform controls. Do not
malfunctions is essential for safe machine stand in the platform.
operation. An unsafe working condition exists if 1 Fully lower the platform.
the manual platform lowering function does not
operate in the event of a main power loss. 2 Place a 2x4 inch (5x10 cm) block or similar
piece of wood in front of both wheels on one
1 Turn the key switch to ground control and pull side and drive the machine up onto them.
3 Raise the platform.
position at both the platform and ground
controls. Result: When the platform is raised 7 feet
(2.1 m) from the ground, an alarm should
2 Raise the platform approximately
sound.
2 feet (0.6 m).
CE models: When the platform is
3 Pull the manual platform lowering handle or
raised 7 feet (2.1 m) from the
push the manual lowering button located next
ground, an alarm should sound
to the ground controls.
and the lift and drive functions
Result: The platform should lower. The descent should not operate.
alarm will not sound.
4 Lower the platform and drive the machine off
the blocks.
TABLE A PROCEDURES
A-9 A-10
Test the Pothole Guards Test the Lift/Drive Select Switch
The pothole guards should (before serial number 17408)
automatically deploy when the A properly functioning Lift/Drive Select Switch
platform is raised. The pothole is essential for safe machine operation. An
guards activate two limit switches improperly operating Lift/Drive Select Switch
which controls the machine drive will fail to activate the appropriate platform control
speed. If the pothole guards do which may result in a hazardous situation.
not deploy and the platform is
raised above 6 feet (1.8 meters), 1 Turn the key switch to platform control and pull
an alarm sounds and the machine out the Emergency Stop button to the ON
will not drive. position at both the platform and ground
controls.
1 Raise the platform.
2 Move the lift/drive select switch to the LIFT
Result: When the platform is raised 4 feet
position.
(1.2 meters) from the ground, the pothole
guards should deploy. 3 Press and hold the function enable switch.
2 Press on the pothole guards on one side, and Result: The green power light should come on.
then the other.
4 Slowly move the control handle off center.
Result: The pothole guards should not move.
Result: The platform should raise or lower.
3 Lower the platform.
5 Move the lift/drive select switch to the DRIVE
Result: The pothole guards should return to the position.
stowed position.
6 Press and hold the function enable switch.
4 Place a 2x4 inch (5x10 cm) block or similar
piece of wood under the pothole guard. Raise Result: The green power light should come on.
the platform. 7 Slowly move the control handle off center.
Result: When the platform is raised Result: The drive and steer functions should
approximately 6 feet (1.8 meters), an alarm operate.
should sound and the drive function should not
work.
5 Lower the platform and remove the block of
wood.
TABLE A PROCEDURES
A-11
Perform 30 Day Service
The 30 day maintenance procedure is a one-time
sequence of procedures to be performed after the
first 30 days or 50 hours of usage. After this
interval, refer to the maintenance tables for
continued scheduled maintenance.
1 Perform the following maintenance procedures:

B-3 Inspect Tires and Wheels
B-12 Replace the Hydraulic Filter
Table B Procedures
B-1 6 Check the battery acid level of each battery. If
needed, replenish with distilled water to the
Check the Batteries bottom of the battery fill tube. Do not overfill.
Proper battery condition is essential to good 7 Install the battery vent caps.
machine performance and operational safety.
Improper fluid levels or damaged cables and 8 Check each battery pack and verify that the
connections can result in component damage batteries are wired correctly.
and hazardous conditions.
Bodily injury hazard. Batteries

contain acid. Avoid spilling or
contacting battery acid. Neutralize
battery acid spills with baking
soda and water.
Electrocution hazard. Contact
with hot or live circuits may
result in death or serious injury.
Remove all rings, watches and
other jewelry.
Perform this test after fully
charging the batteries.
1 Put on protective clothing and eye wear.
2 Disconnect the battery pack from the machine.
3 Be sure that the battery cable connections are
free of corrosion.
4 Be sure that the battery hold downs and cable
connections are tight.
5 Remove the battery vent caps and check the
specific gravity of each battery cell with a
hydrometer.
Result: If any battery cell displays a specific
gravity of less than 1.098, the battery must be
replaced.
TABLE B PROCEDURES
B-2 6 Inspect the center chassis area and scissor

arms for burnt, chafed and pinched cables.
Inspect the Electrical Wiring
7 Inspect the following areas for burnt, chafed,
Maintaining electrical wiring in good condition is corroded, pinched and loose wires:
essential to safe operation and good machine
performance. Failure to find and replace burnt, ECM to platform controls
chafed, corroded or pinched wires could result in Power to platform wiring
unsafe operating conditions and may cause
8 Raise the platform and return the safety arm to
component damage.
the stowed position.
Electrocution hazard. Contact 9 Lower the platform to the stowed position and
with hot or live circuits could turn the machine off.
Remove all rings, watches and
other jewelry.
1 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
2 Turn the key switch to ground control and pull
position.
3 Raise the platform approximately 8 feet (2.4 m)
from the ground.
4 Lift the safety arm, move to the center of the
scissor arm and rotate down to a vertical
position.
5 Lower the platform onto the safety arm.
Crushing hazard. Keep hands
clear of the safety arm when
lowering the platform.
4 - 10 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339
TABLE B PROCEDURES
B-3 B-4
Inspect the Tires and Wheels Test the Key Switch
(including castle nut torque) Proper key switch action and response is essential
Maintaining the tires and wheels in good to safe machine operation. The machine can be
condition is essential to safe operation and good operated from the ground or platform controls and
performance. Tire and/or wheel failure could result the activation of one or the other is accomplished
in a machine tip-over. Component damage may with the key switch. Failure of the key switch to
also result if problems are not discovered and activate the appropriate control panel could cause
repaired in a timely fashion. a hazardous operating situation.
1 Check the tire surface and sidewalls for cuts, 1 Pull out the Emergency Stop button to the ON
cracks or unusual wear. position at both the ground and platform

controls.
2 Check each wheel for damage, bends and
cracks. 2 Turn the key switch to platform control.
3 Remove the cotter pin and check each castle 3 Check the platform up/down function from the
nut for proper torque. ground controls.
4 Install a new cotter pin. Result: The machine functions should not
operate.
Always replace the cotter pin with
a new one when removing the 4 Turn the key switch to ground control.
castle nut or when checking the 5 Check the machine functions from the
torque of the castle nut. platform controls.
Tires and wheels Result: The machine functions should not

operate.
Castle nut torque, dry 300 ft-lbs 405 Nm
6 Turn the key switch to the OFF position.
Castle nut torque, lubricated 225 ft-lbs 305 Nm
Result: No machine functions should operate.
Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 4 - 11
TABLE B PROCEDURES
B-5 B-6
Test the Emergency Stop Buttons Test the Service Horn
Properly functioning Emergency Stop buttons A functioning horn is essential to safe machine
are essential for safe machine operation. An operation. The horn is activated at the platform
improperly operating Emergency Stop button controls and sounds at the ground as a warning to
will fail to shut off power and stop all machine ground personnel. An improperly functioning horn
functions resulting in a hazardous situation. will prevent the operator from alerting ground
personnel of hazards or unsafe conditions.
As a safety feature, selecting
and operating the ground controls 1 Turn the key switch to platform control and
will override the platform controls, pull out the Emergency Stop button to the
except the platform Emergency ON position at both the ground and
Stop button. platform controls.
1 Turn the key switch to ground control and pull 2 Push down the horn button at the platform
out the Emergency Stop button to the ON controls.
position at both the ground and platform
controls. Result: The horn should sound.
2 Push in the Emergency Stop button at the The standard machine uses the
ground controls to the OFF position. multifunction alarm to emit the
horn sound. The optional horn will
Result: No machine functions should operate. sound like an automotive type
horn.
3 Turn the key switch to platform control and pull
controls.
4 Push down the Emergency Stop button at the
platform controls to the OFF position.
Result: No machine functions should operate.
The ground control Emergency
Stop button will stop all machine
operation, even if the key switch
is switched to platform control.
TABLE B PROCEDURES
B-7 7 Measure the distance between the test line and

your machine reference point.
Test the Drive Brakes
Proper brake action is essential to safe machine Braking: paved surface
operation. The drive brake function should operate
smoothly, free of hesitation, jerking and unusual Stopping distance 2 ft 0.6 m
noise. Hydraulically released individual wheel
brakes can appear to operate normally when not
fully operational. Result: The machine stops within the specified
braking distance. No action required.
Perform this procedure with the
machine on a firm, level surface Result: The machine does not stop within the
that is free of obstructions. specified braking distance. Proceed to step 8
and determine if the machine is equipped with
Be sure the platform extension a dynamic braking valve.
deck is fully retracted and the
platform is in the stowed position. The brakes must be able to hold
the machine on any slope it is
1 Mark a test line on the ground for reference. able to climb.
2 Turn the key switch to platform control and pull 8 Disconnect the battery pack from the machine.
position at both the ground and platform Electrocution hazard. Contact with
controls. electrically charged circuits could
3 Lower the platform to the stowed position. Remove all rings, watches and
4 Move the drive select toggle switch down for other jewelry.
normal drive operation OR press the drive 9 Locate the drive forward/reverse valve on the
speed selector button until the indicator light is function manifold. Refer to Illustrations 1
OFF.
5 Choose a point on the machine; i.e., contact

patch of a tire, as a visual reference for use
when crossing the test line.
6 Bring the machine to full drive speed before
reaching the test line. Release the function
enable switch or the joystick on the platform
controls when your reference point on the
machine crosses the test line.
a drive forward/reserve valve
TABLE B PROCEDURES
10 Tag the forward and the reverse valve coils. 15 Install the coil nut onto the valve and tighten.
Remove the coils from the valve. Torque to 60 in-lbs / 7 Nm.
The forward valve coil has white 16 Connect the battery pack to the machine.
and brown wires attached.
7 Replace the brakes and repeat this procedure
The reverse valve coil has beginning with step 1. Refer to Repair Procedure
white/black and brown wires 8-1, How to Remove a Drive Brake.
attached.
18 Contact the Genie Industries Service Parts
For reassembly, it will be helpful to Department and order kit part number 105457.
leave the wire harness attached to
19 Install the new valve received in the kit and
the valve coils.
mark the new valve with a white paint pen to
11 Remove the drive forward/reverse valve from the identify new valve installation.
function manifold. Cap the open port of the
20 Repeat this procedure beginning with step 1.
manifold.
If the machine fails to stop within the specified
12 Carefully inspect the hex portion of the valve for
stopping distance after installing new brakes,
an identification stamp.
please contact the Genie Industries Scissors
Result: SV10-4727 is stamped on the hex Service Department, 1-800-536-1800 Ext. 8710.
portion of the drive forward/reverse valve. This
indicates the machine is equipped with a
dynamic brake valve. Proceed to step 13.
Result: SV10-4727 is not stamped on the hex
portion of the drive forward/reverse valve. This
indicates the machine is not equipped with a
dynamic brake valve. Proceed to step 18.
13 Install the drive forward/reverse valve removed
in step 11 into the function manifold and
securely tighten. Torque to 25 ft-lbs / 34 Nm.
14 In order, install the reverse valve coil (with
white/black and brown wires), spacer washer
and the forward valve coil (with white and brown
wires) onto the valve.
For the machine to function
correctly, the reverse valve coil
must be closest to the manifold.
TABLE B PROCEDURES
B-8 B-9
Test the Drive Speed - Test the Drive Speed -
Stowed Position Raised Position
Proper drive function movement is essential to safe Proper drive function movement is essential to safe
machine operation. The drive function should machine operation. The drive function should
respond quickly and smoothly to operator control. respond quickly and smoothly to operator control.
Drive performance should also be free of hesitation, Drive performance should also be free of hesitation,
jerking and unusual noise over the entire jerking and unusual noise over the entire
proportionally controlled speed range. proportionally controlled speed range.
Select a test area that is firm, level Select a test area that is firm,
and free of obstructions. level and free of obstructions.
1 Create start and finish lines by marking two lines 1 Create start and finish lines by marking two
on the ground 40 feet (12.2 m) apart. lines on the ground 40 feet (12.2 m) apart.
2 Turn the key switch to platform control and pull 2 Turn the key switch to platform control and pull
out the Emergency Stop button to the ON out the Emergency Stop button to the ON
position at both the ground and platform position at both the ground and platform
controls. controls.
3 Lower the platform to the stowed position. 3 Raise the platform approximately 6 feet (2 m).
4 Move the drive select toggle switch down for 4 Move the drive select toggle switch down for
normal drive operation OR press the drive normal drive operation OR press the drive
speed selector button until the indicator light is speed selector button until the indicator light is
OFF. OFF.
5 Choose a point on the machine; i.e., contact 5 Choose a point on the machine; i.e., contact
patch of a tire, as a visual reference for use patch of a tire, as a visual reference for use
when crossing the test line. when crossing the test line.
6 Bring the machine to maximum drive speed 6 Bring the machine to maximum drive speed
before reaching the start line. Begin timing before reaching the start line. Begin timing
when your reference point on the machine when your reference point on the machine
crosses the start line. crosses the start line.
7 Continue at full speed and note the time when 7 Continue at full speed and note the time when
the machine reference point passes over the the machine reference point passes over the
finish line. Return the control handle to center. finish line. Return the control handle to center.
Drive speed: Drive speed (maximum):
Stowed position 40 ft / 12.4 sec 12.2 m / 12.4 sec Platform raised 40 ft / 54.5 sec 12.2 m / 54.5 sec
TABLE B PROCEDURES
B-10 B-11
Perform Hydraulic Oil Analysis Check the Electrical Contactor -
See D-1, Test or Replace the Hydraulic Oil. (before serial number 6901)
Maintaining the electrical contactor in good
condition is essential to safe machine operation.
Failure to locate a worn or damaged contactor
could result in an unsafe working condition and
component damage.
1 Open the hydraulic power unit module tray

and locate the electrical contactor mounted
above the hydraulic power unit.
2 Visually inspect the contact points of each
contactor for the following items:
Excessive burns
Excessive arcs
Excessive pitting
Replace the contactor if any
damage is found.
TABLE B PROCEDURES
B-12
Replace the Hydraulic Return
Filter
Replacement of the hydraulic filter is
essential for good machine performance and
service life. A dirty or clogged filter may cause the
machine to perform poorly and continued use may
cause component damage. Extremely dirty
conditions may require that the filter be replaced
more often.
Bodily injury hazard. Beware of

hot oil. Contact with hot oil may
cause severe burns.
The hydraulic filter is mounted on
the function manifold next to the
hydraulic power unit.
1 Clean the area around the hydraulic return
filter, then remove the filter with an oil filter
wrench.
2 Apply a thin layer of oil to the new oil filter
gasket.
3 Install the new filter (Genie part number 55616)
and tighten it securely by hand. Clean up any
oil that may have spilled during the replacement
procedure.
controls. Activate and hold the platform up
toggle switch.
5 Inspect the filter and related components to
be sure that there are no leaks.
Table C Procedure
C-1
Check the Module Tray Latch
Components
Maintaining the module tray latch components in
good condition is essential to good performance
and service life. Failure to detect worn out latch
components may result in module trays opening
unexpectedly, creating an unsafe operating
condition.
Perform this procedure with the

1 Lubricate each module tray latch. Using light
oil, apply a few drops to the side of the latch
pin.
2 Inspect each module tray latch pad (if
equipped). Replace any worn pad before the
latch will fail to securely hold the module tray
closed.
Table D Procedure
D-1 3 Remove the drain plug from the hydraulic tank.
Test or Replace the Hydraulic Oil Bodily injury hazard. Spraying
hydraulic oil can penetrate and
Replacement or testing of the hydraulic oil is burn skin. Loosen hydraulic
essential for good machine performance and connections very slowly to allow
service life. Dirty oil and suction strainer may the oil pressure to dissipate
cause the machine to perform poorly and gradually. Do not allow oil to squirt
continued use may cause component damage. or spray.
Extremely dirty conditions may require oil changes
to be performed more often. 4 Completely drain the tank into a suitable
container. See capacity specifications listed to
This machine uses Dexron the right.
equivalent hydraulic oil. Before
replacing the hydraulic oil, the oil 5 Tag, disconnect and plug the suction hose and
may be tested by an oil distributor return hose from the hydraulic tank.
for specific levels of contamination 6 Remove the hydraulic tank from the machine.
to verify that changing the oil is
necessary. If the hydraulic oil 7 Remove the suction strainer and clean it using
is not replaced at the two year a mild solvent.
inspection, test the oil 8 Clean the inside of the hydraulic tank using a
quarterly. Replace the oil when mild solvent.
it fails the test.
9 Install the suction strainer using thread sealer
Perform this procedure with the on the threads.
10 Install the drain plug using thread sealer on the
1 Disconnect the battery pack from the machine. threads.
2 Open the power unit module tray and place a 11 Install the hydraulic tank.
drain pan or other suitable container under the
hydraulic tank. 12 Fill the tank with hydraulic oil until the fluid is
within the FULL and ADD marks on the oil level
indicator decal. Do not overfill.
TABLE D PROCEDURES
13 Clean up any oil that may have spilled. Properly

dispose of the oil.
14 Operate all machine functions through a full
cycle and check for leaks.

Before Serial Number 21920
Hydraulic tank capacity 5.5 gallons

20.8 liters


After Serial Number 21919
Hydrailic tank capacity 7 gallons

26.5 liters

Service Manual - First Edition Section 5 - Troubleshooting Flow Charts
Troubleshooting Flow Charts

Before Troubleshooting:
Read, understand and obey the safety rules
and operating instructions printed in the
Genie GS-2032 & Genie GS-2046 & Genie
GS-2646 & Genie GS-3246 Operators
Manual.
Observe and Obey: Be sure that all necessary tools and test
equipment are available and ready for use.
Troubleshooting and repair procedures shall be
completed by a person trained and qualified on Read each appropriate flow chart thoroughly.
the repair of this machine. Attempting shortcuts may produce hazardous
conditions.
damaged or malfunctioning machine. Be aware of the following hazards and follow
generally accepted safe workshop practices.
before operating the machine. Crushing hazard. When testing
or replacing any hydraulic
Unless otherwise specified, perform each component, always support
repair procedure with the machine in the the structure and secure it
following configuration: from movement.
Machine parked on a flat level surface
Electrocution hazard. Contact
Platform in stowed position with electrically charged circuits
Key switch in the OFF position with the may result in death or serious
key removed injury. Remove all rings, watches
Wheels chocked and other jewelry.
Bodily injury hazard. Spraying
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
Perform all troubleshooting on a
firm level surface.
Two persons will be required to
safely perform some
troubleshooting procedures.
Section 5 - Troubleshooting Flow Charts Service Manual - First Edition
TROUBLESHOOTING FLOW CHARTS
About This Section General Repair Process
When a malfunction is discovered, the flow charts

in this section will help a service professional Malfunction Identify Troubleshoot
pinpoint the cause of the problem. To use this discovered symptoms
section, basic hand tools and certain pieces of test
equipment are requiredvoltmeter, ohmmeter,
pressure gauges. problem
still exists
The location of terminals mentioned in this section
can be found on the appropriate electrical or Return to Inspect Perform
hydraulic schematics provided in Section 6, service problem and test repair
Schematics. solved
Since various degrees of a particular function

loss may occur, selecting the appropriate flow
chart may be troublesome. When a function will
not operate with the same speed or power as a
machine in good working condition, refer to the
flow chart which most closely describes the
problem.
LED Diagnostic Readout

The diagnostic readout displays numerical codes
that provide information about the machine
operating status and about malfunctions. The
dot to the right of the numbers will blink during
normal operation codes and remain on with fault
codes.
The codes listed in the Operation Code Chart
are common operational status codes and
malfunction codes that can be cleared easily.
The codes listed in the Fault Code Chart

describe malfunctions and can aid in
troubleshooting the machine by pinpointing the
area or component affected.
Fault Code Chart

Fault Code Problem Possible Causes Solution
Reset the ECM. If problem

00 remains, replace the ECM.
Alarm sounds continuously. Remove obstruction to pothole

Error indicator light on at the Pothole guard may be blocked guard OR check pothole limit
platform controls when function or pothole limit switches may switch wiring for open
18 enable switch is engaged. not be activating or there is a connections OR check pothole
Machine will not drive. Machine bad wire connection. limit switch for proper
is not level. adjustment and activation.
Alarm sounds continuously. Remove obstruction to pothole

Error indicator light on at the Pothole guard may be blocked guard OR check pothole limit
platform controls when function or pothole limit switches may switch wiring for open
19 enable switch is engaged. not be activating or there is a connections OR check pothole
Machine will not drive. Machine bad wire connection. limit switch for proper
is level. adjustment and activation.
Release the function enable

Machine will not operate. Error Joystick initialization OK but switch OR check the switch for
33 indicator light on at the platform function enable switch is tied continuity in the joystick
controls. down. controller box (see Repair
Section).
Machine unit will not operate. Replace joystick controller box
ECM does not recognize the
34 Error indicator light on at the
platform controls.
main circuit board OR replace
platform controls. the coil cord.
Machine unit will not operate.
ECM does not recognize the Replace joystick controller box
35 Error indicator light on at the
platform controls. main circuit board.
platform controls.
Only the platform down

Check wiring and terminal at
function operates no other
motor contactor ckt A9-Curtis
functions operate. Error No power output from ECM to
51 indicator light on at the platform the motor contactor.
terminal 3 OR check wiring and
terminal at control ECM pin A9,
controls when the function
ckt A9-Curtis terminal 3.
enable switch is engaged.
Notes
Continued on next page
FAULT CODE CHART

(BEFORE SERIAL NUMBER 17408)
Machine will not drive forward. Check wiring and terminal at

Pump motor starts. Error the forward coil, ckt C6-
No power output from ECM to
52 indicator light on at the platform
the drive forward coil.
Forward coil OR check wiring
controls when the function and terminal at control ECM
enable switch is engaged. pin C6, ckt C6 Forward coil.
Machine will not drive in

reverse. Pump motor starts.
the reverse coil, ckt A7-
Error indicator light on at the No power output from ECM to
53 platform controls when the the drive reverse coil.
Reverse coil OR check wiring
and terminal at ECM pin A7,
function enable switch is
ckt A7 Reverse coil.
engaged.
Platform will not raise. Pump Check wiring and terminal at
motor starts. Error indicator the platform up coil, ckt A6-Up
54 light on at the platform controls
the platform up coil.
coil OR check wiring and
when the function enable terminal at ECM pin A6, ckt A6
switch is engaged. Up coil.
Platform will not lower. Error
the platform lowering coil, ckt
indicator light on at the platform No power output from ECM to
55 controls when the function the platform lowering coil.
B6-Down coil OR check wiring
and terminal at ECM pin B6,
enable switch is engaged.
ckt B6 Down coil.
Machine will not steer right. Check wiring and terminal at

Pump motor starts. Error the steer right coil, ckt C7
steer right coil.
Right coil OR check wiring and
controls when the function terminal at ECM pin C7, C7
enable switch is engaged. Right coil.
Machine will not steer left. Check wiring and terminal at

Pump motor starts. Error the steer left coil, ckt B7 Left
steer left coil.
controls when the function terminal at ECM pin B7, B7
enable switch is engaged. Left coil.

the orifice coil, ckt C9 orifice
Machine will not drive but No power output from ECM to
58 platform will still raise. the brake orifice coil.
terminal at ECM pin C9, C9
orifice coil OR replace Coil.
Notes
FAULT CODE CHART

(BEFORE SERIAL NUMBER 17408)
Machine will not operate. Error

Lift/drive switch is turned "off" Check switch position OR
or in a neutral position. Replace switch.
controls.
Lift/drive switch turned from lift
Machine will not operate. Release function enable switch
to drive or drive to lift while the
63 Flashing green LED at the
function enable switch is
and move lift/drive switch to
platform controls. either lift or drive.
engaged.
Machine will not operate. ECM
88 cannot be reset.
EPROM not programmed. Replace ECM.
Release function enable switch

OR check the function enable
no code Green flashing LED at the
Function enable switch held for
more than 10 seconds without
microswitch for continuity in
platform controls. the joystick controller box.
available activating any function.
Reset controller and check for
fault code 33 at power up.
Machine drive speed reduces

to off limit drive speed OR Low Voltage Cut Back (LVCB)
no code platform raises slowly. Red is activated because battery
Charge batteries.
flashing LED at the platform supply voltage is 18.5V DC or
available controls while function enable less.
switch is activated.
Notes
Normal Operation Code Chart

Code Condition Explanation
Machine was operating normally, then the platform Emergency

Key switch to platform control
Stop button was pushed in and the key switch was turned to
Platform extended above 6 feet
20 ground control. Alarm will go off until key switch is turned to
Ground control and platform Emergency Stop buttons pulled
flashing platform control or the platform Emergency Stop button is pulled
out to the on position
out.

Platform extended above 6 feet
21 Normal operation
flashing
Key switch to ground control

Ground control Emergency Stop button pulled out to the on
To clear this code, be sure joystick is properly connected or pull
22 position
the platform Emergency Stop button out to the on position.
flashing Platform control Emergency Stop button pushed in to the off
position

Ground control and platform Emergency Stop buttons pulled out
23 Turn key switch to platform control.
to the on position
flashing
Error indicator light at platform controls is on

position To clear this code, be sure joystick is properly connected or pull
24
Platform control Emergency Stop button pushed in to the off the platform Emergency Stop button out to the on position.
flashing
position
Platform extended less than 6 feet.

25 out to the on position Turn key switch to platform control.
flashing Error indicator light at platform controls is on
Platform extended less than 6 feet

31 Ground control and platform Emergency Stop buttons pulled Normal operation.
flashing out to the on position.

To clear this code, be sure joystick is properly connected or pull
32 position
the platform Emergency Stop button out to the on position.
flashing Platform control Emergency Stop button pushed in to the off
position.
Up function selected
Note: if joystick controller is returned to center position before
36 function enable button is released, code 31 flashing will appear. If
flashing function enable button is released first, code 36 flashing will
Lift/drive switch to lift position
remain until another function is selected.
Down function selected

Lift/drive switch to lift position
Drive in blue direction function selected

Lift/drive switch to drive position
Drive in yellow direction function selected

to the on position
Lift/drive switch to drive position

Horn is being pressed
40 Note: Horn will operate without code 40 flashing if function enable
to the on position
flashing switch is not pressed in.
Function enable switch pressed.
Fault Code Chart

(after Serial Number 17407)
Normal operation
Machine will not operate. ECM
01 cannot be reset.
EPROM not programmed Replace ECM
Defective control cable OR Troubleshoot cable OR

02 Platform ECM error
platfrom controls platform controls
Undefined platform DIP switch
03 settings
DIP switch settings incorrect Correct DIP switch settings
Chassis up/down switch closed

12 at start up
Malfunctioningup/down switch Troubleshoot up/down switch
Malfunctioning pothole switch

Troubleshoot pothole switch
18 Pothole guard failure OR obstruction in pothole
OR remove obstruction.
guard linkage
Platform left turn switch closed Malfunctioning steer left Troubleshoot steer left
42 at start up microswitch microswitch
Platform right turn switch Malfunctioning steer right Troubleshoot steer right
43 closed at start up microswitch microswitch
Platform lift enable switch Malfunctioning lift enable
45 closed at start up switch
Troubleshoot lift enable switch
Platform drive enable switch Malfunctioning drive enable Troubleshoot drive enable
46 closed at start up switch switch
Platform joystick off neutral at Joystick potentiometer not
47 start up centered
Verify potentiometer setting
Malfunctioning coil OR wire Troubleshoot coil OR inspect

52 Forward coil error
disconnected from coil wire connection
53 Reverse coil error
54 Up coil error
55 Down coil error
56 Right coil error
57 Left coil error
58 Brake coil error
68 Low Voltage Batteries discharged Charge batteries
Chart 1
All Functions Turn keyswitch to the displays Refer to the fault code
ground control and a fault chart to find what chart
Will Not Operate visually inspect the code is associated with your
diagnostic display on the fault code OR consult
ECM. Is the display Genie Industries service
blank or does it display department.
If the Error Indicator a fault code?
light is on at the
platform controls, display is blank
please refer to the
Check voltage on input less than Charge batteries OR
specific chart that side of 275A fuse F2 24V check battery condition
relates to the error code inside battery module and replace bad
that is displayed on the tray. batteries OR check for
short circuits OR check
ECM. battery cables OR check
for open in negative
Be sure the circuit battery cable from
breaker and fuse are batteries to ground point
24V or more
on module tray.
not tripped or blown.
Be sure the batteries

are properly connected. 0V
Check voltage on output Replace 275A fuse F1.
side of 275A fuse F1
Be sure the batteries inside the battery
are fully charged. module tray.
Be sure both 24V

Emergency Stop
buttons are pulled out to Check continuity from B- no Repair open in negative
the ON position. terminal on curtis motor continuity battery cable from B-
controller to the negative terminal on curtis motor
battery cable at the controller to Anderson
Anderson plug. plug.
full
continuity
Models before serial Models before serial
number 6901: Check number 6901: Repair
the voltage on the input open in 24V supply
side of the motor cable from 275A fuse F1
contactor K1. 0V to the Anderson plug
Models after serial OR repair open in 24V
number 6900: Check supply cable from
the voltage at the B+ Anderson plug to motor
terminal on the motor contactor K1.
controller. Models after serial
number 6900: Repair
open in 24V supply
24V cable from 275A fuse F1
to Anderson plug OR
repair open in 24V
supply cable from
Continued on the next Anderson plug to the B+
page. terminal on the motor
controller.
CHART 1
Continued from the Check voltage at input 0V Models before serial

previous page. side of 7A circuit number 6901: Repair
breaker F2. open in white wire from
the input side of the
motor contactor to the
input side of the 7A
circuit breaker (24f-ckt
brkr to relay).
Models after serial
number 6900: Repair
24V open in white wire from
the Anderson connector
to the input side of the
7A circuit breaker.
Check voltage at white Repair open in white

wire at input side of 0V wire from output side of
Emergency Stop button 7A circuit breaker OR
S2. reset or replace 7A
circuit breaker.
24V
Check voltage at input 0V Repair open in white

side of each contact at wire from Emergency
the key switch S2. Stop button to key
switch OR repair open in
white wire jumper to
each contact OR
replace contact on
Emergency Stop button
24V OR replace Emergency
Stop button.
Turn key switch to 0V Check cam on key bad Repair or replace key
ground control position switch. switch.
and check output side of
contact. good
Replace contact OR
refer to Ground Controls
Inoperative, Chart 6 OR
consult Genie Industries
24V Service Department.
Continued on the next

page.
CHART 1
Continued from the Turn key switch to 0V Check cam on key Repair or replace key
previous page. platform control position switch. switch.
and check output side of
each contact. good
Replace bad
microswitch OR refer to
Platform Controls
24V Inoperative, Chart 5 OR
Service Department.
Refer to Chart 2, Pump

Motor Will Not Operate
OR repair open in white
wire (C2 estop chassis)
OR consult Genie
Industries Service
Department.
Chart 2
Pump Motor Activate lift function from
24V or
more Check voltage on B+
less
than Replace positive battery
the ground controls and terminal on motor cable from pump to B+
Will Not check voltage at positive controller.
24V
terminal on motor
Operate- terminal on pump motor. controller.
24V
before serial
no
number 6901 Check continuity on
ground cable from pump
continuity Replace ground cable
on lift pump motor.
motor to M- terminal on
Be sure the circuit motor controller.
breaker and fuse are
not tripped or blown. continuity
Be sure the batteries Check continuity from B- no Replace negative cable
are properly connected. terminal on motor continuity from B- terminal on
controller to the negative motor controller to the
Be sure the batteries battery cable at the Anderson plug.
are fully charged. Anderson plug (AP1).
continuity
less
Activate lift function and than Repair open in white
check voltage at 24V wire (26H) from the
terminal 1 on motor motor controller relay
controller. coil (K1) to the motor
controller.
less than 24V 24V
Activate the lift function Repair open in white

and check voltage at 0V wire (A9-curtis terminal
terminal 3 on the motor 3) from ECM to the
controller. motor controller OR
replace the ECM OR
Service Department.
5V
Activate the lift function Replace the motor

and check voltage at M- 24V controller or contact
terminal on the motor Genie Industries Service
controller. Department.
0V
Replace pump motor

OR consult Genie
Industries Service
Department.

page.
CHART 2
24V or
Activate the lift function more Replace positive cable
Continued from the and check voltage on from K1 to the motor
previous page. the output side of K1. controller OR replace
positive cable from the
motor controller to the
pump motor.
less than 24V
24V or
Activate the lift function more Activate the lift function Repair open in wht wire
and check voltage on and check voltage on 0V (A8-motor) from ECM to
the input side of K1. the white wire on the coil K1 OR replace ECM OR
of K1. conult Genie Industries
Service Department.
24V
Check continuity on the

brn ground wire on the continuity
Repair or replace K1.
coil of K1 to the ground
point on the chassis.
0V no
continuity
Repair open in brown

ground wire from K1 to
the ground point on
chassis.
Check voltage on the 0V Replace 275A fuse (F1)

output side of the 275A OR replace positive
fuse (F1). cable from 275A fuse to
the batteries OR consult
Genie Industries Service
24V Department.
Replace positive battery

cables from output side
of 275A fuse to the
Anderson plug OR
replace positive battery
cables from Anderson
plug to K1 OR consult
Department.
Chart 3
Pump Motor Will Activate the lift function
24V or
more Check voltage on B+
less
than Replace positive battery
from the ground controls terminal on the motor cable from pump to B+
Not Operate - and check voltage at controller.
24V
terminal on the motor
after serial positive terminal on controller.
pump motor.
24V
number 6900
Check continuity on no
Be sure the circuit ground cable from pump continuity Replace ground cable
breaker and fuse are not motor to M- terminal on on lift pump motor.
tripped or blown. the motor controller.
Be sure the batteries are continuity

properly connected.
Check continuity from B- no Replace negative cable
Be sure the batteries are terminal on the motor continuity from B- terminal on the
controller to the negative motor controller to the
fully charged. battery cable at the Anderson plug.
Anderson plug (AP1).
continuity
less
Activate the lift function than Repair open in white
and check voltage at 24V wire (A8-Motor) from the
terminal 1 on the motor ECM to terminal 1 on
controller. the motor controller.
24V
less than 24V
Activate the lift function Repair open in white
and check voltage at 0V wire (A9-motor
terminal 3 on the motor controller terminal 3)
controller. from ECM to the
potentiometer to the
motor controller OR
replace the
potentiometer OR
replace the ECM OR
5V consult Genie Industries
Service Department.
Activate the lift function Replace curtis controller

and check voltage at M- 24V OR consult Genie
terminal on motor Industries Service
controller. Department.
0V
Replace pump motor

OR consult Genie
Industries Service
Continued on the next Department.
page.
CHART 3
Continued from the Check voltage on the 0V Replace 275A fuse OR

previous page. output side of the 275A replace positive cable
fuse (F1). from 275A fuse to the
batteries OR consult
24V Department.
Replace positive battery

cables from output side
of 275A fuse to
Anderson plug OR
replace positive battery
cables from Anderson
plug to the B+ terminal
on the motor controller
OR consult Genie
Industries Service
Department.
Chart 4
All Functions Check hydraulic fluid low Fill with Dexron II
level. equivalent hydraulic
Inoperative, fluid.
Power Unit OK
Starts and Runs Activate each machine Refer to the specific
no
function. Are all chart that relates to the
functions inoperative inoperative function(s).
and the power unit still
starts and runs?
If the Error Indicator
light is on at the yes
platform controls,
please refer to the Connect a 0 to 5000 psi Re-adjust the system
specific chart that (345 bar) pressure more relief valve (GS-2046 &
relates to the error code gauge to the test port on than 2646 models) or the
the function manifold. 3000 drive relief valve (Gs-
that is displayed on the Chock both sides of the 3246 models) OR
psi
ECM. drive wheels at the steer valve(s) may be stuck
end of the machine. open or closed OR
Be sure the circuit Turn the keyswitch to function manifold may
platform control and pull have an internal defect.
breaker and fuse are out the Emergency Stop Consult Genie Industries
not tripped or blown. buttons out to the ON Service Department.
position at both the
Be sure the batteries ground and platform
controls. Activate the
are properly connected. drive forward function
and check the pressure.
are fully charged. less than
3000 psi
Check for a positive no good Replace pump coupling

connection between OR replace pump OR
electric motor and replace motor.
pump by removing
pump from motor, but
leave all hoses
connected. Visually
check coupling
connection.
good
no good
Test hydraulic pump. Replace the pump.
See Repair section.
good
Consult Genie Industries

Service Department.
Chart 5
Ground Turn the keyswitch to Repair open in white
ground control and wire jumper from
Controls make sure both 0V platform control contact
Emergency Stop buttons to the ground control
Inoperative, are pulled out to the ON microswitch at the
Platform positon at both the keyswitch (S2).
ground and platform
Controls controls. Check voltage
on the contact at the
Operate input side of the
keyswitch at the ground
Normally controls (S2).
24V or more
If the Error Indicator Check voltage at output 0V Check if key switch Replace key switch
yes
light is on at the side of contact. internal cam is activating contact for ground
platform controls, ground control contact. controls.
please refer to the
no
specific chart that
relates to the error code 24V Replace key switch.
that is displayed on the
ECM.
Be sure the circuit
Check voltage at the Repair open in white
breaker and fuse are center terminal of the wire jumper from
0V
not tripped or blown. platform up/down toggle keyswitch to center
switch (S3) at the terminal on toggle
Be sure the batteries ground controls. switch.
are properly connected.
Be sure the batteries 24V
are fully charged.
Test or replace platform
up/down toggle switch
S3 (See Repair Section)
wire from toggle switch
to ECM (B12-up switch)
wire from toggle switch
to ECM (A12-down
switch) OR consult
Department.
Chart 6
Platform Turn keyswitch to the Refer to the fault code
ground control and chart to find what chart
Controls visually inspect the yes is associated with your
diagnostic display on the fault code OR consult
Inoperative, ECM. Does it display a Genie Industries service
Ground fault code? department.
Controls no
Operate
Turn keyswitch to Repair open in white
Normally platform control and wire jumper from
make sure both 0V Emergency Stop contact
Emergency Stop buttons to the platform control
are pulled out to the ON contact at the keyswitch
positon at both the (S2).
If the Error Indicator ground and platform
light is on at the controls. Check voltage
platform controls, at the input side of the
platform controls contact
please refer to the on the keyswitch at the
specific chart that ground controls (S2).
relates to the error code
that is displayed on the 24V or more
ECM.
Check voltage at output 0V Check if key switch yes Replace key switch
Be sure the circuit side of contact. internal cam is activating contact for platform
platform control contact. controls.
breaker and fuse are
not tripped or blown. no
Be sure the batteries 24V Replace key switch.
are fully charged.
Check voltage at 0V Repair open in white
terminal A11 at the wire (A11-key switch)
ECM. from keyswitch to A11 at
ECM.
24V
Check voltage at 0V
Replace ECM.
terminal B2 at the ECM.
24V

page.
CHART 6
Turn keyswitch to 0V Replace coil cord

Continued from the platform controls and assembly from the ECM
previous page. check voltage at to the platform controls.
terminal 4 on the main
circuit board at the
platform controls.
24V
Check voltage at the Repair open in wire from

input side of the 0V terminal 4 on main
Emergency Stop button circuit board to input
at the platform controls. side of Emergency Stop
button.
24V
Check voltage at output 0V Replace contact on

side of platform Emergency Stop button
Emergency Stop button. OR replace Emergency
Stop button.
24V
Check voltage at Repair open in wire from

terminal 5 on the main 0V terminal 5 on main
circuit board at the circuit board to output
platform controls. side of Emergency Stop
button.
24V
Check voltage at 0V Replace coil cord from

terminal A4 at the ECM. ECM to platform
controls OR replace
joystick controller OR
replace main circuit
board OR replace ECM
OR consult Genie
24V Industries Service
Department.
Replace ECM OR
Service Department.
Chart 7
Platform Up With key switch in Disconnect the wires 0 or
platform position and from the platform up infinite
Function both Emergency Stop
light is
directional valve coil on ohms Replace platform up
directional valve coil
on
Inoperative buttons pulled out to the function manifold (item H).
on position and the lift/ (item H) and check the
drive selector switch in resistance of the valve
the lift position, activate coil. See Repair Section.
the controller in the up
Be sure all other direction and check to 18-20 ohms
functions operate see if the error indicator
light at the platform
normally. controls is on. Check continuity from no Repair open in brown
the brown ground wire continuity ground wire circuit from
Be sure the circuit at the valve coil to the platform up
breaker and fuse are ground. directional valve coil
(item H) to ground.
not tripped or blown.
continuity
are properly connected. Repair open in white
wire (A6-lift coil) from
Be sure the batteries the platform up
directional valve coil to
are fully charged. the ECM (see Repair
Section) OR replace
ECM OR consult Genie
light is not on Industries Service
Department.
Install a 0 to 4000 PSI 3000 Check for mechanical

pressure gauge at the PSI or restrictions keeping
quick disconnect more platform up function
coupling on the function from moving OR repair
manifold and activate or replace the platform
the platform up function. up directional valve
cartridge (item H) OR
repair or replace
platform lift cylinder(s)
less than 3000 PSI OR consult Genie
Industries Service
Department.
Adjust relief valve (see
Repair Section) OR
repair or replace
platform lift cylinder(s)
OR platform lowering
valve(s) may be stuck
open OR function
manifold could have an
internal defect. Consult
Department.
Chart 8
Platform Down With key switch in With the platform raised
0 or
infinite
platform position and the and the safety arm Replace platform
Function platform raised slightly installed, label and
ohms
lowering valve coil
and both Emergency light is disconnect the wires (item Q).
Inoperative, Stop buttons pulled out on from the coil on the
GS-2046 & to the on position at both
the ground and platform
platform lowering valve
(item Q) at the platform
GS-2646 controls and the lift/drive
switch in the lift position,
lift cylinder and check
the resistance. See
activate the controller in Repair Section.
the down direction and
check to see if the error 23 to 25 ohms
Be sure all other indicator light is on.
functions operate
Check continuity from no Repair open in brown
normally. the brown ground wire continuity ground wire circuit from
at the valve coil to the platform lowering
Be sure the circuit ground. valve coil (item H) to
breaker and fuse are ground.
are properly connected. With the platform raised Repair open in white
and the safety arm platform wire (B6-down coil) from
removed, pull the lowers the platform lowering
manual platform valve coil (item Q) to the
are fully charged. lowering handle at the ECM OR replace the
ground controls. ECM OR repair or
replace the platform
platform does lowering valve cartridge
(item Q) OR consult
not lower
Department.
Check for mechanical
light is not on restrictions keeping
platform from lowering
OR repair or replace the
cartridge (item Q) OR
0.059" orifice inside the
cylinder is plugged OR
repair or replace lift
cylinder OR consult
Department.

page.
CHART 8
switch
Label and disconnect bad
Continued from the the wires from the lift/ Replace lift/drive toggle
previous page. switch (S7).
drive toggle switch (S7)
at the platform controls
and troublshoot toggle
switch (see Repair
Section).
good

restrictions keeping
cartridge (item Q) OR
cylinder is plugged OR
repair or replace lift
cylinder OR replace
platform controls OR
replace ECM OR
Service Department.
Chart 9
Platform Down With key switch in With the platform raised
0 or
infinite
platform position and the and the safety arm Replace defective
Function platform raised slightly installed, label and
ohms
Inoperative, and both Emergency disconnect the wires coil (item Q).
Stop buttons pulled out light is from each coil on the
GS-3246 to the on position at both on platform lowering valves
the ground and platform (item Q) at the platform
controls and the lift/drive lift cylinders and check
switch in the lift position, the resistance of each
activate the controller in valve coil. See Repair
Be sure all other the down direction and Section.
functions operate check to see if the error
indicator light is on. 23 to 25 ohms
normally.
Be sure the circuit no
Check continuity from continuity Repair open in ground
breaker and fuse are the black ground wire at wire circuit from the
the valve coil to ground. platform lowering valve
not tripped or blown. coil (item Q) to ground.
Be sure the batteries continuity
With the platform raised platform See Chart 18 OR check
and the safety arm does not for mechanical
Be sure the batteries removed, push the lower restrictions keeping
are fully charged. manual platform platform from lowering
lowering button at the OR repair or replace the
ground controls. platform lowering valve
cartridge(s) (item Q) OR
platform lowers 0.059" orifice inside the
cylinder(s) is plugged
OR repair or replace lift
Repair open in white cylinder(s) OR consult
wire (B6-down coil) Genie Industries Service
circuit from the ECM to Department.
light is not on the platform lowering
valve coil (item Q) on
the lower cylinder to the
coil (item Q) on the
upper cylinder OR repair
open in brown ground
wire circuit from platform
lowering valve coils to
ground OR repair or
replace the platform
lowering valve cartridge
(item Q) OR replace
Industries Service
Department.

page.
CHART 9
switch
Label and disconnect bad
Continued from the the wires from the lift/ Replace lift/drive toggle
previous page. switch (S7).
drive toggle switch (S7)
at the platform controls
and troublshoot toggle
switch (see Repair
Section).
good

restrictions keeping
cartridge(s) (item Q) OR
cylinder(s) is plugged
OR repair or replace lift
cylinder(s) OR replace
platform controls OR
replace ECM OR
Service Department.
Chart 10
Steer Left With key switch in Disconnect the wires 0 or
platform position and from the coil on the infinite
Function both Emergency Stop light is steer left directional ohms Replace the coil.
buttons pulled out to the on valve on the function
Inoperative on position, activate the manifold (item G) and
steer rocker switch in check the resistance of
the left direction and the valve coil. See
check to see if the error Repair Section.
Be sure all other indicator light at the
functions operate platform controls is on. 26 to 28 ohms
normally.
Be sure the circuit the brown ground wire continuity ground wire circuit from
breaker and fuse are at the valve coil to the steer left directional
ground. valve coil (item G) to
not tripped or blown. ground.
continuity
Repair open in white
wire (B7-left coil) from
Be sure the batteries the coil on the steer left
light is not on
are fully charged. directional valve
(item G) to the ECM OR
repair open in brown
ground wire circuit from
the steer left directional
valve (item G) to ground
OR replace ECM OR
Service Department.
Activate steer left no Check continuity of steer bad Replace steer left/right
function. Does the microswitch. micro switch inside drive
hydraulic power unit turn controller.
on?
good
Check for wire continuity

from the steer
microswitch to the
terminal strip OR
yes board at the platform
controls.

page.
CHART 10
Install a 0 to 2000 PSI Check for mechanical

Continued from the pressure gauge at the restrictions keeping
previous page. 1500
quick disconnect PSI steer left function from
coupling on the function operating OR repair or
manifold and activate replace steer cylinder
the steer left function OR consult Genie
and check the pressure. Industries Service
Department.
less than 1500 PSI
Re-adjust the steer relief

valve (see Repair
Section) OR repair or
replace steer cylinder
OR replace steer left/
right valve cartridge
(item G) OR function
Department.
Chart 11
Steer Right With key switch in Disconnect the wires 0 or
platform position and from the coil on the infinite
Function both Emergency Stop light is steer right directional ohms Replace the coil.
buttons pulled out to the on valve on the function
Inoperative on position, activate the manifold (item G) and
steer rocker switch in check the resistance of
the right direction and the valve coil. See
check to see if the error Repair Section.
Be sure all other indicator light at the
functions operate platform controls is on. 26 to 28 ohms
normally.
Be sure the circuit the brown ground wire continuity ground wire circuit from
breaker and fuse are at the valve coil to the steer right directional
ground. valve coil (item G) to
not tripped or blown. ground.
continuity
wire (C7-right coil) from
Be sure the batteries the coil on the steer right
light is not on
are fully charged. directional valve
(item G) to the ECM OR
repair open in brown
ground wire circuit from
the steer right directional
valve (item G) to ground
OR replace ECM OR
Service Department.
Activate steer right no Check continuity of steer bad Replace steer left/right
function. Does the microswitch. micro switch inside drive
hydraulic power unit turn controller.
on?
good
Check for wire continuity

from the steer
microswitch to the
terminal strip OR
yes board at the platform
controls.

page.
CHART 11
Install a 0 to 2000 psi Check for mechanical

Continued from the (0 to 138 bar) pressure restrictions keeping
previous page. 1500
gauge at the quick psi steer right function from
disconnect coupling on operating OR repair or
the function manifold replace steer cylinder
and activate the steer OR consult Genie
right function and check Industries Service
the pressure. Department.
less than 1500 psi
Re-adjust the steer relief

valve (see Repair
Section) OR repair or
replace steer cylinder
OR replace steer left/
right valve cartridge
(item G) OR function
Department.
Chart 12
All Drive With key switch in Reset the ECM by
error
indicator
platform position and pushing in the platform Refer to chart(s) that are
Functions both Emergency Stop Emergency Stop button on
light is related to the error code
Inoperative, All buttons pulled out to the light is to the off position, switch
on position at both the flashing the lift/drive selector
Industries Service
Other Functions ground and platform
controls, activate drive
switch to the drive
position and pull the
Department.
Operate forward and drive
reverse functions.
Emergency Stop button
up to the on position.
Normally Check to see if the Check the lights at the
green indicator light is platform controls.
flashing at the platform
controls.
If the Error Indicator green light is flashing
light is on at the
platform controls, Test the lift/drive toggle bad Replace lift/drive toggle
please refer to the switch S7 (see Repair switch S7.
Section).
specific chart that
relates to the error code good
light is not
ECM. flashing Replace main circuit
board in the platform
Be sure the circuit controls OR replace
breaker and fuse are ECM OR consult Genie
Industries Service
not tripped or blown. Department.
Be sure the batteries Is the error indicator yes Refer to chart(s) that are
are fully charged. light on at the platform related to the error code
controls? that is displayed on the
Industries Service
Department.
no
Activate the drive Replace joystick

forward or drive reverse no controller OR replace
function. Does the main circuit board OR
hydraulic power unit turn replace ECM OR
on? consult Genie Industries
Service Department.
yes

page.
CHART 12
Chock both sides of the 3500 psi See Chart 13, Brake
Continued from the steer end drive wheels. Release Function
previous page. Install a 0 to 5000 psi Inoperative.
(0 to 345 bar) pressure
gauge to the test port on
the function manifold.
Activate the drive
function in either the
forward or reverse
direction and check the
pressure.
less than
3500 psi
Repair or replace drive
forward/reverse valve
cartridge (item K) OR
rebuild or replace drive
motors OR function
manifold may have an
Department.
Chart 13
Brake Release Chock the wheels at the wheels Rebuild or replace the
steer end and raise the turn Turn the brake release wheels brakes OR replace the
Function non-steer end of the freely valve (item N) clockwise turn brake release valve
machine up all the way and try to (item N) OR consult
Inoperative approximately 4 inches rotate the wheels. Genie Industries Service
(10.2 cm) and place jack Department.
stands under the
machine for support. wheels do not
If the Error Indicator Turn the brake release turn
light is on at the knob (item N)
counterclockwise all the
platform controls, way and pump the hand Attempt to drive the wheels Brake release function is
pump fully 13-15 times machine in either turn operating correctly. If
please refer to the direction and have problems still exist
specific chart that or until much resistance
someone try to rotate consult Genie Industries
is felt. Turn each wheel
relates to the error code the non steer wheels Service Department.
by hand. Each wheel
(This will require 2
that is displayed on the should turn freely
without much effort. people).
ECM.
Be sure the circuit wheels do not
turn
breaker and fuse are wheels
not tripped or blown. do not
turn Plumb a 0 to 500 psi
Be sure the batteries (34.5 bar) into the hose
from the function 200 to Pressure is good.
are properly connected. manifold to the brake. 300 psi Replace brakes OR
Attempt to drive the consult Genie Industries
Be sure the batteries machine in either Service Department.
are fully charged. direction and read the
pressure on the gauge.
less than
200 psi
Replace shuttle valve

(item O) OR replace
brake release valve
(item N) OR function
manifold or brake
release manifold may
have an internal defect
OR consult Genie
Industries Service
Department.
Chart 14
Drive Forward With key switch in Disconnect the wire 0 or
platform position and light is from the drive forward infinite
Function both Emergency Stop on directional valve coil ohms Replace drive forward
buttons pulled out to the (item K) and check the directional valve coil
Inoperative on position at both the resistance. See Repair
(item K).
ground and platform Section.
controller in the forward 18 to 20
Be sure all other direction and check to ohms
light at the platform Check continuity from no Repair open in brown
normally. controls is on. the brown ground wire continuity ground wire circuit from
at the valve coil to the drive forward
Be sure the circuit ground. directional valve coil
breaker and fuse are (item K) to ground.
Be sure the batteries Repair or replace drive

are properly connected. light is not on forward directional valve
(item K) OR repair open
in wht wire (C-6 forward
Be sure the batteries coil) OR repair open in
are fully charged. brown ground wire
circuit from the drive
forward directional valve
to ground OR consult
Replace the drive Genie Industries Service
forward/reverse valve Department.
consult the Genie
Industries Service
Department..
Chart 15
Drive Reverse With key switch in Disconnect the wire 0 or
platform position and light is from the drive reverse infinite
Function both Emergency Stop on directional valve coil ohms Replace drive reverse
buttons pulled out to the (item K) and check the directional valve coil
Inoperative on position at both the resistance. See Repair
(item K).
ground and platform Section.
controller in the reverse 18 to 20
Be sure all other direction and check to ohms
light at the platform Check continuity from no Repair open in brown
normally. controls is on. the brown ground wire continuity ground wire circuit from
at the valve coil to the drive reverse
Be sure the circuit ground. directional valve coil
breaker and fuse are (item K) to ground.
Be sure the batteries Repair or replace drive

are properly connected. light is not on reverse directional valve
(item K) OR repair open
in wht wire (A-7 reverse
Be sure the batteries coil) OR repair open in
are fully charged. brown ground wire
circuit from the drive
reverse directional valve
to ground OR consult
Replace the drive Genie Industries Service
forward/reverse valve Department.
consult the Genie
Industries Service
Department.
Chart 16
Machine Will With key switch in light is Check voltage at white Repair open in white
platform position and on 0V
Not Drive At both Emergency Stop wire (39C-pothole sw) at wire (39C-pothole sw)
buttons pulled out to the S5. from S5 to multi-function
Full Speed ON position at both the
alarm to keyswitch.
ground and platform
24V
controls, and the
platform in the stowed
Be sure the circuit position, drive the
machine in either Raise the platform Adjust limit switch S5 so
breaker and fuse are direction. Is the error approximately 3 feet 0V pothole arm activates
not tripped or blown. indicator light on at the (0.9 m) and check switch OR replace limit
platform controls? voltage at output side of switch contact OR
S5. replace limit switch S5.
are properly connected. 24V
Check voltage on input 0V Repair open in white
are fully charged. side of S6. wire jumper (21B-
pothole jumper) from
Be sure that the drive output side of S5 to
speed select switch is in input side of S6.
24V
the down position.
Check voltage on output 0V Adjust limit switch S6 so

side of S6. pothole arm activates
switch OR replace limit
switch contact OR
replace limit switch S6.
24V
light is
not on Repair open in wht wire
(B10-pothole sw) from
the output side of S6 to
the ECM OR replace
Industries Service
Department.

page.
CHART 16
Chock both sides of the Re-adjust drive relief

Continued from the steer end drive wheels. valve (see Repair
previous page. Install a 0 to 5000 psi less Section) OR replace
(0 to 345 bar) pressure than drive relief valve
gauge to the test port on 3500 psi (item F) OR rebuild or
the function manifold. replace drive motors OR
Drive the machine in function manifold may
either the forward or have an internal defect.
reverse direction and Consult Genie Industries
check the pressure. Service Department.
3500
psi
one or
Raise the steer end of both
machine up wheels
approximately 4 inches do not
(10.2 cm) and place jack Repair or replace drive
move motor(s) OR consult
stands under the
machine for support. Genie Industries Service
With the lift/drive Department.
selector switch in the
drive position, move the
joystick controller to the
full speed forward or
reverse position.
both
wheels
move

wire (B10-pothole
switch) from output side
of S6 to ECM OR
replace ECM OR see
Chart 13, Brake Release
Function Inoperative.
Chart 17
Machine With key switch in light is
platform position and not on Consult Genie Industries
Drives At both Emergency Stop Service Department.
Full Speed buttons pulled out to the
ON position at both the
With Platform ground and platform
controls and the
Raised platform in the stowed
position, drive the
machine in either
direction. Is the error
indicator light on at the
platform controls?
light
is on
Remove obstruction
from pothole guard or
from pothole guard limit
switches OR consult
Department.
Chart 18
Manual Check the adjustment of Re-adjust the manual
the manual platform platform lowering cable
Platform lowering cable. See 4-1
no
and check the manual
in the Repair Section, platform lowering
Lowering How to Adjust the function.
Manual Platform
Function Lowering Cable. Is the
Inoperative - adjustment correct?
GS-2046 & yes

GS-2646 See Chart 7 OR check If manual platform
for mechanical lowering function is still
restrictions keeping inoperative, see Chart 7
manual platform OR consult Genie
Be sure the lowering function from Industries Service
platform lowering operating OR replace Department.
cable is not kinked the manual platform
lowering cable OR see
or pinched. OR consult Genie
Industries Service
Be sure the Department.
platform lowers
using the platform
up/down toggle
switch at the ground
controls.
Chart 19
Manual With the platform raised Activate the manual Check for mechanical
and the safety arm platfrom lowering button restrictions keeping
Platform installed, connect the 24V and check the voltage 24V platform from lowering
positive lead from a on the wht wire at the OR replace the solenoid
Lowering voltmeter to the wht wire solenoid valve on the valves on both lift
Function on the lower lift cylinder upper cylinder. cylinders OR the 0.059"
solenoid valve and the orifice inside each lift
Inoperative - negative lead of the volt
meter to the brown less than 24V
cylinder may be
plugged.
GS-3246 ground wire on the hour
meter. Activate the Repair open in wht wire
manual platfrom from the solenoid valve
lowering button and on the lower lift cylinder
check the voltage at the to the solenoid valve on
Be sure the wiring solenoid valve on the the upper cylinder.
to the platform lower cylinder.
lowering valves on
the cylinders is not less than 24V
kinked or pinched.
Remove the cover from Repair open in wht wire
Be sure the the ground controls, from terminal #4 at the
then activate the manual 24V manual platform
platform lowers platfrom lowering button lowering button to the
using the platform and check the voltage solenoid valve on the
up/down toggle on the wht wire at lower lift cylinder.
terminal #4 on the
switch at the ground manual platform
controls. lowering button.
Be sure the less than 24V

batteries are fully
charged. Check the voltage on 24V Replace the manual
the wht wire at terminal platform lowering button
#3 on the manual contact.
platform lowering button.
less than 24V
Check continuity to Replace the diode on

ground from the blk wire the wht wire from the
on the manual platform continuity Emergency Stop button
lowering battery that to the manual lowering
connects to the brown button and re-charge the
wire on the hour meter. manual platform
lowering batteries OR
replace the batteries.
no continuity
Repair open in ground

wire circuit from the blk
wire at the manual
platform lowering
batteries through the
brown wire to the hour
meter then to ground.
Chart 20
Drive With key switch in Adjust the Back
platform position and yes Pressure Relief Valve
Function both Emergency Stop (item L) (see repair
buttons pulled out to the section).
Overspeeds ON position at both the
While Driving ground and platform
Down An controller in the forward
direction down a slight
Incline, incline. Does the
machine overspeed?
GS-3246 Only
no
The machine should be

Be sure all other functioning normally. If
functions operate not, consult Genie
Industries Service
normally. Department.
Be sure the circuit

breaker and fuse
are not tripped or
blown.
Be sure the
batteries are
properly connected.
Be sure the
batteries are fully
charged.
Chart 21
Drive With key switch in Adjust the Back
platform position and the yes Pressure Relief Valve
Function Emergency Stop buttons (item L) (see repair
pulled out to the ON section).
Hesitates position at both the
While ground and platform
controls, and the steer
Steering, wheels turned fully to
the right, activate drive
GS-3246 controller in the forward
direction. Does the drive
Only function hesitate?
no
Be sure all other The machine should be

functioning normally. If
functions operate not, consult Genie
normally. Industries Service
Department.
Be sure the circuit
breaker and fuse
are not tripped or
blown.
Be sure the
batteries are
properly connected.
Be sure the
batteries are fully
charged.
Service Manual - First Edition Section 6 - Schematics
Schematics
About This Section
There are two groups of schematics in this
section. An illustration legend precedes each
group of drawings.
Electrical Schematics
Observe and Obey: Electrocution hazard. Contact

with electrically charged circuits
Troubleshooting and repair procedures shall be may result in death or serious
completed by a person trained and qualified on injury. Remove all rings, watches
the repair of this machine. and other jewelry.
Immediately tag and remove from service a Hydraulic Schematics
damaged or malfunctioning machine.
Repair any machine damage or malfunction hydraulic oil can penetrate and
before operating the machine. burn skin. Loosen hydraulic
Before Troubleshooting: the oil pressure to dissipate
Read, understand and obey the safety rules gradually. Do not allow oil to
and operating instructions printed in the squirt or spray.
Genie GS-2032 & Genie GS-2046 & Genie General Repair Process
GS-2646 & Genie GS-3246 Operator's Manual.
Be sure that all necessary tools and test
Malfunction Identify Troubleshoot
equipment are available and ready for use. discovered symptoms
problem
still exists
Return to Inspect Perform

service problem and test repair
solved
Section 6 - Schematics Service Manual - First Edition
Electrical Components
Item Description Genie Manufacturer Manufacturer Qty

Part Number Part Number
AP1 ................ Anderson connector ............ 19436 ............. Anderson ............................. 6325-G1 ......................... 2
B1 ................... Alarm, steady tone .............. 39540 ............. Floyd Bell Inc. ...................... UC-09628-Q .................. 1
B2 ................... Alarm, intermittent ............... 18963 ............. Floyd Bell Inc. ...................... XB-09-630-Q .................. 1
F1 ................... Fuse, 275 amp .................... 40833 ............. Buss ..................................... ANN-275 ........................ 2
F2 ................... Circuit breaker ..................... 47811 ............. ETA ...................................... 45-700-IG1-P10 ............. 2
FB1 ................ Flashing beacon .................. 39676 ............. ECCO Electronic Controls ... 6220A ............................. 2
G1 .................. Battery, 225AH, 6V DC ....... 62201 ............. Allied Battery Co.. ................ GC2B, dry ...................... 4
G2 .................. Battery, 0.8AH, 12V DC ...... 55350 ............. Yuasa ................................... NP0.8-12 ........................ 2
H1 .................. Hourmeter ............................ 56100 ............. Curtis Instruments ............... 17305666 ....................... 1
P2 ................... Level sensor, Dual Axis ....... 40836 ............. Power Comp. of Midwest .... L36 ................................. 1
S1 ................... Contact, N.C. ....................... 33020 ............. Square D .............................. 1863 ............................... 1
S2, S12 .......... Contact, N.O. ....................... 45081 ............. Telemecanique .................... ZB2-BE101 .................... 5
S3 ................... Toggle switch, SPDT

3 position momentary .......... 13037 ............. Microswitch Control Inc. ...... 1NT1-7 ........................... 1
S4, S5, S6
S11 ................. Contact - limit switch,
N.C.H.O. .............................. 19491 ............. Telemecanique .................... XESP2151 ..................... 4
S7, S8 ............ Toggle switch, DPDT

2 position maintained .......... 44987 ............. ITT Schadow. ...................... 220536 ........................... 2
S9 ................... Contact, N.C. ....................... 44990 ............. Telemecanique .................... ZA2-BZ1026 ................... 1
S10 ................. Contact, N.O. ....................... 44989 ............. Telemecanique .................... 220518 ........................... 1
U2 .................. Motor controller,

275 amp .............................. 39472 ............. Curtis Instruments ............... 1204-036 ........................ 1
Y2, Y3, Y4 ...... Coil, 20V DC

(size 8) with diode ................ 39347 ............. Hydra Power Systems ......... 6309757 ......................... 3
Y1, Y5, Y6,

Y8 ................... Coil, 20V DC
(size10) with diode ............... 44176 ............. Hydra Power Systems ......... 6359752 ......................... 4
Y7 ................... Coil, 20V DC ........................ 44787 ............. Hydra Power Systems ......... 10166-25 ........................ 3
Module Tray Legend

Module Tray Legend

(after serial number 6900)
Electrical Symbols Legend
Section 6 - Schematics Service Manual
Electrical Schematic
A B C D E F G H I J K L M N
Service Manual Section 6 - Schematics
N M L K J I H G F E D C B A
(from serial number 6901 to 8931)
Ground Controls and Level Sensor Box Legend
Platform Controls Legend

Platform Controls Legend

Hydraulic Symbols Legend
Hydraulic Schematic
Hydraulic Schematic
Hydraulic Schematic
Hydraulic Schematic
Service Manual - First Edition Section 7 - Repair Procedures
Repair Procedures
About This Section
Most of the procedures in this section should only
be performed by a trained service professional
in a suitably equipped workshop. Select the
appropriate repair procedure after troubleshooting
the problem.
Observe and Obey: Perform disassembly procedures to the point

where repairs can be completed. Then to
Repair procedures shall be completed by a re-assemble, perform the disassembly steps in
person trained and qualified on the repair of this reverse order.
machine.
Symbols Legend
damaged or malfunctioning machine. Safety alert symbolused to alert
personnel to potential personal
Repair any machine damage or malfunction injury hazards. Obey all safety
before operating the machine. messages that follow this symbol
to avoid possible injury or death.
Before Repairs Start:
Redused to indicate the
Read, understand and obey the safety rules presence of an imminently
and operating instructions in the Genie GS-2032 hazardous situation which, if not
& Genie GS-2046 & Genie GS-2646 & Genie avoided, will result in death or
GS-3246 Operator's Manual. serious injury.
Be sure that all necessary tools and parts are Orangeused to indicate the
available and ready for use. presence of a potentially
Read each procedure completely and adhere to
avoided, could result in death or
the instructions. Attempting shortcuts may
serious injury.
produce hazardous conditions.
Yellow with safety alert symbol
Unless otherwise specified, perform each repair
procedure with the machine in the following
potentially hazardous situation
configuration:
which, if not avoided, may cause
Machine parked on a flat level surface minor or moderate injury.
Platform in the stowed position Yellow without safety alert
symbolused to indicate the
Key switch in the OFF position with the key presence of a potentially
removed hazardous situation which, if not
Wheels chocked avoided, may result in property
damage.
Greenused to indicate operation
or maintenance information.
Indicates that a specific result is expected after
performing a series of steps.
Section 7 - Repair Procedures Service Manual - First Edition
Platform Controls
1-1
Platform Controller
The platform controller is controlled by an ECM
(Electronic Control Module) located in the power
unit module tray. The ECM aids in troubleshooting
by recognizing machine malfunctions and
displaying fault codes on an LED screen on the
ECM. See the Troubleshooting section of this
manual for a list of fault codes and additional
information. The ECM is not user-serviceable. The
joystick controller is calibrated at the factory and
does not need to be adjusted. For further
information or assistance, consult the Genie
Industries Service Department.
Platform Controller Platform Controller

(before serial number 17408) (after serial number 17407)
a b
e d
f
a Main circuit board
b Lift/drive selector toggle switch a Main circuit board
c Horn button b Emergency stop button
d Emergency stop button c Joystick controller
e LED circuit board d Alarm
f Joystick controller
PLATFORM CONTROLS
1-2 3 Press and hold the lift enable button and the
function enable switch. Move the joystick
Software Configuration handle to the UP position to raise the platform.
Observe the code shown in the LED display
The ECM (Electronic Control Module) contains window, located on the battery pack side of the
programming for all configurations of the Genie GS- machine.
2046 & Genie GS-2646 & Genie GS-3246. The
platform controls can be adjusted to a different Result: The configuration code of the DIP switch
configuration by changing the combination of the will appear in the LED display window.
DIP switch settings. The DIP switch is located on 4 Press and hold the lift enable button and the
the circuit board inside the platform control box. function enable switch. Move the joystick
DIP switches have two positions - ON or OFF. When handle to the DOWN position to lower the
reading the DIP switch code in the DIP Switch platform. Observe the code shown in the LED
Codes Chart on page 7-5, the ON and OFF are display window, located on the battery pack
represented by the numbers 1 (ON) and 0 (OFF). side of the machine.
Select a test area that is firm, level Result: The software revision level will appear
and free of obstructions. in the LED display window. If revision level "b0"
Machines manufactured before or later appears in the display window, the
serial number 17408 are not following procedures will apply. If revision level
adjustable. If your ECM has been "A0" is displayed, the following procedures will
replaced, or if the machine serial not apply.
number is after 17407, you can 5 Push in the Emergency Stop button to the OFF
verify the revision level of the ECM position at both the ground and platform
by using the following procedure: controls and turn the key switch to the OFF
position.
How to Determine the Revision
Level
1 Remove the platform controls from the platform.
2 Turn the key switch to platform control and pull
out the Emergency Stop buttons to the ON
controls.
PLATFORM CONTROLS
1-3 3 Rotate the platform controller box in the position

shown to correctly identify the configuration of
How to Set the DIP Switch the DIP switch settings.
Codes 4 Open the controller box lid and locate the DIP
switch on the circuit board. Move the DIP
Tip-over hazard. Do not adjust the switch settings to correspond with the
DIP switch settings to other than configuration of the machine options, indicated
what is specified in this procedure. in the DIP Switch Code Chart.
Exceeding specifications will
cause death or serious injury. 5 Confirm the settings. See 1-3, How to Determine
the Revision Level.
If replacing the circuit board, note
the individual switch positions on 6 Cover the DIP switch with dielectric grease.
the DIP switch. Set the individual
7 Close the lid and install the fasteners.
switches on the new circuit board
to the same configuration as the 8 Push in the Emergency Stop button to the OFF
old one. position at both the ground and platform controls
and turn the key switch to the OFF position.
If replacing the circuit board, use
dielectric grease on all plug-in Any change in DIP switch settings
connectors. will not take effect until the key
switch is truned to the OFF position.
1 Push in the Emergency Stop button to the OFF
position at the ground and platform controls.
Turn the key switch to the OFF position.
2 Remove the fasteners securing the top of the
controller to the controller case.
c
d
a DIP switch
b Emergency stop button
c Circuit boards
d Joystick controller
e Controller box
f Enlarged view of DIP switch
PLATFORM CONTROLS
DIP Switch Code Chart DIP Switch Function Definitions

A mark in the column indicate that the machine Motion Beacon: The motion beacon option flashes
configuration includes this option. only when operating a function.
Motion Alarm: The motion alarm will beep when
Lift Drive Cut Out

Overload Cut Out
operating any function.
Motion Beacon
Descent Delay
Lift/Drive Cut Out: This cuts out lift and drive
Motion Alarm
Diagnostic
Dip Switch functions when the machine goes out of level.
Display
Code Required for Europe and Australia.
Code
Overload Cut Out: This cuts out lift when the
cylinder is overloaded. Required for France.
32 10000000
Descent Delay: This option halts descent for 4
33 10000100 seconds at approximately 6 feet (2 m).
34 10001000 Required for Europe.
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
PLATFORM CONTROLS
1-4 Test Desired result

Toggle Switches Left position
Toggle switches used for single function switching terminal 1 to 2, 3, 4, 5 & 6 no continuity
are single pole double throw (SPDT) switches. (infinite )
Dual function switching requires a double pole terminal 2 to 3 continuity
double throw (DPDT) switch. (zero )
How to Test a Toggle Switch terminal 2 to 4, 5 & 6 no continuity
Continuity is the equivalent of 0 to terminal 3 to 4, 5 & 6 no continuity

3 ohms. A simple continuity tester terminal 4 to 5 & 6 no continuity
may not accurately test the switch.
terminal 5 to 6 continuity
This procedure covers fundamental switch testing
and does not specifically apply to all varieties of Center position There are no terminal
toggle switches. combinations that will
produce continuity
1 Turn the key switch to the OFF position. Tag (infinite )
and disconnect all wiring from the toggle switch
Right position
to be tested.
The toggle switch at the platform
(zero )
controls requires that the wires
are unplugged from the main terminal 1 to 3, 4, 5 & 6 no continuity
circuit board before testing. (infinite )
2 Connect the leads of an ohmmeter to the terminal 2 to 3, 4, 5 & 6 no continuity
switch terminals in the following combinations
listed below to check for continuity. terminal 3 to 4, 5 & 6 no continuity
Left Center Right terminal 4 to 6 no continuity
terminal 5 to 6 no continuity
1 3 1 3 1 3
2 2 2
Single pole
double throw
1 2 3 1 2 3 1 2 3
(SPDT)
4 5 6 4 5 6 4 5 6
Double pole
double throw
(DPDT)
1 2 3 1 2 3 1 2 3
Platform Components
2-1 8 Remove the retaining fasteners from the
scissor platform pivot pins at the steer end of
Platform the machine.
9 Use a slide hammer to remove the pins.
How to Remove the Platform
Crushing hazard. The platform will
Perform this procedure with the fall if it is not properly supported.
platform extension fully retracted
and locked in position. 10 Remove the plug from the access hole on each
side of the platform.
1 Lower the platform to the stowed position and
turn the machine off. 11 Lift the platform slightly to clear the scissor
arms and slide the platform towards the non-
2 Remove the retaining fastener that holds the steer end of the machine until the non-steer end
platform controls quick disconnect plug to the platform pivot pins are visible through the
bottom of the platform toeboard. access holes in the side of the platform.
3 Twist to disconnect the plug from the platform 12 Remove the retaining fasteners from the
controls. scissor platform pivot pins at the non-steer end
4 Remove the cover to the AC outlet. Label and of the machine.
disconnect the wiring from the outlet. 13 Use a slide hammer to remove the pins.
Electrocution hazard. Contact with Crushing hazard. The platform may
electrically charged circuits may may become unbalanced and fall
result in death or serious injury. when it is removed from the
Remove all rings, watches and machine if it is not properly
other jewelry. supported and secured to the
5 Pull the wiring through the platform tube. forklift.
If your machine is equipped with 14 Carefully lift the platform off of the machine and
an air line to platform option, the place it on a structure capable of supporting it.
air line must be disconnected from Note the position of the wear pads
the platform before removal. before the platform is removed so
6 Support the platform with a forklift at the that when the platform is installed
non-steer end. Do not lift it. they will be in the correct position.
7 Attach a strap from the platform railings to the

carriage on the forklift to help support the
platform.
PLATFORM COMPONENTS
2-2 How to Replace the Platform

Platform Extension Extension Wear Pads
1 Remove the Platform Extension. See 2-2, How
How to Remove the to Remove the Platform Extension.
Platform Extension 2 Drill out the rivets which hold the wear pads in
1 Lower the platform to the stowed position. place.
2 Extend the platform approximately 3 feet (1 m). 3 Install the new wear pad using new rivets.
3 Remove the platform controls from the platform When installing new rivets, make
and lay them off to the side of the machine. sure the rivet heads are not above
the surface of the wear pad.
4 Support the platform extension with a forklift at
the steer end. Do not lift it.
5 Attach a strap from the platform extension
railings to the carriage on the forklift to help
support the platform extension.
6 Remove the mounting fasteners from the
platform extension roller support on both sides
of the machine at the non-steer end of the
platform extension. Remove the roller supports.
7 Carefully slide the platform extension out from
the platform and place it on a stucture capable
of supporting it.
Scissor Components
Steer End Non-steer End

1 Number 4 pivot pin (steer end) 10 Number 4 pivot pin (non-steer end)
2 Number 3 center pivot pin 11 Number 3 inner arm
3 Lift cylinder rod-end pivot pin 12 Number 3 outer arm
5 Number 2 center pivot pin (2pins) 14 Number 2 inner arm
6 Number 2 pivot pin (steer end) 15 Number 2 outer arm
7 Number 1 center pivot pin 16 Number 2 pivot pin (non-steer end)
8 Number 1 inner arm 17 Lift cylinder barrel-end pivot pin
9 Number 1 pivot pin (steer end) (2pins) 18 Number 1 outer arm
SCISSOR COMPONENTS, GS-2046
3-1 5 Use a soft metal drift to remove the number 3

center pivot pin (index #2).
Scissor Assembly
6 Remove the external snap rings from the
number 3 pivot pin (index #13).
How to Disassemble the
Scissor Assembly 7 Use a soft metal drift to remove the number 3
pivot pin (index #13) from the non-steer end of
GS-2046 the machine. Remove the number 3 outer arm
(index #12) from the machine.
Bodily injury hazard. This
procedure requires specific repair Crushing hazard. The number 3
skills, lifting equipment and a outer arm (index #12) may become
suitable workshop. Attempting this unbalanced and fall if not properly
procedure without these skills and supported when it is removed from
tools could result in death or the machine.
serious injury and significant
component damage. Dealer 8 Remove the cable clamps from the number 3
service is required. inner arm (index #11).
When removing a hose assembly 9 Remove the mounting fasteners from the cable
or fitting, the O-ring on the fitting tray support at the steer end.
and/or hose end must be replaced 10 Remove the external snap rings from the
and then torqued to specification number 2 center pivot pin (index #5) at the
during installation. Refer to Section ground controls side. Do not remove the pin.
Two, Hydraulic Hose and Fitting
Torque Specifications. 11 Slide the cable tray towards the battery pack
side of the machine and remove it from the
1 Remove the platform. See 2-1, How to Remove machine.
the Platform.
2 Remove the cables from the side of the number Cables can be damaged if they
3 outer arm (index #12) at the ground controls are kinked or pinched.
side.
12 Attach a lifting strap from an overhead crane to
Component damage hazard. the lug on the rod end of the lift cylinder.
Cables can be damaged if they
13 Remove the pin retaining fasteners from the
are kinked or pinched.
cylinder rod-end pivot pin (index #3). Use a soft
3 Attach a lifting strap from an overhead crane to metal drift to remove the pin.
the number 3 outer arm (index #12). Bodily injury hazard. The cylinder
4 Remove the external snap rings from the may fall if not properly supported
number 3 center pivot pin (index #2). when the pin is removed.
14 Lower the cylinder onto the number 1 center 22 Attach a lifting strap from an overhead crane to
pivot pin (index #7). the number 2 outer arm (index #15) at the
battery pack side.
the number 3 inner arm (index #11). 23 Remove the external snap rings from the
16 Remove the external snap rings from the number 2 center pivot pin (index #5) at the
number 3 pivot pin (index #4). battery pack side.
17 Use a soft metal drift to remove the number 3 24 Use a soft metal drift to remove the number 2
pivot pin (index #4). Remove the number 3 center pivot pin (index #5) at the battery pack
inner arm (index #11) from the machine. side. Remove the number 2 outer arm (index
#15) from the battery pack side of the machine.
Bodily injury hazard. The number
3 inner arm (index #11) may Bodily injury hazard. The number 2
become unbalanced and fall if not outer arm (index #15) at the battery
properly supported when it is pack side may become
removed from the machine. unbalanced and fall if not properly
supported when it is removed from
18 Attach a strap from an overhead crane to the
the machine.
number 2 outer arm (index #15) at the ground
controls side. 25 Attach a lifting strap from an overhead crane to
the number 2 inner arm (index #14).
19 Use a soft metal drift to remove the number 2
center pivot pin (index #5) at the ground controls 26 Remove the external snap rings from the
side. number 2 pivot pin (index #6) from the steer
end of the machine.
number 2 pivot pin (index #16) at the non-steer 27 Use a soft metal drift to remove the number 2
end. pivot pin (index #6). Remove the number 2
inner arm (index #14) from the machine.
pivot pin (index #16) at the non-steer end. Bodily injury hazard. The number
Remove the number 2 outer arm (index #15) 2 outer arm (index #15) at the
from the ground controls side of the machine. battery pack side may become
unbalanced and fall if not properly
2 outer arm (index #15) at the
the machine.
ground controls side may become
unbalanced and fall if not properly 28 Remove the safety arm from the number 2 inner
supported when it is removed from arm (index #14) that was just removed.
the machine.
29 Attach a lifting strap from an overhead crane to 34 Remove the pin retaining fasteners from the lift
the number 1 inner arm (index #8) at the non- cylinder barrel-end pivot pin (index #17). Use a
steering end. soft metal drift to remove the pin. Remove the
cylinder from the machine.
30 Raise the number 1 inner arm (index #8)
approximately 2 feet (0.6 m) and insert the Crushing hazard. The cylinder may
safety arm between the number 1 inner arm become unbalanced and fall when
(index #8) and the number 1 outer arm (index it is removed from the machine if it
#18). Lower the scissor arms onto the safety is not properly attached to the
arm. overhead crane.
Bodily injury hazard. Keep hands Component damage hazard. Be
clear of moving parts when careful not to damage the valve or
inserting the safety arm. fittings on the cylinder while
removing it from the machine.
31 Disconnect and plug the hydraulic hose on the
lift cylinder. Cap the fitting on the cylinder. 35 Place a 4 x 4 x 48 inch (10 x10 x122 cm) long
block across both sides of the chassis under
the number 1 center pivot pin (index #7).
burn skin. Loosen hydraulic 36 Attach a lifting strap from an overhead crane to
connections very slowly to allow the number 1 inner arm (index #8) at the non-
the oil pressure to dissipate steer end. Raise the number 1 inner arm (index
gradually. Do not allow oil to squirt #18) and remove the safety arm. Lower the
or spray. number 1 inner arm (index #8) onto the block
that was placed across the chassis.
32 Tag and disconnect the wires from the solenoid
valve on the cylinder. Bodily injury hazard. Keep hands
clear of moving parts when
lowering the arms onto the block.
the lug on the rod end of the lift cylinder. Raise
the lift cylinder to a vertical position. 37 Remove the cables from the number 1 inner arm
(index #8)and lay them off to the side.
38 Support and secure the entry ladder to an How to Replace the Scissor Arm
appropriate lifting device.
Wear Pads
39 Remove the entry ladder mounting fasteners.
Remove the entry ladder from the machine. 1 Remove the platform. See 2-1, How to Remove
the Platform.
Crushing hazard. The entry ladder
may become unbalanced and fall 2 Remove the mounting fasteners from the
if not properly suported and stationary wear pads on the platform.
secured to the lifting device. Note the position of the wear pads
40 Attach the strap from the overhead crane to the before they are removed so when
number 1 outer arm (index #18). Do not lift it. the new ones are installed they
will be in the correct position.
number 1 center pivot pin (index #7). 3 Support and secure the entry ladder to an
center pivot pin (index #7). 4 Remove the entry ladder mounting fasteners.
Remove the entry ladder from the machine.
1 inner arm (index #18) may Crushing hazard. The entry ladder
become unbalanced and fall if not may become unbalanced and fall if
properly supported when the pin is not properly suported and secured
removed. to the lifting device.
43 Slide the number 1 outer arm (index #18) to the 5 Raise the platform approximately 7 to 8 feet
non-steer end and remove it from the machine. (2.1 to 2.4 m).
Bodily injury hazard. The number 6 Lift the safety arm, move to the center of the
1 outer arm (index #18) may scissor arm and rotate down to a vertical
become unbalanced and fall if not position.
properly supported when removing 7 Lower the platform onto the safety arm.
it from the machine.
8 Mark the mounting position of the level lensor
44 Attach the strap from an overhead crane to the box on the drive chassis.
number 1 inner arm (index #8). Do not lift it.
9 Remove the level sensor box lid.
45 Remove the pin retaining fasteners from both of
the number 1 pivot pins (index #9). Use a slide 10 Mark the mounting position of the level sensor
hammer to remove the pins. on the level sensor box.
46 Remove the number 1 inner arm (index #8) from 11 Remove the level sensor mounting fasteners.
the machine.
Bodily injury hazard. The number 1
inner arm (index #8) may become
supported when removed from the
machine.
12 Remove the level sensor box mounting 19 Remove the old wear pad.
fasteners and slide the box towards the non-
Note the position of the wear pad
steer end of the machine as far as it can go.
before it is removed so when the
Component damage hazard. Be new one is installed it will be in the
careful not to damage the level correct position.
sensor box, limit switch, level
20 Install the new wear pad.
sensor or wiring while moving the
level sensor box. 21 Move the scissor assembly towards the other
side of the machine until the other scissor arm
13 Secure the ends of the scissor arms together at
wear pad is accessible.
both ends of the machine with a tie down strap
or other appropriate device. Crushing hazard. The scissor
assembly will fall if both wear pads
are allowed to slide out of the drive
number 1 inner arm pivot pins (item #9) at the
chassis.
steer end of the machine. Use a slide hammer
to remove the pins. 22 Remove the old wear pad.
15 Attach a lifting strap from an overhead crane to Note the position of the wear pad
the steer end of the scissor arms. before it is removed so when the
new one is installed it will be in the
16 Carefully slide the forks from a forklift under the
correct position.
scissor arms at the non-steer end of the
machine. 23 Install the new wear pad.
17 Raise the scissor arms up until the number 1 24 Slide the scissor assembly back into the drive
inner arm will clear the level sensor box. chassis.
Component damage hazard. Be 25 Lower the scissor assembly into position and
careful not to damage the level install the pivot pins.
sensor box, limit switch or level
sensor while moving the scissor Component damage hazard. Be
assembly. careful not to damage the level
18 Move the scissor assembly towards the non- sensor while installing the scissor
steer end of the machine slightly and to one assembly.
side of the machine until one of the scissor arm
wear pads is accessible. Do not allow both
wear pads to slide out of the drive chassis.
Crushing hazard. The scissor
chassis.
SCISSOR COMPONENTS
Steer End Non-steer End

1 Number 5 pivot pin (steer end) 13 Number 4 inner arm
2 Number 4 center pivot pin 14 Number 4 outer arm
4 Number 3 outer arm 16 Number 3 inner arm
5 Lift cylinder rod end pivot pin 17 Number 3 center pivot pin
7 Number 2 center pivot pin (2 pins) 19 Number 2 inner arm
10 Number 1 inner arm 22 Lift cylinder barrel-end pivot pin
11 Number 1 pivot pin (steer end) (2 pins) 23 Number 1 outer arm
12 Number 5 pivot pin (non-steer end)
How to Disassemble the 7 Use a soft metal drift to remove the number 4
Scissor Assembly the machine. Remove the number 4 outer arm
GS-2646 (index #14) from the machine.
Bodily injury hazard. The Crushing hazard. The number 4

procedures in this section require outer arm (index #14) may become
specific repair skills, lifting unbalanced and fall if not properly
equipment and a suitable supported when it is removed from
workshop. Attempting this the machine.
procedure without these skills and 8 Remove the cables from the upper cable tray
tools could result in death or and lay them off to the side.
serious injury and significant
component damage. Dealer Component damage hazard.
service is required. Cables can be damaged if they
When removing a hose assembly
or fitting, the O-ring on the fitting 9 Remove the mounting fasteners from the upper
and/or hose end must be replaced cable tray supports.
and then torqued to specification
10 Remove the upper cable tray from the scissor
during installation. Refer to Section
assembly.
Two, Hydraulic Hose and Fitting
Torque Specifications. 11 Attach a lifting strap from an overhead crane to
1 Remove the platform. See 2-1, How to Remove
the Platform. 12 Remove the external snap rings from the
2 Remove the cables from the side of the number
4 outer arm (index #14) at the ground controls 13 Use a soft metal drift to remove the number 4
side. pivot pin (index #3) at the steer end. Remove
the number 4 inner arm (index #13) from the
machine.
are kinked or pinched. Crushing hazard. The number 4
the number 4 outer arm (index #14).
supported when it is removed.
number 4 center pivot pin (index #2).
the number 3 outer arm (index #4) at the
5 Use a soft metal drift to remove the number 4 ground controls side.
6 Remove the external snap ring from the number number 3 center pivot pin (index #17).
4 pivot pin (index #2).
16 Use a soft metal drift to remove the number 3 23 Remove the pin retaining fasteners from the lift
center pivot pin (index#17). cylinder rod-end pivot pin (index #5). Use a soft
metal drift to remove the pin.
number 3 pivot pin (index #18) at the non-steer Bodily injury hazard. The cylinder
end of the machine. Do not remove the pin. may fall when the rod-end pivot pin
is removed if it is not properly
18 Use a soft metal drift to tap the number 3 pivot
supported.
pin (index #18) halfway out at the non-steer end
of the machine. Remove the number 3 outer 24 Lower the cylinder onto the number 1 center
arm (index #4) at the ground controls side from pivot pin (index #9).
the machine.
25 Remove the cables from the number 3 inner
Bodily injury hazard. The number arm (index #16) and lay them to the side.
3 outer arm (index #4) at the
supported when it is removed from 27 Remove the external snap rings from the
the machine. number 3 pivot pin (index #6) at the steer end.
19 Attach a lifting strap from an overhead crane to 28 Use a soft metal drift to remove the number 3
the number 3 outer arm (index #4) at the pivot pin (index #6). Remove the number 3
battery pack side. inner arm (index #16) from the machine.
20 Use a soft metal drift to tap the number 3 pivot Bodily injury hazard. The number
pin (index #18) in the other direction. Remove 3 inner arm (index #16) may
the number 3 outer arm (index #4) from the become unbalanced and fall if not
battery pack side of the machine. properly supported when it is
removed from the machine.
3 outer arm (index #4) at the 29 Remove the cable clamps from the lower cable
battey pack side may become tray. Lay the cables to the side.
supported when it is removed from Component damage hazard.
the machine. Cables can be damaged if they
21 Remove the number 3 pivot pin (index #18)
from the non-steer end of the machine. 30 Remove the mounting fasteners from the lower
cable tray supports.
the lug on the rod end of the lift cylinder for 31 Remove the mounting fasteners from the lower
support. Do not lift it. cable tray mounting bracket on the number 2
center pivot pin (index #7) at the ground
controls side of the machine.
32 Slide the cable tray towards the battery pack 40 Use a soft metal drift to tap the number 2 pivot
side of the machine and remove it from the pin (index #21) in the other direction. Remove
machine. the number 2 outer arm (index #20) from the
battery pack side of the machine.
the number 2 outer arm (index #20) at the Bodily injury hazard. The number 2
ground controls side. outer arm (index #20) at the battery
pack side may become
number 2 center pivot pin (index #7) at the
ground controls side.
the machine.
controls side.
number 2 pivot pin (index #8) at the steer end
of the machine.
of the machine. Remove the number 2 outer
arm (index #20) from the ground controls side 43 Use a soft metal drift to remove the number 2
of the machine. pivot pin (index #8). Remove the number 2
2 outer arm (index #20) at the Bodily injury hazard. The number
ground controls side may become 2 inner arm (index #19) may
unbalanced and fall if not properly become unbalanced and fall if not
supported when it is removed from properly supported when it is
the machine. removed from the machine.
37 Attach a lifting strap from an overhead crane to 44 Remove the safety arm from the number 2 inner
the number 2 outer arm (index #20) at the arm (index #19) that was just removed.
battery pack side.
38 Remove the external snap rings from the the number 1 inner arm (index #10).
46 Raise the number 1 inner arm (index #10)
battery pack side.
approximately 2 feet (0.6 m) and install the
39 Use a soft metal drift to remove the number 2 safety arm between the number 1 inner arm
center pivot pin (index #7) at the battery pack (index #10) and the number 1 outer arm
side. (index #23). Lower the scissor arms onto the
safety arm.
2 outer arm (index #20) at the Bodily injury hazard. Keep hands
battery pack side may become clear of moving parts when
unbalanced and fall if not properly inserting the safety arm.
the machine.
47 Disconnect and plug the hydraulic hose on the 52 Attach a lifting strap from an overhead crane to
lift cylinder. Cap the fitting on the cylinder. the number 1 inner arm (index #10) at the non-
steer end. Raise the number 1 inner arm and
remove the safety arm. Lower the number 1
inner arm (index #10) onto the block that was
placed across the chassis.
the oil pressure to dissipate Bodily injury hazard. Keep hands
gradually. Do not allow oil to squirt clear of moving parts when
or spray. lowering the arms onto the block.
48 Tag and disconnect the wires from the solenoid 53 Remove the cables and hydraulic hoses from
valve on the cylinder. the number 1 inner arm (index #10) and lay
them to the side.
the lug on the rod end of the lift cylinder. Raise Component damage hazard.
the lift cyinder to a vertical positon. Cables and hoses can be
damaged if they are kinked or
50 Remove the pin retaining fasteners from the lift
pinched.
cylinder barrel-end pin (index #22). Use a soft
metal drift to remove the pin. Remove the 54 Support and secure the entry ladder to an
cylinder from the machine. appropriate lifting device.
Crushing hazard. The cylinder 55 Remove the mounting fasteners from the entry
may become unbalanced and fall ladder and remove the entry ladder from the
when it is removed from the machine.
machine if it is not properly
attched to the overhead crane.
may become unbalanced and fall
Component damage hazard. Be if not properly supported and
careful not to damage the valve or secured to the lifting device.
fittings on the cylinder while
the number 1 outer arm (index #23). Do not lift
51 Place a 4x4x48 inch (10x10x122 cm) long block it.
across both sides of the chassis under the
58 Use a soft metal drift to remove the number 1 62 Remove the number 1 inner arm (index #10)
center pivot pin (index #9). from the machine.
Bodily injury hazard. The number Bodily injury hazard. The number
1 outer arm (index #23) may 1 inner arm (index #10) may
become unbalanced and fall if not become unbalanced and fall if not
properly supported when the pin is properly supported when it is
removed. removed from the machine.
59 Slide the number 1 outer arm (index #23) to the Component damage hazard. Be
non-steer end and remove it from the machine. sure not to damage the limit switch
or level sensor box components
when the number 1 inner arm
1 outer arm (index #23) may
(index #10) is removed from the
become unbalanced and fall if not
machine.
properly supported when it is
removed from the machine. How to Replace the Scissor Arm
Note the position of the wear pads Wear Pads
before the arm is removed so
when the scissor is assembled 1 Remove the platform. See 2-1, How to Remove
they will be in the correct position. the Platform.
60 Attach the strap from an overhead crane to the 2 Remove the mounting fasteners from the
number 1 inner arm (index #10). Do not lift it. stationary wear pads on the platform.
61 Remove the pin retaining fasteners from both of Note the position of the wear pads
the number 1 pivot pins (index #11) at the steer before they are removed so when
end of the machine. Use a slide hammer to the new ones are installed they
remove the pins. will be in the correct position.
3 Support and secure the entry ladder to an
4 Remove the mounting fasteners from the entry
ladder and remove the entry ladder from the
machine.
may become unbalanced and fall if
not properly supported and secured
to the lifting device.
5 Support and secure the entry ladder to an 17 Attach a lifting strap from an overhead crane to
appropriate lifting device. the steer end of the scissor arms.
6 Remove the mounting fasteners from the entry 18 Carefully slide the forks from a forklift under the
ladder and remove the entry ladder from the scissor arms at the non-steer end of the
machine. machine.
Crushing hazard. The entry ladder 19 Raise the scissor arms up until the number 1
may become unbalanced and fall if inner arm will clear the level sensor box.
Component damage hazard. Be
careful not to damage the level
7 Raise the platform approximately 7 to 8 feet (2.1 sensor box, limit switch or level
to 2.4 m). sensor while moving the scissor
assembly.
scissor arm and rotate down to a vertical 20 Move the scissor assembly towards the non-
position. steer end of the machine slightly and to one
9 Lower the platform onto the safety arm.
wear pads is accessible. Do not allow both wear
10 Mark the mounting position of the level sensor pads to slide out of the drive chassis.
box on the drive chassis.
11 Remove the level sensor box lid. assembly will fall if both wear pads
12 Mark the mounting position of the level sensor chassis.
on the level sensor box.
13 Remove the level sensor mounting fasteners.
14 Remove the level sensor box mounting before it is removed so when the
fasteners and slide the box towards the non- new one is installed it will be in the
steer end of the machine as far as it can go. correct position.
Component damage hazard. Be 22 Move the scissor assembly towards the other
careful not to damage the level side of the machine until the other scissor arm
sensor box, limit switch, level wear pad is accessible.
sensor or wiring while moving the
level sensor box. Crushing hazard. The scissor
15 Secure the ends of the scissor arms together at are allowed to slide out of the drive
both ends of the machine with a tie down strap chassis.
or other appropriate device.
number 1 inner arm pivot pins (item #11) at the
steer end of the machine. Use a slide hammer
to remove the pins.

new one is installed it will be in the
correct position.
24 Slide the scissor assembly back into the drive
chassis.
25 Lower the scissor assembly into position and
install the pivot pins.
sensor while installing the scissor
assembly.
Scissor Components, GS-3246
Steer end Non steer end

2 Number 5 center pivot pin 17 Number 5 inner arm
3 Upper lift cylinder rod-end pivot pin 18 Number 5 outer arm
7 Number 3 outer arm 22 Number 4 pivot pin (non-steer end)
8 Number 3 center pivot pin 23 Upper lift cylinder barrel-end pivot pin
9 Lower lift cylinder rod-end pivot pin 24 Number 3 inner arm
14 Number 1 inner arm 29 Lower lift cylinder barrel-end pivot pin
15 Number 1 pivot pin (steer end) (2 pins) 30 Number 1 outer arm
3-3 6 Remove the external snap rings from the

Scissor Assembly
How to Disassemble the the machine. Remove the number 5 outer arm
Scissor Assembly (index #18) from the machine.
GS-3246 Crushing hazard. The number 5
outer arm (index #18) may become
procedure requires specific repair
skills, lifting equipment and a
the machine.
suitable workshop. Attempting this
procedure without these skills and 8 Remove the cable clamps from the number 5
tools could result in death or inner arm (index #17). Lay the cables off to the
serious injury and significant side of the machine.
component damage. Dealer
service is required. 9 Remove the mounting fasteners from the upper
or fitting, the O-ring on the fitting 10 Remove the mounting fasteners from the upper
and/or hose end must be replaced cable tray mounting bracket on the number 4
and then torqued to specification center pivot pin (index #5) at the ground
during installation. Refer to Section controls side of the machine.
Two, Hydraulic Hose and Fitting 11 Remove the upper cable tray from the scissor
Torque Specifications. assembly.
1 Remove the platform. See 2-1, How to Remove Component damage hazard.
the Platform. Cables can be damaged if they are
2 Remove the cables from the side of the number kinked or pinched.
5 outer arm (index #18) at the ground controls 12 Attach a lifting strap from an overhead crane to
side. the lug on the rod end of the upper lift cylinder.
Component damage hazard. 13 Remove the pin retaining fasteners from the
Cables can be damaged if they are upper cylinder rod-end pivot pin (index #3). Use
kinked or pinched. a soft metal drift to remove the pin.
3 Attach a lifting strap from an overhead crane to Crushing hazard. The cylinder may
the number 5 outer arm (index #18). fall if not properly supported when
4 Remove the external snap rings from the the pin is removed.
number 5 center pivot pin (index #2). 14 Lower the cylinder onto the number 3 center
5 Use a soft metal drift to remove the number 5 pivot pin (index #8).
15 Attach a lifting strap from an overhead crane to 25 Use a soft metal drift to remove the number 2
the number 5 inner arm (index #17). pivot pin (index #12). Remove the number 2
number 5 pivot pin (index #4). Bodily injury hazard. The number 4
pivot pin (index #4). Remove the number 5
the machine.
26 Remove the safety arm from the number 4 inner
5 inner arm (index #17) may
arm (index #20) that was just removed.
properly supported when it is 27 Disconnect and plug the hydraulic hose on the
removed from the machine. lift cylinder. Cap the fitting on the cylinder.
18 Remove the external snap rings from the Bodily injury hazard. Spraying
number 4 center pivot pin (index #5) at the hydraulic oil can penetrate and
ground controls side. burn skin. Loosen hydraulic
gradually. Do not allow oil to squirt
battery pack side.
or spray.
20 Use a soft metal drift to remove both of the
28 Tag and disconnect the wires from the solenoid
number 4 center pivot pins (index #5).
valve on the cylinder.
29 Connect the platform controls to the control
number 4 pivot pin (index #22) at the non-steer
cable that was removed from the platform.
end of the machine.
30 Connect the battery pack. Turn the key switch
to ground control and pull out the Emergency
Stop button to the ON position at both the
outer arm (index #21) from the machine.
platform and ground controls.
31 Activate the up function and raise the number 2
4 outer arm (index #21) may
inner arm (index #26) approximately 2 feet
(0.6 m). Then install the safety arm between the
number 2 inner arm (index #26) and the
number 1 inner arm (index #14).
Bodily injury hazard. Keep hands
24 Remove the external snap rings from the inserting the safety arm.
number 4 pivot pin (index #6) from the steer
end of the machine.
32 Activate the down function to lower the scissor 36 Activate the up fuction and raise the number 2
assembly onto the safety arm. Push in the inner arm (index #26) approximately 2 feet
Emergency Stop buttons and turn the key to the (0.6 m). Remove the safety arm from the
OFF position. machine.
Bodily injury hazard. The scissor Bodily injury hazard. Keep hands
assembly may become clear of moving parts when
unbalanced and fall if not properly removing the safety arm.
supported by the safety arm.
37 Activate the down function and fully lower the
Bodily injury hazard. Keep hands scissor assembly. Push in the Emergency Stop
clear of moving parts when button and turn the key to the OFF position.
inserting the safety arm. Disconnect the battery pack.
33 Attach a lifting strap from an overhead crane to Bodily injury hazard. Keep hands
the lug on the rod end of the upper lift cylinder. clear of moving parts when
Raise the rod end of the cylinder to a vertical lowering the scissor assembly.
position.
34 Remove the pin retaining fasteners from the the number 3 outer arm (index #7) at the
upper lift cylinder barrel-end pivot pin (index ground controls side.
#23). Use a soft metal drift to remove the pin.
Remove the cylinder from the machine.
Crushing hazard. If the overhead
crane is not properly attached, the
cylinder may become unbalanced
and fall when it is removed from 41 Remove the external snap rings from the
the machine. number 3 pivot pin (index #25) at the non-steer
end of the machine. Do not remove the pin.
careful not to damage the valve or 42 Use a soft metal drift to tap the number 3 pivot
fittings on the cylinder while pin (index #25) halfway out at the non-steer end
removing it from the machine. of the machine. Remove the number 3 outer
arm (index #7) at the ground controls side from
the machine.
position at both the platform and ground Bodily injury hazard. The number
controls. 3 outer arm (index #7) at the
machine.
43 Attach a lifting strap from an overhead crane to 51 Remove the pin retaining fasteners from the
the number 3 outer arm (index #7) at the lower lift cylinder rod-end pivot pin (index #9).
battery pack side. Use a soft metal drift to remove the pin.
44 Use a soft metal drift to tap the number 3 pivot 52 Lower the cylinder onto the number 1 center
pin (index #10) at the steer end in the other pivot pin (index #13).
direction. Remove the number 3 outer arm
(index #7) from the battery pack side of the
machine.
outer arm (index #7) at the battery
pack side may become 55 Use a soft metal drift to remove the number 3
unbalanced and fall if not properly pivot pin (index #10). Remove the number 3
supported when it is removed from inner arm (index #24) from the machine.
the machine.
45 Remove the cables from the number 3 inner arm 3 inner arm (index #24) may
(index #24) and lay them off to the side. become unbalanced and fall if not
are kinked or pinched. 56 Attach a lifting strap from an overhead crane to
the number 2 outer arm (index #27) at the
46 Remove the cables from the lower cable tray on
ground controls side.
the number 2 inner arm (index #26). Lay the
cables off th the side. 57 Use a soft metal drift to remove the number 2
47 Remove the mounting fasteners from the lower
controls side.
number 2 pivot pin (index #28) at the non-steer
end of the machine. Do not remove the pin.
ground controls side. Do not remove the pin.
49 Slide the cable tray towards the battery pack
side of the machine and remove it from the
of the machine. Remove the number 2 outer
machine.
arm (index #27) from the ground controls side
Component damage hazard. of the machine.
Cables can be damaged if they are
kinked or pinched.
outer arm (index #27) at the ground
50 Attach a lifting strap from an overhead crane to controls side may become
the lug on the rod end of the lower lift cylinder. unbalanced and fall if not properly
the machine.
60 Attach a lifting strap from an overhead crane to 68 Attach the strap from the overhead crane to the
the number 2 outer arm (index #27) at the number 1 inner arm (index #14).
battery pack side.
69 Using the overhead crane, lift the number 1 inner
61 Remove the external snap rings from the arm (index #14) approximately 2 feet (0.6 m).
number 2 center pivot pin (index #11) at the Place a 4x4x48 inch (10x10x122 cm) long block
battery pack side of the machine. across both sides of the chassis under the
number 1 center pivot pin (index #13). Lower the
scissor arms onto the block.
center pivot pin (index #11) at the battery pack
side of the machine. Bodily injury hazard. Keep hands
lowering the arms onto the block.
pin (index #28) in the other direction. Remove
the number 2 outer arm (index #27) from the 70 Disconnect and plug the hydraulic hose on the
battery pack side of the machine. lift cylinder. Cap the fitting on the cylinder.
Bodily injury hazard. The number Bodily injury hazard. Spraying
2 outer arm (index #27) at the hydraulic oil can penetrate and
ground controls side may become burn skin. Loosen hydraulic
unbalanced and fall if not properly connections very slowly to allow
supported when it is removed from the oil pressure to dissipate
the machine. gradually. Do not allow oil to squirt
or spray.
pivot pin (index #28) from the machine. 71 Tag and disconnect the wires from the solenoid
valve on the cylinder.
the number 2 inner arm (index #26). 72 Attach a lifting strap from an overhead crane to
the lug on the rod end of the lift cylinder.
number 2 pivot pin (index #12) from the steer 73 Remove the pin retaining fasteners from the
end of the machine. lower lift cylinder barrel-end pivot pin (index
#29). Use a soft metal drift to remove the pin.
Remove the cylinder from the machine.
inner arm (index #26) from the machine. Crushing hazard. If the overhead
crane is not properly attached, the
cylinder may become unbalanced
and fall when it is removed from
the machine.
the machine. Component damage hazard. Be
careful not to damage the valve or
74 Support and secure the entry ladder to an 81 Attach a lifting strap from an overhead crane to
appropriate lifting device. the number 1 inner arm (index #14).
Do not lift it.
ladder and remove the entry ladder from the 82 Remove the pin retaining fasteners from both of
machine. the number 1 pivot pins (index #15). Use a slide
hammer to remove the pins.
may become unbalanced and fall if 83 Remove the number 1 inner arm (index #14)
not properly supported and secured from the machine.
Crushing hazard. The number 1
76 Remove the cables from the number 1 inner arm inner arm (index #14) may become
(index #14) and lay them off to the side. unbalanced and fall if not properly
machine.
Cables can be damaged if they are
kinked or pinched. How to Replace the Scissor Arm
77 Attach a lifting strap from an overhead crane to Wear Pads
the number 1 outer arm (index #30). Do not lift
it. 1 Remove the platform. See 2-1, How to Remove
the Platform.
number 1 center pivot pin (index #13). 2 Remove the mounting fasteners from the
stationary wear pads on the platform.
center pivot pin (index #13). Note the position of the wear pads
before they are removed so when
Crushing hazard. The number 1 the new ones are installed they
outer arm (index #30) may become will be in the correct position.
supported when the pin is 3 Support and secure the entry ladder to an
removed. appropriate lifting device.
80 Slide the number 1 outer arm (index #30) to the 4 Remove the mounting fasteners from the entry
non-steer end and remove it from the machine. ladder and remove the entry ladder from the
machine.
Crushing hazard. The number 1
outer arm (index #30) may become 5 Raise the platform approximately 7 to 8 feet
unbalanced and fall if not properly (2.1 to 2.4 m).
supported when removing it from 6 Lift the safety arm, move to the center of the
the machine. scissor arm and rotate down to a vertical
Note the position of the wear pads position.
before the arm is removed so
when the scissor is assembled
they will be in the correct position.
SCISSOR COMPONENTS
7 Lower the platform onto the safety arm. 18 Move the scissor assembly towards the non-
steer end of the machine slightly and to one
Crushing hazard. Keep hands clear
of moving parts when lowering the
wear pads is accessible. Do not allow both wear
arms onto the safety arm.
pads to slide out of the drive chassis.
8 Mark the mounting position of the level sensor
box on the drive chassis.
9 Remove the level sensor box lid. are allowed to slide out of the drive
chassis.
10 Mark the mounting position of the level sensor
on the level sensor box. 19 Install the new wear pad.
11 Remove the level sensor mounting fasteners. Note the position of the wear pad
12 Remove the fasteners from the level sensor box new one is installed it will be in the
and slide the box towards the non-steer end of correct position.
the machine as far as it can go.
20 Move the scissor assembly towards the other
Component damage hazard. Be side of the machine until the other scissor arm
careful not to damage the level wear pad is accessible.
sensor box, limit switch, level
sensor or wiring while moving the Crushing hazard. The scissor
level sensor box. assembly will fall if both wear pads
13 Secure the ends of the scissor arms together at
chassis.
both ends of the machine with a tie down strap
or other appropriate device. 21 Install the new wear pad.
14 Remove the pin retaining fasteners from the Note the position of the wear pad
number 1 inner arm pivot pins (index #15) at the before it is removed so when the
steer end of the machine. Use a slide hammer new one is installed it will be in the
to remove the pins. correct position.
15 Attach a lifting strap from an overhead crane to 22 Slide the scissor assembly back into the drive
the steer end of the scissor arms. chassis.
16 Carefully slide the forks from a forklift under the 23 Lower the scissor assembly into position and
scissor arms at the non-steer end of the install the pivot pins.
machine.
17 Raise the scissor arms up until the number 1 careful not to damage the level
inner arm will clear the level sensor box. sensor box, limit switch or level
sensor while installing the scissor
assembly.
sensor while moving the scissor
assembly.
SCISSOR COMPONENTS
3-4 4 Tag and disconnect the wiring from the solenoid

valve at the barrel end of the lift cylinder.
Lift Cylinder
5 Disconnect the manual lowering cable from the
solenoid.
How to Remove the Lift Cylinder
GS-2046 & 2646 During assembly, the manual
platform lowering cable needs to
be properly adjusted. Refer to 4-1,
How to Adjust the Manual
Platform Lowering Cable.
procedure requires specific repair
skills, lifting equipment and a 6 Remove the mounting fasteners from the
suitable workshop. Attempting this manual lowering cable mounting bracket.
procedure without these skills and Remove the bracket from the cylinder.
tools could result in death or
serious injury and significant 7 Disconnect and plug the hydraulic hose from the
component damage. Dealer lift cylinder. Cap the fitting on the cylinder.
service is strongly recommended. Bodily injury hazard. Spraying
When removing a hose assembly hydraulic oil can penetrate and
or fitting, the O-ring on the fitting burn skin. Loosen hydraulic
and/or hose end must be replaced connections very slowly to allow
and then torqued to specification the oil pressure to dissipate
during installation. Refer to gradually. Do not allow oil to squirt
Section Two, Hydraulic Hose and or spray.
Fitting Torque Specifications. 8 Attach a lifting strap from an overhead crane or
1 Raise the platform approximately 7 to 8 feet similar lifting device to the rod end of the lift
(2.1 to 2.4 m). cylinder for support.
2 Lift the safety arm, move to the center of the 9 Remove the external snap ring from the lift
scissor arm and rotate down to a vertical cylinder rod-end pivot pin. Then use a soft metal
position. drift to remove the pin.
3 Lower the platform onto the safety arm. Crushing hazard. The lift cylinder
Crushing hazard. Keep hands clear not properly supported.
of the safety arm when lowering
the platform. 10 Lower the cylinder to a horizontal position.
If removing the lower lift cylinder,
remove the entry ladder from the
non-steer end of the machine.
SCISSOR COMPONENTS
11 Support and secure the entry ladder to an How to Remove the Lift Cylinder
GS-3246 Models
ladder and remove the entry ladder from the Bodily injury hazard. This
machine. procedure requires specific repair
skills, lifting equipment and a
Crushing hazard. The entry ladder suitable workshop. Attempting this
may become unbalanced and fall if procedure without these skills and
not properly supported and secured tools could result in death or
to the lifting device. serious injury and significant
13 Support the barrel end of the lift cylinder with a component damage. Dealer
lifting device. service is strongly recommended.
14 Remove the external snap ring from the lift When removing a hose assembly
cylinder barrel-end pivot pin. Then use a soft or fitting, the O-ring on the fitting
metal drift to remove the pin. and/or hose end must be replaced
Crushing hazard. The lift cylinder during installation. Refer to Section
may become unbalanced and fall if Two, Hydraulic Hose and Fitting
not properly supported. Torque Specifications.
15 Carefully pull the cylinder out the non-steer end 1 Raise the platform approximately 10 feet (3 m).
of the machine through the scissor arms.
Component damage hazard. Be scissor arm and rotate down to a vertical
careful not to damage the valve or position.
removing it from the machine. 3 Lower the platform onto the safety arm.
of the safety arm when lowering
the platform.
4 Tag and disconnect the wiring from the solenoid
valve at the barrel end of the lift cylinder.
5 Disconnect and plug the hydraulic hose from the
lift cylinder. Cap the fitting on the cylinder.
or spray.
SCISSOR COMPONENTS
6 Attach a lifting strap from an overhead crane or 12 Carefully pull the cylinder out the non-steer end
similar lifting device to the rod end of the lift of the machine through the scissors arms.
cylinder for support.
7 Remove the external snap rings from the lift careful not to damage the valve or
cylinder rod-end pivot pin. Then use a soft metal fittings on the cylinder while
drift to remove the pin. removing it from the machine.
Crushing hazard. The lift cylinder How to Check the Resistance
not properly supported. of a Lowering Valve Coil
8 Lower the cylinder to a horizontal position. 1 Turn the key switch to the OFF position and
disconnect the wire from the valve coil to be
If removing the lower lift cylinder, tested.
remove the entry ladder from the
non-steer end of the machine. 2 Connect the positive lead from the ohmmeter to
the valve coil terminal, then connect the
9 To remove the lower cylinder, support and negative lead from the ohmmeter to the internal
secure the entry ladder to an appropriate lifting ring of the valve coil.
device. Then remove the mounting fasteners
from the entry ladder and remove the entry Lift cylinder lowering valve coil specifications
ladder from the machine. GS-2046 & GS-2646
Crushing hazard. The entry ladder 2 position 2 way N.C. solenoid valve - 20V 23 - 259
may become unbalanced and fall if (hydraulic schematic item Q)
to the lifting device. Lift cylinder lowering valve coil specifications
GS-3246
10 Support and secure the lift cylinder to an
2 position 2 way N.C. solenoid valve - 20V 23 - 259
(hydraulic schematic items Q and R)
11 Remove the external snap ring from the lift
cylinder barrel-end pivot pin. Then use a soft
metal drift to remove the pin.
Crushing hazard. The cylinder may
become unbalanced and fall when
it is removed from the machine if it
is not properly attached and
secured to the lifting device.
Ground Controls
4-1 cable mounting bracket. Turn the lower lock nut
clockwise to decrease the distance or
Manual Platform Lowering counterclockwise to increase the distance.
Cable, GS-2046 & GS-2646 8 Tighten the upper lock nut and re-measure the
distance between the end of the lowering cable
The manual platform lowering cable lowers the and the end of the lowering valve. Re-adjust if
platform in the event of a main power failure. The needed.
manual platform lowering cable is attached to the
barrel end of the lift cylinder and is activated next 9 Install the cable mounting nut onto the lowering
to the ground controls. valve.
10 Raise the platform and rotate the safety arm to
How to Adjust the Manual the storage position.
Platform Lowering Cable
11 Pull the manual lowering handle at the ground
1 Raise the platform approximately 7 to 8 feet controls 2 to 3 times to ensure it is functioning
(2.1 to 2.4 m). correctly.
2 Lift the safety arm, move to the center of the Cable distance 3/16 to1/4 inch 4.7 to 6.4 mm
scissor arm and rotate to a vertical position.
3 Lower the platform onto the safety arm. a
of the safety arm when lowering a manual lowering
the platform. b
cable sheath
b upper lock nut
4 Push the handle on the manual platform lowering c cable mounting
cable all the way in. c
bracket
d lower lock nut
5 Disconnect the cable mounting nut from the e cable mounting nut
lowering valve at the barrel end of the lift d f end of the lowering
cable
cylinder.
g manual lowering valve
6 Pull the cable tight and measure the distance (schematic item Q)
e
between the end of the lowering cable and the
end of the lowering valve.
Result: The measurement should be 3/16 to f
1/4 inch (4.7 to 6.4 mm).
7 To adjust, loosen the upper lock nut on the

g
R
GROUND CONTROLS
4-2 4-3
Manual Platform Lowering - Toggle Switches
GS-3246
See 1-4, Toggle Switches.
The manual platform lowering button lowers the
platform in the event of a main power failure. There
is no adjustment required. Two 12V batteries are
wired in series supplying 24V to the manual
platform lowering button. The batteries are located
inside the ground control panel.
How to Replace the Manual

Platform Lowering Batteries
1 Remove the cover from the ground control
panel.
2 Tag and disconnect the wires from the battery to
be removed.
3 Remove the battery from the machine.
4 Install the new battery and connect the wires.
5 Install the ground control cover.
Hydraulic Pump
5-1 How to Remove the
Hydraulic Pump Hydraulic Pump
The hydraulic pump is attached to the motor which
or fitting, the O-ring on the fitting
makes up the Hydraulic Power Unit.
and/or hose end must be replaced
How to Test the Hydraulic Pump and then torqued to specification
during installation. Refer to
When removing a hose assembly Section Two, Hydraulic Hose and
or fitting, the O-ring on the fitting Fitting Torque Specifications.
1 Tag, disconnect and plug the hoses on the
pump. Cap the fittings on the pump.
during installation. Refer to
Section Two, Hydraulic Hose and Bodily injury hazard. Spraying
Fitting Torque Specifications. hydraulic oil can penetrate and
1 Disconnect and plug the high pressure
hydraulic hose from the hydraulic pump.
Bodily injury hazard. Spraying gradually. Do not allow oil to squirt
hydraulic oil can penetrate and or spray.
2 Remove the pump mounting bolts. Carefully
remove the pump.
or spray.
2 Connect a 0 to 5000 psi (0 to 345 bar) pressure
gauge to the high pressure port on the pump.
position.
4 Activate the platform up function from the
ground controls.
Result: If the pressure gauge reads 3700 psi
(255 bar), immediately stop. The pump is good.
Result: If pressure fails to reach 3700 psi
(255 bar), the pump is bad and will need to be
serviced or replaced.
5 Remove the pressure gauge and reconnect the
hydraulic hose.
Manifolds
6-1
Function Manifold Components (before serial number 17482)
The function manifold is mounted inside the hydraulic power unit tray.
Index Schematic
No. Description Item Function Torque
1 Flow regulator,
0.75 gpm (2.83 L/min) ....................... A ........... Steer circuit ....................................... 35-40 ft-lbs (47-54 Nm)
2 Diagnostic nipple .............................. B ........... Testing .............................................. 10-12 ft-lbs (14-16 Nm)
3 Orifice plug, 0.025 in (0.6 mm) .......... C ........... Brake circuit
4 Orifice washer, 0.040 inch (1 mm) .... D ........... Steering circuit
5 Relief valve, 1500 psi (103.4 bar) ..... E ........... Steering relief ................................... 25-30 ft-lbs (34-41 Nm)
6 Relief valve, 3700 psi (255.1 bar) ..... F ........... System relief ..................................... 25-30 ft-lbs (34-41 Nm)
7 3 position 4 way solenoid valve ........ G ........... Steer left/right .................................... 18-20 ft-lbs (24-27 Nm)
8 2 position 4 way solenoid valve ........ H ........... Platform up ....................................... 23-25 ft-lbs (31-34 Nm)
9 Orifice washer, 0.060 in (1.5 mm) ..... I ............ Brake circuit
10 2 position 2 way solenoid valve ........ J ............ Brake circuit ...................................... 18-20 ft-lbs (24-27 Nm)
11 Check valve ....................................... K ........... Drive circuit ....................................... 35-40 ft-lbs (47-54 Nm)
12 2 position 4 way solenoid valve ........ L ........... Drive speed select circuit ................. 23-25 ft-lbs (31-34 Nm)
13 3 position 4 way solenoid valve ........ M .......... Drive forward/reverse ....................... 18-20 ft-lbs (24-27 Nm)
Important notes:
Schematic item E changed to 1500 PSI (103.4 bar) after serial number 3405
Schematic item C was deleted after serial number 8798
Schematic item J was deleted after serial number 8798
Schematic item A changed to 0.75 GPM (2.8 L/min) after serial number 11500
Schematic item K changed to 200 PSI (13.8 bar) after serial number 16893
Plug Torque Specifications

Description Hex Size Torque Description Hex Size Torque
SAE No. 2 1/8 50 in-lbs / 6 Nm SAE No. 8 5/16 50 ft-lbs / 68 Nm
SAE No. 4 3/16 13 ft-lbs / 18 Nm SAE No. 10 9/16 55 ft-lbs / 75 Nm
MANIFOLDS
MANIFOLDS
6-2
Function Manifold Components (after serial number 17481)
The function manifold is mounted inside the hydraulic power unit tray.
Index Schematic
1 Check valve ....................................... A ........... Steer circuit ....................................... 25-30 ft-lbs (34-41Nm)
2 Diagnostic nipple .............................. B ........... Testing .............................................. 10-12 ft-lbs (14-16 Nm)
3 Flow regulator,
0.75 gpm (2.83 L/min) ....................... C ........... Steer circuit ...................................... 35-40 ft-lbs (47-54 Nm)
4 Orifice washer, 0.040 inch (1 mm) .... D ........... Steering circuit
5 Relief valve, 1500 psi (103.4 bar) ..... E ........... Steering relief ................................... 25-30 ft-lbs (34-41 Nm)
6 Relief valve, 3700 psi (255.1 bar) ..... F ........... System relief ..................................... 25-30 ft-lbs (34-41 Nm)
7 3 position 4 way solenoid valve ........ G ........... Steer left/right .................................... 18-20 ft-lbs (24-27 Nm)
8 2 position 4 way solenoid valve ........ H ........... Platform up ....................................... 23-25 ft-lbs (31-34 Nm)
9 2 position 2 way solenoid valve ........ I ............ Brake circuit ...................................... 18-20 ft-lbs (24-27 Nm)
10 2 position 4 way solenoid valve ........ J ............ Drive speed circuit select ................. 23-25 ft-lbs (31-34 Nm)
11 3 position 4 way solenoid valve ........ K ........... Drive forward/reverse ....................... 18-20 ft-lbs (24-27 Nm)
12 Back presure relief valve .................. L ........... Drive circuit ....................................... 25-30 ft-lbs (34-41 Nm)

MANIFOLDS
MANIFOLDS
6-3 9 The power unit should not be able to lift the

platform. If the power unit lifts the platform,
Valve Adjustments - adjust the internal hex socket counterclockwise
Function Manifold until the platform will not raise.
Tip-over hazard. Do not adjust the
Be sure that the hydraulic oil level relief valve to allow the power unit
is between the FULL and ADD marks to lift more than maximum rated
on the oil level indicator decal. load.
How to Adjust the System Relief 10 Install the relief valve cap.
Valve, GS-2046 & GS-2646 11 Bleed the hydraulic system. Raise the platform
to full height, and then lower it to the stowed
position through two complete cycles.
1 Open the hydraulic power unit module tray and
locate the system relief valve on the function Result: If the pump cavitates or platform fails to
manifold. reach full height, add hydraulic oil until the
pump is functioning correctly. Do not overfill the
2 Place maximum rated load into the platform. hydraulic reservoir. Re-test the system by
Secure the load to the platform. performing steps 8 through 11.
Maximum Capacity Component damage hazard. Do
not continue to operate the
GS-2046 1200 lbs 363 kg machine if the hydraulic pump is
GS-2646 1000 lbs 454 kg
cavitating. If the pump is still
cavitating, see 5-1, How to Test
the Hydraulic Pump.
controls.
How to Adjust the Drive Relief
4 Hold the system relief valve with a wrench and
remove the cap (item #4, function manifold). Valve, GS-3246
5 While activating the platform up function, adjust 1 Connect a 0 to 5000 psi (0 to 345 bar) pressure
the internal hex socket clockwise to increase lift gauge to the test port (item #2) on the function
capacity or counterclockwise to decrease lift manifold.
capacity. Adjust the relief valve until the 2 Turn the key switch to ground control and pull
platform just begins to raise. out the Emergency Stop button to the ON
6 Fully lower the platform. position at both the ground and platform
controls.
7 Add an additional 100 pounds (45.4 kg) to the
platform. Secure the additional weight. 3 Chock both sides of all four wheels. Then slowly
move the control handle from center to the full
8 Activate the platform up function. forward position and observe the pressure
reading on the pressure gauge. Return control
handle to center.
MANIFOLDS
4 Turn the machine off. Hold the relief valve and 6 Adjust the internal hex socket. Turn it clockwise
remove the cap (item #6, function manifold). to increase the pressure or counterclockwise to
decrease the pressure. Install the relief valve
5 Adjust the internal hex socket. Turn it clockwise
cap.
to increase the pressure or counterclockwise to
decrease the pressure. Then install the relief Tip-over hazard. Do not adjust the
valve cap. relief valve higher than specified.
Tip-over hazard. Do not adjust the 7 Repeat steps 3 and 4 to confirm the steering
relief valve higher than specified. relief pressure.
6 Repeat step 3 and re-check the valve pressure. Steering relief valve specification
Drive relief valve specification Pressure 1500 psi 103.4 bar
Pressure 3700 psi 255.1 bar
How to check the Resistance of

How to Adjust the Steering a Valve Coil
Relief Valve 1 Turn the key switch to the OFF position and
disconnect the wires from the valve coil to be
1 Connect a 0 to 5000 psi (0-345 bar) pressure
tested.
gauge to the test port (item #2) on the function
manifold. 2 Coils with 2 terminals: Connect the leads from
the ohmmeter to the valve coil terminals.
out the Emergency Stop button to the ON Coils with 1 terminal: Connect the positive
position at both the ground and platform lead from the ohmmeter to the valve coil
controls. terminal, then connect the negative lead from
the ohmmeter to the internal ring of the valve
3 Press and hold the steer thumb rocker switch to
coil.
the right. Allow the wheels to completely turn to
the right, then continue holding the switch while Valve coil specifications
observing the pressure reading on the pressure Before serial number 11501
gauge. Note the pressure.
Coil, 20V (function manifold items G, J) 26 - 28W
4 Press and hold the steer thumb rocker switch to
the left. Allow the wheels to completely turn to Coil, 20V (function manifold items H, L, M) 18 - 20W
the left, then continue holding the switch while
Valve coil specifications
observing the pressure reading on the pressure
After serial number11500
gauge. Note the pressure.
Coil, 20V (function manifold items G, I) 26 - 28W
5 Turn the machine off. Hold the steering relief
valve with a wrench and remove the cap (item Coil, 20V (function manifold items H, J, K) 18 - 20W
#5, function manifold).
MANIFOLDS
6-4 4 Hold the function relief valve with a wrench and

remove the cap.
Lift Relief Valve, GS-3246
5 While activating the platform up function, adjust
the internal hex socket clockwise to increase lift
How to Adjust the Lift Relief capacity or counterclockwise to decrease lift
Valve, GS-3246 capacity. Adjust the relief valve until the
platform just begins to raise.
Be sure that the hydraulic oil level
is between the FULL and ADD marks 6 Install the relief valve cap.
on the oil level indicator decal.
7 Fully lower the platform.
For machines manufactured before
8 Add an additional 100 pounds (45.4 kg) to the
November 1999, contact the Genie
platform. Secure the additional weight.
Industries Service Parts
Department and order a lift relief kit 9 Activate the platform up function.
(Genie part number 66174). Install
the kit, then complete the following 10 The power unit should not be able to lift the
procedure. For machines platform with the additional weight. If the power
manufactured after October 1999, unit lifts the platform, remove the additional
adjust the lift relief valve weight and repeat steps 4 through 9.
(schematic item M) using the Tip-over hazard. Do not adjust the
following procedure. relief valve to allow the power unit
1 Open the hydraulic power unit module tray and to lift more than maximum rated
locate the lift relief valve located next to the load.
function manifold. Result: If the pump cavitates or platform fails to
2 Place maximum rated load into the platform. reach full height, add hydraulic oil until the
Secure the load to the platform. pump is functioning correctly. Do not overfill the
hydraulic reservoir. Re-test the system by
Maximum Capacity performing steps 8 through 11.
GS-3246
ANSI & CE 700 lbs 318 kg

CSA 500 lbs 227 kg

controls.
MANIFOLDS
11 Bleed the hydraulic system. Raise the platform 6-5

to full height and then lower it to the stowed
position through two complete cycles. Back Pressure Relief Valve,
Component damage hazard. Do
GS-3246
not continue to operate the
machine if the hydraulic pump is
cavitating. If the pump is still How to Adjust the Back
cavitating, see 5-1, How to test the
Hydraulic Pump. Pressure Relief Valve,
GS-3246
Be sure that the hydraulic oil level
is between the FULL and ADD marks
on the oil level indicator decal.
M 1 Open the hydraulic power unit module tray and
locate the lift relief valve located next to the
function manifold.
2 Turn the machine off. Hold the back pressure
relief valve with a wrench and remove the cap
(item #12, function manifold).
5 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Then install the relief
valve cap.
Lift Relief Valve Manifold, GS-3246 Models
Description .................. Relief valve, 2000 psi (241 bar)

Schematic Item ............................................................ M
Function ........................................................ Platform up
Torque ...................................... 25-30 ft-lbs (34-41 Nm)
Steering Axle Components

7-1 7 Support and secure the yoke assembly with an
Yoke and Drive Motor
8 Remove the retaining fastener from the steer
link to the bellcrank.
How to Remove the Yoke
and Drive Motor Note the quantity and location of
the spacers when disconnecting
When removing a hose assembly the steer link from the bellcrank.
or fitting, the O-ring on the fitting
9 Remove the retaining fastener from the top of
the yoke pivot shaft.
during installation. Refer to 10 Lower the yoke assembly out of the chassis.
Section Two, Hydraulic Hose and
Fitting Torque Specifications. Bodily injury hazard. The yoke/
motor assembly may fall if not
1 Block the non-steer wheels, then center a lifting properly supported when it is
jack under the drive chassis at the steer end of removed from the chassis.
the machine.
During re-assembly, be sure that
2 Remove the cotter pin from the wheel castle nut. the spacers are installed onto the
steer link.
a new one when removing the Torque specifications
castle nut.
Castle nut 300 ft-lbs 406.7 Nm
3 Loosen the wheel castle nut. Do not remove it.
4 Raise the machine approximately 2 feet (0.6 m)
and place blocks under the drive chassis for
support.
Crushing hazard. The chassis will
fall if it is not properly supported.
5 Remove the castle nut, then remove the wheel.
6 Tag, disconnect and plug the hoses on the drive
motor. Cap the fittings on the motor.
connections very slowly to
allow the oil pressure to
dissipate gradually. Do not
allow oil to squirt or spray.
STEERING AXLE COMPONENTS
How to Remove a Drive Motor

1 Block the non-steer wheels, then center a lifting
jack under the drive chassis at the steer end of
the machine.
2 Remove the cotter pin on the wheel castle nut of
the motor to be removed.
a new one when removing the
castle nut.
4 Raise the machine approximately 2 inches
(5 cm) and place blocks under the drive chassis
for support.
5 Remove the wheel castle nut, then remove the
wheel.
6 Tag, disconnect and cap the hydraulic hoses on

the drive motor. Cap the fittings on the drive
motor.
the oil pressure to
dissipate gradually. Do not
allow oil to squirt or spray.
7 Support and secure the drive motor to an
8 Remove the drive motor mounting fasteners,
then remove the motor.
Torque specifications
Castle nut 300 ft-lbs 406.7 Nm
STEERING AXLE COMPONENTS
7-2 7-3
Steering Cylinder Steering Bellcrank
How to Remove the 1 Remove the steering cylinder. See 7-2, How to
Remove the Steering Cylinder.
Steering Cylinder
2 Remove the pin retaining fastener from the rod-
When removing a hose assembly end pivot pin. Use a soft metal drift to remove
or fitting, the O-ring on the fitting the pin.
and then torqued to specification 3 Remove the retaining fastener from the center of
during installation. Refer to the bellcrank.
Section Two, Hydraulic Hose and Note the quantity and location of
Fitting Torque Specifications. the spacers on the bellcrank.
1 Block the non-steer wheels. 4 Remove the retaining fasteners from the steer
2 Tag, disconnect and plug the hydraulic hoses links at each end of the bellcrank. Remove the
from the steer cylinder. Cap the fittings on the bellcrank from the machine.
cylinder. Note the quantity and location of
Bodily injury hazard. Spraying the spacers in between the
hydraulic oil can penetrate and bellcrank and the steer links.
gradually. Do not allow oil to
squirt or spray.
barrel-end pivot pin. Use a soft metal drift to
remove the pivot pin.
Note the quantity and location of
the spacers when removing the
rod-end pivot pin.
4 Remove the pin retaining fasteners from the rod-
end pivot pin. Use a soft metal drift to remove
the pin.
5 Remove the steering cylinder from the machine.
Non-Steering Axle Components

8-1 5 Raise the machine approximately 2 inches
(5 cm) and place blocks under the drive chassis
Drive Brake for support.
6 Remove the wheel castle nut, then remove the
How to Remove a Drive Brake wheel.
When removing a hose assembly 7 Tag, disconnect and plug the hose on the brake.
or fitting, the O-ring on the fitting Cap the fittings on the brake.
and then torqued to specification Bodily injury hazard. Spraying
during installation. Refer to Section hydraulic oil can penetrate and
Two, Hydraulic Hose and Fitting burn skin. Loosen hydraulic
Torque Specifications. connections very slowly to
allow the oil pressure to
1 Support and secure the entry ladder to an dissipate gradually. Do not
appropriate lifting device. Then remove the entry allow oil to squirt or spray.
ladder mounting fasteners. Remove the entry
ladder from the machine. 8 Place a lifting jack under the brake for support.
Crushing hazard. The entry ladder 9 Remove the brake mounting fasteners from the
may become unbalanced and fall if drive chassis. Remove the brake.
it is not properly supported and Crushing hazard. The brake may
secured to the lifting device. become unbalanced and fall if it is
2 Block the steer wheels and center a lifting jack not properly supported when the
under the drive chassis at the non-steer end. mounting fasteners are removed
3 Remove the cotter pin from the wheel castle nut. Torque specifications
Always replace the cotter pin with Castle nut 300 ft-lbs 406.7 Nm
a new one when removing the
castle nut.

9-1
The brake release hand pump manifold is mounted behind the entry ladder, next to the battery charger.
Index Schematic
1 Check valve, pilot operated ............... N ........... Manual brake release ....................... 25-30 ft-lbs (34-41 Nm)
2 Shuttle valve ...................................... O ........... Brake release ................................... 8-10 ft-lbs (11-14 Nm)
3 Hand pump ....................................... P ........... Manual brake release ...................... 25-30 ft-lbs (34-41 Nm)
P O

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Phone: 425 881 1800 Phone: 86 21 62483040 Phone: 33 237 260 999
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Phone: 81 3 3453 6082 Phone: 31 7051 78836
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Phone: 44 1636 605030
Fax: 44 1636 611090 Genie Australia Pty Ltd. Genie Latin America
Phone: 61 07 3375 1660 Phone: 561-994-0380
Fax: 61 07 3375 1002 Fax: 561-997-5877

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Technical

First Edition, Third Printing

Basic mechanical, hydraulic and electrical

Readers are encouraged to notify Genie of errors Printed on recycled paper

If you have any questions, please call Genie

Do Not Perform Maintenance

Personal Safety Be sure to wear protective eye wear and

Be sure to properly dispose of old oil or

Electrical System Mounted on the platform control box lid of

pad will send a signal to the ECM through the

Washing electronic components is not suggested.

Component damage hazard.

Section One Safety Rules

Section Two Specifications

Section Three Scheduled Maintenance Inspections

Section Four Scheduled Maintenance Procedures

Section Four Scheduled Maintenance Procedures, continued

Section Five Troubleshooting Flow Charts and Fault Codes

Section Five Troubleshooting Flow Charts and Fault Codes, continued

Section Six Schematics

Section Seven Repair Procedures

Section Seven Repair Procedures, continued

Stowed dimensions Width 453/4 in 116 cm

Length 96 in 243.8 cm Extension length 39 in 99 cm

Width 46 in 116.8 cm All Models

Models with sliding rails Weight 4324 lbs 1961 kg

Height, stowed maximun 781/2 in 199.4 cm Ground clearance 4 in 10.2 cm

Maximum platform extension 39 in 99 cm

Wheelbase 72 7/8 in 185.1 cm

Turning radius, outside 91 3/4 in 233.1 cm

Turning radius, inside 0 in 0 cm

Machine Specifications - Platform dimensions

Stowed dimensions Width 45 3/4 in 116 cm

Length 96 in 243.8 cm Extension length 39 in 99 cm

Width 46 in 116.8 cm All Models

Models with sliding rails Weight 4646 lbs 2107 kg

Height - stowed maximum 85 1/2 in 217.2 cm Ground clearance 4 in 10.2 cm

Maximum platform extension 39 in 99 cm

Wheelbase 72 7/8 in 185.1 cm

Turning radius, outside 91 3/4 in 233.1 cm

Turning radius, inside 0 in 0 cm

Machine Specifications - Platform dimensions

Stowed dimensions Width 45 3/4 in 116 cm

Length 96 in 243.8 cm Extension length 39 in 99 cm

Width 46 in 116.8 cm All Models

Models with sliding rails Weight 5564 lbs 2524 kg

Height - stowed maximum 90 1/2 in 229.9 cm Ground clearance 4 in 10.2 cm

Maximum platform height 32 ft 11.75 m

Maximum platform working height 38 ft 11.6 m

Maximum platform extension 39 in 99 cm

Wheelbase 72 7/8 in 185.1 cm

Turning radius, outside 91 3/4 in 233.1 cm

Turning radius, inside 0 in 0 cm Continuous improvement of our products is a

Performance Specifications - Hydraulic Specifications -

Stowed, maximum 2.2 mph 3.5 km/h Lift pump

GS-2646 Drive relief valve pressure

Platform down 38 to 40 seconds

Hydraulic Hose and Fitting Torque Specifications

Hydraulic Hose and Fitting Torque Specifications

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Scheduled Maintenance Inspections

There are four types of maintenance inspections

Failure to properly complete each Quarterly A+B

Maintenance Inspection Report