GS-2032 Service Manual: Technical Publications

®
Technical
Publications
GS-2032
Service
Manual
(before serial number 17408)
First Edition, Third Printing

REV C1
Part No. 46326
Introduction Service Manual - First Edition
GS-2032
Important Genie North America
Read, understand and obey the safety rules and Telephone (425) 881-1800
operating instructions in the Genie GS-2032 & Toll Free in U.S.A. 800 536-1800
Genie GS-2046 & Genie GS-2646 & Genie Toll Free in Canada 800 426-8089
GS-3246 Operator’s Manual before attempting any Fax (425) 882-9260
maintenance or repair procedure. E-mail: techpub@genieind.com
http://www.genielift.com
This manual provides detailed scheduled
maintenance information for the machine owner
and user. It also provides troubleshooting and Genie Europe
repair procedures for qualified service Office Telephone (44) 01636-605030
professionals. Office Fax (44) 01636-611090
Parts Telephone (44) 01636-605002
Basic mechanical, hydraulic and electrical Parts Fax (44) 01636-611091
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
service center.
Genie Industries has endeavored to deliver the
highest degree of accuracy possible. However, ®
continuous improvement of our products is a Genie

Copyright © 1997 by Genie Industries
policy. Therefore, product specifications
are subject to change without notice. First Edition: First Printing August, 1997
Second Printing March, 1999
Readers are encouraged to notify Genie of errors Third Printing October, 1999
and send in suggestions for improvement. All
communications will be carefully considered for "Genie" is a registered trademark
future printings of this and other manuals. Please of Genie Industries in the U.S.A. and many other
countries. "GS" is a trademark of
write to the technical publications team in care of Genie Industries.
Genie Industries, PO Box 97030, Redmond WA
98073-9730 USA. These machines comply with
ANSI/SIA 92.6-1990.
If you have any questions, please call Genie Printed on recycled paper
Industries.
Printed in U.S.A.
ii Genie GS-2032 Part No. 46326

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
operator’s manual are also safety hazards
when maintenance and repair procedures
are performed.
Do Not Perform Maintenance

Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
- manufacturer’s instructions and safety rules
- employer’s safety rules and worksite
regulations
- applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.
Part No. 46326 Genie GS-2032 iii

SAFETY RULES
Personal Safety protective clothing if the situation warrants

it.
Any person working on or around a machine must
be aware of all known safety hazards. Personal Be aware of potential crushing hazards
safety and the continued safe operation of the such as moving parts and free swinging or
machine should be your top priority. 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: Workplace Safety
Safety alert symbol—used to alert Be sure to keep sparks, flames and lighted
personnel to potential personal tobacco away from flammable and
injury hazards. Obey all safety combustible materials such as battery
messages that follow this symbol gases and engine fuels. Always have an
to avoid possible injury or death. approved fire extinguisher within easy reach.
Red—used to indicate the
presence of an imminently
hazardous situation which, if not Be sure that all tools and working areas are
avoided, will result in death or properly maintained and ready for use.
serious injury. Keep work surfaces clean and free of
Orange—used to indicate the debris that could get into machine
presence of a potentially components and cause damage.
hazardous situation which, if not
avoided, could result in death or
serious injury. Be sure that your workshop or work area
is properly ventilated and well lit.
Yellow with safety alert symbol—
used to indicate the presence of a
potentially hazardous situation
Be sure any forklift, overhead crane or other lifting
which, if not avoided, may cause
or supporting device is fully capable of
minor or moderate injury.
supporting and stabilizing the weight to be
Yellow without safety alert lifted. Use only chains or straps that are in
symbol—used to indicate the good condition and of ample capacity.
presence of a potentially
avoided, may result in property Be sure that fasteners intended for one time use
damage. (i.e., cotter pins and self-locking nuts) are
Green—used to indicate operation not reused. These components may fail if
or maintenance information. they are used a second time.
Be sure to wear protective eye wear and other Be sure to properly dispose of old oil or
other fluids. Use an approved container.
Please be environmentally safe .
iv Genie GS-2032 Part No. 46326

Theory of Operation
Power Source The GS-2032 machines are equipped with
operational controls which are found in two
The Genie GS-2032 machines are powered by locations: the ground controls, located on the
four six-volt (225 AH) batteries. The four batteries hydraulic tank side of the machine, and the
are wired in series to produce 24 volts. platform controls, located in the platform. All lift and
drive functions are available at the platform
Hydraulic System controls. Only platform up/down functions are
available at the ground controls.
All machine functions are performed by the
The ECM uses input from the ground or platform
hydraulic system. The hydraulic system is powered
controls to activate the various machine functions.
by a single-section gear pump. When the pump is
The ECM has predetermined settings for the
activated, it supplies hydraulic fluid under pressure
various machine functions.
to the function manifold, where the control valves
are located. To protect from over-pressurization of The joystick is fitted with a 5000 ohm
the hydraulic system, the pump is provided with a potentiometer. With the joystick in the neutral
pressure relief valve. position, the potentiometer will measure 2730
ohms. These signals are sent to the multiplex card,
Activating a machine function is accomplished by
then down to the ECM to control the voltage
actuating or moving a switch and/or control handle,
supplied to the proportional valve. Two
which sends voltage to the ECM. The ECM then
microswitches mounted on the joystick tell the
sends the signal to the appropriate directional
ECM the drive direction desired. A thumb rocker
control valve. The directional valve determines
switch on the top of the joystick is used for
which direction the hydraulic fluid will travel.
steering.
Computer software determines the volume of fluid
in relation to the proportional valve input voltage. Mounted on the platform control box lid of
machines before serial number 17408 are buttons
Electrical System and a switch that, when activated, sends a signal
to the ECM through the multiplex card. On
Limit switches are found in various locations on the
machines after serial number 17407, the platform
machine. The function of a limit switch is to
control box lid has a decal/membrane pad. This is
communicate the operating position of the machine
a touch-activated pad incorporating wiring,
to the ECM (Electronic Control Module). When a
switches and LEDs that are resistant to the
change in signal is received from a limit switch, the
environment. Activating any of the buttons on the
ECM responds by limiting the drive speed to 0.5
pad will send a signal to the ECM through the
miles per hour (0.8 km/h), according to the default
multiplex card.
settings in the ECM software.
A diagnostic display is located at the battery pack
Machine Controls side of the machine to aid in troubleshooting. If the
Part No. 46326 Genie GS-2032 v

THEORY OF OPERATION
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-2032 Part No. 46326

Table of Contents
Introduction
Important Information ...................................................................................................... ii
Section One Safety Rules

General Safety Rules ..................................................................................................... iii
Theory of Operation ....................................................................................................... v
Section Two Specifications

Machine Specifications ............................................................................................. 2 - 1
Performance Specifications ...................................................................................... 2 - 2
Hydraulic Specifications ............................................................................................ 2 - 2
Hydraulic Hose and Fitting Torque Specifications ..................................................... 2 - 3
Section Three Scheduled Maintenance Inspections

Introduction ............................................................................................................... 3 - 1
Table A ..................................................................................................................... 3 - 2
Table B ..................................................................................................................... 3 - 3
Table C ..................................................................................................................... 3 - 3
Table D ..................................................................................................................... 3 - 3
Maintenance Inspection Report ................................................................................ 3 - 4
Part No. 46326 Genie GS-2032 vii

TABLE OF CONTENTS
Section Four Scheduled Maintenance Procedures

Introduction ............................................................................................................... 4 - 1
A-1 Inspect the Operator’s 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
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 (before serial number 17408) ....................... 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 (before serial number 6901) ........................... 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-2032 Part No. 46326

TABLE OF CONTENTS
Section Five Troubleshooting Flow Charts and Fault Codes

Chart
Number Chart Title Page
Introduction ............................................................................................................... 5 - 1
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 All Functions Inoperative, Power Unit Starts and Runs ........................................... 5 - 14
4 Ground Controls Inoperative, Platform Controls Operate Normally ......................... 5 - 15
5 Platform Controls Inoperative, Ground Controls Operate Normally ......................... 5 - 16
6 Platform Up Function Inoperative ........................................................................... 5 - 18
7 Platform Down Function Inoperative ....................................................................... 5 - 19
8 Steer Left Function Inoperative ............................................................................... 5 - 21
9 Steer Right Function Inoperative ............................................................................ 5 - 23
10 All Drive Functions Inoperative, All Other Functions Operate Normally .................. 5 - 25
10A Brake Release Function Inoperative ....................................................................... 5 - 27
11 Drive Forward Function Inoperative ........................................................................ 5 - 28
12 Drive Reverse Function Inoperative ........................................................................ 5 - 29
13 Machine Will Not Drive At Full Speed ..................................................................... 5 - 30
14 Machine Drives At Full Speed With Platform Raised .............................................. 5 - 32
Part No. 46326 Genie GS-2032 ix

TABLE OF CONTENTS
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-2032 Part No. 46326

TABLE OF CONTENTS
Section Seven Repair Procedures

Introduction ............................................................................................................... 7 - 1
Platform Controls
1-1 Platform Controller ........................................................................................... 7 - 2
1-2 Software Configuration .................................................................................... 7 - 3
1-3 Toggle Switches .............................................................................................. 7 - 6
Platform Components
2-1 Platform .......................................................................................................... 7 - 8
2-2 Platform Extension .......................................................................................... 7 - 9
Scissor Components
3-1 Scissor Assembly, GS-2032 ......................................................................... 7 - 10
3-2 Lift Cylinder ................................................................................................... 7 - 16
Ground Controls
4-1 Manual Platform Lowering Cable ................................................................... 7 - 18
4-2 Toggle Switches, See 1-3, Toggle Switches .................................................... 7 - 6
Hydraulic Pump
5-1 Hydraulic Pump ............................................................................................. 7 - 19
Manifolds
6-1 Function Manifold Components (before serial number 11501) ........................ 7 - 20
6-2 Function Manifold Components (after serial number 11500) ........................... 7 - 22
6-3 Valve Adjustment - Function Manifold ........................................................... 7 - 24
Part No. 46326 Genie GS-2032 xi

TABLE OF CONTENTS
Section Seven Repair Procedures, continued

Steering Axle Components
7-1 Yoke and Drive Motor .................................................................................... 7 - 26
7-2 Steering Cylinder ........................................................................................... 7 - 27
7-3 Steering Bellcrank ......................................................................................... 7 - 28
Non-steering Axle Components
8-1 Drive Brake ................................................................................................... 7 - 29
Brake Release Hand Pump Components
9-1 Brake Release Hand Pump Components ....................................................... 7 - 30
xii Genie GS-2032 Part No. 46326

Service Manual - First Edition Section 2 - Specifications
Specifications
Machine Specifications
Stowed dimensions Tires and wheels
Length 96 in 243.8 cm Tire size (solid rubber) 15 x 5 x111/4 in

38.1 x 12.7 x 28.5 cm
Length, platform extended 1351/2 in 344.2 cm
Load range 2,400 lbs 1,089 kg
Width 32 in 81.3 cm
Tire contact area 8 sq in 20.3 sq cm
Height, stowed maximum
Rails up - CE 827/8 210.3 cm Overall tire diameter 15 in 38.1 cm
Height, stowed maximum Wheel diameter 111/4 in 28.5 cm

Rails up - ANSI 781/2 in 199.1 cm
Wheel width 5 in 12.7 cm
Height, stowed maximum
Rails lowered 761/2 in 193.8 cm Castle nut torque 300 ft-lbs 406.7 Nm
Height, stowed maximum Platform dimensions

rails removed 39 in 99 cm
Length 89 in 226.1 cm
Height, guard rail level 39 in 99.1 cm
Weight 3438 lbs 1559 kg Width 311/4 in 65 cm
Ground clearance 4.0 in 10.2 cm Extension length 291/2 in 79.4 cm
Ground clearance Maximum load capacity 800 lbs 363 kg

Pothole guards deployed 7/8 in 2.2 cm
Fluid Capacities
Operational dimensions
Hydraulic tank capacity 5.5 gallons 20.8 liters
Maximum platform height 20 ft 5.8 m
Hydraulic system capacity 6 gallons 22.7 liters
Maximum platform (including tank)
working height 25.1 ft 6.1 m
Maximum platform extension 39 in 1m Continuous improvement of our products is a

Genie policy. Product specifications are subject to
Wheelbase 73 in 185 cm change without notice.
Turning raduis, outside 92 in 233.7 cm
Turning raduis, inside 0 in 0 cm
Part No. 46326 Genie GS-2032 2-1

Section 2 - Specifications Service Manual - First Edition
SPECIFICATIONS
Performance Specifications Hydraulic Specifications

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
maximum 40 ft / 54.5 sec 12.2 m / 54.5 sec Displacement .244 cu in
per revolution 4 cc
Gradeability 30%
Displacement 4 gpm
Function speed, maximum (2500 psi/172 bar) 15 L/min
from platform controls
Hydraulic tank 10 micron with 25 psi
Platform up 29 to 31 seconds
return line filter (1.7 bar) bypass
Platform down 25 to 27 seconds
Function manifold
System relief valve pressure 3500 psi

241.3 bar
Steer relief valve pressure 1000 psi

69 bar
2-2 Genie GS-2032 Part No. 46326

Service Manual - First Edition Section 2 - Specifications
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 SAE Dash
Size Installing 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
1 Replace the O-ring. The O-ring must be 3 Be sure that the face seal O-ring is seated and
replaced anytime the seal has been broken. retained properly.
The O-ring cannot be re-used if the fitting or
4 Position the tube and nut squarely on the face
hose end has been tightened beyond finger
seal end of the fitting and tighten the nut finger
tight.
tight.
The O-rings used in the Parker
Seal Lok® fittings and hose ends 5 Tighten the nut or fitting to the appropriate
are a custom-size O-ring. They torque per given size as shown in the table
are not a standard SAE size above.
O-ring. They are available in the 6 Operate all machine functions and inspect the
O-ring field service kit (Genie part hoses and fittings and related components to
number 49612). be sure that there are no leaks.
2 Lubricate the O-ring before installation.

Section 2 - Specifications Service Manual - First Edition
This page intentionally left blank.

Service Manual - First Edition Section 3 - Scheduled Maintenance Inspections
Scheduled Maintenance Inspections

About This Section
Dealer
Tools are New parts service
required required suggested
The Schedule
There are four types of maintenance inspections

that must be performed according to a schedule—
daily, quarterly, annual and two year. To account
for repeated procedures, the Maintenance Tables
Observe and Obey: and the Maintenance Inspection Report have been
divided into four subsections—A, B, C, D. Use the
Maintenance inspections shall be completed by following chart to determine which group(s) of
a person trained and qualified on the procedures are required to perform a scheduled
maintenance of this machine. 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.
Machines that have been out of service for a
period longer than 3 months must complete the Complete step-by-step instructions for each
quarterly inspection. 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
Table A Tools are New parts

Dealer
service
A-1 Inspect the Operator's and Safety Manuals
A-2 Inspect the Decals and Placards
A-3 Inspect for Damage and

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)

Service Manual - First Edition Section 3 - Scheduled Maintenance Inspections
MAINTENANCE TABLES
Table B, continued Tools are New parts

Dealer
service
B-4 Test the Key Switch
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 Checklist C Y N R
Dealer
Tools are New parts Refer toservice
Table C
Refer to Table A
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 serial number 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 symbol—used 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 Red—used 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. Orange—used to indicate the
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 symbol—used to indicate the
· 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 Green—used 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 Operator’s and Inspect the
Safety Manuals Decals and Placards
Maintaining the operator’s 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 Genie
GS-2032 & Genie GS-2046 & Genie GS-2646
2 Check to make sure that the operator’s,
& Genie GS-3246 Operator's Manual and use
responsibilities and safety manuals are present
the decal list and illustrations to determine that
and complete in the storage container in the
all decals and placards are in place.
platform.
2 Inspect all decals for legibility and damage.
3 Examine the pages of each manual to be sure
Replace any damaged or illegible decal
that they are legible and in good condition.
immediately.
4 Always return the manuals to the storage
Contact your authorized Genie
container after use.
distributor or Genie Industries if
Contact your authorized Genie replacement decals are needed.
distributor or Genie Industries if
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
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 and manual
lowering valve
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
Hydraulic oil type Dexron equivalent
Hydraulic tank capacity 5.5 gallons

20.8 liters
Hydraulic system 6 gallons

(including tank) 22.7 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.
As a safety feature, selecting
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 block or similar piece of wood
under both wheels on one side and drive the
1 Turn the key switch to ground control and pull 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 meters) from the ground, an alarm should
2 Raise the platform approximately
sound.
2 feet (0.6 m).
4 Lower the platform and remove both pieces of
3 Pull the Manual Platform Lowering handle
wood.
located next to the ground controls.
Result: The platform should lower. The descent
alarm will not sound.

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 control 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 block or similar piece of wood
under the pothole guard. Raise the platform. Result: The green power light should come on.
Result: When the platform is raised above 6 7 Slowly move the control handle off center.
feet (1.8 meters), an alarm should sound and Result: The drive and steer functions should
the drive function should not work. operate.
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 Return Filter

Table B Procedures
B-1 5 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 6 Install the battery vent caps.
machine performance and operational safety.
Improper fluid levels or damaged cables and 7 Check each battery pack and verify that the
connections can result in component damage and batteries are wired correctly.
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 Be sure that the battery cable connections are
free of corrosion.
3 Be sure that the battery hold downs and cable
connections are tight.
4 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 5 Lower the platform onto the safety arm.

Inspect the Electrical Wiring Crushing hazard. Keep hands clear
of the safety arm when lowering
Maintaining electrical wiring in good condition is the platform.
essential to safe operation and good machine
performance. Failure to find and replace burnt, 6 Inspect the center chassis area and scissor
chafed, corroded or pinched wires could result in arms for burnt, chafed and pinched cables.
unsafe operating conditions and may cause 7 Inspect the following areas for burnt, chafed,
component damage. corroded, pinched and loose wires:
Electrocution hazard. Contact · ECM to platform controls
with hot or live circuits may
· Power to platform wiring
Remove all rings, watches and 8 Raise the platform and return the safety arm to
other jewelry. the stowed position.
1 Inspect the following areas for burnt, chafed, 9 Lower the platform to the stowed position and
corroded and loose wires: turn the machine off.
· 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.
4 - 10 Genie GS-2032 Part No. 46326

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 406.7 Nm
6 Turn the key switch to the OFF position.
Castle nut torque, lubricated 225 ft-lbs 305 Nm
Result: No function should operate.
Part No. 46326 Genie GS-2032 4 - 11

TABLE B PROCEDURES
B-5 B-6
Test the Emergency Stop Test the Horn
Buttons A functioning horn is essential to safe machine
Properly functioning Emergency Stop buttons operation. The horn is activated at the platform
are essential for safe machine operation. An controls and sounds at the ground as a warning to
improperly operating Emergency Stop button ground personnel. An improperly functioning horn
will fail to shut off power and stop all machine will prevent the operator from alerting ground
functions resulting in a hazardous situation. personnel of hazards or unsafe conditions.
As a safety feature, selecting 1 Turn the key switch to platform control and
and operating the ground controls pull out the Emergency Stop button to the
ON position at both the ground and
will override the platform controls,
except the platform Emergency platform controls.
Stop button. 2 Push down the horn button at the platform
1 Turn the key switch to ground control and pull controls.
out the Emergency Stop button to the ON Result: The horn should sound.
position at both the ground and platform
controls. The standard machine uses the
multifunction alarm to emit the
2 Push in the Emergency Stop button at the horn sound. The optional horn will
ground controls to the OFF position. sound like an automotive type
Result: No functions should operate. 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.
4 - 12 Genie GS-2032 Part No. 46326

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 able
1 Mark a test line on the ground for reference. 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 2 and 3.
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
Part No. 46326 Genie GS-2032 4 - 13

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.
17 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.
4 - 14 Genie GS-2032 Part No. 46326

TABLE B PROCEDURES
B-8 B-9
Test the Drive Speed - Test the Drive Speed -
Stowed Position Raised Position
Proper drive functions are essential to safe Proper drive functions are 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
speed selector button until the indicator light is 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 start and finish lines.
when crossing the start and finish lines.
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 (maximum):
Drive speed:
Platform raised 40 ft / 54.5 sec 12.2 m / 54.5 sec
Stowed position 40 ft/ 12.4 sec 12.2 m/12.4 sec
Part No. 46326 Genie GS-2032 4 - 15

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 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.
4 - 16 Genie GS-2032 Part No. 46326

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.
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 oil 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.
4 Turn the key switch to ground control and pull
controls. Activate and hold the platform up
toggle switch.
5 Inspect the filter and related components to
be sure that there are no leaks.
Part No. 46326 Genie GS-2032 4 - 17

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

platform in the stowed position.
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.
4 - 18 Genie GS-2032 Part No. 46326

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 at
This machine uses Dexron right.
equivalent hydraulic oil. Before
replacing the hydraulic oil, the oil 5 Remove the return filter mounting bracket
may be tested by an oil distributor fasteners from the manifold. Push the filter and
for specific levels of contamination accumulator out of the way.
to verify that changing the oil is 6 Remove the motor controller mounting bracket
necessary. If the hydraulic oil retaining fasteners and move the motor
is not replaced at the two year controller to the side.
inspection, test the oil
quarterly. Replace the oil when 7 Remove the hydraulic tank from the machine.
it fails the test. 8 Remove the suction strainer and clean it using
Perform this procedure with the a mild solvent.
platform in the stowed position. 9 Clean the inside of the hydraulic tank using a
1 Disconnect the battery pack from the machine. mild solvent.
2 Open the power unit compartment and place a 10 Install the suction strainer using thread sealer
drain pan or other suitable container under the on the threads.
hydraulic tank. 11 Install the drain plug using thread sealer on the
threads.
Part No. 46326 Genie GS-2032 4 - 19

TABLE D PROCEDURE
12 Install the hydraulic filter bracket and the motor

controller bracket.
Electrocution hazard. The
connectors on the motor controller
will short out to ground if the
motor controller mounting bracket
is not installed before the battery
pack is connected.
13 Install the hydraulic tank.
14 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.
15 Clean up any oil that may have spilled. Properly
dispose of the oil.
16 Operate all machine functions through a full
cycle and check for leaks.
Hydraulic oil type - Dexron equivalent
Hydraulic tank capacity 5.5 gallons

20.8 liters
Hydraulic system 6 gallons

(including tank) 22.7 liters
4 - 20 Genie GS-2032 Part No. 46326

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 Operator’s
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 appropiate 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 required—voltmeter, ohmmeter and
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

Before Serial Number 17408
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.
Notes

FAULT CODE CHART

(BEFORE SERIAL NUMBER 17408)

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.
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

Before Serial Number 17408
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 out
flashing platform control or the platform Emergency Stop button is pulled
to the on position.
out.

Platform extended above 6 feet.
21 Normal operation.
flashing
to the on position.
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.

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.

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

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

to the on position.
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.
platform 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.
Malfunctioning up/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.
Malfuctioning 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.
Notes

Chart 1
All Functions Turn key switch to Troubleshoot ground
platform control and light is on and platform control
Will Not Operate press and hold the systems separately OR
function enable switch. consult the Genie
Visually inspect the Industries Service
power-on LED. Department.
light is not on
Be sure the circuit
breaker and fuse are less than Charge batteries OR
Check voltage on input check battery condition
not tripped or blown. side of 275A (F1) fuse 24V
and replace bad
inside battery module batteries OR check for
Be sure the batteries tray. short circuits OR check
are properly connected. battery cables OR check
for open in negative
Be sure the batteries battery cable from
24V or more batteries to ground point
are fully charged. on module tray.
Be sure both
Emergency Stop 0V
Check voltage on output Replace 275A fuse.
switches are pulled out side of 275A fuse inside
to the ON position. the battery module tray.
24V
Check continuity from B- no Repair open in negative

terminal on motor continuity battery cable from B-
controller to the negative terminal on motor
battery cable at the controller to Anderson
Anderson plug. plug.
full
continuity
Before serial number Repair open in 24V
6901: Check voltage on supply cable from 275A
the input side of the fuse to Anderson plug
motor contactor (K1). 0V OR
After serial number Before serial number
6900: check voltage on 6901: repair open in
terminal B+ on the motor 24V supply cable from
controller. Anderson plug to motor
contactor (K1).
After serial number
6900: repair open in
24V supply cable from
Anderson plug to
24V terminal B+ on the motor
controller.
Continued on the next

page.

CHART 1
Continued from the Check voltage at input Before serial number

side of 7A circuit 0V 6900:Repair open in wht
previous page. breaker F2. wire from input side of
motor contactor to input
side of 7A circuit
breaker (24f-circuit
breaker to relay).
After serial number
6901: repair open in
24V wire from motor
controller to 7A circuit
breaker.
Check voltage at wht Repair open in wht wire

wire at input side of 0V from output side of 7A
Emergency Stop Switch circuit breaker OR reset
S1. or replace 7A circuit
breaker.
24V
Check voltage at input 0V Repair open in wht wire

side of each contact at from Emergency Stop
the key switch S2. Switch to key switch OR
repair open in wht wire
jumper to each contact
OR replace contact on
Emergency Stop Switch
24V OR replace Emergency
Stop Switch.
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 5 OR
consult Genie Industries
24V Service Department.

page.
5 - 10 Genie GS-2032 Part No. 46326

CHART 1
Continued from the Turn key switch to 0V Check cam on key bad Repair or replace key
platform control position switch. switch.
previous page. and check output side of
each contact.
good
Replace bad contact OR

refer to Platform
Controls Inoperative,
24V Chart 6 OR consult the
Genie Industries Service
Department.
Refer to Chart 2, Pump

Motor Will Not Operate
OR repair open in wht
wire (C2 estop chassis)
OR consult the Genie
Industries Service
Department.
Part No. 46326 Genie GS-2032 5 - 11

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 24V cable from pump to B+
Will Not Operate check voltage at positive controller U2. terminal on motor
terminal on pump motor controller.
M1.
24V
no
Check continuity on continuity Replace ground cable
Be sure the circuit ground cable from pump on pump motor.
breaker and fuse are motor to M- terminal on
motor controller.
not tripped or blown.
continuity
Be sure the batteries
are properly connected. Check continuity from B- no Replace negative cable
terminal on controller to continuity from B- terminal on
Be sure the batteries the negative battery controller to the
are fully charged. cable at the Anderson Anderson plug.
plug AP1.
continuity
less than
Activate lift function and 24V Before serial number
check voltage at 6901: Repair open in
terminal 1 on the motor wht wire (A8-motor)
controller. from K1 contact to
controller.
After serial number
6900: Repair open in
less than 24V 24V wht wire (A8-motor)
from ECM.
Activate lift function and Before serial number

0V 8932: Repair open in
check voltage at
terminal 3 on controller. wht wire (A9-mtr cont
terminal 3) from ECM to
controller OR replace
ECM OR consult Genie
Industries Service
Department.
After serial number
8931: Repair open in
5V wht wire (A9-mtr cont
terminal 3) OR relpace
1k ohm potentiometer
on controller.
Activate lift function and 24V Replace controller or

check voltage at M- contact Genie Industries
terminal on controller. Service Department.
0V
page. Replace pump motor
Industries Service
Department.
5 - 12 Genie GS-2032 Part No. 46326

CHART 2
Activate lift function and 24V or Replace positive cable

Continued from the check voltage on the more from K1 to the motor
previous page. output side of motor controller U2 OR
controller relay K1. replace the positive
cable from the motor
controller to the pump
motor.
less than 24V
Activate lift function and 24V or Activate lift function and Repair open in wht wire
check voltage on the more check voltage on the 0V (A8-motor) from the
input side of motor wht wire on the coil of ECM to the motor
controller relay. the motor controller controller relay OR
relay. replace the ECM OR
conult the Genie
Industries Service
Department.
24V
Check continuity on the continuity Repair or replace the

brown ground wire on motor controller relay.
the coil of the motor
controller relay to the
ground point on the
0V chassis.
no
continuity
Repair open in brn
ground wire from K1 to
the ground point on
chassis.
Check voltage on the 0V Replace 275A fuse OR

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

cables from output side
of 275A fuse to
Anderson plug (AP1)
OR replace positive
battery cables from
Anderson plug to K1 OR
Consult Genie Industries
Service Department.
Part No. 46326 Genie GS-2032 5 - 13

Chart 3
All Functions Check the hydraulic fluid low Fill with Dexron II
level. equivalent hydraulic
Inoperative, fluid.
Power Unit OK
Starts and Runs
Check for a positive no good Replace the pump
connection between the coupling OR replace the
electric motor and pump OR replace the
pump by removing the motor.
Be sure, if the Error pump from the motor,
Indicator light is on at leaving all hoses
the platform controls, connected. Visually
check the coupling
you refer to the specific connection.
chart that relates to the
error code that is good
displayed on the ECM.
no good
Test the hydraulic pump. Replace the pump.
Be sure the circuit See Repair section.
breaker and fuse are
not tripped or blown. good
Be sure the batteries Consult the Genie

are properly connected. Industries Service
Department.
are fully charged.
5 - 14 Genie GS-2032 Part No. 46326

Chart 4
Ground With the key switch in Repair open in the wht
ground position and the wire jumper from the
Controls Emergency Stop buttons
0V
platform control contact
pulled out to the ON to the ground control
Inoperative, position at both the contact at the key switch
Platform ground and platform (S2).
controls, check voltage
Controls on the contact at the
input side of the key
Operate switch at the ground
controls (S2).
Normally
24V or more
Check voltage at the 0V Check if the key switch Replace the key switch
Be sure, if the Error yes
output side of the internal cam is activating contact for ground
Indicator light is on at contact. the ground control controls.
the platform controls, contact.
you refer to the specific
no
chart that relates to the
error code that is 24V Replace the key switch.
Be sure the circuit
Check voltage at the Repair open in the wht
not tripped or blown. center terminal of the wire jumper from the key
0V
platform up/down toggle switch to the center
Be sure the batteries switch (S3) at the terminal on toggle
are properly connected. ground controls. switch.
Be sure the batteries 24V

are fully charged.
Test or replace the
platform up/down toggle
switch S3 (See Repair
Section) OR repair open
in the wht wire from the
toggle switch to the
ECM (B12-up switch)
OR repair open in the
wht wire from the toggle
switch to the ECM (A12-
down switch) OR
consult the Genie
Industries Service
Department.
Part No. 46326 Genie GS-2032 5 - 15

Chart 5
Platform Turn the key switch to Repair open in the wht
platform control and wire jumper from the
Controls make sure both 0V Emergency Stop contact
Emergency Stop buttons to the platform control
Inoperative, are pulled out to the ON contact at the key switch
Ground position at both the S2.
ground and platform
Controls controls. Check voltage
at the input side of the
Operate platform controls contact
on the key switch S2.
Normally
24V or more
Check voltage at the 0V Check if the key switch yes Replace the key switch
Be sure, if the Error output side of contact. internal cam is activating contact for platform
Indicator light is on at platform control contact. controls.
the platform controls,
you refer to the specific no
chart that relates to the 24V
error code that is Replace the key switch.
Be sure the circuit
breaker and fuse are Check voltage at 0V Repair open in wht wire
terminal A11 at the (A11-key sw) from the
not tripped or blown. ECM U1. key switch to terminal
A11 at the ECM.
are properly connected. 24V
Be sure the batteries 0V

Check voltage at Replace the ECM.
are fully charged. terminal B2 at the ECM.
24V
Turn the key switch to 0V Replace control cable

platform controls and, from the ECM to the
Before serial number platform controls.
6902: check voltage at
terminal 4 on the main
circuit board at the
platform controls.
After serial number
6900: check voltage at
the input side of the
Emergency Stop button
(S9).
24V

page.
5 - 16 Genie GS-2032 Part No. 46326

CHART 5
Before serial number 0V Replace the main circuit

Continued from the
6091: Check voltage at board.
previous page. the input side of the
Emergency Stop switch
at the platform controls.
24V
Check voltage at output 0V Replace contact on

side of platform Emergency Stop switch
Emergency Stop switch. OR replace Emergency
Stop switch.
24V
Check voltage at Before serial number

terminal 5 on the main 0V 6091: replace the main
circuit board at the circuit board.
platform controls. After serial number
6900: repair open in the
wire from terminal 22 to
terminal 5 on the main
control board.
24V
Check voltage at 0V Replace control cable

terminal A4 at the ECM. from the ECM to the
platform controls.
24V
Replace the ECM OR

consult the Genie
Industries Service
Department.
Part No. 46326 Genie GS-2032 5 - 17

Chart 6
Platform Up With the key switch in Connect the positive Repair open in the wht
platform position and lead from a volt meter to wire (A6-up coil) from
Function both Emergency Stop the coil on the platform the platform up
Inoperative buttons pulled out to the up directional valve 0V directional valve coil to
ON position and the lift/ light is (item G) wire terminal the ECM (see Repair
drive selector switch in on without disconnecting Section) OR replace
the lift position, activate the wire and the ECM OR consult the
the controller in the UP negative lead of the volt Genie Industries Service
Be sure all other direction and check to meter to the ground Department.
functions operate see if the error indicator point on the manifold.
light at the platform Activate the controller in
normally. controls is on. the UP direction and
check the voltage.
Be sure the circuit
breaker and fuse are 24V
not tripped or blown. 0 or
infinite
Disconnect the wire ohms Replace the platform up
Be sure the batteries from the platform up directional valve coil
are properly connected. directional valve coil on (item G).
the function manifold
Be sure the batteries (item G) and check the
resistance. See Repair
are fully charged. Section.
light is not on
18-20 ohms
Repair or replace the

platform up directional
valve cartridge (item G)
Industries Service
Department.
Install a 0 to 3500 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 platform lift
the platform up function. cylinder OR consult the
Department.
less than
3000 PSI
Adjust the relief valve

OR repair or replace the
platform lift cylinder OR
the platform lowering
valve may be stuck
open OR the function
manifold could have an
internal defect. Consult
the Genie Industries
Service Department.
5 - 18 Genie GS-2032 Part No. 46326

Chart 7
Platform Down With the key switch in With the platform raised Repair open in the wht
the platform position and and the safety arm wire (B6-down coil) from
Function the platform raised installed, connect the the platform lowering
slightly and the leads of a volt meter to valve coil (item R) to the
Inoperative Emergency Stop buttons the wires on the platform ECM OR repair open in
pulled out to the ON light is lowering coil on the 0V the brown ground wire
position at both the on cylinder without circuit from the coil to
ground and platform removing the wires. With the battery module tray
Be sure all other controls and the lift/drive the key switch in the OR replace the ECM
functions operate switch in the lift position, platform position and the OR consult the Genie
activate the controller in lift/drive toggle switch in Industries Service
normally. the DOWN direction and the lift position, activate Department.
check to see if the error the controller in the
Be sure the circuit indicator light is on. DOWN direction and
breaker and fuse are check the voltage.
24V
0 or
are properly connected. Label and disconnect infinite
the wires from the coil ohms Replace platform
Be sure the batteries on the platform lowering lowering valve coil
valve (item R) at the (item R).
are fully charged. platform lift cylinder and
check the resistance
(See Repair Section).
23 to 25
ohms
With the platform raised platform Repair or replace the

and the safety arm lowers platform lowering valve
removed, pull the cartridge (item R).
manual platform
lowering handle at the
light is not on ground controls.
platform does
not lower
Check for mechanical

restrictions keeping the
platform from lowering
OR repair or replace the
platform lowering valve
cartridge (item R) OR
repair or replace the lift
cylinder OR consult the
Department.

page.
Part No. 46326 Genie GS-2032 5 - 19

CHART 7
switch
Label and disconnect bad Replace the lift/drive
Continued from the the wires from the lift/ toggle switch.
previous page. drive toggle switch at
the platform controls
and troubleshoot the
toggle switch (see
Repair Section).
good
Replace the platform

controls OR replace the
ECM OR consult the
Department.
5 - 20 Genie GS-2032 Part No. 46326

Chart 8
Steer Left With the key switch in Connect the positive Repair open in the wht
platform position and lead from a volt meter to wire (B7-left coil) from
Function both Emergency Stop the steer left directional the coil on the steer left
buttons pulled out to the light is valve coil (item F) wire directional valve (item F)
Inoperative ON position, activate the on terminal without to the ECM OR repair
steer rocker switch in disconnecting the wire, 0V open in the brown
the LEFT direction and and the negative lead of ground wire circuit from
check to see if the error the volt meter to the the manifold to the
Be sure all other indicator light at the brown ground wire on battery module tray OR
functions operate platform controls is on. the manifold. Activate replace the ECM OR
the steer rocker switch consult the Genie
normally. in the LEFT direction and Industries Service
check the voltage. Department.
Be sure the circuit
0 or
Disconnect the wires infinite
Be sure the batteries from the coil on the ohms
are properly connected. steer left directional Replace the coil.
valve on the function
Be sure the batteries manifold (item F) and
check the resistance of
are fully charged. the valve coil (See
light is not on Repair Section).
26 to 28
ohms Repair or replace the
steer directional valve
cartridge (item F) OR
consult the Genie
Industries Service
Department.
Activate the steer left no Check continuity of the bad Replace the steer left/
function. Does the motor steer microswitch. right micro switch inside
turn on? the drive controller
handle.
good
Check for wire continuity

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

page.
Part No. 46326 Genie GS-2032 5 - 21

CHART 8
Install a 0 to 2000 psi Check for mechanical

Continued from the pressure gauge at the 1200 restrictions keeping the
previous page. quick disconnect psi steer left function from
coupling on the function moving OR repair or
manifold and activate replace the steer
the steer left function. cylinder OR consult the
Department.
less than
1200 psi
Reset the steer relief

valve pressure (item C)
on the function manifold
to 1200 psi OR replace
the relief valve.
1200 psi

steer cylinder OR
replace the steer left/
right valve cartridge OR
could have an internal
defect. Consult the
Department.
5 - 22 Genie GS-2032 Part No. 46326

Chart 9
Steer Right With the key switch in Connect the positive Repair open in the wht
platform position and lead from a volt meter to wire (wire C7-rt coil)
Function both Emergency Stop the steer right directional from the steer right
buttons pulled out to the light is valve coil (item F) wire directional valve coil
Inoperative ON position, activate the on terminal without (item F) to the ECM OR
steer rocker switch in disconnecting the wire, 0V repair open in brown
the LEFT direction and and the negative lead of ground wire circuit from
check to see if the error the volt meter to the the manifold to the
Be sure all other indicator light at the brown ground wire on battery module tray OR
functions operate platform controls is on. the function manifold. replace the ECM OR
Activate the steer rocker consult the Genie
normally. switch in the RIGHT Industries Service
direction and check the Department.
Be sure the circuit voltage.
not tripped or blown. 24V
0 or
Be sure the batteries Disconnect the wires infinite
are properly connected. from the steer right ohms
directional valve coil on Replace the coil.
Be sure the batteries (item F) and check the
are fully charged. resistance of the valve
light is not on coil. See Repair Section.
26 to 28
ohms Repair or replace the
steer directional valve
(item F) OR consult the
Department.
Activate the steer right no Check continuity of the bad Replace the steer left/
function. Does the motor steer microswitch. right micro switch inside
turn on? the drive controller
handle.
good
Check for wire continuity

from the steer
microswitch to the main
circuit board OR replace
main circuit board at the
yes platform controls.

page.
Part No. 46326 Genie GS-2032 5 - 23

CHART 9
Install a 0 to 2000 psi Check for mechanical

Continued from the pressure gauge at the 1200 restrictions keeping the
previous page. quick disconnect psi steer right function from
coupling on the function moving OR repair or
manifold and activate replace the steer
the steer right function. cylinder OR consult the
Department.
less than
1200 psi

steer cylinder OR
replace the steer left/
right valve cartridge OR
could have an internal
defect. Consult the
Department.
5 - 24 Genie GS-2032 Part No. 46326

Chart 10
All Drive With the key switch in Reset the ECM by
error
Refer to the chart(s) that
indicator
platform position and the pushing in the platform are related to the error
Functions Emergency Stop buttons Emergency Stop button
light is
code that is displayed
on
Inoperative, All pulled out to the ON to the OFF position, on the ECM OR consult
position at both the light is switch the lift/drive the Genie Industries
Other Functions ground and platform
controls, activate drive
flashing selector switch to the
drive position and pull
Service Department.
Operate forward and drive the Emergency Stop

reverse functions. button up to the ON
Normally Check to see if the position. Check the
green indicator light is lights at the platform
flashing at the platform controls.
controls.
Be sure, if the Error green light is
Indicator light is on at flashing
the platform controls,
you refer to the specific Test the lift/drive toggle bad Replace lift/drive toggle
switch S7 (see Repair switch.
chart that relates to the Section). Is switch
error code that is good?
light is not good
Be sure the circuit flashing
breaker and fuse are Replace the main circuit
not tripped or blown. board OR replace the
ECM OR Consult the
Be sure the batteries Genie Industries Service
Department.
are properly connected.

are fully charged.
Is the error indicator yes Refer to chart(s) that are
light on at the platform related to the error code
controls? that is displayed on the
ECM OR consult the
Department.
no
Does the power unit no Replace the joystick

run? controller OR replace
the main circuit board
OR replace the ECM
Industries Service
Department.
yes

page.
Part No. 46326 Genie GS-2032 5 - 25

CHART 10
See Chart 3. Is the no Replace or repair

Continued from the coupler between the coupler, motor, and/or
previous page. motor and pump in good pump.
condition?
yes
3000 psi
Chock both sides of the or more See Chart 10A, Brake
front drive wheels. Release Function
Connect a 0 to 5000 psi Inoperative.
(0 to 345 bar) pressure
gauge to the test port on
and drive the machine in
either the forward or
reverse direction.
less than
3000 psi
drive forward/reverse
valve cartridge OR
rebuild or replace the
drive motors OR the
manifold may have an
internal defect. Consult
the Genie Industries
Service Department.
5 - 26 Genie GS-2032 Part No. 46326

Chart 10A
Brake Release Chock the wheels at the wheels Turn the brake release wheels Rebuild or replace the
steer end. Jack the non- turn valve (item N) clockwise turn brakes OR replace the
Function steer end of the all the way and try to brake release valve
machine up rotate the wheels. (item N) OR consult the
Inoperative approximately 4 inches Genie Industries Service
(10 cm) and place jack Department.
stands under the
machine for support.
Be sure, if the Error Turn the brake release
Indicator light is on at knob (item N)
counterclockwise all the
the platform controls, way and pump the hand wheels
you refer to the specific pump fully 13-15 times do not
chart that relates to the or until much resistance turn
is felt. Turn each wheel
error code that is by hand. Each wheel
displayed on the ECM. should turn freely
without much effort.
Be sure the circuit
Attempt to drive the If machine still does not
Be sure the batteries machine in either wheels drive at full speed with
direction and have an turn the platform in the
are properly connected. assistant try to rotate the stowed position, replace
non-steer wheels. This the joystick controller
Be sure the batteries will require 2 people. OR replace the main
are fully charged. circuit board at the
wheels platform controls OR
do not replace the ECM OR
turn consult the Genie
wheels Industries Service
do not Department.
turn
Plumb a 0 to 500 psi 200 to Pressure is good.

(34.5 bar) gauge into the 300 psi Replace the brakes OR
hose from the function consult the Genie
manifold to the brake. Industries Service
Attempt to drive the Department.
machine in either
direction and read the
pressure on the gauge.
less
than
200 psi
Replace the shuttle
valve (item O) OR the
0.025" orifice (item E)
may be plugged OR
replace the brake
release valve (item N)
OR the function
manifold or brake
release manifold may
have an internal defect
Industries Service
Department.
Part No. 46326 Genie GS-2032 5 - 27

Chart 11
Drive Forward With the key switch in Connect the positive Repair open in the wht
platform position and the lead from a volt meter to wire (C6-forward coil)
Function Emergency Stop buttons the drive forward from the drive forward
Inoperative pulled out to the ON directional valve coil directional valve coil to
position at both the light is (item J) wire terminal the ECM OR repair
on 0V
ground and platform without disconnecting open in the brown
controls, activate drive the wire, and the ground wire circuit from
controller in the forward negative lead of the volt the manifold to the
Be sure all other direction and check to meter to the brown battery module tray OR
functions operate see if the error indicator ground wire on the replace the ECM OR
light at the platform manifold. Activate drive consult the Genie
normally. controls is on. in the forward direction Industries Service
and check the voltage. Department.
Be sure the circuit
0 or
Disconnect the wires infinite Replace the drive
Be sure the batteries from the drive forward forward directional valve
ohms
are properly connected. light is not on directional valve coil coil (item J).
(item J) and check the
Be sure the batteries resistance. See Repair
Section.
are fully charged.
Replace the drive

forward/reverse valve
cartridge (item J) OR 18 to 20
consult the Genie ohms
Industries Service
Department.

drive forward directional
valve (item J) OR
consult the Genie
Industries Service
Department.
5 - 28 Genie GS-2032 Part No. 46326

Chart 12
Drive Reverse With the key switch in Connect the positive Repair open in the wht
platform position and the lead from a volt meter to wire from the drive
Function Emergency Stop buttons the drive reverse reverse directional valve
Inoperative pulled out to the ON directional valve coil coil (A7-reverse coil) to
position at both the light is (item J) wire terminal the ECM OR repair
ground and platform on without disconnecting 0V open in the brown
controls, activate the the wire, and the ground wire circuit from
drive controller in the negative lead of the volt the manifold to the
Be sure all other reverse direction and meter to the brown battery module tray OR
functions operate check to see if the error ground wire on the replace the ECM OR
indicator light at the function manifold. consult the Genie
normally. platform controls is on. Activate drive in the Industries Service
reverse direction and Department.
Be sure the circuit check the voltage.
not tripped or blown. 24V
Be sure the batteries 0 or

Disconnect the wires infinite Replace the drive
are properly connected. light is not from the drive reverse ohms reverse directional valve
on directional valve coil coil (item J).
Be sure the batteries (item J) and check the
resistance. See Repair
are fully charged. Section.
Replace the drive

forward/reverse valve
cartridge (item J) OR 18 to 20
consult the Genie ohms
Industries Service
Department.

drive reverse directional
valve (item J) OR
consult the Genie
Industries Service
Department.
Part No. 46326 Genie GS-2032 5 - 29

Chart 13
Machine Will With the key switch in Raise the platform Raise the platform more
platform position and the light is approximately 3 feet than 6 feet (1.8 m) and
Not Drive At Emergency Stop buttons not on (0.9 m) and drive yes drive the machine. If the
Full Speed pulled out to the ON machine. Does the machine does not drive
position at both the machine drive at a and an alarm sounds,
ground and platform reduced speed? the machine is operating
controls, and the normally. Check the
platform in the stowed pothole guards for
position, drive the no obstructions OR test the
Be sure the circuit
breaker and fuse are machine in either pothole guard limit
direction. Is the error Consult the Genie switches (see Repair
not tripped or blown. indicator light on at the Industries Service section).
platform controls? Department.
are properly connected. light
is on
Be sure the batteries Check voltage at the wht 0V Repair open in the wht
are fully charged. wire (39C-pothole sw) at wire (39C-pothole sw)
S5. from S5 to the multi-
function alarm to the key
switch.
24V
Raise the platform Adjust the limit switch

approximately 3 feet 0V S5 so the pothole arm
(0.9 m) and check the activates the switch OR
voltage at the output replace the limit switch
side of S5. contact OR replace the
limit switch S5.
24V
Check voltage at the wht 0V Repair open in the wht

wire (21B-pothole sw)on wire jumper (21B-
the input side of S6. pothole jumper) from the
output side of S5 to the
input side of S6.
24V
Check voltage on the 0V Adjust limit switch S6 so

output side of S6. the pothole arm
activates the switch OR
replace the limit switch
contact OR replace the
limit switch S6.
24V

page.
5 - 30 Genie GS-2032 Part No. 46326

CHART 13
Repair open in the wht

Continued from the wire (B10-pothole
previous page. switch) from the output
side of S6 to the ECM
OR replace the ECM.
Chock both sides of the Reset the relief valve

front drive wheels. less pressure OR replace the
Install a 0 to 5000 psi than relief valve OR rebuild
(0 to 345 bar) pressure 3000 psi or replace the drive
gauge to the test port on motors OR the function
the function manifold manifold may have an
and drive the machine in internal defect. Consult
either the forward or the Genie Industries
reverse direction. Service Department.
more
than
3000 psi
one or
Chock the wheels at the both
non-steer end. Jack the wheels
steer end of machine up do not
approximately 4 inches Repair or replace drive
turn motor(s) OR consult the
(10 cm) and place jack
stands under the Genie Industries Service
machine for support. Department.
With the lift/drive
selector switch in the
drive position, move the
joystick controller to the
full speed forward or
reverse position.
both
wheels
turn
See Chart 10A, Brake
Release Function
Inoperative.
Part No. 46326 Genie GS-2032 5 - 31

Chart 14
Machine With the key switch in light is
Consult the Genie
platform position and the not on
Drives At Emergency Stop buttons
Industries Service
Department.
Full Speed 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
Be sure the circuit indicator light on at the
platform controls?
breaker and fuse
are not tripped or light
is on
blown.
See Chart 13 OR
Be sure the remove the obstruction
batteries are from the pothole guard
properly connected. Industries Service
Department.
Be sure the
batteries are fully
charged.
5 - 32 Genie GS-2032 Part No. 46326

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 may
Troubleshooting and repair procedures shall be result in death or serious injury.
completed by a person trained and qualified on Remove all rings, watches and
the repair of this machine. 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 squirt
and operating instructions printed in the 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 ........................ 1
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. ................. T-105, dry ...................... 8
H1 .................. Hour meter ........................... 56100 ............. Curtis Instruments ............... 17305666 ....................... 1
K1 ................... Relay, 180 amp ................... 19550 ............. Curtis Instruments ............... 13220544 ....................... 1
P2 ................... Level sensor, Dual Axis ....... 40836 ............. Power Comp. of Midwest .... L36 ................................. 1
R1 .................. Resistor, 75 Ohm ................ 51590 ............. Dale ..................................... RS-10-38, 75 Ohm ........ 1
S1 ................... Contact, N.C. ....................... 33020 ............. Square D .............................. 1863 ............................... 1
S2 ................... Contact - keyswitch, N.O. ... 45081 ............. Telemecanique .................... ZB2-BE101 .................... 1
S3 ................... Toggle switch, SPDT

3 position momentary .......... 13037 ............. Microswitch Control Inc. ...... 1NT1-7 ........................... 1
S4, S5, S6 ...... Contact - limit switch,

N.C.H.O. .............................. 19491 ............. Telemecanique .................... XESP2051 ..................... 3
S7 ................... Toggle switch, DPDT

2 position maintained .......... 44987 ............. ITT Schadow. ...................... 220536 ........................... 1
S9 ................... Contact, N.C. ....................... 44990 ............. Telemecanique .................... ZA2-BZ1026 ................... 1
S10 ................. Contact, N.O. ....................... 44989 ............. Telemecanique .................... ZA2-BZ1016 ................... 1
U2 .................. Motor controller,

48V, 275 amp ...................... 39472 ............. Curtis Instruments ............... 1204-036 ........................ 1
Y2, Y3, Y4 ...... Coil, 20V DC with diode ....... 39347 ............. Hydra Power Systems ......... 6309757 ......................... 3
Y5, Y6, Y8 ...... Coil, 20V DC with diode ....... 44176 ............. Hydra Power Systems ......... 6359752 ......................... 3
Y7 ................... Coil, 20V DC ........................ 44787 ............. Hydra Power Systems ......... 10166-25 ........................ 1


Module Tray Legend


Module Tray Legend

(after serial number 6900)

Electrical Symbols Legend

SENSOR
LEVEL
N
P2
WHT
A6 A6-UP COIL
WHT
GRN
RED
ECM
BLK
YEL
Y8
BRN
U1
RED
M
A5-LEVEL SENSOR-RED A5
C11-LEVEL SENSOR-WHT C11
DATA LINK - (YEL) C1 DOWN
B1 B6 B6-
DATA LINK + (BLK) COIL
GROUND FROM JOYSTICK (GRN) A2
L
Y7
EMERGENCY STOP TO JOYSTICK (WHT) B2

EMERGENCY STOP FROM JOYSTICK (RED) A4
FORWARD
C6 C6-
JUMPER C10 COIL
C5
Y6
A11-KEY SWITCH A11

K
B11-UP LIMIT SW B11

POTHOLE
POTHOLE
A7 A7- REVERSE
SWITCH
SWITCH
COIL
Y5
S5
S6
39C 21B B10-POTHOLE SW B10

B7 B7-LEFT COIL
J
ALARM
39C
B4
B1
Y4
JUMPER A10
B9-MULTIFUNCTION ALARM B9 RIGHT
C7 C7-
SWITCH
COIL
DOWN
PLUG C3
LIMIT
44D
Y3
PLUG A3
I
S4
PLUG A1
C12-DOWN LIMIT C12
BRAKE
C9 C9-
COIL
C2-EMERGENCY STOP C2
B12-UP/DOWN SW UP B12 Y2
A12-UP/DOWN SW DOWN A12
UP/DOWN
H
SWITCH
PARALLEL
A8-MOTOR A8 C8 C9-
COIL
S3
A9-MOTOR CONTROLLER A9
Y1
TERMINAL 3
B8-OPT SERVICE HORN B8 B3 GROUND
FLASHING
BEACON
G
OPTION
FB
MOTION
OPTION
ALARM
23F
42F
F
PLATFORM 45F
OPTION
METER
HOUR
H1
CHASSIS
KEY SWITCH
B
B
T
S2
E
EMERGENCY
M1 MOTOR
STOP
CONTROLLER
S1
B+
B-
MOTOR
A1
26H
3 1
D
U2
D1
A2
M-
CONTROLLER
Part No. 46326

Service Manual
F2 7 AMP
BREAKER
MOTOR
CIRCUIT
RELAY
K1
C
AC INPUT
24F
CHARGER
+
BATTERY
110VAC
AP1 ( - )
AP1 (+)
G2
Electrical Schematic
Genie GS-2032
B
BATTERY
Section 6 - Schematics
275 AMP
FUSE
4-6V
F1
G1
A
6-7
1
8
Service Manual Section 6 - Schematics
N M L K J I H G F E D C B A

SENSOR
LEVEL
P2
N
WHT
A6 A6-UP COIL
ECM
WHT
GRN
RED
BLK
YEL
Y8
U1
RED BRN
M
A5-LEVEL SENSOR-RED A5
C11-LEVEL SENSOR-WHT C11
DATA LINK - (YEL) C1 DOWN
B1 B6 B6-
DATA LINK + (BLK) COIL
GROUND FROM JOYSTICK (GRN) A2
Y7
L
EMERGENCY STOP TO JOYSTICK (WHT) B2

EMERGENCY STOP FROM JOYSTICK (RED) A4
FORWARD
C6 C6-
JUMPER C10 COIL
C5
Y6
A11-KEY SWITCH A11

K
B11-UP LIMIT SW B11

A7- REVERSE
POTHOLE
POTHOLE
A7
SWITCH
SWITCH
COIL
Y5
S5
S6
39C 21B B10-POTHOLE SW B10

B7 B7-LEFT COIL
J
ALARM
39C
B4
B1
Y4
JUMPER A10
B9-MULTIFUNCTION ALARM B9 RIGHT
C7 C7-
SWITCH
COIL
DOWN
PLUG C3
LIMIT
44D
Y3
PLUG A3
S4
I
PLUG A1
C12-DOWN LIMIT C12
BRAKE
C9 C9-
COIL
C2-EMERGENCY STOP C2
B12-UP/DOWN SW UP B12 Y2
A12-UP/DOWN SW DOWN A12
S3
UP/DOWN
SWITCH
H
PARALLEL
A8-MOTOR A8 C8 C9-
COIL
A9-MOTOR CONTROLLER A9
Y1
TERMINAL 3
B8-OPT SERVICE HORN B8 B3 GROUND
FLASHING
BEACON
OPTION
G
FB
MOTION
OPTION
ALARM
23F
42F
PLATFORM 45F
F
OPTION
METER
HOUR
H1
CHASSIS
KEY SWITCH
75 OHM
DALE
R1
B
B
T
S2
E
EMERGENCY
M1 MOTOR
STOP
S1
CONTROLLER
Service Manual
B+
Part No. 46326

B-
A1
MOTOR
3 1
D
D1
U2
A2
M-
F2 7 AMP
BREAKER
CIRCUIT
(from serial number 6901 to 8931)
C
AC INPUT
+
CHARGER
BATTERY
110VAC
AP1 ( - )
AP1 (+)
G2
Genie GS-2032
BATTERY
Section 6 - Schematics
275 AMP
FUSE
4-6V
F1
G1
A
6-9
1
8
Part No. 46326 Genie GS-2032 6 - 10

Section 6 - Schematics Service Manual
A B C D E F G H I J K L M N
6 - 11 Genie GS-2032 Part No. 46326

Part No. 46326 Genie GS-2032 6 - 12

Section 6 - Schematics Service Manual
A B C D E F G H I J K L M N
6 - 13 Genie GS-2032 Part No. 46326

Part No. 46326 Genie GS-2032 6 - 14

Ground Controls and Level Sensor Box Legend
Part No. 46326 Genie GS-2032 6 - 15

Platform Controls Legend

6 - 16 Genie GS-2032 Part No. 46326

Platform Controls Legend

Part No. 46326 Genie GS-2032 6 - 17

Hydraulic Symbols Legend
6 - 18 Genie GS-2032 Part No. 46326

Hydraulic Schematic
Part No. 46326 Genie GS-2032 6 - 19

Hydraulic Schematic
Hydraulic Schematic
Part No. 46326 Genie GS-2032 6 - 20

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 reverse order.
this machine.
Symbols Legend
damaged or malfunctioning machine. Safety alert symbol—used 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:
Red—used to indicate the
Read, understand and obey the safety rules presence of an imminently
and operating instructions in the Genie hazardous situation which, if not
GS-2032 & Genie GS-2046 & Genie avoided, will result in death or
GS-2646 & Genie GS-3246 Operator's Manual. serious injury.
Be sure that all necessary tools and parts are Orange—used 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
symbol—used 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.
Green—used 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 a Main circuit board
b Lift/drive selector toggle switch b Emergency stop button
c Horn button c Joystick controller
d Emergency stop button d Alarm
e LED circuit board
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 GS-2032. machine.
The platform controls can be adjusted to a
different configuration by changing the Result: The configuration code of the DIP
combination of the DIP switch settings. switch will appear in the LED display window.
The DIP switch is located on the circuit board 4 Press and hold the lift enable button and the
inside the platform control box. DIP switches have function enable switch. Move the joystick
two positions - ON or OFF. When reading the DIP handle to the DOWN position to lower the
switch code in the DIP Switch Codes Chart on platform. Observe the code shown in the LED
page 7-5, the ON and OFF are represented by the display window, located on the battery pack
numbers 1 (ON) and 0 (OFF). side of the machine.
Select a test area that is firm, Result: The software revision level will appear
level 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 were 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 position at both the ground and platform
ECM by using the following controls and turn the key switch to the OFF
procedure: 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
How to Set the DIP Switch Codes 2 Remove the fasteners securing the top of the
controller to the controller case.
Tip-over hazard. Do not adjust the
DIP switch settings to other than 3 Rotate the platform controller box to the
what is specified in this procedure. position shown to correctly identify the
Exceeding specifications will configuration of the DIP switch settings.
cause death or serious injury. 4 Open the controller box lid and locate the DIP
If replacing the circuit board, note switch on the circuit board. Move the DIP
the individual switch positions on switch settings to correspond with the
the DIP switch. Set the DIP switch configuration of the machine options, indicated
on the new circuit board to the in the DIP Switch Code Chart.
same configuration as the old one. 5 Confirm the settings. See 1-3, How to
If replacing the circuit board, use Determine the Revision Level.
dielectric grease on all plug in 6 Cover the DIP switch with dielectric grease.
connectors.
7 Close the lid and install the fasteners.
1 Push in the Emergency Stop button to the OFF
position at the ground and platform controls. 8 Push in the Emergency Stop button to the OFF
Turn the key switch to the OFF position. position at both the ground and platform
controls and turn the key switch to the OFF
a position.
b Any change in DIP settings will

not take effect until the key switch
c is turned to the OFF position.
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
Overload Cut Out

Lift Drive Cut Out
Motion Beacon
operating any function.
Descent Delay
Diagnostic Dip Switch Motion Alarm Lift/Drive Cut Out: This cuts out lift and drive
Display Code Code functions when the machine goes out of level.
Required for Europe and Australia.
Overload: This cuts out lift when the cylinder is
32 10000000 overloaded. Required for France.
33 10000100 •
34 10001000 • Descent Delay: This option halts descent for 4
35 10010000 • seconds at approximately 6 feet (2 m).
36 10100000 • Required for Europe.
37 11000000 •
38 10001100
Tip-over hazard. Do not adjust the
• •
39 10010100 DIP switch settings to other than
• •
40 10100100 • •
what is specified in this procedure.
41 11000100 • • Exceeding specifications will
42 10011100 • • • cause death or serious injury.
43 10101100 • • • If replacing the circuit board, note
44 11001100 • • • the toggle positions on the DIP
45 10110100 • • • switches. Set the DIP switches on
46 11010100 • • • the new circuit board to the same
47 11100100 • • • configuration of the old one.
48 10111100 • • • •
49 11011100 • • • • If replacing the circuit board, use
50 11101100 • • • • dielectric grease on all plug-in
51 11110100 • • • • connectors.
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
1-3 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 Ω)
Dual function switching requires a double pole terminal 2 to 3 continuity
double throw (DPDT) switch. (zero Ω)
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 Center position There are no terminal
and does not specifically apply to all varieties of combinations that will
toggle switches. produce continuity
(infinite Ω)
1 Turn the key switch to the OFF position. Tag
and disconnect all wiring from the toggle switch Right position
to be tested. terminal 1 to 2 continuity
(zero Ω)
The toggle switch at the platform
controls requires that the wires terminal 1 to 3, 4, 5 & 6 no continuity
are unplugged from the main (infinite Ω)
circuit board before testing.
terminal 2 to 3, 4, 5 & 6 no continuity
2 Connect the leads of an ohmmeter to the
switch terminals in the following combinations terminal 3 to 4, 5 & 6 no continuity
listed below to check for continuity. terminal 4 to 5 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 plugs from the access holes in the
side of the platform.
1 Lower the platform to the stowed position.
11 Lift the steer end of the platform slightly to clear
2 Remove the retaining fastener that holds the the scissor arms and slide the platform towards
platform controls quick disconnect plug to the the non-steer end of the machine until the non-
bottom of the platform. steer end platform pivot pins are visible through
3 Twist to disconnect the plug from the platform the access holes in the side of the platform.
controls. 12 Remove the retaining fasteners from the
4 Remove the cover to the AC outlet. Label and scissor platform pivot pins at the non-steer end
disconnect the wiring from the outlet. of the machine.
Electrocution hazard. Contact with 13 Use a slide hammer to remove the pins.
electrically charged circuits may Crushing hazard. The platform will
result in death or serious injury. fall if it is not properly supported.
Remove all rings, watches and
other jewelry. 14 Carefully lift the platform off of the machine and
place it on a structure capable of supporting it.
5 Pull the wiring through the platform tube.
Note the position of the wear pads
If your machine is equipped with before the platform is removed so
an air line to platform option, the when the platform is installed they
air line must be disconnected from will be in the correct position.
the platform before removal.
6 Support the platform with a forklift at the
non-steer end. Do not lift it.
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 structure capable
of supporting it.

Scissor Components (machines before serial number 632)
1 12
3 13
5 14
15
7
8 16
17
10 18
11
GS-2032
Steer End Non-steer End
1 Number 4 pivot pin (steer-end) 10 Number 1 inner arm
2 Number 3 center pivot pin 11 Number 1 pivot pins (steer end) (2 pins)
3 Lift cylinder rod end pivot pin 12 Number 4 pivot pin (non-steer end)
4 Number 3 inner arm 13 Number 3 outer arm
5 Number 3 pivot pin (steer end) 14 Number 3 pivot pin (non-steer end)
6 Number 2 center pivot pins (2 pins) 15 Number 2 outer arm
7 Number 2 inner arm 16 Number 2 pivot pin (non-steer end)
8 Number 2 pivot pin (steer end) 17 Lift cylinder barrel end pivot pin
9 Number 1 center pivot pin 18 Number 1 outer arm
7 - 10 Genie GS-2032 Part No. 46326

SCISSOR COMPONENTS
3-1 7 Use a soft metal drift to remove the number 3

pivot pin (index #14). Remove the number 3
Scissor Assembly outer arm (index #13) from the machine.
Bodily injury hazard. The number
How to Disassemble the 3 outer arm (index #13) may
Scissor Assembly become unbalanced and fall if not
GS-2032 Models properly supported when it is
removed from the machine.
This procedure requires specific
8 Remove the cable clamps from the number 3
repair skills, lifting equipment and
inner arm (index #4).
a suitable workshop. Attempting
this procedure without these skills 9 Remove the mounting fasteners from the cable
and tools may result in death or tray support at the steer end.
serious injury and significant
component damage. Dealer 10 Remove the external snap rings from the
service is required. number 2 center pivot pin (index #6) at the
ground controls side. Do not remove the pin.
1 Remove the platform. See 2-1, How to Remove
the Platform. 11 Slide the cable tray towards the battery pack
side of the machine and remove it from the
2 Remove the cables from the side of the number machine and lay it off to the side.
3 outer arm (index #13) at the ground controls
side. Component damage hazard.
Cables can be damaged if they
Component damage hazard. are kinked or pinched.
are kinked or pinched. 12 Attach a lifting strap from an overhead crane to
lug on the rod end of the lift cylinder.
3 Attach a lifting strap from an overhead crane to
the number 3 outer arm (index #13). 13 Remove the pin retaining fasteners from the
cylinder rod-end pivot pin (index #3). Use a soft
4 Remove the external snap rings from the metal drift to remove the pin.
number 3 center pivot pin (index #2).
Bodily injury hazard. The cylinder
5 Use a soft metal drift to remove the number 3 may fall if not properly supported
center pivot pin (index #2). when the pin is removed.
6 Remove the external snap rings from the 14 Lower the cylinder onto the number 1 center
number 3 pivot pin (index #14). pivot pin (index #9).
Part No. 46326 Genie GS-2032 7 - 11

SCISSOR COMPONENTS
15 Attach a lifting strap from an overhead crane 23 Attach a lifting strap from an overhead crane to
to the number 3 inner arm (index #4). the number 2 inner arm (index #7).
16 Remove the external snap rings from the 24 Remove the external snap rings from the
number 3 pivot pin (index #5). number 2 pivot pin (index #8).
17 Use a soft metal drift to remove the number 3 25 Use a soft metal drift to remove the number 2
pivot pin (index #5). Remove the number 3 pivot pin (index #8). Remove the number 2
inner arm (index #4) from the machine. inner arm (index #7) from the machine.
Bodily injury hazard. The Bodily injury hazard. The number
number 3 inner arm (index #4) 2 inner arm (index #7) may
may become unbalanced and become unbalanced and fall if not
fall if not properly supported properly supported when it is
when it is removed from the removed from the machine.
machine.
26 Remove the safety arm from the number 2
18 Attach a strap from an overhead crane to the inner arm (index #7) that was just removed.
number 2 outer arm (index #15).
27 Attach the strap from the overhead crane to the
19 Remove the external snap rings from the number 1 inner arm (index #10).
number 2 center pivot pin (index #6) at the
28 Raise the number 1 inner arm (index #10)
battery pack side.
approximately 2 feet (0.6 m) and insert the
20 Use a soft metal drift to remove both of the safety arm between the number 1 inner arm
number 2 center pivot pins (index #6). (index #10) and the number 1 outer arm
(index #18).
21 Remove the external snap rings from the
number 2 pivot pin (index #16). Bodily injury hazard. Keep hands
clear of moving parts when
22 Use a soft metal drift to remove the number 2
inserting the safety arm.
pivot pin (index #16). Remove the number 2
outer arm (index #15) from the machine. 29 Disconnect and plug the hydraulic hose on the
lift cylinder. Cap the fitting on the cylinder.
Bodily injury hazard. The
number 2 outer arm (index #15) Bodily injury hazard. Spraying
may become unbalanced and hydraulic oil can penetrate and
fall if not properly supported burn skin. Loosen hydraulic
when it is removed from the connections very slowly to allow
machine. the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
7 - 12 Genie GS-2032 Part No. 46326

SCISSOR COMPONENTS
30 Tag and disconnect the wires from the solenoid 36 Attach the strap from the overhead crane to the
valve on the cylinder. number 1 outer arm (index #18). Do not lift it.
31 Attach the strap from an overhead crane to the 37 Remove the external snap rings from the
lug on the rod-end of the lift cylinder. number 1 center pivot pin (index #9).
32 Remove the pin retaining fasteners from the 38 Use a soft metal drift to remove the number 1
cylinder barrel-end pin (index #17). Use a soft center pivot pin (index #9).
metal drift to remove the pin. Remove the
cylinder from the machine.
1 outer arm (index #18) may
Crushing hazard. If the overhead become unbalanced and fall if not
crane is not properly attached, the properly supported when the pin is
cylinder may become unbalanced removed.
and fall when it is removed from
39 Slide the number 1 outer arm (index #18) to the
the machine.
non-steer end and remove it from the machine.
Component damage hazard. Be
careful not to damage the valve or
1 outer arm (index #18) may
fittings on the cylinder while
become unbalanced and fall if not
removing it from the machine.
properly supported when
33 Place a 4 x 4 x 32 inch (10 x 10 x 80 cm) long removing it from the machine.
block across both sides of the chassis under
Note the position of the wear pads
the number 1 center pivot pin
before the arm is removed so
(index number #9).
when the scissor is assembled
34 Attach the strap from the overhead crane to the they will be in the correct position.
number 1 inner arm (index #10). Raise the
40 Attach the strap from an overhead crane to the
inner arm slightly and remove the safety arm.
number 1 inner arm (index #10). Do not lift it.
Lower the arms on to the block.
41 Remove the pin retaining fasteners from both
Bodily injury hazard. Keep hands
of the number 1 pivot pins (index #10). Use a
clear of moving parts when
slide hammer to remove the pins.
lowering the arms onto the block.
42 Remove the number 1 inner arm (index #10)
35 Remove the cables from the number 1 inner
from the machine.
arm (index #10) and lay them off to the side.
Component damage hazard.
1 inner arm (index #10) may
become unbalanced and fall if not
are kinked or pinched.
properly supported when removed
from the machine.
Part No. 46326 Genie GS-2032 7 - 13

SCISSOR COMPONENTS
How to Replace the Scissor Arm 10 Remove the pin retaining fasteners from the
number 1 inner arm pivot pins at the steer end
Wear Pads of the machine. Use a slide hammer to remove
1 Remove the platform. See 2-1, How to Remove the pins.
the Platform. 11 Attach a strap from an overhead crane to the
2 Remove the mounting fasteners from the steer end of the scissor arms.
stationary wear pads on the platform. 12 Carefully slide the forks from a forklift under the
Note the position of the wear pads scissor arms at the non-steer end of the
before they are removed so when machine.
the new ones are installed they 13 Raise the scissor arms up until the number 1
will be in the correct position. inner arm will clear the level sensor box.
3 Support and secure the entry ladder to an Component damage hazard. Be
appropriate lifting device. Then remove the careful not to damage the level
entry ladder mounting fasteners. Remove the sensor box, limit switch or level
entry ladder from the machine. sensor while moving the scissor
4 Raise the platform approximately 7 to 8 feet assembly.
(2.1 to 2.4 m). 14 Move the scissor assembly towards the non-
5 Lift the safety arm, move to the center of the steer end of the machine slightly and to one
scissor arm and rotate down to a vertical side of the machine until one of the scissor arm
position. wear pads is accessible. Do not allow both
wear pads to slide out of the drive chassis.
Crushing hazard. Keep hands
clear of the safety arm when The scissor assembly will fall if
lowering the platform. both wear pads are allowed to
slide out of the drive chassis.
6 Lower the platform onto the safety arm.
15 Remove the old wear pad.
7 Mark the mounting position of the level sensor
box on the drive chassis. Note the position of the wear pad
before it is removed so when the
8 Remove the fasteners from the level sensor new one is installed it will be in the
box and slide it towards the non-steer end of correct position.
the machine until it contacts the level sensor.
16 Install the new wear pad.
9 Secure the ends of the scissor arms together at
both ends of the machine with a tie down strap
or other appropriate device.
7 - 14 Genie GS-2032 Part No. 46326

17 Move the scissor assembly towards the other

side of the machine until the other scissor arm
wear pad is accessible.
The scissor assembly will fall if
both wear pads are allowed to
slide out of the drive chassis.
18 Remove the old wear pad.
Note the position of the wear pad
before it is removed so when the
new one is installed it will be in the
correct position.
19 Install the new wear pad.
20 Slide the scissor assembly back into the drive
chassis.
21 Lower the scissor assembly into position and
install the pivot pins.
careful not to damage the level
sensor box, limit switch or level
sensor while installing the scissor
assembly.
Part No. 46326 Genie GS-2032 7 - 15

SCISSOR COMPONENTS
3-2 5 Disconnect the manual lowering cable from the

solenoid.
Lift Cylinder
During assembly, the manual
platform lowering cable needs to
How to Remove the Lift Cylinder be properly adjusted. Refer to 4-1,
This procedure requires specific How to Adjust the Manual
repair skills, lifting equipment and Platform Lowering Cable.
a suitable workshop. Attempting 6 Remove the mounting fasteners from the
this procedure without these skills manual lowering cable mounting bracket.
and tools may result in death or Remove the bracket from the cylinder.
serious injury and significant
component damage. Dealer 7 Disconnect and plug the hydraulic hose from
service is strongly recommended. the lift cylinder. Cap the fitting on the cylinder.
When removing a hose assembly Bodily injury hazard. Spraying
or fitting, the O-ring on the fitting hydraulic oil can penetrate and
and/or hose end must be replaced burn skin. Loosen hydraulic
and then torqued to specification connections very slowly to allow
during installation. Refer to the oil pressure to dissipate
Section Two, Hydraulic Hose and gradually. Do not allow oil to squirt
Fitting Torque Specifications. or spray.
1 Raise the platform approximately 7 to 8 feet 8 Attach a strap from an overhead crane or
(2.1 to 2.4 m). similar lifting device to the rod end of the lift
cylinder for support.
2 Lift the safety arm, move to the center of the
scissor arm and rotate down to a vertical 9 Remove the external snap ring from the lift
position. cylinder rod-end pivot pin. Then use a soft
metal drift to remove the pin.
Crushing hazard. The lift cylinder
Crushing hazard. Keep hands will fall if not properly supported.
clear of the safety arm when
lowering the platform. 10 Lower the cylinder.
4 Tag and disconnect the wiring from the
solenoid valve at the barrel end of the lift
cylinder.
7 - 16 Genie GS-2032 Part No. 46326

SCISSOR COMPONENTS
Component damage hazard. Be How to Check the Resistance

careful not to damage the level
sensor box, limit switch or level of a Lowering Valve Coil
sensor while lowering the cylinder. 1 Turn the key switch to the OFF position and
11 Support and secure the entry ladder to an disconnect the wires from the valve coil to be
appropriate lifting device. tested.
12 Remove the mounting fasteners from the entry 2 Connect the positive lead from the ohmmeter to
ladder and remove the entry ladder from the the valve coil terminal, then connect the
machine. negative lead from the ohmmeter to the internal
ring of the valve coil.
Crushing hazard. The entry ladder
may become unbalanced and fall Platform lowering valve coil specifications
if not properly supported and
secured to the lifting device. 2 position 2 way N.C. solenoid valve - 20V 23 - 25W
(hydraulic schematic item R)
13 Support the barrel end of the lift cylinder with a
lifting device.
14 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 lift cylinder
may become unbalanced and fall
if not properly supported.
15 Carefully pull the cylinder out the non-steer end
of the machine through the scissor arms.
careful not to damage the valve or
fittings on the cylinder while
removing it from the machine.
Part No. 46326 Genie GS-2032 7 - 17

Ground Controls
4-1 8 Tighten the upper lock nut and re-measure the
distance between the end of the lowering cable
Manual Platform Lowering Cable and the end of the lowering valve. Re-adjust if
needed.
The manual platform lowering cable lowers the
platform in the event of a main power failure. The 9 Install the cable mounting nut onto the lowering
manual platform lowering cable is attached to the valve.
barrel end of the lift cylinder and is activated next 10 Raise the platform and rotate the safety arm to
to the ground controls. the storage position.
How to Adjust the Manual 11 Pull the manual lowering handle at the ground
controls 2 to 3 times to ensure it is functioning
Platform Lowering Cable correctly.
1 Raise the platform approximately 7 to 8 feet
Cable distance 3/16 to 1/4 inch 4.7 to 6.4 mm
(2.1 to 2.4 m).
2 Lift the safety arm, move to the center of the a
scissor arm and rotate down to a vertical
position.
b
Crushing hazard. Keep hands c a manual lowering cable
clear of the safety arm when sheath
lowering the platform. d
b upper lock nut
c cable mounting
4 Push the handle on the manual platform bracket
lowering cable all the way in. d lower lock nut
e e cable mounting nut
5 Disconnect the cable mounting nut from the f end of the lowering
cable
lowering valve at the barrel end of the lift
f g manual lowering valve
cylinder.
6 Pull the cable tight and measure the distance
between the end of the lowering cable and the g
end of the lowering valve. R
Result: The measurement should be 3/16 to
1/4 inch (4.7 to 6.4 mm).
4-2
7 To adjust, loosen the upper lock nut on the Toggle Switches
cable mounting bracket. Turn the lower lock nut
clockwise to decrease the distance or See 1-3, Toggle Switches.
counterclockwise to increase the distance.
7 - 18 Genie GS-2032 Part No. 46326

Hydraulic Pump
5-1 4 Activate the platform up function from the
ground controls.
Hydraulic Pump
Result: If the pressure gauge reads 3000 psi
The hydraulic pump is attached to the motor which (207 bar), immediately stop. The pump is good.
makes up the Hydraulic Power Unit. Result: If pressure fails to reach 3000 psi
(207 bar), the pump is bad and will need to be
How to Test the Hydraulic Pump serviced or replaced.
When removing a hose assembly 5 Remove the pressure gauge and reconnect the
or fitting, the O-ring on the fitting hydraulic hose.
and/or hose end must be replaced
and then torqued to specification How to Remove the
during installation. Refer to
Section Two, Hydraulic Hose and
Hydraulic Pump
Fitting Torque Specifications. When removing a hose assembly
1 Disconnect and plug the high pressure or fitting, the O-ring on the fitting
hydraulic hose from the hydraulic pump. and/or hose end must be replaced
and then torqued to specification
Bodily injury hazard. Spraying during installation. Refer to
hydraulic oil can penetrate and Section Two, Hydraulic Hose and
burn skin. Loosen hydraulic Fitting Torque Specifications.
the oil pressure to dissipate 1 Tag, disconnect and plug the hoses on the
gradually. Do not allow oil to squirt pump. Cap the fittings on the pump.
or spray. Bodily injury hazard. Spraying
2 Connect a 0 to 5000 psi (0 to 345 bar) pressure hydraulic oil can penetrate and
gauge to the high pressure port on the pump. burn skin. Loosen hydraulic
3 Turn the key switch to ground control and pull the oil pressure to dissipate
out the Emergency Stop button to the ON gradually. Do not allow oil to squirt
position at both the ground and platform or spray.
controls.
2 Remove the pump mounting bolts. Carefully
remove the pump.
Part No. 46326 Genie GS-2032 7 - 19

Function Manifold
6-1
Function Manifold Components (before serial number 17482)
The function manifold is mounted inside the hydraulic power unit module.
Index Schematic
No. Description Item Function Torque
1 Flow Regulator,
0.5 gpm (1.9 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 2 position 2 way solenoid valve ......... I ............ Brake circuit ...................................... 18-20 ft-lbs (24-27 Nm)
10 Orifice Washer, 0.060 in (1.5 mm) .... J ............ Brake circuit
11 Check valve ....................................... K ........... Brake circuit ...................................... 35-40 ft-lbs (47-54 Nm)
12 2 position 4 way solenoid valve ......... L ........... Drive speed select circuit .................. 25-30 ft-lbs (34-41 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
SAE No. 6 1/ 4 18 ft-lbs / 24 Nm SAE No. 12 5/8 75 ft-lbs / 102 Nm
7 - 20 Genie GS-2032 Part No. 46326

FUNCTION MANIFOLD
Part No. 46326 Genie GS-2032 7 - 21

FUNCTION MANIFOLD
6-2
Function Manifold Components (after serial number 17481)
The function manifold is mounted inside the hydraulic power unit module.
Index Schematic
1 Check valve ....................................... A ........... Steer circuit ....................................... 35-40 ft-lbs (47-54 Nm)
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 select circuit .................. 25-30 ft-lbs (34-41 Nm)
11 3 position 4 way solenoid valve ......... K ........... Drive forward/reverse ....................... 18-20 ft-lbs (24-27 Nm)
12 Relief valve, 130 psi (9 bar) .............. L ........... Back pressure ................................... 25-30 ft-lbs (34-41 Nm)

7 - 22 Genie GS-2032 Part No. 46326

FUNCTION MANIFOLD
Part No. 46326 Genie GS-2032 7 - 23

FUNCTION MANIFOLD
6-3 7 Add an additional 100 pounds (45.4 kg) to the

platform. Secure the additional weight.
Valve Adjustments -
8 Activate the platform up function.
Function Manifold
9 The power unit should not be able to lift the
Be sure that the hydraulic oil level platform. If the power unit lifts the platform,
is between the FULL and ADD marks adjust the internal hex socket counterclockwise
on the oil level indicator decal. until the platform will not raise.
How to Adjust the System Relief Tip-over hazard. Do not adjust the
relief valve to allow the power unit
Valve to lift more than maximum rated
load.
1 Open the hydraulic power unit module tray and
locate the system relief valve on the function 10 Install the relief valve cap.
manifold.
11 Remove the weight from the platform.
2 Place maximum rated load onto the platform.
Secure the load to the platform. 12 Bleed the hydraulic system. Raise the platform
to full height and then lower it to the stowed
Maximum Capacity position through two complete cycles.
Result: If the pump cavitates or platform fails to
GS-2032 1000 lbs 454 kg
reach full height, add hydraulic oil until the
3 Turn the key switch to ground control and pull pump is functioning correctly. Do not overfill the
out the Emergency Stop button to the ON hydraulic reservoir. Re-test the system by
position at both the ground and platform performing steps 8 through 11.
controls. Component damage hazard. Do
4 Hold the system relief valve with a wrench and not continue to operate the
remove the cap (item 6, function manifold). machine if the hydraulic pump is
cavitating. If the pump is still
5 While activating the platform up function, adjust cavitating, see 5-1, How to Test
the internal hex socket clockwise to increase the Hydraulic Pump.
lift capacity or counterclockwise to decrease lift
capacity. Adjust the relief valve until the
platform just begins to raise.
6 Fully lower the platform.
7 - 24 Genie GS-2032 Part No. 46326

FUNCTION MANIFOLD
How to Adjust the Steering Relief How to Check the Resistance

Valve of a Valve Coil
1 Connect a 0 to 5000 psi (0 to 345 bar) pressure 1 Turn the key switch to the OFF position and
gauge to the test port on the function manifold disconnect the wires from the valve coil to be
(item 2, function manifold). tested.
2 Turn the key switch to the ground controls and 2 Coils with 2 terminals: Connect the leads
pull out the Emergency Stop button to the ON from the ohmmeter to the valve coil terminals.
Coils with 1 terminal: Connect the positive
controls.
lead from the ohmmeter to the valve coil
3 Press and hold the steer thumb rocker switch terminal, then connect the negative lead from
to the right. Allow the wheels to completely turn the ohmmeter to the internal ring of the valve
to the right, then continue holding the switch coil.
while observing the pressure reading on the
pressure gauge. Note the pressure. Valve coil specifications
Before serial number 11501
4 Press and hold the steer thumb rocker switch
to the left. Allow the wheels to completely turn Coil, 20V (function manifold items G, J) 26 - 28W
to the left, then continue holding the switch
Coil, 20V (function manifold items H, L, M) 18 - 20W
while observing the pressure reading on the
pressure gauge. Valve coil specifications
After serial number 11500
5 Turn the machine off. Hold the steering relief
valve and remove the cap (item 5, function Coil, 20V (function manifold items G, I) 26 - 28W
manifold).
Coil, 20V (function manifold items H, J, K) 18 - 20W
6 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Then install the relief
valve cap.
Tip-over hazard. Do not adjust
the relief valves higher than
specified.
7 Repeat steps 3 and 4 to confirm the steering
relief pressure.
Steering relief valve specification
Pressure 1500 psi 103.4 bar
Part No. 46326 Genie GS-2032 7 - 25

Steering Axle Components

7-1 6 Tag, disconnect and plug the hoses on the
drive motor. Cap the fittings on the motor.
Yoke and Drive Motor
How to Remove the Yoke burn skin. Loosen hydraulic
and Drive Motor connections very slowly to
allow the oil pressure to
When removing a hose assembly
dissipate gradually. Do not
or fitting, the O-ring on the fitting
allow oil to squirt or spray.
and/or hose end must be replaced
and then torqued to specification 7 Support and secure the yoke assembly to an
during installation. Refer to appropriate lifting device.
8 Remove the retaining fastener from the steer
Fitting Torque Specifications.
link at the yoke assembly.
1 Block the non-steering wheels, and then
Note the quantity and location of
center a lifting jack under the drive chassis at
the spacers when disconnecting
the steer end of the machine.
the steer link from the yoke
2 Remove the cotter pin from the wheel castle assembly.
nut.
9 Remove the retaining fastener from the top of
Always replace the cotter pin with the yoke pivot shaft.
a new one when removing the
10 Lower the yoke assembly out of the chassis
castle nut.
while guiding the bellcrank pivot shaft out of the
3 Loosen the wheel castle nut. Do not remove it. bellcrank.
4 Raise the machine approximately 14 inches Bodily injury hazard. The yoke/
(36 cm) and place blocks under the drive motor assembly may fall if not
chassis for support. properly supported when it is
removed from the chassis.
Crushing hazard. The chassis will
fall if it is not properly supported. During re-assembly, be sure that
the spacers are installed onto the
5 Remove the castle nut, then remove the wheel.
steer link.
Torque specifications
Castle nut 300 ft-lbs 406.7 Nm
7 - 26 Genie GS-2032 Part No. 46326

STEERING AXLE COMPONENTS
How to Remove a Drive Motor 7-2

1 Block the non-steering wheels, and then Steering Cylinder
center a lifting jack under the drive chassis at
the steer end of the machine. How to Remove the
2 Remove the cotter pin on the wheel lug nut of Steering Cylinder
the motor to be removed.
When removing a hose assembly
Always replace the cotter pin with or fitting, the O-ring on the fitting
a new one when removing the and/or hose end must be replaced
castle nut. and then torqued to specification
3 Loosen the wheel castle nut. Do not remove it. during installation. Refer to
4 Raise the machine approximately 2 inches Fitting Torque Specifications.
(5 cm) and place blocks under the drive
chassis for support. 1 Block the non-steer wheels.
5 Remove the wheel castle nut, then remove the 2 Tag, disconnect and plug the hydraulic hoses
wheel. from the steering cylinder. Cap the fittings on
the cylinder.
6 Tag, disconnect and plug the hoses on the
drive motor. Cap the fittings on the motor. Bodily injury hazard. Spraying
Bodily injury hazard. Spraying burn skin. Loosen hydraulic
hydraulic oil can penetrate and connections very slowly to allow
burn skin. Loosen hydraulic the oil pressure to dissipate
connections very slowly to gradually. Do not allow oil to
allow the oil pressure to squirt or spray.
dissipate gradually. Do not
allow oil to squirt or spray. 3 Remove the pin retaining fasteners from the
barrel-end pivot pin. Use a soft metal drift to
7 Remove the drive motor mounting fasteners, remove the pivot pin.
then remove the motor.
Note the quantity and location of
Torque specifications the spacers when removing the
barrel-end pivot pin.
Part No. 46326 Genie GS-2032 7 - 27

STEERING AXLE COMPONENTS
4 Remove the pin retaining fasteners from the 7-3

rod-end pivot pin. Use a soft metal drift to
remove the pin. Steering Bellcrank
Note the quantity and location of 1 Remove the steering cylinder. See 7-2, How to
the spacers when removing the Remove the Steering Cylinder.
rod-end pivot pin.
2 Remove the retaining fastener from the center
5 Remove the steering cylinder from the of the bellcrank.
machine.
Note the quantity and the location
of the spacers on the bellcrank.
3 Remove the retaining fasteners from the steer
links at each end of the bellcrank. Remove the
bellcrank from the machine.
Note the quantity and the location
of the spacers in between the
bellcrank and the steer links.
7 - 28 Genie GS-2032 Part No. 46326

Non-steering Axle Components

8-1 7 Tag, disconnect and plug the hose on the
brake. Cap the fittings on the brake.
Drive Brake
How to Remove a Drive Brake burn skin. Loosen hydraulic
When removing a hose assembly connections very slowly to
or fitting, the O-ring on the fitting allow the oil pressure to
and/or hose end must be replaced dissipate gradually. Do not
and then torqued to specification allow oil to squirt or spray.
during installation. Refer to 8 Place a lifting jack under the brake for support.
Fitting Torque Specifications. 9 Remove the brake mounting fasteners from the
drive chassis. Remove the brake.
1 Support and secure the entry ladder to an
appropriate lifting device. Then remove the Crushing hazard. The brake may
entry ladder mounting fasteners. Remove the become unbalanced and fall if it is
entry ladder from the machine. not properly supported when the
mounting fasteners are removed.
Crushing hazard. The entry ladder
may become unbalanced and fall Torque specifications
if not properly supported and
secured to the lifting device.
2 Block the steer wheels and center a lifting jack
under the drive chassis at the non-steer end.
3 Remove the cotter pin on the wheel castle nut.
Always replace the cotter pin with
a new one when removing the
castle nut.
4 Loosen the wheel castle nut. Do not remove it.
5 Raise the machine approximately 2 inches
(5 cm) and place blocks under the drive
chassis for support.
6 Remove the wheel castle nut, then remove the
wheel.
Part No. 46326 Genie GS-2032 7 - 29


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)

7 - 30 Genie GS-2032 Part No. 46326

Distributed By:
Genie North America Genie China Genie France

Phone: 425 881 1800 Phone: 86 21 62483040 Phone: 33 237 260 999
Toll Free in USA 800 536 1800 Fax: 86 21 62588180 Fax: 33 237 260 998
Toll Free in Canada 800 426 8089
Fax: 425 883 3475 Genie Japan Genie Holland
Phone: 81 3 3453 6082 Phone: 31 7051 78836
Genie UK Limited Fax: 81 3 3453 6083 Fax: 31 7051 13993
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

GS-2032 Service Manual: Technical Publications

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GS-2032 Service Manual: Technical Publications

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®

First Edition, Third Printing

continuous improvement of our products is a Genie

ii Genie GS-2032 Part No. 46326

Do Not Perform Maintenance

Part No. 46326 Genie GS-2032 iii

Personal Safety protective clothing if the situation warrants

iv Genie GS-2032 Part No. 46326

Part No. 46326 Genie GS-2032 v

machine malfunctions, a fault code will be shown in

Component damage hazard.

vi Genie GS-2032 Part No. 46326

Section One Safety Rules

Section Two Specifications

Section Three Scheduled Maintenance Inspections

Part No. 46326 Genie GS-2032 vii

Section Four Scheduled Maintenance Procedures

viii Genie GS-2032 Part No. 46326

Section Five Troubleshooting Flow Charts and Fault Codes

Part No. 46326 Genie GS-2032 ix

Section Six Schematics

x Genie GS-2032 Part No. 46326

Section Seven Repair Procedures

Part No. 46326 Genie GS-2032 xi

Section Seven Repair Procedures, continued

xii Genie GS-2032 Part No. 46326

Length 96 in 243.8 cm Tire size (solid rubber) 15 x 5 x111/4 in

Height, stowed maximum Wheel diameter 111/4 in 28.5 cm

Height, stowed maximum Platform dimensions

Weight 3438 lbs 1559 kg Width 311/4 in 65 cm

Ground clearance 4.0 in 10.2 cm Extension length 291/2 in 79.4 cm

Ground clearance Maximum load capacity 800 lbs 363 kg

Maximum platform extension 39 in 1m Continuous improvement of our products is a

Turning raduis, outside 92 in 233.7 cm

Turning raduis, inside 0 in 0 cm

Part No. 46326 Genie GS-2032 2-1

Performance Specifications Hydraulic Specifications

Stowed, maximum 2.2 mph 3.5 km/h Lift pump

System relief valve pressure 3500 psi

Steer relief valve pressure 1000 psi

2-2 Genie GS-2032 Part No. 46326

Hydraulic Hose and Fitting Torque Specifications

Hydraulic Hose and Fitting Torque Specifications

Part No. 46326 Genie GS-2032 2-3

This page intentionally left blank.

2-4 Genie GS-2032 Part No. 46326

Scheduled Maintenance Inspections

There are four types of maintenance inspections

Failure to properly complete each Quarterly A+B

Maintenance Inspection Report

Make copies of the Maintenance Inspection

Part No. 46326 Genie GS-2032 3-1

Table A Tools are New parts

A-1 Inspect the Operator's and Safety Manuals

A-2 Inspect the Decals and Placards

A-3 Inspect for Damage and

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