Genie GS1930 - 2876 Parts Manual

Part No.
72876
September 2006
refer to inside cover for serial number information Rev C2
Introduction April 2003
Important Serial Number Information

Read, understand and obey the safety rules and Genie Industries offers the following Service
operating instructions in the Genie GS-1530 and Manuals for these models:
GS-1930 Operator's Manual before attempting any
maintenance or repair procedure. Title Part No.
This manual provides detailed scheduled Genie GS-1530 and GS-1930 Service Manual
maintenance information for the machine owner (before serial number 17408) ............................... 39528
and user. It also provides troubleshooting and
repair procedures for qualified service
professionals.
Basic mechanical, hydraulic and electrical
skills are required to perform most procedures.
However, several procedures require specialized
skills, tools, lifting equipment and a suitable
workshop. In these instances, we strongly
recommend that maintenance and repair be
performed at an authorized Genie dealer
service center.
Technical Publications
Genie Industries has endeavored to deliver the
highest degree of accuracy possible. However,
continuous improvement of our products is a Genie
policy. Therefore, product specifications
are subject to change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.
Contact Us: Copyright © 1997 by Genie Industries
72876 Rev C April 2003

PO Box 97030 Second Edition, Third Printing
Redmond, WA 98073-9730 USA
"Genie" is a registered trademark of Genie
www.genieindustries.com Industries in the USA and many other countries.
"GS" is a trademark of Genie Industries.
e-mail: techsup@genieind.com
Printed on recycled paper
Printed in U.S.A.
ii Genie GS-1530 and GS-1930 Part No. 72876

April 2003 Section 1 • Safety Rules
Safety Rules
Danger
Failure to obey the instructions and safety rules
in this manual and the Genie GS-1530 and
GS-1930 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. 72876 Genie GS-1530 and GS-1930 iii

Section 1 • Safety Rules April 2003
SAFETY RULES
Personal Safety Be sure to wear protective eye wear and

other protective clothing if the situation
Any person working on or around a machine must warrants it.
be aware of all known safety hazards. Personal
safety and the continued safe operation of the Be aware of potential crushing hazards
machine should be your top priority. such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved steel-toed
shoes.
Read each procedure thoroughly. This
manual and the decals on the machine,
use signal words to identify the following:
Safety alert symbol—used to alert Workplace Safety
personnel to potential personal Be sure to keep sparks, flames and
injury hazards. Obey all safety lighted tobacco away from flammable and
messages that follow this symbol combustible materials like battery gases
to avoid possible injury or death. and engine fuels. Always have an approved fire
Red—used to indicate the extinguisher within easy reach.
presence of an imminently
Be sure that all tools and working areas
hazardous situation which, if not
are properly maintained and ready for
avoided, will result in death or
use. Keep work surfaces clean and free of
serious injury.
debris that could get into machine components and
Orange—used to indicate the cause damage.
presence of a potentially
hazardous situation which, if not Be sure any forklift, overhead crane or
avoided, could result in death or other lifting or supporting device is fully
serious injury. capable of supporting and stabilizing the
weight to be lifted. Use only chains or straps that
Yellow with safety alert symbol— are in good condition and of ample capacity.
used to indicate the presence of a
potentially hazardous situation Be sure that fasteners intended for one
which, if not avoided, may cause time use (i.e., cotter pins and self-locking
minor or moderate injury. nuts) are not reused. These components
may fail if they are used a second time.
Yellow without safety alert
symbol—used to indicate the Be sure to properly dispose of old oil or
presence of a potentially other fluids. Use an approved container.
hazardous situation which, if not Please be environmentally safe .
avoided, may result in property
Be sure that your workshop or work area
damage.
is properly ventilated and well lit.
Green—used to indicate operation
or maintenance information.
iv Genie GS-1530 and GS-1930 Part No. 72876

April 2003
Table of Contents
Introduction
Important Information ...................................................................................................... ii
Section One Safety Rules

General Safety Rules ..................................................................................................... iii
Section Two Specifications - Rev C

Machine Specifications, GS-1530 ............................................................................. 2 - 1
Performance Specifications, GS-1530 ...................................................................... 2 - 1
Machine Specifications, GS-1930 ............................................................................. 2 - 2
Performance Specifications, GS-1930 ...................................................................... 2 - 2
Machine Specifications, GS-1932 (Australia Outdoor) .............................................. 2 - 3
Performance Specifications, GS-1932 (Australia Outdoor) ....................................... 2 - 3
Hydraulic Specifications - All Models ........................................................................ 2 - 4
Manifold Component Specifications .......................................................................... 2 - 5
Hydraulic Hose and Fitting Torque Specifications ..................................................... 2 - 6
Section Three Scheduled Maintenance Procedures

Introduction ............................................................................................................... 3 - 1
Pre-delivery Preparation Report ............................................................................... 3 - 3
Maintenance Inspection Report ................................................................................ 3 - 5
Checklist A Procedures - Rev C
A-1 Perform Pre-operation Inspection ................................................................... 3 - 6
A-2 Perform Function Tests ................................................................................... 3 - 6
A-3 Perform 30 Day Service .................................................................................. 3 - 7
A-4 Grease the Steer Yokes .................................................................................. 3 - 7
Part No. 72876 Genie GS-1530 and GS-1930 v

September 2006
TABLE OF CONTENTS
Section Three Maintenance Procedures, continued

Checklist B Procedures - Rev C
B-1 Inspect the Batteries ....................................................................................... 3 - 8
B-2 Inspect the Electrical Wiring ............................................................................ 3 - 9
B-3 Inspect the Tires and Wheels (including castle nut torque) ............................ 3 - 10
B-4 Test the Key Switch ...................................................................................... 3 - 10
B-5 Test the Automotive-style Horn (if equipped) ................................................. 3 - 11
B-6 Test the Drive Brakes .................................................................................... 3 - 12
B-7 Test the Drive Speed - Stowed Position ........................................................ 3 - 14
B-8 Test the Drive Speed - Raised Position ......................................................... 3 - 15
B-9 Perform Hydraulic Oil Analysis ...................................................................... 3 - 16
B-10 Replace the Hydraulic Tank Return Filter ....................................................... 3 - 16
B-11 Check the Module Tray Latch Components ................................................... 3 - 17
Checklist C Procedure - Rev C
C-1 Check the Scissor Arm Wear Pads ............................................................... 3 - 18
Checklist D Procedure - Rev B
D-1 Test or Replace the Hydraulic Oil .................................................................. 3 - 19
Section Four Repair Procedures

Introduction ............................................................................................................... 4 - 1
Platform Controls - Rev B
1-1 Circuit Boards .................................................................................................. 4 - 2
1-2 Joystick Controller ........................................................................................... 4 - 3
1-3 Controller Adjustments .................................................................................... 4 - 5
1-4 Software Configuration .................................................................................. 4 - 12
Platform Components - Rev A
2-1 Platform ........................................................................................................ 4 - 16
2-2 Platform Extension ........................................................................................ 4 - 17
vi Genie GS-1530 and GS-1930 Part No. 72876

April 2003
TABLE OF CONTENTS
Section Four Repair Procedures, continued

Scissor Components - Rev A
3-1 Scissor Assembly, GS-1530 ......................................................................... 4 - 18
3-2 Scissor Assembly, GS-1930 ......................................................................... 4 - 24
3-3 Lift Cylinder ................................................................................................... 4 - 32
Ground Controls - Rev B
4-1 Manual Platform Lowering Cable .................................................................. 4 - 34
4-2 Toggle Switches ............................................................................................ 4 - 36
4-3 Control Relays .............................................................................................. 4 - 37
4-4 Tilt Level Sensor (before serial number 50444) ............................................. 4 - 38
4-5 Tilt Level Sensor (after serial number 50443) ............................................... 4 - 46
Hydraulic Pump - Rev B
5-1 Function Pump .............................................................................................. 4 - 54
Function Manifold - Rev B
6-1 Function Manifold Components (from serial number 17408 to 35799) .......... 4 - 56
6-2 Function Manifold Components (after serial number 35799) ......................... 4 - 58
6-3 Valve Adjustments - Function Manifold ......................................................... 4 - 60
6-4 Valve Coils .................................................................................................... 4 - 66
Hydraulic Tank - Rev A
7-1 Hydraulic Tank .............................................................................................. 4 - 68
Steer Axle Components - Rev B
8-1 Yoke and Drive Motor ................................................................................... 4 - 69
8-2 Steer Cylinder ............................................................................................... 4 - 71
8-3 Steer Bellcrank .............................................................................................. 4 - 72
Non-steer Axle Components - Rev B
9-1 Drive Brake ................................................................................................... 4 - 73
Brake Release Hand Pump Components - Rev A
10-1 Brake Release Hand Pump Components ...................................................... 4 - 74
Part No. 72876 Genie GS-1530 and GS-1930 vii

April 2003
TABLE OF CONTENTS
Section Five Troubleshooting Flow Charts and Fault Codes

Introduction ............................................................................................................... 5 - 1
Fault Code Chart (after serial number 17407) - Rev A ................................................ 5 - 3
Chart
Number Chart Title
1 All Functions Will Not Operate - Rev A ..................................................................... 5 - 4
2 Pump Motor Will Not Operate - Rev A ...................................................................... 5 - 6
3 All Functions Inoperative, Power Unit Starts and Runs - Rev A ................................ 5 - 8
4 Ground Controls Inoperative,
Platform Controls Operate Normally - Rev A ............................................................ 5 - 9
5 Platform Controls Inoperative,
Ground Controls Operate Normally - Rev A ............................................................ 5 - 10
6 Platform Up Function Inoperative - Rev A ............................................................... 5 - 11
7 Platform Down Function Inoperative - Rev A .......................................................... 5 - 12
8 Steer Left Function Inoperative - Rev A .................................................................. 5 - 13
9 Steer Right Function Inoperative - Rev A ................................................................ 5 - 15
10 All Drive Functions Inoperative,
All Other Functions Operate Normally - Rev A ....................................................... 5 - 17
10A Brake Release Function Inoperative - Rev A .......................................................... 5 - 18
11 Drive Forward Function Inoperative - Rev A ........................................................... 5 - 19
12 Drive Reverse Function Inoperative - Rev A ........................................................... 5 - 20
13 Machine Will Not Drive At Full Speed - Rev A ........................................................ 5 - 21
14 Machine Drives At Full Speed With Platform Raised - Rev A ................................. 5 - 22
15 Limit Switch Function Inoperative - Rev A .............................................................. 5 - 23
16 Fault Code 02 - ECM / Platform Communication Error - Rev A .............................. 5 - 24
viii Genie GS-1530 and GS-1930 Part No. 72876

April 2003
TABLE OF CONTENTS
Section Six Schematics

Introduction ............................................................................................................... 6 - 1
Electrical Components - Rev C ................................................................................. 6 - 2
ECM Pin-out Legend - Rev B .................................................................................... 6 - 4
Control Relay Layout - Rev A .................................................................................... 6 - 6
Platform Controls Wiring Diagram
(from serial number 17408 to 51014) - Rev B ........................................................... 6 - 8
(from serial number 51015 to 59999) - Rev A ........................................................... 6 - 9
Ground Controls Wiring Diagram - Rev C ............................................................... 6 - 10
Level Sensor Box Wiring Diagram - Rev A ............................................................. 6 - 11
Electrical Symbols Legend - Rev C ........................................................................ 6 - 12
Electrical Schematic
(from serial number 17408 to 21064) - Rev C ......................................................... 6 - 13
(from serial number 40926 to 49804) - Rev B ......................................................... 6 - 25
Part No. 72876 Genie GS-1530 and GS-1930 ix

April 2003
TABLE OF CONTENTS
Section Six Schematics, continued

Hydraulic Schematic Legend and Component Reference - Rev B .......................... 6 - 35
Hydraulic Schematic
Hydraulic Schematic
x Genie GS-1530 and GS-1930 Part No. 72876

April 2003 Section 2 • Specifications
REV C
Specifications
Machine Specifications, GS-1530 Performance Specifications,
GS-1530
Batteries
Type 6V DC Drive speed, maximum
Group T-105 Platform stowed 2.5 mph

40 ft / 10.7 sec
Quantity 8 4 km/h
12.2 m / 10.7 sec
Battery capacity, maximum 225AH
Platform raised 0.5 mph
Reserve capacity @ 25A rate 447 minutes 40 ft / 55 sec
0.7 km/h
Fluid capacities
12.2 m / 55 sec
Hydraulic tank 5 gallons
Braking distance, maximum
18.9 liters
High range on paved surface 2 ft
Hydraulic system (including tank) 5.5 gallons
61 cm
20.8 liters
Load capacity, maximum
Tires and wheels
Platform retracted 600 lbs
Tire size (solid rubber) 12 x 4.5 x 8.6 in
272 kg
30.5 x 11.4 x 21.8 cm
Platform only 350 lbs
Tire contact area 9 sq in 159 kg
58 sq cm Extension only 250 lbs
113 kg
Overall tire diameter 12 in
30.5 cm Function speed, maximum from platform controls
(with 1 person in platform)
Wheel diameter 8.6 in
21.8 cm Platform up 15 to 17 seconds
Platform down 16 to 18 seconds
Wheel width 4.5 in
11.4 cm Airborne noise emissions <70 dB
Maximum sound level at normal operation workstations
Castle nut torque, dry 300 ft-lbs (A-weighted)
406.7 Nm
Gradeability 30%
Castle nut torque, lubricated 225 ft-lbs
305 Nm
Continuous improvement of our products is a
Genie policy. Product specifications are
For operational specifications, refer to the subject to change without notice.
Operators Manual.
Part No. 72876 Genie GS-1530 and GS-1930 2-1

Section 2 • Specifications April 2003
SPECIFICATIONS REV C

GS-1930
Batteries
Type 6V DC Drive speed, maximum
Group T-105 Platform stowed 2.5 mph

40 ft / 10.7 sec
Quantity 8 4 km/h
12.2 m / 10.7 sec
Reserve capacity @ 25A rate 447 minutes 40 ft / 55 sec
0.7 km/h
Fluid capacities
12.2 m / 55 sec
18.9 liters
High range on paved surface 2 ft
61 cm
20.8 liters
Load capacity, maximum
Tires and wheels
Platform retracted 500 lbs
Tire size (solid rubber) 12 x 4.5 x 8.6 in
227 kg
30.5 x 11.4 x 21.8 cm
Platform only 250 lbs
58 sq cm Extension only 250 lbs
113 kg
Overall tire diameter 12 in
30.5 cm Function speed, maximum from platform controls
(with 1 person in platform)
Wheel diameter 8.6 in
21.8 cm Platform up 15 to 17 seconds
Platform down 22 to 24 seconds
Wheel width 4.5 in
11.4 cm Airborne noise emissions <70 dB
Maximum sound level at normal operation workstations
Castle nut torque, dry 300 ft-lbs (A-weighted)
406.7 Nm
Gradeability
305 Nm ANSI, CSA, CE 30%
Australia 25%
For operational specifications, refer to the

Operators Manual. Continuous improvement of our products is a
subject to change without notice.
2-2 Genie GS-1530 and GS-1930 Part No. 72876

REV C SPECIFICATIONS

(Australia Outdoor) GS-1932 (Australia Outdoor)
Batteries Drive speed, maximum
Type 6V DC Platform stowed 2.5 mph

40 ft / 10.7 sec
Group T-105 4 km/h
12.2 m / 10.7 sec
Quantity 8
40 ft / 55 sec
Reserve capacity @ 25A rate 447 minutes 0.7 km/h
12.2 m / 55 sec
Fluid capacities
18.9 liters High range on paved surface 2 ft
61 cm
20.8 liters Load capacity, maximum
Tires and wheels Platform retracted 500 lbs

227 kg
Tire size (solid rubber) 12 x 4.5 x 8.6 in Platform only 250 lbs
30.5 x 11.4 x 21.8 cm 113 kg
Extension only 250 lbs
58 sq cm
Function speed, maximum from platform controls
Overall tire diameter 12 in (with 1 person in platform)
30.5 cm
Platform up 15 to 17 seconds
Wheel diameter 8.6 in Platform down 22 to 24 seconds
21.8 cm
Airborne noise emissions <70 dB
Wheel width 4.5 in Maximum sound level at normal operation workstations
11.4 cm (A-weighted)
Castle nut torque, dry 300 ft-lbs Gradeability 25%
406.7 Nm

Continuous improvement of our products is a
305 Nm
subject to change without notice.
For operational specifications, refer to the
Operators Manual.

Hydraulic Specifications Function pump
Hydraulic Oil Specifications Type Gear
Before serial number 52640 Displacement per revolution 0.244 cu in

Hydraulic oil type Shell Donax TG (Dexron III) 4 cc
After serial number 52639 Flow rate @ 2500 psi / 172 bar 4 gpm
Hydraulic oil type Chevron Rykon MV equivalent 15 L/min
Approximate SAE grade 5W-20 Hydraulic tank return filter 10 micron with
Viscosity index rating 200 25 psi / 1.7 bar bypass
Chevron Rykon MV oil is fully compatible and Function manifold
mixable with Shell Donax TG (Dexron III) oils.
Genie specifications require hydraulic oils which are System relief valve pressure 3500 psi
designed to give maximum protection to hydraulic 241 bar
systems, have the ability to perform over a wide
temperature range, and have a minimum viscosity index Lift relief valve pressure 3000 psi
rating of 150. They should provide excellent antiwear, (added after serial number 35799) 207 bar
oxidation, corrosion inhibition, seal conditioning, and
foam and aeration suppression properties. Steer relief valve pressure 1500 psi
103 bar
Optional fluids
Biodegradable Petro Canada Premium ECO 46

Statoil Hydra Way Bio Pa 32
BP Biohyd SE-S
Fire resistant UCON Hydrolube HP-5046

Quintolubric 822
Mineral based Shell Tellus T32

Shell Tellus T46
Genie specifications require

additional equipment and special
installation instructions for the
approved optional fluids. Consult
the Genie Industries Service
Department before use.

REV C
Manifold Component
Specifications
Plug torque
SAE No. 2 50 in-lbs / 6 Nm
SAE No. 4 13 ft-lbs / 18 Nm
Valve Coil Resistance
Description Specification
Solenoid valve, 3 position 4 way 25 to 27 Ω

20V DC with diode (schematic item AF and BI)

20V DC with diode (schematic item AG)
Solenoid valve, N.O. poppet 25 to 27 Ω

20V DC with diode (schematic item AH)

20V DC with diode (schematic item AI and BJ)

20V DC with diode (schematic item BG)

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. Genie specifications require that fittings and hose ends be torqued to specification when they
are removed and installed or when new hoses or fittings are installed.
SAE O-ring Boss Port SAE O-ring Boss Port

(tube fitting - installed into Aluminum) (tube fitting - installed into Steel)
SAE Dash size Torque SAE Dash size Torque
-4 11 ft-lbs / 14.9 Nm -4 16 ft-lbs / 21.7 Nm
-6 23 ft-lbs / 31.2 Nm -6 35 ft-lbs / 47.5 Nm
-8 40 ft-lbs / 54.2 Nm -8 60 ft-lbs / 81.3 Nm
-10 69 ft-lbs / 93.6 Nm -10 105 ft-lbs / 142.4 Nm
-12 93 ft-lbs / 126.1 Nm -12 140 ft-lbs / 190 Nm
-16 139 ft-lbs / 188.5 Nm -16 210 ft-lbs / 284.7 Nm
-20 172 ft-lbs / 233.2 Nm -20 260 ft-lbs / 352.5 Nm
-24 208 ft-lbs / 282 Nm -24 315 ft-lbs / 427.1 Nm
Seal-Lok Fittings
®
JIC 37° Fittings
(hose end) (swivel nut or hose connection)
SAE Dash size Torque SAE Dash size Thread Size Flats
-4 18 ft-lbs / 24.4 Nm -4 7/16-20 2
-6 27 ft-lbs / 36.6 Nm -6 9/16-18 1 1/4
-8 40 ft-lbs / 54.2 Nm -8 3/4-16 1
-10 63 ft-lbs / 85.4 Nm -10 7/8-14 1
-12 90 ft-lbs / 122 Nm -12 1 1/16-12 1
-16 120 ft-lbs / 162.7 Nm -16 1 5/16-12 1
-20 140 ft-lbs / 190 Nm -20 1 5/8-12 1
-24 165 ft-lbs / 223.7 Nm -24 1 7/8-12 1

REV C SPECIFICATIONS
Torque Procedure 3 Working clockwise on the body hex fitting, make

a second mark with a permanent ink marker to
JIC 37° fittings indicate the proper tightening position.
1 Align the tube flare (hex nut) against the nose of Use the JIC 37° Fittings table on
the fitting body (body hex fitting) and tighten the the previous page to determine the
hex nut to the body hex fitting to hand-tight, correct number of flats for the
approximately 30 in-lbs / 3.4 Nm. proper tightening position.
2 Make a reference mark on one of the flats of the The marks indicate that the correct
hex nut, and continue it on to the body hex tightening positions have been
fitting with a permanent ink marker. determined. Use the second mark
on the body hex fitting to properly
a tighten the joint after it has been
loosened.
c
d
b
a
c
b
a hydraulic hose
b hex nut
c reference mark
d body hex fitting a body hex fitting
b reference mark
c second mark
4 Tighten the hex nut until the mark on the hex nut
is aligned with the second mark on the body hex
fitting.
5 Operate all machine functions and inspect the
hoses and fittings and related components to
confirm that there are no leaks.

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

April 2003 Section 3 • 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 perform each procedure avoided, will result in death or
as presented and scheduled could serious injury.
result in death, serious injury or
substantial 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.
Repair any machine damage or malfunction
before operating the machine. Yellow with safety alert symbol—
Keep records on all inspections for three years. potentially hazardous situation
Machines that have been out of service for a which, if not avoided, may cause
period longer than 3 months must complete the minor or moderate injury.
quarterly inspection. Yellow without safety alert
Unless otherwise specified, perform each symbol—used to indicate the
maintenance procedure with the machine in the
following configuration:
· Machine parked on a firm, level surface damage.
· Platform in the stowed position Green—used to indicate operation
· Key switch in the off position with the key
removed Indicates that a specific result is expected after
· Wheels chocked performing a series of steps.

Section 3 • Scheduled Maintenance Procedures April 2003
SCHEDULED MAINTENANCE PROCEDURES
Maintenance Symbols Legend Pre-delivery Preparation Report
The following symbols have been The pre-delivery preparation report contains
used in this manual to help checklists for each type of scheduled inspection.
communicate the intent of the
instructions. When one or more of Make copies of the Pre-delivery Preparation Report
the symbols appears at the to use for each inspection. Store completed forms
beginning of a maintenance as required.
procedure, it conveys the meaning Maintenance Schedule
below.
There are four types of maintenance inspections
that must be performed according to a schedule—
Indicates that tools will be required to daily, quarterly, annual, and two year. The
perform this procedure. Scheduled Maintenance Procedures Section and
the Maintenance Inspection Report have been
divided into four subsections—A, B, C and D. Use
the following chart to determine which group(s) of
Indicates that new parts will be required
procedures are required to perform a scheduled
to perform this procedure.
inspection.
Indicates that a cold motor or pump will Inspection Table or Checklist

be required to perform this procedure.
Daily or every 8 hours A
Quarterly or every 250 hours A+B

Indicates that dealer service will be
required to perform this procedure. Annually or every 1000 hours A+B+C
Two year or every 2000 hours A+B+C+D
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
as required.

Pre-Deliver
Pre-Deliveryy Preparation
Fundamentals Instructions
It is the responsibility of the dealer to perform the Use the operator’s manual on your machine.
Pre-delivery Preparation.
The Pre-delivery Preparation consists of completing
The Pre-delivery Preparation is performed prior to each the Pre-operation Inspection, the Maintenance items
delivery. The inspection is designed to discover if and the Function Tests.
anything is apparently wrong with a machine before it is
put into service. Use this form to record the results. Place a check in
the appropriate box after each part is completed.
A damaged or modified machine must never be used. Follow the instructions in the operator’s manual.
If damage or any variation from factory delivered
condition is discovered, the machine must be tagged If any inspection receives an N, remove the machine
and removed from service. from service, repair and re-inspect it. After repair, place
a check in the R box.
Repairs to the machine may only be made by a
qualified service technician, according to the Legend
manufacturer's specifications. Y = yes, completed
Scheduled maintenance inspections shall be performed N = no, unable to complete
by qualified service technicians, according to the R = repaired
manufacturer's specifications and the requirements Comments
listed in the responsibilities manual.
Pre-Delivery Preparation Y N R
Pre-operation inspection
completed
Maintenance items completed
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Genie Industries USA Genie UK

18340 NE 76th Street The Maltings, Wharf Road
PO Box 97030 Grantham, Lincolnshire
Redmond, WA 98073-9730 NG31- 6BH England
(425) 881-1800 (44) 1476-584333
Part No. 72876 Genie GS-1530 and GS-1930
Copyright © 2002 by Genie Industries. Genie® is a registered trademark of Genie Industries. 3-3
Rev A
This page intentionally left blank.

September 2006 Section 3 • Scheduled Maintenance Procedures
Maintenance Inspection Report

Model Checklist A - Rev C Y N R Checklist B - Rev C Y N R
A-1 Pre-operation inspect B-1 Batteries
Serial number
A-2 Function tests B-2 Electrical wiring
Date Perform after 40 hours: B-3 Tires and wheels
A-3 30 day service B-4 Emergency stop
Hour meter
Perform every 100 hours: B-5 Key switch
Machine owner A-4 Grease steer yokes B-6 Horn (if equipped)
B-7 Drive brakes
Inspected by (print) B-8 Drive speed - stowed
B-9 Drive speed - raised
Inspector signature
B-10 Hydraulic oil analysis
Inspector title B-11 Hydraulic tank return
filter
Inspector company B-12 Latch components
Instructions
Checklist C - Rev C Y N R
· Make copies of this report to use for
each inspection. C-1 Scissor arm wear pads
· Select the appropriate checklist(s) for

the type of inspection to be Checklist D - Rev B Y N R
performed. D-1 Hydraulic oil
Daily or 8 hour
Inspection: A
Quarterly or 250 hour
Inspection: A+B
Annual or 1000 hours
Inspection: A+B+C
2 Year or 2000 hour
Inspection: A+B+C+D
· Place a check in the appropriate box
after each inspection procedure is
completed.
· Use the step-by-step procedures in
this section to learn how to perform
these inspections.
· If any inspection receives an “N,” tag
and remove the machine from
service, repair and re-inspect it. After
repair, place a check in the “R” box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
Comments

Checklist A Procedures REV C
A-1 A-2
Perform Pre-operation Perform Function Tests
Inspection Completing the function tests is essential to safe
Completing a Pre-operation Inspection is essential machine operation. Function tests are designed to
to safe machine operation. The Pre-operation discover any malfunctions before the machine is
Inspection is a visual inspection performed by the put into service. A malfunctioning machine must
operator prior to each work shift. The inspection is never be used. If malfunctions are discovered, the
designed to discover if anything is apparently wrong machine must be tagged and removed from
with a machine before the operator performs the service.
function tests. The Pre-operation Inspection also Complete information to perform this procedure is
serves to determine if routine maintenance available in the Genie GS-1530 and GS-1930
procedures are required. Operator's Manual. Refer to the Operator's Manual
Complete information to perform this procedure is on your machine.
available in the Genie GS-1530 and GS-1930
Operator's Manual. Refer to the Operator's Manual
on your machine.

June 2006 Section 3 • Scheduled Maintenance Procedures
REV C CHECKLIST A PROCEDURES
A-3 A-4
Perform 30 Day Service Grease the Steer Yokes
The 30 day maintenance procedure is a one-time Genie specifications require that

sequence of procedures to be performed after the this procedure be performed every
first 30 days or 50 hours of use. After this interval, 100 hours of operation.
refer to the maintenance checklists for continued
scheduled maintenance. Regular application of lubrication to the steer yokes
is essential to good machine performance and
1 Perform the following maintenance procedures: service life. Continued use of an insufficiently
· B-3 Inspect the Tires and Wheels (including greased steer yoke will result in component
castle nut torque) damage.
· B-11 Replace the Hydraulic Tank Return 1 Locate the grease fitting on the top of the steer
Filter yoke.
2 Pump multipurpose grease into the steer yoke
until the steer yoke is full and grease is being
forced past the bearings. Repeat this step for
the other steer yoke.
Grease type Multipurpose grease

Section 3 • Scheduled Maintenance Procedures September 2006
Checklist B Procedures REV C
B-1 4 Remove the battery vent caps from all batteries

and check the specific gravity of each battery
Inspect the Batteries cell with a hydrometer.
Result: If any battery cell displays a specific
gravity of less than 1.026, the battery must be
replaced.
Proper battery condition is essential to good
machine performance and operational safety. 5 Check the battery acid level of each battery. If
Improper fluid levels or damaged cables and needed, replenish with distilled water to the
connections can result in component damage and bottom of the battery fill tube. Do not overfill.
hazardous conditions.
6 Install the battery vent caps.
Electrocution hazard. Contact with
7 Check each battery pack and verify that the
electrically charged circuits could
batteries are wired correctly.
result in death or serious injury.
Remove all rings, watches and a b c
other jewelry.
- +
Bodily injury hazard. Batteries QD1
contain acid. Avoid spilling or - + - -
contacting battery acid. Neutralize
battery acid spills with baking soda +
+
and water.
F6 -
+
Perform this procedure after fully + +
275A Fuse
charging the batteries.
For a more accurate determination
of battery condition, fully charge a quick disconnect QD1
the batteries and allow the b 275A fuse F6
batteries to rest 24 hours before c batteries B5
performing this procedure to allow
the battery cells to equalize.
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 retaining fasteners and
cable connections are tight.

REV C CHECKLIST B PROCEDURES
B-2 4 Raise the platform approximately 8 feet / 2.4 m

from the ground.
Inspect the Electrical Wiring
5 Rotate the safety arm away from the machine
and let it hang down.
6 Lower the platform onto the safety arm.
Maintaining electrical wiring in good condition is
Crushing hazard. Keep hands clear
essential to safe operation and good machine
of the safety arm when lowering
performance. Failure to find and replace burnt,
the platform.
chafed, corroded or pinched wires could result in
unsafe operating conditions and may cause 7 Inspect the center chassis area and scissor
component damage. arms for burnt, chafed and pinched cables.
Electrocution hazard. Contact with 8 Inspect the following areas for burnt, chafed,
electrically charged circuits could corroded, pinched and loose wires:
· ECM to platform controls
Remove all rings, watches and
other jewelry. · Power to platform wiring
1 Inspect the following areas for burnt, chafed, 9 Inspect for a liberal coating of dielectric grease
corroded and loose wires: in all connections between the ECM and the
platform controls.
· Ground control panel
10 Raise the platform and return the safety arm to
· Hydraulic power unit module tray the stowed position.
· Battery pack module tray
11 Lower the platform to the stowed position and
· Scissor arms turn the machine off.
· Platform controls
2 Inspect for a liberal coating of dielectric grease
in all connections between the ECM and the
platform controls.
3 Turn the key switch to ground control and pull
out the red Emergency Stop button to the on
position at both the ground and platform
controls.

CHECKLIST B PROCEDURES REV C
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
to safe machine operation. The machine can be
operated from the ground or platform controls and
the activation of one or the other is accomplished
Maintaining the tires and wheels in good with the key switch. Failure of the key switch to
condition is essential to safe operation and good activate the appropriate control panel could cause a
performance. Tire and/or wheel failure could result hazardous operating situation.
in a machine tip-over. Component damage may
Perform this procedure from the
also result if problems are not discovered and
ground using the platform controls.
repaired in a timely fashion.
Do not stand in the platform.
1 Check the tire surface and sidewalls for cuts, 1 Pull out the red Emergency Stop button to the
cracks, punctures and unusual wear. on position at both the ground and platform
2 Check each wheel for damage, bends and controls.
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. Refer to Section 2, ground controls.
Specifications.
Result: The machine functions should not
Always replace the cotter pin with
operate.
a new one when removing the
castle nut or when checking the 4 Turn the key switch to ground control.
torque of the castle nut.
5 Check the machine functions from the platform
4 Install a new cotter pin. Bend the cotter pin to controls.
lock it in place.
Result: The machine functions should not
operate.
6 Turn the key switch to the off position.
Result: No function should operate.
3 - 10 Genie GS-1530 and GS-1930 Part No. 72876

B-5
Test the Automotive-style Horn
(if equipped)
A functioning horn is essential to safe machine
operation. The horn is activated at the platform
controls and sounds at the ground as a warning to
ground personnel. An improperly functioning horn
will prevent the operator from alerting ground
personnel of hazards or unsafe conditions.
1 Turn the key switch to platform control and

pull out the red Emergency Stop button to the
on position at both the ground and
platform controls.
2 Push down the horn button at the platform
controls.
Result: The horn should sound.
Part No. 72876 Genie GS-1530 and GS-1930 3 - 11

B-6 6 Bring the machine to top drive speed before

reaching the test line. Release the function
Test the Drive Brakes enable switch or the joystick when your
reference point on the machine crosses the
test line.
7 Measure the distance between the test line and
Proper brake action is essential to safe machine
your machine reference point. Refer to Section
operation. The drive brake function should operate
2, Specifications.
smoothly, free of hesitation, jerking and unusual
noise. Hydraulically-released individual wheel Result: The machine stops within the specified
brakes can appear to operate normally when not braking distance. No action required.
fully operational.
Result: The machine does not stop within the
Perform this procedure with the specified braking distance. Proceed to step 8
machine on a firm, level surface and determine if the machine is equipped with
that is free of obstructions. a dynamic braking valve.
Be sure the platform extension The brakes must be able to hold

deck is fully retracted and the the machine on any slope it is able
platform is in the stowed position. to climb.
1 Mark a test line on the ground for reference. 8 Disconnect the battery pack from the machine.
2 Turn the key switch to platform control and pull Electrocution hazard. Contact with
out the red Emergency Stop button to the on electrically charged circuits could
position at both the ground and platform result in death or serious injury.
controls. Remove all rings, watches and
other jewelry.
3 Lower the platform to the stowed position.
9 Locate the drive forward/reverse valve on the
4 Press the drive function select button. Refer to function manifold. Refer to Illustrations 2.
Illustration 1.
Stop
®
Illustration 1
a drive function select button BN8
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.
a
Illustration 2
a drive forward/reserve valve

10 Tag the forward and the reverse valve coils. 16 Connect the battery pack to the machine.
Remove the coils from the valve.
17 Replace the brakes and repeat this procedure
The forward valve coil has white beginning with step 1. Refer to Repair Procedure
and brown wires attached. 9-1, How to Remove a Drive Brake.
The reverse valve coil has 18 Contact the Genie Industries Service Parts
white/black and brown wires Department and order kit part number 105457.
attached.
19 Install the new valve received in the kit and
For reassembly, it will be helpful to mark the new valve with a white paint pen to
leave the wire harness attached to identify new valve installation.
the valve coils.
20 Repeat this procedure beginning with step 1.
11 Remove the drive forward/reverse valve from the
If the machine fails to stop within the specified
function manifold. Cap the open port of the
stopping distance after installing new brakes,
manifold.
please contact the Genie Industries Scissors
12 Carefully inspect the hex portion of the valve for Service Department, 1-800-536-1800 Ext. 8710.
an identification stamp.
Result: SV10-4727 is stamped on the hex
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.
15 Install the coil nut onto the valve and tighten.
Torque to 60 in-lbs / 7 Nm.

B-7 5 Choose a point on the machine; i.e., contact

patch of a tire, as a visual reference for use
Test the Drive Speed - when crossing the start and finish lines.
Stowed Position 6 Bring the machine to top drive speed before
reaching the start line. Begin timing when your
reference point on the machine crosses the
start line.
Proper drive functions are essential to safe
machine operation. The drive function should 7 Continue at full speed and note the time when
respond quickly and smoothly to operator control. your reference point on the machine passes
Drive performance should also be free of hesitation, over the finish line. Refer to Section 2,
jerking and unusual noise over the entire Specifications.
proportionally controlled speed range.
Perform this procedure with the

machine on a firm, level surface
that is free of obstructions.
1 Create start and finish lines by marking two
lines on the ground 40 feet / 12.2 m apart.
2 Turn the key switch to platform control and pull
controls.
4 Models with drive function select button:
Press the drive function select button.
Stop
®
a drive function select button BN8

B-8 4 Press and hold the function enable switch on the

joystick.
Test the Drive Speed -
5 Raise the platform approximately 4 feet / 1.2 m
Raised Position from the ground.
6 Models with lift function enable button:
Release the lift function enable button.
Proper drive functions are essential to safe Models with drive function select button:
machine operation. The drive function should Press the drive function select button.
respond quickly and smoothly to operator control. 7 Choose a point on the machine; i.e., contact
Drive performance should also be free of patch of a tire, as a visual reference for use
hesitation, jerking and unusual noise over the when crossing the start and finish lines.
entire proportionally controlled speed range.
8 Bring the machine to top drive speed before
Perform this procedure with the reaching the start line. Begin timing when your
machine on a firm, level surface reference point on the machine crosses the
that is free of obstructions. start line.
1 Create start and finish lines by marking two 9 Continue at full speed and note the time when
lines on the ground 40 feet / 12.2 m apart. your reference point on the machine passes
over the finish line. Refer to Section 2,
Specifications.
controls.
3 Models with lift function enable button: Press
and hold the lift function enable button.
Models with drive function select button:
Press the lift function select button.
Stop
®
a
Stop
®
a lift function enable button BN9

b lift function select button BN9
c drive function select button BN8

B-9 B-10
Perform Hydraulic Oil Analysis Replace the Hydraulic Tank
Return Filter
Replacement or testing of the hydraulic oil is

essential for good machine performance and Replacement of the hydraulic tank return filter is
service life. Dirty oil and a clogged suction strainer essential for good machine performance and
may cause the machine to perform poorly and service life. A dirty or clogged filter may cause the
continued use may cause component damage. machine to perform poorly and continued use may
Extremely dirty conditions may require oil changes cause component damage. Extremely dirty
to be performed more often. conditions may require that the filter be replaced
Before replacing the hydraulic oil, more often.
the oil may be tested by an oil Beware of hot oil. Contact with
distributor for specific levels of hot oil may cause severe burns.
contamination to verify that
changing the oil is necessary. If The hydraulic tank return filter is
the hydraulic oil is not replaced mounted on the function manifold
at the two year inspection, test next to the hydraulic power unit.
the oil quarterly. Replace the oil
1 Clean the area around the oil filter. Remove the
when it fails the test. See D-1,
filter with an oil filter wrench.
Test or Replace the Hydraulic Oil.
2 Apply a thin layer of oil to the new oil filter
gasket.
3 Install the new filter and tighten it securely by
hand.
4 Use a permanent ink marker to write the date
and number of hours from the hour meter
(if equipped) on the filter.
controls.
6 Activate and hold the platform up toggle switch.
7 Inspect the filter and related components to
be sure that there are no leaks.
8 Clean up any oil that may have spilled.

B-11 Models after serial number 35799:

Check the Module Tray Latch 1 Lubricate each module tray rotary latch. Using
Components light oil, apply a few drops to each of the
springs and to the sides of the rotary latch
mechanism.
Maintaining the module tray latch components in

good condition is essential to good performance
a
and service life. Failure to detect worn out latch
components may result in module trays opening
unexpectedly, creating an unsafe operating
condition.
Models before serial number 35800:

b
1 Open both module trays and 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 a rotary latch springs
latch fails to securely hold the module tray b module tray rotary latch
closed.
2 Inspect each module tray latch U-bolt. Tighten
The module tray latch pad is any loose U-bolt retaining fastener before the
attached to the drive chassis and latch fails to securely hold the module tray
located above the module tray closed.
latch when the module tray is
closed.

Checklist C Procedure REV C
C-1
Check the Scissor Arm Wear
Pads
Maintaining the scissor arm wear pads in good

condition is essential to safe machine operation.
Continued use of worn our wear pads may result in
component damage and unsafe operating
conditions.

platform in the stowed position.
1 Measure the thickness of each scissor arm wear
pad at the non-steer end of the machine.
2 Replace both wear pads if either one is less
than 0.21 inch / 5.3 mm thick. Refer to Repair
Procedure 3-1 or 3-2, How to Replace the
Scissor Arm Wear Pads.
3 Apply a thin layer of dry film lubricant to the area
of the chassis where the scissor arm wear pads
make contact.
Scissor arm wear pad specification
Wear pad thickness, minimum 0.21 inch

5.3 mm
0.21 inches / 5.3 mm

REV B
Checklist D Procedure
D-1 3 Remove the drain plug from the hydraulic tank
and allow all of the oil to drain into a suitable
Test or Replace the Hydraulic Oil container. Refer to Section 2, Specifications, for
capacity information.
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 a clogged suction strainer
the oil pressure to dissipate
may 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 Tag, disconnect and plug the hydraulic tank
return hose at the top of the hydraulic tank.
Before replacing the hydraulic oil,
the oil may be tested by an oil 5 Remove the motor controller mounting bracket
distributor for specific levels of retaining fasteners and move the motor
contamination to verify that controller to the side.
changing the oil is necessary. If 6 Remove the return filter mounting bracket
the hydraulic oil is not replaced fasteners from the manifold. Push the filter and
at the two year inspection, test accumulator out of the way.
the oil quarterly. Replace the oil
when it fails the test. 7 Tag, disconnect and plug the hydraulic pump
inlet hose at the side of the hydraulic tank.
platform in the stowed position. 8 Remove the hydraulic tank retaining fasteners
and remove the hydraulic tank from the
1 Disconnect the battery pack from the machine.
machine.
2 Open the power unit module tray.
9 Remove the suction strainer from the tank and
clean it using a mild solvent.
10 Clean the inside of the hydraulic tank using a
mild solvent.
11 Install the suction strainer using thread sealer on
the threads.

CHECKLIST D PROCEDURES REV B
12 Install and tighten the hydraulic tank drain plug 16 Install the hydraulic pump return hose onto the
using thread sealer on the threads. Torque to fitting at the top of the hydraulic tank and
specification. tighten the hose clamp.
17 Fill the tank with hydraulic oil until the fluid is
Torque specifications within the FULL and ADD marks on the oil level
Hydraulic tank drain plug, dry 75 in-lbs indicator decal. Do not overfill.
8.5 Nm
18 Activate the pump to fill the hydraulic system
Hydraulic tank drain plug, lubricated 56 in-lbs with oil and bleed the system of air and check
6.3 Nm for leaks.
Component damage hazard. The
13 Install the hydraulic tank and install and tighten pump can be damaged if operated
the hydraulic tank retaining fasteners. Torque to without oil. Be careful not to empty
specification. the hydraulic tank while in the
process of filling the hydraulic
Torque specifications system.
Hydraulic tank retaining fasteners, dry 70 in-lbs 19 Repeat steps 17 through 18 until the hydraulic
7.9 Nm system and tank are both full.
Hydraulic tank retaining fasteners, lubricated 52 in-lbs 20 Clean up any oil that may have spilled. Properly
5.9 Nm discard the used oil and filter.
14 Install the hydraulic pump inlet hose onto the

fitting at the side of the hydraulic tank and
tighten the hose clamp.
15 Install the hydraulic filter bracket and the motor
controller bracket and tighten the fasteners.
connectors on the motor controller
will short to ground if the motor
controller mounting bracket is not
installed before the battery pack is
connected.

April 2003 Section 4 • 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. To
Repair procedures shall be completed by a re-assemble, perform the disassembly steps in
person trained and qualified on the repair of this reverse order.
machine.
Symbols Legend
Immediately tag and remove from service a
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-1530 and GS-1930 Operator's Manual. avoided, will result in death or
serious injury.
Be sure that all necessary tools and parts are
available and ready for use. Orange—used to indicate the
Read each procedure completely and adhere to
the instructions. Attempting shortcuts may
avoided, could result in death or
produce hazardous conditions.
serious injury.
Unless otherwise specified, perform each repair
Yellow with safety alert symbol—
procedure with the machine in the following
configuration:
potentially hazardous situation
· Machine parked on a firm, level surface which, if not avoided, may cause
minor or moderate injury.
· Platform in the stowed position
Yellow without safety alert
· Key switch in the off position with the key symbol—used to indicate the
removed presence of a potentially
· Wheels chocked hazardous situation which, if not
· All external AC power supply disconnected damage.
from the machine
Green—used to indicate operation
Indicates that a specific result is expected after
performing a series of steps.

Section 4 • Repair Procedures April 2003
Platform Controls REV B
The platform controls, used to operate the machine

from the platform or while standing on the ground,
can also be used to tune the performance of the P2
9F
ON
1
2
EMERGENCY STOP
3
machine.
ALCO ADF085
h
4
BUTTON
5
6
7
2
8
a
Moving the joystick or activating a button or toggle
1
switch sends a signal to the Electronic Control JC1 U3
JOYSTICK b
Module (ECM). When the ECM is in the function CONTROLLER
PLATFORM
CONTROLS
CIRCUIT
mode, the platform controls are used to operate g BOARD
the various machine functions. When the ECM is in c

the programming mode (PS is shown in the
diagnostic display window), the platform controls f
d
are used to adjust the function speed parameters.
The platform controls contains an electronic circuit

board, joystick, membrane decal, buttons, switches
and LEDs. Potentiometer-equipped joysticks can
be adjusted to maintain performance. H1
e ALARM
For further information or assistance, consult the

Models before serial number 51015
Genie Industries Service Department. (potentiometer-equipped joystick)
P2
EMERGENCY STOP
BUTTON
2 5. 1 4.
2
a
NC 1
U3
9F
ON
1
PLATFORM CONTROLS
f h
2
CIRCUIT BOARD
ALCO ADF085
4
JC1 5
6
7
JOYSTICK
8
S/N Al 00000000
P/N 000000
Date 0000
CONTROLLER
H1 e
ALARM
Models after serial number 51014

(hall effect joystick)
a red Emergency Stop button P2

b platform controls circuit board U3
c circuit board retaining fastener
d circuit board voltage regulator D7
e alarm H1
f joystick controller JC1
g potentiometer R15
h DIP switch SW25

REV B PLATFORM CONTROLS
1-1 1-2
Circuit Boards Joystick Controller
How to Remove the Platform Maintaining the joystick at the proper setting is
essential to safe machine operation. The joystick
Controls Circuit Board should operate smoothly over its entire range of
1 Push in the red Emergency Stop button to the motion.
off position at both the ground and platform A Hall-effect joystick controller was incorporated
controls. into the platform controls after serial number
2 Remove the platform control box lid retaining 51014. It does not require any calibration.
fasteners. Open the control box lid.
How to Calibrate the Joystick
3 Locate the membrane circuit board mounted to
the inside of the platform control box lid.
Controller
(before serial number 51015)
electrically charged circuits could This procedure applies only
result in death or serious injury. to models with a
Remove all rings, watches and potentiometer-equipped joystick.
other jewelry.
1 Turn the key switch to platform controls and pull
Component damage hazard. out the red Emergency Stop button to the on
Electrostatic discharge (ESD) can position at both the ground and platform
damage printed circuit board controls.
components. Maintain firm contact
with a metal part of the machine 2 Remove the platform control box lid retaining
that is grounded at all times when fasteners. Open the control box lid.
handling printed circuit boards OR Electrocution hazard. Contact with
use a grounded wrist strap. electrically charged circuits could
4 Carefully disconnect the three wire harness result in death or serious injury.
connectors from the platform controls circuit Remove all rings, watches and
board. other jewelry.
5 Carefully remove the platform controls circuit

board retaining fasteners.
6 Carefully remove the platform controls circuit
board from the platform control box lid.

PLATFORM CONTROLS REV B
3 Locate the potentiometer on the base of the 5 Loosen the set screw on the potentiometer
joystick controller. shaft just enough to let the shaft rotate.
6 With the joystick in the neutral position, adjust
the potentiometer to 2.05V DC at the
potentiometer shaft. Tighten the set screw.
7 Move the joystick full stroke in both directions
several times. Return the joystick to the neutral
position.
Result: The volt meter should read 2.05V DC.
Result: If the volt meter does not read 2.05V
DC, repeat steps 5 through 7.
9 Wait a few seconds and then turn the key
switch to platform controls.
Result: The error light on the top of the platform
control box should go out and Code 47 should
a joystick controller JC1
b potentiometer shaft
not be present on the diagnostic display at the
c potentiometer set screw battery module side of the machine.
d platform controls circuit board U3
e potentiometer R15 Result: If the error indicator light is still on or if
f brown wire code 47 is present on the diagnostic display,
g purple wire repeat steps 5 through 9.
4 With a volt meter set to read DC voltage, place 10 Turn the key switch to the off position.
the volt meter negative lead on the purple wire.
Place the volt meter positive lead on the brown 11 Close the lid and install the fasteners.
wire.
other jewelry.

1-3 4 Press and hold the lift function enable button

OR press the lift function select button.
Controller Adjustments
Platform lift speed and raised drive speed,
controlled by the ECM which is located in the
battery pack module tray, are adjustable to
compensate for wear in the hydraulic pump and
drive motors.
The raised drive speed and lift speed are
determined by the percentage of total controller
output. For further information or assistance,
consult the Genie Industries Service Department.
Tip-over hazard. Do not adjust the

lift and/or drive speed higher than
specified in this procedure. Setting
the function speeds greater than
specifications could cause the
machine to tip over resulting in
death or serious injury.
Tip-over hazard. This procedure a yellow arrow
must only be performed by a b joystick controller JC1
c lift function select button BN9
trained service professional. d red Emergency Stop button P2
Attempting this procedure without e lift function enable button BN9
the necessary skills will result in
death or serious injury. 5 Slowly move the joystick in the direction
indicated by the yellow arrow.
Select a test area that is firm, level
and free of obstructions. Result: The software revision level will appear
in the diagnostic display.
How to Determine the Revision Result: If the software revision level does not
Level appear in the diagnostic display, turn the key
switch to ground control and repeat steps 4 and
1 Remove the platform controls from the platform. 5. The software revision level will appear in the
2 Place the platform controls close to the diagnostic display.
diagnostic display on the power unit side of the 6 Push in the red Emergency Stop button to the
machine. off position at both the ground and platform
3 Turn the key switch to platform control and pull controls and turn the key switch to the off
out the red Emergency Stop buttons to the on position.
controls.

How to Adjust the Lift Speed 3 Press and hold the lift function enable and horn
buttons, and turn the key switch to platform
Tip-over hazard. Do not adjust the controls.
specified in this procedure. Setting Result: The diagnostic display will show "PS."
Tip-over hazard. This procedure
must only be performed by a
trained service professional.
Attempting this procedure without
the necessary skills will result in
death or serious injury. a function enable switch SW5
b joystick controller JC1 with thumb
Software revision A0 and B0: steering rocker SW6
c horn button BN5
1 Push in the red Emergency Stop button to the d machine on incline button
e lift function enable button BN9
off position at both the ground and platform f red Emergency Stop button P2
controls. Turn the key switch to the off position.
4 Release the lift function enable and horn
2 Pull out the red Emergency Stop button to the buttons.
on position at both the ground and platform
controls. 5 Press and hold the lift function enable button.
Result: The diagnostic display will show the
maximum lift speed percentage.
6 Use the steering thumb rocker switch on the
joystick to increase or decrease the maximum
lift speed percentage. Refer to Section 2,
Specifications.
Any change in software settings
will not take effect until the key
switch is turned to the off position.

Software revision C0 and higher: 5 Press the lift function select button.
1 Push in the red Emergency Stop button to the 6 Use the steering thumb rocker switch on the
off position at the ground and platform controls. joystick to increase or decrease the maximum
Turn the key switch to the off position. lift speed percentage. Refer to Section 2,
Specifications.
2 Pull out the red Emergency Stop button to the
on position at the ground and platform controls. 7 Turn the key switch to the off position.
3 At the platform controls, press and hold the lift Any change in software settings
function select and horn buttons and turn the will not take effect until the key
key switch to platform controls. switch is turned to the off position.
Result: The diagnostic display will show "PS."
a function enable switch SW5

steering rocker SW6
c horn button BN5
d machine on incline button
e lift function select button BN9
f drive function select BN8
g red Emergency Stop button P2
4 Release the lift function select and horn

buttons.

How to Adjust the Stowed Drive 5 Press the drive function select button.
Speed Result: The diagnostic display will show the
stowed drive speed percentage.
Tip-over hazard. Do not adjust the
trained service professional. a function enable switch SW5
Attempting this procedure without b joystick controller JC1 with thumb
the necessary skills will result in steering rocker SW6
death or serious injury. c horn button BN5
d machine on incline button BN6
Software revision D0 and higher: e lift function select button BN9
1 Push in the red Emergency Stop button to the g red Emergency Stop button P2
off position at the ground and platform controls. 6 Use the steering thumb rocker switch on the
Turn the key switch to the off position. joystick to increase or decrease the stowed
2 Pull out the red Emergency Stop button to the drive speed percentage. Refer to Section 2,
on position at the ground and platform controls. Specifications.
3 Press and hold the lift function select and horn 7 Turn the key switch to the off position.
buttons and turn the key switch to platform Any change in software settings
controls. will not take effect until the key
Result: The diagnostic display will show "PS." switch is turned to the off position.

buttons.

How to Adjust the Raised Drive 3 Press and hold the lift function enable and horn
Speed controls.
Tip-over hazard. Do not adjust the Result: The diagnostic display will show "PS."
trained service professional.
Attempting this procedure without a function enable switch SW5
the necessary skills will result in b joystick controller JC1 with thumb
death or serious injury. steering rocker SW6
c horn button BN5
Software revision A0 and B0: d machine on incline button
e lift function enable button BN9
1 Push in the red Emergency Stop button to the f red Emergency Stop button P2
off position at the ground and platform controls.
4 Release the lift function enable and horn
Turn the key switch to the off position.
buttons.
5 Press and hold the horn button.
on position at the ground and platform controls.
raised drive speed percentage.
raised drive speed percentage. Refer to Section
2, Specifications.
Any change in software settings

Software revision C0: 6 Press and hold the horn button.

1 Push in the red Emergency Stop button to the Result: The diagnostic display will show the
off position at the ground and platform controls. raised drive speed percentage.
2 Pull out the red Emergency Stop button to the joystick to increase or decrease the maximum
on position at the ground and platform controls. lift speed percentage. Refer to Section 2,
Specifications.
3 Press and hold the lift function select and horn
buttons, and turn the key switch to platform 8 Turn the key switch to the off position.
controls. Any change in software settings
Result: The diagnostic display will show "PS". will not take effect until the key

steering rocker SW6
c horn button BN5

buttons.
5 Press the drive function select button.

Software revision D0 and higher: 6 Use the steering thumb rocker switch on the
1 Push in the red Emergency Stop button to the lift speed percentage. Refer to Section 2,
off position at the ground and platform controls. Specifications.
on position at the ground and platform controls. Any change in software settings
3 Press and hold the lift function select and horn switch is turned to the off position.
controls.

steering rocker SW6
c horn button BN5

buttons.
5 Press and hold the horn button.
raised drive speed percentage.

1-4 How to Determine the DIP Switch

Software Configuration Configuration
1 Remove the platform controls from the platform.
The ECM (Electronic Control Module) contains
programming for all configurations of the Genie 2 Place the platform controls close to the
GS-1530 and GS-1930. The platform controls can diagnostic display on the power unit side of the
be adjusted to a different configuration by changing machine.
the combination of the DIP switch settings. The
DIP switch is located on the circuit board inside the 3 Turn the key switch to platform control and pull
platform control box. out the red Emergency Stop buttons to the on
DIP switches have two positions - ON or OFF. When position at both the ground and platform
reading the DIP switch code in the DIP Switch controls.
Code Chart, the ON and OFF are represented by the 4 Press and hold the lift function enable button
numbers 1 (ON) and 0 (OFF). OR press the lift function select button.
Select a test area that is firm, level 5 Slowly move the joystick in the direction
and free of obstructions. indicated by the blue arrow.
Result: The DIP switch configuration will appear
in the diagnostic display.

How to Set the DIP Switch Codes 4 Locate the DIP switch on the circuit board.
Move the DIP switch settings to correspond
Tip-over hazard. Do not adjust the with the configuration of the machine options,
DIP switch settings to other than indicated in the DIP Switch Code Chart.
what is specified in this procedure. SW25
Exceeding specifications could DIP
SWITCH
P2
EMERGENCY
STOP
cause the machine to tip over d BUTTON
2
resulting in death or serious injury.
1
JC1
JOYSTICK
U3
CONTROLLER PLATFORM
If replacing the circuit board, note CONTROLS
CIRCUIT
BOARD a
the toggle positions on the DIP
c
switch. Set the DIP switch on the
new circuit board to the same
configuration as the old board.
H1
ALARM
1 Push in the red Emergency Stop button to the

off position at the ground and platform controls.
2 Remove the fasteners securing the top of the ON (1)
b
platform controls and open the platform control OFF (0)
box. 1 2 3 4 5 6 7 8
3 Rotate the platform control box to the position

a platform controls circuit board U3
shown to correctly identify the configuration of b enlarged view of DIP switch SW25
the DIP switch settings. c joystick controller JC1
d DIP switch SW25
5 Close the lid and install the fasteners.

6 Confirm the settings. See 1-3, How to
Determine the DIP Switch Configuration.
7 Push in the red Emergency Stop button to the
off position at both the ground and platform
controls and turn the key switch to the off
position.
Any change in DIP settings will not
take effect until the key switch is
turned to the off position.

DIP Switch Code Chart DIP Switch Function Definitions

A mark in the column indicates that the machine If replacing the circuit board, note
configuration includes this option. the toggle positions on the DIP
switches. Set the DIP switches on
the new circuit board to the same
OFF for GS-30 models
configuration of the old board.
Battery Drain Alarm

OFF for all models
Overload Cut Out
Lift Drive Cut Out
Diagnostic DIP Motion Beacon: The motion beacon option flashes
Motion Beacon
Descent Delay
Motion Alarm
Display Switch only when operating a function.

Code Code
Motion Alarm: The motion alarm will sound when
operating any function.
00 00000000 Lift/Drive Cut Out: This cuts out lift and drive
01 00000100 • functions when the machine exceeds the rating on
the serial plate. Required for Europe and Australia
02 00001000 •
before serial number 48817. Installed on all
03 00010000 •
machines after serial number 48816.
04 00100000 •
05 01000000 • Overload: This cuts out all functions when the
06 00001100 • • pressure sensor is overloaded. The Emergency
07 00010100 • • Stop button must be cycled before any function
08 00100100 • • can be resumed. Required for France.
09 01000100 • •
Descent Delay: This option halts descent at
10 00011100 • • • approximately 7 feet / 2.1 m. All controls must be
11 00101100 • • • released for 4 to 6 seconds before descent is
12 01001100 • • • re-enabled. Required for Europe.
13 00110100 • • •
14 01010100 • • • Battery Drain Alarm: When the machine is turned
15 01100100 • • • on and no function is activated for 10 minutes, the
16 00111100 • • • • alarm will sound once every 3 seconds. This option
17 01011100 • • • • can be activated by moving DIP switch 7 to
position 1.
18 01101100 • • • •
19 01110100 • • • •
DIP Switch Legend
20 01111100 • • • • •
ON (1) ON ALCO ADFO8S
21 00011000 • •
22 00101000 • •
• • OFF (0)
23 01001000 OE 1 2 3 4 5 6 7 8
24 00111000 • • •
OFF for GS-1530 OFF for
25 01011000 • • • all models
and GS-1930
26 01101000 • • •
Motion Beacon Battery Drain Alarm
27 01111000 • • • •
28 00110000 • • Motion Alarm Descent Delay
29 01010000 • •
Lift/Drive Cut Out Overload Cut Out
30 01110000 • • •
31 01100000 • •

DIP Switch Settings

Diagnostic Diagnostic Diagnostic Diagnostic
ON ALCO ADFO8S ON ALCO ADFO8S ON ALCO ADFO8S ON ALCO ADFO8S
display code display code display code display code
00 08 16 24
OE 1 2 3 4 5 6 7 8 OE 1 2 3 4 5 6 7 8 OE 1 2 3 4 5 6 7 8 OE 1 2 3 4 5 6 7 8
DIP switch code: 00000000 DIP switch code: 00100100 DIP switch code: 00111100 DIP switch code: 00111000
Options: None Options: motion alarm, descent delay Options: motion alarm, lift drive cut out, Options: motion alarm, lift drive cut out,
overload cut out, descent delay overload cut out
Diagnostic ON ALCO ADFO8S Diagnostic ON ALCO ADFO8S Diagnostic ON ALCO ADFO8S Diagnostic ON ALCO ADFO8S
01 09 17 25
OE 1 2 3 4 5 6 7 8 OE 1 2 3 4 5 6 7 8 OE 1 2 3 4 5 6 7 8 OE 1 2 3 4 5 6 7 8
Options: descent delay Options: motion beacon, descent delay Options: motion beacon, lift drive cut out, Options: motion beacon, lift drive cut out,
overload cut out, descent delay overload cut out
Diagnostic ON ALCO ADFO8S

Diagnostic ON ALCO ADFO8S Diagnostic ON ALCO ADFO8S Diagnostic ON ALCO ADFO8S
02 10 18 26
OE 1 2 3 4 5 6 7 8 OE 1 2 3 4 5 6 7 8 OE 1 2 3 4 5 6 7 8 OE 1 2 3 4 5 6 7 8
Options: overload cut out Options: lift drive cut out, overload cut out, Options: motion beacon, motion alarm, Options: motion beacon, motion alarm,
descent delay overload cut out, descent delay overload cut out
03 11 19 27
OE 1 2 3 4 5 6 7 8 OE 1 2 3 4 5 6 7 8 OE 1 2 3 4 5 6 7 8 OE 1 2 3 4 5 6 7 8
Options: lift drive cut out Options: motion alarm, overload cut out, Options: motion beacon, motion alarm, Options: motion beacon, motion alarm,
descent delay lift drive cut out, descent delay lift drive cut out, overload cut out
04 12 20 28
OE 1 2 3 4 5 6 7 8 OE 1 2 3 4 5 6 7 8 OE 1 2 3 4 5 6 7 8 OE 1 2 3 4 5 6 7 8
Options: motion alarm Options: motion beacon, overload cut out, Options: motion beacon, motion alarm, Options: motion alarm, lift drive cut out
descent delay lift drive cut out, overload cut out, descent delay
05 13 21 29
OE 1 2 3 4 5 6 7 8 OE 1 2 3 4 5 6 7 8 OE 1 2 3 4 5 6 7 8 OE 1 2 3 4 5 6 7 8
Options: motion beacon Options: motion alarm, lift drive cut out, Options: lift drive cut out, overload cut out Options: motion beacon, lift drive cut out
descent delay
06 14 22 30
OE 1 2 3 4 5 6 7 8 OE 1 2 3 4 5 6 7 8 OE 1 2 3 4 5 6 7 8 OE 1 2 3 4 5 6 7 8
Options: overload cut out, descent delay Options: motion beacon, lift drive cut out, Options: motion alarm, overload cut out Options: motion beacon, motion alarm,
descent delay lift drive cut out
07 15 23 31
OE 1 2 3 4 5 6 7 8 OE 1 2 3 4 5 6 7 8 OE 1 2 3 4 5 6 7 8 OE 1 2 3 4 5 6 7 8
Options: lift drive cut out, descent delay Options: motion beacon, motion alarm, Options: motion beacon, overload cut out Options: motion beacon, motion alarm
descent delay

Platform Components REV A
2-1 7 Support the platform with a forklift at the

non-steer end. Do not apply any lifting
Platform pressure.
8 Attach a strap from the platform railings to the
How to Remove the Platform carriage on the forklift to help support the
Perform this procedure with the platform.
platform extension fully retracted 9 Remove the platform pivot pin retaining
and locked in position. fasteners from the platform pivot pins at the
1 Lower the platform to the stowed position. steer end of the machine.
2 Disconnect the battery packs from the machine. 10 Use a slide hammer to remove the pins.
Electrocution hazard. Contact with Crushing hazard. The platform will

electrically charged circuits could fall if not properly supported.
cause death or serious injury. 11 Remove the plugs from the access holes in the
Remove all rings, watches and side of the platform.
other jewelry.
12 Lift the steer end of the platform slightly to clear
3 Remove the retaining fastener securing 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
4 Twist to disconnect the plug from the platform the access holes in the side of the platform.
controls. 13 Remove the platform pivot pin retaining
5 Remove the cover from the AC outlet. Label fasteners from the platform pivot pins at the
and disconnect the wiring from the outlet. non-steer end of the machine.
Electrocution hazard. Contact with 14 Use a slide hammer to remove the pins.
electrically charged circuits could Crushing hazard. The platform will
result in death or serious injury. fall if not properly supported.
other jewelry. 15 Carefully lift the platform off of the machine and
place it on a structure capable of supporting it.
6 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.

REV A PLATFORM COMPONENTS
2-2 7 Remove the platform roller wheels from the

machine.
Platform Extension
8 Carefully slide the platform extension out from
the platform and place it on a structure capable
How to Remove the of supporting it.
Platform Extension
How to Replace the Platform
Extension Wear Pads
2 Extend the platform approximately 3 feet / 1 m.
1 Remove the Platform Extension. See 2-2, How
3 Remove the platform controls from the platform to Remove the Platform Extension.
and lay them off to the side of the machine.
2 Drill out the rivets which hold the wear pads in
4 Support the platform extension with a forklift at place.
the steer end. Do not apply any lifting pressure.
3 Install the new wear pads using new rivets.
5 Attach a strap from the platform extension
railings to the carriage on the forklift to help When installing new rivets, make
support the platform extension. sure the rivet heads are not above
the surface of the wear pad.
6 Remove the two retaining fasteners from each
platform extension roller bracket assembly.
Remove each assembly from the machine.
Do not remove the platform roller
bolt.
a roller bracket assembly

b assembly retaining fastener
c platform roller bolt

Scissor Components REV A
1 11
12
3
13
4 14
15
6 16
7 17
18
8
19
9
10
GS-1530
Steer End Non-steer End
1 Number 4 pivot pin (steer end) 11 Number 4 pivot pin (non-steer end)
2 Number 3 center pivot pin 12 Number 3 inner arm
3 Lift cylinder rod-end pivot pin 13 Number 3 outer arm
5 Number 2 center pivot pin (2 pins) 15 Lift cylinder
6 Number 2 inner arm 16 Number 2 outer arm
8 Number 1 center pivot pin 18 Lift cylinder barrel-end pivot pin
9 Number 1 inner arm 19 Number 1 outer arm
10 Number 1 pivot pin (steer end) (2 pins)

REV A SCISSOR COMPONENTS
3-1 3 Attach a lifting strap from an overhead crane to

the number 3 outer arm (index #13).
Scissor Assembly,
4 Remove the external snap rings from the
GS-1530 number 3 center pivot pin (index #2).
How to Disassemble the 5 Use a soft metal drift to remove the number 3
center pivot pin (index #2).
Scissor Assembly,
GS-1530 number 3 pivot pin (index #14).
Bodily injury hazard. This 7 Use a soft metal drift to remove the number 3
procedure requires specific repair pivot pin (index #14). Remove the number 3
skills, lifting equipment and a outer arm (index #13) from the machine.
suitable workshop. Attempting this
procedure without these skills and Bodily injury hazard. The number
tools could result in death or 3 outer arm (index #13) may
serious injury and significant become unbalanced and fall if not
component damage. Dealer properly supported when it is
service is required. removed from the machine.
When removing a hose assembly 8 Remove the cable clamps from the number 3
or fitting, the O-ring on the fitting inner arm (index #12).
and/or hose end must be replaced 9 Remove the mounting fasteners from the cable
and then torqued to specification tray support at the steer end.
during installation. Refer to
Section Two, Hydraulic Hose and 10 Remove the external snap rings from the
Fitting Torque Specifications. number 2 center pivot pin (index #5) 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. 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.

SCISSOR COMPONENTS REV A
12 Attach a lifting strap from an overhead crane to 21 Remove the external snap rings from the
the lug on the rod end of the lift number 2 pivot pin (index #17) at the non-steer
cylinder (index #15). end.
13 Remove the pin retaining fasteners from the 22 Use a soft metal drift to remove the number 2
cylinder rod-end pivot pin (index #3). Use a soft pivot pin (index #17). Remove the number 2
metal drift to remove the pin. outer arm (index #16) from the machine.
Bodily injury hazard. The cylinder Bodily injury hazard. The number
may fall if not properly supported 2 outer arm (index #16) may
when the pin is removed. become unbalanced and fall if not
properly supported when it is
14 Lower the lift cylinder (index #15) onto the
removed from the machine.
number 1 center pivot pin (index #8).
23 Attach a lifting strap from an overhead crane to
the number 2 inner arm (index #6).
number 2 pivot pin (index #7).
number 3 pivot pin (index #4).
25 Use a soft metal drift to remove the number 2
pivot pin (index #7). Remove the number 2
inner arm (index #6) from the machine.
Bodily injury hazard. The number
2 inner arm (index #6) may
become unbalanced and fall if not
26 Remove the safety arm from the number 2 inner
arm (index #6) that was just removed.
number 2 center pivot pin (index #5) at the
battery pack side of the machine.
20 Use a soft metal drift to remove both of the
number 2 center pivot pins (index #5).

28 Raise the number 1 inner arm (index #9) 32 Remove the pin retaining fasteners from the lift
approximately 2 feet / 0.6 m and insert the cylinder barrel-end pin (index #18). Use a soft
safety arm between the number 1 inner arm metal drift to remove the pin. Remove the lift
(index #9) and the number 1 outer arm cylinder (index #15) from the machine.
(index #19).
Crushing hazard. The lift cylinder
Bodily injury hazard. Keep hands (index #15) may become
clear of moving parts when unbalanced and fall when it is
lowering the scissor arms onto the removed from the machine if it is
safety arm. not properly attached to the
overhead crane.
29 Tag, disconnect and plug the hydraulic hose on
the lift cylinder (index #15). Cap the fitting on Component damage hazard. Be
the cylinder. careful not to damage the valve or
fittings on the cylinder while
removing it from the machine.
burn skin. Loosen hydraulic 33 Place a 4 x 4 x 32 inch / 10 x 10 x 80 cm long
connections very slowly to allow block across both sides of the chassis under
the oil pressure to dissipate the number 1 center pivot pin (index #8).
or spray.
the number 1 inner arm (index #9). Raise the
30 Tag and disconnect the wires and manual inner arm slightly and remove the safety arm.
lowering cable from the solenoid valve on the Lower the arms onto the block.
cylinder.
Bodily injury hazard. Keep hands
31 Attach a lifting strap from an overhead crane to clear of moving parts when
the lug on the rod end of the lift cylinder lowering the arms onto the block.
(index #15). Raise the lift cylinder to a vertical
35 Remove the cables from the number 1 inner
position.
arm (index #9) and lay them off to the side.
Component damage hazard.
Do not lift it.

37 Remove the external snap rings from the How to Replace the Scissor Arm
number 1 center pivot pin (index #8).
Wear Pads
center pivot pin (index #8). 1 Remove the platform. See 2-1, How to Remove
the Platform.
1 outer arm (index #19) may 2 Remove the mounting fasteners from the
become unbalanced and fall if not stationary wear pads on the platform.
properly supported when the pin is Note the position of the wear pads
removed. before they are removed so when
39 Slide the number 1 outer arm (index #19) to the the new ones are installed they
non-steer end and remove it from the machine. will be in the correct position.
Bodily injury hazard. The number 3 Support and secure the entry ladder to an
1 outer arm (index #19) may appropriate lifting device.
become unbalanced and fall if not 4 Remove the entry ladder mounting fasteners.
properly supported when it is Remove the entry ladder from the machine.
Crushing hazard. The entry ladder
Note the position of the wear pads may become unbalanced and fall
before the arm is removed so if not properly supported and
when the scissor assembly is secured to the lifting device.
installed they will be in the correct
position. 5 Raise the platform 6 to 7 feet / 1.8 to 2.1 m.
40 Attach a lifting strap from an overhead crane to 6 Lift the safety arm, move it to the center of the
the number 1 inner arm (index #9). Do not scissor arm and rotate down to a vertical
apply any lifting pressure. position.
41 Remove the pin retaining fasteners from both of 7 Lower the scissor arms onto the safety arm.
the number 1 pivot pins (index #10) at the steer
Crushing hazard. Keep hands
end of the machine. Use a slide hammer to
clear of the safety arm when
remove the pins.
lowering the platform.
42 Remove the number 1 inner arm (index #9)
8 Mark the mounting position of the level sensor
from the machine.
box on the drive chassis.
9 Remove the level sensor box cover.
properly supported when removed
from the machine.

10 Mark the mounting position of the level sensor 17 Move the scissor assembly towards the non-
on the level sensor box. steer end of the machine slightly and to one
side of the machine until one of the scissor arm
11 Remove the level sensor box mounting
wear pads is accessible. Do not allow both
fasteners and slide the box towards the non-
wear pads to slide out of the drive chassis.
steer end of the machine as far as it can go.
Crushing hazard. The scissor
Component damage hazard. Be
assembly will fall if both wear pads
careful not to damage the level
are allowed to slide out of the drive
sensor box, limit switch, level
chassis.
sensor or wiring while moving the
level sensor box. 18 Remove the old wear pad.
12 Secure the ends of the scissor arms together at Note the position of the wear pad
both ends of the machine with a strap or other before it is removed so when the
suitable device. new one is installed it will be in the
correct position.
13 Remove the pin retaining fasteners from the
number 1 inner arm pivot pins (item #11) at the 19 Install the new wear pad.
steer end of the machine. Use a slide hammer
20 Move the scissor assembly towards the other
to remove the pins.
side of the machine until the other scissor arm
14 Attach a lifting strap from an overhead crane to wear pad is accessible.
the steer end of the scissor arms.
15 Slide the forks from a forklift under the scissor assembly will fall if both wear pads
arms at the non-steer end of the machine. are allowed to slide out of the drive
chassis.
16 Raise the scissor arms up with the overhead
crane until the number 1 inner arm will clear the 21 Remove the old wear pad.
level sensor box.
Note the position of the wear pad
Component damage hazard. Be before it is removed so when the
careful not to damage the level new one is installed it will be in the
sensor box, limit switch or level correct position.
sensor while moving the scissor
22 Install the new wear pad.
assembly.
23 Slide the scissor assembly back into the drive
chassis.
24 Lower the scissor assembly into position and
install the pivot pins.
sensor box, limit switch or level
sensor while installing the scissor
assembly.

1 13
14
15
3 16
4 17
18
5
6 19
20
21
8
22
9
23
10
24
11
12
GS-1930
Steer End Non-steer End
2 Number 4 center pivot pin 14 Number 4 inner arm
3 Number 4 pivot pin (steer end) 15 Number 4 outer arm
4 Number 3 outer arm 16 Number 4 pivot pin (non-steer end)
5 Lift cylinder rod-end pivot pin 17 Number 3 inner arm
6 Number 3 pivot pin (steer end) 18 Number 3 center pivot pin
7 Number 2 center pivot pin (2 pins) 19 Number 3 pivot pin (non-steer end)
8 Lift cylinder 20 Number 2 inner arm
9 Number 2 pivot pin (steer end) 21 Number 2 outer arm
10 Number 1 center pivot pin 22 Number 2 pivot pin (non-steer end)
11 Number 1 inner arm 23 Lift cylinder barrel-end pivot pin
12 Number 1 pivot pin (steer end) (2 pins) 24 Number 1 outer arm

3-2 3 Attach a lifting strap from an overhead crane to

Scissor Assembly,
GS-1930 number 4 center pivot pin (index #2).
How to Disassemble the 5 Use a soft metal drift to remove the number 4
center pivot pin (index #2).
Scissor Assembly,
6 Remove the external snap ring from the number
GS-1930 4 pivot pin (index #16) at the non-steer end of
Bodily injury hazard. The the machine.
procedures in this section require 7 Use a soft metal drift to remove the number 4
specific repair skills, lifting pivot pin (index #16) from the non-steer end of
equipment and a suitable the machine. Remove the number 4 outer arm
workshop. Attempting this (index #15) from the machine.
procedure without these skills and
tools could result in death or Crushing hazard. The number 4
serious injury and significant outer arm (index #15) may
component damage. Dealer become unbalanced and fall if not
service is required. properly supported when it is
When removing a hose assembly
or fitting, the O-ring on the fitting 8 Remove the cables from the upper cable tray
and/or hose end must be replaced and lay them off to the side.
and then torqued to specification Component damage hazard.
during installation. Refer to Cables can be damaged if they
Section Two, Hydraulic Hose and are kinked or pinched.
Fitting Torque Specifications.
9 Remove the mounting fasteners from the upper
1 Remove the platform. See 2-1, How to Remove cable tray supports.
the Platform.
10 Remove the upper cable tray from the scissor
2 Remove the cables from the side of the number assembly.
4 outer arm (index #15) at the ground controls
side. 11 Attach a lifting strap from an overhead crane to
Cables can be damaged if they 12 Remove the external snap rings from the
are kinked or pinched. number 4 pivot pin (index #3).

13 Use a soft metal drift to remove the number 4 20 Use a soft metal drift to tap the number 3 pivot
pivot pin (index #3) at the steer end. Remove pin (index #19) in the other direction. Remove
the number 4 inner arm (index #14) from the the number 3 outer arm (index #4) from the
machine. battery pack side of the machine.
Crushing hazard. The number 4 Bodily injury hazard. The number
inner arm (index #14) may 3 outer arm (index #4) at the
become unbalanced and fall if not battery pack side may become
properly supported when it is unbalanced and fall if not properly
removed from the machine. supported when it is removed from
the machine.
the number 3 outer arm (index #4) at the 21 Remove the number 3 pivot pin (index #19)
ground controls side. from the non-steer end of the machine.
15 Remove the external snap rings from the 22 Attach a lifting strap from an overhead crane to
number 3 center pivot pin (index #18). the lug on the rod end of the lift cylinder for
support. Do not apply any lifting pressure.
center pivot pin (index #18). 23 Remove the pin retaining fasteners from the lift
cylinder rod-end pivot pin (index #5). Use a soft
metal drift to remove the pin.
number 3 pivot pin (index #19) at the non-steer
end of the machine. Do not remove the pin. Bodily injury hazard. The cylinder
may fall when the rod-end pivot
18 Use a soft metal drift to tap the number 3 pivot
pin is removed if not properly
pin (index #19) halfway out at the non-steer end
supported.
of the machine. Remove the number 3 outer
arm (index #4) at the ground controls side from 24 Lower the cylinder onto the number 1 center
the machine. pivot pin (index #10).
Bodily injury hazard. The number 25 Remove the cables from the number 3 inner
3 outer arm (index #4) at the arm (index #17) and lay them to the side.
ground controls side may become
unbalanced and fall if not properly
supported when it is removed from
the machine. 27 Remove the external snap rings from the
number 3 pivot pin (index #6) at the steer end.
the number 3 outer arm (index #4) at the
battery pack side.

28 Use a soft metal drift to remove the number 3 36 Use a soft metal drift to tap the number 2 pivot
pivot pin (index #6). Remove the number 3 pin (index #22) halfway out at the non-steer end
inner arm (index #17) from the machine. of the machine. Remove the number 2 outer
arm (index #21) from the ground controls side
of the machine.
become unbalanced and fall if not Bodily injury hazard. The number
properly supported when it is 2 outer arm (index #21) at the
removed from the machine. ground controls side may become
unbalanced and fall if not properly
29 Remove the cables from the lower cable tray
supported when it is removed from
and lay them off to the side.
the machine.
the number 2 outer arm (index #21) at the
battery pack side.
30 Remove the mounting fasteners from the lower
cable tray supports.
31 Remove the mounting fasteners from the lower battery pack side.
cable tray mounting bracket on the number 2
center pivot pin (index #7) at the ground
center pivot pin (index #7) at the battery pack
controls side of the machine.
side.
32 Slide the cable tray towards the battery pack
side of the machine and remove it from the
2 outer arm (index #21) at the
machine.
battery pack side may become
33 Attach a lifting strap from an overhead crane to unbalanced and fall if not properly
the number 2 outer arm (index #21) at the supported when it is removed from
ground controls side. the machine.
ground controls side.
center pivot pin (index #7) at the ground
controls side.

40 Use a soft metal drift to tap the number 2 pivot 46 Raise the number 1 inner arm (index #11)
pin (index #22) in the other direction at the non- approximately 2 feet / 60 cm and install the
steer end. Remove the number 2 outer arm safety arm between the number 1 inner arm
(index #21) from the battery pack side of the (index #11) and the number 1 outer arm
machine. (index #24). Lower the scissor arms onto the
safety arm.
2 outer arm (index #21) at the Bodily injury hazard. Keep hands
battery pack side may become clear of moving parts when
unbalanced and fall if not properly lowering the scissor arms onto the
supported when it is removed from safety arm.
the machine.
47 Tag, disconnect and plug the hydraulic hose on
41 Attach a lifting strap from an overhead crane to the lift cylinder. Cap the fitting on the cylinder.
42 Remove the external snap rings from the hydraulic oil can penetrate and
number 2 pivot pin (index #9) at the steer end burn skin. Loosen hydraulic
of the machine. connections very slowly to allow
or spray.
48 Tag and disconnect the wires and manual
lowering cable from the solenoid valve on the
cylinder.
properly supported when it is 49 Attach a lifting strap from an overhead crane to
removed from the machine. the lug on the rod end of the lift cylinder
(index #8). Raise the lift cylinder to a vertical
44 Remove the safety arm from the number 2 inner
position.
arm (index #20) that was just removed.

50 Remove the pin retaining fasteners from the lift 54 Support and secure the entry ladder to an
cylinder barrel-end pin (index #23). Use a soft appropriate lifting device.
metal drift to remove the pin. Remove the lift
55 Remove the entry ladder mounting fasteners.
cylinder (index #8) from the machine.
Remove the entry ladder from the machine.
Crushing hazard. The entry ladder
(index #8) may become
may become unbalanced and fall
unbalanced and fall when it is
if not properly supported and
removed from the machine if not
secured to the lifting device.
properly attached to the overhead
crane. 56 Attach a lifting strap from an overhead crane to
the number 1 outer arm (index #24). Do not
apply any lifting pressure.
careful not to damage the valve or
fittings on the cylinder while 57 Remove the external snap rings from the
removing it from the machine. number 1 center pivot pin (index #10).
51 Place a 4 x 4 x 48 inch / 10 cm x 10 cm x 1.2 m 58 Use a soft metal drift to remove the number 1
long block across both sides of the chassis center pivot pin (index #10).
under the number 1 center pivot pin
(index #10). Bodily injury hazard. The number
1 outer arm (index #24) may
52 Attach a lifting strap from an overhead crane to become unbalanced and fall if not
the number 1 inner arm (index #11) at the non- properly supported when the pin is
steer end. Raise the number 1 inner arm and removed.
remove the safety arm. Lower the number 1
inner arm (index #11) onto the block that was 59 Slide the number 1 outer arm (index #24) to the
placed across the chassis. non-steer end and remove it from the machine.
Bodily injury hazard. Keep hands Bodily injury hazard. The number
clear of moving parts when 1 outer arm (index #24) may
lowering the arms onto the block. become unbalanced and fall if not
53 Remove the cables and hydraulic hoses from removed from the machine.
the number 1 inner arm (index #11) and lay
them to the side. Note the position of the wear pads
before the arm is removed so
Component damage hazard. when the scissor is assembled
Cables and hoses can be they will be in the correct position.
damaged if they are kinked or
pinched.

60 Attach the strap from an overhead crane to the How to Replace the Scissor Arm
number 1 inner arm (index #11). Do not lift it.
Wear Pads
61 Remove the pin retaining fasteners from both of
the number 1 pivot pins (index #12) at the steer 1 Remove the platform. See 2-1, How to Remove
end of the machine. Use a slide hammer to the Platform.
remove the pins. 2 Remove the mounting fasteners from the
62 Remove the number 1 inner arm (index #11) stationary wear pads on the platform.
from the machine. Note the position of the wear pads
Bodily injury hazard. The number before they are removed so when
1 inner arm (index #11) may the new ones are installed they
become unbalanced and fall if not will be in the correct position.
properly supported when it is 3 Support and secure the entry ladder to an
removed from the machine. appropriate lifting device.
Component damage hazard. Be 4 Remove the entry ladder mounting fasteners.
sure not to damage the limit switch Remove the entry ladder from the machine.
or level sensor box components
when the number 1 inner arm Crushing hazard. The entry ladder
(index #11) is removed from the may become unbalanced and fall
machine. if not properly supported and
5 Raise the platform 6 to 7 feet / 1.8 to 2.1 m.
6 Lift the safety arm, move it to the center of the
scissor arm and rotate down to a vertical
position.
7 Lower the scissor arms onto the safety arm.
box on the drive chassis.
9 Remove the level sensor box cover.
on the level sensor box.

11 Remove the level sensor box mounting 18 Remove the old wear pad.
fasteners and slide the box towards the non-
Note the position of the wear pad
steer end of the machine as far as it can go.
before it is removed so when the
Component damage hazard. Be new one is installed it will be in the
careful not to damage the level correct position.
sensor box, limit switch, level
sensor or wiring while moving the
level sensor box. 20 Move the scissor assembly towards the other
side of the machine until the other scissor arm
12 Secure the ends of the scissor arms together at
wear pad is accessible.
both ends of the machine with a strap or other
suitable device. Crushing hazard. The scissor
number 1 inner arm pivot pins (item #11) at the
chassis.
steer end of the machine. Use a slide hammer
to remove the pins. 21 Remove the old wear pad.
14 Attach a lifting strap from an overhead crane to Note the position of the wear pad
the steer end of the scissor arms. before it is removed so when the
new one is installed it will be in the
15 Slide the forks from a forklift under the scissor
correct position.
arms at the non-steer end of the machine.
16 Raise the scissor arms up with the overhead
crane until the number 1 inner arm will clear the 23 Slide the scissor assembly back into the drive
level sensor box. chassis.
Component damage hazard. Be 24 Lower the scissor assembly into position and
careful not to damage the level install the pivot pins.
sensor while moving the scissor Component damage hazard. Be
assembly. careful not to damage the level
17 Move the scissor assembly towards the non- sensor while installing the scissor
steer end of the machine slightly and to one assembly.
side of the machine until one of the scissor arm
wear pads is accessible. Do not allow both
wear pads to slide out of the drive chassis.
chassis.

3-3 Before serial number 23568

i
Lift Cylinder
a
How to Remove the Lift Cylinder
h
Bodily injury hazard. This
b
procedure requires specific repair
skills, lifting equipment and a g
suitable workshop. Attempting this
procedure without these skills and f E
tools could result in death or e D c
serious injury and significant Y7
component damage. Dealer
service is strongly recommended.
or fitting, the O-ring on the fitting d
and/or hose end must be replaced
and then torqued to specification
Section 2, Hydraulic Hose and
Fitting Torque Specifications. a lift cylinder
b lowering cable
1 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. c solenoid valve (schematic item D)
d cable mounting bracket
2 Lift the safety arm, move it to the center of the e spring
scissor arm and rotate down to a vertical f orifice (schematic item E)
g connector fitting
position. h hydraulic hose
3 Lower the platform onto the safety arm. i hard line assembly

clear of the safety arm when After serial number 23567
4 Tag and disconnect the wiring from the solenoid
valve at the barrel end of the lift cylinder.
d
D
c
Y7
f
E
g

5 Loosen the adjustment nuts on the solenoid, 11 Lower the cylinder.

then disconnect the manual lowering cable from
12 Support and secure the entry ladder to an
the solenoid.
appropriate lifting device.
During assembly, the manual
13 Remove the fasteners from the entry ladder and
platform lowering cable needs to
remove the entry ladder from the machine.
be properly adjusted. See 4-1,
How to Adjust the Manual Platform Crushing hazard. The entry ladder
Lowering Cable. could become unbalanced and fall
if not properly supported and
6 Remove the mounting fasteners from the
manual lowering cable mounting bracket.
Remove the bracket from the cylinder. 14 Attach a lifting strap from an overhead crane or
similar lifting device to the barrel end of the lift
7 Before serial number 23568: Disconnect and
cylinder for support.
plug the hydraulic hardline from the lift cylinder.
Cap the fitting on the cylinder. 15 Remove the external snap ring from the lift
After serial number 23567: Disconnect and cylinder barrel-end pivot pin. Use a soft metal
plug the hydraulic hose from the lift cylinder. drift to remove the pin.
Cap the fitting on the cylinder.
Bodily injury hazard. Spraying will fall if not properly supported
hydraulic oil can penetrate and when the pin is removed.
connections very slowly to allow 16 Support and secure the lift cylinder to an
the oil pressure to dissipate appropriate lifting device.
gradually. Do not allow oil to squirt 17 Remove the lift cylinder through the scissor
or spray. arms at the non-steer end of the machine.
8 Before serial number 23568: Remove the Component damage hazard. Be
hardline retaining strap from the cylinder. careful not to damage the valve or
fittings on the cylinder while
removing it from the machine.
the rod end of the lift cylinder for support.
10 Remove the external snap ring from the lift
cylinder rod-end pivot pin. Use a soft metal drift
to remove the pin.
will fall if not properly supported.
sensor while lowering the cylinder.

Ground Controls REV B
4-1 5 Disconnect the cable mounting nut from the

lowering valve at the barrel end of the lift
Manual Platform Lowering Cable cylinder.
The manual platform lowering cable lowers the a

platform in the event of a main power failure. The
manual platform lowering cable is attached to the
a manual lowering cable
barrel end of the lift cylinder and is activated next b
sheath
to the ground controls. b upper lock nut
c cable mounting
How to Adjust the Manual c
d
bracket
lower lock nut
Platform Lowering Cable e cable mounting nut
d f end of the lowering
1 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. cable
g manual lowering valve
2 Lift the safety arm, move it to the center of the (schematic item D)
e
position.
3 Lower the platform onto the safety arm.
f
lowering the platform. g
4 Push the handle on the manual platform Y7
lowering cable all the way in. D
6 Pull the cable tight and measure the distance

between the end of the lowering cable and the
end of the lowering valve.
Result: The measurement should be 3/16 to
1/4 inch / 4.7 to 6.4 mm.
Platform manual lowering cable specification
Gap, lowering cable to valve 3/16 to 1/4 inch

4.7 to 6.4 mm
Skip to step 10 if the measurement is correct.

REV B GROUND CONTROLS
7 To adjust, loosen the upper lock nut on the

cable mounting bracket. Turn the lower lock nut
clockwise to decrease the distance or
counterclockwise to increase the distance.
8 Tighten the upper lock nut and re-measure the
distance between the end of the lowering cable
and the end of the lowering valve. Re-adjust if
needed.
9 Install the cable mounting nut onto the lowering
valve.
10 Raise the platform and rotate the safety arm to
the stowed position.
11 Pull the manual lowering handle at the ground
controls 2 to 3 times to ensure it is functioning
correctly.

GROUND CONTROLS REV B
4-2 2 Connect the leads of an ohmmeter to the switch

terminals in the following combinations listed
Toggle Switches below to check for continuity.
Toggle switches used for single function switching Left Center Right
are single pole double throw (SPDT) switches.
How to Test a Single Pole Double

Throw Toggle Switch
Continuity is the equivalent of 0 to
3 ohms. A simple continuity tester
may not accurately test the switch.
This procedure covers fundamental switch testing 1 3 1 3 1 3
2 2 2
and does not specifically apply to all varieties of
toggle switches.
1 Turn the key switch to the OFF position. Tag 1 2 3 1 2 3 1 2 3

and disconnect all wiring from the toggle switch 4 5 6 4 5 6 4 5 6
to be tested. Test Desired result
Disconnect the wires from the Left position
toggle switch before testing.
terminal1 1 to
2 2,33 1 2 3 1 2 continuity
no 3
(infinite Ω)
terminal 2 to 3 continuity
(zero Ω)
Center position There are no terminal

combinations that will produce
continuity (infinite W)
Right position
(zero Ω)
terminal 1 to 3 no continuity
(infinite Ω)
terminal 2 to 3 no continuity

4-3 3 Connect 24V DC and a ground wire to terminals

85 and 86, then test the following terminal
Control Relays combinations.
Relays used for single function switching are single Test Desired result
pole double throw (SPDT) relays.
terminal 87a to 87 and 30 no continuity
(infinite Ω)
How to Test a Single Pole Double
Throw Relay (zero Ω)
cause death or serious injury.
other jewelry. 85 87 87a
1 Label and then disconnect all the wiring from

the relay to be tested.
86 30
2 Connect the leads from an ohmmeter or
continuity tester to each terminal combination Relay schematic - deactivated
and check for continuity. Terminals 85 and 86
represent the coil and should not be tested in
any other combination.
Test Desired result 85 87 87a
terminal 85 to 86 with resistor 310 to 330Ω

terminal 87 to 87a and 30 no continuity
(infinite Ω) 86 30
terminal 87a to 30 continuity Relay schematic - activated

(zero Ω)
87
87a
86 85
30
Terminal Number Legend

terminal no. 87a - N.C.
terminal no. 85 - ground
terminal no. 30 - common
terminal no. 86 - coil
terminal no. 87 - N.O.

4-4 3 Block the wheels at the non-steer end of the

machine.
Tilt Level Sensor
4 Center a lifting jack under the drive chassis at
(before serial number 50444) the steer end of the machine.
How to Install and Calibrate the 5 Raise the machine approximately

2 inches / 5 cm.
1.5° Level Sensor
6 Place a 0.91 x 6 x 6 inch / 23.1 mm x
This procedure is for models equipped with a 15 cm x 15 cm thick steel block under both
1.5° side / 3° front / 5° rear level sensor. wheels at the steer end of the machine.
Type Serial range 7 Lower the machine onto the blocks.
GS-1530 Australia from 24998 to 50443

GS-1930 ANSI, CSA from 24998 to 50443
GS-1930 Australia from 48338 to 50443 position.
GS-1932 (Australia outdoor) before 50444 10 Lower the platform onto the safety arm.
Tip-over hazard. Failure to install
or calibrate the tilt level sensor as
instructed will compromise 11 Remove the tilt level sensor box cover retaining
machine stability and cause the fasteners. Remove the cover.
machine to tip over, resulting in
death or serious injury. Do not The tilt level sensor box is located
install or calibrate the level sensor on top of the chassis at the steer
other than specified in this end of the machine.
procedure. If you are not installing a new level sensor,
Perform this procedure with the proceed to step 20.
machine on a firm, level surface 12 Turn the key switch to the OFF position and push
that is free of obstructions. in the red Emergency Stop button to the OFF
1 Remove the platform controls from the platform. position at the ground controls.
2 Turn the key switch to platform control and pull 13 Tag and disconnect the wiring harness from the
out the red Emergency Stop buttons to the ON level sensor, limit switch and alarm.
controls.

14 Remove the tilt level sensor box retaining Steer end

fasteners. Remove the tilt level sensor box from
the machine. a
15 Remove the tilt level sensor retaining fasteners.

Remove the tilt level sensor from the level
Y
sensor box. f X
b
16 Place the new tilt level sensor in the tilt level
sensor box with the "X" on the level sensor
c
base closest to the long side of the tilt level
e
sensor box and the "Y" on the level sensor
base closest to the short side of the tilt level d
sensor box. Install the level sensor retaining
fasteners.
Tip-over hazard. The tilt level
sensor must be installed with the
"X" on the level sensor base
closest to the long side of the tilt
level sensor box and the "Y" on
the level sensor base closest to
the short side of the tilt level
sensor box. Failure to install the tilt
level sensor as instructed could
cause the machine to tip over
Non-steer end
a scissor chassis
17 Install the level sensor box onto the machine. b tilt level sensor
Install the level sensor box retaining fasteners. c level sensor box
d alarm
18 Connect the wiring harness to the level sensor, e box retaining fastener
limit switch and alarm. f level sensor retaining fastener
19 Turn the key switch to the ground control and

ON position at the ground controls.

20 Tighten the level sensor adjusting fasteners 33 Models before serial number 48817: Raise
until the bubble in the top of the level sensor is the platform 7 to 8 feet / 2.1 to 2.1 m.
centered in the circles.
Result: The tilt sensor alarm should sound.
Result: The tilt sensor alarm should not sound.
Result: If the tilt sensor alarm does not sound,
Be sure there are threads showing adjust the tilt level sensor until the alarm just
through the top of the adjusting begins to sound OR the down limit switch may
fasteners. need to be adjusted.
21 Raise the platform slightly. CE models: When the platform is
raised 7 to 8 feet / 2.1 to 2.4 m
22 Return the safety arm to the stowed position.
from the ground, an alarm should
23 Lower the platform to the stowed position. sound and the lift and drive
functions should not operate.
24 Raise the machine approximately
2 inches / 5 cm. Models after serial number 48816: Raise the
platform 7 to 8 feet / 2.1 to 2.4 m.
25 Remove the blocks from under both wheels.
Result: The platform should stop and an alarm
26 Lower the machine and remove the jack. should sound.
27 Remove the blocks from the wheels at the Result: If the platform does not stop or the tilt
non-steer end of the machine. sensor alarm does not sound, adjust the tilt
28 Block the wheels at the steer end of the level sensor until the alarm just begins to sound
machine. OR the down limit switch may need to be
adjusted.
the non-steer end of the machine. 34 Lower the platform to the stowed position.
30 Raise the machine approximately 35 Raise the machine approximately

5 inches / 13 cm. 5 inches / 13 cm.
31 Place a 4.73 x 6 x 6 inch / 12.1 x 15 x 15 cm 36 Remove the blocks from under both wheels.
thick steel block under both wheels at the 37 Lower the machine and remove the jack.
non-steer end of the machine.
38 Remove the blocks from the wheels at the steer
32 Lower the machine onto the blocks. end of the machine.
the ground controls side of the machine.
2 inches / 5 cm.

41 GS-1530 and GS-1930: Place a 0.62 x 6 x 6 53 Models before serial number 48817: Raise
inch / 15.7 mm x 15 cm x 15 cm thick steel the platform 7 to 8 feet / 2.1 to 2.4 m.
block under both wheels at the ground controls
side of the machine.
GS-1932: Place a 0.82 x 6 x 6 inch / 17 mm x
adjust the tilt level sensor until the alarm just
15 cm x 15 cm thick steel block under both
begins to sound OR the down limit switch may
wheels at the ground controls side of the
need to be adjusted.
machine.
CE models: When the platform is
42 Lower the machine onto the blocks.
43 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. from the ground, an alarm should
sound and the lift and drive
44 Adjust the tilt level sensor retaining fasteners
Models after serial number 48816: Raise the
just until the tilt sensor alarm does not sound.
46 Raise the machine approximately should sound.
2 inches / 5 cm.
Result: If the platform does not stop or the tilt
47 Remove the blocks from under both wheels. sensor alarm does not sound, adjust the tilt
level sensor until the alarm just begins to sound
48 Lower the machine and remove the jack. OR the down limit switch may need to be
49 Center a lifting jack under the drive chassis at adjusted.
the battery pack side of the machine. 54 Lift the safety arm, move it to the center of the
50 Raise the machine approximately scissor arm and rotate down to a vertical
2 inches / 5 cm. position.
51 GS-1530 and GS-1930: Place a 0.76 x 6 x 6 55 Lower the scissor arms onto the safety arm.
inch / 19.3 mm x 15 cm x 15 cm thick steel Crushing hazard. Keep hands
block under both wheels at the battery pack clear of the safety arm when
side of the machine. lowering the platform.
GS-1932: Place a 0.82 x 6 x 6 inch / 20.8 mm x 56 Install the tilt level sensor box cover.
wheels at the battery pack side of the machine. 57 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
52 Lower the machine onto the blocks. 58 Return the safety arm to the stowed position.
2 inches / 5 cm.
62 Lower the machine and remove the jack.

How to Install and Calibrate the 3 Block the wheels at the non-steer end of the
machine.
2° Level Sensor
This procedure is for models equipped with a the steer end of the machine.
2° side / 3° front / 5° rear level sensor.
Type Serial range 2 inches / 5 cm.
GS-1530 ANSI, CSA, CE before 50444 6 Place a 0.91 x 6 x 6 inch / 23.1 mm x

GS-1530 Australia before 24998 wheels at the steer end of the machine.
GS-1930 ANSI, CSA before 24998 7 Lower the machine onto the blocks.
GS-1930 CE before 50444 8 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
GS-1930 Australia before 48338 9 Lift the safety arm, move it to the center of the
position.
Tip-over hazard. Failure to install
instructed will compromise Crushing hazard. Keep hands
machine stability and cause the clear of the safety arm when
machine to tip over, resulting in lowering the platform.
death or serious injury. Do not
install or calibrate the level sensor 11 Remove the tilt level sensor box cover retaining
other than specified in this fasteners. Remove the cover.
procedure. The tilt level sensor box is located
Perform this procedure with the on top of the chassis at the steer
machine on a firm, level surface end of the machine.
that is free of obstructions. If you are not installing a new level sensor,
1 Remove the platform controls from the platform. proceed to step 20.
2 Turn the key switch to platform control and pull 12 Turn the key switch to the OFF position and push
out the red Emergency Stop buttons to the ON in the red Emergency Stop button to the OFF
position at both the ground and platform position at the ground controls.
controls. 13 Tag and disconnect the wiring harness from the
level sensor, limit switch and alarm.

14 Remove the tilt level sensor box retaining Steer end

the machine. a

Remove the tilt level sensor from the level Y
sensor box. f X
b
16 Place the new tilt level sensor in the tilt level
sensor box with the "X" on the level sensor c
e
base closest to the short side of the tilt level d
sensor box.
closest to the long side of the tilt
resulting in death or serious injury. Non-steer end
17 Install the level sensor box onto the machine. a scissor chassis
Install the level sensor box retaining fasteners. b tilt level sensor
c level sensor box
18 Connect the wiring harness to the level sensor, d alarm
limit switch and alarm. e box retaining fastener
f level sensor retaining fastener

20 Tighten the level sensor adjusting fasteners 33 Models before serial number 48817: Raise
until the bubble in the top of the level sensor is the platform 7 to 8 feet / 2.1 to 2.1 m.
centered in the circles.
Be sure there are threads showing
through the top of the adjusting
fasteners.
Result: The tilt sensor alarm should not sound. need to be adjusted.
21 Raise the platform slightly. CE models: When the platform is
27 Remove the blocks from the wheels at the Result: If the platform does not stop or the tilt
non-steer end of the machine. sensor alarm does not sound, adjust the tilt
28 Block the wheels at the steer end of the level sensor until the alarm just begins to sound
machine. OR the down limit switch may need to be
adjusted.
the non-steer end of the machine. 34 Lower the platform to the stowed position.
30 Raise the machine approximately 35 Raise the machine approximately

5 inches / 13 cm. 5 inches / 13 cm.
31 Place a 4.73 x 6 x 6 inch / 12.1 x 15 x 15 cm 36 Remove the blocks from under both wheels.
thick steel block under both wheels at the 37 Lower the machine and remove the jack.
non-steer end of the machine.
38 Remove the blocks from the wheels at the steer
32 Lower the machine onto the blocks. end of the machine.
2 inches / 5 cm.

41 Place a 0.85 x 6 x 6 inch / 21.5 mm x 53 Models before serial number 48817: Raise
15 cm x 15 cm thick steel block under both the platform 7 to 8 feet / 2.1 to 2.1 m.
machine.
43 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. begins to sound OR the down limit switch may
need to be adjusted.
44 Adjust the tilt level sensor retaining fasteners
just until the tilt sensor alarm does not sound.
49 Center a lifting jack under the drive chassis at Result: If the platform does not stop or the tilt
the battery pack side of the machine. sensor alarm does not sound, adjust the tilt
50 Raise the machine approximately level sensor until the alarm just begins to sound
2 inches / 5 cm. OR the down limit switch may need to be
adjusted.
51 Place a 0.98 x 6 x 6 inch / 25 mm x
15 cm x 15 cm thick steel block under both 54 Lift the safety arm, move it to the center of the
wheels at the battery pack side of the machine. scissor arm and rotate down to a vertical
position.
56 Install the tilt level sensor box cover.
57 Raise the platform slightly.
2 inches / 5 cm.
62 Lower the machine and remove the jack.

4-5 2 Turn the key switch to platform control and pull

out the red Emergency Stop buttons to the on
Tilt Level Sensor position at both the ground and platform
(after serial number 50443) controls.
How to Install and Calibrate the
1.5° Level Sensor scissor arm and rotate down to a vertical
position.
This procedure is for models equipped with a
1.5° side / 3° front / 3° rear level sensor. 5 Lower the platform onto the safety arm.
Type Serial range Crushing hazard. Keep hands

GS-1530 Australia after 50443 lowering the platform.
GS-1930 ANSI, CSA, Australia after 50443 6 Remove the tilt level sensor box cover retaining
fasteners. Remove the cover.
GS-1932 (Australia outdoor) after 50443
The tilt level sensor box is located
on top of the chassis at the steer
Tip-over hazard. Failure to install end of the machine.
instructed will compromise If you are not installing a new level sensor,
machine stability and cause the proceed to step 15.
machine to tip over, resulting in 7 Turn the key switch to the off position and push
death or serious injury. Do not in the red Emergency Stop button to the off
install or calibrate the level sensor position at the ground controls.
other than specified in this
procedure. 8 Tag and disconnect the wiring harness from the
level sensor, limit switch and alarm.
machine on a firm, level surface 9 Remove the tilt level sensor box retaining
that is free of obstructions. fasteners. Remove the tilt level sensor box from
the machine.
sensor box.

11 Place the new tilt level sensor in the tilt level Steer end
a
base closest to the short side of the tilt level
Y
sensor box. Install the level sensor retaining f X
b
fasteners.
c
e
closest to the long side of the tilt d
Non-steer end
a scissor chassis
b tilt level sensor
c level sensor box
d alarm
e box retaining fastener

12 Install the level sensor box onto the machine. 22 Lower the machine onto the blocks.
Install the level sensor box retaining fasteners.
13 Connect the wiring harness to the level sensor,
limit switch and alarm.
Result: The tilt sensor alarm does sound. Adjust
the tilt level sensor retaining fasteners just until
the tilt sensor alarm does not sound.
15 Tighten the level sensor adjusting fasteners
until the bubble in the top of the level sensor is 25 Raise the machine approximately
centered in the circles. 2 inches / 5 cm.
Result: The tilt sensor alarm should not sound. 26 Remove the blocks from under both wheels.
Be sure there are threads showing 27 Lower the machine and remove the jack.
through the top of the adjusting
fasteners. 28 Center a lifting jack under the drive chassis at
the battery pack side of the machine.
17 Return the safety arm to the stowed position. 2 inches / 5 cm.
18 Lower the platform to the stowed position. 33 GS-1530 and GS-1930: Place a 0.76 x 6 x 6
inch / 19.3 mm x 15 cm x 15 cm thick steel
GS-1932: Place a 0.82 x 6 x 6 inch / 20.8 mm x
2 inches / 5 cm.
21 GS-1530 and GS-1930: Place a 0.62 x 6 x 6 wheels at the ground controls side of the
inch / 15.7 mm x 15 cm x 15 cm thick steel machine.
GS-1932: Place a 0.67 x 6 x 6 inch / 17 mm x
machine.

32 Models before serial number 48817: Raise 37 Return the safety arm to the stowed position.
the platform 7 to 8 feet / 2.1 to 2.4 m.
Result: The tilt sensor alarm does not sound. 2 inches / 5 cm.
Adjust the tilt level sensor until the alarm just
need to be adjusted. 41 Lower the machine and remove the jack.
should sound.
Result: The platform does not stop or the tilt
sensor alarm does not sound. Adjust the tilt
OR the down limit switch may need to be
adjusted.
position.

How to Install and Calibrate the 5 Lower the platform onto the safety arm.
2° Level Sensor Crushing hazard. Keep hands
This procedure is for models equipped with a lowering the platform.
2° side / 3° front / 3° rear level sensor.
6 Remove the tilt level sensor box cover retaining
Type Serial range fasteners. Remove the cover.
GS-1530 ANSI, CSA, CE after 50443 The tilt level sensor box is located
on top of the chassis at the steer
GS-1930 CE after 50443 end of the machine.
If you are not installing a new level sensor,
Tip-over hazard. Failure to install proceed to step 15.
or calibrate the tilt level sensor as 7 Turn the key switch to the OFF position and push
instructed will compromise in the red Emergency Stop button to the OFF
machine stability and cause the position at the ground controls.
machine to tip over, resulting in
death or serious injury. Do not 8 Tag and disconnect the wiring harness from the
install or calibrate the level sensor level sensor, limit switch and alarm.
other than specified in this
9 Remove the tilt level sensor box retaining
procedure.
Perform this procedure with the the machine.
machine on a firm, level surface
that is free of obstructions.
1 Remove the platform controls from the platform. sensor box.
out the red Emergency Stop buttons to the ON
controls.
position.

11 Place the new tilt level sensor in the tilt level Steer end
base closest to the long side of the tilt level a
base closest to the short side of the tilt level
Y
sensor box. Install the level sensor retaining f X
b
fasteners.
c
"X" on the level sensor base e
closest to the long side of the tilt d

Non-steer end
a scissor chassis
b tilt level sensor
c level sensor box
d alarm
e box retaining fastener

12 Install the level sensor box onto the machine. 23 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
Install the level sensor box retaining fasteners.
13 Connect the wiring harness to the level sensor,
Result: The tilt sensor alarm does sound. Adjust
limit switch and alarm.
the tilt level sensor retaining fasteners just until
14 Turn the key switch to the ground control and the tilt sensor alarm does not sound.
15 Tighten the level sensor adjusting fasteners
2 inches / 5 cm.
until the bubble in the top of the level sensor is
centered in the circles. 26 Remove the blocks from under both wheels.
Result: The tilt sensor alarm should not sound. 27 Lower the machine and remove the jack.
Be sure there are threads showing 28 Center a lifting jack under the drive chassis at
through the top of the adjusting the battery pack side of the machine.
fasteners.
16 Raise the platform slightly. 2 inches / 5 cm.
17 Return the safety arm to the stowed position. 30 Place a 0.98 x 6 x 6 inch / 24.9 mm x 15 cm x
15 cm thick steel block under both wheels at
2 inches / 5 cm.
21 Place a 0.85 x 6 x 6 inch / 21.6 mm x 15 cm x
15 cm thick steel block under both wheels at

32 Models before serial number 48817: Raise 37 Return the safety arm to the stowed position.
the platform 7 to 8 feet / 2.1 to 2.4 m.
Result: The tilt sensor alarm does not sound. 2 inches / 5 cm.
Adjust the tilt level sensor until the alarm just
need to be adjusted. 41 Lower the machine and remove the jack.
should sound.
Result: The platform does not stop or the tilt
sensor alarm does not sound. Adjust the tilt
OR the down limit switch may need to be
adjusted.
position.

Hydraulic Pump REV B
5-1 4 Activate the platform up function from the

ground controls.
Function Pump
Result: If the pressure gauge reads
The hydraulic pump is attached to the motor which 3200 psi / 221 bar, immediately stop. The pump
makes up the Hydraulic Power Unit. is good.
Result: If pressure fails to reach
How to Test the Hydraulic Pump 3200 psi / 221 bar, the pump is bad and will
When removing a hose assembly need to be serviced or replaced.
or fitting, the O-ring on the fitting Component damage hazard.
and/or hose end must be replaced There is no relief valve in the
and then torqued to specification hydraulic pump and the pump can
during installation. Refer to be damaged if the pressure is
Section Two, Hydraulic Hose and allowed to exceed
Fitting Torque Specifications. 3200 psi / 221 bar. When testing
1 Disconnect and plug the high pressure the pump, activate the pump in
hydraulic hose from the hydraulic pump. one second intervals until
3200 psi / 221 bar is confirmed.
Bodily injury hazard. Spraying Do not over-pressurize the pump.
burn skin. Loosen hydraulic 5 Remove the pressure gauge and reconnect the
connections very slowly to allow hydraulic hose.
the oil pressure to dissipate Bodily injury hazard. Spraying
gradually. Do not allow oil to squirt hydraulic oil can penetrate and
or spray. burn skin. Loosen hydraulic
2 Connect a 0 to 5000 psi / 0 to 350 bar pressure connections very slowly to allow
gauge to the high pressure port on the pump. the oil pressure to dissipate
3 Turn the key switch to ground control and pull or spray.
controls.

REV B HYDRAULIC PUMP
How to Remove the

Hydraulic Pump
or fitting, the O-ring on the fitting
Section Two, Hydraulic Hose and
1 Remove the mounting fasteners from the
hydraulic filter bracket at the function manifold.
Push the filter off to the side.
2 Tag, disconnect and cap the hydraulic hoses on
the pump.
or spray.
3 Remove the pump mounting bolts. Carefully
remove the pump.
Tip-over hazard. After replacing
the hydraulic pump, it is critical to
return the lift speed and raised
drive speed settings to original
factory specifications. Failure to
restore the machine to original
factory specifications could cause
the machine to tip over resulting in

Function Manifold REV B
6-1
Function Manifold Components (from serial number 17408 to 35799)
The function manifold is mounted inside the hydraulic power unit module tray
Index Schematic
No. Description Item Function Torque
1 Diagnostic nipple ....................................... AA ...................... Testing
2 Flow regulator, 0.75 gpm / 2.8 L/min ......... AB ...................... Steer circuit ............................ 35 ft-lbs / 47 Nm
3 Relief valve, 3500 psi / 241.3 bar .............. AC ...................... System relief ........................... 20 ft-lbs / 27 Nm
4 Orifice - washer, 0.040 in / 1 mm .............. AD ...................... Steer circuit
5 Relief valve, 1500 psi / 103.4 bar .............. AE ...................... Steer relief .............................. 20 ft-lbs / 27 Nm
6 Solenoid valve, 3 position 4 way ............... AF ....................... Steer left/right ......................... 20 ft-lbs / 27 Nm
7 Solenoid valve, 2 position 4 way ............... AG ...................... Platform up ............................. 25 ft-lbs / 34 Nm
8 Solenoid valve,
2 position 2 way, N. O. .............................. AH ...................... Brake circuit ............................ 20 ft-lbs / 27 Nm
9 Solenoid valve, 3 position 4 way ............... AI ........................ Drive forward/reverse ............. 25 ft-lbs / 34 Nm
10 Check valve, 5 psi / 0.3 bar ....................... AJ ....................... Brake circuit ............................ 25 ft-lbs / 34 Nm
11 Check valve, 5 psi / 0.3 bar ....................... AK ...................... Steer circuit ............................ 20 ft-lbs / 27 Nm

REV B FUNCTION MANIFOLD
1 2
AA
AB
AK
11 3
AC
AD
4
5
AE
Y4
6
Y3 AF
7
Y8 AG
8
Y2 AH
Y6
Y5
AJ
AI
10 9

FUNCTION MANIFOLD REV B
6-2
Function Manifold Components (after serial number 35799)
The function manifold is mounted inside the hydraulic power unit module tray
Index Schematic
1 Diagnostic nipple ....................................... BA ...................... Testing
2 Flow regulator, 0.75 gpm / 2.8 L/min ......... BB ...................... Steer circuit ............................ 35 ft-lbs / 47 Nm
3 Relief valve, 3500 psi / 241.3 bar .............. BC ...................... System relief ........................... 20 ft-lbs / 27 Nm
4 Relief valve, 3000 psi / 207 bar ................. BD ...................... Lift relief ................................. 20 ft-lbs / 27 Nm
5 Orifice - washer, 0.040 in / 1 mm .............. BE ...................... Steer circuit
6 Relief valve, 1500 psi / 103.4 bar .............. BF ....................... Steering relief ......................... 20 ft-lbs / 27 Nm
7 Solenoid valve, 2 position 4 way ............... BG ...................... Platform up ............................. 25 ft-lbs / 34 Nm
8 Check valve, 10 psi / 0.7 bar ..................... BH ...................... Drive circuit ............................. 25 ft-lbs / 34 Nm
9 Solenoid valve, 3 position 4 way ............... BI ........................ Steer left/right ......................... 20 ft-lbs / 27 Nm
10 Solenoid valve, 3 position 4 way ............... BJ ....................... Drive forward/reverse ............. 25 ft-lbs / 34 Nm
11 Check valve ............................................... BK ...................... Steer circuit ............................ 20 ft-lbs / 27 Nm

1 2
BB
BA
3
BC
4
BD
BE
5
6
BF
7
Y8 BG
8
BH
BK
Y4
9
Y3 BI
Y6
Y5
BJ
11 10

6-3 5 Hold the system relief valve with a wrench and

remove the cap (item AC).
Valve Adjustments -
AA
Function Manifold AB
AK
How to Adjust the System Relief AC
a
AD
Valve
Be sure that the hydraulic oil level AE
b
is between the FULL and ADD marks
AF
on the oil level indicator decal.
Before serial number 35800: AG
1 Open the hydraulic power unit module tray and

locate the system relief valve on the function AH
manifold (item AC).

2 Place maximum rated load into the platform. AJ
AI
Secure the load to the platform. Refer to
Section 2, Specifications. a system relief valve
b function manifold
6 Models with lift function enable button:
Perform this test from the ground
Press and hold the lift function enable button.
with the platform controls. Do not
Models with drive function select button:
stand in the platform.
Press the lift function select button.
7 Press and hold the function enable switch.
position at both the ground and platform 8 While activating the platform up function, adjust
controls. the internal hex socket clockwise, just until the
platform begins to raise.
9 Fully lower the platform.
10 Add an additional 50 pounds / 22.7 kg to the
platform. Secure the additional weight.
Result: The power unit should not be able to lift
the platform.
Result: If the power unit lifts the platform, adjust
the internal hex socket counterclockwise until
the adjustment is correct.
12 Install the relief valve cap.

13 Bleed the hydraulic system by raising the 3 Chock both sides of the wheels at the steer end
platform to full height. If the pump cavitates or of the machine.
platform fails to reach full height, add hydraulic
oil until the pump is functioning correctly. Do not
overfill the hydraulic reservoir. Perform this test from the ground
Component damage hazard. Do
not continue to operate the
machine if the hydraulic pump is 5 Turn the key switch to platform control and pull
cavitating. out the red Emergency Stop button to the on
After serial number 35799:
controls.
1 Open the hydraulic power unit module tray and 6 Press and hold the function enable switch.
locate the system relief valve on the function
manifold (item BC). 7 Move and hold the joystick fully in either
direction while observing the pressure reading
BA
a on the pressure gauge. Note the pressure.
BB
Refer to Section 2, Specifications.
BC
8 Turn the machine off. Hold the system relief
b valve with a wrench and remove the cap
(item BC).
BD
BE 9 Adjust the internal hex socket. Turn it clockwise
c
to increase the pressure or counterclockwise to
BF decrease the pressure.
BG
Tip-over hazard. Failure to adjust
the relief valves to specification
could cause the machine to tip
BH
BK
over resulting in death or serious
injury. Do not adjust the relief
BI valve pressures higher than
specifications.
BJ
11 Repeat steps 5 through 7 to confirm the relief
a test port
b system relief valve valve pressure.
c function manifold
2 Connect a 0 to 5000 psi / 0 to 350 bar

pressure gauge to the test port on the function
manifold (item BA).

How to Adjust the Platform Lift 2 Connect a 0 to 5000 psi / 0 to 350 bar pressure
gauge to the test port on the function manifold
Relief Valve (item BA).
(after serial number 35799) 3 Chock both sides of the wheels at the steer end
Be sure that the hydraulic oil level of the machine.
is between the full and add marks 4 Remove the platform controls from the platform.
on the oil level indicator decal.
1 Open the hydraulic power unit module tray and with the platform controls. Do not
locate the system relief valve on the function stand in the platform.
manifold (item BC).
a out the red Emergency Stop button to the on
BA
BB position at both the ground and platform
controls.
BC
b 6 Press and hold the function enable switch.
BD 7 Move and hold the joystick fully in either

c
BE
direction while observing the pressure reading
d on the pressure gauge. Note the pressure.
BF Refer to Section 2, Specifications.
8 Turn the machine off. Hold the system relief
BG
valve with a wrench and remove the cap
(item BC).
BH
BK 9 Adjust the internal hex socket. Turn it clockwise
BI
decrease the pressure.
BJ Tip-over hazard. Failure to adjust
a test port over resulting in death or serious
b system relief valve injury. Do not adjust the relief
c lift relief valve
d function manifold valve pressures higher than
specifications.


valve pressure.
12 Place maximum rated load into the platform.
Secure the load to the platform. Refer to
Section 2, Specifications.
controls.
14 Hold the lift relief valve with a wrench and
remove the cap (item BD).
15 While activating the platform up function, adjust
the internal hex socket clockwise, just until the
platform begins to raise.
16 Fully lower the platform.
17 Add an additional 50 pounds (22.7 kg) to the
platform. Secure the additional weight.
Result: The power unit should not be able to lift
the platform.
Result: If the power unit lifts the platform, adjust
the internal hex socket counterclockwise until
the adjustment is correct.
20 Bleed the hydraulic system by raising the
platform to full height. If the pump cavitates or
the platform fails to reach full height, add
hydraulic oil until the pump is functioning
correctly. Do not overfill the hydraulic tank.
Component damage hazard. Do
not continue to operate the
machine if the hydraulic pump is
cavitating.

How to Adjust the Steer Relief 2 Connect a 0 to 5000 psi / 0 to 350 bar pressure
gauge to the test port (item AA or BA) on the
Valve function manifold.
1 Open the hydraulic power unit module tray and a
BA
locate the steer relief valve on the function BB
manifold (items AE or BF).

a BC
AA
AB
AK BD
BE
AC c
AD
BF
b
AE
b
BG
c AF
BH
AG BK
BI
AH
BJ
AJ
AI
Models after serial number 35799
Models before serial number 35800
a test port
a test port b steer relief valve
b steer relief valve c function manifold
c function manifold
controls.

5 Activate the function enable switch and press

and hold the steer thumb rocker switch to the
right. Allow the wheels to completely turn to the
right. Continue holding the switch while
observing the pressure reading on the pressure
gauge. Note the pressure. Refer to Section 2,
Specifications.
6 Press and hold the steer thumb rocker switch to
the left. Allow the wheels to completely turn to
the left. Continue holding the switch while
observing the pressure reading on the pressure
gauge.
7 Turn the machine off. Hold the steer relief valve
with a wrench and remove the cap
(item AE or BF).
8 Adjust the internal hex socket. Turn it clockwise
decrease the pressure.
Tip-over hazard. Failure to adjust
over resulting in death or serious
injury. Do not adjust the relief
valve pressures higher than
specifications.
valve pressure.

6-4 How to Test a Coil Diode

Valve Coils Genie incorporates spike suppressing diodes in all
of its coils. Properly functioning coil diodes protect
How to Test a Coil the electrical circuit by suppressing voltage spikes.
Voltage spikes naturally occur within a function
A properly functioning coil provides an circuit following the interruption of electrical current
electromotive force which operates the solenoid to a coil. Faulty diodes can fail to protect the
valve. Critical to normal operation is continuity electrical system, resulting in a tripped circuit
within the coil that provides this force field. breaker or component damage.
Electrocution hazard. Contact with Electrocution hazard. Contact with
electrically charged circuits could electrically charged circuits could
result in death or serious injury. result in death or serious injury.
Remove all rings, watches and Remove all rings, watches and
other jewelry. other jewelry.
1 Tag and disconnect the wire harness from the 1 Test the coil for resistance. See 6-4 How to
coil to be tested. Test a Coil.
2 Test the coil resistance.
Result: The resistance should be within
specification, plus or minus 30%.
Result: If the resistance is not within
specification, plus or minus 30%, replace the
coil.
Valve Coil Resistance Specifications
Description Specification

20V DC with diode (schematic item AF and BI)

20V DC with diode (schematic item AG)
Solenoid valve, N.O. poppet 25 to 27 Ω

20V DC with diode (schematic item AH)

20V DC with diode (schematic item AI and BJ)

20V DC with diode (schematic item BG)

2 Connect a 10W resistor to the negative terminal 4 Connect the negative lead to the other terminal
of a known good 9V DC battery. Connect the on the coil.
other end of the resistor to a terminal on the
If testing a single-terminal coil,
coil.
connect the negative lead to the
The battery should read 9V DC or internal metallic ring at either end
more when measured across the of the coil.
terminals.
5 Momentarily connect the positive lead from the
W
Resistor, 10W multimeter to the positive terminal on the 9V
Genie part number 27287 battery. Note and record the current reading.
6 At the battery or coil terminals, reverse the
connections. Note and record the current
reading.
COIL Result: Both current readings are greater than
a
d AMMETER 0 mA and are different by a minimum of 20%.
The coil is good.
c - Result: If one or both of the current readings are

0 mA, or if the two current readings do not differ
by a minimum of 20%, the coil and/or its
+
b
10 W 9V internal diode are faulty and the coil should be
RESISTOR BATTERY
replaced.
c
b
+
-
a multimeter
b 9V DC battery
c 10W resistor
d coil
Note: Dotted lines in illustration indicate a

reversed connection as specified in step 6
3 Set a multimeter to read DC voltage.

The multimeter, when set to read
DC voltage, should be capable of
reading up to 800 mA.

Hydraulic Tank REV A
7-1 2 Open the power unit module tray.

Hydraulic Tank 3 Remove the drain plug from the hydraulic tank
and allow all of the oil from the tank to drain into
The primary functions of the hydraulic tank are to a suitable container. Refer to Section 2,
cool, clean and deaerate the hydraulic fluid during Specifications.
operation. It utilizes internal suction strainers for Bodily injury hazard. Spraying
the pump supply lines and has an external return hydraulic oil can penetrate and
line filter. burn skin. Loosen hydraulic
How to Remove the the oil pressure to dissipate
Hydraulic Tank gradually. Do not allow oil to squirt
or spray.
work area and surfaces where this 4 Tag, disconnect and plug the hydraulic tank
procedure will be performed must return hose at the top of the hydraulic tank.
be clean and free of debris that 5 Remove the motor controller mounting bracket
could get into the hydraulic retaining fasteners and move the motor
system. controller to the side.
When removing a hose assembly 6 Remove the return filter mounting bracket
or fitting, the O-ring on the fitting fasteners from the manifold. Push the filter and
and/or hose end must be replaced accumulator out of the way.
during installation. Refer to 7 Tag, disconnect and plug the hydraulic pump
Section Two, Hydraulic Hose and inlet hose at the side of the hydraulic tank.
8 Remove the hydraulic tank retaining fasteners
Perform this procedure with the and remove the hydraulic tank from the
platform in the stowed position. machine.
1 Disconnect the battery pack from the machine.
other jewelry.

REV B
Steer Axle Components
8-1 7 Tag, disconnect and plug the hydraulic hoses
on the drive motor. Cap the fittings on the drive
Yoke and Drive Motor motor.
How to Remove the Yoke hydraulic oil can penetrate and
and Drive Motor Assembly burn skin. Loosen hydraulic
or spray.
during installation. Refer to Component damage hazard.
Section Two, Hydraulic Hose and Hoses can be damaged if they are
Fitting Torque Specifications. kinked or pinched.
1 Block the non-steer wheels. 8 Support and secure the yoke assembly to an
appropriate lifting device.
the steer end of the machine. 9 Remove the retaining fastener from the steer
link at the yoke assembly.
3 Remove the cotter pin from the wheel castle
nut. Note the quantity and location of
the spacers when disconnecting
Always replace the cotter pin with
the steer link from the yoke
a new one when removing the
assembly.
castle nut.
10 Remove the retaining fastener from the top of
4 Loosen the wheel castle nut. Do not remove it.
the yoke pivot shaft.
11 Lower the yoke assembly out of the chassis.
6 inches / 15 cm. Place blocks under the
chassis for support. Bodily injury hazard. The yoke/
motor assembly may fall if not
Crushing hazard. The chassis
could fall if not properly supported.
removed from the chassis.
6 Remove the wheel castle nut. Remove the
During re-assembly, be sure that
wheel.
the spacers are installed onto the
steer link.

STEER AXLE COMPONENTS REV B
How to Remove a Drive Motor 7 Tag, disconnect and plug the hydraulic hoses
on the drive motor. Cap the fittings on the drive
1 Block the non-steer wheels. motor.
2 Center a lifting jack under the drive chassis at Bodily injury hazard. Spraying
the steer end of the machine. hydraulic oil can penetrate and
3 Remove the cotter pin from the wheel castle nut
connections very slowly to
of the motor to be removed.
allow the oil pressure to
Always replace the cotter pin with dissipate gradually. Do not
a new one when removing the allow oil to squirt or spray.
castle nut.
4 Loosen the wheel castle nut. Do not remove it. Hoses can be damaged if they are
kinked or pinched.
2 inches / 5 cm. Place blocks under the chassis 8 Remove the drive motor mounting fasteners.
for support. Remove the motor.
Crushing hazard. The chassis Torque specifications
Drive motor mounting fasteners, dry 75 ft-lbs
6 Remove the wheel castle nut. Remove the 101.7 Nm
wheel.
Drive motor mounting fasteners, lubricated 56 ft-lbs
76.3 Nm

REV B STEER AXLE COMPONENTS
8-2 4 Remove the pin retaining fasteners from the

rod-end pivot pin. Remove the pin.
Steer Cylinder
Note the quantity and location of
the spacers when removing the
How to Remove the rod-end pivot pin.
Steer Cylinder
5 Remove the steer cylinder from the machine.
1 Block the non-steer wheels.
2 Tag, disconnect and plug the hydraulic hoses
from the steer cylinder. Cap the fittings on the
cylinder.
gradually. Do not allow oil to
squirt or spray.
Hoses can be damaged if they are
kinked or pinched.
barrel-end pivot pin. Remove the pivot pin.
the spacers when removing the
barrel-end pivot pin.

STEER AXLE COMPONENTS REV B
8-3 7 Turn the yokes to the side so the bellcrank can

be removed.
Steer Bellcrank
8 Remove the bellcrank from the machine.
How to Remove the Steer Note the quantity and the location
Bellcrank of the spacers in between the
bellcrank and the steer links.
1 Remove the steer cylinder. See 8-2, How to
Remove the Steer Cylinder.
2 From serial number 17408 to 43000: Remove
the retaining fastener from the center pivot pin
of the bellcrank.
After serial number 43000: Remove the
retaining fastener from the center pivot pin of
the bellcrank. Remove the pin.
Note the quantity and the location
of the spacers on the bellcrank.
3 Block the non-steer wheels.
the steer end.
5 Remove the retaining fasteners from the steer
links at each end of the bellcrank.
the spacers between the bellcrank
and the steer links.
14 inches / 36 cm. Place blocks under the
chassis for support.

REV B
Non-steer Axle Components
9-1 7 Raise the machine approximately
2 inches / 5 cm. Place blocks under the chassis
Drive Brake for support.
How to Remove a Drive Brake could fall if not properly supported.
When removing a hose assembly 8 Remove the wheel castle nut. Remove the
or fitting, the O-ring on the fitting wheel.
and then torqued to specification 9 Tag, disconnect and plug the hydraulic hose
during installation. Refer to from the brake. Cap the fitting on the brake.
1 Support and secure the entry ladder to an burn skin. Loosen hydraulic
appropriate lifting device. connections very slowly to allow
2 Remove the entry ladder mounting fasteners. gradually. Do not allow oil to squirt
Remove the entry ladder from the machine. or spray.
Crushing hazard. The entry ladder 10 Place a lifting jack under the brake for support.
may become unbalanced and fall
if it is not properly supported and 11 Remove the fasteners that attach the brake to
secured to the lifting device. the drive chassis. Remove the brake.
3 Block the steer wheels. Crushing hazard. The brake will
fall if not properly supported when
4 Center a lifting jack under the drive chassis at the mounting fasteners are
the non-steer end. removed.
5 Remove the cotter pin from the wheel castle
nut. Torque specifications
Always replace the cotter pin with Brake mounting fasteners, dry 75 ft-lbs
a new one when removing the 102 Nm
castle nut. Brake mounting fasteners, lubricated 56 ft-lbs
6 Loosen the wheel castle nut. Do not remove it. 76 Nm

Brake Release Hand Pump Components

REV A
10-1
Brake Release Hand Pump Components
The brake release hand pump manifold is mounted behind the entry ladder next to the battery charger.
Index Schematic
1 Check valve, pilot operated .............. A ............... Manual brake release circuit ........ 25-30 ft-lbs / 34-41 Nm
2 Shuttle valve ..................................... B ............... Brake release ................................. 8-10 ft-lbs / 11-14 Nm
3 Hand pump ....................................... C ............... Manual brake release ................... 25-30 ft-lbs / 34-41 Nm
B
3 2

April 2003 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-1530 and GS-1930 Operator’s
Manual.
Be sure that all necessary tools and test
Observe and Obey: equipment are available and ready for use.
Troubleshooting and repair procedures shall be Read each appropriate flow chart thoroughly.
completed by a person trained and qualified on Attempting shortcuts may produce hazardous
the repair of this machine. conditions.
Immediately tag and remove from service a Be aware of the following hazards and follow
damaged or malfunctioning machine. generally accepted safe workshop practices.
Repair any machine damage or malfunction Crushing hazard. When testing

before operating the machine. or replacing any hydraulic
component, always support
Unless otherwise specified, perform each the structure and secure it
repair procedure with the machine in the from movement.
following configuration:
Electrocution hazard. Contact
· Machine parked on a firm, level surface
with electrically charged circuits
· Platform in stowed position could result in death or serious
· Key switch in the off position with the injury. Remove all rings, watches
key removed and other jewelry.
· Wheels chocked Bodily injury hazard. Spraying
gradually. Do not allow oil to
squirt or spray.
Two persons will be required to
safely perform some
troubleshooting procedures.

Section 5 • Troubleshooting Flow Charts April 2003
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,
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 Fault Code Chart
describe malfunctions and can aid in
troubleshooting the machine by pinpointing the
area or component affected.

REV A
Fault Code Chart
(after serial number 17407)
Fault Code Problem Possible Causes Solution
Internal ECM error. EPROM not programmed. Replace ECM.
01
ECM/Platform Malfunctioning control cable Troubleshoot control cable
02 communication error. OR malfunctioning platform OR troubleshoot platform
(See Chart 16) controls. controls.
Undefined platform DIP DIP switch settings Correct DIP switch settings.
03 switch settings. incorrect.
Chassis up/down toggle Malfunctioning up/down Troubleshoot up/down
12 closed at start up. switch. switch.
(See Chart 4)
Pothole guard failure. Malfunctioning pothole Troubleshoot pothole switch
18 switch OR obstruction in OR remove obstruction.
(See Charts 10, pothole guard linkage.
13 or 14)
Limit switch failure. Malfunctioning limit switch Troubleshoot limit switch
19 OR wire disconnected from OR inspect wire connection.
(See Chart 15) limit switch.
Platform left turn switch Malfunctioning steer left Troubleshoot steer left
42 fault. microswitch. microswitch.
(See Chart 5 or
Chart 8)
Platform right turn switch Malfunctioning steer right Troubleshoot steer right
43 fault. microswitch. microswitch.
(See Chart 5 or
Chart 9)
Platform drive enable Malfunctioning drive enable Troubleshoot drive enable
46 switch fault. switch. switch.
(See Chart 5)
Platform joystick fault. Joystick potentiometer not Verify potentiometer setting.
47 centered.
Forward coil fault. Malfunctioning coil OR wire Troubleshoot coil OR
52 disconnected from coil. inspect wire connection.
(See Chart 11)
Reverse coil fault. Malfunctioning coil OR wire Troubleshoot coil OR
(See Chart 12)
Up coil fault. Malfunctioning coil OR wire Troubleshoot coil OR
(See Chart 6)
Down coil fault. Malfunctioning coil OR wire Troubleshoot coil OR
(See Chart 7)
Steer right coil fault. Malfunctioning coil OR wire Troubleshoot coil OR
(See Chart 9)
Steer left coil fault. Malfunctioning coil OR wire Troubleshoot coil OR
(See Chart 8)
Brake coil fault. Malfunctioning coil OR wire Troubleshoot coil OR
(See Chart 10 or
Chart 10A)
Series/parallel coil fault. DIP switch settings are Troubleshoot and correct
59 incorrect. DIP switch settings.
Low battery voltage. Batteries discharged. Charge batteries.
68
ECM has been erased. Static strap may be missing Replace static strap.
88 from the machine.

Chart 1 REV A
All Functions With the key switch Troubleshoot ground

turned to platform and platform control
Will Not control and both light is on systems separately OR
Operate Emergency Stop buttons consult the Genie
pulled out to the ON Industries Service
position, press and hold Department.
the function enable
switch. Visually inspect
Be sure the circuit the power-on LED.
breaker and fuse are
not tripped or blown. light is not on
Be sure both After serial number Repair or replace the

bad
Emergency Stop 25141: Troubleshoot the wire circuit from the
CR48 power relay to U5 platform controls to
switches are pulled out CR48 OR repair or
to the ON position. replace the CR48 socket
OR replace CR48.
Be sure the batteries good
are fully charged and
properly connected.
less than
Check voltage on the 20V Replace F6 OR check
Be sure the hydraulic output side of the 275A for short circuits OR
tank is filled to the fuse F6. check battery cables OR
check for open in
correct level. negative battery cable
from batteries to ground
point on module tray.
20V or more
Check continuity from no Repair open in the

the B- terminal on the continuity negative battery cable
motor controller U6 to from the B- terminal at
the negative battery motor controller U6 to
cable at QD1. QD1.
continuity
Check voltage on 0V Repair open in the 24V

terminal D1 at the pump cable circuit from F6 to
motor M6. QD1 OR replace or
repair QD1 OR repair
open in 24V cable circuit
from QD1 through
terminal B+ at U6 to
terminal D1 at M6.
20V or more
Continued on the next

page.

REV A CHART 1
Continued from the Check voltage at input 0V Repair open in wire from
side of Emergency Stop the input side of P1 to
previous page. button P1. circuit breaker CB2 OR
reset or replace CB2 OR
repair open in the wire
from CB2 to QD1.
20V or more
Check voltage at the Repair open in the wire

input side of each 0V from P1 to KS1 OR
contact at key switch repair open in the wire
KS1. jumper to each contact
OR replace contact on
P1 OR replace P1.
20V or more
0V bad
Check the output side of Check the cam on KS1. Repair or replace KS1.
the platform control
contact at KS1. good
Replace contact OR
refer to Platform
Controls Inoperative,
20V or more Chart 6 OR consult the
Genie Industries Service
Department.
0V bad
Turn KS1 to the ground Check the cam on KS1. Repair or replace KS1.
control position and
check output side of
each contact. good
Replace contact OR
refer to Ground Controls
Inoperative, Chart 5 OR
consult the Genie
20V or more Industries Service
Department.
Refer to Chart 2, Pump

Motor Will Not Operate
OR repair open in WH
wire (C2 estop chassis)
OR consult the Genie
Industries Service
Department.

Chart 2 REV A
Pump Motor With the key switch

20V or
more Activate the lift function 0V Repair open in the
turned to ground and check voltage on ground cable circuit from
Will Not controls and both terminal M- at U6. terminal A1 at M5 to
Operate Emergency Stop buttons terminal M- at U6 OR
pulled out to the ON replace M5 OR consult
20V or more
position, activate the lift the Genie Industries
function and check for Service Department.
voltage on the positive Replace U6 OR consult
Be sure the circuit terminal D1 at pump the Genie Industries
breaker and fuse are motor M5. Service Department.
not tripped or blown.
0V
Be sure the batteries
are fully charged and After serial number bad Repair or replace the
25141: Troubleshoot the wire circuit from the
properly connected. CR48 power relay to U5 platform controls to
CR48 OR repair or
replace the CR48 socket
OR replace CR48.
good
20V or
Check voltage on the B+ more Replace positive battery
terminal at motor cable from the B+
controller U6. terminal at U6 to D1 at
M5.
0V
Check for continuity in Replace the cable from

the positive cable circuit no the B+ terminal at U6 to
from the B+ terminal at continuity QD1 OR repair or
U6 through battery quick replace QD1 OR replace
disconnect QD1 through the cable from QD1 to
the 275A fuse F6 to the F6 OR replace F6 OR
battery B5. replace the cable from
F6 to B5.
continuity
no
Check for continuity in continuity Replace ground cable
the ground cable circuit from terminal A1 at M5
from terminal A1 at to terminal M- at U6.
pump motor M5 to the
M- terminal at motor
controller U6.
continuity

page.

REV A CHART 2
Check for continuity in no Replace ground cable

Continued from the the ground cable circuit
previous page. continuity from terminal B- at U6 to
from terminal B- at U6 QD1 OR repair or
through QD1 to the replace QD1 OR replace
battery B5. the cable from QD1 to
B5.
continuity
Activate the lift function 0V Repair open in the WH

and check voltage on A8 motor contr enable
terminal 1 at U6. wire from terminal 1 at
U6 to pin A8 of the AMP
connector at ECM U5.
20V or more
Activate the lift function Repair open in the WH

0V A9-motor cont enable
and check voltage on
terminal 3 at U6. wire from pin A9 at U5
to terminal 3 at U6 OR
replace U5 OR consult
5V
the Genie Industries
Service Department.
Replace M5 OR consult
Service Department.

Chart 3 REV A
All Functions Check for a positive bad Replace pump coupling

connection between OR replace the pump
Inoperative, electric motor and OR replace M5.
pump by removing
Power Unit pump from motor M5,
Starts and Runs leaving all hoses
connected. Visually
check the coupling
connection.
Be sure, if the Error good

Indicator light is on at
bad
the platform controls, Test the hydraulic pump. Replace the pump.
See Repair section.
you refer to the specific
chart that relates to the
good
error code that is
displayed on the ECM. Consult the Genie
Industries Service
Be sure the circuit Department.
properly connected.
Be sure the hydraulic

tank is filled to the
correct level.

REV A
Chart 4
Ground With key switch turned Repair open in WH wire
to ground controls and from KS1 to Emergency
Controls both Emergency Stop Stop button P1 OR
0V
buttons pulled out to the repair or replace P1 OR
Inoperative, ON position, check repair open in WH wire
Platform voltage on the ground from P1 to circuit
control contact at the breaker CB2.
Controls input side of the key
switch KS1.
Operate
20V or more
Normally
Check voltage on output 0V Check if internal cam at yes Replace contact for
side of ground control KS1 is activating the ground controls at KS1.
contact at KS1. ground control contact.
Be sure, if the Error
Indicator light is on at no
the platform controls,
you refer to the specific 20V or more Replace KS1.
error code that is
displayed on the ECM.
Check voltage on the 0V Repair open in WH wire
Be sure the circuit center terminal of the jumper from KS1 to the
platform up/down toggle center terminal at TS66.
breaker and fuse are switch TS66 at the
not tripped or blown. ground controls.
Be sure the batteries 20V or more

are properly connected.
Test or replace TS66
Be sure the batteries (See Repair Section)
are fully charged. OR repair open in the
WH B12 UP/DWN SWITCH
UP wire from TS66 to the
ECM U5 OR repair open
in the WH A12 UP/DWN
SWITCH DWN wire from
TS66 to U5 OR consult
Service Department.

Chart 5 REV A
Platform With the key switch Repair open in WH wire

turned to platform from KS1 to Emergency
Controls control and both 0V Stop button P1 OR
Emergency Stop buttons repair open in the WH
Inoperative, pulled out to the ON wire from P1 to circuit
Ground position, check voltage breaker CB2.
on the input side of the
Controls platform control contact
on key switch KS1.
Operate
20V or more
Normally
Check voltage on output 0V Check if internal cam at yes Replace contact for
side of platform control KS1 is activating platform controls at KS1.
contact at KS1. platform control contact.
Indicator light is on at no
you refer to the specific 20V or more Replace KS1.
error code that is
displayed on the ECM.
Check voltage on 0V Repair open in WH A11-
Be sure the circuit terminal A11 at the ECM keyswitch wire from KS1
breaker and fuse are U5. to terminal A11 at U5.
20V or more
Be sure the batteries 0V
are fully charged and Check voltage on Replace U5.
terminal B2 at U5.
properly connected.
20V or more
Check voltage at the Repair or replace P2 OR

output side of the 0V replace control cable
Emergency Stop button from U5 to the platform
P2. controls.
20V or more
Check voltage on 0V Replace control cable

terminal A4 at U5. from U5 to the platform
controls.
20V or more
Replace control cable

from U5 to the platform
controls OR replace the
platform controls OR
consult the Genie
Industries Service
Department.

REV A
Chart 6
Platform Up Models with lift Connect the positive Repair open in the WH
function enable lead from a volt meter to A6-up coil wire from the
Function button: With the key the coil on the platform platform up directional
switch turned to platform up directional valve valve coil (item AG or
Inoperative controls and both (item AG or BG) wire
0V
BG) to the ECM U5 (see
Emergency Stop buttons light is terminal without Repair Section) OR
pulled out to the ON on disconnecting the wire replace U5 OR consult
position, press and hold and the negative lead of the Genie Industries
Be sure all other the lift function enable the volt meter to the Service Department.
button and activate the ground point on the
functions operate controller in the UP manifold. Activate the
normally. direction and check to controller in the UP
see if the error indicator direction and check the
Be sure the circuit light at the platform voltage.
controls is on.
breaker and fuse are Models with drive
function select button: 20V or more
not tripped or blown. 0 or
With the key switch infinite
Be sure the batteries turned to platform Disconnect the wire ohms Replace the platform up
controls and both from the platform up directional valve coil
are fully charged and Emergency Stop buttons directional valve coil on (item AG or BG).
properly connected. pulled out to the ON the function manifold
position, press the lift (item AG or BG) and
function select button check the resistance.
and activate the See Repair Section.
controller in the UP
direction and check to
18-20 ohms
see if the error indicator
light at the platform
controls is on. Repair or replace the
platform up directional
valve cartridge (item AG
or BG) OR consult the
light is not on Department.
3000
Install a 0 to 5000 PSI PSI or Are there mechanical Remove the mechanical
(350 bar) pressure restrictions keeping yes restrictions keeping
more
gauge at the quick platform up function platform up function
disconnect coupling from moving? from moving.
(item AA or BA) on the
function manifold and
activate the platform up no
function.
Repair or replace the
less than platform lift cylinder OR
3000 PSI consult the Genie
Industries Service
Adjust the system relief Department.
valve (item AC or BC)
OR repair or replace the
platform lift cylinder OR
the platform lowering
valve (item D) may be
stuck open OR the
function manifold could
have an internal defect.
Consult the Genie
Industries Service
Department.

Chart 7 REV A
Platform Down With the key switch With the platform raised Repair open in the WH
turned to platform and the safety arm B6-down coil wire from
Function controls and both installed, connect the the platform lowering
Emergency Stop buttons leads of a volt meter to valve coil (item D) to the
Inoperative pulled out to the on the wires on the platform ECM U5 OR repair open
position and the platform lowering coil (item D) on 0V in the brown ground wire
raised slightly, the cylinder without circuit from the coil to
Models with lift removing the wires. the battery module tray
Be sure all other function enable Models with lift OR replace U5 OR
button: press and hold light is function enable consult the Genie
functions operate the lift function enable on button: Press and hold Industries Service
normally. button and activate the the lift function enable Department.
controller in the DOWN button and activate the
Be sure the circuit direction and check to controller in the DOWN
see if the error indicator direction and check the
breaker and fuse are light is on. voltage.
not tripped or blown. Models with drive Models with drive
function select button: function select button:
Be sure the batteries press the lift function Press the lift function
select button and select button and
are fully charged and activate the controller in activate the controller in
properly connected. the DOWN direction and the DOWN direction and
check to see if the error check the voltage.
indicator light is on.
20V or more
0 or
Label and disconnect infinite
the wires from the coil ohms Replace platform
on the platform lowering lowering valve coil
valve (item D) at the (item D).
platform lift cylinder and
check the resistance
(See Repair Section).
23 to 25 ohms
With the platform raised platform

and the safety arm lowers
platform lowering valve
removed, pull the cartridge (item D).
light is not on manual platform
lowering handle at the
ground controls.
platform does
not lower
Are there mechanical no Repair or replace the

restrictions keeping the platform lowering valve
platform from lowering? cartridge (item D) OR
repair or replace the lift
cylinder OR replace the
yes orifice or orifice washer
(item E) OR consult the
Remove mechanical Genie Industries Service
restrictions keeping the Department.
platform from lowering.
Replace the platform
controls OR replace the
ECM U5 OR consult the
Department.

REV A
Chart 8
Steer Left With the key switch Connect the positive Repair open in the WH
turned to platform lead from a volt meter to B7-left coil wire from the
Function controls and both the WH C7-rt coil wire coil on the steer left
Emergency Stop buttons terminal at the steer directional valve (item
Inoperative pulled out to the ON right directional valve AF or BI) to the ECM U5
light is
position, on coil (item AF or BI) 0V OR repair open in the
Models with lift without disconnecting brown ground wire
function enable the wire, and the circuit from the coil to
Be sure all other button: activate the negative lead of the volt the wire harness OR
function enable switch meter to the brown replace U5 OR consult
functions operate and activate the steer ground wire at the valve the Genie Industries
normally. rocker switch in the LEFT coil. Activate the steer Service Department.
direction and check to rocker switch in the
Be sure the circuit see if the error indicator RIGHT direction and
light at the platform check the voltage.
breaker and fuse are controls is on.
not tripped or blown. Models with drive
20V or more
function select button:
Be sure the batteries press the drive function
select button and Disconnect the wires Repair or replace the
are fully charged and activate the function from the coil on the 25 to 27 steer directional valve
properly connected. enable switch and steer left directional ohms cartridge (item AF or BI)
activate the steer rocker valve on the function OR consult the Genie
switch in the LEFT manifold (item AF or BI) Industries Service
direction and check to and check the Department.
see if the error indicator resistance of the valve
light at the platform coil (See Repair
controls is on. Section).
0 or infinite
ohms
Replace the steer left
light is not on directional valve coil
(item AF or BI).
bad
Activate the function Check continuity of the Replace SW6.
enable switch and no steer left/right
activate the steer left microswitch SW6 inside
function. Does the motor the joystick controller
turn on? handle JC1.
good

wire circuit from SW6 to
yes the platform controls
circuit board U3 OR
Service Department.

page.

CHART 8 REV A
Install a 0 to 2000 psi Are there mechanical yes Remove the mechanical
Continued from the (138 bar) pressure 1500 PSI restrictions keeping the restrictions.
previous page. gauge at the quick steer left function from
disconnect coupling on moving?
the function manifold
and activate the steer no
left function.
steer cylinder OR
consult the Genie
less than Industries Service
1500 PSI Department.
Reset the steer relief Repair or replace the

valve pressure 1500 PSI steer cylinder OR
(item AE or BF) replace the steer left/
(See Repair Section). right valve cartridge
(item AF or BI) OR the
less than function manifold could
1500 PSI have an internal defect.
Consult the Genie
Replace the steer relief Industries Service
valve (item AE or BF). Department.

REV A
Chart 9
Steer Right With the key switch Connect the positive Repair open in the WH
turned to platform lead from a volt meter to C7-rt coil wire from the
Function controls and both the WH B7-left coil wire coil on the steer right
Emergency Stop buttons terminal at the steer left directional valve (item
Inoperative pulled out to the ON directional valve coil AF or BI) to the ECM U5
light is
position, on (item AF or BI) without 0V OR repair open in the
Models with lift disconnecting the wire, brown ground wire
function enable and the negative lead of circuit from the coil to
Be sure all other button: activate the the volt meter to the the wire harness OR
function enable switch brown ground wire at replace U5 OR consult
functions operate and activate the steer the valve coil. Activate the Genie Industries
normally. rocker switch in the the steer rocker switch Service Department.
RIGHT direction and in the LEFT direction and
Be sure the circuit check to see if the error check the voltage.
indicator light at the
breaker and fuse are platform controls is on.
20V or more
not tripped or blown. Models with drive
function select button:
Be sure the batteries press the drive function Disconnect the wires Repair or replace the
select button and from the coil on the 25 to 27 steer directional valve
are fully charged and activate the function steer right directional ohms cartridge (item AF or BI)
properly connected. enable switch and valve on the function OR consult the Genie
activate the steer rocker manifold (item AF or BI) Industries Service
switch in the RIGHT and check the Department.
direction and check to resistance of the valve
see if the error indicator coil (See Repair
light at the platform Section).
controls is on.
0 or infinite
ohms
Replace the steer right

directional valve coil
light is not on (item AF or BI).
bad
Activate the function Check continuity of the Replace SW6.
enable switch and no steer left/right
activate the steer right microswitch SW6 inside
function. Does the motor the joystick controller
turn on? handle JC1.
good

wire circuit from SW6 to
the platform controls
yes circuit board U3 OR
Service Department.

page.

CHART 9 REV A
Install a 0 to 2000 psi Are there mechanical yes Remove the mechanical
Continued from the (138 bar) pressure 1500 PSI restrictions keeping the restrictions.
previous page. gauge at the quick steer left function from
disconnect coupling on moving?
the function manifold
and activate the steer no
right function.
steer cylinder OR
consult the Genie
less than Industries Service
1500 PSI Department.
Reset the steer relief Repair or replace the

valve pressure 1500 PSI steer cylinder OR
(item AE or BF) replace the steer left/
(See Repair Section). right valve cartridge
(item AF or BI) OR the
less than function manifold could
1500 PSI have an internal defect.
Consult the Genie
Replace the steer relief Industries Service
valve (item AE or BF). Department.

REV A
Chart 10
All Drive With the key switch Reset the ECM U5 by Refer to the chart(s) that
turned to platform pushing in Emergency light is are related to the error
Functions controls and both light is Stop button P2 to the on code that is displayed
Emergency Stop buttons on OFF position. Pull the on U5 OR consult the
Inoperative, All pulled out to the ON Emergency Stop button Genie Industries Service
Other position, activate drive P2 up to the ON position. Department.
forward and drive Check to see if the error
Functions reverse functions.
Check to see if the error
indicator light is on at
the platform controls.
Operate indicator light is on at
the platform controls. light is
Normally not on
Replace the platform

controls OR consult the
light is Genie Industries Service
Be sure, if the Error not on Department.
Indicator light is on at
you refer to the specific
chart that relates to the Replace the platform yes Replace the platform
controls with known controls.
error code that is operating platform
displayed on the ECM. controls. Activate the
drive function. Does the
Be sure the circuit drive function operate?
no
Be sure the batteries Replace the ECM U5
are fully charged and Industries Service
properly connected. Department.

Chart 10A REV A
Brake Release Chock the wheels at the wheels Turn the brake release wheels Rebuild or replace the
steer end of the turn valve (item A) clockwise turn brakes OR replace the
Function machine. Jack the non- all the way and try to brake release valve
steer end of the rotate the wheels. (item A) OR consult the
Inoperative machine up Genie Industries Service
approximately 4 inches Department.
wheels
(10 cm) and place jack
stands under the do not
machine for support. turn
Turn the brake release
Indicator light is on at knob (item A) Attempt to drive the If machine still does not
the platform controls, counterclockwise all the machine in either wheels drive at full speed with
way and pump the hand direction and have an turn the platform in the
you refer to the specific pump (item C) fully assistant try to rotate the stowed position, replace
chart that relates to the 13-15 times or until non steer wheels. This the platform controls OR
error code that is much resistance is felt. will require 2 people. replace the platform
Turn each wheel by controls circuit board U3
displayed on the ECM. hand. Each wheel OR replace the ECM U5
should turn freely OR consult the Genie
Be sure the circuit without much effort. wheels Industries Service
breaker and fuse are do not Department.
turn
are fully charged and Plumb a 0 to 500 psi (35 Replace the shuttle
properly connected. bar) gauge into the hose valve (item B) OR
from the function less than replace the brake
manifold to the brake. 200 psi release valve (item A)
Attempt to drive the OR the function
machine in either manifold or brake
direction and read the release manifold may
wheels pressure on the gauge. have an internal defect
do not OR consult the Genie
turn
200 to Industries Service
300 psi Department.
Pressure is good.
Replace the brakes OR
consult the Genie
Industries Service
Department.
Plumb a 0 to 500 psi (35 Replace the shuttle

bar) gauge into the hose valve (item B) OR
from the function less than replace the brake
manifold to the brake. 200 psi release valve (item A)
Attempt to drive the OR the function
machine in either manifold or brake
direction and read the release manifold may
pressure on the gauge. have an internal defect
200 to Industries Service
300 psi Department.
Pressure is good.
Replace the brakes OR
consult the Genie
Industries Service
Department.

REV A
Chart 11
Drive Forward With the key switch Connect the positive Repair open in the WH
turned to platform lead from a volt meter to C6-fwd coil wire from
Function controls and both the drive forward the drive forward
Emergency Stop buttons directional valve coil directional valve coil
Inoperative pulled out to the ON
light is
(item AI or BJ) wire (item AI or BJ) to the
on 0V
position, activate drive terminal without ECM U5 OR repair open
controller in the forward disconnecting the wire, in the brown ground wire
direction and check to and the negative lead of circuit from the coil to
Be sure all other see if the error indicator the volt meter to the the wire harness OR
light at the platform brown ground wire on replace U5 OR consult
functions operate controls is on. the coil. Activate drive in the Genie Industries
normally. the forward direction Service Department.
and check the voltage.
Be sure the circuit
breaker and fuse are 20V or more
Disconnect the wires infinite
Be sure the batteries from the drive forward ohms Replace the drive
directional valve coil forward directional valve
are fully charged and (item AI or BJ) and coil (item AI or BJ).
properly connected. check resistance of the
coil. See Repair Section.
light is not on
18 to 20 ohms

drive forward directional
valve (item AI or BJ)
Industries Service
Department.
Check the connection at

the ECM U5 OR replace
the drive forward/
reverse valve cartridge
(item AI or BJ) OR
consult the Genie
Industries Service
Department.

Chart 12 REV A
Drive Reverse With the key switch Connect the positive Repair open in the WH
turned to platform lead from a volt meter to A7-rev coil wire from the
Function controls and both the drive reverse drive reverse directional
Emergency Stop buttons directional valve coil valve coil (item AI or BJ)
Inoperative pulled out to the ON
light is
(item AI or BJ) wire to the ECM U5 OR
on 0V
position, activate drive terminal without repair open in the brown
controller in the reverse disconnecting the wire, ground wire circuit from
direction and check to and the negative lead of the coil to the wire
Be sure all other see if the error indicator the volt meter to the harness OR replace U5
light at the platform brown ground wire on OR consult the Genie
functions operate controls is on. the coil. Activate drive in Industries Service
normally. the REVERSE direction Department.
and check the voltage.
Be sure the circuit
breaker and fuse are 20V or more
Disconnect the wires infinite
Be sure the batteries from the drive reverse ohms Replace the drive
directional valve coil reverse directional valve
are fully charged and (item AI or BJ) and coil (item AI or BJ).
properly connected. check resistance of the
coil. See Repair Section.
light is not on
18 to 20 ohms

drive reverse directional
valve (item AI or BJ)
Industries Service
Department.
Check the connection at

the ECM U5 OR replace
the drive forward/
reverse valve cartridge
(item AI or BJ) OR
consult the Genie
Industries Service
Department.

REV A
Chart 13
Machine Will With the key switch Raise the platform Raise the platform to
turned to platform light is approximately 3 feet more than 6 feet (1.8 m)
Not Drive At controls and both not on (0.9 m) and drive the yes and drive the machine. If
Emergency Stop buttons machine. the machine does not
Full Speed pulled out to the ON Does the machine drive drive and an alarm
position and the platform at a reduced speed? sounds, the machine is
in the stowed position, operating normally.
drive the machine in Check the pothole
either direction. Is the no guards for obstructions
Be sure the circuit error indicator light on at OR test the pothole
breaker and fuse are the platform controls? Consult the Genie guard limit switches
not tripped or blown. Industries Service (See Repair section).
Department.
light
Be sure the batteries is on
properly connected.
Check voltage at the Repair open in the WH
WH 39C-pothole sw 0V 39C-pothole sw wire
wire at pothole limit from LS7 to the multi-
switch LS7. function alarm H5.
20V or more
Raise the platform Adjust LS7 so the

approximately 3 feet 0V pothole arm activates
(0.9 m) and check the the switch OR replace
voltage at the output the limit switch contact
side of LS7. OR replace LS7.
20V or more
Check voltage at the Repair open in the WH

WH 21B-pothole sw wire 0V 21B-pothole jumper wire
on the input side of limit from the output side of
switch LS8. LS7 to the input side of
LS8.
20V or more
Check voltage on the 0V Adjust LS8 so the

output side of LS8. pothole arm activates
the switch OR replace
the limit switch contact
OR replace the LS8.
20V or more
Repair open in the WH

B10-pothole sw wire
from the output side of
LS8 to the ECM U5 OR
replace U5 OR see Chart
10A, Brake Release
Function Inoperative.

Chart 14 REV A
Machine With the key switch

light is
not on Check limit switch LS7 good Check the controller
turned to platform and LS8 for correct adjustments (See
Drives At Full controls and both adjustment. Repair Section) OR
Speed With Emergency Stop buttons replace the platform
pulled out to the ON controls OR replace the
bad
Platform position and the platform
in the stowed position,
ECM U5 OR consult the
Raised drive the machine in
either direction. Is the
Adjust LS7 or LS8 (See
Repair Section) OR
Department.
error indicator light on at repair or replace limit

the platform controls? switch wire circuit.
light
Be sure the circuit is on
not tripped or blown. See Chart 13 OR
remove the obstruction
from the pothole guard
Be sure the batteries OR consult the Genie
are fully charged and Industries Service
properly connected. Department.

REV A
Chart 15
Limit Switch With the key switch
20V or
more Adjust the pothole limit
turned to platform switch LS7 OR adjust
Function controls and both pothole limit switch LS8.
Inoperative Emergency Stop buttons
pulled out to the ON
position and the platform
in the stowed position,
check voltage on the
WH B10 pothole sw wire
Be sure the circuit at the ECM U5.
not tripped or blown. 0V
Be sure the limit Check voltage at down 0V Check voltage on the 0V Adjust LS6 OR replace
switches are clear of limit switch LS6. Is there other terminal at LS6. the LS6 contacts.
debris. 20V or more on one side
of LS6?
20V or more
Be sure the pothole
guards are deploying. Repair or replace the
44D wire from alarm H5
Be sure the batteries 20V or more to LS6.
properly connected.
With the platform raised 0V Check LS8 for correct good Repair or replace the
to 6 feet (1.8 m), check adjustment. wire circuit between
for 20V or more on one terminal B10 at ECM U5
side of LS8. and LS8 OR replace U5
bad
Adjust LS8.
20V or more
Check for 20V or more 0V Check LS7 for correct good Replace the LS8
on both sides of LS7. adjustment. contacts OR repair or
replace the wire circuit
between LS8 and LS7
bad OR replace the LS7
contacts.
20V or more Adjust LS7.

wire circuit between LS7
and the positive terminal
at alarm H5

Chart 16 REV A
Fault Code 02 - With the key switch Before serial number Before serial number
turned to platform 25142: Check for 25142: Replace U5.
ECM / Platform controls and both voltage on terminal B2
0V
After serial number
Emergency Stop buttons 0V at the ECM U5. 25141: Troubleshoot
Communication pulled out to the ON After serial number CR48.
Error position, check for 25141: Check for
voltage on the positive voltage on terminal 30 at
terminal 1 of the relay CR48.
Emergency Stop button
P2 at the platform
20V or more
controls.
Be sure the circuit
breaker and fuse are Disconnect the control Repair or replace the
not tripped or blown. cable quick disconnect 0V quick disconnect plug
plug at the ECM and OR replace the harness
check for voltage at pigtail.
Be sure the batteries terminal C of the quick
are fully charged and disconnect plug.
properly connected.
20V or more
Connect the control Repair or replace the

cable quick disconnect 0V quick disconnect plug
plug at the ECM. OR replace the control
Disconnect the control cable.
20V or more cable quick disconnect
plug at the platform and
check for voltage at
terminal C of the quick
disconnect plug.
20V or more
Replace the coil cord

assembly OR replace
the platform controls.
Open the platform 0V Repair or replace the

control box. With the wire between P2 and
negative lead of an U3.
ohmmeter connected to
the negative terminal of
the battery B5, check for
voltage at terminal 1 of
the voltage regulator on
the platform controls
circuit board U3.
20V or more
Continued on
page 28.

REV A CHART 16
a Platform controls circuit board

b voltage regulator terminal 2
c voltage regulator terminal 1
d circuit board voltage regulator
e voltage regulator terminal 3

CHART 16 REV A
0V
Check for voltage at Replace U3.
Continued from terminal 3 of the voltage
page 26. regulator on U3.
5V
Check for continuity in Check for continuity in continuity Consult the Genie
the blue data (+) line the green data (-) line or Industries Service
from pin D of the continuity the yellow data (-) line Department.
platform controls quick from pin E of the
disconnect to terminal platform controls quick
B1 at U5. disconnect to terminal
C1 at U5.
no continuity

no continuity assembly OR replace
the control cable from
the platform to U5.

assembly OR replace
the control cable from
the platform to U5.

April 2003 Section 6 • Schematics
Schematics
About This Section
There are two groups of schematics in this
section. An illustration legend precedes each
group of drawings.
Electrical Schematics
Observe and Obey: Electrocution hazard. Contact

with electrically charged circuits
Troubleshooting and repair procedures shall be could result in death or serious
completed by a person trained and qualified on injury. Remove all rings, watches
the repair of this machine. and other jewelry.
Immediately tag and remove from service a Hydraulic Schematics
damaged or malfunctioning machine.
Repair any machine damage or malfunction hydraulic oil can penetrate and
before operating the machine. burn skin. Loosen hydraulic
Before Troubleshooting: the oil pressure to dissipate
Read, understand and obey the safety rules gradually. Do not allow oil to
and operating instructions printed in the squirt or spray.
Genie GS-1530 and GS-1930 Operator's General Repair Process
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 April 2003
Electrical Components
REV C
Item Description Genie Part Manufacturer Manufacturer Qty

Number Part Number
B5 ................. Battery, 225AH, 6V DC .............. 62201 ........ Trojan Battery Co. .................. T-105, dry ..................... 4
CB2 .............. Circuit breaker, 7A ..................... 47811 ........ ETA ......................................... 45-700-IG1-P10 ............ 1
CR5 .............. Relay, 24V DC

(before serial number 43737) ........................... 56302 ........ Potter-Brumfield ..................... VF4-15H11-CO5 ........... 1
(after serial number 43736) .............................. 78098 ........ Siemens .................................. VF4-45H11-CO5 ........... 1
CR48 ............ Relay, 24V DC

(before serial number 43737) ........................... 56302 ........ Potter-Brumfield ..................... VF4-15H11-CO5 ........... 1
(after serial number 43736) .............................. 78098 ........ Siemens .................................. VF4-45H11-CO5 ........... 1
F6 ................. Fuse, 275A ................................. 40833 ........ Buss ........................................ ANN-275 ....................... 1
FB1 .............. Flashing beacon ......................... 39676 ........ ECCO Electronic Controls ...... 6220A ............................ 2
G6 ................ Hour meter

(before serial number 21065) ........................... 19506 ........ ENM Corporation .................... T40A4508 ..................... 1
(from serial number 21065 to 40925) ............... 56100 ........ Curtis Instruments .................. 17305666 ...................... 1
(after serial number 40925) .............................. 19506 ........ ENM Corporation .................... T40A4508 ..................... 1
H1, H5 .......... Alarm, steady tone ..................... 39540 ........ Floyd Bell Inc. ......................... UC-09628-Q .................. 1
H2 ................ Alarm, 24V DC ........................... 81579 ........ Hella. ...................................... 95346 ............................ 1
KS1 .............. Contact - key switch, N.O.

(before serial number 37962) ........................... 45081 ........ Telemecanique ....................... ZB2-BE101 ................... 1
(from serial number 37962 to 52966) ............... 66816 ........ Telemecanique ....................... ZBE-101 ........................ 1
(after serial number 52966) .............................. 96008 ........ Hobbs ..................................... X-88652 ........................ 1
LS6 ............... Contact - limit switch, N.C. ......... 19491 ........ Telemecanique ....................... XESP2151 ..................... 1
LS7, LS8 ...... Contact - limit switch, N.C.H.O. . 19491 ........ Telemecanique ....................... XESP2151 ..................... 2
P1 ................. Contact, N.C.

(before serial number 36367) ........................... 29732 ........ Telemecanique ....................... ZB2-BE102 ................... 1
(after serial number 36366) .............................. 66818 ........ Telemecanique ....................... ZBE102 ......................... 1
P2 ................. Contact, N.C

(before serial number 36367) ........................... 44990 ........ Telemecanique ....................... ZA2-BZ1026 .................. 1
(after serial number 36366) .............................. 66818 ........ Telemecanique ....................... ZBE102 ......................... 1

REV C ELECTRICAL COMPONENTS
Item Description Genie Part Manufacturer Manufacturer Qty

Number Part Number
QD1 .............. Battery connector ....................... 19436 ........ Anderson ................................ 6325-G1 ........................ 1
R21 .............. Resistor, 75 ohm ........................ 51590 ........ Dale ........................................ RS-10-38, 75 ohm ........ 1
TS66 ............ Toggle switch, SPDT

3 position momentary ................. 13037 ........ Microswitch Control Inc. ......... 1NT1-7 .......................... 1
U6 ................ Motor controller, 24V DC, 275A

(before serial number 47731) ........................... 66047 ........ Curtis ...................................... 1204-036 ....................... 1
(after serial number 47730) .............................. 78385 ........ General Electric ...................... IC3645SE6B300GN1 .... 1
U27 .............. Inductor, noise suppression,

47 mH, 2.5A, 0.034 ohm ........... 47124 ........ Dale ........................................ IHD3-47MH15% ............ 1
Y2 ................. Coil, 20V DC with diode ............. 39347 ........ Hydra Power Systems ............ 6309757 ........................ 1
Y3, Y4 .......... Coil, 20V DC with diode

(before serial number 35800) ........................... 39347 ........ Hydra Power Systems ............ 6309757 ........................ 2
(after serial number 35799) .............................. 52594 ........ Hydra Power Systems ............ 6309820 ........................ 2
Y5, Y6, Y8 .... Coil, 20V DC with diode

(before serial number 35800) ........................... 44176 ........ Hydra Power Systems ............ 6359752 ........................ 3
(after serial number 35799) .............................. 52595 ........ Hydra Power Systems ............ 6359792 ........................ 3
Y7 ................. Coil, 20V DC

(before serial number 23568) ........................... 44787 ........ Hydra Power Systems ............ 10166-25 ....................... 1
Y7 ................. Coil, 20V DC with diode

(after serial number 23567) .............................. 66467 ........ Hydra Power Systems ............ 10188-91 ....................... 1

ECM Pin-out Legend

REV B
C 1 12
B 1 12
A 1 12
ECM PIN-OUT LEGEND ECM PIN-OUT LEGEND

From serial number 17408 to 21064 From serial number 21065 to 25141
Item Description Item Description
A1 Spare A1 Flashing beacon FB1 (output)
A2 Ground from platform controls (input) A2 Ground from platform controls (input)
(White wire at platform) (White wire at platform)
A3 Spare A3 Spare
A4 Power from platform controls to ECM (input) A4 Power from platform controls to ECM (input)
(Red wire at platform) (Red wire at platform)
A5 Level sensor power S7 (output) A5 Level sensor power S7 (output)
A6 Platform up coil Y8 (output) A6 Platform up coil Y8 (output)
A7 Drive reverse coil Y5 (output) A7 Drive reverse coil Y5 (output)
A8 Motor controller U6, terminal 1 (output) A8 Motor controller U6, terminal 1 (output)
A9 Motor controller U6, terminal 3 (output) A9 Motor controller U6, terminal 3 (output)
A10 Overload sensor PS2 (input) A10 Overload sensor PS2 (input)
A11 Key switch to platform control (input) A11 Key switch to platform control (input)
A12 Platform down TS66 (input) A12 Platform down TS66 (input)
B1 Platform data link (+) (input) B1 Platform data link (+) (input)
(Blue wire at platform) (Blue wire at platform)
B2 Power to platform controls (output) B2 Power to platform controls (output)
(Black wire at platform) (Black wire at platform)
B3 ECM ground (output) B3 ECM ground (output)
B4 Spare B4 Spare
B5 Spare B5 Spare
B6 Platform down coil Y7 (output) B6 Platform down coil Y7 (output)
B7 Steer left coil Y4 (output) B7 Steer left coil Y4 (output)
B8 Automotive-style horn H2 (option) (output) B8 Automotive-style horn H2 (option) (output)
B9 Multi-function alarm H5 (output) B9 Multi-function alarm H5 (output)
B10 Pothole limit switch (input) B10 Pothole limit switch (input)
B11 Drive enable power (input) B11 Drive enable power (input)
B12 Platform up at ground controls TS66 (input) B12 Platform up TS66 (input)
C1 Platform data link (—) (input) C1 Platform data link (—) (input)
(Yellow wire at platform) (Yellow wire at platform)
C2 Key switch to ground control (input) C2 Power to ECM (input)
C3 Spare C3 Spare
C4 Spare C4 Spare
C5 Spare C5 Spare
C6 Drive forward coil Y6 (output) C6 Drive forward coil Y6 (output)
C7 Steer right coil Y3 (output) C7 Steer right coil Y3 (output)
C8 Spare C8 Spare
C9 Brake release coil Y2 (output) C9 Brake release coil Y2 (output)
C10 Spare C10 Spare
C11 Level sensor signal S7 (input) C11 Level sensor signal S7 (input)
C12 Down limit switch LS6 (input) C12 Down limit switch LS6 (input)

REV B ECM PIN-OUT LEGEND
C 1 12
B 1 12
A 1 12
ECM PIN-OUT LEGEND ECM PIN-OUT LEGEND

From serial number 25142 to 35799 From serial number 35799 to 59999
A1 Flashing beacon FB1 (output) A1 Flashing beacon FB1 (output)
A2 Ground from platform controls (input) A2 Ground from platform controls (input)
(Blue wire at platform) (Blue wire at platform)
A3 Spare A3 Spare
A4 Power from platform controls to ECM (input) A4 Power from platform controls to ECM (input)
(White wire at platform) (White wire at platform)
A5 Level sensor power S7 ((output) A5 Level sensor power S7 (output)
A6 Platform up coil Y8 (output) A6 Platform up coil Y8 (output)
A7 Drive reverse coil Y5 (output) A7 Drive reverse coil Y5 (output)
A8 Motor controller U6, terminal 1 (output) A8 Motor controller U6, terminal 1
A9 Motor controller U6, terminal 3 (output) A9 Motor controller U6, terminal 3
A10 Overload sensor PS2 (input) A10 Overload sensor PS2 (input)
A11 Key switch to platform control (input) A11 Key switch to platform control (input)
A12 Platform down TS66 (input) A12 Platform down TS66 (input)
B1 Platform data link (+) (input) B1 Platform data link (+) (input)
(Black wire at platform) (Black wire at platform)
B2 Spare B2 Spare
B3 ECM ground (output) B3 ECM ground (output)
B4 Spare B4 Spare
B5 Spare B5 Spare
B6 Platform down coil Y7 (output) B6 Platform down coil Y7 (output)
B7 Steer left coil Y4 (output) B7 Steer left coil Y4 (output)
B8 Automotive-style horn H2 (option) (output) B8 Automotive-style horn H2 (option) (output)
B9 Multi-function alarm H5 (output) B9 Multi-function alarm H5 (output)
B10 Pothole limit switch (input) B10 Pothole limit switch (input)
B11 Drive enable power (input) B11 Drive enable power (input)
B12 Platform up TS66 (input) B12 Platform up TS66 (input)
C1 Platform data link (—) (input) C1 Platform data link (—) (input)
(Yellow wire at platform) (Yellow wire at platform)
C2 Power to ECM (input) C2 Power to ECM (input)
C3 Spare C3 Spare
C4 Spare C4 Spare
C5 Spare C5 Spare
C6 Drive forward coil Y6 (output) C6 Drive forward coil Y6 (output)
C7 Steer right coil Y3 (output) C7 Steer right coil Y3 (output)
C8 Spare C8 Spare
C9 Brake release coil Y2 (output) C9 Spare
C10 Spare C10 Spare
C11 Level sensor signal S7 (input) C11 Level sensor signal S7 (input)
C12 Down limit switch LS6 (input) C12 Down limit switch LS66 (input)

Control Relay Layout

REV A
a b c d
e f g
h i j k
a batteries B5
b Electronic Control Module (ECM) U5
c CR48 power relay to U5 (not used
before serial number 25142)
d lid - ECM box
e module tray rotary latch
f battery quick disconnect QD1
g 275A fuse F6
h automotive-style horn H2 (option)
i multi-function alarm H5
j CR5 horn relay
k tilt level sensor S7

This page intentionally left blank.


(from serial number 17408 to 51014) REV B
SW25
DIP SWITCH OE
ON
1
P2
2
3
EMERGENCY STOP
ALCO
4
5
BUTTON
6
ADFO8S
7
8
BK
2
RD
1
RD
U3
PLATFORM
OR
PP
CONTROLS
CIRCUIT
WH/BK BOARD
WH
WH/RD
JC1 WH/BL
JOYSTICK
CONTROLLER
BN
H1
ALARM
WH
YL
RD
BK
BL
OR
RD
BK
WIRE COLOR
TO
LEGEND
COIL Color Description
CORD BL Blue
ASSEMBLY BK Black
BN Brown
GN Green
ABBREVIATION LEGEND OR Orange
Item Description PP Purple
RD Red
H1 Alarm
WH White
JC1 Joystick controller WH/BL White/Blue
P2 Emergency Stop button at platform controls WH/BK White/Black
SW25 DIP switch WH/RD White/Red
U3 Platform controls circuit board YL Yellow


REV A (from serial number 51015 to 59999)
P2
EMERGENCY STOP
BUTTON
2 5. 1 4.
BK
NC 1
RD
SW25
DIP SWITCH
BN U3
9F
ON
PLATFORM CONTROLS
1
GN CIRCUIT BOARD
2
WH
ALCO ADF085
4
5
6
RD
7
BK
OR
8
S/N Al 00000000
P/N 000000
PP
Date 0000
BL
GY
JC1
JOYSTICK
CONTROLLER
BN RD
YL BL WH BK RD
WH
OR
RD
BK
BL
H1
ALARM
TO
COIL
CORD WIRE COLOR
ASSEMBLY
LEGEND
Color Description
BL Blue
BK Black
ABBREVIATION LEGEND BN Brown
Item Description GN Green
H1 Alarm GY Gray
OR Orange
JC1 Joystick controller
PP Purple
P2 Emergency Stop button at platform controls RD Red
SW25 DIP switch WH White
U3 Platform controls circuit board YL Yellow

Ground Controls Wiring Diagram

REV C
Ground Controls
51F
A11
KS1 G6
B TS66 P1
CB2 +
3 50F 1 (UP)
25F
B1 29F
(DOWN) 53F NC 51F 41F
4 45F
2 -
B12 A12 24F
52F
76F
50F 49F
KS1 Ground Controls

(PLATFORM)
N.O. N.O. (before serial number 21065 and
from serial number 40926 to 52966)
A11 A11 KEY SWITCH
G6
48F TS66 P1
KS1 CB2 +
(GROUND) (UP)
25F
N.O. N.O. 29F
52F
(DOWN) 53F NC 51F 41F
-
45F B12 A12 24F
76F
50F 49F
KS1
(PLATFORM)
NO NO
Ground Controls
(from serial number 21065 to 40925)
A11 A11 KEY SWITCH
54F
G6
48F TS66 P1 3
KS1 CB2
(GROUND) (UP)
25F
NO NO 1
29F
52F (DOWN) 53F NC 51F 41F
45F B12 A12 24F

2
76F
ABBREVIATION LEGEND
Item Description
CB2 Circuit breaker, 7A
G6 Hour meter
KS1 Key switch
P1 Emergency Stop
TS66 Platform up/down toggle switch

Level Sensor Box Wiring Diagram

REV A
LS6
Level Sensor
S7 B9 44D
- H5
N.O.
N.C. B11
+
39C
RD BK WH
A5 C11
70D
29F 27D
44D
75D
23D
C12
LS6 Level Sensor

S7 B9 44D
- H5
N.O.
N.C. B11
+
39C
RD BK WH
A5 70D C11
75D 29F 27D
44D
23F
C12
WIRE COLOR LEGEND ABBREVIATION LEGEND

Color Description Item Description
BK Black H5 Multi-function alarm
RD Red LS6 Down limit switch
WH White S7 Level sensor

Electrical Symbols Legend

REV C
KS1
PS2 M- B+ T2 B+ KEY SWITCH
T2
T
A2 3 A2 3
A8-MOTOR CONTR. ENABLE
Pressure switch B
B- 1 B- 1
normally closed PLATFORM
CONTROL
Motor controller T
N.C. N.C.H.O. B
GROUND
D1 CONTROL
M5 Key switch
Limit switch
Wire with A1
description
Motor
N.O.
Switch U9
LEVEL SENSOR
CIRCUIT BOARD
Circuits crossing S7
LEVEL
no connection SENSOR
Level sensor
Battery charger
Toggle switch
Diode -
+
Emergency Stop button 6V battery

Normally closed
Connection Solenoid valve
CB2
no terminal
Resistor, 75 ohm
Circuit breaker
Connector
30 86
87A 87 85 Inductor, Solenoid valve

noise suppression with diode
3 1 Relay
JC1 JOYSTICK CONTROLLER
2 R15
5000 ohm
POTENTIOMETER SW6 STEER
Hour meter
RIGHT
LEFT
SW5
Fuse FUNCTION
ENABLE
Joystick controller
FB
JC1
HALL JOYSTICK
GENERATOR CONTROLLER
Flashing beacons Horn or alarm

SW6
FB1 STEER LEFT/ RIGHT
RIGHT
LEFT
SW5
FUNCTION
ENABLE
LED

Electrical Schematic REV C

A B C D E F G H I J K L M N
QD4
1 WH RD C C
WH A A
KS1 BL B B
KEY SWITCH
BK D D
T
39C OR E E
CB2 P1 B
7A EMERGENCY N.C. N.O. N.C.H.O.
2
CIRCUIT
BREAKER
STOP
PLATFORM
H5
CONTROL MULTI-FUNCTION
ALARM LS6 PS2 LS7
T DOWN PLATFORM POTHOLE
LIMIT SWITCH OVERLOAD GUARD 21B
PRESSURE SWITCH
B SWITCH
(OPTION)
N.C.H.O.
GROUND
CONTROL
TS66 LS8
3 PLATFORM
POTHOLE
GUARD
UP/DOWN SWITCH
SWITCH
DOWN
UP
RD
WH
30 86
CR5 N.O.
4
ESTOP TO JOYSTICK
ESTOP FROM JOYSTICK
DATA LINK (HIGH)

DATA LINK (LOW)
B12-UP/DWN SW UP
B10-POTHOLE SW
B8-OPT SERVICE HORN
B9-MULTIFUNCT ALM
C2-EMERG STOP
C12-DWN LIMIT
GND FROM JOYSTICK
C11-LVL SNSR-WHT
A5-LVL SNSR-RED
A9-CURTISTERM 3
A12-UP/DWN SW DWN
A11-KEY SWITCH
OVERLOAD SENSOR OPTION
HORN RELAY
87 85 (H2 OPTION)
LEVEL
SENSOR
CIRCUIT
R21 BOARD
75 OHM
U27 S7
47 mH LEVEL
SENSOR
QD1 (+) INDUCTOR,
NOISE
5 SUPPRESSION
BN
F6 M5
275A FUSE D1 MOTOR
B8 A8 A9 A12 B12 C2 B9 B11 C12 A10 B10 A11 B2 A4 A2 B1 C1 C11 A5
M5 OUT OUT OUT IN IN IN OUT IN IN IN IN IN OUT IN IN IN IN IN OUT
A1
U5
6 ELECTRONIC CONTROL MODULE
U9
BATTERY
CHARGER OUT OUT OUT OUT OUT OUT OUT OUT
B3 C9 C7 B7 A7 C6 B6 A6
B5 AC INPUT
T2 B+
4-6V M-
BATTERY A2 3 FB
-
GND
C9-BRK COIL
C7-RT COIL
B7-LEFT COIL
A7-REV COIL
C6-FWD COIL
B6-DWN COIL
A6-UP COIL
B- 1
+
7 - F8
50A FUSE U6 MOTOR
CONTROLLER FB
+
- G6 FB H2 Y2 Y3 Y4 Y5 Y6 Y7 Y8
U13 HOUR FLASHING AUTOMOTIVE-STYLE BRAKE STEER STEER DRIVE DRIVE PLATFORM PLATFORM
DC/AC INVERTER METER BEACONS HORN RELEASE RIGHT LEFT REVERSE FORWARD DOWN UP
+
(OPTION) (OPTION) (OPTION)

- (OPTION)
+
8 QD1 (-)
GND GND

REV C Electrical Schematic

N M L K J I H G F E D C B A
C C BK POWER TO PLATFORM CONTROLS

BK P2
EMERGENCY STOP
A A RD POWER TO GROUND CONTROLS
RD 1
B B WH GROUND
D D BL DATA LINK (HIGH) PIO4

E E YL DATA LINK (LOW) PIO5
1 OR WH/YL
ABBREVIATION LEGEND QD3 2
3
R15
Item Description 4 BR
5000 OHM SW6STEER
B5 Battery SW25 5
POTENTIOMETER
DIP SWITCHES 2
RIGHT
6
LEFT
BN Button
BN5 = Horn 7 PP
SW5
8 FUNCTION
BN9 = Lift enable ENABLE
24V DC 5V DC WH/BK
CR5 Horn relay (with H2 option) PIO2
D7 Voltage regulator (Platform controls circuit board) D7 BK
F6 Fuse, 275A PIO3 VOLTAGE
FB1 Flashing beacons REGULATOR
G Gauge 3
G6 = Hour meter POUT1 POWER LED L19
G7 = Battery charge indicator POUT2 FAULT LED L25
GND Ground POUT3 HIGH TORQUE LED L21
H Horn or alarm POUT4 BATTERY LEVEL 1
H1 = Horn
POUT5 BATTERY LEVEL 2
H2 = Automotive-style horn (option)
H5 = Multifunction alarm POUT6 BATTERY LEVEL 3 G7
JC1 Joystick controller POUT7 BATTERY LEVEL 4
KS1 Key switch POUT8 BATTERY LEVEL 5 4
L LED or light
L19 = Power
L25 = Fault U3 PLATFORM CONTROLS
LS Limit switch PLATFORM CONTROLS MEMBRANE DECAL PANEL
PRINTED CIRCUIT BOARD
LS6 = Platform up/down
LS7 = Pothole
LS8 = Pothole PIN1 HIGH TORQUE BN6
M5 Hydraulic power unit PIN2 HORN BN5 5

N.C. Normally closed PIN4 LIFT ENABLE BN9
N.C.H.O Normally closed held open
P Power switch
P1 = Emergency Stop button at ground controls
P2 = Emergency Stop button at platform controls WH/BL
PIN9
PS2 Platform overload pressure switch (option)
WH/RD
QD Quick disconnect PIN8
QD1 = Battery quick disconnect WH
PIN10
QD3 = Control cable to ground 6
QD4 = Control cable to platform
RD
R Resistor POUT11 +
R15 = 5000 ohm potentiometer H1 ALARM
R21 = 75 ohm resistor BK
S7 Tilt level sensor
PIN11 -
SW Switch
SW5 = Function enable
SW6 = Steer left/right
7
TS66
SW25 = DIP switch
Platform up/down toggle switch
PLATFORM CONTROLLER
U Electronic component
U3 = Encoder printed circuit board
U5 = Electronic control module
U6 = Motor controller WIRE COLOR
U9 = Battery charger LEGEND
U13 = Voltage inverter (option)
U27 = 47 mH inductor, noise suppression
Color Description
BL Blue 8
Y Valve coil
Y2 = Brake release BK Black
Y3 = Steer right BN Brown
Y4 = Steer left GN Green
Y5 = Drive reverse OR Orange
Y6 = Drive forward RD Red
Y7 = Platform down WH White
Y8 = Platform up YL Yellow


QD4
1 WH RD C C
WH A A
KS1 BL B B
KEY SWITCH
BK D D
T
39C OR E E
CB2 P1 B
2
CIRCUIT
BREAKER
STOP
PLATFORM
H5
ALARM LS6 PS2 LS7
PRESSURE SWITCH
B SWITCH
(OPTION)
N.C.H.O.
GROUND
CONTROL
TS66 LS8
3 PLATFORM
POTHOLE
GUARD
UP/DOWN SWITCH
SWITCH
DOWN
UP
RD
WH
30 86
CR5 N.O.
4
ESTOP TO JOYSTICK
ESTOP FROM JOYSTICK
DATA LINK (HIGH)

DATA LINK (LOW)
B12-UP/DWN SW UP
B10-POTHOLE SW
B8-OPT SERVICE HORN
B9-MULTIFUNCT ALM
C2-EMERG STOP
C12-DWN LIMIT
GND FROM JOYSTICK

C11-LVL SNSR-WHT
A11-KEY SWITCH
A5-LVL SNSR-RED
A9-CURTISTERM 3
A12-UP/DWN SW DWN
HORN RELAY
87 85 (H2 OPTION)
LEVEL
SENSOR
CIRCUIT
R21 BOARD
75 OHM
U27 S7
47 mH LEVEL
QD1 (+) INDUCTOR,
NOISE
SENSOR
5 SUPPRESSION
BN
F6 M5
275A FUSE D1 MOTOR
A1
A1 OUT U5
U9
BATTERY
B3 C9 C7 B7 A7 C6 B6 A6
B5 AC INPUT
T2 B+
4-6V M-
BATTERY A2 3 FB
-
GND
C9-BRK COIL
C7-RT COIL
B7-LEFT COIL
A7-REV COIL
C6-FWD COIL
B6-DWN COIL
A6-UP COIL
B- 1
+
7 - F8
50A FUSE U6 MOTOR 3 1
CONTROLLER FB
+
- G6 2 FB H2 Y2 Y3 Y4 Y5 Y6 Y7 Y8
+

- (OPTION)
+
8 QD1 (-)
GND GND



BK P2
RD EMERGENCY STOP
A A RD POWER TO GROUND CONTROLS 1
B B WH GROUND

1 OR WH/YL

3
R15
4 BR
5000 OHM SW6STEER
Item Description SW25 5
POTENTIOMETER
B5 Battery DIP SWITCHES 2
RIGHT
6
LEFT
BN Button 7 PP
SW5
BN5 = Horn 8 FUNCTION
CB2 Circuit breaker, 7A 24V DC 5V DC WH/BK

PIO3 VOLTAGE
F6 Fuse, 275A REGULATOR
FB1 Flashing beacons
G Gauge
POUT1 POWER LED L19
3
G6 = Hour meter

H1 = Horn POUT5 BATTERY LEVEL 2
H5 = Multifunction alarm
POUT6 BATTERY LEVEL 3 G7
L LED or light
L19 = Power
LS Limit switch
PLATFORM CONTROLS MEMBRANE DECAL PANEL
LS7 = Pothole
PIN2 HORN BN5

M5 Hydraulic power unit 5
P Power switch
PIN9
PS2 Platform overload pressure switch (option) WH/RD
PIN8
QD Quick disconnect WH
QD1 = Battery quick disconnect PIN10
QD4 = Control cable to platform RD
POUT11 +
R Resistor
BK
R21 = 75 ohm resistor PIN11 -
SW Switch
PLATFORM CONTROLLER
SW25 = DIP switch 7
Color Description
BL Blue 8
Y Valve coil


QD4
1 WH RD C C
WH A A
KS1 BL B B
KEY SWITCH
BK D D
T
39C OR E E
CB2 P1 B
2 CIRCUIT
BREAKER
STOP
PLATFORM
H5
ALARM LS6 PS2 LS7
PRESSURE SWITCH
B SWITCH
(OPTION)
N.C.H.O.
GROUND
CONTROL
3 TS66 LS8
POTHOLE
PLATFORM
GUARD
UP/DOWN SWITCH
SWITCH
DOWN
UP
RD
WH
30 86
CR5 N.O.
4
ESTOP TO JOYSTICK
ESTOP FROM JOYSTICK
DATA LINK (HIGH)

DATA LINK (LOW)
B12-UP/DWN SW UP
B10-POTHOLE SW
B8-OPT SERVICE HORN
B9-MULTIFUNCT ALM
C2-EMERG STOP
C12-DWN LIMIT
GND FROM JOYSTICK

C11-LVL SNSR-WHT
A11-KEY SWITCH
A5-LVL SNSR-RED
A9-CURTISTERM 3
A12-UP/DWN SW DWN
HORN RELAY
87 85 (H2 OPTION)
LEVEL
SENSOR
CIRCUIT
R21 BOARD
75 OHM
U27 S7
47 mH LEVEL
QD1 (+) INDUCTOR,
NOISE
SENSOR
5 SUPPRESSION
BN
F6 M5
275A FUSE D1 MOTOR
A1
A1 OUT U5
U9
BATTERY
B3 C9 C7 B7 A7 C6 B6 A6
B5 AC INPUT
T2 B+
4-6V M-
BATTERY A2 3 FB
-
GND
C9-BRK COIL
C7-RT COIL
B7-LEFT COIL
A7-REV COIL
C6-FWD COIL
B6-DWN COIL
A6-UP COIL
B- 1
+
7 - F8
CONTROLLER FB
+
- G6 2 FB H2 Y2 Y3 Y4 Y5 Y6 Y7 Y8
+

- (OPTION)
+
8 QD1 (-)
GND GND



BK P2
RD EMERGENCY STOP
B B WH GROUND

1 OR WH/YL

3
R15
4 BR
5000 OHM SW6STEER
Item Description SW25 5
POTENTIOMETER
B5 Battery DIP SWITCHES 2
RIGHT
6
LEFT
BN Button 7 PP
SW5
BN5 = Horn 8 FUNCTION
CB2 Circuit breaker, 7A 24V DC 5V DC WH/BK

PIO3 VOLTAGE
F6 Fuse, 275A REGULATOR
G Gauge
POUT1 POWER LED L19
3
G6 = Hour meter

L LED or light POUT9 DRIVE LED L17
L19 = Power POUT10 LIFT LED L16
L25 = Fault U3
PLATFORM CONTROLS PLATFORM CONTROLS
LS Limit switch PRINTED CIRCUIT BOARD
LS6 = Platform up/down MEMBRANE DECAL PANEL
LS7 = Pothole
PIN1 HIGH TORQUE BN6
LS8 = Pothole
PIN2 HORN BN5
M5 Hydraulic power unit 5
N.C. Normally closed PIN3 DRIVE ENABLE BN8
N.C.H.O Normally closed held open PIN4 LIFT ENABLE BN9
P Power switch
PIN9
PS2 Platform overload pressure switch (option) WH/RD
PIN8
QD Quick disconnect WH
POUT11 +
R Resistor
BK
R21 = 75 ohm resistor PIN11 -
SW Switch
PLATFORM CONTROLLER
SW25 = DIP switch 7
Color Description
BL Blue 8
Y Valve coil


QD4
1 76F 78F
WH RD C C
77F
WH A A
KS1 30 86
KEY SWITCH CR48 BL B B
POWER BK D D
T RELAY 87 85
TO U5 OR E E
CB2 P1 B 23D
7A EMERGENCY
CIRCUIT STOP
2 BREAKER PLATFORM
CONTROL
39C
T N.C. + N.O. N.C.H.O.
B
LS6 H5 - PS2 LS7
GROUND DOWN ALARM PLATFORM POTHOLE
CONTROL LIMIT OVERLOAD GUARD 21B
SWITCH PRESSURE SWITCH
TS66 SWITCH
3 PLATFORM (OPTION) N.C.H.O.
UP/DOWN SWITCH
LS8
DOWN
UP
POTHOLE
RD
WH
GUARD
SWITCH
30 86
CR5 N.O.
EMERG STOP
ESTOP FROM JOYSTICK
DATA LINK (HIGH)

DATA LINK (LOW)
B12-UP/DWN SW UP
B8-HORN OPTION
B9-MULTIFUNCT ALM
B10-POTHOLE SW
C12-DWN LIMIT
GND FROM JOYSTICK
C11-LVL SNSR-WHT
A5-LVL SNSR-RED
A9-MOTOR CONTROLLER
A12-UP/DWN SW DWN

4 HORN RELAY
A11-KEY SWITCH
87 85 (H2 OPTION)
LEVEL
SENSOR
CIRCUIT
R21 BOARD
75 OHM
U27 S7
47 mH LEVEL
QD1 (+) INDUCTOR,
NOISE
SENSOR
5 SUPPRESSION
BN
F6 M5
275A FUSE D1 MOTOR
B8 A8 A9 A12 B12 A11 C12 B9 A10 B10 C2 A4 B11 A2 B1 C1 C11 A5
M5 OUT OUT OUT IN IN IN IN OUT IN IN IN IN IN IN IN IN IN OUT
A1
A1 OUT U5
ELECTRONIC CONTROL MODULE
6 U9
BATTERY
B3 C9 C7 B7 A7 C6 B6 A6
B5 AC INPUT
T2 B+
4-6V M-
BATTERY A2 3 FB
-
GND
C9-BRK COIL
C7-RT COIL
B7-LEFT COIL
A7-REV COIL
C6-FWD COIL
B6-DWN COIL
A6-UP COIL
B- 1
+
7 - F8
CONTROLLER FB
+
- G6 2 FB H2 Y2 Y3 Y4 Y5 Y6 Y7 Y8
+

- (OPTION)
+
8 QD1 (-)
GND GND



BK P2
RD EMERGENCY STOP
B B WH GROUND

ABBREVIATION LEGEND 1 OR WH/YL
Item Description QD3 2
3
R15
B5 Battery
4 BR
5000 OHM SW6STEER
BN Button SW25 5
POTENTIOMETER
BN5 = Horn DIP SWITCHES
RIGHT
6 2
LEFT
BN8 = Drive enable 7 PP
SW5
BN9 = Lift enable 8 FUNCTION
CB2 Circuit breaker, 7A ENABLE
CR Control relay WH/BK
24V DC 5V DC
CR5 = Horn relay (with H2 option) PIO2
CR48 = Power relay to U5 D7 BK
PIO3 VOLTAGE
D7 Voltage regulator (Platform controls circuit board)
REGULATOR
F6 Fuse, 275A
FB1 Flashing beacons 3
POUT1 POWER LED L19
G Gauge
G6 = Hour meter POUT2 FAULT LED L25
G7 = Battery charge indicator POUT3 HIGH TORQUE LED L21
GND Ground POUT4 BATTERY LEVEL 1
H Horn or alarm BATTERY LEVEL 2
POUT5
H1 = Horn
H2 = Automotive-style horn (option) POUT6 BATTERY LEVEL 3 G7
H5 = Multifunction alarm POUT7 BATTERY LEVEL 4
KS1 Key switch
4
POUT9 DRIVE LED L17
L LED or light
POUT10 LIFT LED L16
L16 = Lift
L17 = Drive
U3
PLATFORM CONTROLS PLATFORM CONTROLS
L19 = Power PRINTED CIRCUIT BOARD
L25 = Fault MEMBRANE DECAL PANEL
LS Limit switch PIN1 HIGH TORQUE BN6
LS7 = Pothole PIN2 HORN BN5
LS8 = Pothole PIN3 DRIVE ENABLE BN8
5
M5 Motor
P Power switch
WH/BL
P1 = Emergency Stop button at ground controls PIN9
P2 = Emergency Stop button at platform controls WH/RD
PIN8
PS2 Platform overload pressure switch (option) WH
PIN10
QD Quick disconnect
QD1 = Battery quick disconnect 6
QD3 = Control cable to ground RD
POUT11 +
R Resistor H1 ALARM
BK
R15 = 5000 ohm potentiometer PIN11 -
R21 = 75 ohm resistor
SW Switch
S7
SW25 = DIP switches
Tilt level sensor
PLATFORM CONTROLLER 7
U5 = Electronic control module WIRE COLOR
U6 = Motor controller
U13 = Voltage inverter (option) Color Description
U27 = 47 mH inductor, noise suppression BL Blue 8
Y Valve coil BK Black
Y2 = Brake release
BN Brown
Y3 = Steer right
Y4 = Steer left
GN Green


QD4
1 76F 78F
WH RD C C
77F
WH A A
KS1 30 86
POWER BK D D
T RELAY 87 85
TO U5 OR E E
CB2 P1 B 23D
7A EMERGENCY
CIRCUIT STOP
2 BREAKER PLATFORM
CONTROL 39C
H5 -
B
LS6 PS2 LS7
TS66 SWITCH
UP/DOWN SWITCH
LS8
DOWN
UP
POTHOLE
RD
WH
GUARD
SWITCH
30 86
CR5 N.O.
EMERG STOP
ESTOP FROM JOYSTICK
DATA LINK (HIGH)

DATA LINK (LOW)
B12-UP/DWN SW UP
B10-POTHOLE SW
B8-HORN OPTION
B9-MULTIFUNCT ALM
C12-DWN LIMIT
GND FROM JOYSTICK
C11-LVL SNSR-WHT
A5-LVL SNSR-RED
A9-MOTOR CONTROLLER
A12-UP/DWN SW DWN

HORN RELAY
4
A11-KEY SWITCH
87 85 (H2 OPTION)
LEVEL
SENSOR
CIRCUIT
R21 BOARD
75 OHM
U27 S7
47 mH LEVEL
QD1 (+) INDUCTOR,
NOISE
SENSOR
SUPPRESSION
5 BN
F6 M5
275A FUSE D1 MOTOR
A1
A1 OUT U5
6 U9
BATTERY
B3 C9 C7 B7 A7 C6 B6 A6
B5 AC INPUT
T2 B+
4-6V M-
BATTERY A2 3 FB
-
GND
C9-BRK COIL
C7-RT COIL
B7-LEFT COIL
A7-REV COIL
C6-FWD COIL
B6-DWN COIL
A6-UP COIL
B- 1
+
7 - F8
CONTROLLER FB
+
- G6 2 FB H2 Y2 Y3 Y4 Y5 Y6 Y7 Y8
+

- (OPTION)
+
8 QD1 (-)
GND GND



BK P2
RD EMERGENCY STOP
1
B B WH GROUND

ABBREVIATION LEGEND E E YL DATA LINK (LOW) PIO5
1 OR WH/YL
3
R15
B5 Battery
4 BR
5000 OHM SW6STEER
BN Button SW25 5
POTENTIOMETER
RIGHT
6
LEFT
BN8 = Drive enable
7 SW5 2
BN9 = Lift enable PP
8 FUNCTION
CR Control relay
24V DC 5V DC WH/BK
PIO3 VOLTAGE
REGULATOR
F6 Fuse, 275A
G Gauge POUT1 POWER LED L19 3
H Horn or alarm
H1 = Horn
KS1 Key switch DRIVE LED L17
4
POUT9
L LED or light
POUT10 LIFT LED L16
L16 = Lift U3
L17 = Drive PLATFORM CONTROLS
L19 = Power PLATFORM CONTROLS
L25 = Fault MEMBRANE DECAL PANEL
5
M5 Motor
PIN4 LIFT ENABLE BN9
N.C. Normally closed
P Power switch WH/BL
P1 = Emergency Stop button at ground controls PIN9
P2 = Emergency Stop button at platform controls WH/RD
PIN8
PS2 Platform overload pressure switch (option) WH
PIN10
QD Quick disconnect
QD1 = Battery quick disconnect 6
POUT11 +
R Resistor H1 ALARM
BK
R15 = 5000 ohm potentiometer PIN11 -
SW Switch
S7
SW25 = DIP switches
Tilt level sensor
PLATFORM CONTROLLER 7
U5 = Electronic control module WIRE COLOR
U13 = Voltage inverter (option) Color Description
U27 = 47 mH inductor, noise suppression BL Blue 8
Y Valve coil BK Black
Y2 = Brake release
BN Brown
Y3 = Steer right


QD4
1 76F 78F
WH RD C C
77F
WH A A
KS1 30 86
POWER BK D D
T RELAY 87 85
TO U5 OR E E
CB2 P1 B 23D
7A EMERGENCY
CIRCUIT STOP
2 BREAKER PLATFORM
CONTROL
39C
H5 -
B
LS6 PS2 LS7
3 TS66 SWITCH
PLATFORM (OPTION) N.C.H.O.
UP/DOWN SWITCH
LS8
DOWN
UP
POTHOLE
RD
WH
GUARD
SWITCH
30 86
CR5 N.O.
EMERG STOP
ESTOP FROM JOYSTICK
DATA LINK (HIGH)

DATA LINK (LOW)
B12-UP/DWN SW UP
B8-HORN OPTION
B9-MULTIFUNCT ALM
B10-POTHOLE SW
C12-DWN LIMIT
GND FROM JOYSTICK
C11-LVL SNSR-WHT
4
A5-LVL SNSR-RED
A9-MOTOR CONTROLLER
A12-UP/DWN SW DWN

HORN RELAY
A11-KEY SWITCH
87 85 (H2 OPTION)
LEVEL
SENSOR
CIRCUIT
R21 BOARD
75 OHM
U27 S7
47 mH LEVEL
QD1 (+) INDUCTOR,
NOISE
SENSOR
5 SUPPRESSION
BN
F6 M5
275A FUSE D1 MOTOR
A1
A1 OUT U5
6 U9
BATTERY
CHARGER OUT OUT OUT OUT OUT OUT OUT
B3 C7 B7 A7 C6 B6 A6
B5 AC INPUT
T2 B+
4-6V M-
BATTERY A2 3 FB
-
GND
C7-RT COIL
B7-LEFT COIL
A7-REV COIL
C6-FWD COIL
B6-DWN COIL
A6-UP COIL
B- 1
+
7 - F8
CONTROLLER FB
+
- G6 2 FB H2 Y3 Y4 Y5 Y6 Y7 Y8
U13 HOUR FLASHING AUTOMOTIVE-STYLE STEER STEER DRIVE DRIVE PLATFORM PLATFORM
DC/AC INVERTER METER BEACONS HORN RIGHT LEFT REVERSE FORWARD DOWN UP
+

- (OPTION)
+
8 QD1 (-)
GND GND



BK P2
RD EMERGENCY STOP
B B WH GROUND

3
R15
B5 Battery 4 BR
5000 OHM SW6STEER
BN Button SW25 5
POTENTIOMETER
DIP SWITCHES
RIGHT
BN5 = Horn 6 2
LEFT
SW5
ENABLE
CR Control relay 24V DC 5V DC WH/BK
PIO3 VOLTAGE
D7 Voltage regulator (Platform controls circuit board) REGULATOR
F6 Fuse, 275A
FB1 Flashing beacons POUT1 POWER LED L19 3
G Gauge
POUT2 FAULT LED L25
G6 = Hour meter
H1 = Horn
JC1 Joystick controller 4
KS1 Key switch POUT9 DRIVE LED L17
L LED or light POUT10 LIFT LED L16
L16 = Lift U3
L17 = Drive PLATFORM CONTROLS PLATFORM CONTROLS
MEMBRANE DECAL PANEL
L25 = Fault
PIN2 HORN BN5
LS7 = Pothole 5
M5 Hydraulic power unit PIN4 LIFT ENABLE BN9

N.C.H.O. Normally closed held open
WH/BL
P Power switch PIN9
P1 = Emergency Stop button at ground controls WH/RD
PIN8
P2 = Emergency Stop button at platform controls
WH
PS2 Platform overload pressure switch (option) PIN10
QD Quick disconnect 6
QD1 = Battery quick disconnect RD
POUT11 +
QD3 = Control cable to ground
QD4 = Control cable to platform H1 ALARM
BK
R Resistor PIN11 -
R15 = 5000 ohm potentiometer
SW Switch
SW25 = DIP switches PLATFORM CONTROLLER 7
U3 = Encoder printed circuit board WIRE COLOR
U6 = Motor controller LEGEND
U9 = Battery charger Color Description
U13 = Voltage inverter (option) BL Blue 8
BK Black
Y Valve coil
BN Brown
Y3 = Steer right
Y4 = Steer left
GN Green

Electrical Schematic REV B

QD4
1 76F 78F
WH RD C C
77F
WH A A
KS1 30 86
POWER BK D D
T RELAY 87 85
TO U5 OR E E
CB2 P1 B 23D
7A EMERGENCY
CIRCUIT STOP
2 BREAKER PLATFORM
CONTROL
39C
H5 -
B
LS6 PS2 LS7
3 TS66 SWITCH
UP/DOWN SWITCH
LS8
DOWN
UP
POTHOLE
RD
WH
GUARD
SWITCH
30 86
CR5 N.O.
EMERG STOP
ESTOP FROM JOYSTICK
DATA LINK (HIGH)

DATA LINK (LOW)
B12-UP/DWN SW UP
B10-POTHOLE SW
B8-HORN OPTION
B9-MULTIFUNCT ALM
C12-DWN LIMIT
GND FROM JOYSTICK
C11-LVL SNSR-WHT
A5-LVL SNSR-RED
A9-MOTOR CONTROLLER
A12-UP/DWN SW DWN

4 HORN RELAY
A11-KEY SWITCH
87 85 (H2 OPTION)
LEVEL
SENSOR
CIRCUIT
R21 BOARD
75 OHM
U27 S7
47 mH LEVEL
QD1 (+) INDUCTOR,
NOISE
SENSOR
5 SUPPRESSION
BN
F6 M5
275A FUSE D1 MOTOR
A1
A1 OUT U5
6 U9
BATTERY
B3 C7 B7 A7 C6 B6 A6
B5 AC INPUT
T2 B+
4-6V M-
BATTERY A2 3 FB
-
GND
C7-RT COIL
B7-LEFT COIL
A7-REV COIL
C6-FWD COIL
B6-DWN COIL
A6-UP COIL
B- 1
+
7 - F8
50A FUSE U6 MOTOR
CONTROLLER FB
+
- G6 FB H2 Y3 Y4 Y5 Y6 Y7 Y8
+

- (OPTION)
+
8 QD1 (-)
GND GND

REV B Electrical Schematic


BK P2
RD EMERGENCY STOP
B B WH GROUND

ABBREVIATION LEGEND E E YL DATA LINK (LOW) PIO5
1 OR WH/YL
3
R15
B5 Battery
4 BR
5000 OHM SW6STEER
BN Button SW25 5
POTENTIOMETER
RIGHT
6 2
LEFT
SW5
CR Control relay WH/BK
24V DC 5V DC
PIO3 VOLTAGE
REGULATOR
F6 Fuse, 275A
POUT1 POWER LED L19 3
G Gauge
H1 = Horn
KS1 Key switch
4
POUT9 DRIVE LED L17
L LED or light
POUT10 LIFT LED L16
L16 = Lift U3
L25 = Fault
PIN2 HORN BN5
LS7 = Pothole
5
P Power switch WH/BL
PIN9
P2 = Emergency Stop button at platform controls PIN8
WH
QD3 = Control cable to ground POUT11 +
BK
R Resistor PIN11 -
SW Switch
BK Black
Y Valve coil
BN Brown
Y3 = Steer right


1 QD4
76F 78F
WH RD C C
77F
WH A A
KS1 30 86
POWER BK D D
T RELAY 87 85
TO U5 OR E E
CB2 P1 B 23D
7A EMERGENCY
CIRCUIT STOP
2 BREAKER PLATFORM
39C
CONTROL
H5 -
B
LS6 PS2 LS7
3 TS66 SWITCH
UP/DOWN SWITCH
LS8
DOWN
UP
POTHOLE
RD
WH
GUARD
SWITCH
30 86
U27 CR5 N.O.

4
DRIVER POWER
ECM POWER
DATA LINK (HIGH)

DATA LINK (LOW)
B12-UP/DWN SW UP
A11-KEY SWITCH
B10-POTHOLE SW
B8-HORN OPTION
B9-MULTIFUNCT ALM
C12-DWN LIMIT
GND FROM JOYSTICK
C11-LVL SNSR-WHT
A5-LVL SNSR-RED
A9-MOTOR CONTROLLER
A12-UP/DWN SW DWN

HORN RELAY
47 mH INDUCTOR, 87 85 (H2 OPTION)
NOISE SUPPRESSION
LEVEL
SENSOR
(CE MODELS ONLY CIRCUIT
AFTER SERIAL NUMBER 50511) R21 BOARD
75 OHM
S7
LEVEL
QD1 (+) SENSOR
5
BN
F6 M5
275A FUSE D1 MOTOR
B8 A8 A9 A12 B12 A11 C12 B9 A10 B10 C2 B11 A4 A2 B1 C1 C11 A5
A1
U5
6 A1 OUT ELECTRONIC CONTROL MODULE
U9
BATTERY
B3 C7 B7 A7 C6 B6 A6
B5 AC INPUT T2 B+
4-6V
BATTERY A2 3 FB
-
GND
C7-RT COIL
B7-LEFT COIL
A7-REV COIL
C6-FWD COIL
B6-DWN COIL
A6-UP COIL
B- 1
+
7 - F8
50A FUSE U6 MOTOR
CONTROLLER FB
+
- G6 FB H2 Y3 Y4 Y5 Y6 Y7 Y8
+

- (OPTION)
+
8 QD1 (-)
GND GND



BK P2
RD EMERGENCY STOP
1
B B WH GROUND

E E OR DATA LINK (LOW) PIO5

3
R15
B5 Battery 4 BR
5000 OHM SW6STEER
BN Button SW25 5
POTENTIOMETER
DIP SWITCHES
RIGHT
BN5 = Horn 6 2
LEFT
SW5
ENABLE
CR Control relay 24V DC 5V DC WH/BK
PIO3 VOLTAGE
D7 Voltage regulator (Platform controls circuit board) REGULATOR
F6 Fuse, 275A
FB1 Flashing beacons POUT1 POWER LED L19 3
G Gauge
POUT2 FAULT LED L25
G6 = Hour meter

H1 = Horn
JC1 Joystick controller 4
KS1 Key switch POUT9 DRIVE LED L17
L LED or light POUT10 LIFT LED L16
L16 = Lift U3
L25 = Fault
LS6 = Platform up/down PIN2 HORN BN5
LS7 = Pothole 5

WH/BL
P Power switch PIN9
PIN8
P2 = Emergency Stop button at platform controls WH
POUT11 +
BK
R Resistor PIN11 -
SW Switch
BK Black
Y Valve coil
BN Brown
Y3 = Steer right
Y4 = Steer left
GN Green


QD4
1 76F 78F
WH RD C C
77F
WH A A
KS1 30 86
POWER BK D D
T RELAY 87 85
TO U5 OR E E
CB2 P1 B 23D
7A EMERGENCY
CIRCUIT STOP
2 BREAKER PLATFORM
39C
CONTROL
H5 -
B
LS6 PS2 LS7
3 TS66 SWITCH
UP/DOWN SWITCH
LS8
DOWN
UP
POTHOLE
RD
WH
GUARD
SWITCH
30 86
U27 CR5 N.O.

4
DRIVER POWER
ECM POWER
DATA LINK (HIGH)

DATA LINK (LOW)
B12-UP/DWN SW UP
A11-KEY SWITCH
B8-HORN OPTION
B9-MULTIFUNCT ALM
B10-POTHOLE SW
C12-DWN LIMIT
GND FROM JOYSTICK
C11-LVL SNSR-WHT
A5-LVL SNSR-RED
A9-MOTOR CONTROLLER
A12-UP/DWN SW DWN

HORN RELAY
NOISE SUPPRESSION
LEVEL
SENSOR
75 OHM
S7
LEVEL
QD1 (+) SENSOR
5 BN
F6 M5
275A FUSE D1 MOTOR
A1
U5
6 A1 OUT ELECTRONIC CONTROL MODULE
U9
BATTERY
B3 C7 B7 A7 C6 B6 A6
B5 AC INPUT T2 B+
4-6V
BATTERY A2 3 FB
-
GND
C7-RT COIL
B7-LEFT COIL
A7-REV COIL
C6-FWD COIL
B6-DWN COIL
A6-UP COIL
B- 1
+
7 - F8
50A FUSE U6 MOTOR
CONTROLLER FB
+
- G6 FB H2 Y3 Y4 Y5 Y6 Y7 Y8
+

- (OPTION)
+
8 QD1 (-)
GND GND



BK P2
RD EMERGENCY STOP
1
WH
B B WH GROUND PIO3 PIO2
D D BL DATA LINK + BL
PIO4
JC1
24V DC 5V DC HALL JOYSTICK
BN
E E YL DATA LINK - YL
PIO5 D7
ABBREVIATION LEGEND QD3

VOLTAGE
REGULATOR
GY
Item Description SW6
B5 Battery STEER LEFT/ RIGHT
BN Button 1 GN
BN5 = Horn 2 2
RIGHT
LEFT
BN8 = Drive enable 3
4 WH
SW5
BN9 = Lift enable FUNCTION
5 ENABLE
CB2 Circuit breaker, 7A 6
CR Control relay 7 BL
CR5 = Horn relay (with H2 option)
CR48 = Power relay to U5
SW25 8
PP
DIP SWITCHES
F6 Fuse, 275A BK 3
G Gauge
G6 = Hour meter
G7 = Battery charge indicator POUT1 POWER LED L19
GND Ground POUT2 FAULT LED L25
H Horn or alarm POUT3 HIGH TORQUE LED L21
H5 = Multifunction alarm 4
JC1 Joystick controller POUT6 BATTERY LEVEL 3 G7
KS1 Key switch POUT7 BATTERY LEVEL 4
L LED or light POUT8 BATTERY LEVEL 5
L16 = Lift POUT9 DRIVE LED L17
L17 = Drive
POUT10 LIFT LED L16
L19 = Power
LS Limit switch PLATFORM CONTROLS
PRINTED CIRCUIT BOARD 5
LS8 = Pothole
PIN2 HORN BN5
M5 Hydraulic power unit
N.C.H.O. Normally closed held open PIN4 LIFT ENABLE BN9

P Power switch
OR
PS2 Platform overload pressure switch (option) BK
6
PIN8
QD Quick disconnect RD
PIN10
QD1 = Battery quick disconnect
QD4 = Control cable to platform POUT11 +
R21 75 ohm resistor H1 ALARM
SW Switch
PIN11
BK
- PLATFORM
CONTROLLER
SW6 = Steer left/right 7
SW25 = DIP switches
U Electronic component WIRE COLOR
U3 = Encoder printed circuit board LEGEND
U5 = Electronic control module Color Description
BL Blue
U9 = Battery charger
BK Black
U13 = Voltage inverter (option) 8
U27 = 47 mH inductor, noise suppression BN Brown
Y Valve coil GN Green
Y3 = Steer right GY Gray
Y4 = Steer left OR Orange
Y5 = Drive reverse PP Purple


QD4
1 76F
WH RD C C
WH A A
KS1
30 86
CR48 BL B B
KEY SWITCH POWER BK D D
51F RELAY 87 85
TO U5 OR E E
B
CB2 P1 23D
7A EMERGENCY
52F 3 1 A11
CIRCUIT STOP
2 BREAKER
B1
39C
4 2 N.C. + N.O. N.C.H.O.
H5 -
76F
LS6 PS2 LS7
DOWN ALARM PLATFORM POTHOLE
LIMIT OVERLOAD GUARD 21B
TS66 SWITCH
UP/DOWN SWITCH
LS8
DOWN
UP
POTHOLE
RD
WH
GUARD
SWITCH
30 86
U27 CR5 N.O.
DRIVER POWER
ECM POWER
DATA LINK (HIGH)

DATA LINK (LOW)
B12-UP/DWN SW UP
A11-KEY SWITCH
B8-HORN OPTION
B9-MULTIFUNCT ALM
B10-POTHOLE SW
C12-DWN LIMIT
GND FROM JOYSTICK
C11-LVL SNSR-WHT
A5-LVL SNSR-RED
A9-MOTOR CONTROLLER
A12-UP/DWN SW DWN

4 47 mH INDUCTOR, 87 85
HORN RELAY
(H2 OPTION)
NOISE SUPPRESSION
LEVEL
SENSOR
75 OHM
S7
LEVEL
QD1 (+) SENSOR
5 BN
F6 M5
275A FUSE D1 MOTOR
A1
U5
A1 OUT ELECTRONIC CONTROL MODULE
6 U9
BATTERY
B3 C7 B7 A7 C6 B6 A6
B5 AC INPUT T2 B+
4-6V
BATTERY A2 3 FB
-
GND
C7-RT COIL
B7-LEFT COIL
A7-REV COIL
C6-FWD COIL
B6-DWN COIL
A6-UP COIL
B- 1
+
7 - F8
50A FUSE U6 MOTOR
CONTROLLER FB
+
- G6 FB H2 Y3 Y4 Y5 Y6 Y7 Y8
+

- (OPTION)
+
8 QD1 (-)
GND GND



BK P2
RD EMERGENCY STOP
WH
B B WH GROUND PIO3 PIO2
D D BL DATA LINK + BL
PIO4
JC1
BN
E E YL DATA LINK - YL
PIO5 D7

VOLTAGE
REGULATOR
GY
BN Button 1 GN
BN5 = Horn 2
2
RIGHT
LEFT
4 WH
SW5
5 ENABLE
CR5 = Horn relay (with H2 option)
CR48 = Power relay to U5
SW25 8
PP
DIP SWITCHES
F6 Fuse, 275A BK 3
G Gauge
G6 = Hour meter
L17 = Drive
POUT10 LIFT LED L16
L19 = Power
LS Limit switch PLATFORM CONTROLS
PRINTED CIRCUIT BOARD 5
LS8 = Pothole
PIN2 HORN BN5
P Power switch
P2 = Emergency Stop button at platform controls OR
PIN9
6
PIN8
QD4 = Control cable to platform POUT11 +
R21 75 ohm resistor H1 ALARM
SW Switch
PIN11
BK
- PLATFORM
CONTROLLER
SW25 = DIP switches
BL Blue
BK Black


76F 78F
WH RD 4
1 77F
WH WH 3
KS1
30 86
CR48 WH BL 1
KEY SWITCH POWER WH BK 2
51F RELAY 87 85
TO U5 WH OR 5
B
CB2 P1 23D
7A EMERGENCY
52F 3 1 A11
CIRCUIT STOP
BREAKER
B1
2 39C
4 2 N.C. + N.O. N.C.H.O.
H5 -
76F
LS6 PS2 LS7
DOWN ALARM PLATFORM POTHOLE
LIMIT OVERLOAD GUARD 21B
TS66 SWITCH
3 UP/DOWN SWITCH
LS8
DOWN
UP
POTHOLE
RD
WH
GUARD
SWITCH
30 86
U27 CR5 N.O.
DRIVER POWER
ECM POWER
DATA LINK (HIGH)

DATA LINK (LOW)
B12-UP/DWN SW UP
A11-KEY SWITCH
B10-POTHOLE SW
B8-HORN OPTION
B9-MULTIFUNCT ALM
C12-DWN LIMIT
GND FROM JOYSTICK
C11-LVL SNSR-WHT
A5-LVL SNSR-RED
A9-MOTOR CONTROLLER
A12-UP/DWN SW DWN

HORN RELAY
4 NOISE SUPPRESSION
LEVEL
SENSOR
75 OHM
S7
LEVEL
QD1 (+) SENSOR
BN
5 F6 M5
275A FUSE D1 MOTOR
A1
U5
A1 OUT ELECTRONIC CONTROL MODULE
U9
6 BATTERY
B3 C7 B7 A7 C6 B6 A6
B5 AC INPUT T2 B+
4-6V
BATTERY A2 3 FB
-
GND
C7-RT COIL
B7-LEFT COIL
A7-REV COIL
C6-FWD COIL
B6-DWN COIL
A6-UP COIL
B- 1
+
- F8
50A FUSE U6 MOTOR
7 CONTROLLER FB
+
- G6 FB H2 Y3 Y4 Y5 Y6 Y7 Y8
+

- (OPTION)
+
QD1 (-)
GND GND
8


4 4 BK POWER TO PLATFORM CONTROLS

BK P2
RD EMERGENCY STOP
3 3 RD POWER TO GROUND CONTROLS
WH
1
1 1 WH GROUND PIO3 PIO2
2 2 BL DATA LINK (HIGH)

BL
PIO4
JC1
OR BN GENERATOR
5 5 OR DATA LINK (LOW) PIO5 D7 CONTROLLER

VOLTAGE
REGULATOR
GY
1 GN
BN Button
BN5 = Horn 2 2
RIGHT
LEFT
4 WH
SW5
5 ENABLE
CR5 = Horn relay (with H2 option) SW25 8
PP
CR48 = Power relay to U5 DIP SWITCHES
F6 Fuse, 275A BK 3
G Gauge
G6 = Hour meter
L17 = Drive POUT10 LIFT LED L16
L19 = Power
PLATFORM CONTROLS
LS Limit switch PRINTED CIRCUIT BOARD MEMBRANE DECAL PANEL
LS6 = Platform up/down 5
PIN3 DRIVE ENABLE BN8
P Power switch
OR
6
PIN8
PIN10
QD1 = Battery quick disconnect
POUT11 +
R21 75 ohm resistor
SW Switch
SW5 = Function enable PIN11
BK
-
H1 ALARM
PLATFORM
CONTROLLER
SW25 = DIP switches
BL Blue
BK Black

Hydraulic Schematic Legend and

Component Reference
Hydraulic Schematic Legend and REV B
Component Reference
AA AB
AK
AC Relief valve
AD Filter
Check valve,
pilot to open
AE
AF Priority
D
flow regulator
E Shuttle valve
AG
Fixed displacement
pump
AH 0.040”
(1 mm)
Orifice with size
A Brake
AJ
AI
Bi-directional motor
Function manifold components B
Check valve
C
Hand pump
BA BB
Lift cylinder components
M
Brake release hand pump manifold
components Variable speed motor
Dual acting cylinder
BC
BD Y7
Single acting cylinder
BE
Solenoid operated Solenoid operated

BF
3 position 4 way 2 position 2 way valve,
directional valve normally closed with
1.03 CU. IN.
BG D manual over-ride 16.9 cc
E Accumulator
BH Y8
BK
BI
Y2
BJ
Solenoid operated
Solenoid operated
Lift cylinder components 2 position 4 way
Function manifold components 2 position 2 way
(after serial number 23567) directional valve
(after serial number 35799) directional valve

REV B Hydraulic Schematic

LEFT RIGHT LEFT RIGHT

LIFT 1
BRAKE BRAKE DRIVE MOTOR DRIVE MOTOR
CYLINDER
STEER STEER
LEFT RIGHT HAND
PUMP
B C
Y7 F
D A 2
1.03 CU. IN.
16.9 cc
MANUAL
GS-1530 = 0.046” / 1.17 mm RELEASE
E GS-1930 = 0.037” / 0.94 mm
The lift cylinder orifice is located

S1 S2 LIFT underneath the fitting on the lift cylinder. BRAKE HP M1 M3 M2 M4 3
Y4 Y3
AK 5 psi
0.35 bar
AF 4
AH
AE
TP Y2
AA
AD Y6 Y5
1500 psi
AB 103.4 bar 0.040” 5
1 mm
0.75 gpm
AI
2.8 L/min
5 psi
AJ 0.35 bar
AG
Y8
6
AC
3500 psi
241.3 bar
FUNCTION MANIFOLD
PRESSURE TANK 7
ABBREVIATION LEGEND
Item Description
POWER
UNIT M 10 MICRON WITH
25 psi / 1.7 bar
AA
AB
Test port
Flow regulator, steer circuit
BYPASS AC Relief valve, system
ABBREVIATION LEGEND AD Orifice washer, steer circuit
100 MESH
Item Description AE Relief valve, steer
A Check valve, manual brake release AF Steer left/right 8
B Shuttle valve, brake release AG Platform up
C Hand pump, manual brake release AH Brake circuit
D Platform lowering valve AI Drive forward/reverse
E Orifice, platform down circuit AJ Check valve, brake circuit
F Accumulator AK Check valve, steer circuit

Hydraulic Schematic
REV B Hydraulic Schematic

LIFT LEFT RIGHT LEFT RIGHT

BRAKE BRAKE 1
CYLINDER DRIVE MOTOR DRIVE MOTOR
STEER STEER
LEFT RIGHT
HAND
PUMP
B C
Y7
D F A 2
1.03 CU. IN.
16.9 cc MANUAL
GS-1530 = 0.046” / 1.17 mm RELEASE
E GS-1930 = 0.037” / 0.94 mm
The lift cylinder orifice is located

underneath the fitting on the lift cylinder.
LIFT S1 S2 BRAKE HP M1 M4 3
Y4 Y3
BK 10 psi
0.7 bar
BI
4
BE
1500 psi
0.040” 103.4 bar
1 mm Y5
Y6
BB BF
BG BJ
0.75 gpm
Y8 2.8 L/min 5
TP 10 psi
BH 0.7 bar
BA
3000 to 3200 psi

BD 207 to 221 bar
BC 6
3500 psi
241.3 bar
FUNCTION MANIFOLD
PRESSURE TANK 7
IMPORTANT NOTES ABBREVIATION LEGEND
POWER
UNIT M 10 MICRON WITH
25 psi / 1.7 bar
BD Refer to Repair Procedure 6-3, Valve Adjustments —
Function Manifold, for platform lift relief valve setting.
BA
BB
Test port
Flow regulator, steer circuit
BYPASS
BC Relief valve, system
ABBREVIATION LEGEND BD Relief valve, lift
100 MESH Item Description BE Orifice washer, steer circuit
A Check valve, manual brake release BF Relief valve, steer 8
B Shuttle valve, brake release BG Platform up
C Hand pump, manual brake release BH Check valve, drive circuit
D Platform lowering valve BI Steer left/right
E Orifice, platform down circuit BJ Drive forward/reverse
F Accumulator BK Check valve, steer circuit

Hydraulic Schematic
Part No.
Rev C2
72876
Service Manual GS-1530 & GS-1930
Genie North America
Phone 425.881.1800
Toll Free USA and Canada
Distributed By:
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Fax 425.883.3475
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Phone +61 7 3375 1660
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Genie GS1930 - 2876 Parts Manual

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Genie GS1930 - 2876 Parts Manual

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Part No.

Important Serial Number Information

Contact Us: Copyright © 1997 by Genie Industries

72876 Rev C April 2003

ii Genie GS-1530 and GS-1930 Part No. 72876

Do Not Perform Maintenance

Part No. 72876 Genie GS-1530 and GS-1930 iii

Personal Safety Be sure to wear protective eye wear and

iv Genie GS-1530 and GS-1930 Part No. 72876

Section One Safety Rules

Section Two Specifications - Rev C

Section Three Scheduled Maintenance Procedures

Part No. 72876 Genie GS-1530 and GS-1930 v

Section Three Maintenance Procedures, continued

Section Four Repair Procedures

vi Genie GS-1530 and GS-1930 Part No. 72876

Section Four Repair Procedures, continued

Part No. 72876 Genie GS-1530 and GS-1930 vii

Section Five Troubleshooting Flow Charts and Fault Codes

viii Genie GS-1530 and GS-1930 Part No. 72876

Section Six Schematics

Part No. 72876 Genie GS-1530 and GS-1930 ix

Section Six Schematics, continued

x Genie GS-1530 and GS-1930 Part No. 72876

Type 6V DC Drive speed, maximum

Group T-105 Platform stowed 2.5 mph

Part No. 72876 Genie GS-1530 and GS-1930 2-1

Machine Specifications, GS-1930 Performance Specifications,

Type 6V DC Drive speed, maximum

Group T-105 Platform stowed 2.5 mph

For operational specifications, refer to the

2-2 Genie GS-1530 and GS-1930 Part No. 72876

Machine Specifications, GS-1932 Performance Specifications,

Type 6V DC Platform stowed 2.5 mph

Tires and wheels Platform retracted 500 lbs

Castle nut torque, lubricated 225 ft-lbs

Part No. 72876 Genie GS-1530 and GS-1930 2-3

Hydraulic Specifications Function pump

Hydraulic Oil Specifications Type Gear

Before serial number 52640 Displacement per revolution 0.244 cu in

Biodegradable Petro Canada Premium ECO 46

Fire resistant UCON Hydrolube HP-5046

Mineral based Shell Tellus T32

Genie specifications require

2-4 Genie GS-1530 and GS-1930 Part No. 72876

SAE No. 2 50 in-lbs / 6 Nm

SAE No. 4 13 ft-lbs / 18 Nm

SAE No. 6 18 ft-lbs / 24 Nm

SAE No. 8 50 ft-lbs / 68 Nm

SAE No. 10 55 ft-lbs / 75 Nm

SAE No. 12 75 ft-lbs / 102 Nm

Valve Coil Resistance

Solenoid valve, 3 position 4 way 25 to 27 Ω

Solenoid valve, 2 position 4 way 18 to 20 Ω

Solenoid valve, N.O. poppet 25 to 27 Ω

Solenoid valve, 3 position 4 way 18 to 20 Ω

Solenoid valve, 2 position 4 way 18 to 20 Ω

Part No. 72876 Genie GS-1530 and GS-1930 2-5

Hydraulic Hose and Fitting Torque Specifications

SAE O-ring Boss Port SAE O-ring Boss Port

SAE Dash size Torque SAE Dash size Torque

-4 11 ft-lbs / 14.9 Nm -4 16 ft-lbs / 21.7 Nm

-6 23 ft-lbs / 31.2 Nm -6 35 ft-lbs / 47.5 Nm