Service Manual: Refer To Inside Cover For Serial Number Information

Service Manual Part No.
72963
September 2006
Refer to inside cover for serial number information Rev C2
June 2004
Important Serial Number Information

Read, understand and obey the safety rules and Genie Industries offers the following Service
operating instructions in the appropriate Operator's Manuals for these models:
Manual on your machine before attempting any
maintenance procedure. Title Part No.
Basic mechanical, hydraulic and electrical Genie GS-2032 Service Manual,

skills are required to perform most procedures. First Edition
However, several procedures require specialized (before serial number 17408) .............................. 46326
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
www.genieindustries.com 72963 Rev C June 2004

Second Edition, Third Printing
e-mail: techsup@genieind.com
"Genie" is a registered trademark of Genie
Industries in the USA and many other countries.
"GS" is a trademark of Genie Industries.
Printed on recycled paper
Printed in U.S.A.
ii Genie GS-2032 and GS-2632 Part No. 72963

June 2004
Safety Rules
Danger
Failure to obey the instructions and safety rules
in this manual and the appropriate Operator's
Manual on your machine will result in death or
serious injury.
Many of the hazards identified in the
operator’s manual are also safety hazards
when maintenance and repair procedures
are performed.
Do Not Perform Maintenance

Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
- manufacturer’s instructions and safety rules
- employer’s safety rules and worksite
regulations
- applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.
Part No. 72963 Genie GS-2032 and GS-2632 iii

June 2004
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
hazardous situation which, if not
avoided, will result in death or Be sure that all tools and working areas
serious injury. are properly maintained and ready for use.
Orange—used to indicate the Keep work surfaces clean and free of
presence of a potentially debris that could get into machine components and
hazardous situation which, if not cause damage.
avoided, could result in death or
serious injury.
Be sure that your workshop or work area is
Yellow with safety alert symbol— properly ventilated and well lit.
used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause
Be sure any forklift, overhead crane or
minor or moderate injury.
other lifting or supporting device is fully
Yellow without safety alert capable of supporting and stabilizing the
symbol—used to indicate the weight to be lifted. Use only chains or straps that
presence of a potentially are in good condition and of ample capacity.
avoided, may result in property
damage. Be sure that fasteners intended for one
Green—used to indicate operation time use (i.e., cotter pins and self-locking
or maintenance information. nuts) are not reused. These components
may fail if they are used a second time.
Be sure to properly dispose of old oil or

other fluids. Use an approved container.
Please be environmentally safe .
iv Genie GS-2032 and GS-2632 Part No. 72963

June 2004
Table of Contents
Introduction
Important Information ......................................................................................... ii
Section 1 Safety Rules

General Safety Rules ........................................................................................ iii
Section 2 Rev Specifications

A Machine Specifications ................................................................................ 2 - 1
A Performance Specifications ......................................................................... 2 - 1
A Hydraulic Specifications ............................................................................... 2 - 2
A Manifold Component Specifications ............................................................. 2 - 3
A Hydraulic Hose and Fitting Torque Specifications ......................................... 2 - 4
Section 3 Rev Scheduled Maintenance Procedures

Introduction .................................................................................................. 3 - 1
Pre-delivery Preparation Report .................................................................... 3 - 3
Maintenance Inspection Report .................................................................... 3 - 5
B Checklist A Procedures
A-1 Perform Pre-operation Inspection ........................................................ 3 - 6
A-2 Perform Function Tests ...................................................................... 3 - 6
A-3 Perform 30 Day Service ...................................................................... 3 - 7
A-4 Grease the Steer Yokes ...................................................................... 3 - 7
Part No. 72963 Genie GS-2032 and GS-2632 v

September 2006
TABLE OF CONTENTS
Section 3 Rev Scheduled Maintenance Procedures, continued

D Checklist B Procedures
B-1 Inspect the Batteries ........................................................................... 3 - 8
B-2 Inspect the Electrical Wiring ............................................................... 3 - 9
B-3 Inspect the Tires and Wheels (including castle nut torque) ................ 3 - 10
B-4 Test the Emergency Stop ................................................................. 3 - 10
B-5 Test the Key Switch ......................................................................... 3 - 11
B-6 Test the Automotive-style Horn (if equipped) ..................................... 3 - 11
B-7 Test the Drive Brakes ....................................................................... 3 - 12
B-8 Test the Drive Speed - Stowed Position ............................................ 3 - 15
B-9 Test the Drive Speed - Raised Position ............................................. 3 - 16
B-10 Perform Hydraulic Oil Analysis ......................................................... 3 - 17
B-11 Replace the Hydraulic Tank Return Filter .......................................... 3 - 17
B-12 Check the Module Tray Latch Components ....................................... 3 - 18
C Checklist C Procedure
C-1 Test the Platform Overload System (if equipped) .............................. 3 - 19
D Checklist D Procedures
D-1 Check the Scissor Arm Wear Pads ................................................... 3 - 21
A Checklist E Procedure
E-1 Test or Replace the Hydraulic Oil ...................................................... 3 - 22
vi Genie GS-2032 and GS-2632 Part No. 72963

June 2006
TABLE OF CONTENTS
Section 4 Rev Repair Procedures

Introduction .................................................................................................. 4 - 1
B Platform Controls
1-1 Circuit Boards ..................................................................................... 4 - 2
1-2 Joystick Controller .............................................................................. 4 - 3
1-3 Controller Adjustments ....................................................................... 4 - 5
1-4 Software Configuration ...................................................................... 4 - 13
B Platform Components
2-1 Platform ............................................................................................ 4 - 16
2-2 Platform Extension ........................................................................... 4 - 17
D Scissor Components
3-1 Scissor Assembly, GS-2032 ............................................................. 4 - 18
3-2 Scissor Assembly, GS-2632 ............................................................. 4 - 24
3-3 Lift Cylinder ...................................................................................... 4 - 32
3-4 Platform Overload System ............................................................... 4 - 34
C Ground Controls
4-1 Manual Platform Lowering Cable ....................................................... 4 - 36
4-2 Control Relays .................................................................................. 4 - 37
4-3 Level Sensor (before serial number 47665) ....................................... 4 - 38
4-4 Level Sensor (after serial number 47664) .......................................... 4 - 44
A Hydraulic Pump
5-1 Function Pump ................................................................................. 4 - 50
Part No. 72963 Genie GS-2032 and GS-2632 vii

June 2006
TABLE OF CONTENTS
Section 4 Rev Repair Procedures, continued

C Function Manifold
6-1 Function Manifold Components
(from serial number 17408 to 17481) ................................................. 4 - 52
6-5 Function Manifold Components -
Models with Traction Control ............................................................. 4 - 60
6-6 Valve Adjustments - Function Manifold ............................................ 4 - 62
6-7 Valve Coils ....................................................................................... 4 - 70
A Hydraulic Tank
7-1 Hydraulic Tank ................................................................................. 4 - 72
A Steer Axle Components
8-1 Yoke and Drive Motor ....................................................................... 4 - 73
8-2 Steer Cylinder ................................................................................... 4 - 75
8-3 Steer Bellcrank ................................................................................. 4 - 76
A Non-steer Axle Components
9-1 Drive Brake ...................................................................................... 4 - 77
A Brake Release Hand Pump Components
10-1 Brake Release Hand Pump Components .......................................... 4 - 78
viii Genie GS-2032 and GS-2632 Part No. 72963

June 2004
Section 5 Rev Fault Codes

Introduction .................................................................................................. 5 - 1
A Fault Code Chart (after serial number 17407) ................................................ 5 - 3
Chart
Number Chart Title
1 A All Functions Will Not Operate ..................................................................... 5 - 4
2 A Pump Motor Will Not Operate ....................................................................... 5 - 6
3 A All Functions Inoperative, Power Unit Starts and Runs ................................. 5 - 8
4 A Ground Controls Inoperative,
Platform Controls Operate Normally ............................................................. 5 - 9
5 A Platform Controls Inoperative,
Ground Controls Operate Normally ............................................................. 5 - 10
6 A Platform Up Function Inoperative ............................................................... 5 - 11
7 A Platform Down Function Inoperative ........................................................... 5 - 12
8 A Steer Left Function Inoperative .................................................................. 5 - 14
9 A Steer Right Function Inoperative ................................................................ 5 - 16
10 A All Drive Functions Inoperative,
All Other Functions Operate Normally ........................................................ 5 - 18
10A A Brake Release Function Inoperative ........................................................... 5 - 19
11 A Drive Forward Function Inoperative ............................................................ 5 - 20
12 A Drive Reverse Function Inoperative ............................................................ 5 - 21
13 A Machine Will Not Drive At Full Speed ......................................................... 5 - 22
14 A Machine Drives At Full Speed With Platform Raised .................................. 5 - 23
15 A Limit Switch Function Inoperative ............................................................... 5 - 24
16 A Fault Code 02 - ECM / Platform Communication Error ................................ 5 - 26
17 B Fault Code 59 - Parallel/Series Coil Fault ................................................... 5 - 29
Part No. 72963 Genie GS-2032 and GS-2632 ix

June 2004
Section 6 Rev Schematics

Introduction .................................................................................................. 6 - 1
B Control Relay Layout, GS-2032 (ANSI, CSA and Australia models) ............. 6 - 2
B Control Relay Layout, GS-2032 (CE models) and GS-2632 (all models) ....... 6 - 3
B ECM Pin-out Legend .................................................................................... 6 - 4
B Platform Controls Wiring Diagram
(models with potentiometer-equipped joystick) ............................................. 6 - 6
A Platform Controls Wiring Diagram
(models with hall-effect joystick) .................................................................. 6 - 7
B Ground Controls Wiring Diagram ................................................................... 6 - 8
B Level Sensor Box Wiring Diagram ................................................................ 6 - 9
B Electrical Symbols Legend ......................................................................... 6 - 10
B Electrical Schematic -
(from serial number 17408 to 21064) .......................................................... 6 - 11
A Electrical Schematic -
A Electrical Schematic -
B Component Reference and Hydraulic Symbols Legend ............................... 6 - 25
B Hydraulic Schematic -
A Hydraulic Schematic -
Models with Traction Control ...................................................................... 6 - 29
x Genie GS-2032 and GS-2632 Part No. 72963

June 2004 Section 2 • Specifications
REV A
Specifications
Machine Specifications Performance Specifications
Batteries Drive speed, maximum
Type 6V DC Platform stowed 2.2 mph

40 ft / 12.4 sec
Group T-105 3.5 km/h
12.2 m / 12.4 sec
Quantity 4
Platform raised 0.5 mph
Battery capacity, maximum 225AH
40 ft / 55 sec
Reserve capacity @ 25A rate 447 minutes 0.8 km/h
12.2 m / 55 sec
Fluid capacities
Braking distance, maximum
Hydraulic tank 5 gallons
18.9 liters High range on paved surface 2 ft
61 cm
Hydraulic system (including tank) 5.5 gallons
20.8 liters Function speed, maximum from platform controls
(with 1 person in platform)
Tires and wheels
Platform up 29 to 31 seconds
Tire size (solid rubber) 15 x 5 in Platform down 25 to 27 seconds
38.1 x 12.7 cm
Gradeability
Tire contact area 10 sq in
64.5 cm2 GS-2032 30%
GS-2632 25%
Castle nut torque, dry 300 ft-lbs
406.7 Nm Airborne noise emissions >70 dB
Maximum sound level at normal operation workstations
Castle nut torque, lubricated 225 ft-lbs (A-weighted)
305 Nm
Continuous improvement of our products is a

For operational specifications, refer to the Genie policy. Product specifications are subject
Operator's Manual. to change without notice.
Part No. 72963 Genie GS-2032 and GS-2632 2-1

Section 2 • Specifications June 2004
SPECIFICATIONS REV A
Hydraulic Specifications Function pump
Hydraulic Oil Specifications Type Gear
Hydraulic oil type Chevron Rykon MV equivalent Displacement per revolution 0.244 cu in
Approximate SAE grade 5W-20 4 cc
Viscosity index rating 200 Flow rate @ 2500 psi / 172 bar 4 gpm
Chevron Rykon MV oil is fully compatible and 15 L/min
mixable with Shell Donax TG (Dexron III) oils. Hydraulic tank return filter 10 micron with
Genie specifications require hydraulic oils which are 25 psi / 1.7 bar bypass
designed to give maximum protection to hydraulic
systems, have the ability to perform over a wide Function manifold
temperature range, and have a minimum viscosity index
rating of 150. They should provide excellent antiwear, System relief valve pressure, maximum 3500 psi
oxidation, corrosion inhibition, seal conditioning, and 241 bar
foam and aeration suppression properties.
Lift relief valve pressure 3000 to 3200 psi
Optional fluids 207 to 221 bar
Biodegradable Petro Canada Premium ECO 46 Steer relief valve pressure 1500 psi
Statoil Hydra Way Bio Pa 32 103 bar
BP Biohyd SE-S
Fire resistant UCON Hydrolube HP-5046 Continuous improvement of our products is a

Quintolubric 822 Genie policy. Product specifications are subject
Mineral based Shell Tellus T32 to change without notice.
Shell Tellus T46
Chevron Aviation A
Genie specifications require

additional equipment and special
installation instructions for the
approved optional fluids. Consult
the Genie Industries Service
Department before use.
2-2 Genie GS-2032 and GS-2632 Part No. 72963

REV A SPECIFICATIONS
Manifold Component Valve Coil Resistance

Specifications Description Specification
Plug torque Solenoid valve, N.C. 23 - 25>

2 position 2 way 20V DC
SAE No. 2 50 in-lbs / 6 Nm (schematic item D, before serial number 28937)
SAE No. 4 13 ft-lbs / 18 Nm Solenoid valve, N.C. 23 - 25>

2 position 2 way 20V DC with diode
SAE No. 6 18 ft-lbs / 24 Nm (schematic item D, after serial number 28936)
SAE No. 8 50 ft-lbs / 68 Nm Solenoid valve, 2 position 2 way N.O. 25 to 27Ω
SAE No. 10 55 ft-lbs / 75 Nm 20V DC with diode
(schematic items AI, BK, CI and CL)
SAE No. 12 75 ft-lbs / 102 Nm
Solenoid valve, 2 position 4 way 18 to 20Ω
20V DC with diode
(schematic items AH, AJ, BI, BL, CJ and CN)

20V DC with diode
(schematic items AK, BJ and CK)

20V DC with diode
(schematic items AG, BH and CH)
Continuous improvement of our products is a

Genie policy. Product specifications are subject
to change without notice.

SPECIFICATIONS REV A
Hydraulic Hose and Fitting

Torque Specifications
Your machine is equipped with JIC 37° flared
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 JIC 37° Fittings

(tube fitting - installed into Aluminum) (swivel nut or hose connection)
SAE Dash size Torque SAE Dash size Thread Size Flats
-4 11 ft-lbs / 14.9 Nm -4 7/16-20 2
-6 23 ft-lbs / 31.2 Nm -6 9/16-18 1 1/4
-8 40 ft-lbs / 54.2 Nm -8 3/4-16 1
-10 69 ft-lbs / 93.6 Nm -10 7/8-14 1
-12 93 ft-lbs / 126.1 Nm -12 1 1/16-12 1
-16 139 ft-lbs / 188.5 Nm -16 1 5/16-12 1
-20 172 ft-lbs / 233.2 Nm -20 1 5/8-12 1
-24 208 ft-lbs / 282 Nm -24 1 7/8-12 1
SAE O-ring Boss Port

(tube fitting - installed into Steel)
SAE Dash size Torque
-4 16 ft-lbs / 21.7 Nm
-6 35 ft-lbs / 47.5 Nm
-8 60 ft-lbs / 81.3 Nm
-10 105 ft-lbs / 142.4 Nm
-12 140 ft-lbs / 190 Nm
-16 210 ft-lbs / 284.7 Nm
-20 260 ft-lbs / 352.5 Nm
-24 315 ft-lbs / 427.1 Nm

REV A 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. Refer to
Figure 2.
1 Align the tube flare (hex nut) against the nose of
the fitting body (body hex fitting) and tighten the Use the JIC 37° Fittings table on
hex nut to the body hex fitting to hand-tight, the previous page to determine the
approximately 30 in-lbs / 3.4 Nm. correct number of flats for the
proper tightening position.
2 Make a reference mark on one of the flats of the
hex nut, and continue it on to the body hex The marks indicate that the correct
fitting with a permanent ink marker. Refer to tightening positions have been
Figure 1. 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
Figure 1
a hydraulic hose
b hex nut
c reference mark
d body hex fitting Figure 2
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.

REV A
This page intentionally left blank.

June 2004 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 properly complete each avoided, will result in death or
inspection when required may serious injury.
cause death, serious injury or
substantial machine damage. Orange—used to indicate the
presence of a potentially
Immediately tag and remove from service a hazardous situation which, if not
damaged or malfunctioning machine. avoided, could result in death or
serious injury.
Repair any machine damage or malfunction
before operating the machine. Yellow with safety alert symbol—
used to indicate the presence of a
Keep records on all inspections for three years. potentially hazardous situation
Unless otherwise specified, perform each which, if not avoided, may cause
procedure with the machine in the following minor or moderate injury.
configuration: Yellow without safety alert
· Machine parked on a firm, level surface symbol—used to indicate the
presence of a potentially
· Platform in the stowed position hazardous situation which, if not
· Key switch in the off position with the key avoided, may result in property
removed damage.
· Wheels chocked Green—used to indicate operation

or maintenance information.
· All external AC power supply disconnected
from the machine Indicates that a specific result is expected after
performing a series of steps.
Indicates that an incorrect result has occurred
after performing a series of steps.

Section 3 • Scheduled Maintenance Procedures June 2004
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 five types of maintenance inspections
that must be performed according to a schedule—
Indicates that tools will be required to daily, quarterly, semi-annually, annually, and
perform this procedure. two year. The Scheduled Maintenance Procedures
Section and the Maintenance Inspection Report
have been divided into five subsections—A, B, C,
D, and E. Use the following chart to determine
Indicates that new parts will be required
which group(s) of procedures are required to
to perform this procedure.
perform a scheduled inspection.
Indicates that a cold motor or pump will Inspection 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. Semi-annually or every 500 hours A+B+C
Annually or every 1000 hours A+B+C+D
Two year or every 2000 hours A+B+C+D+E
Maintenance Inspection Report
The maintenance inspection report contains

checklists for each type of scheduled inspection.
Make copies of the Maintenance Inspection Report

to use for each inspection. Store completed forms
for three years.

Pre-Delivery 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 the Pre-operation Inspection, the Maintenance items
each 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 N = no, unable to complete
performed by qualified service technicians, according R = repaired
to the manufacturer's specifications and the Comments
requirements 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. 72963 Genie GS-2032 and GS-2632
Copyright © 2002 by Genie Industries. Genie® is a registered trademark of Genie
3-3
Industries. Rev A

Maintenance Inspection Report

Model Checklist A - Rev B Y N R Checklist B - Rev D Y N R
A-1 Pre-operation B-1 Batteries
Serial number inspection B-2 Electrical wiring
Date A-2 Function tests B-3 Tires and wheels
Perform after 40 hours: B-4 Emergency stop
Hour meter A-3 30 day service B-5 Key switch
Perform every 100 hours: B-6 Horn (if equipped)
Machine owner
A-4 Grease steer yokes 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 filter
B-12 Latch components
Inspector company
Instructions Checklist C - Rev C Y N R

· Make copies of this report to use for C-1 Platform overload
each inspection. (if equipped)
· Select the appropriate checklist(s) for
the type of inspection to be Checklist D - Rev D Y N R
performed. D-1 Scissor arm wear pads
Daily or 8 hours
Inspection: A Checklist E - Rev A Y N R
Quarterly or 250 hours E-1 Hydraulic oil
Inspection: A+B
Semi-annually or Comments
500 hours
Inspection: A+B+C
Annually or
1000 hours
Inspection: A+B+C+D
Two year or
2000 hours
Inspection: A+B+C+D+E
· 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

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

REV B CHECKLIST A PROCEDURES
A-3 A-4
Perform 30 Day Service Grease the Steer Yokes
The 30 day maintenance procedure is a onetime Genie specifications require that

procedure to be performed after the first 30 days or this procedure be performed every
40 hours of usage. After this interval, refer to the 100 hours of operation.
maintenance tables for continued scheduled
Regular application of lubrication to the steer yokes
maintenance.
is essential to good machine performance and
1 Perform the following maintenance procedures: service life. Continued use of an insufficiently
greased steer yoke will result in component
· B-3 Inspect the Tires and Wheels damage.
(including castle nut torque)
· B-10 Replace the Hydraulic Tank 1 Locate the grease fitting on the top of the steer
Return 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 D
B-1 Models without maintenance-free or sealed

batteries:
Inspect the Batteries
5 Remove the battery vent caps and check the
specific gravity of each battery cell with a
hydrometer.
Proper battery condition is essential to good Result: If any battery cell displays a specific
machine performance and operational safety. gravity of less than 1.026, the battery must be
Improper fluid levels or damaged cables and replaced.
connections can result in component damage and
6 Check the battery acid level of each battery. If
hazardous conditions.
needed, replenish with distilled water to the
Bodily injury hazard. Batteries bottom of the battery fill tube. Do not overfill.
contain acid. Avoid spilling or
7 Install the battery vent caps.
contacting battery acid. Neutralize
battery acid spills with baking soda 8 Check each battery pack and verify that the
and water. batteries are wired correctly.
Electrocution hazard. Contact a b c
with hot or live circuits could
result in death or serious injury.
QD1
Remove all rings, watches and - +
other jewelry.
F6
275A Fuse
+
Perform this test after fully

charging the batteries. - -
For a more accurate determination - - + +

of battery condition, fully charge
the batteries and allow the
batteries to rest 24 hours before a batteries B5
b quick disconnect QD1
performing this procedure to allow
c 275A fuse F6
the battery cells to equalize.
1 Put on protective clothing and eye wear.
2 Disconnect the battery pack from the machine.
3 Be sure that the battery cable connections are
free of corrosion.
4 Be sure that the battery hold downs and cable
connections are tight.

September 2006 Section 3 • Scheduled Maintenance Procedures
REV D CHECKLIST B PROCEDURES
B-2 5 Raise the platform approximately 8 feet / 2.4 m

from the ground.
Inspect the Electrical Wiring
6 Rotate the safety arm away from the machine
and let it hang down.
7 Lower the platform onto the safety arm.
Maintaining electrical wiring in good condition is Crushing hazard. Keep hands
essential to safe operation and good machine clear of the safety arm when
performance. Failure to find and replace burnt, lowering the platform.
chafed, corroded or pinched wires could result in
unsafe operating conditions and may cause 8 Inspect the center chassis area and scissor
component damage. arms for burnt, chafed and pinched cables.
Electrocution hazard. Contact with 9 Inspect the following areas for burnt, chafed,
hot or live circuits could result in corroded, pinched and loose wires:
death or serious injury. Remove all · Scissor arms
rings, watches and other jewelry.
· ECM to platform controls
1 Inspect the underside of the chassis for
· Power to platform wiring
damaged or missing ground strap(s).
10 Inspect for a liberal coating of dielectric grease
2 Inspect the following areas for burnt, chafed, in all connections between the ECM and the
corroded and loose wires: platform controls.
· Ground control panel 11 Raise the platform and return the safety arm to
· Hydraulic power unit module tray the stowed position.
· Battery pack module tray 12 Lower the platform to the stowed position and
· Scissor arms turn the machine off.
· Platform controls
3 Inspect for a liberal coating of dielectric grease
in all connections between the ECM and the
platform controls.
4 Turn the key switch to ground control and pull
out the Emergency Stop button to the on
position at both the ground and platform
controls.

CHECKLIST B PROCEDURES REV D
B-3 B-4
Inspect the Tires and Wheels Test the Emergency Stop
(including castle nut torque) A properly functioning Emergency Stop is essential
for safe machine operation. An improperly
operating red Emergency Stop button will fail to
shut off power and stop all machine functions,
Maintaining the tires and wheels in good resulting in a hazardous situation.
condition is essential to safe operation and good As a safety feature, selecting
performance. Tire and/or wheel failure could result and operating the ground controls
in a machine tip-over. Component damage may will override the platform controls,
also result if problems are not discovered and except the platform red
repaired in a timely fashion. Emergency Stop button.
1 Check the tire surface and sidewalls for cuts, 1 Turn the key switch to ground control and pull
cracks or unusual wear. out the red Emergency Stop button to the on
2 Check each wheel for damage, bends and position at both the ground and platform
cracks. controls.
3 Remove the cotter pin and check each castle 2 Push in the red Emergency Stop button at the
nut for proper torque. Refer to Section 2, ground controls to the off position.
Specifications. Result: No machine functions should operate.
Always replace the cotter pin with
3 Turn the key switch to platform control and pull
a new one when removing the
out the red Emergency Stop button to the on
castle nut or when checking the
torque of the castle nut.
controls.
4 Install a new cotter pin. Bend the cotter pin to
4 Push down the red Emergency Stop button at
lock it in place.
the platform controls to the off position.
Result: No machine functions should operate.
The red Emergency Stop button at
the ground controls will stop all
machine operation, even if the key
switch is switched to platform
control.
3 - 10 Genie GS-2032 and GS-2632 Part No. 72963

B-5 B-6
Test the Key Switch Test the Automotive-style Horn
Proper key switch action and response is essential (if equipped)
to safe machine operation. The machine can be A functioning horn is essential to safe machine
operated from the ground or platform controls and operation. The horn is activated at the platform
the activation of one or the other is accomplished controls and sounds at the ground as a warning to
with the key switch. Failure of the key switch to ground personnel. An improperly functioning horn
activate the appropriate control panel could cause will prevent the operator from alerting ground
a hazardous operating situation. personnel of hazards or unsafe conditions.
Perform this procedure from the 1 Turn the key switch to platform control and
ground using the platform controls. pull out the Emergency Stop button to the
Do not stand in the platform. on position at both the ground and
1 Pull out the Emergency Stop button to the on platform controls.
position at both the ground and platform 2 Push down the horn button at the platform
controls. controls.
2 Turn the key switch to platform control.
Result: The horn should sound.
3 Check the platform up/down function from the
ground controls.
Result: The machine functions should not
operate.
4 Turn the key switch to ground control.
5 Check the machine functions from the platform
controls.
Result: The machine functions should not
operate.
6 Turn the key switch to the off position.
Result: No machine functions should operate.
Part No. 72963 Genie GS-2032 and GS-2632 3 - 11

B-7 6 Bring the machine to full drive speed before

reaching the test line. Release the function
Test the Drive Brakes enable switch or the joystick on the platform
controls when your reference point on the
machine crosses the test line.
7 Measure the distance between the test line
Proper brake action is essential to safe machine and your machine reference point. Refer to
operation. The drive brake function should operate Section 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 flat, 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
platform is in the stowed position. able 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
out the Emergency Stop button to the on with electrically charged circuits
position at both the ground and platform could result in death or serious
controls. injury. Remove all rings, watches
and other jewelry.
2 Lower the platform to the stowed position.
9 Locate the drive forward/reverse valve on the
3 Models with drive function select button: function manifold. Refer to Illustrations 2.
Press the drive function select button. Refer to
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. 15 Install the coil nut onto the valve and tighten.
Remove the coils from the valve. Torque to 60 in-lbs / 7 Nm.
The forward valve coil has white 16 Connect the battery pack to the machine.
and brown wires attached.
17 Replace the brakes and repeat this procedure
The reverse valve coil has beginning with step 1. Refer to Repair
white/black and brown wires Procedure 9-1, How to Remove a Drive Brake.
attached.
18 Contact the Genie Industries Service Parts
For reassembly, it will be helpful Department and order kit part number 105457.
to leave the wire harness
19 Install the new valve received in the kit and
attached to the valve coils.
mark the new valve with a white paint pen to
For GS-2032 and GS-2632 before serial number identify new valve installation.
GS3204-51608 proceed to step 11.
20 Repeat this procedure beginning with step 1.
For GS-2032 and GS-2632 after serial number
If the machine fails to stop within the specified
GS3204-51607 proceed to step 20.
stopping distance after installing new brakes,
11 Remove the drive forward/reverse valve from please contact the Genie Industries Scissors
the function manifold. Cap the open port of the Service Department, 1-800-536-1800 Ext. 8710.
manifold.
12 Carefully inspect the hex portion of the valve
for 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
indicates the machine is not equipped with a
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.

21 Remove the drive forward/reverse valve from 28 Contact the Genie Industries Service Parts
the function manifold. Cap the open port of the Department and order kit part number 105458.
manifold.
29 Install the new valve received in the kit and
22 Carefully inspect the hex portion of the valve mark the new valve with a white paint pen to
for an identification stamp. identify new valve installation.
Result: SV10-5905 is stamped on the hex 30 Repeat this procedure beginning with step 1.
portion of the drive forward/reverse valve.
If the machine fails to stop within the specified
This indicates the machine is equipped with
stopping distance after installing new brakes,
a dynamic brake valve. Proceed to step 22.
please contact the Genie Industries Scissors
Result: SV10-5905 is not stamped on the hex Service Department, 1-800-536-1800 Ext. 8710.
indicates the machine is not equipped with a
23 Install the drive forward/reverse valve removed
in step 20 into the function manifold and
securely tighten. Torque to 25 ft-lbs / 34 Nm.
24 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.
25 Install the coil nut onto the valve and tighten.
Torque to 60 in-lbs 7 Nm.
26 Connect the battery pack to the machine.
27 Replace the brakes and repeat this procedure
beginning with step 1. Refer to Repair
Procedure 9-1, How to Remove a Drive Brake.

B-8 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 maximum 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
7 Continue at full speed and note the time when
machine operation. The drive function should
the machine reference point passes over the
respond quickly and smoothly to operator control.
finish line. Refer to Section 2, Specifications.
Drive performance should also be free of
hesitation, jerking and unusual noise over the
entire 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.
controls.
4 Models with drive function select button:
Press the drive function select button.
Stop
®
a drive function select button BN8

B-9 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.
Models with drive function select button:
Proper drive functions are essential to safe
Press the drive function select button.
machine operation. The drive function should
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 maximum drive speed
Perform this procedure with the before reaching the start line. Begin timing
machine on a firm, level surface when your reference point on the machine
that is free of obstructions. crosses the 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. the machine reference point 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-10 B-11
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 filter is mounted on
the hydraulic oil is not replaced the function manifold next to the
at the two year inspection, test hydraulic power unit.
the oil quarterly. Replace the oil
when it fails the test. See D-1, 1 Clean the area around the oil filter. Remove the
Test or Replace the Hydraulic Oil. filter with an oil filter wrench.
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 during
the replacement procedure. Properly dispose of
the used filter.

B-12
Check the Module Tray Latch
Components
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
latch fails to securely hold the module tray
closed.
The module tray latch pad is
attached to the drive chassis and
located above the module tray
latch when the module tray is
closed.
Models after serial number 35799:
1 Lubricate each module tray rotary latch. Using
light oil, apply a few drops to each of the
springs and to the sides of the rotary latch
mechanism.
a rotary latch springs
b module tray rotary latch
2 Inspect each module tray latch U-bolt. Tighten

any loose U-bolt retaining fastener before the
latch fails to securely hold the module tray
closed.

REV C
Checklist C Procedure
C-1
Test the
Platform Overload System
(if equipped)
Genie specifications require that

this procedure be performed every a
500 hours or six months,
whichever comes first OR when b
the machine fails to lift the
maximum rated load.
Testing the platform overload system regularly is
essential to safe machine operation. Continued
use of an improperly operating platform overload a overload pressure switch
system could result in the system not sensing an b maximum height limit switch
overloaded platform condition. Machine stability
1 Locate the lift valve coil on the function
could be compromised resulting in the machine
manifold.
tipping over.
The platform overload system is designed to
a
prevent machine operation in the event the
machine is overloaded. Models equipped with the
platform overload option are provided with two
additional machine control components: the
overload pressure switch and a maximum height
limit switch.
The overload pressure switch, which is adjustable

and located at the barrel-end of the lift cylinder, is
used to determine when the hydraulic lift cylinder
requires too much pressure to support the load
inside the platform. When this occurs, the pressure
switch will send a signal to the ECM, which will not
allow the machine to function until the extra weight
is removed from the platform. b
The maximum height limit switch, located in the a test port

middle of the drive chassis under the scissor arms, b lift valve coil
is used to disable the lift valve coil when the 2 Tag and disconnect the black and white wires of
platform is near maximum height. When activated, the up limit switch wire harness from the
the limit switch keeps the lift cylinder from going blue/black wires of the manifold wire harness at
over lift relief which would cause the pressure the lift valve coil on the manifold.
switch to falsely indicate an overload condition.

CHECKLIST C PROCEDURES REV C
3 Securely connect together the terminals of the 9 Fully raise the platform. Release the toggle
two blue/black wires of the manifold wire switch.
harness, disconnected from the limit switch wire
Result - models with software revision A0 and
harness in step 2.
A1: The alarm should not sound and fault code
4 Turn the key switch to ground control and pull 54 should be present in the diagnostic display.
out the red Emergency Stop button to the on The system is functioning correctly.
Result - models with software revision A2 and
controls.
higher: The alarm should not sound. The
5 Fully raise the platform. Release the toggle system is functioning correctly.
switch.
Result - all models: The alarm sounds. The
Result: The alarm should sound. system is not functioning correctly.
Troubleshoot the limit switch, limit switch wire
Result: The alarm does not sound. Calibrate the
harness or limit switch mount bracket OR the
platform overload system. See Maintenance
platform overload system needs to be
Procedure D-2, Calibrate the Platform Overload
calibrated. See Maintenance Procedure D-2,
System (if equipped).
Calibrate the Platform Overload System (if
6 Using the manual lowering knob, lower the equipped).
platform to the stowed position.
To determine the software revision
7 Disconnect the two blue/black wires of the level, refer to Repair Procedure
manifold wire harness at the lift valve coil on the 1-2, How to Determine the
manifold. Revision Level.
8 Securely connect the black and white wires of 10 Lower the platform to the stowed position.
the up limit switch wire harness to the two
blue/black wires of the manifold wire harness at
the lift valve coil on the manifold.

REV D
Checklist D Procedure
D-1 2 Measure the thickness of the wear pad at the
battery pack side of the non-steer end of the
Check the Scissor Arm Wear machine.
Pads Result: The measurement is 0.21 inch / 5.3 mm
or more. Proceed to step 2.
Result: The measurement is less than
Maintaining the scissor arm wear pads in good 0.21 inch / 5.3 mm. Replace both wear pads.
condition is essential to safe machine operation. Refer to Repair Procedure 3-1 or 3-2, How to
Continued use of worn out wear pads may result in Replace the Scissor Arm Wear Pads.
component damage and unsafe operating
3 Apply a thin layer of dry film lubricant to the
conditions.
area of the chassis where the scissor arm wear
Perform this procedure with the pads make contact.
platform in the stowed position.
Wear pad specification
1 Measure the thickness of the wear pad at the
ground controls side of the non-steer end of the
Thickness, minimum 0.21 inch
machine. 5.3 mm
Result: The measurement is 0.21 inch / 5.3 mm
or more. Proceed to step 2.
Result: The measurement is less than
0.21 inch / 5.3 mm. Replace both wear pads.
Refer to Repair Procedure 3-1 or 3-2, How to
Replace the Scissor Arm Wear Pads.
0.21 inches / 5.3 mm

Checklist E Procedure REV A
E-1 5 Remove the suction strainer and clean it using

a mild solvent.
Test or Replace the Hydraulic Oil
6 Clean the inside of the hydraulic tank using a
mild solvent.
7 Install the suction strainer using thread sealer
Replacement or testing of the hydraulic oil is on the threads.
essential for good machine performance and 8 Install the drain plug using thread sealer on the
service life. Dirty oil and a clogged suction strainer threads. Torque to specification.
may cause the machine to perform poorly and
continued use may cause component damage.
Torque specifications
Extremely dirty conditions may require oil changes
to be performed more often. Hydraulic tank drain plug, dry 75 in-lbs
8.5 Nm
Before replacing the hydraulic oil,
the oil may be tested by an oil Hydraulic tank drain plug, lubricated 56 in-lbs
distributor for specific levels of 6.3 Nm
contamination to verify that
changing the oil is necessary. If 9 Install the hydraulic tank and install and tighten
the hydraulic oil is not replaced the hydraulic tank retaining fasteners. Torque to
at the two year inspection, test specification.
the oil quarterly. Replace the oil
when it fails the test. Torque specifications
Perform this procedure with the Hydraulic tank retaining fasteners, dry 35 in-lbs
platform in the stowed position. 4 Nm
1 Disconnect the battery pack from the machine. Hydraulic tank retaining fasteners, lubricated 26 in-lbs
2.9 Nm
2 Open the power unit module tray. Remove the
drain plug from the hydraulic tank and allow all
of the oil to drain into a suitable container. Refer 10 Connect the hydraulic hoses to the hydraulic
to Section 2, Specifications, for capacity tank.
information.
11 Fill the tank with hydraulic oil until the fluid is
Bodily injury hazard. Spraying within the FULL and ADD marks on the oil level
hydraulic oil can penetrate and indicator decal. Do not overfill.
burn skin. Loosen hydraulic
12 Activate the pump to fill the hydraulic system
connections very slowly to allow
with oil and bleed the system of air and check
the oil pressure to dissipate
for leaks.
gradually. Do not allow oil to squirt
or spray. 13 Repeat steps 11 and 12 until the hydraulic tank
and system are both full.
3 Tag, disconnect and cap the hydraulic hoses
from the hydraulic tank. 14 Clean up any oil that may have spilled. Properly
discard the used oil.
4 Remove the hydraulic tank mounting fasteners.
Remove the hydraulic tank from the machine.

June 2004 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. Perform disassembly procedures to
the point where repairs can be completed. To
Observe and Obey: re-assemble, perform the disassembly steps in
reverse order.
Repair procedures shall be completed by a
person trained and qualified on the repair of this Symbols Legend
machine.
Safety alert symbol—used to alert
Immediately tag and remove from service a personnel to potential personal
damaged or malfunctioning machine. injury hazards. Obey all safety
messages that follow this symbol
Repair any machine damage or malfunction
to avoid possible injury or death.
before operating the machine.
Red—used to indicate the
Before Repairs Start: presence of an imminently
Read, understand and obey the safety rules avoided, will result in death or
and operating instructions in the appropriate serious injury.
operator's manual on your machine.
Orange—used to indicate the
Be sure that all necessary tools and parts are presence of a potentially
available and ready for use. hazardous situation which, if not
Read each procedure completely and adhere to avoided, could result in death or
the instructions. Attempting shortcuts may serious injury.
produce hazardous conditions. Yellow with safety alert symbol—
Unless otherwise specified, perform each repair used to indicate the presence of a
procedure with the machine in the following potentially hazardous situation
configuration: which, if not avoided, may cause
minor or moderate injury.
· Machine parked on a firm, level surface
Yellow without safety alert
· Platform in the stowed position
symbol—used to indicate the
· Key switch in the off position with the key presence of a potentially
removed hazardous situation which, if not
· The red Emergency Stop button in the off avoided, may result in property
position at both ground and platform controls damage.
· Wheels chocked Green—used to indicate operation
or maintenance information.
· All external AC power supply disconnected
from the machine Indicates that a specific result is expected after
performing a series of steps.
Indicates that an incorrect result has occurred
after performing a series of steps.

Section 4 • Repair Procedures June 2004
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
3
machine. EMERGENCY STOP
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

Genie Industries Service Department. Platform controls with
potentiometer-equipped joystick
P2
EMERGENCY STOP
BUTTON
2 5. 1 4.
2
a
NC 1
U3
9F
ON
PLATFORM CONTROLS 1
f CIRCUIT BOARD
2
3
4
5
ALCO ADF085
h
JC1
6
7
8
S/N Al 00000000
JOYSTICK
P/N 000000
Date 0000
CONTROLLER
H1 e
ALARM
Platform controls with

hall-effect joystick
a Emergency Stop button P2

b platform controls circuit board U3
c circuit board retaining fastener
d circuit board voltage regulator
e alarm H1
f joystick controller JC1
g potentiometer
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 Emergency Stop button to the off motion.
position at both the ground and platform Platform controls equipped with Hall-effect
controls. joysticks do not require any calibration.
2 Loosen the platform control box lid retaining
fasteners. Open the control box lid. How to Calibrate the
3 Locate the circuit board mounted to the inside
Potentiometer-equipped Joystick
of the platform control box lid. 1 Turn the key switch to platform controls and pull
Electrocution hazard. Contact with out the 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 2 Remove the platform control box lid retaining
other jewelry. fasteners. Open the control box lid.
Component damage hazard. Electrocution hazard. Contact with
Electrostatic discharge (ESD) can electrically charged circuits could
damage printed circuit board result in death or serious injury.
components. Maintain firm contact Remove all rings, watches and
with a metal part of the machine other jewelry.
that is grounded at all times when
handling printed circuit boards OR
use a grounded wrist strap.
4 Carefully disconnect the three wire harness
connectors from the platform controls circuit
board.
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. 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 slot
not be present on the diagnostic display at the
c potentiometer shaft set screw battery module side of the machine.
d platform controls circuit board U3
e potentiometer 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.
Electrocution hazard. Contact with
electrically charged circuits could
Remove all rings, watches and
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, stowed drive speed, raised
drive speed and high torque drive speed are are
adjustable to compensate for wear in the hydraulic
pump and drive motors.
The function speeds 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.
a yellow arrow
Tip-over hazard. This procedure b joystick controller JC1
must only be performed by a c lift function select button BN9
trained service professional. d Emergency Stop button P2
Attempting this procedure without e lift function enable button BN9
the necessary skills will result in 5 Slowly move the joystick in the direction
death or serious injury. indicated by the yellow arrow.
Select a test area that is firm, level Result: The software revision level will appear
and free of obstructions. 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
diagnostic display.
2 Place the platform controls close to the
diagnostic display on the ground controls side 6 Push in the Emergency Stop button to the off
of the machine. position at both the ground and platform
controls and turn the key switch to the off
position.
out the Emergency Stop buttons to the on
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."
the drive speed greater than
specifications will cause death or
serious injury.
Tip-over hazard. This procedure
must only be performed by a
trained service professional.
Attempting this procedure without
the necessary skills will result in
a function enable switch SW5
Software revision A0 and B0: b joystick controller JC1 with thumb
steering rocker SW6
1 Push in the Emergency Stop button to the off c horn button BN5
position at the ground and platform controls. d machine on incline button BN6
e lift function enable button BN9
Turn the key switch to the off position. f red Emergency Stop button P2
2 Pull out the Emergency Stop button to the on 4 Release the lift function enable and horn
position at the ground and platform controls. buttons.
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: 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.
Turn the key switch to the off position.
2 Pull out the red Emergency Stop button to the
on position at the ground and platform controls. Any change in software settings
3 At the platform controls, press and hold the lift switch is turned to the off position.
function select and horn buttons and turn the
key switch to platform controls.
Result: The diagnostic display will show "PS."

b joystick controller JC1 with thumb
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.
5 Press the lift function select button.

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.
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 High Torque 5 Press the drive function select button.
Drive Speed Result: The diagnostic display will show the
stowed drive speed percentage.
the drive speed greater than
trained service professional. a function enable switch SW5
Attempting this procedure without b joystick controller JC1 with thumb
the necessary skills will result in rocker switch 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 Press and hold the machine on incline button.
2 Pull out the red Emergency Stop button to the stowed high torque drive speed percentage.
on position at the ground and platform controls.
3 Press and hold the lift function select and horn joystick to increase or decrease the stowed
buttons and turn the key switch to platform high torque drive speed percentage. Refer to
controls. Section 2, Specifications.
Result: The diagnostic display will show "PS." 8 Turn the key switch to the off position.
4 Release the lift function select and horn Any change in software settings
buttons. will not take effect until the key
Result: The diagnostic display will show the switch is turned to the off position.

How to Adjust the Raised Drive 3 Press and hold the lift function enable and horn
buttons, and turn the key switch to platform
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
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
buttons.
2 Pull out the red Emergency Stop button to the
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.
Result: The diagnostic display will show "PS."

Software revision D0 and higher: 5 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 7 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.

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-2032 and GS-2632. The machine can be diagnostic display on the hydraulic module side
adjusted to a different configuration by changing of the machine.
the toggle settings on the DIP switch. 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
Each of the eight toggles of the DIP switch have controls.
two positions: on or off. When reading the DIP
4 Press and hold the lift function enable button
switch code in the DIP Switch Code Chart, the on
OR press the lift function select button.
and off are represented by the numbers 1 (on) and
0 (off). 5 Slowly move the joystick in the direction
SW25
indicated by the blue arrow.
DIP P2
SWITCH
EMERGENCY
STOP Result: The DIP switch configuration will appear
c BUTTON
in the diagnostic display.

2
1
JC1
JOYSTICK
U3
CONTROLLER PLATFORM
CONTROLS
CIRCUIT
BOARD a
d
H1
ALARM
before serial number 48055
ON ALCO ADF085 b
ON (1)
OFF (0)
9F
1 2 3 4 5 6 7 8
P2
EMERGENCY STOP
BUTTON
2 5. 1 4.
NC 1
U3
9F
c
ON
d
1
PLATFORM CONTROLS
2
3
CIRCUIT BOARD
ALCO ADF085
4
5
JC1
6
7
8
S/N Al 00000000
JOYSTICK
P/N 000000
Date 0000
CONTROLLER
a
a yellow arrow
H1 b joystick controller JC1
ALARM
c lift function select button BN9

after serial number 48054
d red Emergency Stop button P2
a platform controls circuit board U3
b enlarged view of DIP switch SW25
c joystick controller JC1
d DIP switch SW25

How to Set the DIP Switch Codes SW25

DIP
SWITCH
P2
EMERGENCY
STOP
Tip-over hazard. Do not adjust the c BUTTON
2
1
DIP switch settings to other than JC1
U3
JOYSTICK
what is specified in this procedure. CONTROLLER PLATFORM
CONTROLS
CIRCUIT
Exceeding specifications could BOARD a

cause the machine to tip over d
resulting in death or serious injury.
If replacing the circuit board, note H1
ALARM
the toggle positions on the DIP

switch. Set the DIP switch on the before serial number 48055
new circuit board to the same ON ALCO ADF085 b

ON (1)
configuration as the old board.
OFF (0)
1 Push in the red Emergency Stop button to the 9F

1 2 3 4 5 6 7 8
off position at the ground and platform controls.

Turn the key switch to the off position. P2
EMERGENCY STOP
BUTTON
2 5. 1 4.
NC 1
2 Remove the fasteners securing the top of the

U3
platform controls and open the platform control
9F
c
ON
d
1
PLATFORM CONTROLS
2
3
CIRCUIT BOARD
ALCO ADF085
4
5
JC1
6
7
box.
8
S/N Al 00000000
JOYSTICK
P/N 000000
Date 0000
CONTROLLER
3 Rotate the platform control box to the position

shown to correctly identify the configuration of a
the DIP switch settings. H1
ALARM
4 Locate the DIP switch on the circuit board. after serial number 48054
Move the DIP switch settings to correspond

a platform controls circuit board U3
with the configuration of the machine options, b enlarged view of DIP switch SW25
indicated in the DIP Switch Code Chart. 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 of the DIP
switch before removal. Set the DIP
switch toggle positions on the new
circuit board to the same
ON for 2032 and 2632
configuration of the old board.
Battery Drain Alarm

OFF for all models
Lift Drive Cut Out
Diagnostic DIP Overload Cut Out
Motion Beacon
Display Switch If replacing the circuit board, use

Descent Delay
Motion Alarm
Code Code dielectric grease on all plug-in

connectors.
Motion Beacon: The motion beacon option flashes
only when operating a function.
32 10000000 •
33 10000100 • • Motion Alarm: The motion alarm will sound when
34 10001000 • • operating any function.
35 10010000 • • Lift/Drive Cut Out: This cuts out lift and drive
36 10100000 • • functions when the machine exceeds the rating on
37 11000000 • • the serial plate. Required for Europe and Australia
38 10001100 • • • before serial number 47055. Configured on all
39 10010100 • • • machines after serial number 47054.
40 10100100 • • •
Platform Overload: This cuts out all functions when
41 11000100 • • •
the pressure sensor is overloaded. The additional
42 10011100 • • • •
weight must be removed from the platform and the
43 10101100 • • • • Emergency Stop button must be cycled before any
44 11001100 • • • • function can be resumed. Required for France.
45 10110100 • • • •
46 11010100 • • • • Descent Delay: This option halts descent at
47 11100100 • • • • approximately 7 feet / 2.1 m. All controls must be
48 10111100 • • • • • released for 4 to 6 seconds before descent is
49 11011100 • • • • • re-enabled. Required for CE models.
50 11101100 • • • • • Battery Drain Alarm: When the machine is turned
51 11110100 • • • • • on and no function is activated for 10 minutes, the
52 11111100 • • • • • • alarm will sound once every 3 seconds. This option
53 10011000 • • • can be activated by moving DIP switch 7 to
54 10101000 • • • position 1.
55 11001000 • • • When this option is configured, the flashing dot in
56 10111000 • • • • the diagnostic display window will remain
57 11011000 • • • • illuminated when the lift mode is selected and
58 11101000 • • • • activated.
59 11111000 • • • • •
60 10110000 • • •
61 11010000 • • •
62 11110000 • • • •
63 11100000 • • •

Platform Components REV B
2-1 8 Attach a strap from the platform railings to the

carriage on the forklift to help support the
Platform platform.
9 Remove the platform pivot pin retaining
How to Remove the Platform fasteners from the platform pivot pins at the
Perform this procedure with the steer end of the machine.
platform extension fully retracted 10 Use a slide hammer to remove the pins.
and locked in position.
Crushing hazard. The platform will
1 Machines with voltage inverter: Disconnect fall if it is not properly supported.
the battery pack from the machine.
11 Remove the plugs from the access holes in the
Electrocution hazard. Contact with side of the platform.
result in death or serious injury. 12 Lift the steer end of the platform slightly to clear
Disconnect the battery pack from the scissor arms and slide the platform towards
the machine before removing the the non-steer end of the machine until the non-
platform. steer end platform pivot pins are visible through
the access holes in the side of the platform.
13 Remove the platform pivot pin retaining
3 Remove the retaining fastener that holds the fasteners from the platform pivot pins at the
platform controls quick disconnect plug to the non-steer end of the machine.
bottom of the platform.
14 Use a slide hammer to remove the pins.
4 Disconnect the plug from the platform controls.
Crushing hazard. The platform will
5 Remove the cover from the AC outlet. Label fall if it is not properly supported.
and disconnect the wiring from the outlet.
15 Carefully lift the platform off of the machine and
6 Pull the wiring through the platform tube. place it on a structure capable of supporting it.
If your machine is equipped with Note the position of the wear pads
an air line to platform option, the before the platform is removed so
air line must be disconnected from when the platform is installed they
the platform before removal. will be in the correct position.
7 Support the platform with a forklift at the
non-steer end. Do not lift it.

REV B 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
Crushing hazard. The platform
1 Lower the platform to the stowed position. extension could become
unbalanced and fall if not properly
2 Extend the platform approximately 3 feet / 1 m.
supported and secured to the
3 Remove the platform controls from the platform forklift.
and lay them off to the side of the machine.
How to Replace the Platform
4 Support the platform extension with a forklift at
the steer end. Do not lift it.
Extension Wear Pads
5 Attach a strap from the platform extension 1 Remove the Platform Extension. See 2-2, How
railings to the carriage on the forklift to help to Remove the Platform Extension.
support the platform extension. 2 Drill out the rivets which hold the wear pads in
6 Remove the two retaining fasteners from each place.
platform extension roller bracket assembly. 3 Install the new wear pads using new rivets.
Remove each assembly from the machine.
When installing new rivets, make
Do not remove the platform roller sure the rivet heads are not above
bolt. the surface of the wear pad.
a roller bracket assembly

b assembly retaining fastener
c platform roller bolt

Scissor Components REV B
1 11
12
3
13
4 14
15
6 16
7 17
18
8
19
9
10
GS-2032
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 (2pins) 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) (2pins)

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

the number 3 outer arm (index #13).
Scissor Assembly, GS-2032
4 Remove the external snap rings from the
number 3 center pivot pin (index #2).
How to Disassemble the
Scissor Assembly, GS-2032 5 Use a soft metal drift to remove the number 3
center pivot pin (index #2).
Bodily injury hazard. This
procedure requires specific repair
number 3 pivot pin (index #14).
skills, lifting equipment and a
suitable workshop. Attempting this 7 Use a soft metal drift to remove the number 3
procedure without these skills and pivot pin (index #14). Remove the number 3
tools could result in death or outer arm (index #13) from the machine.
serious injury and significant
component damage. Dealer Bodily injury hazard. The number
service is required. 3 outer arm (index #13) may
become unbalanced and fall if not
When removing a hose assembly properly supported when it is
or fitting, the O-ring on the fitting removed from the machine.
and/or hose end must be replaced
and then torqued to specification 8 Remove the cable clamps from the number 3
during installation. Refer to inner arm (index #12).
Section Two, Hydraulic Hose and 9 Remove the mounting fasteners from the cable
Fitting Torque Specifications. tray support at the steer end.
1 Remove the platform. See 2-1, How to Remove 10 Remove the external snap rings from the
the Platform. number 2 center pivot pin (index #5) at the
2 Remove the cables from the side of the number ground controls side. Do not remove the pin.
3 outer arm (index #13) at the ground controls 11 Slide the cable tray towards the battery pack
side. side of the machine. Remove it from the
Component damage hazard. machine and lay it off to the side.
Cables can be damaged if they Component damage hazard.
are kinked or pinched. Cables can be damaged if they
are kinked or pinched.
12 Attach a lifting strap from an overhead crane to
the lug on the rod end of the lift
cylinder (index #15).

SCISSOR COMPONENTS REV B
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.
the number 2 inner arm (index #6).
25 Use a soft metal drift to remove the number 2
pivot pin (index #7). Remove the number 2
pivot pin (index #4). Remove the number 3
inner arm (index #6) from the machine.
inner arm (index #12) from the machine.
Bodily injury hazard. The number
2 inner arm (index #6) may
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. 28 Raise the number 1 inner arm (index #9)
approximately 2 feet / 0.6 m and insert the
20 Use a soft metal drift to remove both of the
safety arm between the number 1 inner arm
number 2 center pivot pins (index #5).
(index #9) and the number 1 outer arm
21 Remove the external snap rings from the (index #19).
number 2 pivot pin (index #17) at the non-steer
Bodily injury hazard. Keep hands
end.
clear of moving parts when
lowering the scissor arms onto the
safety arm.

29 Tag, disconnect and plug the hydraulic hose on 34 Attach a lifting strap from an overhead crane to
the lift cylinder (index #15). Cap the fitting on the number 1 inner arm (index #9). Raise the
the cylinder. inner arm slightly and remove the safety arm.
Lower the arms onto the block.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and Bodily injury hazard. Keep hands
burn skin. Loosen hydraulic clear of moving parts when
connections very slowly to allow lowering the arms onto the block.
35 Remove the cables from the number 1 inner
arm (index #9) and lay them off to the side.
or spray.
Component damage hazard.
30 Tag and disconnect the wires from the solenoid
Cables can be damaged if they
valve on the cylinder.
the lug on the rod end of the lift cylinder
(index #15). Raise the lift cylinder to a vertical
Do not lift it.
position.
32 Remove the pin retaining fasteners from the lift
cylinder barrel-end pin (index #18). Use a soft
metal drift to remove the pin. Remove the lift 38 Use a soft metal drift to remove the number 1
cylinder (index #15) from the machine. center pivot pin (index #8).
Crushing hazard. The lift cylinder Bodily injury hazard. The number
(index #15 )may become 1 outer arm (index #19) may
unbalanced and fall when it is become unbalanced and fall if not
removed from the machine if it is properly supported when the pin is
not properly attached to the removed.
overhead crane.
Component damage hazard. Be
careful not to damage the valve or
fittings on the cylinder while
removing it from the machine.
33 Place a 4 x 4 x 32 inch / 10 x 10 x 80 cm long
block across both sides of the chassis under
the number 1 center pivot pin (index #8).

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

1 13
14
15
3 16
4 17
18
5
6 19
20
21
8
22
9
23
10
24
11
12
GS-2632
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-2632
How to Disassemble the
Scissor Assembly, GS-2632 5 Use a soft metal drift to remove the number 4
Bodily injury hazard. The
6 Remove the external snap ring from the number
procedures in this section require
4 pivot pin (index #16) at the non-steer end of
specific repair skills, lifting
the machine.
equipment and a suitable
workshop. Attempting this 7 Use a soft metal drift to remove the number 4
procedure without these skills and pivot pin (index #16) from the non-steer end of
tools could result in death or the machine. Remove the number 4 outer arm
serious injury and significant (index #15) from the machine.
component damage. Dealer
service is required. Crushing hazard. The number 4
outer arm (index #15) may
When removing a hose assembly become unbalanced and fall if not
or fitting, the O-ring on the fitting properly supported when it is
and/or hose end must be replaced removed from the machine.
and then torqued to specification
during installation. Refer to 8 Remove the cables from the upper cable tray
Section Two, Hydraulic Hose and and lay them off to the side.
Fitting Torque Specifications. Component damage hazard.
1 Remove the platform. See 2-1, How to Remove Cables can be damaged if they
the Platform. are kinked or pinched.
2 Remove the cables from the side of the number 9 Remove the mounting fasteners from the upper
4 outer arm (index #15) at the ground controls cable tray supports.
side. 10 Remove the upper cable tray from the scissor
Component damage hazard. assembly.
Cables can be damaged if they 11 Attach a lifting strap from an overhead crane to
are kinked or pinched. the number 4 inner arm (index #14).

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. 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 lift it.
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 it is 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
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
29 Remove the cable clamps from the lower cable
tray. Lay the cables to the side.
the machine.
Cables can be damaged if they
the number 2 outer arm (index #21) at the
battery pack side.
30 Remove the mounting fasteners from the lower
cable tray supports.
number 2 center pivot pin (index #7) at the
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.
34 Remove the external snap rings from the 40 Use a soft metal drift to tap the number 2 pivot
number 2 center pivot pin (index #7) at the pin (index #22) in the other direction at the non-
ground controls side. steer end. Remove the number 2 outer arm
(index #21) from the battery pack side of the
35 Use a soft metal drift to remove the number 2 machine.
center pivot pin (index #7) at the ground
controls side. Bodily injury hazard. The number
2 outer arm (index #21) at the
battery pack side may become
the machine.

41 Attach a lifting strap from an overhead crane to 48 Tag and disconnect the wires from the solenoid
the number 2 inner arm (index #20). valve on the cylinder.
42 Remove the external snap rings from the 49 Attach a lifting strap from an overhead crane to
number 2 pivot pin (index #9) at the steer end the lug on the rod end of the lift cylinder
of the machine. (index #8). Raise the lift cylinder to a vertical
position.
pivot pin (index #9). Remove the number 2 50 Remove the pin retaining fasteners from the lift
inner arm (index #20) from the machine. cylinder barrel-end pin (index #23). Use a soft
metal drift to remove the pin. Remove the lift
cylinder (index #8) from the machine.
become unbalanced and fall if not Crushing hazard. The lift cylinder
properly supported when it is (index #8 )may become
removed from the machine. unbalanced and fall when it is
removed from the machine if it is
44 Remove the safety arm from the number 2 inner
not properly attached to the
arm (index #20) that was just removed.
overhead crane.
46 Raise the number 1 inner arm (index #11) fittings on the cylinder while
approximately 2 feet / 60 cm and install the removing it from the machine.
safety arm between the number 1 inner arm
51 Place a 4 x 4 x 48 inch / 10 cm x 10 cm x 1.2 m
(index #11) and the number 1 outer arm
long block across both sides of the chassis
(index #24). Lower the scissor arms onto the
under the number 1 center pivot pin
safety arm.
(index #10).
Bodily injury hazard. Keep hands
clear of moving parts when
the number 1 inner arm (index #11) at the non-
lowering the scissor arms onto the
steer end. Raise the number 1 inner arm and
safety arm.
remove the safety arm. Lower the number 1
47 Tag, disconnect and plug the hydraulic hose on inner arm (index #11) onto the block that was
the lift cylinder. Cap the fitting on the cylinder. placed across the chassis.
Bodily injury hazard. Spraying Bodily injury hazard. Keep hands
hydraulic oil can penetrate and clear of moving parts when
burn skin. Loosen hydraulic lowering the arms onto the block.
or spray.

53 Remove the cables and hydraulic hoses from 59 Slide the number 1 outer arm (index #24) to the
the number 1 inner arm (index #11) and lay non-steer end and remove it from the machine.
them to the side.
Component damage hazard. 1 outer arm (index #24) may
Cables and hoses can be become unbalanced and fall if not
damaged if they are kinked or properly supported when it is
pinched. removed from the machine.
54 Support and secure the entry ladder to an Note the position of the wear pads
appropriate lifting device. before the arm is removed so
when the scissor is assembled
55 Remove the entry ladder mounting fasteners.
they will be in the correct position.
Remove the entry ladder from the machine.
60 Attach the strap from an overhead crane to the
Crushing hazard. The entry ladder
number 1 inner arm (index #11). Do not lift it.
may become unbalanced and fall
if not properly supported and 61 Remove the pin retaining fasteners from both of
secured to the lifting device. the number 1 pivot pins (index #12) at the steer
end of the machine. Use a slide hammer to
remove the pins.
the number 1 outer arm (index #24). Do not
lift it. 62 Remove the number 1 inner arm (index #11)
from the machine.
number 1 center pivot pin (index #10). Bodily injury hazard. The number
Bodily injury hazard. The number removed from the machine.
1 outer arm (index #24) may
sure not to damage the limit switch
properly supported when the pin is
or level sensor box components
removed.
when the number 1 inner arm
(index #11) is removed from the
machine.

How to Replace the Scissor Arm 10 Mark the mounting position of the level sensor
on the level sensor box.
Wear Pads
11 Remove the level sensor box mounting
1 Remove the platform. See 2-1, How to Remove fasteners and slide the box towards the non-
the Platform. steer end of the machine as far as it can go.
2 Remove the mounting fasteners from the Component damage hazard. Be
stationary wear pads on the platform. careful not to damage the level
Note the position of the wear pads sensor box, limit switch, level
before they are removed so when sensor or wiring while moving the
the new ones are installed they level sensor box.
will be in the correct position. 12 Secure the ends of the scissor arms together at
3 Support and secure the entry ladder to an both ends of the machine with a tie down strap
appropriate lifting device. or other appropriate device.
4 Remove the entry ladder mounting fasteners. 13 Remove the pin retaining fasteners from the
Remove the entry ladder from the machine. number 1 inner arm pivot pins (item #11) at the
steer end of the machine. Use a slide hammer
Crushing hazard. The entry ladder to remove the pins.
if not properly supported and 14 Attach a lifting strap from an overhead crane to
secured to the lifting device. the steer end of the scissor arms.
5 Raise the platform 6 to 7 feet / 1.8 to 2.1 m. 15 Slide the forks from a forklift under the scissor
6 Lift the safety arm, move it to the center of the
scissor arm and rotate down to a vertical 16 Raise the scissor arms up with the overhead
position. crane until the number 1 inner arm will clear the
level sensor box.
Crushing hazard. Keep hands careful not to damage the level
clear of the safety arm when sensor box, limit switch or level
lowering the platform. sensor while moving the scissor
assembly.
box on the drive chassis. 17 Move the scissor assembly towards the non-
steer end of the machine slightly and to one
9 Remove the level sensor box cover.
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.

18 Remove the old wear pad.

correct position.
20 Move the scissor assembly towards the other
side of the machine until the other scissor arm
wear pad is accessible.
chassis.
21 Remove the old wear pad.
correct position.
23 Slide the scissor assembly back into the drive
chassis.
24 Lower the scissor assembly into position and
install the pivot pins.
careful not to damage the level
sensor while installing the scissor
assembly.

SCISSOR COMPONENTS REV A
3-3 GS-2032 models before

i serial number 23568
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.
When removing a hose assembly
or fitting, the O-ring on the fitting d
during installation. Refer to
Section Two, 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)
position g connector fitting
h hydraulic hose
i hard line assembly
GS-2632 models &

GS-2032 models after serial number 23567
D
c
Y7
f
E
g

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

SCISSOR COMPONENTS REV D
3-4 4 Turn the key switch to ground control and pull

Platform Overload System position at both the ground and platform
controls.
Calibrate the 5 Apply a piece of tape onto the side of the
Platform Overload System platform at a point which corresponds to the
(if equipped) maximum load position of the capacity indicator
decal on the side of the platform.
On machines with platform overload systems,
6 Raise the platform until the position indicator
proper calibration is essential to safe machine
corresponds to the maximum load position of
operation. An improperly calibrated platform
the capacity indicator decal on the platform.
overload system could result in the system failing
Release the toggle switch.
to sense an overloaded platform. The stability of
the machine is compromised and it could tip over. Tip-over hazard. Raising the
platform with maximum load
Perform this procedure after fully
above the maximum load position,
charging the batteries.
as shown on the capacity indicator
Perform this procedure with toggle decal on the side of the platform,
position 4 and 5 of DIP switch could result in the machine tipping
SW25, located in the platform over, resulting in death or serious
control box, set to the on position. injury. Do not raise the platform
above the maximum load position
Perform this procedure after
of the capacity indicator decal on
confirming that the maximum
the side of the platform.
height limit switch and the limit
switch bracket are not damaged To perform this step, the lift relief
and are functioning correctly. valve will need to be adjusted.
Be sure the hydraulic oil level is 7 Lift the safety arm, move it to the center of the
between the FULL and ADD marks scissor arm and rotate down to a vertical
on the hydraulic tank. position.
1 Apply a thin layer of dry film lubricant to the 8 Remove the cover from the platform overload
area of the chassis where the scissor arm wear pressure switch box. Using a wrench, turn the
pads make contact. nut of the platform overload pressure switch
into the hydraulic line in 90° increments until the
2 Chock both sides of the wheels at the steer end
overload alarm does not sound.
of the machine.
To allow the platform overload
3 Using a suitable lifting device, place a test
system to reset, the red
weight, corresponding to the maximum load as
Emergency Stop button must be
indicated on the capacity indicator decal, in the
cycled after each quarter turn of
center of the platform floor. Secure the weight
the nut.
to the platform. Refer to the chart below.
Turning the nut into the hydraulic
GS-2032 677 kg line will deactivate the alarm;
turning the nut out of the hydraulic
GS-2632 508 kg
line will activate the alarm.

REV D SCISSOR COMPONENTS
9 Slowly turn the nut of the platform overload 14 Raise the platform to 25 cm less than full height.
pressure switch out of the hydraulic line just
until the overload alarm sounds.
scissor arm and rotate down to a vertical
To allow for the platform overload position.
system delay, wait 3 seconds
16 Raise the platform in 5 cm increments until the
between each quarter turn of the
overload alarm sounds. Adjust the up limit
nut.
switch until it actuates just before this point was
10 Turn the nut one quarter turn into the hydraulic reached.
line.
17 Install the cover onto the platform overload
11 Return the safety arm to the stowed position. pressure switch box and install and tighten the
cover retaining fasteners. Do not over tighten.
12 Using the manual lowering knob, lower the
platform to the stowed position and remove all 18 Apply Sentry Seal to one of the fasteners
test weight from the platform. securing the cover onto the platform overload
pressure switch box.
13 Using a suitable lifting device, place a test
weight in the center of the platform floor. 19 Return the safety arm to the stowed position.
Secure the weight to the platform. Refer to the
20 Using the machine controls, lower the platform
chart below.
to the stowed position and remove all test
GS-2032 363 kg weight from the platform.
GS-2632 227 kg
21 Calibrate the lift relief valve. See 6-3, How to
Adjust the Platform Lift Relief Valve.
TROUBLESHOOTING THE PLATFORM OVERLOAD SYSTEM

CONDITION POSSIBLE CAUSE SOLUTION
CANNOT LIFT RATED LOAD RELIEF VALVE SETTING INCREASE RELIEF VALVE PRESSURE
AT MAX HEIGHT THE PRESSURE SWITCH TURN OFF RED EMERGENCY STOP
ALARM CONTINUES TO SOUND AFTER SYSTEM NEEDS TO BE RESET BUTTON, WAIT THREE SECONDS AND TURN
ADJUSTMENT BACK ON
UP LIMIT SWITCH OUT OF ADJUSTMENT LOWER THE UP LIMIT SWITCH SLIGHTLY
WRONG RATED LOAD FOR HEIGHT BEING
PUT CORRECT RATED LOAD IN PLATFORM
TESTED
TURN THE PRESSURE SWITCH NUT INTO
PRESSURE SWITCH OUT OF ADJUSTMENT
THE HYDRAULIC LINE 1/4 TURN
BATTERIES ARE NOT FULLY CHARGED CHARGE BATTERIES
OVERLOAD SYSTEM NOT ADJUSTED
REPEAT CALIBRATION PROCEDURE
PROPERLY
SLIDER CHANNEL NOT LUBRICATED LUBRICATE SLIDER CHANNELS
AT DOWN LIMIT THE PRESSURE SWITCH TURN OFF RED EMERGENCY STOP
ALARM CONTINUES TO SOUND AFTER SYSTEM NEEDS TO BE RESET BUTTON, WAIT THREE SECONDS AND TURN
ADJUSTMENT BACK ON
DOWN LIMIT SWITCH OUT OF ADJUSTMENT RAISE THE DOWN LIMIT SWITCH
WRONG RATED LOAD FOR HEIGHT BEING
PUT CORRECT RATED LOAD IN PLATFORM
TESTED
TURN THE PRESSURE SWITCH NUT INTO
OVERLOAD SYSTEM NOT ADJUSTED
THE HYDRAULIC LINE 1/4 TURN OR
PROPERLY
REPEAT CALIBRATION PROCEDURE

Ground Controls REV C
4-1 Skip to step 10 if the measurement is correct.

Manual Platform Lowering Cable 7 To adjust, loosen the upper lock nut on the
cable mounting bracket. Turn the lower lock nut
The manual platform lowering cable lowers the clockwise to decrease the distance or
platform in the event of a main power failure. The counterclockwise to increase the distance.
manual platform lowering cable is attached to the
barrel end of the lift cylinder and is activated next a
to the ground controls.
a Manual lowering cable
b
How to Adjust the Manual sheath
b Upper lock nut
Platform Lowering Cable c cable mounting
bracket
1 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. c
d Lower lock nut
e Cable mounting nut
2 Lift the safety arm, move it to the center of the d f End of the lowering
scissor arm and rotate to a vertical position. cable
g Manual lowering valve
3 Lower the platform onto the safety arm. (schematic item D)
e
f
4 Push the handle on the manual platform
lowering cable all the way in.
5 Disconnect the cable mounting nut from the g
lowering valve at the barrel end of the lift
cylinder. D
6 Pull the cable tight and measure the distance 8 Tighten the upper lock nut.
between the end of the lowering cable and the 9 Measure the distance between the end of the
end of the lowering valve. lowering cable and the end of the lowering
Result: The measurement should be 3/16 to valve. Adjust if needed.
1/4 inch / 4.7 to 6.4 mm. 10 Install the cable mounting nut onto the lowering
valve.
Platform manual lowering cable specification
11 Raise the platform and return the safety arm to
Gap, lowering cable to valve 3/16to 1/4 inch the stowed position.
4.7 to 6.4 mm
12 Pull the manual lowering handle at the ground
controls 2 to 3 times to ensure it is functioning
correctly.

REV C GROUND CONTROLS
4-2 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
terminal 87 to 30 continuity
Throw Relay (zero Ω)
85 87 87a
other jewelry.
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.
85 87 87a
Test Desired result
terminal 85 to 86 with resistor 280 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.

GROUND CONTROLS REV C
4-3 4 Center a lifting jack under the drive chassis at

the steer end of the machine.
Level Sensor
5 Raise the machine approximately
(before serial number 47665) 2 inches / 5 cm.
The tilt sensor sounds when the incline of the 6 Place a 1.27 x 6 x 6 inch / 32.3 mm x
chassis exceeds the rating on the serial plate. 15 cm x 15 cm thick steel block under both
wheels at the steer end of the machine.
How to Install and Calibrate the 7 Lower the machine onto the blocks.
1.5° Level Sensor
8 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
This procedure is for the following models:
• GS-2032 (ANSI and CSA models) scissor arm and rotate down to a vertical
position.
Tip-over hazard. Failure to install
or calibrate the tilt level sensor as 10 Lower the scissor arms onto the safety arm.
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 18.
2 Turn the key switch to platform control and pull 12 Tag and disconnect the wiring harness from the
out the red Emergency Stop buttons to the ON level sensor, limit switch and alarm.
13 Remove the tilt level sensor box retaining
controls.
fasteners. Remove the tilt level sensor box from
3 Block the wheels at the non-steer end of the the machine.
machine.
14 Remove the tilt level sensor retaining fasteners.
Remove the tilt level sensor from the level
sensor box.

15 Place the new tilt level sensor in the tilt level Steer end
sensor box with the "X" on the level sensor a
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 Y
f X
sensor box. Install the level sensor retaining b
fasteners.
Tip-over hazard. The tilt level c
sensor must be installed with the e
"X" on the level sensor base
closest to the long side of the tilt d
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
16 Install the level sensor box onto the machine.
Install the level sensor box retaining fasteners.
17 Connect the wiring harness to the level sensor,
limit switch and alarm.
18 Tighten the level sensor adjusting fasteners Non-steer end
until the bubble in the top of the level sensor is
a scissor chassis
centered in the circles. b tilt level sensor
c level sensor box
Be sure there are threads showing d alarm
through the top of the adjusting e box retaining fastener
fasteners. f level sensor retaining fastener
Result: The tilt sensor alarm should not sound. 22 Raise the machine approximately
2 inches / 5 cm.
19 Raise the platform slightly.
23 Remove the blocks from under both wheels.
20 Return the safety arm to the stowed position.
24 Lower the machine and remove the jack.
25 Remove the blocks from the wheels at the
non-steer end of the machine.

26 Block the wheels at the steer end of the 39 Place a 0.78 x 6 x 6 inch / 20 mm x
machine. 15 cm x 15 cm thick steel block under both
wheels at the ground controls side of the
27 Center a lifting jack under the drive chassis at
machine.
the non-steer end of the machine.
40 Lower the machine onto the blocks.
5 inches / 13 cm. 41 Raise the platform 6 to 7 feet / 1.8 to 2.1 m.
29 Place a 4.07 x 6 x 6 inch / 103.4 mm x 42 Adjust the tilt level sensor retaining fasteners
15 cm x 15 cm thick steel block under both just until the tilt sensor alarm does not sound.
wheels at the non-steer end of the machine.
31 Raise the platform 6 to 7 feet / 1.8 to 2.1 m. 2 inches / 5 cm.
Result: The tilt sensor alarm should sound. 45 Remove the blocks from under both wheels.
CE models: When the platform is 46 Lower the machine and remove the jack.
raised 7 to 8 feet / 2.1 to 2.4 m
from the ground, an alarm should
the battery pack side of the machine.
sound and the lift and drive
functions should not operate. 48 Raise the machine approximately
2 inches / 5 cm.
49 Place a 0.95 x 6 x 6 inch / 24 mm x
15 cm x 15 cm thick steel block under both
5 inches / 13 cm.
wheels at the battery pack side of the machine.
36 Remove the blocks from the wheels at the steer
Result: The tilt sensor alarm should sound.
end of the machine.
Result: If the tilt sensor alarm does not sound,
adjust the tilt level sensor until the alarm just
the ground controls side of the machine.
begins to sound OR the down limit switch may
38 Raise the machine approximately need to be adjusted.
2 inches / 5 cm.
CE models: When the platform is
raised 7 to 8 feet / 2.1 to 2.4 m
from the ground, an alarm should
functions should not operate.

52 Lift the safety arm, move it to the center of the How to Install and Calibrate the
position. 2° Level Sensor
53 Lower the scissor arms onto the safety arm. This procedure is for the following models:
Crushing hazard. Keep hands • GS-2032 (CE and Australia models)

clear of the safety arm when • GS-2632
Tip-over hazard. Failure to install
54 Install the tilt level sensor box cover. or calibrate the tilt level sensor as
instructed will cause death or
55 Raise the platform approximately 7 to 8 feet /
serious injury. Do not install or
2.1 to 2.4 m.
calibrate the level sensor other
56 Return the safety arm to the stowed position. than specified in this procedure.
57 Lower the platform to the stowed position. Perform this procedure with the
machine on a firm, level surface
that is free of obstructions.
2 inches / 5 cm.
The degree of level sensor is listed
under "maximum inclination of the
60 Lower the machine and remove the jack. chassis" on the serial plate.
out the red Emergency Stop buttons to the ON
controls.
3 Block the wheels at the non-steer end of the
machine.
the steer end of the machine.
2 inches / 5 cm.
6 Place a 1.27 x 6 x 6 inch / 32.3 mm x
wheels at the steer end of the machine.

7 Lower the machine onto the blocks. Steer end

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

scissor arm and rotate down to a vertical Y
f X
position. b

c
clear of the safety arm when e
d
11 Remove the tilt level sensor box cover retaining
fasteners. Remove the cover.
The tilt level sensor box is located
on top of the chassis at the steer
end of the machine.
If you are not installing a new level sensor,
proceed to step 18.
12 Tag and disconnect the wiring harness from the
level sensor, limit switch and alarm.
13 Remove the tilt level sensor box retaining Non-steer end
fasteners. Remove the tilt level sensor box from
a scissor chassis
the machine.
b tilt level sensor
14 Remove the tilt level sensor retaining fasteners. c level sensor box
d alarm
Remove the tilt level sensor from the level e box retaining fastener
sensor box. f level sensor retaining fastener
15 Place the new tilt level sensor in the tilt level 16 Install the level sensor box onto the machine.
sensor box with the "X" on the level sensor Install the level sensor box retaining fasteners.
base closest to the long side of the tilt level
sensor box and the "Y" on the level sensor 17 Connect the wiring harness to the level sensor,
base closest to the short side of the tilt level limit switch and alarm.
sensor box.
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 short side of the tilt level
sensor box. Failure to install the tilt
level sensor as instructed could

18 Tighten the level sensor adjusting fasteners CE models: When the platform is
until the bubble in the top of the level sensor is raised 7 to 8 feet / 2.1 to 2.4 m
centered in the circles. from the ground, an alarm should
Be sure there are threads showing
functions should not operate.
through the top of the adjusting
fasteners. 32 Lower the platform to the stowed position.
Result: The tilt sensor alarm should not sound. 33 Raise the machine approximately
5 inches / 13 cm.
36 Remove the blocks from the wheels at the steer
end of the machine.
2 inches / 5 cm.
25 Remove the blocks from the wheels at the 2 inches / 5 cm.
non-steer end of the machine.
39 Place a 1.06 x 6 x 6 inch / 27 mm x
26 Block the wheels at the steer end of the 15 cm x 15 cm thick steel block under both
machine. wheels at the ground controls side of the
machine.
the non-steer end of the machine. 40 Lower the machine onto the blocks.
28 Raise the machine approximately 41 Raise the platform 6 to 7 feet / 1.8 to 2.1 m.
5 inches / 13 cm.
42 Adjust the tilt level sensor retaining fasteners
29 Place a 4.07 x 6 x 6 inch / 103.4 mm x just until the tilt sensor alarm does not sound.
wheels at the non-steer end of the machine.
2 inches / 5 cm.

47 Center a lifting jack under the drive chassis at 4-4

Level Sensor
2 inches / 5 cm.
(after serial number 47664)
49 Place a 1.23 x 6 x 6 inch / 31 mm x The tilt sensor sounds when the incline of the
15 cm x 15 cm thick steel block under both chassis exceeds the rating on the serial plate.
wheels at the battery pack side of the machine.
How to Install and Calibrate the
1.5° Level Sensor
This procedure is for the following models:
Result: If the tilt sensor alarm does not sound, • GS-2032 (ANSI and CSA models)
adjust the tilt level sensor until the alarm just • GS-2032 (CE models after
begins to sound OR the down limit switch may serial number GS3204-51682)
need to be adjusted. • GS-2632 (CE models after
serial number GS3204-51682)
CE models: When the platform is
raised 7 to 8 feet / 2.1 to 2.4 m Tip-over hazard. Failure to install
from the ground, an alarm should or calibrate the tilt level sensor as
sound and the lift and drive instructed will compromise
functions should not operate. machine stability and cause the
machine to tip over, resulting in
52 Lift the safety arm, move it to the center of the death or serious injury. Do not
scissor arm and rotate down to a vertical install or calibrate the level sensor
position. other than specified in this
53 Lower the scissor arms onto the safety arm. procedure.
Crushing hazard. Keep hands Perform this procedure with the

clear of the safety arm when machine on a firm, level surface
lowering the platform. that is free of obstructions.
54 Install the tilt level sensor box cover. 1 Remove the platform controls from the platform.
55 Raise the platform slightly. 2 Turn the key switch to platform control and pull
56 Return the safety arm to the stowed position. position at both the ground and platform
controls.
2 inches / 5 cm.

4 Lift the safety arm, move it to the center of the Steer end
a
position.
5 Lower the platform onto the safety arm.
Y
Crushing hazard. Keep hands f X
b
c
If you are not installing a new level sensor, e
proceed to step 15.
d
6 Turn the key switch to the off position and push
in the red Emergency Stop button to the off
position at the ground controls.
7 Tag and disconnect the level sensor wire
harness from the chassis wire harness.
The wire harness connection is
located next to the level sensor,
on top of the chassis at the steer
end of the machine.
8 Remove the level sensor retaining fasteners.
Remove the level sensor from the machine. Non-steer end
9 Tag and disconnect the level sensor wires from a limit switch
the level sensor connector plug. b level sensor mount bracket
c level sensor S7
10 Securely install the wires of the new level d alarm H5
sensor into the level sensor connector plug. e level sensor retaining fastener
f scissor chassis
11 Place the new level sensor onto the level
sensor mount bracket with the "X" on the level 12 Install the level sensor retaining fasteners
sensor base closest to the long side of the level through the level sensor and springs, and into
sensor mount and the "Y" on the level sensor the mount bracket. Tighten the fasteners and
base closest to the short side of the level measure the distance between the level sensor
sensor mount. and the level sensor mount bracket.
Tip-over hazard. The level sensor Result: The measurement should be

must be installed with the "X" on approximately 3/8 inch / 10 mm.
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 result in
the machine tipping over, causing

13 Connect the chassis wire harness to the level 26 Remove the blocks from under both wheels.
sensor wire harness.
14 Turn the key switch to the ground control and
pull out the red Emergency Stop button to the
on position at the ground controls.
15 Adjust the level sensor retaining fasteners until
2 inches / 5 cm.
the bubble in the top of the level sensor is
centered in the circles. 30 Place a 0.8 x 6 x 6 inch / 20.3 mm x 15 cm x 15
cm thick steel block under both wheels at the
Result: The tilt sensor alarm should not sound.
battery pack side of the machine.
Result: The platform should stop and an alarm
19 Center a lifting jack under the drive chassis at should sound.
Result: The platform does not stop or the level
20 Raise the machine approximately sensor alarm does not sound. Adjust the level
2 inches / 5 cm. sensor until the alarm just begins to sound OR
the down limit switch may need to be adjusted.
21 Place a 0.66 x 6 x 6 inch / 16.8 mm x 15 cm x
15 cm thick steel block under both wheels at 33 Lift the safety arm, move it to the center of the
the ground controls side of the machine. scissor arm and rotate down to a vertical
position.
Result: The level sensor alarm should not
sound.
Result: The level sensor alarm does sound.
Adjust the level sensor retaining fasteners just
until the level sensor alarm does not sound. 36 Return the safety arm to the stowed position.
24 Lower the platform to the stowed position. 37 Lower the platform to the stowed position.
25 Raise the machine approximately 38 Raise the machine approximately
2 inches / 5 cm. 2 inches / 5 cm.

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 the following models: lowering the platform.
• GS-2032 (Australia models) If you are not installing a new level sensor,
• GS-2032 (CE models before proceed to step 15.
serial number GS3204-51683)
• GS-2632 (ANSI, CSA and Australia models) 6 Turn the key switch to the off position and push
• GS-2632 (CE models before in the red Emergency Stop button to the off
serial number GS3204-51683) position at the ground controls.
Tip-over hazard. Failure to install 7 Tag and disconnect the level sensor wire
or calibrate the tilt level sensor as harness from the chassis wire harness.
instructed will compromise The wire harness connection is
machine stability and cause the located next to the level sensor,
machine to tip over, resulting in on top of the chassis at the steer
death or serious injury. Do not end of the machine.
install or calibrate the level sensor
other than specified in this 8 Remove the level sensor retaining fasteners.
procedure. Remove the level sensor from the machine.
Perform this procedure with the 9 Tag and disconnect the level sensor wires from
machine on a firm, level surface the level sensor connector plug.
that is free of obstructions. 10 Securely install the wires of the new level
1 Remove the platform controls from the platform. sensor into the level sensor connector plug.

controls.
position.

11 Place the new level sensor onto the level Steer end
sensor mount bracket with the "X" on the level a
sensor base closest to the long side of the level
sensor mount and the "Y" on the level sensor
base closest to the short side of the level Y
f X
sensor mount. b
Tip-over hazard. The level sensor

must be installed with the "X" on c
the level sensor base closest to e
the long side of the tilt level sensor
box and the "Y" on the level d
sensor base closest to the short
side of the tilt level sensor box.
Failure to install the tilt level
sensor as instructed could result in
the machine tipping over, causing
12 Install the level sensor retaining fasteners
through the level sensor and springs, and into
the mount bracket. Tighten the fasteners and
measure the distance between the level sensor
and the level sensor mount bracket.
Non-steer end
Result: The measurement should be
approximately 3/8 inch / 10 mm. a limit switch
b level sensor mount bracket
13 Connect the chassis wire harness to the level c level sensor S7
sensor wire harness. d alarm H5
e level sensor retaining fastener
14 Turn the key switch to the ground control and f scissor chassis
pull out the red Emergency Stop button to the
on position at the ground controls. 16 Raise the platform slightly.
15 Adjust the level sensor retaining fasteners until
the bubble in the top of the level sensor is 18 Lower the platform to the stowed position.
centered in the circles.
Result: The tilt sensor alarm should not sound. the ground controls side of the machine.

20 Raise the machine approximately 32 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
2 inches / 5 cm.
Result: The platform should stop and an alarm
21 Place a 0.9 x 6 x 6 inch / 22.9 mm x 15 cm x 15 should sound.
cm thick steel block under both wheels at the
Result: The platform does not stop or the level
ground controls side of the machine.
sensor alarm does not sound. Adjust the level
22 Lower the machine onto the blocks. sensor until the alarm just begins to sound OR
the down limit switch may need to be adjusted.
Result: The level sensor alarm should not
sound.
position.
Result: The level sensor alarm does sound.
Adjust the level sensor retaining fasteners just
until the level sensor alarm does not sound. Crushing hazard. Keep hands
2 inches / 5 cm.
2 inches / 5 cm.
2 inches / 5 cm. 40 Lower the machine and remove the jack.
30 Place a 1.04 x 6 x 6 inch / 26.4 mm x 15 cm x
15 cm thick steel block under both wheels at

Hydraulic Pump REV A
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 an electric 3200 psi / 221 bar, immediately stop. The pump
motor which 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 3200 psi / 221
Fitting Torque Specifications. bar. When testing the pump,
1 Disconnect and plug the high pressure activate the pump in one second
hydraulic hose from the hydraulic pump. intervals until 3200 psi / 221 bar is
confirmed. Do not over-pressurize
Bodily injury hazard. Spraying 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.
out the Emergency Stop button to the ON
controls.

REV A HYDRAULIC PUMP
How to Remove the

Hydraulic Pump
or fitting, the O-ring on the fitting
Fitting Torque Specifications.
1 Remove the mounting fasteners from the
hydraulic filter bracket at the function manifold.
Move the filter off to the side.
2 Tag, disconnect and plug the hydraulic hoses
on the pump. Cap the fittings on the pump.
or spray.
3 Remove the pump mounting bolts. Carefully
remove the pump.

Manifolds REV C
6-1
Function Manifold Components (from serial number 17408 to 17481)
The function manifold is mounted inside the hydraulic power unit module tray.
Index Schematic
No. Description Item Function Torque
1 Check valve, 30 psi / 2 bar ........................ AA ............... Steer circuit .................................... 20 ft-lbs / 27 Nm
2 Diagnostic nipple ....................................... AB ............... Testing ........................................... 10 ft-lbs / 14 Nm
3 Flow regulator, 0.75 gpm / 2.8 L/min ......... AC ............... Steer circuit .................................... 35 ft-lbs / 47 Nm
4 Orifice - washer, 0.040 in / 1 mm ............... AD ............... Steer circuit
5 Relief valve, 1500 psi / 103.4 bar .............. AE ............... Steering relief ................................ 20 ft-lbs / 27 Nm
6 Relief valve, 3500 psi / 241.3 bar .............. AF ................ System relief .................................. 20 ft-lbs / 27 Nm
7 Solenoid valve, 3 position 4 way ............... AG ............... Steer left/right ................................ 20 ft-lbs / 27 Nm
8 Solenoid valve, 2 position 4 way ............... AH ............... Platform up .................................... 25 ft-lbs / 34 Nm
9 Solenoid valve,
2 position 2 way, N.O. ............................... AI ................. Brake circuit ................................... 20 ft-lbs / 27 Nm
10 Solenoid valve, 2 position 4 way ............... AJ ................ Drive speed select circuit ............... 25 ft-lbs / 34 Nm
11 Solenoid valve, 3 position 4 way ............... AK ............... Drive forward/reverse .................... 25 ft-lbs / 27 Nm
12 Check valve, 200 psi / 13.8 bar ................. AL ................ Brake circuit ................................... 25 ft-lbs / 34 Nm

REV C MANIFOLDS

MANIFOLDS REV C
6-2
Index Schematic
1 Check valve, 30 psi / 2 bar ........................ AA ............... Steer circuit .................................... 20 ft-lbs / 27 Nm
2 Diagnostic nipple ....................................... AB ............... Testing ........................................... 10 ft-lbs / 14 Nm
3 Flow regulator, 0.75 gpm / 2.8 L/min ......... AC ............... Steer circuit .................................... 35 ft-lbs / 47 Nm
4 Orifice - washer, 0.040 in / 1 mm ............... AD ............... Steer circuit
5 Relief valve, 1500 psi / 103.4 bar .............. AE ............... Steering relief ................................ 20 ft-lbs / 27 Nm
6 Relief valve, 3500 psi / 241.3 bar .............. AF ................ System relief .................................. 20 ft-lbs / 27 Nm
7 Solenoid valve, 3 position 4 way ............... AG ............... Steer left/right ............................... 20 ft-lbs / 27 Nm
8 Solenoid valve, 2 position 4 way ............... AH ............... Platform up .................................... 25 ft-lbs / 34 Nm
9 Solenoid valve,
2 position 2 way, N.O. ............................... AI ................. Brake circuit ................................... 20 ft-lbs / 27 Nm
10 Solenoid valve, 2 position 4 way ............... AJ ................ Drive speed select circuit ............... 25 ft-lbs / 34 Nm
11 Solenoid valve, 3 position 4 way ............... AK ............... Drive forward/reverse .................... 25 ft-lbs / 34 Nm
12 Relief valve, 130 psi / 9 bar ....................... AL ................ Brake circuit ................................... 20 ft-lbs / 27 Nm

REV C MANIFOLDS

MANIFOLDS REV C
6-3
Index Schematic
1 Diagnostic nipple ....................................... BA ............... Testing ........................................... 10 ft-lbs / 14 Nm
2 Flow regulator valve,
0.75 gpm / 2.8 L/min .................................. BB ............... Steer circuit .................................... 35 ft-lbs / 47 Nm
3 Relief valve,
3000 to 3200 psi / 207 to 221 bar .............. BC ............... Platform up .................................... 20 ft-lbs / 27 Nm
4 Relief valve, 3500 psi / 241.3 bar .............. BD ............... System relief .................................. 20 ft-lbs / 27 Nm
5 Orifice - washer, 0.040 in / 1 mm ............... BE ............... Steer circuit
6 Relief valve, 1500 psi / 103.4 bar .............. BF ................ Steering relief ................................ 20 ft-lbs / 27 Nm
7 Relief valve, 130 psi / 9 bar ....................... BG ............... Brake relief .................................... 20 ft-lbs / 27 Nm
8 Solenoid valve, 3 position 4 way ............... BH ............... Steer left/right ................................ 20 ft-lbs / 27 Nm
9 Solenoid valve, 2 position 4 way ............... BI ................. Drive speed select circuit ............... 25 ft-lbs / 34 Nm
10 Solenoid valve, 3 position 4 way ............... BJ ................ Drive forward/reverse .................... 25 ft-lbs / 34 Nm
11 Solenoid valve,
2 position 2 way, N.O. ............................... BK ............... Brake circuit ................................... 20 ft-lbs / 27 Nm
12 Solenoid valve, 2 position 4 way ............... BL ................ Platform up .................................... 25 ft-lbs / 34 Nm
13 Check valve, 5 psi / 0.3 bar ....................... BM ............... Steer circuit .................................... 20 ft-lbs / 27 Nm

REV C MANIFOLDS

MANIFOLDS REV C
6-4
Index Schematic
1 Diagnostic nipple ....................................... BA ............... Testing ........................................... 10 ft-lbs / 14 Nm
0.75 gpm / 2.8 L/min .................................. BB ............... Steer circuit .................................... 35 ft-lbs / 47 Nm
3 Relief valve,
3000 to 3200 psi / 207 to 221 bar .............. BC ............... Platform up .................................... 20 ft-lbs / 27 Nm
4 Relief valve, 3500 psi / 241.3 bar .............. BD ............... System relief .................................. 20 ft-lbs / 27 Nm
5 Orifice - washer, 0.040 in / 1 mm ............... BE ............... Steer circuit
6 Relief valve, 1500 psi / 103.4 bar .............. BF ................ Steering relief ................................ 20 ft-lbs / 27 Nm
7 Relief valve, 130 psi / 9 bar ....................... BG ............... Brake relief .................................... 20 ft-lbs / 27 Nm
8 Solenoid valve, 3 position 4 way ............... BH ............... Steer left/right ................................ 20 ft-lbs / 27 Nm
9 Solenoid valve, 2 position 4 way ............... BI ................. Drive speed select circuit ............... 25 ft-lbs / 34 Nm
10 Solenoid valve, 3 position 4 way ............... BJ ................ Drive forward/reverse .................... 25 ft-lbs / 34 Nm
11 Solenoid valve,
2 position 2 way, N.O. ............................... BK ............... Brake circuit ................................... 20 ft-lbs / 27 Nm
12 Solenoid valve, 2 position 4 way ............... BL ................ Platform up .................................... 25 ft-lbs / 34 Nm
13 Check valve, 5 psi / 0.3 bar ....................... BM ............... Steer circuit .................................... 20 ft-lbs / 27 Nm

REV C MANIFOLDS
1 2
BB
BA
BC
3
BD
4
BE 5
BF
6
BM
BG
7
Y3
BH
Y4 8
BI
Y1 9
Y6
Y8 Y5
Y2
BL BK BJ
13 12 11 10

MANIFOLDS REV C
6-5
Function Manifold Components - Models with Traction Control
Index Schematic
1 Diagnostic nipple ....................................... CA ............... Testing ........................................... 10 ft-lbs / 14 Nm
0.75 gpm / 2.8 L/min .................................. CB ............... Steer circuit .................................... 35 ft-lbs / 47 Nm
3 Relief valve,
3000 to 3200 psi / 207 to 221 bar .............. CC ............... Platform up .................................... 20 ft-lbs / 27 Nm
4 Relief valve, 3500 psi / 241.3 bar .............. CD ............... System relief .................................. 20 ft-lbs / 27 Nm
5 Orifice - washer, 0.040 in / 1 mm ............... CE ............... Steer circuit
6 Relief valve, 1500 psi / 103.4 bar .............. CF ............... Steering relief ................................ 20 ft-lbs / 27 Nm
7 Check valve, 30 psi / 2 bar ........................ CG ............... Brake circuit ................................... 20 ft-lbs / 27 Nm
8 Solenoid valve, 3 position 4 way ............... CH ............... Steer left/right ................................ 20 ft-lbs / 27 Nm
9 Solenoid valve,
2 position 2 way, N.O. ............................... CI ................. Brake circuit ................................... 20 ft-lbs / 27 Nm
10 Solenoid valve, 2 position 4 way ............... CJ ................ Drive speed select circuit ............... 25 ft-lbs / 34 Nm
11 Solenoid valve, 3 position 4 way ............... CK ............... Drive forward/reverse .................... 25 ft-lbs / 34 Nm
12 Solenoid valve, 2 position 2 way ............... CL ................ High speed bypass ........................ 20 ft-lbs / 27 Nm
13 Flow divider/combiner valve ...................... CM ............... Drive slip limit ................................ 25 ft-lbs / 34 Nm
14 Solenoid valve, 2 position 4 way ............... CN ............... Platform up .................................... 25 ft-lbs / 34 Nm
15 Check valve, 10 psi / 0.7 bar ..................... CO ............... Steer circuit .................................... 20 ft-lbs / 27 Nm

REV C MANIFOLDS

MANIFOLDS REV C
6-6 3 Turn the key switch to ground control and pull

out the red Emergency Stop button to the ON
Valve Adjustments - position at both the ground and platform
Function Manifold controls.
4 Hold the system relief valve with a wrench and
How to Adjust the remove the cap (item AF).
System Relief Valve 5 While activating the platform up function, adjust
the internal hex socket clockwise to increase lift
(before serial number 36101) capacity or counterclockwise to decrease lift
1 Open the hydraulic power unit module tray and capacity. Adjust the relief valve until the
locate the system relief valve on the function platform just begins to raise.
manifold (item AF). 6 Fully lower the platform.
2 Place maximum rated load into the platform.
7 Add an additional 50 pounds / 22.7 kg to the
Secure the load to the platform.
platform. Secure the additional weight.
Load capacity, maximum
8 Activate the platform up function.
GS-2032 800 lbs
363 kg Result: The power unit should not be able to lift
the platform.
GS-2632 500 lbs
227 kg Result: If the power unit lifts the platform, adjust
the internal hex socket counterclockwise until
the platform will not raise.
AC
AD Tip-over hazard. Do not adjust the
AB
AA
relief valve to allow the power unit
AE
to lift more than maximum rated
load.
a
AF
9 Install the relief valve cap.
Y3 10 Remove the weight from the platform.
Y4
b AG
11 Bleed the hydraulic system. Raise the platform
Y8 to full height, and then lower it to the stowed
AH
position through two complete cycles.
Y2
AI Result: If the pump cavitates or platform fails to
reach full height, add hydraulic oil until the
pump is functioning correctly and the platform
AL
Y1
AJ
Y6
reaches full height. Do not overfill the hydraulic
Y5
tank.
AK
Component damage hazard. Do
a system relief valve not continue to operate the
b function manifold
machine if the hydraulic pump is
cavitating. If the pump is still
cavitating, see 5-1, How to Test
the Hydraulic Pump.

REV C MANIFOLDS
How to Adjust the Models without traction control

(from serial number 36101 to 49425)
System Relief Valve
BB
BA
Be sure that the hydraulic oil level c
is between the FULL and ADD marks BC
on the oil level indicator decal.
a
1 Open the hydraulic power unit module tray and BD
BE
locate the system relief valve on the function b
manifold (item BD or CD).
BF
2 Connect a 0 to 5000 psi / 0 to 350 bar pressure
gauge to the test port on the function manifold BG
(item BA or CA). BM Y3
Y4
BH
Models with traction control
CB Y1 BI
Y6
CA Y8
Y2
Y5
BJ
c CC
BL BK
a
CE CD a system relief valve
b function manifold
b c test port
CF
Models without traction control
CG (from serial number 49426 to 59999)
CO
Y3
BB
Y4
CH
BA
Y2
CI c
BC
CM
Y1 a
CJ BD
Y6
BE
b
Y8 Y5
Y1A
CK
BF
CN CL
BM
a system relief valve BG
b function manifold
c test port
BH
BI
BJ
BL BK

MANIFOLDS REV C
3 Chock both sides of the wheels at the steer end

of the machine.
Perform this test from the ground
with the platform controls. Do not
stand in the platform.
controls.
6 Press and hold the function enable switch.
7 Move and hold the joystick controller fully in
either direction while observing the pressure
reading on the pressure gauge. Note the
pressure. Refer to Section 2, Specifications.
8 Turn the machine off. Hold the system relief
valve with a wrench and remove the cap
(item BD or CD).
9 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure.
Tip-over hazard. Failure to adjust
the relief valves to specification
could cause the machine to tip
over resulting in death or serious
injury. Do not adjust the relief
valve pressures higher than
specifications.
10 Install the relief valve cap.
11 Repeat steps 5 through 7 to confirm the relief
valve pressure.

REV C MANIFOLDS
How to Adjust the 3 Press and hold the steer thumb rocker switch to
the right. Allow the wheels to completely turn to
Steering Relief Valve the right, then continue holding the switch while
(before serial number 36101) observing the pressure reading on the pressure
gauge. Note the pressure.
1 Connect a 0 to 5000 psi / 0 to 350 bar pressure
gauge to the test port (item AB) on the function 4 Press and hold the steer thumb rocker switch to
manifold. the left. Allow the wheels to completely turn to
the left, then continue holding the switch while
AC observing the pressure reading on the pressure
c
AB AD gauge. Note the pressure. Refer to Section 2,
AA Specifications.
AE
a 5 Turn the machine off. Hold the steering relief
AF
(item AE).
Y3
Y4
b AG to increase the pressure or counterclockwise to
Y8
decrease the pressure. Install the relief valve
AH cap.
Y2
AI Tip-over hazard. Failure to adjust
AL
Y1
AJ over resulting in death or serious
Y6
Y5
AK valve pressures higher than
specifications.
a steer relief valve
b function manifold 7 Repeat steps 3 and 4 to confirm the relief valve
c test port pressure.
controls.

MANIFOLDS REV C

Steering Relief Valve
(after serial number 36100) BB
BA
1 Connect a 0 to 5000 psi / 0 to 350 bar pressure c
gauge to the test port (item BA or CA) on the BC
function manifold.
BD
Models with traction control
BE
CB b
BF
a
CA
c CC BG
BM Y3
CD
CE Y4
BH
b CF
a Y1 BI
Y6
CG Y8 Y5
CO Y2
BJ
Y3
Y4
CH BL BK
a system relief valve

Y2
CI b function manifold
c test port
CM
Y1
CJ Models without traction control
Y6 (from serial number 49426 to 59999)
Y8 Y5
Y1A
CK
BB
CN CL
a steer relief valve BA

c
b function manifold
BC
c test port
BD
BE
b
a
BF
BM
BG
BH
BI
BJ
BL BK

REV C MANIFOLDS

controls.
3 Press and hold the steer thumb rocker switch to
the right. Allow the wheels to completely turn to
the right, then continue holding the switch while
observing the pressure reading on the pressure
gauge. Note the pressure.
4 Press and hold the steer thumb rocker switch to
the left. Allow the wheels to completely turn to
the left, then continue holding the switch while
observing the pressure reading on the pressure
gauge. Note the pressure. Refer to Section 2,
Specifications.
5 Turn the machine off. Hold the steering relief
(item BF or CF).
decrease the pressure. Install the relief valve
cap.
Tip-over hazard. Failure to adjust
over resulting in death or serious
specifications.
7 Repeat steps 3 and 4 to confirm the relief valve
pressure.

MANIFOLDS REV C

Platform Lift Relief Valve
BB
BA
Be sure that the hydraulic oil level d BC
is between the FULL and ADD marks a
on the oil level indicator decal.
b
1 Open the hydraulic power unit module tray and BD
BE
locate the system relief valve on the function c
manifold (item BD or CD).
BF
BG
BB
BM Y3
BA Y4
BH
d BC
a
Y1 BI
b Y6
BD
BE Y8
Y2
Y5
BJ
c
BL BK
BF
a lift relief valve
b system relief valve
BG c function manifold
BM Y3
d test port
Y4
BH
Y1 BI
Y6
BB
Y8 Y5
Y2
BJ
BA
BL BK d a
BC
a lift relief valve
b system relief valve
b
c function manifold BD
BE
d test port
c
BF
BM
BG
BH
BI
BJ
BL BK

REV C MANIFOLDS
2 Connect a 0 to 5000 psi / 0 to 350 bar pressure Confirm the Lift Relief Valve Pressure:
gauge to the test port on the function manifold
(item BA or CA). 12 Place the maximum rated load in the platform.
Secure the load to the platform. Refer to
3 Chock both sides of the wheels at the steer end Section 2, Specifications.
of the machine.
4 Remove the platform controls from the platform. out the Emergency Stop button to the ON
Perform this test from the ground controls.
with the platform controls. Do not
stand in the platform. 14 Hold the lift relief valve with a wrench and
remove the cap (item BC or CC).
Confirm the System Relief Valve Pressure:
15 While activating the platform up function, adjust
5 Turn the key switch to platform control and pull the internal hex socket clockwise, just until the
out the Emergency Stop button to the ON platform begins to raise.
controls. 16 Fully lower the platform.
6 Press and hold the function enable switch. 17 Add an additional 100 pounds / 45.4 kg to the
platform. Secure the additional weight.
7 Move and hold the joystick controller fully in
either direction while observing the pressure 18 Raise the platform slightly.
reading on the pressure gauge. Note the Result: The power unit should not be able to lift
pressure. Refer to Section 2, Specifications. the platform.
8 Turn the machine off. Hold the system relief Result: If the power unit lifts the platform, adjust
valve with a wrench and remove the cap the internal hex socket counterclockwise until
(item BD or CD). the adjustment is correct.
9 Adjust the internal hex socket. Turn it clockwise 19 Install the relief valve cap.
decrease the pressure. 20 Remove the weight from the platform.
Tip-over hazard. Failure to adjust 21 Bleed the hydraulic system by raising the
the relief valves to specification platform to full height. If the pump cavitates or
could cause the machine to tip the platform fails to reach full height, add
over resulting in death or serious hydraulic oil until the pump is functioning
injury. Do not adjust the relief correctly. Do not overfill the hydraulic reservoir.
Component damage hazard. Do
specifications.
not continue to operate the
10 Install the relief valve cap. machine if the hydraulic pump is
cavitating.
11 Repeat steps 5 through 7 to confirm the relief
valve pressure.

MANIFOLDS REV C
6-7 Valve Coil Resistance Specifications

Valve Coils Description Specification

How to Test a Coil 20V DC with diode
A properly functioning coil provides an (schematic items AG, BH and CH)
electromotive force which operates the solenoid Solenoid valve, 2 position 4 way 18 to 20Ω
valve. Critical to normal operation is continuity 20V DC with diode
within the coil that provides this force field. (schematic items AH, AJ, BI, BL, CJ and CN)
Electrocution hazard. Contact with Solenoid valve, 2 position 2 way N.O. 25 to 27Ω
electrically charged circuits could 20V DC with diode
result in death or serious injury. (schematic items AI, BK, CI and CL)
other jewelry. 20V DC with diode
1 Tag and disconnect the wire harness from the (schematic items AK, BJ and CK)
coil to be tested. Solenoid valve, N.C. 23 to 25Ω
2 Test the coil resistance. 2 position 2 way 20V DC with diode
(schematic item D, after serial number 28936)
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.

REV C MANIFOLDS
How to Test a Coil Diode 3 Set a multimeter to read DC amperage.
Genie incorporates spike suppressing diodes in all The multimeter, when set to read
of its coils. Properly functioning coil diodes protect DC amperage, should be capable
the electrical circuit by suppressing voltage spikes. of reading up to 800 mA.
Voltage spikes naturally occur within a function 4 Connect the negative lead to the other terminal
circuit following the interruption of electrical current on the coil.
to a coil. Faulty diodes can fail to protect the
electrical system, resulting in a tripped circuit If testing a single-terminal coil,
breaker or component damage. connect the negative lead to the
internal metallic ring at either end
Electrocution hazard. Contact with of the coil.
5 Momentarily connect the positive lead from the
multimeter to the positive terminal on the 9V
battery. Note and record the current reading.
other jewelry.
6 At the battery or coil terminals, reverse the
1 Test the coil for resistance. See 6-8 How to
connections. Note and record the current
Test a Coil.
reading.
2 Connect a 10Ω resistor to the negative terminal
Result: Both current readings are greater than
of a known good 9V DC battery. Connect the
0 mA and are different by a minimum of 20%.
other end of the resistor to a terminal on the
The coil is good.
coil.
Result: If one or both of the current readings are
The battery should read 9V DC or
0 mA, or if the two current readings do not differ
more when measured across the
by a minimum of 20%, the coil and/or its
terminals.
internal diode are faulty and the coil should be
Ω
Resistor, 10Ω replaced.
Genie part number 27287
COIL
a
d AMMETER
c -
+
b
10 W 9V
RESISTOR BATTERY
c
b
+
-
a multimeter
b 9V DC battery
c 10Ω resistor
d coil
Note: Dotted lines in illustration indicate a
reversed connection as specified in step 6

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.
Component damage hazard. The
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 A
Steer Axle Components
8-1 7 Tag, disconnect and plug the hydraulic hoses
on the drive motor. Cap the fittings.
Yoke and Drive Motor
How to Remove the Yoke burn skin. Loosen hydraulic
and Drive Motor connections very slowly to
allow the oil pressure to
dissipate gradually. Do not
allow oil to squirt or spray.
and then torqued to specification Component damage hazard.
during installation. Refer to Hoses can be damaged if they are
Section Two, Hydraulic Hose and kinked or pinched.
8 Support and secure the yoke assembly to an
1 Block the non-steer wheels. appropriate lifting device.
2 Center a lifting jack under the drive chassis at 9 Remove the retaining fastener from the steer
the steer end of the machine. link at the yoke assembly.
3 Remove the cotter pin from the wheel castle Note the quantity and location of
nut. the spacers when disconnecting
the steer link from the yoke
Always replace the cotter pin with
assembly.
castle nut. 10 Remove the retaining fastener from the top of
the yoke pivot shaft.
4 Loosen the wheel castle nut. Do not remove it.
11 Lower the yoke assembly out of the chassis.
14 inches / 36 cm. Place blocks under the Bodily injury hazard. The yoke/
chassis for support. motor assembly may fall if not
Crushing hazard. The chassis will
removed from the chassis.
fall if it is not properly supported.
During re-assembly, be sure that
6 Remove the wheel castle nut. Remove the
the spacers are installed onto the
wheel.
steer link.

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

REV A 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 steering cylinder from the machine.
1 Block the non-steer wheels.
2 Tag, disconnect and plug the hydraulic hoses
from the steering 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.
3 Remove the pin retaining fasteners from the
barrel-end pivot pin. Remove the pivot pin.
Note the quantity and location of
the spacers when removing the
barrel-end pivot pin.

STEER AXLE COMPONENTS REV A
8-3 5 Remove the bellcrank from the machine.

Steer Bellcrank Note the quantity and the location
of the spacers in between the
bellcrank and the steer links.
How to Remove the
Steer Bellcrank
Perform this procedure with the
machine on a flat, level surface.
1 Remove the steering cylinder. See 8-2, How to
Remove the Steering 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 Remove the retaining fasteners from the steer
links at each end of the bellcrank.
Note the quantity and the location
of the spacers in between the
bellcrank and the steer links.
14 inches / 36 cm. Place blocks under the
chassis for support.
fall if it is not properly supported.
4 Turn the yokes to the side so the bellcrank can
be removed.

REV A
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 fall if it is 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 Disconnect and plug the hydraulic hose from
during installation. Refer to the brake. Cap the fittings on the brake.
1 Support and secure the entry ladder to an burn skin. Loosen hydraulic
appropriate lifting device. connections very slowly to
2 Remove the entry ladder mounting fasteners. dissipate gradually. Do not
Remove the entry ladder from the machine. allow oil to squirt or spray.
Crushing hazard. The entry ladder 10 Place a lifting jack under the brake for support.
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 it is not properly supported
4 Center a lifting jack under the drive chassis at when 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 101.7 Nm
castle nut. Brake mounting fasteners, lubricated 56 ft-lbs
6 Loosen the wheel castle nut. Do not remove it. 76.3 Nm

Brake Release Hand Pump Components REV B
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 Shuttle valve ..................................... J ................ Brake release circuit ............................ 45-50 in-lbs / 5 Nm
2 Check valve, pilot operated .............. K ............... Manual brake release circuit ............ 65-70 in-lbs / 7-8 Nm
3 Hand pump ....................................... L ............... Manual brake release .............................. 30 ft-lbs / 41 Nm
4 Needle valve ..................................... M ............... Manual brake release enable .............. 45-50 in-lbs / 5 Nm
GS-2032, GS-2632
(before serial number GS-3204-52789)
J
M
4
2
K
3 Note: 'alpha' callouts refer

to corresponding notes on
L the hydraulic schematic
L 3
4
M
GS-2032, GS-2632
(after serial number GS-3204-52788)

June 2004 Section 5 • Troubleshooting Flow Charts
Troubleshooting Flow Charts

Before Troubleshooting:
Read, understand and obey the safety rules and
operating instructions in the appropriate
operator's manual on your machine.
Be sure that all necessary tools and test
equipment are available and ready for use.
Observe and Obey:
Read each appropriate flow chart thoroughly.
Troubleshooting and repair procedures shall be Attempting shortcuts may produce hazardous
completed by a person trained and qualified on conditions.
the repair of this machine.
Be aware of the following hazards and follow
Immediately tag and remove from service a generally accepted safe workshop practices.
damaged or malfunctioning machine.
Crushing hazard. When testing
Repair any machine damage or malfunction or replacing any hydraulic
before operating the machine. component, always support
the structure and secure it
Unless otherwise specified, perform each from movement.
repair procedure with the machine in the
following configuration: Electrocution hazard. Contact
· Machine parked on a firm, level surface with electrically charged circuits
could result in death or serious
· Platform in the stowed position injury. Remove all rings, watches
· Key switch in the off position with the key and other jewelry.
removed
· The red Emergency Stop button in the off hydraulic oil can penetrate and
position at both ground and platform controls burn skin. Loosen hydraulic
· Wheels chocked connections very slowly to allow
· All external AC power supply disconnected gradually. Do not allow oil to
from the machine squirt or spray.
Two persons will be required to
safely perform some
troubleshooting procedures.

Section 5 • Troubleshooting Flow Charts June 2004
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
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)
Right coil fault. Malfunctioning coil OR wire Troubleshoot coil OR
(See Chart 9)
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.
(See Chart 17)
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
the power-on LED.
Be sure the circuit light is not on

breaker and fuse are
not tripped or blown. bad
After serial number Repair or replace the
25141: Troubleshoot the wire circuit from the
Be sure both CR48 power relay to U5 platform controls to
Emergency Stop CR48 OR repair or
replace the CR48 socket
switches are pulled out OR replace CR48.
to the ON position. good
Be sure the batteries

are fully charged and Check voltage on the less than Replace F6 OR check
properly connected. output side of the 275A 20V for short circuits OR
fuse F6. check battery cables OR
Be sure the hydraulic check for open in
negative battery cable
tank is filled to the from batteries to ground
correct level. 20V or more
point on module tray.
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 at 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. 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 wht
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
terminal D1 at pump the Genie Industries
motor M5. Service Department.
Be sure the circuit
breaker and fuse are 0V
not tripped or blown.
After serial number bad Repair or replace the
Be sure the batteries 25141: Troubleshoot the wire circuit from the
CR48 power relay to U5 platform controls to
are fully charged and CR48 OR repair or
properly connected. 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 A1 at M5 to M- at
from terminal A1 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 the B- terminal at
from the B- terminal at U6 to QD1 OR repair or
U6 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 the motor.
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.

are fully charged and
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.
chart that relates to the
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
breaker and fuse are platform up/down toggle center terminal at TS66.
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.
Be sure, if the Error
Indicator light is on at no
you refer to the specific 20V or more Replace KS1.
chart that relates to the
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 From serial number Connect the positive Repair open in the WH
17408 to 21262: With lead from a volt meter to A6-up coil wire from the
Function the key switch turned to the coil on the platform platform up directional
platform controls and up directional valve valve coil (item AG or
Inoperative both Emergency Stop (item AG or BG) wire
0V
BG) to the ECM U5 (see
buttons pulled out to the light is terminal without Repair Section) OR
ON position, press and on disconnecting the wire replace U5 OR consult
hold the lift function and the negative lead of the Genie Industries
Be sure all other enable button and the volt meter to the Service Department.
functions operate activate the controller in ground point on the
the UP direction and manifold. Activate the
normally. check to see if the error controller in the UP
indicator light at the direction and check the
Be sure the circuit platform controls is on. voltage.
breaker and fuse are After serial number
21262: With the key
not tripped or blown. switch turned to platform 20V or more
0 or
controls and both infinite
Be sure the batteries Emergency Stop buttons Disconnect the wire ohms Replace the platform up
are fully charged and pulled out to the ON from the platform up directional valve coil
position, press the lift directional valve coil on (item AG or BG).
properly connected. function select button the function manifold
and activate the (item AG or BG) and
controller in the UP check the resistance.
direction and check to See Repair Section.
see if the error indicator
light at the platform
18-20 ohms
controls is on.
Repair or replace the

platform up directional
valve cartridge (item AG
or BG) OR consult the
light is not on Genie Industries Service
Department.
3000
Install a 0 to 5000 PSI PSI or Are there mechanical Remove the mechanical
(345 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.
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
From serial number removing the wires. the battery module tray
Be sure all other 17408 to 21262: press From serial number OR replace U5 OR
functions operate and hold the lift function light is 17408 to 21262: consult the Genie
enable button and on Press and hold the lift Industries Service
normally. activate the controller in function enable button Department.
the DOWN direction and and activate the
Be sure the circuit check to see if the error controller in the DOWN
breaker and fuse are indicator light is on. direction and check the
After serial number voltage.
not tripped or blown. 21262: press the lift After serial number
function select button 21262: Press the lift
Be sure the batteries and activate the function select button
are fully charged and controller in the DOWN and activate the
direction and check to controller in the DOWN
properly connected. see if the error indicator direction and check the
light is on. voltage.
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
light is not on removed, pull the cartridge (item D).
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 REV A
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
From serial number without disconnecting brown ground wire
17408 to 21262: the wire, and the circuit from the coil to
Be sure all other activate the function negative lead of the volt the wire harness OR
functions operate enable switch and meter to the brown replace U5 OR consult
activate the steer rocker ground wire at the valve the Genie Industries
normally. 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
breaker and fuse are light at the platform check the voltage.
controls is on.
not tripped or blown. After serial number
20V or more
21262: press the drive
Be sure the batteries function select button
are fully charged and and activate the function Disconnect the wires Repair or replace the
enable switch and from the coil on the 25 to 27 steer directional valve
properly connected. activate the steer rocker steer left directional ohms cartridge (item AF or BI)
switch in the LEFT valve on the function OR consult the Genie
direction and check to manifold (item AF or BI) Industries Service
see if the error indicator and check the Department.
light at the platform resistance of the valve
controls is on. coil (See Repair
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.

REV A CHART 8
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.

Chart 9 REV A
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
From serial number disconnecting the wire, brown ground wire
17408 to 21262: and the negative lead of circuit from the coil to
Be sure all other activate the function the volt meter to the the wire harness OR
functions operate enable switch and brown ground wire at replace U5 OR consult
activate the steer rocker the valve coil. Activate the Genie Industries
normally. switch in the RIGHT the steer rocker switch Service Department.
direction and check to in the LEFT direction and
Be sure the circuit see if the error indicator check the voltage.
breaker and fuse are light at the platform
controls is on.
not tripped or blown. 20V or more
After serial number
21262: press the drive
Be sure the batteries function select button Disconnect the wires Repair or replace the
are fully charged and and activate the function from the coil on the 25 to 27 steer directional valve
enable switch and steer right directional ohms cartridge (item AF or BI)
properly connected. activate the steer rocker valve on the function OR consult the Genie
switch in the RIGHT 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 right

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 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.

REV A CHART 9
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.

Chart 10 REV A
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
Be sure, if the Error light is Genie Industries Service
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
error code that is controls with known controls.
displayed on the ECM. operating platform
controls. Activate the
drive function. Does the
Be sure the circuit drive function operate?
not tripped or blown. no
Be sure the batteries Replace the ECM U5

are fully charged and OR consult the Genie
properly connected. Industries Service
Department.

REV A
Chart 10A
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
turn
Be sure, if the Error machine for support.
Indicator light is on at Turn the brake release
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
you refer to the specific way and pump the hand direction and have an turn the platform in the
chart that relates to the pump (item C) fully assistant try to rotate the stowed position, replace
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
displayed on the ECM. Turn each wheel by controls circuit board U3
hand. Each wheel OR replace the ECM U5
Be sure the circuit should turn freely OR consult the Genie
without much effort. wheels Industries Service
breaker and fuse are do not Department.
not tripped or blown. 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.

Chart 11 REV A
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
functions operate light at the platform brown ground wire on replace U5 OR consult
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
0 or
Disconnect the wires infinite
Be sure the batteries from the drive forward ohms Replace the drive
are fully charged and directional valve coil forward directional valve
(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.

REV A
Chart 12
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
functions operate light at the platform brown ground wire on OR consult the Genie
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
0 or
Disconnect the wires infinite
Be sure the batteries from the drive reverse ohms Replace the drive
are fully charged and directional valve coil reverse directional valve
(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.

Chart 13 REV A
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.
Be sure the batteries light
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.

REV A
Chart 14
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.
Be sure the circuit light
breaker and fuse are is on
See Chart 13 OR
remove the obstruction
Be sure the batteries from the pothole guard
are fully charged and OR consult the Genie
properly connected. Industries Service
Department.

Chart 15 REV A
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
Be sure the circuit WH B10 pothole sw wire
at the ECM U5.
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

REV A

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

an ohmmeter connected wire between P2 and
to the negative terminal U3.
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.

REV B
Chart 17
Fault Code 59 - With the key switch Check for continuity in no Repair or replace the
turned to platform the WH C-8 prll coil wire continuity WH C-8 prll coil wire
Parallel/Series controls and both
0V
from the ECM U5 to the from the ECM U5 to the
Emergency Stop buttons drive speed select coil drive speed select coil.
Coil Fault pulled out to the ON (item AJ or BI or CJ).
position and the
machine on incline LED
continuity
activated, check for
Be sure all other voltage on the positive
functions operate terminal at the Drive Replace U5 OR consult
speed select valve coil the Genie Industries
normally. (item AJ or BI or CJ). Service Department.
Be sure the circuit
20V or more
not tripped or blown. Check for continuity in no Repair or replace the
the brown ground wire continuity ground wire circuit from
Be sure the batteries circuit from the drive the drive speed select
are fully charged and speed select valve coil coil to ground.
properly connected. (item AJ or BI or CJ) to
ground.
continuity
18 to 20
Disconnect the wires ohms Consult the Genie
from the drive speed Industries Service
select valve coil (item AJ Department.
or BI or CJ) and check
resistance of the coil.
See Repair Section.
0 or infinite
ohms
Replace the drive speed
select valve coil (item AJ
or BI or CJ).

REV A

June 2004 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

Troubleshooting and repair procedures shall be result in death or serious injury.
completed by a person trained and qualified on Remove all rings, watches and
the repair of this machine. other jewelry.
Immediately tag and remove from service a Hydraulic Schematics
damaged or malfunctioning machine.
Repair any machine damage or malfunction hydraulic oil can penetrate and
before operating the machine. burn skin. Loosen hydraulic
Before Troubleshooting: the oil pressure to dissipate
Read, understand and obey the safety rules
or spray.
and operating instructions in the appropriate
operator's manual on your machine. General Repair Process
Be sure that all necessary tools and test
equipment are available and ready for use.
Malfunction Identify Troubleshoot
discovered symptoms
problem
still exists
Return to Inspect Perform

service problem and test repair
solved

Section 6 • Schematics June 2004
Control Relay Layout -

GS-2032 (ANSI, CSA and Australia models) REV B
a b c d
-LHA-
e f g
h i j k
a electronic control module (ECM) U5

b CR48 power relay to U5 (not used
before serial number 25142)
c hydraulic tank
d motor controller U6
e function manifold
f hydraulic pump
g 24V DC motor
h automotive-style horn H2 (option)
i multifunction alarm H5
j CR5 horn relay
k tilt level sensor S7

Control Relay Layout -

REV B GS-2032 (CE models) and
GS-2632 (all models)
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
d ECM box lid
e module tray rotary latch
f battery quick disconnect QD1
g 275A fuse F6
h automotive-style horn H2 (option)
i multifunction alarm H5
j CR5 horn relay
k tilt level sensor S7

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
A2 Platform ground from joystick A2 Platform ground from joystick
(White wire at platform) (White wire at platform)
A3 Spare A3 Spare
A4 Emergency Stop from platform A4 Emergency Stop from platform
(Red wire at platform) (Red wire at platform)
A5 Level sensor power A5 Level sensor power
A6 Platform up valve coil A6 Platform up valve coil
A7 Drive reverse valve coil A7 Drive reverse valve coil
A8 Motor controller terminal 1 A8 Motor controller terminal 1
A9 Motor controller terminal 3 A9 Motor controller terminal 3
A10 Overload sensor A10 Overload sensor
A11 Key switch to platform A11 Key switch to platform
A12 Platform down at ground controls A12 Platform down from ground controls
B1 Platform data link + B1 Platform data link +

(Blue wire at platform) (Blue wire at platform)
B2 Emergency Stop to platform B2 Emergency Stop to platform
(Black wire at platform) (Black wire at platform)
B3 Ground for electronic control module B3 Ground for electronic control module
B4 Spare B4 Spare
B5 Spare B5 Spare
B6 Platform down valve coil B6 Platform down valve coil
B7 Steer left valve coil B7 Steer left valve coil
B8 Automotive-style horn (option) B8 Automotive-style horn (option)
B9 Multifunction alarm B9 Multifunction alarm
B10 Pothole limit switch B10 Pothole limit switch
B11 Spare B11 Spare
B12 Platform up at ground controls B12 Platform up from ground controls
C1 Platform data link — C1 Platform data link —

(yellow wire at platform) (Yellow wire at platform)
C2 Emergency Stop at ground controls (main power) C2 Emergency Stop at ground controls (main power)
C3 Spare C3 Spare
C4 Spare C4 Spare
C5 Spare C5 Spare
C6 Drive forward valve coil C6 Drive forward valve coil
C7 Steer right valve coil C7 Steer right valve coil
C8 Parallel coil C8 Parallel coil
C9 Brake release valve coil C9 Brake release valve coil
C10 Spare C10 Spare
C11 Level sensor signal C11 Level sensor signal
C12 Down limit switch C12 Down limit switch

REV B ECM PIN-OUT LEGEND
C 1 12
B 1 12
A 1 12
42<?8=>DC;464=3 42<?8=>DC;464=3
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1! 6\QcXY^WRUQS_^ 1! 6\QcXY^WRUQS_^
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2\eUgYbUQd`\QdV_b] 2\eUgYbUQd`\QdV_b]
1# C`QbU 1# C`QbU
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1% <UfU\cU^c_b`_gUb 1% <UfU\cU^c_b`_gUb
1& @\QdV_b]e`fQ\fUS_Y\ 1& @\QdV_b]e`fQ\fUS_Y\
1' 4bYfUbUfUbcUfQ\fUS_Y\ 1' 4bYfUbUfUbcUfQ\fUS_Y\
1( =_d_bS_^db_\\UbdUb]Y^Q\! 1( =_d_bS_^db_\\UbdUb]Y^Q\!
1) =_d_bS_^db_\\UbdUb]Y^Q\# 1) =_d_bS_^db_\\UbdUb]Y^Q\#
1! ?fUb\_QTcU^c_b 1! ?fUb\_QTcU^c_b
1!! ;UicgYdSXd_`\QdV_b] 1!! ;UicgYdSXd_`\QdV_b]
1!" @\QdV_b]T_g^Vb_]Wb_e^TS_^db_\c 1!" @\QdV_b]T_g^Vb_]Wb_e^TS_^db_\c

2! @\QdV_b]TQdQ\Y^[ 2! @\QdV_b]TQdQ\Y^[

2\QS[gYbUQd`\QdV_b] 2\QS[gYbUQd`\QdV_b]
2" C`QbU 2" C`QbU
2# 7b_e^TV_bU\USdb_^YSS_^db_\]_Te\U 2# 7b_e^TV_bU\USdb_^YSS_^db_\]_Te\U
2$ C`QbU 2$ C`QbU
2% C`QbU 2% C`QbU
2& @\QdV_b]T_g^fQ\fUS_Y\ 2& @\QdV_b]T_g^fQ\fUS_Y\
2' CdUUb\UVdfQ\fUS_Y\ 2' CdUUb\UVdfQ\fUS_Y\
2( 1ed_]_dYfUcdi\UX_b^_`dY_^ 2( 1ed_]_dYfUcdi\UX_b^_`dY_^
2) =e\dYVe^SdY_^Q\Qb] 2) =e\dYVe^SdY_^Q\Qb]
2! @_dX_\U\Y]YdcgYdSX 2! @_dX_\U\Y]YdcgYdSX
2!! C`QbU 2!! C`QbU
2!" @\QdV_b]e`Vb_]Wb_e^TS_^db_\c 2!" @\QdV_b]e`Vb_]Wb_e^TS_^db_\c

3! @\QdV_b]TQdQ\Y^[° 3! @\QdV_b]TQdQ\Y^[°

IU\\_ggYbUQd`\QdV_b] IU\\_ggYbUQd`\QdV_b]
3" 5]UbWU^SiCd_`QdWb_e^TS_^db_\c]QY^`_gUb 3" 5]UbWU^SiCd_`QdWb_e^TS_^db_\c]QY^`_gUb
3# C`QbU 3# C`QbU
3$ C`QbU 3$ C`QbU
3% C`QbU 3% C`QbU
3& 4bYfUV_bgQbTfQ\fUS_Y\ 3& 4bYfUV_bgQbTfQ\fUS_Y\
3' CdUUbbYWXdfQ\fUS_Y\ 3' CdUUbbYWXdfQ\fUS_Y\
3( @QbQ\\U\S_Y\ 3( @QbQ\\U\S_Y\
3) 2bQ[UbU\UQcUfQ\fUS_Y\ 3) 2bQ[UbU\UQcUfQ\fUS_Y\
3! C`QbU 3! C`QbU
3!! <UfU\cU^c_bcYW^Q\ 3!! <UfU\cU^c_bcYW^Q\
3!" 4_g^\Y]YdcgYdSX 3!" 4_g^\Y]YdcgYdSX

Platform Controls Wiring Diagram

(models with potentiometer-equipped joystick) REV B
SW25
DIP SWITCH
OE
ON
1
P2
2
3
ALCO
4
EMERGENCY STOP
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
RD
BK
YL
BL
OR
RD
BK
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
JC1 Joystick controller OR Orange
PP Purple
P2 Emergency Stop button at platform controls RD Red
SW25 DIP switch WH White
U3 Platform controls circuit board YL Yellow

Platform Controls Wiring Diagram

REV A (models with hall-effect joystick)
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
ASSEMBLY
8*3&$0-03
-&(&/%
$PMPS %FTDSJQUJPO
%/ %OXH
%. %ODFN
011A4E80C8>=;464=3 %1 %URZQ
8cT\ 3TbRaX_cX^] *1 *UHHQ
*< *UD\
8! 1\Qb]
25 2UDQJH
:3! :_icdYS[S_^db_\\Ub
33 3XUSOH
@" 5]UbWU^SiCd_`Redd_^Qd`\QdV_b]S_^db_\c
5' 5HG
CG"% 49@cgYdSX
:+ :KLWH
E# @\QdV_b]S_^db_\cSYbSeYdR_QbT </ <HOORZ

Ground Controls Wiring Diagram

REV B
A11 A11 KEY SWITCH
KS1 B 51F G6
TS66 P1
3 1 CB2 +
(UP)
25F
B1
29F
(DOWN) 53F NC 51F 41F
4 2 -
B12 A12 24F
52F
76F
50F 49F
KS1
(PLATFORM)
N.O. N.O.
A11 A11 KEY SWITCH
G6
48F TS66 P1
KS1 CB2 +
(UP)
(GROUND) 25F
N.O. N.O. 29F
52F
(DOWN) 53F NC 51F 41F
-
45F B12 A12 24F
76F

50F 49F
KS1
(PLATFORM)
NO NO
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

50F 49F
KS1
(PLATFORM)
NO NO
A11 A11 KEY SWITCH
G6
+
TS66 P1 25F
KS1 CB2
(GROUND) (UP) 29F
41F
NO NO -
52F (DOWN) 53F NC 51F
24F
45F B12 A12
42F
76F
23F
(before serial number 21065)

Level Sensor Box Wiring Diagram

REV B
LS6
S7 B9 44D
- H5
N.O.
N.C. B11
+
39C
RD BK WH
A5 C11
70D
29F 27D
44D
75D
23D
C12
LS6
S7 B9 44D
- H5
N.O.
N.C. B11
+
39C
RD BK WH
A5 70D C11
75D 29F 27D
44D
23F
C12
(before serial number 21065)
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 B
N.O.
U6 KS1
A2 3 KEY SWITCH
T
B+ 1
A8-MOTOR CONTR. ENABLE
B
Pressure switch M- B-
PLATFORM
normally open CONTROL
T
Motor controller
B
N.C. N.C.H.O. GROUND

CONTROL
M5 Key switch
Limit switch
Wire with Motor
description
U9
LED
S7
LEVEL
SENSOR
Circuits crossing
no connection Level sensor
Switch Battery charger
-
Diode
+
6V battery
Toggle switch Solenoid valve
Horn or alarm
Connection
no terminal
Emergency Stop button
Normally closed
Inductor,
noise suppression Solenoid valve
Connector CB2
with diode
Circuit breaker
3 1
5K JC1 JOYSTICK CONTROLLER
30 86
OR
POTENTIOMETER
WH/YL
2 SW6
87A 87 85 STEER LEFT/ RIGHT
Hour meter BR
RIGHT
Relay
LEFT
G6 PP
SW5
FUNCTION
ENABLE
WH/BK
FB
Flashing beacons Joystick controller

Fuse
FB1

Electrical Schematic REV B

A B C D E F G H I J K L M N
WH A A
1 WH C C
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.
CIRCUIT STOP
BREAKER PLATFORM
H5 -
CONTROL
2 LS6 PS2 LS7
T DOWN MULTI- PLATFORM POTHOLE
LIMIT SWITCH FUNCTION OVERLOAD GUARD 21B
ALARM PRESSURE SWITCH
B SWITCH
(OPTION)
N.C.H.O.
GROUND
CONTROL
TS66 LS8
PLATFORM UP/DOWN POTHOLE
SWITCH GUARD
3 SWITCH
RD
WH
UP LIMIT
ESTOP TO JOYSTICK
ESTOP FROM JOYSTICK
DATA LINK +
DATA LINK -
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
4
U27
47 mH S7
INDUCTOR, LEVEL
NOISE SENSOR
QD1 (+) SUPPRESSION
30 86
BR
87 85
5 F6 M5 CR5
275A FUSE D1 MOTOR HORN RELAY
(H2 OPTION) B8 A8 A9 A12 B12 C2 C12 B11 B9 A10 B10 A11 B2 A4 A2 B1 C1 C11 A5
M5 OUT OUT OUT IN IN IN IN IN OUT IN IN IN OUT IN IN IN IN IN OUT
A1
U5
ELECTRONIC CONTROL MODULE
6
OUT OUT OUT OUT OUT OUT OUT OUT OUT
B3 C8 C9 C7 B7 A7 C6 B6 A6
B5 AC INPUT
T2 B+
4-6V M-
BATTERY A2 3 FB
-
GND
C8-PRLL COIL
C9-BRK COIL
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 Y1 Y2 Y3 Y4 Y5 Y6 Y7 Y8
U13 HOUR FLASHING AUTOMOTIVE-STYLE PARALLEL BRAKE STEER STEER DRIVE DRIVE PLATFORM PLATFORM
DC/AC INVERTER METER BEACONS HORN RELEASE RIGHT LEFT REVERSE FORWARD DOWN UP
+
(OPTION) (OPTION) (OPTION)

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

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

JC1 JOYSTICK CONTROLLER
E E DATA LINK (LOW) PIO5
1 OR WH/YL
QD3 OR
2
3
R15
YL
4 BR
5000 OHM SW6STEER
SW25 5
POTENTIOMETER
DIP SWITCHES 2
RIGHT
6
LEFT
7 PP
SW5
8 FUNCTION
ENABLE
24V DC 5V DC WH/BK
PIO2
D7 BK
PIO3 VOLTAGE
REGULATOR
POUT1 POWER LED L19

3
POUT2 FAULT LED L25
POUT3 HIGH TORQUE LED L21
POUT4 BATTERY LEVEL 1
POUT6 BATTERY LEVEL 3 G7
POUT8 BATTERY LEVEL 5 4
POUT9 DRIVE LED L17
POUT10 LIFT LED L16
U3
PLATFORM CONTROLS PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
MEMBRANE DECAL PANEL
ABBREVIATION LEGEND ABBREVIATION LEGEND
Item Description Item Description PIN1 HIGH TORQUE BN6
B Battery N.C. Normally closed
PIN2 HORN BN5
B5 = Main power N.C.H.O. Normally closed held open 5
B7 = Auxiliary down (GS-3246 only) N.O. Normally open PIN3 DRIVE ENABLE BN8
BN Button P Power switch
PIN4 LIFT ENABLE BN9
BN5 = Horn P1 = Emergency Stop button at ground controls
BN6 = High torque P2 = Emergency Stop button at platform controls
BN9 = Lift enable PS2 Platform overload pressure switch (option) WH/BL
BN23 = Auxiliary down (GS-3246 only) QD Quick disconnect PIN9
CB2 Circuit breaker, 7A QD1 = Battery quick disconnect WH/RD
CR Control relay PIN8
QD3 = Control cable to ground WH
CR5 = Horn (with H2 option) QD4 = Control cable to platform PIN10
CR48 = Power to U5 R Resistor 6
D7 Voltage regulator R15 = 5000 ohm potentiometer RD
F Fuse R21 = 75 ohm resistor POUT11 +
F6 = 275A
F8 = 50A (with U13 option)
S7 Tilt level sensor H1 ALARM
SW Switch BK
FB Flashing beacons (option) SW5 = Function enable
PIN11 -
G Gauge SW6 = Steer left/right
G6 = Hour meter SW25 = DIP switch
G7 = Battery charge indicator TS66 Platform up/down toggle switch
PLATFORM CONTROLLER
GND Ground U Electronic component
H Horn or alarm U3 = Encoder printed circuit board
7
H1 = Horn U5 = Electronic control module
H2 = Automotive-style horn (option) U6 = Motor controller
H5 = Multifunction alarm U9 = Battery charger
JC1 Joystick controller U13 = Voltage inverter (option)
KS1 Key switch U27 = 0.034 ohm inductor, noise suppression
L LED or light Y Valve coil
L16 = Lift Y1 = Parallel
L17 = Drive Y1A = High speed bypass (option)
L19 = Power Y2 = Brake release WIRE COLOR LEGEND 8
L21 = High Torque Y3 = Steer right
Y4 = Steer left
Color Description Color Description
L25 = Fault BL Blue RD Red
LS Limit switch Y5 = Drive reverse
Y6 = Drive forward BK Black WH White
LS2 = Platform up (GS-3246 only) BN Brown YL Yellow
LS6 = Platform down Y7 = Platform down
Y8 = Platform up GN Green WH/BL White/Blue
LS7 = Pothole
LS8 = Pothole Y9 = Platform down (GS-3246 only) GY Gray WH/BK White/Black
Y10 = Auxiliary down (GS-3246 only) OR Orange WH/RD White/Red
M5 Hydraulic power unit
Y11 = Auxiliary down (GS-3246 only) PP Purple WH/YL White/Yellow

Electrical Schematic

WH A A
1 WH C C
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.
CIRCUIT STOP
BREAKER PLATFORM
H5 -
CONTROL
2 LS6 PS2 LS7

T DOWN MULTI- PLATFORM POTHOLE
LIMIT SWITCH FUNCTION OVERLOAD GUARD 21B
ALARM PRESSURE SWITCH
B SWITCH
(OPTION)
N.C.H.O.
GROUND
CONTROL
TS66 LS8
UP/DOWN POTHOLE
SWITCH GUARD
3 SWITCH
RD
WH
UP LIMIT
ESTOP TO JOYSTICK
ESTOP FROM JOYSTICK
DATA LINK +
DATA LINK -
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
4
U27
47 mH S7
INDUCTOR, LEVEL
NOISE SENSOR
QD1 (+) SUPPRESSION
30 86
BR
87 85
5 F6 M5 CR5
(H2 OPTION) B8 A8 A9 A12 B12 C2 C12 B9 A10 B11 B10 A11 B2 A4 A2 B1 C1 C11 A5
M5 OUT OUT OUT IN IN IN IN OUT IN IN IN IN OUT IN IN IN IN IN OUT
A1
A1 OUT U5
6 OUT OUT OUT OUT OUT OUT OUT OUT OUT

B3 C8 C9 C7 B7 A7 C6 B6 A6
B5 AC INPUT
T2 B+
4-6V M-
BATTERY A2 3 FB
-
GND
C8-PRLL COIL
C9-BRK COIL
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 3 1
7 CONTROLLER FB
+
- G6 2 FB H2 Y1 Y2 Y3 Y4 Y5 Y6 Y7 Y8
+

- (OPTION)
+
QD1 (-)
GND
8



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

1 OR WH/YL
QD3 OR
2
3
R15
YL
4 BR
5000 OHM SW6STEER
SW25 5
POTENTIOMETER
DIP SWITCHES 2
RIGHT
6
LEFT
7 PP
SW5
8 FUNCTION
ENABLE
24V DC 5V DC WH/BK
PIO2
D7 BK
PIO3 VOLTAGE
REGULATOR
POUT1 POWER LED L19

3
POUT2 FAULT LED L25
POUT9 DRIVE LED L17
POUT10 LIFT LED L16
U3
MEMBRANE DECAL PANEL
PIN2 HORN BN5
PIN4 LIFT ENABLE BN9
BN9 = Lift enable PS2 Platform overload pressure switch (option) WH/BL
BN23 = Auxiliary down (GS-3246 only) QD Quick disconnect PIN9
PIN8
CR Control relay QD3 = Control cable to ground WH
CR5 = Horn (with H2 option) QD4 = Control cable to platform PIN10
D7 Voltage regulator R15 = 5000 ohm potentiometer RD
F6 = 275A S7 Tilt level sensor H1 ALARM
F8 = 50A (with U13 option) SW Switch BK
FB Flashing beacons (option) SW5 = Function enable
PIN11 -
PLATFORM CONTROLLER
7
Y4 = Steer left
LS7 = Pothole


76F 78F
WH A A
77F
1 KS1 30 86
WH C C
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
BREAKER PLATFORM
CONTROL 39C
2 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
UP/DOWN (OPTION)
SWITCH N.C.H.O.
3
LS8
POTHOLE
RD
WH
GUARD
SWITCH
UP LIMIT
EMERG STOP
ESTOP FROM JOYSTICK
DATA LINK +
DATA LINK -
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

A11-KEY SWITCH
4
U27
47 mH S7
INDUCTOR, LEVEL
NOISE SENSOR
QD1 (+) SUPPRESSION
30 86
BR
87 85
5 F6 M5 CR5
(H2 OPTION) B8 A8 A9 A12 B12 A11 C12 B9 A10 B10 B11 C2 A4 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
U5
A1 OUT ELECTRONIC CONTROL MODULE

B3 C8 C9 C7 B7 A7 C6 B6 A6
B5 AC INPUT
T2 B+
4-6V M-
BATTERY A2 3 FB
-
GND
C8-PRLL COIL
C9-BRK COIL
C7-RT COIL
B7-LEFT COIL
A7-REV COIL
C6-FWD COIL
B6-DWN COIL
A6-UP COIL
B- 1
+
- F8
CONTROLLER FB
7
+
- G6 2 FB H2 Y1 Y2 Y3 Y4 Y5 Y6 Y7 Y8
+

- (OPTION)
+
QD1 (-)
GND
8



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

1 OR WH/YL
QD3 OR
2
3
R15
YL
4 BR
5000 OHM SW6STEER
SW25 5
POTENTIOMETER
DIP SWITCHES 2
RIGHT
6
LEFT
7 PP
SW5
8 FUNCTION
ENABLE
24V DC 5V DC WH/BK
PIO2
D7 BK
PIO3 VOLTAGE
REGULATOR
3
POUT1 POWER LED L19
POUT2 FAULT LED L25
POUT9 DRIVE LED L17
POUT10 LIFT LED L16
U3
ABBREVIATION LEGEND ABBREVIATION LEGEND MEMBRANE DECAL PANEL
PIN2 HORN BN5
BN5 = Horn P1 = Emergency Stop button at ground controls PIN4 LIFT ENABLE BN9
BN9 = Lift enable PS2 Platform overload pressure switch (option)
BN23 = Auxiliary down (GS-3246 only) WH/BL
QD Quick disconnect PIN9
CR Control relay QD3 = Control cable to ground PIN8
CR5 = Horn (with H2 option) QD4 = Control cable to platform WH
PIN10
D7 Voltage regulator R15 = 5000 ohm potentiometer
RD
F6 = 275A
F8 = 50A (with U13 option)
S7
SW
Tilt level sensor
Switch
H1 ALARM
BK
FB Flashing beacons (option) SW5 = Function enable PIN11 -
H Horn or alarm
H1 = Horn
U3 = Encoder printed circuit board
U5 = Electronic control module PLATFORM CONTROLLER 7
Y4 = Steer left
LS7 = Pothole


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

A11-KEY SWITCH
4
U27
47 mH S7
INDUCTOR, LEVEL
NOISE SENSOR
QD1 (+) SUPPRESSION
30 86
BR
87 85
5 F6 M5 CR5
(H2 OPTION) B8 A8 A9 A12 B12 A11 C12 B9 A10 B10 B11 C2 A4 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
U5
A1 OUT ELECTRONIC CONTROL MODULE

B3 C8 C9 C7 B7 A7 C6 B6 A6
B5 AC INPUT
T2 B+
4-6V M-
BATTERY A2 3 FB
-
GND
C8-PRLL COIL
C9-BRK COIL
C7-RT COIL
B7-LEFT COIL
A7-REV COIL
C6-FWD COIL
B6-DWN COIL
A6-UP COIL
B- 1
+
- F8
7 CONTROLLER FB
+
- G6 2 FB H2 Y1 Y2 Y3 Y4 Y5 Y6 Y7 Y8
+

- (OPTION)
+
QD1 (-)
GND
8



BK P2
EMERGENCY STOP
RD 1
B B WH GROUND

1 OR WH/YL
QD3 OR
2
3
R15
YL
4 BR
5000 OHM SW6STEER
SW25 5
POTENTIOMETER
DIP SWITCHES 2
RIGHT
6
LEFT
7 PP
SW5
8 FUNCTION
ENABLE
24V DC 5V DC WH/BK
PIO2
D7 BK
PIO3 VOLTAGE
REGULATOR
3
POUT1 POWER LED L19
POUT2 FAULT LED L25
POUT9 DRIVE LED L17
POUT10 LIFT LED L16
U3
B5 = Main power N.C.H.O. Normally closed held open PIN2 HORN BN5 5
BN23 = Auxiliary down (GS-3246 only) QD Quick disconnect WH/BL
PIN9
PIN10
RD
F6 = 275A S7 Tilt level sensor
F8 = 50A (with U13 option) SW Switch H1 ALARM
BK
PLATFORM CONTROLLER
7
Y4 = Steer left
LS7 = Pothole


QD4
1 76F 78F
WH RD C C
77F
KS1 30 86
WH A A
POWER BK D D
T RELAY 87A 87 85
TO U5 OR E E
CB2 P1 B
7A EMERGENCY
CIRCUIT STOP 23D
2 BREAKER PLATFORM
CONTROL 39C
N.C. N.O. N.C.H.O.

T
B LS6 H5 PS2 LS7

DOWN MULTI- PLATFORM POTHOLE
GROUND LIMIT FUNCTION OVERLOAD GUARD 21B
CONTROL SWITCH ALARM PRESSURE SWITCH
TS66 SWITCH
(OPTION)
3 UP/DOWN
RD
WH
N.C.H.O.
SWITCH
LS8 N.O.
POTHOLE
GUARD
SWITCH
30 86
CR5 LEVEL
ESTOP FROM JOYSTICK
DATA LINK +
DATA LINK -
B12-UP/DWN SW UP
B10-POTHOLE SW
B8-OPT SERVICE HORN
B9-MULTIFUNCT ALM
B11-UP LIMIT
C12-DWN LIMIT
C2-EMERG STOP
GND FROM JOYSTICK

A11-KEY SWITCH
A9-CURTISTERM 3
A12-UP/DWN SW DWN
SENSOR
C11-LVL SNSR-WHT
A5-LVL SNSR-RED
HORN RELAY CIRCUIT
U27 87 85 (H2 OPTION) BOARD
0.034 OHM
4 INDUCTOR,
NOISE
R21 S7
SUPPRESSION LEVEL
(CE MODELS ONLY 75 OHM
SENSOR
AFTER SERIAL
NUMBER 47940)
BN
QD1 (+) B8 A8 A9 A12 B12 A11 C12 B9 A10 B10 A4 B11 C2 A2 B1 C1 C11 A5
OUT OUT OUT IN IN IN IN OUT IN IN IN IN IN IN IN IN IN OUT
5
F6 M5
275A FUSE D1 MOTOR U5
M5 A1 OUT

U9 A1 B3 C8 C9 C7 B7 A7 C6 A6 B6
BATTERY
CHARGER
6 (HARD-WIRED
AFTER SERIAL
GND
C8-PRLL COIL
C9-BRK COIL
C7-RT COIL
B7-LEFT COIL
A7-REV COIL
C6-FWD COIL
B6-DWN COIL
NUMBER 46645)
A6-UP COIL
B5 AC INPUT
T2 B+
4-6V M-
BATTERY A2 3 FB
-
B- 1
+
7 - F8
50A FUSE U6 MOTOR
FB
CONTROLLER
Y1A
+
HIGH SPEED
- G6 FB H2 Y1 BYPASS Y2 Y3 Y4 Y5 Y6 Y8 Y7
U13 HOUR FLASHING AUTOMOTIVE-STYLE PARALLEL (OPTION) BRAKE STEER STEER DRIVE DRIVE PLATFORM PLATFORM
DC/AC INVERTER METER BEACONS HORN RELEASE RIGHT LEFT REVERSE FORWARD UP DOWN
+

-
+
8 QD1 (-)
GND GND



BK P2
EMERGENCY STOP
RD 1
B B WH GROUND

1 OR WH/YL
QD3 OR
2
3
R15
YL
4 BR
5000 OHM SW6STEER
SW25 5
POTENTIOMETER
DIP SWITCHES 2
RIGHT
6
LEFT
7 PP
SW5
8 FUNCTION
ENABLE
24V DC 5V DC WH/BK
PIO2
D7 BK
PIO3 VOLTAGE
REGULATOR
3
POUT1 POWER LED L19
POUT2 FAULT LED L25
POUT9 DRIVE LED L17
POUT10 LIFT LED L16
U3
PIN1 HIGH TORQUE BN6
B5 = Main power N.C.H.O. Normally closed held open PIN2 HORN BN5 5
B7 = Auxiliary down (GS-3246 only) N.O. Normally open
PIN3 DRIVE ENABLE BN8
BN23 = Auxiliary down (GS-3246 only) QD Quick disconnect WH/BL
PIN9
PIN10
F Fuse RD
R21 = 75 ohm resistor POUT11 +
F6 = 275A S7 Tilt level sensor
F8 = 50A (with U13 option) SW Switch H1 ALARM
BK
7
H Horn or alarm
H1 = Horn
H2 = Automotive-style horn (option)
U5 = Electronic control module
U6 = Motor controller
PLATFORM CONTROLLER
Y4 = Steer left
LS7 = Pothole

Electrical Schematic REV A

QD4
1 B 1 76F 78F
WH RD C C
77F
WH A A
2 30 86
CR48 BL B B
CB2 P1 POWER
7A EMERGENCY
PLATFORM
CONTROL KS1 RELAY 87A 87 85
BK D D
CIRCUIT STOP KEY SWITCH TO U5 OR E E

BREAKER B1 4
23D
2 3
39C
GROUND N.C. N.O. N.C.H.O.

CONTROL
LS6 H5 PS2 LS7

LIMIT FUNCTION OVERLOAD GUARD 21B
SWITCH ALARM PRESSURE SWITCH
TS66 SWITCH
(OPTION)
3 UP/DOWN
RD
WH
N.C.H.O.
SWITCH
LS8 N.O.
POTHOLE
GUARD
SWITCH
30 86
CR5 LEVEL
ESTOP FROM JOYSTICK
DATA LINK +
DATA LINK -
B12-UP/DWN SW UP
B10-POTHOLE SW
B8-OPT SERVICE HORN
B9-MULTIFUNCT ALM
B11-UP LIMIT
C12-DWN LIMIT
C2-EMERG STOP
GND FROM JOYSTICK

A9-CURTISTERM 3
A12-UP/DWN SW DWN
SENSOR
C11-LVL SNSR-WHT
A5-LVL SNSR-RED
A11-KEY SWITCH
HORN RELAY CIRCUIT
0.034 OHM
4 INDUCTOR,
NOISE
R21 S7
SUPPRESSION LEVEL
(CE MODELS ONLY) 75 OHM
SENSOR
BN
QD1 (+) B8 A8 A9 A12 B12 A11 C12 B9 A10 B10 B11 C2 A4 A2 B1 C1 C11 A5
5
F6 M5
M5 A1 OUT

U9 A1 B3 C8 C9 C7 B7 A7 C6 A6 B6
BATTERY
CHARGER
6
GND
C8-PRLL COIL
C9-BRK COIL
C7-RT COIL
B7-LEFT COIL
A7-REV COIL
C6-FWD COIL
B6-DWN COIL
A6-UP COIL
B5 AC INPUT
T2 B+
4-6V M-
BATTERY A2 3 FB
-
B- 1
+
7 - F8
50A FUSE U6 MOTOR
FB
CONTROLLER
Y1A
+
HIGH SPEED
- G6 FB H2 Y1 BYPASS Y2 Y3 Y4 Y5 Y6 Y8 Y7
U13 HOUR FLASHING AUTOMOTIVE-STYLE PARALLEL (OPTION) BRAKE STEER STEER DRIVE DRIVE PLATFORM PLATFORM
+

-
+
8 QD1 (-)
GND GND

REV A Electrical Schematic


BK P2
EMERGENCY STOP
RD 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 OR DATA LINK - YL
PIO5 D7
GENERATOR CONTROLLER
VOLTAGE
QD3 REGULATOR
GY
SW6
STEER LEFT/ RIGHT
1 GN 2
2
RIGHT
LEFT
3
4 WH
SW5
FUNCTION
5 ENABLE
6
7 BL
SW25 8
PP
DIP SWITCHES
BK
3
POUT1 POWER LED L19

POUT2 FAULT LED L25
POUT9 DRIVE LED L17
ABBREVIATION LEGEND ABBREVIATION LEGEND POUT10 LIFT LED L16
B Battery N.C. Normally closed U3 PLATFORM CONTROLS
PLATFORM CONTROLS
B5 = Main power N.C.H.O. Normally closed held open
PRINTED CIRCUIT BOARD MEMBRANE DECAL PANEL 5
BN Button P Power switch PIN1 HIGH TORQUE BN6
BN6 = High torque P2 = Emergency Stop button at platform controls PIN2 HORN BN5
BN9 = Lift enable PS2 Platform overload pressure switch (option) PIN3 DRIVE ENABLE BN8
BN23 = Auxiliary down (GS-3246 only) QD Quick disconnect
CB2 Circuit breaker, 7A PIN4 LIFT ENABLE BN9
QD1 = Battery quick disconnect
CR Control relay QD3 = Control cable to ground
CR5 = Horn (with H2 option) QD4 = Control cable to platform
OR
CR48 = Power to U5 R Resistor PIN9 6
D7 Voltage regulator R15 = 5000 ohm potentiometer BK
F Fuse PIN8
R21 = 75 ohm resistor
RD
F6 = 275A S7 Tilt level sensor PIN10
F8 = 50A (with U13 option) SW Switch
RD
FB Flashing beacons (option) SW5 = Function enable POUT11 +
H1 ALARM
PLATFORM
G6 = Hour meter SW25 = DIP switch BK
G7 = Battery charge indicator TS66 Platform up/down toggle switch PIN11 -
7
CONTROLLER
Y4 = Steer left
LS7 = Pothole

Electrical Schematic REV A

B 1 76F 78F
WH WH RD 4
1 77F
WH WH 3
2 30 86
CR48 WH BL 1
CB2 P1 POWER
7A EMERGENCY
PLATFORM
CONTROL KS1 RELAY 87A 87 85
WH BK 2
CIRCUIT STOP KEY SWITCH TO U5 WH OR 5

BREAKER B1 4
23D
3
39C
2 N.O.
GROUND N.C. N.C.H.O.
CONTROL
LS6 H5 PS2 LS7

LIMIT FUNCTION OVERLOAD GUARD 21B
SWITCH ALARM PRESSURE SWITCH
TS66 SWITCH
(OPTION)
UP/DOWN
RD
WH
N.C.H.O.
SWITCH
3
LS8 N.O.
POTHOLE
GUARD
SWITCH
30 86
CR5 LEVEL
ESTOP FROM JOYSTICK
DATA LINK +
DATA LINK -
B12-UP/DWN SW UP
B10-POTHOLE SW
B8-OPT SERVICE HORN
B9-MULTIFUNCT ALM
B11-UP LIMIT
C12-DWN LIMIT
C2-EMERG STOP
GND FROM JOYSTICK

A9-CURTISTERM 3
A12-UP/DWN SW DWN
SENSOR
C11-LVL SNSR-WHT
A5-LVL SNSR-RED
A11-KEY SWITCH
HORN RELAY CIRCUIT
0.034 OHM
INDUCTOR,
4 NOISE
R21 S7
SUPPRESSION LEVEL
(CE MODELS ONLY) 75 OHM
SENSOR
BN
QD1 (+) B8 A8 A9 A12 B12 A11 C12 B9 A10 B10 B11 C2 A4 A2 B1 C1 C11 A5
5 F6 M5
M5 A1 OUT

U9 A1 B3 C8 C9 C7 B7 A7 C6 A6 B6
BATTERY
CHARGER
GND
C8-PRLL COIL
C9-BRK COIL
C7-RT COIL
B7-LEFT COIL
A7-REV COIL
C6-FWD COIL
B6-DWN COIL
A6-UP COIL
B5 AC INPUT
T2 B+
4-6V M-
BATTERY A2 3 FB
-
B- 1
+
- F8
50A FUSE U6 MOTOR
7 CONTROLLER FB
+
- G6 FB H2 Y1 Y2 Y3 Y4 Y5 Y6 Y8 Y7
+

-
+
QD1 (-)
GND GND
8

REV A Electrical Schematic

4 4 BK POWER TO PLATFORM CONTROLS

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

BL
PIO4
JC1
24V DC 5V DC HALL JOYSTICK
OR BN GENERATOR
5 5 OR DATA LINK (LOW) PIO5 D7 CONTROLLER
VOLTAGE
QD3 REGULATOR
GY
SW6
STEER LEFT/ RIGHT
1 GN 2
2
RIGHT
LEFT
3
4 WH
SW5
FUNCTION
5 ENABLE
6
7 BL
SW25 8
PP
DIP SWITCHES
BK
3
POUT1 POWER LED L19

POUT2 FAULT LED L25
POUT9 DRIVE LED L17
ABBREVIATION LEGEND ABBREVIATION LEGEND POUT10 LIFT LED L16
B Battery N.C. Normally closed U3 PLATFORM CONTROLS
PLATFORM CONTROLS
B5 = Main power N.C.H.O. Normally closed held open PRINTED CIRCUIT BOARD MEMBRANE DECAL PANEL 5
BN Button P Power switch PIN1 HIGH TORQUE BN6
PIN2 HORN BN5
BN9 = Lift enable PS2 Platform overload pressure switch (option) PIN3 DRIVE ENABLE BN8
BN23 = Auxiliary down (GS-3246 only) QD Quick disconnect
CB2 Circuit breaker, 7A PIN4 LIFT ENABLE BN9
QD1 = Battery quick disconnect
CR Control relay QD3 = Control cable to ground
CR5 = Horn (with H2 option) QD4 = Control cable to platform OR
CR48 = Power to U5 R Resistor PIN9 6
D7 Voltage regulator R15 = 5000 ohm potentiometer BK
PIN8
F Fuse R21 = 75 ohm resistor RD
F6 = 275A S7 Tilt level sensor PIN10
F8 = 50A (with U13 option) SW Switch
FB Flashing beacons (option) SW5 = Function enable RD
G Gauge SW6 = Steer left/right POUT11 +
H1 ALARM
PLATFORM
G7 = Battery charge indicator TS66 Platform up/down toggle switch BK
GND Ground U Electronic component PIN11 -
7
H Horn or alarm
H1 = Horn
H2 = Automotive-style horn (option)
U5 = Electronic control module
U6 = Motor controller
CONTROLLER
Y4 = Steer left
LS7 = Pothole

Hydraulic Symbols Legend and

Component Reference
Hydraulic Symbols Legend and REV B
Component Reference
AC BB
AB AD BA
AA AE
BC
Filter Relief valve

AF BD Check valve,
BE pilot to open
Y4
Check valve (AL) was Y3

replaced by relief valve (AL) AG BF
at serial number 17482
Priority
Y8
AH BG flow regulator Shuttle valve
E D
AL BM Fixed displacement
Y4 Y7
Y2
AI Y3
BH
pump
Y1
Y1 BI
AL AJ
Brake
Y6 Y6 Platform overload
Y5
AK Y8
Y2
Y5 Bi-directional motor pressure switch
BJ
BL BK
Function manifold components Function manifold components
(from serial number 17408 to 36100) (from serial number 36101 to 49245)
M 1.03 CU. IN.
(16.9 cc)
Hand pump
Lift cylinder components
(before serial number 23568) Variable speed motor Accumulator
CB
BB
BA CA
CC
BC
Check valve Dual acting cylinder
CD Single acting cylinder
CE
BD
BE
CF 0.040 in Y7
1 mm
BF CG Orifice with size
BM CO Solenoid operated
Y4
Y3
2 position 2 way valve, Solenoid operated
BG CH normally closed with 3 position 4 way
D manual over-ride directional valve
Y2 Y7
CI
BH CM E
Y1
Y8
CJ
BI Y6
Y8 Y5
Y1A
CK
BJ
BL BK CN CL
Y2
Function manifold components Function manifold components Solenoid operated
Solenoid operated
(from serial number 49246 to 59999) Models with Traction Control 2 position 4 way
Lift cylinder components 2 position 2 way
directional valve
(after serial number 23567) directional valve

REV B Hydraulic Schematic

LEFT RIGHT
RIGHT
1
BRAKE BRAKE LEFT
LIFT
DRIVE MOTOR DRIVE MOTOR
PLATFORM CYLINDER
STEER STEER OVERLOAD
LEFT RIGHT (OPTION) BRAKE
J L
N.O. F HAND 2
COM Y7 PUMP
N.C. D
1.03 CU. IN.
16.9 cc K
0.046 in BRAKE
E MANUAL
RELEASE
R 1.17 mm
RELEASE
M MANIFOLD
B1 HP 3
S1 S2 LIFT BRAKE HP M1 M4
Y4 Y3
AA 30 psi 4
2 bar AJ
AG
Y1
AI
AD AE
Y2
TP
0.040 in 1500 psi
AB 1 mm 103.4 bar 5
Y6 Y5
SEE NOTE
AC AK
0.75 gpm
2.8 L/min
AL 200 psi
13.8 bar
AH 6
Y8
AF
3500 psi
241.3 bar
7
PRESSURE TANK
ABBREVIATION LEGEND
Item Description
M
POWER AA Check valve, steer circuit
ABBREVIATION LEGEND AB Test port
UNIT 10 MICRON WITH
25 psi / 1.7 bar Item Description AC Flow regulator, steer circuit
BYPASS D Platform lowering valve AD Orifice washer, steer circuit
E Orifice, platform down circuit AE Relief valve, steer
F Accumulator AF Relief valve, system 8
100 MESH AG Steer left/right
J Shuttle valve, brake release
AH Platform up
K Check valve, manual brake release circuit AI Brake circuit
IMPORTANT NOTES L Hand pump, manual brake release circuit AJ Drive speed select
M Platform lowering valve AK Drive forward/reverse
Item Description
AL Changed to 130 psi / 9 bar relief valve after serial number 17481 R Platform overload pressure switch AL Check valve OR relief valve, brake circuit

Hydraulic Schematic

LEFT RIGHT 1
LIFT BRAKE BRAKE LEFT RIGHT
PLATFORM CYLINDER DRIVE MOTOR DRIVE MOTOR
STEER STEER
OVERLOAD LEFT RIGHT
(OPTION) BRAKE
J L
N.O. Y7 F HAND 2
COM PUMP
N.C.
D 1.03 CU. IN.
K
16.9 cc
BRAKE
R E 0.046 in
1.17 mm
MANUAL
RELEASE
RELEASE
M MANIFOLD
B1 HP 3
LIFT S1 S2 BRAKE HP M1 M3 M2 M4
Y4 Y3
BM SEE NOTE
BH BI 4
5 psi
0.3 bar
Y1
BL BB
BE BF
TP Y2
1500 psi
0.040 in
BA 0.75 gpm 1 mm
103.4 bar BK 5
2.8 L/min
Y8
BG Y6 Y5
BD BC
3000 to 3200 psi BJ
207 to 221 bar
130 psi 6
3500 psi 9 bar
241.3 bar
PRESSURE TANK

Item Description Item Descripton 7
D Platform lowering valve BA Test port
E Orifice, platform down circuit BB Flow regulator, steer circuit
POWER
M
10 MICRON WITH BC Relief valve, lift
UNIT 25 psi / 1.7 bar F Accumulator
BYPASS BD Relief valve, system
J Shuttle valve, brake release BE Orifice washer, steer circuit
K Check valve, manual brake release circuit BF Relief valve, steer
L Hand pump, manual brake release circuit BG Relief valve, brake circuit
100 MESH M Platform lowering valve BH Steer left/right
BI Drive speed select
8
R Platform overload pressure switch
BJ Drive forward/reverse
BK Brake circuit
IMPORTANT NOTES BL Platform up
Item Description BM Check valve, steer circuit
BM Changed to 10 psi (0,7 bar) after serial number 43739

Hydraulic Schematic
REV A Hydraulic Schematic

PLATFORM LIFT CYLINDER STEER STEER LEFT RIGHT LEFT RIGHT 1

OVERLOAD LEFT RIGHT BRAKE BRAKE DRIVE DRIVE
(CE MODELS) MOTOR MOTOR
The lift cylinder orifice is
located underneath the BRAKE
fitting on the lift cylinder.
D M L
PS2 MANUAL
F RELEASE 2
Y7
R
1.03 CU. IN.
16.9 cc HAND
BRAKE PUMP
E RELEASE
MANIFOLD
0.046” / 1.17 mm
B1
3
LIFT V S1 S2 AC B HP M1 M4
FUNCTION MANIFOLD
Y4 Y3 AD
4
AC AE
Y1
AG
0.040”
1 mm 1500 psi
103 bar AF Y6 Y5 5
AI
0.75 gpm
TP 2.8 L/min AH 130 psi
9 bar
AA
AJ
6
AB Y8
FUNCTION MANIFOLD
1800 to 3500 psi
124 to 241 bar
3500 psi maximum

241 bar maximum
ABBREVIATION LEGEND
Item Descripton 7
BA Test port
PRESSURE TANK ABBREVIATION LEGEND
BB Flow regulator, steer circuit
BC Relief valve, lift
Item Description BD Relief valve, system
M
POWER 10 MICRON WITH
D Platform lowering valve BE Orifice washer, steer circuit
UNIT 25 psi / 1.7 bar E Orifice, platform down circuit BF Relief valve, steer
BYPASS BG Relief valve, brake circuit
F Accumulator
J Shuttle valve, brake release BH Steer left/right
BI Drive speed select 8
K Check valve, manual brake release circuit BJ Drive forward/reverse
L Hand pump, manual brake release circuit BK Brake circuit
M Platform lowering valve BL Platform up
R Platform overload pressure switch BM Check valve, steer circuit

Hydraulic Schematic

Models with Traction Control
LEFT RIGHT 1
LIFT BRAKE BRAKE LEFT RIGHT
PLATFORM CYLINDER DRIVE MOTOR DRIVE MOTOR
STEER STEER
OVERLOAD LEFT RIGHT
(OPTION) BRAKE
J L
N.O. Y7 F HAND 2
COM PUMP
N.C.
D 1.03 CU. IN.
K
16.9 cc
BRAKE
R E 0.046 in
1.17 mm
MANUAL
RELEASE
RELEASE
M MANIFOLD
B1 HP 3
LIFT S1 S2 BRAKE HP M1 M3 M2 M4
Y4 Y3 Y1A
CO CL
CH 4
CJ
10 psi
0.7 bar Y1
CN CB
CE CF
TP Y2
0.040 in
1500 psi
103.4 bar CM 5
CA 0.75 gpm 1 mm CI
2.8 L/min
CC
Y8
CD Y6 Y5
CG
CK
30 psi 6
2 bar
3500 psi 3000 to 3200 psi
241.3 bar 207 to 221 bar
PRESSURE TANK
POWER
Item Description Item Description 7
D Platform lowering valve CA Test port
UNIT
E Orifice, platform down circuit CB Flow regulator, steer circuit
M
10 MICRON WITH CC Relief valve, lift
25 psi / 1.7 bar
F Accumulator
CD Relief valve, system
BYPASS J Shuttle valve, brake release CE Orifice washer, steer circuit
K Check valve, manual brake release circuit CF Relief valve, steer
L Hand pump, manual brake release circuit CG Check valve, brake circuit
100 MESH M Platform lowering valve CH Steer left/right
R Platform overload pressure switch CI Brake circuit 8
CJ Drive speed select
CK Drive forward/reverse
CL High speed bypass
CM Flow divider/combiner
CN Platform up
CO Check valve, steer circuit

Hydraulic Schematic
Models with Traction Control
Part No.
Rev C2
72963
Service Manual GS-2032 & GS-2632
Genie North America
Phone 425.881.1800
Toll Free USA and Canada
Distributed By:
800.536.1800
Fax 425.883.3475
Genie Australia Pty Ltd.

Phone +61 7 3375 1660
Fax +61 7 3375 1002
Genie Scandinavia
Phone +46 31 575100 Genie China
Fax +46 31 579020 Phone +86 21 53852570
Fax +86 21 53852569
Genie France
Phone +33 (0)2 37 26 09 99 Genie Malaysia
Fax +33 (0)2 37 26 09 98 Phone +65 98 480 775
Fax +65 67 533 544
Genie Iberica
Phone +34 93 579 5042 Genie Japan
Fax +34 93 579 5059 Phone +81 3 3453 6082
Fax +81 3 3453 6083
Genie Germany
Phone 0800 180 9017 Genie Korea
Phone +49 422 149 1818 Phone +82 25 587 267
Fax +49 422 149 1820 Fax +82 25 583 910
Genie U.K. Genie Brasil

Phone +44 (0)1476 584333 Phone +55 11 41 665 755
Fax +44 (0)1476 584334 Fax +55 11 41 665 754
Genie Mexico City Genie Holland

Phone +52 55 5666 5242 Phone +31 183 581 102
Fax +52 55 5666 3241 Fax +31 183 581 566

Service Manual: Refer To Inside Cover For Serial Number Information

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Service Manual Part No.

Important Serial Number Information

Basic mechanical, hydraulic and electrical Genie GS-2032 Service Manual,

Contact Us: Copyright © 1997 by Genie Industries

www.genieindustries.com 72963 Rev C June 2004

Printed on recycled paper

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

Do Not Perform Maintenance

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

Personal Safety Be sure to wear protective eye wear and

Be sure to properly dispose of old oil or

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

Section 1 Safety Rules

Section 2 Rev Specifications

Section 3 Rev Scheduled Maintenance Procedures

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

Section 3 Rev Scheduled Maintenance Procedures, continued

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

Section 4 Rev Repair Procedures

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

Section 4 Rev Repair Procedures, continued

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

Section 5 Rev Fault Codes

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

Section 6 Rev Schematics

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

Type 6V DC Platform stowed 2.2 mph

Continuous improvement of our products is a

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

Hydraulic Specifications Function pump

Hydraulic Oil Specifications Type Gear

Fire resistant UCON Hydrolube HP-5046 Continuous improvement of our products is a

Genie specifications require

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

Manifold Component Valve Coil Resistance

Plug torque Solenoid valve, N.C. 23 - 25>

SAE No. 4 13 ft-lbs / 18 Nm Solenoid valve, N.C. 23 - 25>

Solenoid valve, 3 position 4 way 18 to 20Ω

Solenoid valve, 3 position 4 way 25 to 27Ω

Continuous improvement of our products is a

Part No. 72963 Genie GS-2032 and GS-2632 2-3

Hydraulic Hose and Fitting

SAE O-ring Boss Port JIC 37° Fittings

-4 11 ft-lbs / 14.9 Nm -4 7/16-20 2

-6 23 ft-lbs / 31.2 Nm -6 9/16-18 1 1/4

-8 40 ft-lbs / 54.2 Nm -8 3/4-16 1

-10 69 ft-lbs / 93.6 Nm -10 7/8-14 1

-12 93 ft-lbs / 126.1 Nm -12 1 1/16-12 1

-16 139 ft-lbs / 188.5 Nm -16 1 5/16-12 1

-20 172 ft-lbs / 233.2 Nm -20 1 5/8-12 1

-24 208 ft-lbs / 282 Nm -24 1 7/8-12 1

SAE O-ring Boss Port

SAE Dash size Torque

-10 105 ft-lbs / 142.4 Nm

-12 140 ft-lbs / 190 Nm

-16 210 ft-lbs / 284.7 Nm

-20 260 ft-lbs / 352.5 Nm

-24 315 ft-lbs / 427.1 Nm

2-4 Genie GS-2032 and GS-2632 Part No. 72963

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

Part No. 72963 Genie GS-2032 and GS-2632 2-5

This page intentionally left blank.

2-6 Genie GS-2032 and GS-2632 Part No. 72963