September 2009

Introduction

Important
Read, understand and obey the safety rules and This Parts and Service Manual Supplement
operating instructions in the appropriate Operator's provides service parts information and schematics
Manual on your machine before attempting any for the GS-2646 with Powered Extension Deck
maintenance procedure. and Aircraft Protection, which are not included in
your Parts or Service Manuals. Please add this
Basic mechanical, hydraulic and electrical
parts information and calibration procedures to the
skills are required to perform most procedures.
Parts and Service Manuals for your machine.
However, several procedures require specialized
skills, tools, lifting equipment and a suitable
workshop. In these instances, we strongly
recommend that maintenance and repair be
performed at an authorized Genie dealer
service center.

Technical Publications
Genie Industries has endeavored to deliver the
highest degree of accuracy possible. However,
continuous improvement of our products is a Genie
policy. Therefore, product specifications
are subject to change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.

Contact Us: Copyright © 1997 by Genie Industries

www.genieindustries.com 115371 Rev C September 2009

First Edition, Third Printing
e-mail: awp.techpub@terex.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.

1-2 GS-2646 Part No. 115371

September 2009

Table of Contents

Section 1
Important Information ................................................................................... 1 - 2
Table of Contents ........................................................................................ 1 - 3

Section 2 Rev Parts Information

A Decals ......................................................................................................... 2 - 2
Scissor Assembly ........................................................................................ 2 - 4
Lift Cylinder Assembly ................................................................................. 2 - 6
Platform Components .................................................................................. 2 - 8
Platform Limit Switch Assembly ................................................................ 2 - 10
Ground Control Box ................................................................................... 2 - 12
Platform Controls ....................................................................................... 2 - 14
Joystick Controller ..................................................................................... 2 - 16
Battery Pack Module (No Charger Option) ................................................ 2 - 18
Air Line to Platform .................................................................................... 2 - 20
Hydraulic Hoses and Fittings ..................................................................... 2 - 22

Section 3 Rev Specifications

A Machine Specifications ................................................................................ 3 - 1
Performance Specifications ......................................................................... 3 - 2
Hydraulic Specifications ............................................................................... 3 - 3
Manifold Component Specifications ............................................................. 3 - 4
Hydraulic Hose and Fitting Torque Specifications ....................................... 3 - 5
SAE and Metric Fasteners Torque Charts ................................................... 3 - 7

Part No. 115371 GS-2646 1-3

 September 2009

TABLE OF CONTENTS

Section 4 Rev Repair Procedures

Introduction .................................................................................................. 4 - 1
A Platform Controls
1-1 Circuit Boards .................................................................................... 4 - 3
1-2 Controller Adjustments ....................................................................... 4 - 4
A Platform Components
2-1 Platform Extension ............................................................................. 4 - 6
2-2 Platform ............................................................................................... 4 -8
2-3 Extension Cylinder ............................................................................. 4 - 9
2-4 Wear Pads ....................................................................................... 4 - 10
A Manifolds
3-1 Powered Extension Deck
Function Manifold Components ........................................................ 4 - 12
3-2 Powered Extension Deck
Solenoid Valve Body Components ................................................... 4 - 13
3-3 Valve Coils ....................................................................................... 4 - 14

Section 5 Rev Schematics

Introduction .................................................................................................. 5 - 1
A Electrical Component Legend ...................................................................... 5 - 2
A Wire Color Legend ....................................................................................... 5 - 3
A Limit Switch Legend ..................................................................................... 5 - 4
A Electrical Symbols Legend ........................................................................... 5 - 5
Electrical Schematics - ANSI
A GS-2646 with Powered Extension Deck ...................................................... 5 - 6

Hydraulic Schematics
A Component Reference and Hydraulic Symbols Legend ............................ 5 - 12
A GS-2646 with Powered Extension Deck .................................................... 5 - 14

1-4 GS-2646 Part No. 115371

September 2009 Section 2 • Parts Information

Parts
Figures

Part No. 115371 GS-2646 2-1

Section 2 • Parts Information September 2009

Decals REV A

40434 28176 65052 133221 97772 114386 or 43618

28236 28174 133233 133234
or 28235 44736

43618
40434

133219
or 133226
133220
62057

62057
44981
82557

44255
43619 44255
Serial
label 133268
38149

82561 46287
72853 82561
114385 133222
44753 114385
82567 52475
52475 114361
44981 46287
28174
or 28235 133268
97712
133268 31508
43658
or 44980
46287
72970
72143 43089 82559 82558 133268 72086 114361 31060 72086 114360 82657
82366 65052 28175 44737 46287 133276 52475 52475 52475 31788 44737

2-2 GS-2646 Part No. 115371

September 2009 Section 2 • Parts Information

REV A DECALS

Item Part No. Description Qty. Item Part No. Description Qty.
1 28174 Label - Power to Platform, 28 72970 Instructions - Battery Charger
230V ............................................. 2 Operation ...................................... 1
2 28175 Warning - Compartment 29 82366 Label - Chevron Rando HD .......... 1
Access .......................................... 1
30 82557 Label - Platform Controls
3 28176 Label - Missing Manuals ............... 1 Location ........................................ 1
4 28235 Label - Power to Platform, 31 82558 Warning - Skin Injection
115V ............................................. 2 Hazard .......................................... 1
5 28236 Warning - Improper Operation ...... 1 32 82559 Instructions - Annual
Inspection ..................................... 1
6 31060 Danger - Tip-over Hazard,
Limit Switch .................................. 1 33 82561 Danger - Crushing Hazard ........... 2
7 31508 Danger - Electrocution Hazard ..... 1 34 82567 Ground Control Panel ................... 1
8 31788 Danger - Battery Safety ................ 1 35 82657 Instructions - Battery
Connection Diagram ..................... 1
9 38149 Label - Patents ............................. 1
36 97712 Danger/Instructions - Brake
10 40434 Label - Lanyard Anchorage .......... 5
Release Safety and Operation ..... 1
11 43089 Instructions - Operation,
37 97772 Platform Control Panel ................. 1
Ground Control ............................. 1
38 114360 Danger - Tip-over Hazard,
12 43618 Label - Directional Arrows ............ 2
Batteries ....................................... 1
13 43619 Label - Safety Arm ........................ 1
39 114361 Label - Transport Diagram ........... 2
14 43658 Label - Power to Charger,
40 114385 Danger - Electrocution Hazard ..... 2
230V ............................................. 1
41 114386 Danger - General Safety Rules,
15 44255 Danger - Crushing Hazard ........... 4
28 mph / 12.5 m/sec ..................... 1
16 44736 Danger - Tip-over, Tilt Alarm ........ 1
42 133219 Instructions - Maximum Wind
17 44737 Danger - Tip-over, Trays Open .... 2 Speed, 35 mph / 15.6 m/sec ........ 1
18 44753 Label - LED Diagnostic 43 133220 Instructions - Maximum
Readout ........................................ 1 Capacity, 650 lbs / 295 kg ............ 1
19 44980 Label - Power to Charger, 44 133221 Extension Deck Control Panel,
115V ............................................. 1 Ground .......................................... 1
20 44981 Label - Air Line to Platform, 45 133222 Extension Deck Control Panel,
110 PSI ......................................... 2 Platform ........................................ 1
21 46287 Notice - Tire Specification ............ 4 46 133226 Instructions - Maximum Wind
Speed, 28 mph / 12.5 m/sec ........ 1
22 52475 Label - Transport Tie-down .......... 5
47 133233 Instructions - Operation,
23 62057 Cosmetic - Genie GS-2646 .......... 2
Platform Control ............................ 1
24 65052 Label - ECM Fault Codes ............. 2
48 133234 Danger - General Safety Rules,
25 72086 Label - Lifting Eye ......................... 4 35 mph / 15.6 m/sec ..................... 1
26 72143 Label - Emergency Stop ............... 1 49 133268 Label - Wheel Load ...................... 4
27 72853 Danger - Improper Use Hazard .... 1 50 133276 Label - Emergency Lowering ........ 1

Part No. 115371 GS-2646 2-3

Section 2 • Parts Information September 2009

Scissor Assembly REV A

1 6 8 9 10 15 16
2 7 11
9 3 12
44 4 14
5 47

23 17

13 14
46
20 19 18

21

45 22

23

20 19 24

13 14

25
44
26

43
27
42

41
28
40
14 30 29

31

32

7 35 34 33

39 14 38 37 36

2-4 GS-2646 Part No. 115371

September 2009 Section 2 • Parts Information

REV A SCISSOR ASSEMBLY

Item Part No. Description Qty. Item Part No. Description Qty.
1 96932 Pivot Pin, 3/4 x 20.125 inches ....... 1 27 97235 Inner Arm Assembly, Number 1
1/4
with Word Decals
2 45748 Rod End, x 2.75 inches ........... 2
(USA, Canada, Australia) ............. 1
3 8915 Screw - HHC, — 66055 Bearing,
1/4 -20 x 1.25 inches 1.5 x 1.75 x 1.25 inches ............... 6
4 6356 Lock Washer, 1/4 inch 28 96662 Pivot Pin, 1.5 x 12.5 inches .......... 1
5 6091 Nylock Nut, 1/4 -20 29 105092 Carriage Bolt,
3/8 -16 x 1.25 inches, GR 5
6 9116 Carriage Bolt, 1/4 -20 x 1.25
30 105074 Pothole Pusher Bracket ................ 1
7 18504 Locking Flange Nut, 1/4 -20
31 96595 Chassis Slider
8 137284 Outer Arm, Number 4
(ground controls side) ................... 1 32 97237 Outer Arm Assembly, Number 1
with Word Decals
9 105189 Cable Bridge Bar, Long ................ 2
(USA, Canada, Australia) ............. 1
10 96130 Pivot Pin, 1.25 x 8.85 inches ........ 2
33 96196 Hose Routing Plate ...................... 2
11 96373 External Snap Ring,
34 78736 Hose Clamp, 2 inches, Plastic ...... 4
1.25 inches
35 96905 Carriage Bolt,
12 96390 Flat Washer, 1/4 -20 x 2.5 inches
1.27 x 2.13 x 0.13 inch
36 96862 Pivot Pin, 1 x 19.375 inches ......... 1
13 6326 Screw - HHC, 3/8 -16 x 3 inches
37 45226 Rod End, 3/8 x 3.69 inches ........... 3
14 4828 Nylock Nut, 3/8 -16
38 8516 Screw - HHC,
15 96595 Platform Slider 3/8 -16 x 1.5 inches, GR 5

16 137283 Inner Arm Assembly,

39 97241 Chassis Mount Assembly ............. 1
Number 4 ...................................... 1
— 36369 Bearing,
— 66055 Bearing,
0.75 x 1 x 0.75 inch ...................... 2
1.5 x 1.75 x 1.25 inches ............... 6
40 Ref. Lift Cylinder (refer to page 2-8)
17 137285 Outer Arm, Number 4
(battery pack side) ........................ 1 41 96735 Link Bumper, Large ...................... 4
18 96900 Pivot Pin, 1.5 x 8.848 inches ........ 6 42 96812 Pivot Pin, 1.5 x 9.375 inches ........ 1
19 39835 Flat Washer, 1.54 inches 43 97234 Inner Arm Assembly, Number 2 ... 1
20 18383 External Snap Ring, — 66055 Bearing,
1.5 inches ................................... 12 1.5 x 1.75 x 1.25 inches ............... 8

21 58000 Safety Arm Assembly ................... 1 44 105187 Cable Bridge, Short ...................... 2

22 97244 Inner Arm Assembly, Number 3 ... 1 45 96978 Cable Bridge Hook ....................... 2
— 66055 Bearing, 46 84747 Chassis Mount Assembly ............. 1
1.5 x 1.75 x 1.25 inches ............... 8 — 36369 Bearing,
23 96787 Cable Bridge Clip ......................... 3 0.75 x 1 x 0.75 inch ...................... 2

24 96899 Pivot Pin, 1.5 x 27.4 inches .......... 6 47 14033 Screw - HHC,
3/8 -16 x 2.75 inches, GR 5
25 96836 Link Bumper, Small ...................... 8
26 96605 Outer Arm, Number 2 and 3 ......... 4

Part No. 115371 GS-2646 2-5

Section 2 • Parts Information September 2009

Lift Cylinder Assembly REV A

14

13

11 12

10

9 1

8 3

7
4

2-6 GS-2646 Part No. 115371

September 2009 Section 2 • Parts Information

REV A LIFT CYLINDER ASSEMBLY

Item Part No. Description Qty.

1 55560 Long Orifice,
0.059 inch / 1.5 mm ...................... 1
— 105481 Kit, Long Orifice,
0.059 inch / 1.5 mm
— 105479 Kit, Two Orifice,
0.059 inch / 1.5 mm
2 137229 Lift Cylinder ................................... 1
— 105969 Seal Kit
3 96852 Down Coil Wire Harness .............. 1
4 39878 Fitting ............................................ 1
5 28443 Cable Tie, 11.5 inches .................. 3
6 39232 Emergency Down Cable ............... 1
7 44973 Coil Nut ......................................... 1
8 66467 Coil, 20V DC with Diode ............... 1
9 66465 Solenoid Valve Assembly
(includes items 7 and 8) ............... 1
— 40477 Solenoid Valve,
N.C. with Coil Nut
— 44979 Seal Kit
10 41557 Cable Bracket ............................... 1
11 7339 Screw - HHC,
1/4 -20 x 0.5 inch, GR 5

12 6356 Lock Washer, 1/4 inch

13 96770 Clamp ........................................... 1
14 105478 Bearing,
1.5025 x 1.5075 x 1.5 ................... 4

Part No. 115371 GS-2646 2-7

Section 2 • Parts Information September 2009

Platform Components REV A

1 2 3 4 5 6 7 8 9 10 11 12

14

39

38

13
37

14
35 36 28 35 34 33
15
31

32
31

15

14 16

12

29 19

30 28 17
29 19 18
20 19
27 28

26 25 24 23 22 21

2-8 GS-2646 Part No. 115371

September 2009 Section 2 • Parts Information

REV A PLATFORM COMPONENTS

Item Part No. Description Qty. Item Part No. Description Qty.
— 115356 Platform Assembly with Decal, 21 66920 Entry Side Rail
115V, 28 mph - Complete (battery pack side) ........................ 1
— 115362 Platform Assembly with Decal,
22 115359 Main Deck Assembly
230V, 28 mph - Complete
with Decal .................................... 1
— 115363 Platform Assembly with Decal,
115V, 35 mph - Complete 23 125848 Main Side Rail
— 115364 Platform Assembly with Decal, (battery pack side) ........................ 1
230V, 35 mph - Complete
24 137035 Hydraulic Hose Guard .................. 1
1 125910 Extension Deck
25 137138 Hose Clamp .................................. 3
Bumper Assembly ........................ 1
26 137036 Tee Fitting Mount .......................... 1
2 125909 Bumper, Foam, Short ................... 4
27 8915 Screw - HHC, 1/4 -20 x 1.25
3 115357 Extension End Rail Assembly ...... 1
inches, GR 5
4 Ref. Platform Control Box
28 6091 Nylock Nut, 1/4 -20
Mount Bracket (refer to 401.1)
29 6175 Screw - HHC,
5 Ref. Platform Control Box 3/8 -16 x 1 inch, GR 5
(refer to 401.1)
30 8179 Screw - HHC, 1/4 -20 x 2.25
6 115358 Extension Deck Side
inches, GR 5
Rail Assembly with Decal
(ground controls side) ................... 1 31 125968 Wearpad, Narrow ......................... 4
7 125916 Pin ................................................ 2 32 125885 Wearpad, Wide ............................. 2
8 10262 Snap Ring, External, 0.75 inch ..... 8 33 7339 Screw - HHC,
1/4 -20 x 0.5 inch, GR 5
9 125835 Cylinder, Extension Deck ............. 2
34 6356 Lock Washer, 1/4 inch
10 125850 Main Side Rail
(ground controls side) ................... 1 35 8514 Screw - FHSC,
1/4 -20 x 0.75 inch
11 125926 Main Deck Bumper ....................... 2
36 6638 Flat Washer, 1/4 inch
12 125874 Bumper, Foam, Long .................... 8
37 125890 Extension Deck ............................ 1
13 78666 Cable Tie, 12.4 x 0.5 ................ 116
38 144371 Extension Deck Side
14 125872 Bumper, Foam, Elbow ................ 12
Rail Assembly with Decals
15 137024 Bumper, Foam, Short ................... 4 28 MPH (battey pack side) ........... 1
16 43392 Bumper ....................................... 14 — 144372 Extension Deck Side
Rail Assembly with Decals
17 115372 Swing Gate Assembly,
35 MPH (battey pack side) ........... 1
28 mph, GS-2646 ........................ 1
— 115373 Swing Gate Assembly, 39 125875 Bumper, Foam, Long .................... 2
35 mph, GS-2646
18 66923 Entry Side Rail
(ground controls side) ................... 1
19 4828 Nylock Nut, 3/8 -16
20 5224 Screw - HHC,
3/8 -16 x 2 inches, GR 5

Part No. 115371 GS-2646 2-9

Section 2 • Parts Information September 2009

Platform Limit Switch Assembly REV A

1 2 3 4 5 6 7

9 11

9 10

2 - 10 GS-2646 Part No. 115371

September 2009 Section 2 • Parts Information

REV A PLATFORM LIMIT SWITCH ASSEMBLY

Item Part No. Description Qty.

1 137031 Spacer .......................................... 1
2 137029 Cover ............................................ 2
3 8914 Screw - HHC,
1/4 -20 x 0.625 inch, GR 5

4 25969 Spring Clip, 1/4 -20

5 88356-12BL3 Limit Switch, Blue ......................... 1
6 6179 Screw - RHSM,
10-32 x 1.25 inches
7 125833 Inner Mast ..................................... 2
8 Ref. Main Deck Assembly
9 105092 Carriage Bolt,
3/8 -16 x 1.25 inches, GR 5

10 4828 Nylock Nut, 3/8 -16

11 7713 Low Profile Nylock Nut, 3/8 -16

Part No. 115371 GS-2646 2 - 11

Section 2 • Parts Information September 2009

Ground Control Box REV A

1 2
3

7 6 6 5

2 - 12 GS-2646 Part No. 115371

September 2009 Section 2 • Parts Information

REV A GROUND CONTROL BOX

Item Part No. Description Qty.

1 115360 Ground Control Box
Assembly with Decal - Complete
— 137040 Enclosure
— 137041 Plate
— 137055 Switch Body
— 137056 Switch Body
— 137057 PC Board
— 45414 Screw - SHC, 1/4 -20 x 1.25
inches, GR 8 ................................. 4
— 49819 Screw - PHPM,
10-32 x 0.5 inch, GR 2
— 54255 Secondary Lock, 12 Way
— 56286 Screw - PHPM,
8-32 x 0.75 inch
— 56302 Relay, 24V DC, 40/30A ................ 5
— 60447 Secondary Lock,, 8 Way
— 6146 Flat Washer, #10
2 6889 Low Profile Nylock Nut, 1/4 -20
3 45414 Screw - SHC,
1/4 -20 x 1.25 inches, GR 8

4 137003 Ground Control Mount .................. 1

5 6091 Nylock Nut, 1/4 -20
6 6638 Flat Washer, 1/4 inch
7 8915 Screw - HHC, 1/4 -20 x 1.25
inches, GR 5
8 137054 Switch ........................................... 1
9 137053 Push Button, Green ...................... 1

Part No. 115371 GS-2646 2 - 13

Section 2 • Parts Information September 2009

Platform Controls REV A

5
4

2 - 14 GS-2646 Part No. 115371

September 2009 Section 2 • Parts Information

REV A PLATFORM CONTROL BOX

Item Part No. Description Qty.

1 100840 Platform Controls - Complete
— 78903 Joystick Controller
— 96209 Coil Cord Assembly
(includes connector) ..................... 1
— 100998 Enclosure ...................................... 1
— 51860 Alarm Assembly, 12V DC
(does not include retainer nut) .... 1
— 72326 Retainer Nut ................................. 1
— 109503 Circuit Board Assembly ................ 1
— 66812 Red Emergency Stop Button ........ 1
— 66817 Base with N.C. Contact ................ 1
— 66818 N.C. Contact
2 115365 Platform Control Mount
Assembly with Decal .................... 1
— 104995 Platform Control Mount
— 65052 Decal
3 137033 Plate, Platform Control Mount ...... 1
4 6090 Screw - HHC,
1/4 -20 x 0.75 inch, GR 5

5 6356 Lock Washer, 1/4 inch

6 18605 Nylock Nut, 8-32
7 66856 Screw - SHC, 8-32 x 0.75 inch
8 115361 Platform Controls
Assembly with Decal,
Extension - Complete
— 109803 Cover, Push Button
— 125970 Platform Controls
— 96209 Coil Cord Assembly ...................... 1
— 137039 Enclosure ...................................... 1
— 137053 Push Button, Green ...................... 1
— 137054 Switch, Rotary Cam ...................... 1
— 137055 Switch Body, Single ...................... 1
— 137056 Switch Body, Single ...................... 1
— 18605 Flange Screw,
5/16 -18 x 0.75 inch
— 66856 Screw - SHC,
8-32 x 0.75 inch

Part No. 115371 GS-2646 2 - 15

Section 2 • Parts Information September 2009

Joystick Controller REV A

1 2 3

5 5

2 - 16 GS-2646 Part No. 115371

September 2009 Section 2 • Parts Information

REV A JOYSTICK CONTROLLER

Item Part No. Description Qty.

— 78903 Joystick Controller - Complete
1 105171 Joystick Enable Switch Kit ............ 1
2 105115 Joystick Turn Switch
Assembly Kit ................................. 1
3 150157 Joystick Handle/Switch
Update Kit
(for joystick assembly 604038P)
(inspect decal on joystick
housing) ........................................ 1
— 105109 Joystick Turn Switch Actuator
(for all joysticks except
604038P)
4 97015 Thumb Rocker Boot ...................... 1
5 97014 Joystick Handle Set - Complete
with Hardware
(for all joysticks except
604038P) ...................................... 1
6 97013 Joystick Boot ................................ 1
7 105172 Joystick Wire Harness
Connector Kit ................................ 1
— 105168 Platform Control Receptacle Kit

Part No. 115371 GS-2646 2 - 17

Section 2 • Parts Information September 2009

Battery Pack Module (No Charger Option) REV A

1 1 3 4 5 6 7 8 9
2 2 2

15

14

12 13

1 2

2
11 10

2 - 18 GS-2646 Part No. 115371

September 2009 Section 2 • Parts Information

BATTERY PACK MODULE (NO CHARGER OPTION)

REV A

Item Part No. Description Qty.

1 6878 Carriage Bolt, 1/4 -20 x 0.75
2 6091 Nylock Nut, 1/4 -20
3 96078 Fuse Bracket ................................ 1
4 13000 Screw - HHC,
5/16 -18 x 1.25 inch

5 40833 Fuse, 275A

6 66717 Fuse Holder
(include mounting fasteners) ........ 1
7 115156 Battery Tray Assembly
with Word Decals .......................... 1
8 30784-2550 Threaded Rod,
1/4 -20 x 25.5 inches ..................... 1

9 76502 Battery, Dry ................................... 4

— 105150 Battery, Maintenance Free
10 5397 Flat Washer, 1/4 inch
11 137038 Bracket
12 16487 Screw - RHSM,
10-32 x 1.5 inches
13 6178 Nylock Nut, 10-32
14 88356-21183 Limit Switch
15 55675 Rotary Latch ................................. 1

Part No. 115371 GS-2646 2 - 19

Section 2 • Parts Information September 2009

Air Line to Platform REV A

1 2 3 4

2 - 20 GS-2646 Part No. 115371

September 2009 Section 2 • Parts Information

AIR LINE TO PLATFORM

REV A

Index Part No. Description Quantity This Figure

— 47686 Air Line to Platform - Complete,
GS-2646 ...................................... —
1 27903 Hose - Low Pressure,
0.375 inch (0.952 cm)
GS-2646 ......... 482 inches (12.2 m)
2 27902 Clamp - Hose, Two Ear,
0.625 inch (1.5 cm) ....................... 2
3 105959 Elbow, 90°, 3/8 NPT, Male ........... 1
4 96245 Bracket, Roller Mount
(Ground Controls Side) ................ 1
5 105958 Coupler, Interface, Rectus 25 ....... 1
6 27904 Hose End, 90°, Barbed ................. 1
7 27900 Adapter - Female Bulkhead,
10 MPT (includes mounting
fasteners) ...................................... 1
8 105957 Plug, Interface, Rectus 25 ............ 1

Part No. 115371 GS-2646 2 - 21

Section 2 • Parts Information September 2009

Hydraulic Hoses and Fittings

RETRACT RETRACT

12
19 19

EXTEND 18 18 EXTEND

17

17

16 16

15 14

15 14
12

POPPET VALVE and

MANIFOLD BLOCK
13

12 12
B3 R1
AUX
MANIFOLD
IN OUT
11 11

10

MOTOR
PUMP
M1 M3 M2 M4 S1 S2 V L IN OUT
HP T 1 3 1 FILTER 4 5 TANK 6 7 8

FUNCTION MANIFOLD
B P 2 9
TP
ACC
LEGEND

CONNECTOR

HOSE ASSEMBLY

TUBE ASSEMBLY

2 - 22 GS-2646 Part No. 115371

September 2009 Section 2 • Parts Information

HYDRAULIC HOSES AND FITTINGS

Index Part No. Description Quantity This Figure Index Part No. Description Quantity This Figure
1 96397 Connector, 070120-8-8 ................ 1 13 69503 Swivel Connector, Female,
1/4 X 1 X 5/16 ............................... 1
2 39878 Connector, 070120-6-6 ................ 1
14 137047 Hose Assembly, Manifold to Link,
3 96348 Hose Assembly, Manifold to Filter
Boeing GS-2646 - Components:
(from SN GS4607-84403) -
Genie part numbers 48805, 48805,
Components: Genie part numbers
and 48751 @ 33 inches ............... 2
96406, 96406 and 75631
@ 25 inches ................................. 1 15 137048 Hose Assembly, Links, Boeing
GS-2646 - Components: Genie part
4 96398 Connector, 070120-12-8 .............. 1
numbers 137086, 137086 and
5 96355 Tube Assembly, Draw .................. 1 48751 @ 383 inches .................... 2
6 96354 Tube Assembly, Draw .................. 1 16 137049 Hose Assembly, Platform, Boeing
GS-2646 - Components: Genie part
7 22664 Elbow, 070220-12-10 ................... 1
numbers 48805, 48806 and 48751
8 39876 Elbow, 070220-6-8 ....................... 1 @ 102 inches ............................... 2
9 96353 Hose Assembly, Pressure 17 137074 Tee Run, Bulkhead, 070958-4 ..... 2
Components: Genie part numbers
_ 34615 Bulkhead Nut, 070118-4 ............... 2
39890, 39890 and 56776
@ 50 inches ................................. 1 18 137050 Hose Assembly, Platform
Extension, Boeing GS-2646 -
10 144230 Hose Assembly, Pressure
Components: Genie part numbers
Components: Genie part numbers
48805, 48805 and 48751
39890, 39890 and 56776
@ 38 inches ................................. 2
@ 65.50 inches ............................ 1
19 137051 Hose Assembly, Platform Retract,
11 39878 Connector, 070120-6-6 ................ 2
Boeing GS-2646 - Components:
12 39877 Connector, 070120-4-4 ................ 3 Genie part numbers 48805, 48805
and 48751 @ 100 inches ............. 2

Part No. 115371 GS-2646 2 - 23

September 2009 Section 3 • Specifications

REV A
Specifications
Machine Specifications Tires and wheels

Batteries, Standard Tire size (solid rubber) 15 x 5 in

38.1 x 12.7 cm
Voltage 6V DC
Tire contact area 15 sq in
Group GC2 96.7 cm2

Type T-105 Castle nut torque, dry 300 ft-lbs

406.7 Nm
Quantity 4
Castle nut torque, lubricated 225 ft-lbs
Battery capacity, maximum 225AH 305 Nm
Reserve capacity @ 25A rate 447 minutes

Weight, each 62 lbs Continuous improvement of our products is a

28 kg Genie policy. Product specifications are
subject to change without notice.
Batteries, Maintenance-free (option)

Voltage 6V DC

Group GC2

Type 6V-AGM

Quantity 4

Battery capacity, maximum 200AH

Reserve capacity @ 25A rate 380 minutes

Weight, each 62 lbs

28 kg

Fluid capacities

Hydraulic tank 3.75 gallons

14.2 liters

Hydraulic system (including tank) 4.5 gallons

18 liters

For operational specifications, refer to the

Operator's Manual.

Part No. 115371 GS-2646 3-1

Section 3 • Specifications September 2009

SPECIFICATIONS REV A

Performance Specifications
Drive speed, maximum

Platform stowed, fast 2.2 mph

40 ft / 12.4 sec
3.5 km/h
12.2 m / 12.4 sec

Platform stowed, slow 1.1 mph

40 ft / 24.8 sec
1.8 km/h
12.2 m / 24.8 sec

Platform raised 0.5 mph

40 ft / 55 sec.
1.8 km/h
12.2 m 55 sec

Braking distance, maximum

High range on paved surface 24 in ± 12 in

61 cm ± 30 cm

Gradeability 25%

Airborne noise emissions <70 dB

Maximum sound level at normal operation workstations
(A-weighted)
Function speed, maximum from platform controls
(with 1 person in platform)

Platform up 28 to 32 seconds
Platform down 31 to 35 seconds

Function speed, extension deck extend and retract

from platform controls or ground controls

Extend 28 to 32 seconds
Retract 31 to 35 seconds

Rated work load at full height, maximum

GS-2646 750 lbs

340 k

Continuous improvement of our products is a

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

3-2 GS-2646 Part No. 115371

September 2009 Section 3 • Specifications

REV A SPECIFICATIONS

Hydraulic Specifications Function pump

Hydraulic Oil Specifications Type Gear

Hydraulic oil type Chevron Rando HD equivalent Displacement per revolution 0.244 cu in
Viscosity grade Multi-viscosity 4 cc
Viscosity index 200 Flow rate @ 2500 psi / 172 bar 4 gpm
Cleanliness level, minimum 15/13 15 L/min

Water content, maximum 200 ppm Hydraulic tank return filter 10 micron with
25 psi / 1.7 bar bypass
Chevron Rando HD oil is fully compatible and
mixable with Shell Donax TG (Dexron III) oils. Function manifold
Genie specifications require hydraulic oils which are System relief valve pressure, maximum 3500 psi
designed to give maximum protection to hydraulic 241 bar
systems, have the ability to perform over a wide
temperature range, and the viscosity index should Lift relief valve pressure 1800 to 3500 psi
exceed 140. They should provide excellent antiwear, 124 to 241 bar
oxidation, corrosion inhibition, seal conditioning, and
foam and aeration suppression properties. Steer relief valve pressure 1500 psi
103 bar
Optional fluids
Powered extension deck manifold
Biodegradable Petro Canada Premium MV 46
Statoil Hydra Way Bio SE 32 Relief valve pressure, maximum 2200 psi
BP Biohyd SE-S 152 bar

Fire resistant UCON Hydrolube HP-5046

Quintolubric 822 Continuous improvement of our products is a
Mineral based Shell Tellus T32 Genie policy. Product specifications are
Shell Tellus T46 subject to change without notice.
Chevron Aviation A

Continued use of Chevron

Aviation A hydraulic fluid when
ambient temperatures are
consistently above 32°F / 0°C may
result in component damage.
Note: Use Chevron Aviation A hydraulic fluid
when ambient temperatures consistently below
0°F / -17°C.

Note: Use Shell Tellus T46 hydraulic oil when oil

temperatures consistently exceed 205°F / 96°C.
Note: Genie specifications require additional
equipment and special installation instructions for
the approved optional fluids. Consult the Genie
Industries Service Department before use.

Part No. 115371 GS-2646 3-3

Section 3 • Specifications September 2009

SPECIFICATIONS REV A

Manifold Component Valve Coil Resistance

Specifications Note: The following coil resistance specifications are at
an ambient temperature of 68°F / 20°C. As valve coil
Plug torque resistance is sensitive to changes in air temperature,
the coil resistance will typically increase or decrease by
SAE No. 2 50 in-lbs / 6 Nm 4% for each 18°F / -7.7°C that your air temperature
SAE No. 4 13 ft-lbs / 18 Nm increases or decreases from 68°F / 20°C.

SAE No. 6 18 ft-lbs / 24 Nm Description Specification

SAE No. 8 50 ft-lbs / 68 Nm Solenoid valve, 3 position 4 way 27.2Ω

20V DC with diode (schematic items AC)
SAE No. 10 55 ft-lbs / 75 Nm
Solenoid valve, 2 position 4 way 19Ω
SAE No. 12 75 ft-lbs / 102 Nm 20V DC with diode (schematic item AI)

Solenoid valve, 2 position 2 way N.C. 25Ω

20V DC with diode (schematic item N)

Solenoid valve, 2 position 4 way 19Ω

20V DC with diode (schematic items AE)

Solenoid valve, 3 position 5 way 19Ω

20V DC with diode (schematic item AG)

Solenoid valve, 3 position 4 way 19Ω

20V DC with diode (schematic item DA)

Solenoid valve, 2 position 2 way N.C. 19Ω

20V DC with diode (schematic item T)

Continuous improvement of our products is a

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

3-4 GS-2646 Part No. 115371

September 2009 Section 3 • Specifications

REV A SPECIFICATIONS

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

Part No. 115371 GS-2646 3-5

Section 3 • Specifications September 2009

SPECIFICATIONS REV A

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

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

4 Tighten the hex nut until the mark on the hex

nut is aligned with the second mark on the body
hex fitting.
5 Operate all machine functions and inspect the
hoses and fittings and related components to
confirm that there are no leaks.

3-6 GS-2646 Part No. 115371

September 2009 Section 3 • Specifications

REV A SPECIFICATIONS

SAE FASTENER TORQUE CHART

• This chart is to be used as a guide only unless noted elsewhere in this manual •
A574 High Strength
SIZE THREAD Grade 5 Grade 8 Black Oxide Bolts
LUBED DRY LUBED DRY LUBED
in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm
1/4 20 80 9 100 11.3 110 12.4 140 15.8 130 14.7
28 90 10.1 120 13.5 120 13.5 160 18 140 15.8
LUBED DRY LUBED DRY LUBED
ft - lbs Nm f t - lbs Nm f t - lbs Nm f t - lbs Nm f t - lbs Nm
5/16 18 13 17.6 17 23 18 24 25 33.9 21 28.4
24 14 19 19 25.7 20 27.1 27 36.6 24 32.5
3/8 16 23 31.2 31 42 33 44.7 44 59.6 38 51.5
24 26 35.2 35 47.4 37 50.1 49 66.4 43 58.3
7/16 14 37 50.1 49 66.4 50 67.8 70 94.7 61 82.7
20 41 55.5 55 74.5 60 81.3 80 108.4 68 92.1
1/2 13 57 77.3 75 101.6 80 108.4 110 149 93 126
20 64 86.7 85 115 90 122 120 162 105 142
9/16 12 80 108.4 110 149 120 162 150 203 130 176
18 90 122 120 162 130 176 170 230 140 189
5/8 11 110 149 150 203 160 217 210 284 180 244
18 130 176 170 230 180 244 240 325 200 271
3/4 10 200 271 270 366 280 379 380 515 320 433
16 220 298 300 406 310 420 420 569 350 474
7/8 9 320 433 430 583 450 610 610 827 510 691
14 350 474 470 637 500 678 670 908 560 759
8 480 650 640 867 680 922 910 1233 770 1044
1
12 530 718 710 962 750 1016 990 1342 840 1139
7 590 800 790 1071 970 1315 1290 1749 1090 1477
1 1/8
12 670 908 890 1206 1080 1464 1440 1952 1220 1654
7 840 1138 1120 1518 1360 1844 1820 2467 1530 2074
1 1/4
12 930 1260 1240 1681 1510 2047 2010 2725 1700 2304
6 1460 1979 1950 2643 2370 3213 3160 4284 2670 3620
1 1/2
12 1640 2223 2190 2969 2670 3620 3560 4826 3000 4067

METRIC FASTENER TORQUE CHART

• This chart is to be used as a guide only unless noted elsewhere in this manual •

Size Class 4.6 4.6 Class 8.8 8.8 Class 10.9 10.9 Class 12.9 12.9

(m m ) LUBED DRY LUBED DRY LUBED DRY LUBED DRY

in- lbs Nm in- lbs Nm in-lbs Nm in-lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm
5 16 1.8 21 2.4 41 4.63 54 6.18 58 6.63 78 8.84 68 7.75 91 10.3
6 19 3.05 36 4.07 69 7.87 93 10.5 100 11.3 132 15 116 13.2 155 17.6
7 45 5.12 60 6.83 116 13.2 155 17.6 167 18.9 223 25.2 1.95 22.1 260 29.4
LUBED DRY LUBED DRY LUBED DRY LUBED DRY
f t- lbs Nm f t- lbs Nm f t -lbs Nm f t -lbs Nm f t - lbs Nm f t - lbs Nm f t - lbs Nm ft - lbs Nm
8 5.4 7.41 7.2 9.88 14 19.1 18.8 25.5 20.1 27.3 26.9 36.5 23.6 32 31.4 42.6
10 10.8 14.7 14.4 19.6 27.9 37.8 37.2 50.5 39.9 54.1 53.2 72.2 46.7 63.3 62.3 84.4
12 18.9 25.6 25.1 34.1 48.6 66 64.9 88 69.7 94.5 92.2 125 81 110 108 147
14 30.1 40.8 40 54.3 77.4 105 103 140 110 150 147 200 129 175 172 234
16 46.9 63.6 62.5 84.8 125 170 166 226 173 235 230 313 202 274 269 365
18 64.5 87.5 86.2 117 171 233 229 311 238 323 317 430 278 377 371 503
20 91 124 121 165 243 330 325 441 337 458 450 610 394 535 525 713
22 124 169 166 225 331 450 442 600 458 622 612 830 536 727 715 970
24 157 214 210 285 420 570 562 762 583 791 778 1055 682 925 909 1233

Part No. 115371 GS-2646 3-7

September 2009
Observe and Obey:
Repair procedures shall be completed by a
person trained and qualified on the repair of this
machine.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating the machine.
Before Repairs Start:
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 parts are
available and ready for use.
Use only Genie approved replacement parts.
Read each procedure completely and adhere to
the instructions. Attempting shortcuts may
produce hazardous conditions.
Unless otherwise specified, perform each repair
procedure with the machine in the following
configuration:
· Machine parked on a firm, level surface
· Platform in the stowed position
· Key switch in the off position with the key
removed
· The red Emergency Stop button in the off
position at both ground and platform controls
· Wheels chocked
· All external AC power supply disconnected
from the machine
Part No. 115371
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. Then to
re-assemble, perform the disassembly steps in
reverse order.
Symbols Legend
Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicates an imminently hazardous
situation which, if not avoided, will
result in death or serious injury.
Indicates a potentially hazardous
situation which, if not avoided,
could result in death or serious
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may cause minor or moderate
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may result in property damage.
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.
GS-2646 4-1
Section 4 • Repair Procedures September 2009

Powered Extension Deck Controls REV A

The powered extension deck ground control box

and platform control box are used to extend and
retract the powered extension deck. The powered
extension deck ground control box can also be
used to adjust the extension deck, extend and
retract speed.
Activating the button and switch on the powered
extension deck ground control box, or the platform
control box, sends a signal to the printed circuit
board mounted inside the powered extension deck
ground control box. When the printed circuit board
receives a signal, it enables the powered extension
deck to extend and retract.

The powered extension deck ground control box

consist of an electronic circuit board, relays,
function enable button and a extend/retract switch.

The powered extension deck platform control box

consist of a function enable button and a extend/
retract switch.
For further information or assistance, consult the
Genie Industries Service Department.

a Function Enable button

b Extend/Retract switch
c relay
d printed circuit board

4-2 GS-2646 Part No. 115371

September 2009 Section 4 • Repair Procedures

REV A POWERED EXTENSION DECK CONTROLS

1-1
Circuit Boards

How to Remove the Ground

Controls Circuit Board
1 Push in the red Emergency Stop button to the
off position at both the ground and platform
controls.
2 Remove the fasteners securing the ground
control box together. Open the control box.
3 Locate the circuit board mounted on the right
side of the ground control box.
Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
Component damage hazard.
Electrostatic discharge (ESD) can
damage printed circuit board
components. Maintain firm contact
with a metal part of the machine
that is grounded at all times when
handling printed circuit boards OR
use a grounded wrist strap.
4 Carefully tag and disconnect the wires from the
circuit board.
5 Carefully remove the circuit board retaining
fasteners and remove the circuit board from the
control box.

Part No. 115371 GS-2646 4-3

Section 4 • Repair Procedures
POWERED EXTENSION DECK CONTROLS
1-2
Controller Adjustments
The powered extension deck extend and retract
speed are adjustable to compensate for wear in
the hydraulic pump.
The function speeds are determined by the
percentage of total controller output.
For further information or assistance, consult the
Genie Industries Service Department.
How to Adjust the Powered
Extension Deck Extend Speed
Note: Perform this procedure with the machine on
firm, level surface and with the platform in the
stowed position.
1 Turn the key switch to the on position and pull
out the red Emergency Stop button to the on
position at both the ground and platform
controls.
2 Push in the Function Enable button at the
powered extension deck ground controls.
3 Select extend at the powered extension deck
ground controls and begin timing the extension
deck when it starts to extend.
4 Note the time it takes extension deck to
reach full extension. Refer to Section 2,
Specifications.
Result: The time it takes the powered extension
deck to fully extend, is within specification.
Proceed to step 8.
Result: The time it takes the powered extension
deck to fully extend, is not within specification.
Proceed to step 5.
5 Remove the fasteners securing the powered
extension deck ground control box together.
Set the fasteners to the side and carefully
remove the cover.
4-4
September 2009
REV A
6 Using the illustration below as a guide, locate
the Extend Speed Adjust screw on the printed
circuit board, mounted on the right side of the
ground control box. Turn clockwise to increase
speed, or turn counterclockwise to decrease
speed. Test the function speed. Repeat this
procedure beginning with step 2.
Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
Component damage hazard.
Electrostatic discharge (ESD) can
damage printed circuit board
components. Maintain firm contact
with a metal part of the machine
that is grounded at all times when
handling printed circuit boards OR
use a grounded wrist strap.
7 Install the cover onto the powered extension
deck control box, and secure into place using
the fasteners removed in step 5. Do not over
tighten the fasteners.
8 Turn the key switch to the off position and push
in the red Emergency Stop button to the off
position at both the ground and platform
controls.
a printed circuit board
b Extend/Retract switch
c Enable button
GS-2646 Part No. 115371
September 2009
REV A
How to Adjust the Powered
Extension Deck Retract Speed
Note: Perform this procedure with the machine on
firm, level surface and with the platform in the
stowed position.
1 Turn the key switch to the on position and pull
out the red Emergency Stop button to the on
position at both the ground and platform
controls.
2 Push in the Function Enable button at the
powered extension deck ground controls.
3 Select extend at the powered extension deck
ground controls and fully extend the powered
extension deck.
4 Select retract at the powered extension deck
ground controls and begin timing when the
extension deck starts to retract.
5 Note the time it takes extension deck to retract.
Refer to Section 2, Specifications.
Result: The time it takes the powered extension
deck to fully retract is within specification.
Proceed to step 9.
Result: The time it takes the powered extension
deck to fully retract is not within specification.
Proceed to step 6.
6 Remove the fasteners securing the powered
extension deck ground control box together.
Set the fasteners to the side and carefully
remove the cover.
Part No. 115371
Section 4 • Repair Procedures
POWERED EXTENSION DECK CONTROLS
7 Using the illustration below as a guide, locate
the Retract Speed Adjust screw on the printed
circuit board, mounted on the right side of the
ground control box. Turn clockwise to increase
speed, or turn counterclockwise to decrease
speed. Test the function speed. Repeat this
procedure beginning with step 2.
Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
Component damage hazard.
Electrostatic discharge (ESD) can
damage printed circuit board
components. Maintain firm contact
with a metal part of the machine
that is grounded at all times when
handling printed circuit boards OR
use a grounded wrist strap.
8 Install the cover onto the powered extension
deck control box, and secure into place using
the fasteners removed in step 6. Do not over
tighten the fasteners.
9 Turn the key switch to the off position and push
in the red Emergency Stop button to the off
position at both the ground and platform
controls.
a printed circuit board
b Extend/Retract switch
c Enable button
GS-2646 4-5
Section 4 • Repair Procedures September 2009

Platform Components REV A

2-1 9 Remove the fasteners securing the inner and

outer restraint brackets to the main platform
Platform Extension deck and remove the brackets. Set the
brackets and fasteners to the side. Refer to
How to Remove the Powered Illustration 1.
Extension Deck
1 Disconnect the battery packs from the machine.
Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
2 Remove the platform controls from the platform
and lay them off to the side of the machine.
3 Disconnect the platform controls from the
control cable at the platform.
4 Remove the cover from the AC outlet. Tag and
disconnect the wiring from the outlet.
5 Disconnect the wiring from the platform and pull
the wiring free of the platform.
Illustration 1
6 Models with air line to platform option:
Disconnect the air line from the platform. Pull a inner and out restrained brackets
the air line free of the platform. b power extension deck hydraulic hose
location
7 Attach a lifting strap from an overhead crane to c front bumper rail
the front bumper rail.
10 Tag, disconnect and plug the hydraulic hoses
8 Remove the fasteners securing the front from the "T" fittings, at the non-steer end of the
bumper rail to the powered extension deck main platform deck. Cap the "T" fittings and
and remove the bumper rail. Set the bumper rail carefully pull the hoses through the routing
and fasteners to the side. Refer to Illustration 1. hole. Refer to Illustration 1 for hose location.
Bodily injury hazard. The front Bodily injury hazard. Spraying
bumper rail may become hydraulic oil can penetrate and
unbalanced and fall if not properly burn skin. Loosen hydraulic
supported when removed from the connections very slowly to allow
machine. the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.

4-6 GS-2646 Part No. 115371

September 2009 Section 4 • Repair Procedures

REV A PLATFORM COMPONENTS

11 Remove the fasteners securing the left and right 14 Using an overhead crane, attach a pair of chain
inner mast covers to the left and right inner slings equipped with the appropriate sized grab
mast tubes. Set the covers and fasteners to the hooks to the powered extension deck. Refer to
side. Refer to Illustration 2. Illustration 3 for hook placement.
12 Remove the fasteners securing the powered
extension deck limit switch assembly to the
inner mast tube, located inside the left rear
inner mast tube. Carefully set the limit switch
assembly to the side. Refer to Illustration 2.
Component damage hazard.
Cables can be damaged if they
are kinked or pinched.

Illustration 3

15 Carefully remove the powered extension deck

from the main platform deck and place it on a
structure capable of supporting it.
Crushing hazard. The powered
extension deck will fall if not
properly supported.
Component damage hazard.
Hydraulic hoses can be damaged
if they are kinked or pinched.

Illustration 2

a inner mast tube fastener location

b inner mast tube cover
c limit switch assembly

13 Remove the fasteners securing the left and right

inner mast tubes to the main platform deck. Set
the fasteners to the side. Refer to Illustration 2.

Part No. 115371 GS-2646 4-7

Section 4 • Repair Procedures September 2009

PLATFORM COMPONENTS REV A

2-2
Platform

How to Remove the Platform

1 Remove the Powered Extension Deck. See 2-1,
How to Remove the Powered Extension Deck.
2 Attach a lifting strap from an overhead crane to
the bumper rail, at the battery pack side of the
machine. Support the rail. Do not apply lifting
pressure.
3 Remove the fasteners securing the bumper rail
to the main deck and remove the bumper rail.
Set the bumper rail and fasteners to the side.
Refer to Illustration 1.
Bodily injury hazard. The bumper
rail may become unbalanced and
fall if not properly supported when
removed from the machine.
4 Attach a lifting strap from an overhead crane to
the bumper rail, at the ground controls side of
the machine. Support the rail. Do not apply
lifting pressure.
5 Remove the fasteners securing the bumper rail
to the main deck and remove the bumper rail.
Set the bumper rail and fasteners to the side.
Refer to Illustration 1.
Bodily injury hazard. The bumper
rail may become unbalanced and
fall if not properly supported when
removed from the machine.
6 Cut the cable ties securing the hydraulic hoses
to the hose track and set the hoses to the side.
Refer to Illustration 1.
7 Remove the fasteners securing the hose track
to the main deck and remove the hose track.
Set the hose track and the fasteners to the
side. Refer to Illustration 1.
Illustration 1
a bumper rail
b hose track
8 Remove the retaining fasteners securing the
platform to the platform mount at the steer end
of the machine.
9 Support the platform with a forklift at the
non-steer end. Do not apply any lifting
pressure.
10 Attach a strap from the lanyard anchorage point
on the platform railings to the carriage on the
forklift to help support the platform.
11 Lift the steer end of the platform slightly to clear
the platform mount and slide the platform
towards the steer end of the machine until the
platform slide blocks at the non-steer end of the
machine are visible through the access holes in
the bottom of the platform.
Crushing hazard. The platform will
fall if not properly supported.
12 Carefully lift the platform off of the machine and
place it on a structure capable of supporting it.
Note: For ease of installation, note the location and
orientation of the platform slide blocks before
removing the platform.

4-8 GS-2646 Part No. 115371

September 2009 Section 4 • Repair Procedures

REV A PLATFORM COMPONENTS

2-3 8 Carefully remove the cylinder from the inner

mast tube.
Extension Cylinder
Component damage hazard. Be
careful not to damage the hoses
How to Remove a or fittings on the cylinder while
Power Extension Deck Cylinder removing it from the inner mast
tube.
1 Remove the Powered Extension Deck. See 2-1,
How to Remove the Powered Extension Deck. 9 Tag, disconnect and plug the hydraulic hoses
on the cylinder. Cap the fittings on the cylinder.
2 Remove the snap rings from the front retaining
pin at the rod end of the cylinder. Set the snap
rings to the side.
3 Use a soft metal drift to remove the retaining
pin. Set the pin to the side.
4 Remove the fasteners securing the top wear
pad to the rear outer mast tube. Set the wear
pad and the fasteners to the side.
5 Carefully slide the inner mast tube away from
the outer mast tube. Set the inner mast tube on
a structure capable of supporting it.
a extension deck cylinder
6 Remove the snap rings from the rear retaining b hydraulic hose
pin at the barrel end of the cylinder. Set the c connector fitting
snap rings to the side.
7 Use a soft metal drift to remove the retaining
pin. Set the pin to the side.

Part No. 115371 GS-2646 4-9

Section 4 • Repair Procedures
PLATFORM COMPONENTS
2-4
Wear Pads
How to Replace the
Main Deck Wear Pads
1 Remove the Powered Extension Deck. See 2-1,
How to Remove the Powered Extension Deck.
2 Remove the fasteners securing the wear pads
to the main deck at the steer end of the
machine. Set the fasteners to the side.
3 Install the new wear pads using the fasteners
removed in step 2.
How to Replace the Platform
Extension Deck Wear Pads
1 Remove the Powered Extension Deck. See 2-1,
How to Remove the Powered Extension Deck.
2 Remove the fasteners securing the wear pads
to the bottom of the extension deck. Set the
fasteners to the side.
3 Install the new wear pads using the fasteners
removed in step 2.
4 Remove the fasteners securing the top wear
pad to the rear outer mast tube. Set the
fasteners to the side.
5 Remove the snap rings from the front retaining
pin at the rod end of the cylinder. Set the snap
rings to the side.
4 - 10
September 2009
REV A
6 Use a soft metal drift to remove the retaining
pin. Set the pin to the side.
7 Carefully slide the inner mast tube away from
the outer mast tube. Set the inner mast tube on
a structure capable of supporting it.
8 Remove the fasteners securing the top wear
pad to the front inner mast tube. Set the
fasteners to the side.
9 Install the new wear pads using the fasteners
removed in step 8.
10 Remove the fasteners securing the side and
lower wear pads to the rear outer mast tube.
Set the fasteners to the side.
11 Install the new wear pads using the fasteners
removed in step 10.
12 Install the inner mast tube assembly removed in
step 7, into the outer mast tube of the extension
deck.
13 Align the pin hole at the rod end of the cylinder,
to pin hole of the front outer mast tube.
14 Install the retaining pin removed in step 6 and
secure in place using the snap rings removed in
step 5.
15 Install new wear pads to the top of the outer
mast tube and secure in place using the
fasteners removed in step 4.
GS-2646 Part No. 115371
September 2009 Section 4 • Repair Procedures

REV A
Manifolds
3-1
Powered Extension Deck Function Manifold Components
The powered extension function manifold is mounted behind an inspection door on the battery side of the
machine.
Index Schematic
No. Description Item Function Torque
— Coil nut (item DA) ................................................................................................................. 4-5 ft-lbs / 5-7 Nm
1 Solenoid valve, 3 position 4 way ............... DA ...................... Ext. deck extend/retract ......... 25 ft-lbs / 34 Nm
2 Relief valve,
2200 psi / 152 bar maximum ..................... DB ...................... Extension deck circuit ............ 20 ft-lbs / 27 Nm

OUT
B3
B2
R3 IN B1
R2
R1

INSIDE
COIL
OUTSIDE Y85
COIL
DB Y86
2

RETRACT
Note: 'alpha-numeric' callouts
refer to corresponding notes
on the electrical schematic

DA EXTEND
1

How to Install a Valve Cartridge

1 Dip the cartridge in clean oil to lube the O-rings.
2 Screw the cartridge in by hand until the top
Note: 'alpha' callouts refer
O-ring is met, then torque to specification. to corresponding notes on
the hydraulic schematic
3 Install the valve coil onto the valve stem. Install
the coil nut onto the valve stem and torque to
specification.

Part No. 115371 GS-2646 4 - 11

Section 4 • Repair Procedures September 2009

MANIFOLDS REV A

3-2
Powered Extension Deck Solenoid Valve Body Components
The solenoid valve body is mounted on top of the powered extension deck function manifold.
Index Schematic
No. Description Item Function Torque
_ Coil, #8 20V DC, Deutsch with Diode .............................................................................................................. _
_ Coil Nut .................................................................................................................................. 48 in-lbs / 5.4 Nm
1 Solenoid Valve, 2 Position, 2 Way ............ T ......................... Extension deck circuit ............ 13 ft-lbs / 18 Nm

Note: 'alpha' callouts refer

T to corresponding notes on
the hydraulic schematic
Port 1

Port 2

How to Install a Valve Cartridge

1 Dip the cartridge in clean oil to lube the O-rings.
2 Screw the cartridge in by hand until the top
O-ring is met, then torque to specification.
3 Install the valve coil onto the valve stem. Install
the coil nut onto the valve stem and torque to
specification.

4 - 12 GS-2646 Part No. 115371

September 2009
REV A
3-3
Valve Coils
How to Test a Coil
A properly functioning coil provides an
electromagnetic force which operates the solenoid
valve. Critical to normal operation is continuity
within the coil. Zero resistance or infinite
resistance indicates the coil has failed.
Since coil resistance is sensitive to temperature,
resistance values outside specification can
produce erratic operation. When coil resistance
decreases below specification, amperage
increases. As resistance rises above specification,
voltage increases.
While valves may operate when coil resistance is
outside specification, maintaining coils within
specification will help ensure proper valve function
over a wide range of operating temperatures.
Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
Note: If the machine has been in operation, allow
the coil to cool at least 3 hours before performing
this test.
1 Tag and disconnect the wiring from the coil to
be tested.
2 Test the coil resistance using a multimeter set
to resistance (Ω). Refer to the Valve Coil
Resistance Specification table.
Result: If the resistance is not within the
adjusted specification, plus or minus 10%,
replace the coil.
Part No. 115371 GS-2646
Section 4 • Repair Procedures
MANIFOLDS
Valve Coil Resistance
Specification
Note: The following coil resistance specifications
are at an ambient temperature of 68°F / 20°C. As
valve coil resistance is sensitive to changes in air
temperature, the coil resistance will typically
increase or decrease by 4% for each 18°F / -7.7°C
that your air temperature increases or decreases
from 68°F / 20°C.
Valve Coil Resistance Specifications
Description Specification
Solenoid valve, 3 position 4 way 27.2Ω
20V DC with diode (schematic item AC)
Solenoid valve, 2 position 4 way 19Ω
20V DC with diode (schematic item AI)
Solenoid valve, 2 position 2 way N.C. 25Ω
20V DC with diode (schematic item N)
Solenoid valve, 2 position 4 way 19Ω
20V DC with diode (schematic items AE)
Solenoid valve, 3 position 5 way 19Ω
20V DC with diode (schematic item AG)
Solenoid valve, 3 position 4 way 19Ω
20V DC with diode (schematic item DA)
Solenoid valve, 2 position 2 way N.C. 19Ω
20V DC with diode (schematic item T)
4 - 13
Section 4 • Repair Procedures September 2009

MANIFOLDS REV A

How to Test a Coil Diode COIL

a
MULTI
d
Genie incorporates spike suppressing diodes in all METER
of its coils. Properly functioning coil diodes protect
the electrical circuit by suppressing voltage spikes. c -
Voltage spikes naturally occur within a function

+
circuit following the interruption of electrical current b
to a coil. Faulty diodes can fail to protect the 10 W 9V
RESISTOR BATTERY
electrical system, resulting in a tripped circuit
breaker or component damage. c
b

Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
1 Test the coil for resistance. See 3-3 How to
Test a Coil.
2 Connect a 10Ω resistor to the negative terminal
of a known good 9V DC battery. Connect the
other end of the resistor to a terminal on the
coil.
Note: The battery should read 9V DC or more
when measured across the terminals.
Ω
Resistor, 10Ω
Genie part number 27287
3 Set a multimeter to read DC amperage.
Note: The multimeter, when set to read DC
amperage, should be capable of reading up to
800 mA.
4 Connect the negative lead to the other terminal
on the coil.
Note: If testing a single-terminal coil, connect the
negative lead to the internal metallic ring at either
+
-
end of the coil.
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
5 Momentarily connect the positive lead from the
multimeter to the positive terminal on the 9V
battery. Note and record the current reading.
6 At the battery or coil terminals, reverse the
connections. Note and record the current
reading.
Result: Both current readings are greater than
0 mA and are different by a minimum of 20%.
The coil is good.
Result: If one or both of the current readings are
0 mA, or if the two current readings do not differ
by a minimum of 20%, the coil and/or its
internal diode are faulty and the coil should be
replaced.

4 - 14 GS-2646 Part No. 115371

September 2009 Section 5 • 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/burn hazard.

Troubleshooting and repair procedures shall be
completed by a person trained and qualified on
the repair of this machine.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating the machine.
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.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.
Hydraulic Schematics
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
General Repair Process
Malfunction Identify Troubleshoot
discovered symptoms

problem
still exists

Return to Inspect Perform

service problem and test repair
solved

Part No. 115371 GS-2646 5-1

Section 5 • Schematics September 2009

Electrical Component Legend

REV A

ELECT RICAL COM PONENT LEG END ELECTRICAL COMPONENT LEGEND

I te m Desc ription Item Description
B5 Batter y P Power switch
BN Button P1 = Emergency Stop button at ground controls
BN5 = Hor n P2 = Emergency Stop button at platform controls
BN6 = High to rq ue PT Pressure transducer
BN8 = Dri ve sele ct PT1 = Left front outrigger (GS -3232)
BN9 = Li ft sel ect PT2 = Right front outrigger (GS-3232)
BN1 05 = Outrigger exte nd (G S -3232) PT3 = Right rear outrigger (GS-3232)
BN1 06 = Outrigger function e nable ( GS -3232 ) PT4 = Left rear outrigger (GS -3232)
BN1 07 = Outrigger r etract (GS-3232)
BN1 08 = Powere d extension deck function enabl e, QD Quick disconnect
QD1 = Battery quick disconnect
ground control box
BN1 09 = Powere d extension deck function enabl e, QD3 = Control cable to ground
pla tfor m control box QD4 = Control cable to platform
C5 Cap acitor , 4700 uF QD20 = Cable to outrigger control pad (GS-3232)
QD21 = No charger option
CB 2 Circuit breaker, 7A
CR Contro l relay R Resistor
R24 = 25 ohm
CR5 = Horn r elay ( with H2 opti on)
CR48 = Power r ela y to U5 (e -stop) R26 = 1.5K ohm
CR103 = Ground cut-out (p owe re d extensi on deck) SW Switch
CR104 = T hrottle cut-out (powere d extension deck) SW 5 = Function enable
CR105 = Ground cut-out, redundant (powered extension SW 6 = Steer left/right
deck) SW 48 = Powered extension deck extend/retract
CR106 = Re tract ( powered extensio n d eck) S Sens or
CR107 = Exte nd ( pow ered extension deck) S7 = Tilt level sensor
D7 Voltage regulato r (Platform con tr ols circu it b oar d) S8 = 2 axis tilt level sensor (GS-3232)
F6 Fuse, 275A TS66 Platform up/down toggle switch
FB Flashi ng beaco ns U Electronic component
G Ga uge U3 = Platform controls printed circuit board
G6 = Hou r m eter U5 = Electronic control module
G8 = Diag nostic Display U6 = Motor controller
G ND Gr ound U9 = Battery charger
H Horn o r alarm U13 = V oltage inverter (option)
H1 = Horn U36 = Outrigger control printed circuit board (GS-3232)
H2 = Automotive- style hor n (opti on) U39 = Outrigger control CPU (GS-3232)
H5 = Multifunction al arm U40 = Outrigger control power supply chip (GS-3232)
H8 = Multifunction al arm o utrigger co ntrol p ad ( GS -3232) U41 = Outrigger control transmit/receive chip (GS-3232)
JC1 Joystick con tr oller U42 = Outrigger electronic control module (GS-3232)
K S1 Key switch U46 = P owered extension deck printed circuit board
L LE D or light Y Valve coil
L16 = Lift Y1 = Parallel (GS-2032, GS-2632 and all GS-46)
L17 = Dr ive Y3 = Steer right
L21 = High torque Y4 = Steer left
L30 = W ork lig ht ( opti on) Y5 = Drive reverse
L51 = LF outri gger (GS -3232 ) Y6 = Drive forward
L52 = RF outrigger ( GS -32 32) Y7 = Platform down
L53 = LR outrigger (GS-3232) Y8 = Platform up
L54 = RR o utrigger ( GS -3232) Y9 = Platform down (GS-3246)
L69 = Lift enable (outrig ge r contro l pad) (GS-3 23 2) Y33 = Left rear outrigger (GS-3232)
L70 = Lift erro r ( outri gge r contro l pad) (G S-3232) Y34 = Right rear outrigger (GS-3232)
LS Limi t switch Y35 = Left front outrigger (GS-3232)
LS 5A = Up Li mit Switch (G S-3232) Y36 = Right front outrigger (GS-3232)
LS 5B = Up Li mit Switch (G S-3232) Y39 = Outrigger retract (GS-3232)
LS 6 = Pla tfor m down Y40 = Outrigger extend (GS-3232)
LS 7 = Potho le Y85 = P owered extension deck retract
LS 8 = Potho le Y86 = P owered extension deck extend
LS 29 = Powered e xtensio n d eck Y109 = Powered extension deck extend
LS 30 = Quick disconnect (no char ger o ption)
M5 Hydraulic power unit
NC Norma lly close d
NC HO Norma lly close d held op en
NO HC Norma lly open held cl osed

5-2 GS-2646 Part No. 115371

September 2009 Section 5 • Schematics

Wire Color Legend

REV A

WIRE COLOR LEGEND

C olor Description
BK Black
BL Blue
BL/BK Blue/Black
BL/WH Blue/Wh ite
BN Bro wn
GN Green
GN/BK Green/Black
GN/WH Green/Wh ite
GY Gray
OR Orange
OR/BK Orange/Black
OR/WH Orange/White
PP Purple
RD Red
R D/BK Red/Black
R D/WH Red/White
WH White
WH/BK White/Black
WH/RD White/Red

Part No. 115371 GS-2646 5-3

Section 5 • Schematics September 2009

Limit Switch Legend

REV A

Limit Switch Legend

a pothole switches LS7, LS8

b down limit switch LS6
c quick disconnect limit switch LS30
(no charger option)
d powered extension deck limit switch LS29

5-4 GS-2646 Part No. 115371

September 2009 Section 5 • Schematics

Electrical Symbols Legend

REV A

N.C.
T2 B+
N.O.

A2 3
MOTOR CONTR. ENABLE

Pressure switch, B- 1
LEVEL SENSOR
CIRCUIT BOARD

normally open
S7
Motor controller LEVEL
N.C. N.O. N.C.H.O. N.O.H.C. SENSOR

D1 Level sensor
M5
Limit switch
Wire with description
A1

Motor

Button or switch U9 Solenoid valve

Circuits crossing no
connection

Battery charger
Toggle switch Solenoid valve with diode
Diode -
+

6V DC Battery
Emergency stop button
Capacitor
Circuits connection
CB2

WH B 1 OR
Circuit breaker
2
Connector KS1
KEY PLATFORM
SWITCH CONTROL
30 86

B1 4
87A 87 85

3
Control relay
GROUND
CONTROL

Hour meter Key switch

Fuse

JC1
HALL JOYSTICK
GENERATOR CONTROLLER

Horn or alarm SW6

Light or STEER LEFT/ RIGHT

flashing beacon
RIGHT
LEFT

SW5
FUNCTION
ENABLE

Joystick
Inductor, LED
noise suppression

Part No. 115371 GS-2646 5-5

Section 5 • Schematics September 2009

Electrical Schematic
GS-2646 (after serial number GS4608-90827) REV A

P1
EMERGENCY B 1 OR
STOP
WH
2
KS1
CB2 KEY PLATFORM
CONTROL
7A SWITCH
- NOTE - CIRCUIT
BREAKER B1 4
MACHINE SHOWN
IN THE STOWED 3
POSITION WITH
THE POWER OFF GROUND
CONTROL

L30
WORK LIGHT
(OPTION)

BLACK AND WHITE WIRES CUT POWER

TO MOTOR CONTROLLER WHEN THE
CHARGER IS PLUGGED IN (OPTION).
N.C.
QD1 (+)
LS30
QUICK DISCONNECT F6 275A FUSE BK
LIMIT SWITCH
(NO CHARGER OPTION) WH
M5 GN
A9 OUT
MOTOR D1
BK
A8 OUT
U9 M5
BATTERY
CHARGER
A1
WH
BK A1 OUT
WH
OUT
AC INPUT B8
B+ M-
OR

U6 3
- MOTOR
CONTROLLER
QD21 B- 1
+

QUICK DISCONNECT
(NO CHARGEROPTION) - NOT CONNECTED CR5
WITH MOTOR
CONTROLLER
HORN RELAY
WH

QD21 30 86
+

CUT OFF POWER (H2 OPTION)

- U13 OPTION AND NO
CHARGER OPTION FB
DC/AC INVERTER 87 85
FLASHING
(OPTION)
BEACONS
+

- (OPTION) H2
G6 AUTO-STYLE
HORN
HOUR
+

(OPTION)

B5 QD1(-) METER
GND
4-6V
BATTERY

ES0141S

5-6 GS-2646 Part No. 115371

September 2009 Section 5 • Schematics

Electrical Schematic
REV A GS-2646 (after serial number GS4608-90827)

MC ENABALE WH/BK
MC THROTTLE GN
MC THROTTLE CUT-OUT WH/RD
FUNCTION ENABALE (BASE) WH
FUNCTION ENABALE (PLATFORM) BK
GROUND BN
24V RD
MANIFOLD CUT-OUT BN
POWER EXTENSION DECK (OPTION)

RD RD 4 4
WH WH 3 3
BL 1 1
30 4 86

+ CR48 BK 2 2
POWER
H5 87 85 RELAY TO U5 OR 5 5 QD4
ALARM (E-STOP)
N.O.H.C.
-
N.C.H.O.
LS6
DOWN
TS66 LS7 LIMIT
SWITCH
PLATFORM POTHOLE
UP/DOWN GUARD
SWITCH
UP

DOWN

N.C.H.O.
RD

WH

LS8
POTHOLE N.O.
GUARD
OVERLOAD POWER

DATA LINK (HIGH)

DATA LINK (LOW)
ECM POWER
GND FROM JOYSTICK
SWITCH
LVL SNSR - WHT

LVL SNSR - RED

LEVEL
SENSOR
UP/DWN SW DWN

KEY SWITCH

POTHOLE LIMIT SWITCH

DRIVER POWER

UP LIMIT SWITCH
ALARM
UP/DWN SW UP

CIRCUIT
DWN LIMIT

BOARD

S7
LEVEL
SENSOR

BK
OR/BK

RD/BK

BL/BK

WH
OR

OR
GN
RD

RD

RD

BK
BK
BL

BL

BL

A12 B12 A11 B9 B10 A4 B11 C12 A10 C11 A5 C2 A2 B1 C1

IN IN IN OUT IN IN IN IN IN IN OUT IN IN IN IN

U5
ELECTRONIC CONTROL MODULE

OUT OUT OUT OUT OUT OUT OUT OUT

B3 C8 C7 B7 A7 C6 B6 A6
BN

GN/BK
BL

WH/BK

WH
GN/BK

RD/BK

BL/BK

Y1 Y3 Y4 Y5 Y6 Y9 Y7 Y8
PARALLEL STEER STEER DRIVE DRIVE PLATFORM PLATFORM PLATFORM
RIGHT LEFT REVERSE FORWARD DOWN DOWN UP
(GS-3246)

GND

ES0141S

Part No. 115371 GS-2646 5-7

Section 5 • Schematics September 2009

Electrical Schematic
GS-2646 (after serial number GS4608-90827) REV A

WH/BK MC ENABALE
GN MC THROTTLE
WH/RD MC THROTTLE CUT-OUT
WH FUNCTION ENABALE (BASE)
BK FUNCTION ENABALE (PLATFORM)
BN GROUND EN10
RD 24V
BN MANIFOLD CUT-OUT POWER EXTENSION DECK
POWER EXTENSION DECK (OPTION) PLATFORM CONTROL BOX

BN109 SW48
FUNCTION EXTENSION DECK
ENABLE EXT/RET
OR
RD BK

BN108
FUNCTION

RD

RD
BK

WH/BK
ENABLE CR106
CR107 RETRACT
EXTEND
WH

30 11 86 30 10 86

SW48 87 85 87 85

EXTENSION
BK

BN

BN
WH/BK
DECK
EXT/RET

- NOTE -
MACHINE SHOWN IN THE
STOWED POSITION WITH
THE POWER OFF

ES0141S

5-8 GS-2646 Part No. 115371

September 2009 Section 5 • Schematics

Electrical Schematic
REV A GS-2646 (after serial number GS4608-90827)

- NOTE -
MACHINE SHOWN IN THE
STOWED POSITION WITH
THE POWER OFF
EXTENSION DECK LIMIT SWITCH
DRIVE & LIFT CUT-OUT
LS29
N.O.
WH WH BK
BL
RD

OR

EN9
POWER EXTENSION DECK
GROUND CONTROL BOX
CR105 CR104 CR103
GROUND THROTTLE GROUND
OR

OR
BN

CUT-OUT CUT-OUT CUT-OUT

(REDUNDANT)
OR

BN
GN

30 9 86 30 8 86 30 7 86 U46
POWER EXTENSION DECK
87 85 87 85 87 85 PRINTED CIRCUIT BOARD
WH/RD
BN

BN

BN
BN

WH/BK

BK
WH/RD R26
1.5K OHM
WH/BK 1WATT
R26
1.5K OHM
1WATT

BN
BN

WH/BK
BK

BK

BN

Y109 Y86 Y85

EXTEND EXTEND RETRACT

ES0141S

Part No. 115371 GS-2646 5-9

Section 5 • Schematics September 2009

Electrical Schematic
GS-2646 (after serial number GS4608-90827) REV A

- NOTE -
MACHINE SHOWN IN THE
STOWED POSITION WITH
P2 THE POWER OFF
QD3 EMERGENCY
STOP
BK
4 4 BK POWER TO PLATFORM
RD
3 3 RD POWER TO GROUND

1 1 WH GROUND PIO3
PIO2
2 2 BL DATA LINK (HIGH) PIO4

5 5 OR DATA LINK (LOW) PIO5

24V DC

U3 D7 5V DC

PLATFORM CONTROLS VOLTAGE

PRINTED CIRCUIT BOARD REGULATOR

BN HALL EFFECT JC1

GENERATOR JOYSTICK
GY CONTROLLER

GN
WH
BL

SW5 SW6
PP FUNCTION ENABLE STEER
LEFT/ RIGHT
OR
LEFT

RIGHT

PIN9
BK
PIN8
RD
PIN10

BK
PLATFORM CONTROLS
MEMBRANE DECAL
POUT1 LIFT LED L16
POUT2 DRIVE LED L17
POUT3 HIGH TORQUE LED L21

G8
POUT4 DIAGNOSTIC
DISPLAY

PIN1 HIGH TORQUE BN6

PIN2 HORN BN5

PIN3 DRIVE ENABLE BN8

PIN4 LIFT ENABLE BN9

RD
POUT11 +

BK
H1
ALARM
PLATFORM
PIN11 - CONTROLLER

ES0141S

5 - 10 GS-2646 Part No. 115371

September 2009 Section 5 • Schematics

REV A

This page intentionally left blank.

Part No. 115371 GS-2646 5 - 11

Section 5 • Schematics September 2009

Component Reference and

Hydraulic Symbols Legend REV A

M
Hydraulic cylinder
Variable speed motor Brake

Pilot operated
check valve with
needle valve
Shuttle valve

Fixed displacement
Relief valve pump Y4 Y3

Solenoid operated
Y7 3 position 4 way
directional valve
Y1
Solenoid operated Bi-directional motor
2 position 2 way Solenoid operated
directional valve 2 position 4 way
normally closed directional valve
Y6 Y5

0.037 incn Solenoid operated

0.94 mm
3 position 4 way
directional valve
Orifice Priority flow regulator
with size
Accumulator
Y6 Y5
PS2
Solenoid operated
Platform overload Filter 3 position 5 way
pressure switch Check valve
directional valve

Y109
Solenoid operated
Solenoid operated 2 position 2 way
2 position 2 way valve, directional valve
normally closed

5 - 12 GS-2646 Part No. 115371

September 2009 Section 5 • Schematics

Component Reference and

REV A Hydraulic Symbols Legend

AC
AB AD

AA

Y4
Y3
Y1

Y8

AJ AI AH
AF
AG AE
Function manifold,
GS-2032, GS-2632, GS-3232
GS-2046, GS-2646 and GS-3246

OUT
B3
B2
R3 IN B1
R2
R1
J
INSIDE
COIL
OUTSIDE
COIL
Y85
T M
Y86

K
RETRACT
EXTEND
DB DA L
Function manifold, Solenoid valve manifold,
Powered extension deck Powered extension deck Brake release manifold

Part No. 115371 GS-2646 5 - 13

Section 5 • Schematics September 2009

Hydraulic Schematic
GS-2646 (after serial number GS4607-84839) REV A

LEFT RIGHT
PLATFORM
LIFT CYLINDER
OVERLOAD BRAKE RELEASE BRAKE
(CE MODELS)
PRESSURE
370 to 450 psi
26 to 31 bar MANUAL
N M RELEASE
PS2
0.037 inch
0.94 mm HAND
R Y7
PUMP

BRAKE
0.059 inch
RELEASE L
THE ORIFICE IS LOCATED 1.5 mm
O
MANIFOLD
UNDERNEATH THE HOSE
FITTING ON THE LIFT CYLINDER
B1
STEER STEER LEFT RIGHT
LEFT RIGHT P
4.75 CU. IN. DRIVE DRIVE
78 cc
MOTOR MOTOR

FORWARD

REVERSE
V S1 S2 HP B AC M1 M3 M2 M4

AC

Y4 Y3
AE
Y1

AD
L

0.25 gpm Y6 Y5
0.95 L/min
AG
1500 psi
103 bar
AI
AA 0.75 gpm
2.8 L/min AH 50 psi
AF
TP
3.4 bar

AJ

AB
Y8
FUNCTION MANIFOLD
0.25 gpm @ 1800 to 3700 psi
0.95 L/min @ 124 to 255 bar

0.25 gpm @ 3700 psi

0.95 L/min @ 255 bar

P T

ABBREVIATION LEGEND
Item Description
M AA Test port
AB Relief valve, system
POWER UNIT 10 MICRON WITH
4 gpm @ 2500 psi 25 psi / 1.7 bar AC Steer left/right
15 L/min @ 172 bar BYPASS AD Check valve, steer circuit
AE Drive speed
AF Relief valve, brake release
HYDRAULIC TANK AG Drive forward/reverse
To Powered Extension Deck Manifold In Port
AH Flow regulator/relief valve
AI Platform up
To Powered Extension Deck Manifold Out Port
AJ Relief valve, lift
DA 3 position, 4 way directional valve –
outrigger cylinder extend/retract
HS0036N DB Relief valve, outrigger circuit

5 - 14 GS-2646 Part No. 115371

September 2009 Section 5 • Schematics

Hydraulic Schematic
REV A GS-2646 (from serial number GS4608-90828)

RETRACT

EXTEND

1
POWERED Y109
EXTENSION
SOLENOID
T
VALVE BLOCK
2

B3 B2 B1 R3 R2 R1

POWERED
EXTENSION
DECK
MANIFOLD

DA
Y85 Y86

IN
DB
OUT
2200 psi
152 bar

From Pump 0.25 gpm @ 3700 psi

0.95 L/mim @ 255 bar

To Function Manifold (P) PORT

ABBREVIATION LEGEND cont.

Item Description
L Hand pump, manual brake release
M Needle valve, manual brake release
N Platform lowering valve
O Orifice, platform down circuit
P Accumulator
Q Relief valve, platform down
R Pressure switch, platform overload
T 2 position, 2 way directional valve,
powered extension deck circuit

HS0041C

Part No. 115371 GS-2646 5 - 15