Genie Maintenance Manuals From SN 12C-101, 14D-101, 16P-101, P-1000 Service Manual

Service and Repair Manual

GS™-1530/1532

Refer to the

GS™-1930/1932

GS™-2032/2632/3232

GS™-2046/2646/3246

GS™-4047

October 2023

Serial Number Range

inside cover

This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics

For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.

Original Instructions
Part No. 1272217GT
Rev E1

Service and Repair Manual October 2023

GS-1530, GS-1532, GS-1930, GS-1932

GS-4047

Introduction

Introducti on Introducti on

Serial Number Range

Compliance

Machine Classification

Group A/Type 3 as defined by ISO 16368

Machine Design Life

Unrestricted with proper operation, inspection
and scheduled maintenance.

Contact Us:

Internet: www.genielift.com
E-mail: [e-mail]

Find a Manual for this Model

Go to https://www.genielift.com

Use the links to locate Service Manuals,
Maintenance Manuals, Service and Repair
Manuals, Parts Manuals and Operator's
Manuals.

Copyright © 2016 by Terex Corporation

1272215GT Rev E, March 2021
First Edition, Fifth Printing

Genie is a registered trademark of Terex South Dakota, Inc.
in the U.S.A. and many other countries.

“GS” is a trademark of Terex South Dakota, Inc.

Use the following chart to identify the specific
serial number for models included in this
manual.

from SN GS3010A-110000
from SN GS3011C-10000 to GS3016C-23999
from SN GS3014D-101 to GS3016D-607
from SN GS3016P-151487 to GS3016P-160599
from SN GS30C-24000
from SN GS30D-6080 to GS30D-40100
from SN GS30P-160600 to GS30P-200100

GS-2032, GS-2632, GS-3232

from SN GS3211A-110000
from SN GS3212C-10000 to GS3216C-17299
from SN GS3216P-142676 to GS3216P-148699
from SN GS32C-17300
from GS32D-101 to GS32D-10100
from SN GS32P-148700 to GS32P-200100

GS-2046, GS-2646, GS-3246

from SN GS4612A-110000
from SN GS4612C-10000 to GS4616C-18099
from SN GS4614D-101 to GS4616D-5029
from SN GS4616P-138362 to GS4616P-141799
from SN GS46C-18100
from SN GS46D-5030 to GS46D-20100
from SN GS46P-141800 to GS46P-200100

from SN GS4712C-101 to GS4716C-4499
from SN GS4714D-101 to GS4716D-3959
from SN GS4716P-101 to GS4716P-999
from SN GS47C-4500
from SN GS47D-3960
from SN GS47P-1000

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October 2023 Service and Repair Manual

Reference Examples:

Introduction

Revision History

Revision Date Section Procedure / Page / Description

A 3/2016

A1 5/2016 Repair Procedures 2-3, 2-4, 9-11

Diagnostics H067 fault

A2 5/2016 Repair Procedure 2-6

Diagnostics Type CXXX and UXXX fault codes

A3 9/2016 Introduction Serial Number Legend

Specifications Add drive speed stowed parameters

B 4/2017 Repair Procedure 11-1

Diagnostics Battery charger and fault codes

B1 12/2017 Schematics GS46, GS47 AS/CE

C 1/2019 All Sections Added GS-1330m

D 8/2019 All Sections Added GS-4655

E 3/2021

All Sections Remove GS-1330m, GS-4655

E1 9/2023 Repair Procedure 9-11

Initial Release

Add ending serial break

Section – Repair Procedure, 4-2

Section – Fault Codes, All charts

Section – Schematics, Legends and
schematics

Part No. 1272217GT GS

Electronic Version

Click on any content or procedure in the Table of Contents to view the

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update.

Service and Repair Manual October 2023

Introduction

Revision History(continued)

Revision Date Section Procedure / Page / Description

Reference Examples:

Section – Repair Procedure, 4-2

Section – Fault Codes, All charts

Section – Schematics, Legends and
schematics

Electronic Version

Click on any content or procedure in the Table of Contents to view the

update.

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October 2023 Service and Repair Manual

Introduction

Serial Number Legend

To August 31, 2016

1. Model

2. Model year

3. Facility code

From September 1, 2016

1. Model

2. Facility code

3. Sequence number

4. Sequence number

5. Serial label located on chassis

6. Serial number (stamped on chassis)

4. Serial label located on chassis

5. Serial number (stamped on chassis)

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Service and Repair Manual October 2023

Safety Rules

Section 1 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 modify or alter a MEWP without prior
written permission from the manufacturer.

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.

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hazardous situation which, if not

hazardous situation which, if not

hazardous situation which, if not

hazardous situation which, if not

Be sure that fasteners intended for one

Safety Rules

Personal Safety

Any person working on or around a machine
must be aware of all known safety hazards.
Personal safety and the continued safe
operation of the machine should be your top
priority.

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 personnel to potential

Be sure to wear protective eye wear
and other protective clothing if the
situation warrants it.

personal injury hazards. Obey
all safety messages that follow
this symbol to avoid possible
injury or death.

Indicates a imminently

avoided, will result in death or
serious injury.

Indicates a potentially

avoided, could result in death or
serious injury.

Indicates a potentially

avoided, may cause minor or
moderate injury.

Indicates a potentially

avoided, may result in property
damage.

Workplace Safety

Any person working on or around a machine
must be aware of all known safety hazards.
Personal safety and the continued safe
operation of the machine should be your top
priority.

Be sure to keep sparks, flames and
lighted tobacco away from flammable
and combustible materials like battery
gases and engine fuels. Always have
an approved fire extinguisher within
easy reach.

Be sure that all tools and working areas
are properly maintained and ready for
use. Keep work surfaces clean and free
of debris that could get into machine
components and cause damage.

Be sure any forklift, overhead crane or
other lifting or supporting device is fully
capable of supporting and stabilizing
the weight to be lifted. Use only chains
or straps that are in good condition and
of ample capacity.

time use (i.e., cotter pins and self­locking 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.

Be sure that your workshop or work
area is properly ventilated and well lit.

Be aware of potential crushing hazards
such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved
steel-toed shoes.

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October 2023

Table of Contents

Introduction Introduction ........................................................................................................... ii

Find a Manual for this Model .................................................................................. ii

Serial Number Range ............................................................................................. ii

Revision History ..................................................................................................... iii

Serial Number Legend ............................................................................................ v

Section 1 Safety Rules ......................................................................................................... vi

General Safety Rules ............................................................................................ vi

Section 2 Specifications ....................................................................................................... 1

Machine Specifications ........................................................................................... 1

Performance Specifications (models without proportional lift function) .................. 3

Performance Specifications (models with proportional lift) .................................... 5

Hydraulic Oil Specifications .................................................................................... 7

Hydraulic Component Specifications .................................................................... 10

Manifold Component Specifications ..................................................................... 11

Hydraulic Hose and Fitting Torque Specifications ................................................ 12

Torque Procedure ................................................................................................. 13

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Table of Contents

Section 3 Repair Procedures ............................................................................................. 15

Introduction ........................................................................................................... 15

Platform Controls ............................................................................................... 17

1-1 Circuit Board................................................................................................... 19

1-2 Joystick ........................................................................................................... 20

1-3 Platfrom Controls Alarm ................................................................................. 21

1-4 Platform Emergency Stop Button ................................................................... 21

Ground Controls ................................................................................................. 23

2-1 Software Revision Level ................................................................................. 24

2-2 Machine Setup ............................................................................................... 25

2-3 Loading or Updating Machine Software ......................................................... 26

2-4 Using a Wi-Fi Router to Connect to the SmartLink Web Service Tool .......... 31

2-5 Service Override Mode .................................................................................. 33

2-6 Level Sensors ................................................................................................ 35

2-7 Manual Platform Lowering Cable ................................................................... 50

2-8 Outrigger Calibration ...................................................................................... 52

Hydraulic Tank .................................................................................................... 53

3-1 Hydraulic Tank ............................................................................................... 53

Hydraulic Pump .................................................................................................. 54

4-1 Hydraulic Pump .............................................................................................. 54

How to Remove the Hydraulic Pump .............................................................. 55

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October 2023

Table of Contents

Manifolds ............................................................................................................. 56

5-1 Function Manifold Components –

GS-1530, GS-1532, GS-1930 and GS-1932 ................................................ 56

5-2 Function Manifold Components –

GS-2032, GS-2632, GS-3232, GS-2046, GS-2646 and GS-3246 ............... 58

5-3 Function Manifold Components – GS-4047 ................................................... 60

5-4 Check Valve Manifold Components –

GS-1530, GS-1532, GS-1930 and GS-1932 ................................................ 62

5-5 Lift Pressure Selector Manifold Components – GS-4047 .............................. 63

5-6 Outrigger Function Manifold Components – GS-3232 ................................... 64

5-7 Outrigger Cylinder Manifold Components – GS-3232 ................................... 65

5-8 Valve Adjustments – Function Manifold ......................................................... 66

5-9 Valve Coils...................................................................................................... 72

Steer Axle Components ..................................................................................... 74

6-1 Yoke and Drive Motor ..................................................................................... 74

6-2 Steer Cylinder ................................................................................................. 75

6-3 Steer Bellcrank ............................................................................................... 76

Non-Steer Axle Components ............................................................................. 77

7-1 Drive Brake ..................................................................................................... 77

Brake Release Hand Pump Components ......................................................... 78

8-1 Brake Release Hand Pump Components ...................................................... 78

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Scissor Components ......................................................................................... 79

9-1 Scissor Assembly, GS-1530 and GS-1532 .................................................... 80

9-2 Scissor Assembly, GS-1930 and GS-1932 .................................................... 86

9-3 Scissor Assembly, GS-2032 and GS-2046 .................................................... 94

9-4 Scissor Assembly, GS-2632 and GS-2646 .................................................. 101

9-5 Scissor Assembly, GS-3232 and GS-3246 .................................................. 109

9-6 Scissor Assembly, GS-4047 ........................................................................ 118

9-7 Scissor Arm Wear Pads ............................................................................... 126

9-8 Platform Height Sensor ................................................................................ 128

9-9 Lift Cylinder .................................................................................................. 130

9-10 Pressure Transducer .................................................................................. 141

9-11 Platform Overload System ......................................................................... 143

9-12 Platform Overload Recovery ...................................................................... 148

Platform Components ...................................................................................... 150

10-1 Platform ...................................................................................................... 150

10-2 Platform Extension Deck ............................................................................ 151

Battery Charger ................................................................................................ 152

11-1 Battery Charger .......................................................................................... 152

Selecting a Charge Profile ............................................................................ 153

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Table of Contents

Section 4 Diagnostics ....................................................................................................... 155

Introduction ......................................................................................................... 155

GCON I/O Map without Load Sense (all machines except GS-3232)................ 158

GCON I/O Map with Load Sense (all machines except GS-3232) ..................... 159

GCON I/O Map without Load Sense GS-3232 only) .......................................... 160

GCON I/O Map with Load Sense (GS-3232 only) .............................................. 162

Operation Indicator Codes (OIC) ........................................................................ 164

Diagnostic Trouble Codes (DTC) ....................................................................... 165

Troubleshooting "HXXX" and "PXXX" Faults ..................................................... 166

Fault Inspection Procedure ................................................................................. 167

Type "HXXX" Faults ........................................................................................... 169

Type "PXXX" Faults ............................................................................................ 173

Type "UXXX" Faults ........................................................................................... 174

Type "FXXX" Faults ............................................................................................ 177

Type "CXXX" Faults ........................................................................................... 180

Battery Charger .................................................................................................. 182

Charger Fault Codes ..................................................................................... 183

Charger Error Codes ..................................................................................... 184

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Section 5 Schematics ........................................................................................................ 188

Introduction ......................................................................................................... 188

Electrical Component and Wire Color Legends ................................................. 189

Wiring Diagram Ground and Platform Controls .................................................. 192

Limit Switch Legend ........................................................................................... 193

Electrical Symbol Legend ................................................................................... 194

Hydraulic Symbols Legend ................................................................................. 195

Hydraulic Component Abbreviation Legend ....................................................... 196

Hydraulic Schematics ...................................................................................... 198

Hydraulic Schematic, GS-1530, 1532, 1930, 1932

(from serial number GS3010A-110000, GS3011C-10000,

GS3014D-101, GS3016P-142281)............................................................. 198

Hydraulic Schematic, GS-2032, 2632, 3232, 2046, 2646, 3246

(from serial number GS3211A-110000 to GS3214A-119070,
GS3212C-10000 to GS3214C-11873, GS4612A-110000 to

GS4614A-117177, GS4614C-10000 to GS4614C-12073) ........................ 199

Hydraulic Schematic, GS-2032, 2632, 3232, 2046, 2646, 3246

(from serial number GS3214A-119071, GS3214C-11874,

GS4614A-117178, GS4614C-12074, GS4614D-101) ............................... 200

Hydraulic Schematic, GS-3232 (from serial number

GS3211A-110000, GS3212C-10000, GS3216P-142677) ......................... 201

Hydraulic Schematic, GS-4047

(from serial number GS4712C-101 to GS4714C-1459) ............................. 202

Hydraulic Schematic, GS-4047

(from serial number GS4714C-1460, GS4714D-101, GS4716P-101) ....... 203

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Table of Contents

Electrical Schematics – ANSI / CSA Models .................................................. 204

Electrical Schematic GS-1530 / GS-1930, ANS / CSA

(from serial number GS3010A-110000 to GS3011A-110827) ................... 205

Electrical Schematic, GS-1530 / GS-1930, ANSI / CSA

(from serial number GS3011A-110828 to GS3014A-136972,

GS3014D-101 to GS3015D-1113) ............................................................. 209

Electrical Schematic, GS-1530 / GS-1930, ANSI / CSA

(from serial number GS3014A-136973, GS3015D-1114 to

GS3016D-5426, GS3016P-142281 to GS3016P-158208) ......................... 213

Electrical Schematic, GS-1530/1930, ANSI/CSA

(from serial number GS3016D-5427, GS3016P-158209) .......................... 217

Electrical Schematic, GS-3232, ANSI / CSA

(from serial number GS3211A-110000 to GS3214A-135714) ................... 219

Electrical Schematic, GS-3232, ANSI / CSA

(from serial number GS3214A-135715 to GS3215A-141898) ................... 223

Electrical Schematic, GS-3232, ANSI / CSA (from serial number

GS3215A-141899, GS3216P-142677 to GS3216P-146462) ..................... 227

Electrical Schematic, GS-3232, ANSI / CSA

(from serial number GS3216P-146463) ..................................................... 231

Electrical Schematic, GS-2032, 2632, 2046, 2646, ANSI / CSA

(from serial number GS3211A-110000 to GS3214A-135714,
GS4612A-110000 to GS4614A-135366, GS4613D-101 to

GS4615D-1303) .......................................................................................... 235

Electrical Schematic, GS-2032, 2632, 2046, 2646, ANSI/CSA

(from serial number GS3214A-1135715 to GS3215A-141898,

GS4614A-135367 to GS4615A-137959, GS4615D-1304) ......................... 239

Electrical Schematic, GS-2032, 2632, 2046, 2646, ANSI / CSA

(from serial number GS3215A-141899, GS3216P-142676 to
GS3216P-146462, GS4615A-137960, GS4615D-1305 to

GS4616D-4432, GS4616P-138362 to GS4616P-139710) ......................... 243

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Electrical Schematic, GS-2032, 2632, 2046, 2646, ANSI / CSA

(from serial number GS3216P-146463, GS4616D-4433,

GS4616P-139711) ...................................................................................... 247

Electrical Schematic, GS-3246 / GS-4047, ANSI / CSA

(from serial number GS4612A-110000 to GS4614A-135366,

GS4614D-101 to GS4615D-1303, GS4714D-101 to GS4715D-749) ........ 249

Electrical Schematic, GS-3246 / GS-4047, ANSI / CSA

(from serial number GS4614A-135367 to GS4615A-137959,
GS4615D-1304 to GS4616D-4432, GS4616P-138362 to

GS4616P-139710, GS4715D-750 to GS4716D-3101) .............................. 253

Electrical Schematic, GS-3246, GS4047 ANSI / CSA

(from serial number GS4616D-4433, GS4616P-139711,

GS4716D-3102, GS4716P-101)................................................................. 257

Electrical Schematics – CE and Australia Models ........................................ 258

Electrical Schematic GS-1530, 1532, 1930, 1932, AS / CE

(from serial number GS3010A-110000 to GS3011A-110827) ................... 259

Electrical Schematic, GS-1530/32_GS-1930/32, AS / CE

(from serial number GS3011A-110828 to GS3014A-136972,
GS3011C-10000 to GS3015C-18038, GS3014D-101 to

GS3015D-1113) ......................................................................................... 263

Electrical Schematic, GS-1530, 1532, 1930, 1932, AS / CE

(from serial number GS3014A-136973, GS3015C-18039,
GS3015D-1114 to GS3016D-5426, GS3016P-142281 to

GS3016P-158208) ...................................................................................... 267

Electrical Schematic, GS-1530, 1532, 1930, 1932, AS / CE

(from serial numbers GS3015D-5427, GS3016P-158209) ........................ 271

Electrical Schematic, GS-3232, AS / CE

(from serial number GS3211A-110000 to GS3214A-135714,

GS3212C-10000 to GS3215C-14503) ....................................................... 273

Electrical Schematic, GS-3232, AS / CE (from serial number

GS3214A-135715 to GS3215A-141898, GS3215C-14504) ...................... 277

Electrical Schematic, GS-3232, AS / CE (from serial number

GS3215A-141899, GS3216P-142676 to GS3216P-146462) ..................... 281

Electrical Schematic, GS-3232, AS / CE

(from serial number GS3216P-146463) ..................................................... 285

Electrical Schematic, GS-2032, 2632, 2046, 2646, AS / CE

(from serial number GS3211A-110000 to GS3214A-135714,
GS3212C-10000 to GS3215C-14377, GS4612A-110000 to
GS4614A-135366, GS4612C-10000 to GS4615C-14503,

GS4613D-101 to GS4615D-1303) .............................................................

289

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Electrical Schematic, GS-2032, 2632, 2046, 2646, AS / CE

(from serial number GS3214A-135715 to GS3215A-141898,
GS3215C-14378, GS4614A-135367 to GS4615A-137959,

GS4615C-14504, GS4615D-1304) ............................................................ 293

Electrical Schematic, GS-2032, 2632, 2046, 2646, AS / CE

(from serial number GS3215A-141899, GS3216P-142676 to
GS3216P-146462, GS4615A-137960, GS4616P-138362 to

GS4616P-139710) ...................................................................................... 297

Electrical Schematic, GS-2032, 2632, 2046, 2646, AS / CE

(from serial number GS3216P-146463, GS4616P-139711) ...................... 301

Electrical Schematic, GS-3246, AS / CE (from serial number

GS4612A-110000 to GS4614A-135366, GS4612C-10000 to

GS4615C-14503, GS4614D-101 to GS4615D-1303) ................................ 303

Electrical Schematic, GS-3246, AS / CE (from serial number

GS4614A-135367 to GS4615A-137959, GS4615C-14504,

GS4615D-1304) .......................................................................................... 307

Electrical Schematic, GS-3246, AS / CE (from serial number

GS4615A-137960, GS4616P-138362, GS4616P to GS4616P-139710) ... 311

Electrical Schematic, GS-3246, AS / CE

(from serial number GS4616D-4433, GS4616P-139711) .......................... 315

Electrical Schematic, GS-4047, AS / CE (from serial number

GS4712C-101 to GS4715C-2130, GS4714D-101 to GS4715D-749) ........ 317

Electrical Schematic, GS-4047, AS / CE (from serial number

GS4715C-2131, GS4715D-750 to GS4716D-3101) .................................. 321

Electrical Schematic, GS-4047, AS / CE

(from serial number GS4716D-3102) ......................................................... 325

Electrical Schematic – Foot Switch (option) All Models .............................. 326

Foot Switch (option) All Models .......................................................................... 327

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October 2023 Service and Repair Manual

Batteries, Standard, GS-4047

(if equipped) GS-3232, GS-4047

3.4 gallons

Specifications

Section 2 Specificati ons

Machine Specifications

For operational specifications, refer to the
Operator's Manual.

Batteries, Standard
All models except GS-4047

Voltage 6V DC

Group GC2

Type T-105

Quantity 4

Battery capacity, maximum C20 = 225AH

Reserve capacity @ 25A rate 447 minutes

Weight, each

Voltage 12V DC

Group GC2

Type T-1275

Quantity 4

Battery capacity, maximum C20 = 150AH

Reserve capacity @ 25A rate 280 minutes

Weight, each

Batteries, Maintenance-free (option)
All models except GS-4047

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

82 lbs

37 kg

62 lbs

28 kg

Platform Overload Pressure Transducer
(if equipped) All models except GS-3232,
GS-4047

Input voltage 8 to 30 VDC

Signal voltage 1 to 5 V

Platform Overload Pressure Transducer

Input voltage 8 to 30 VDC

Signal voltage 0.25 to 6.25 V

Angle Sensor (if equipped)

Input voltage 8 to 30 VDC

Signal voltage 3 to 4 V, PMW output

Outrigger Pressure Transducer, GS-3232 only

Input voltage 8 to 30 VDC

Signal voltage 1 to 5 V

Fluid capacities

Hydraulic tank
All models except GS-4047

Hydraulic tank, GS-4047

12.9 liters

5.9 gallons

22.4 liters

Hydraulic system (including tank) GS­1530, GS-1532, GS-1930, GS-1932

Hydraulic system (including tank)
GS-2032, GS-2632, GS-2046, GS-

3.8 gallons

14.2 liters

4.5 gallons
17 liters

2646

Hydraulic system (including tank) GS­3232, GS-3246

Hydraulic system (including tank) GS­4047

5.5 gallons

20.8 liters

7.5 gallons

28.4 liters

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Service and Repair Manual October 2023

GS-3246, GS-4047

Specifications

Tires and wheels

GS-1530, GS-1532, GS-1930, GS-1932

Tire size (solid rubber)

Tire contact area

Castle nut torque, dry

Castle nut torque, lubricated

GS-2032, GS-2632, GS-3232, GS-2046, GS-2646,

12 x 4.5 in

30.5 x 11.4 cm

9 sq in

58 cm

300 ft-lbs

406.7 Nm

225 ft-lbs

305 Nm

2

Tire size (solid rubber)

Tire contact area

Castle nut torque, dry

Castle nut torque, lubricated

15 x 5 in

38.1 x 12.7 cm

15 sq in

96.7 cm

300 ft-lbs

406.7 Nm

225 ft-lbs

305 Nm

2

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Drive speed, maximum

GS-1530, GS-1532, GS-1930, GS-1932

Airborne noise emissions

Specifications

Performance Specifications
(models without proportional
lift)

Platform stowed, fast

12.2 m / 10.9 sec

Platform raised

GS-2032, GS-2632, GS-3232, GS-2046, GS-2646,
GS-3246

Platform stowed, fast

o serial number

t
GS3216P-145830
GS4616P-139575

Platform stowed, fast

from serial number

GS3216P-145831
GS4616P-139576

Platform raised

:

12.2 m / 12.4 sec

:

12.2 m / 12.4 sec

2.5 mph

40 ft / 10.9 sec

4 km/h

0.5 mph

40 ft / 55 sec

0.8 km/h

12.2 m / 55 sec

2.2 mph

40 ft / 12.4 sec

3.5 km/h

2.0 mph

40 ft / 12.4 sec

3.2 km/h

0.5 mph

40 ft / 55 sec

0.8 km/h

12.2 m / 55 sec

GS-4047

Platform stowed, fast

Platform raised

Braking distance, maximum

High range on paved surface

Gradeability

GS-1930, GS-1932,
GS-2632,GS-3232,
GS-3246 and GS-4047

GS-1530, GS-1532, GS-2032,
GS-2046 and GS-2646

Sound pressure level at ground
workstation

Sound pressure level at platform
workstation

2.0 mph

40 ft / 13.6 sec

3.2 km/h

12.2 m / 13.6 sec

0.5 mph

40 ft / 55 sec

0.8 km/h

12.2 m / 55 sec

1 - 3 ft

0.3 - 0.9 m

25%

30%

< 70 dBA

< 70 dBA

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Service and Repair Manual October 2023

GS-1530 and GS-1532

GS-1930 and GS-1932

GS-2046 and GS-2646

GS-3232 Outrigger leveling capacity, maximum

Specifications

Performance Specifications
(without proportional lift), continued

Function speed, maximum from platform
controls (with 1 person in platform)

Platform up (fast mode)
Platform up (slow mode)
Platform down

Platform up (fast mode)
Platform up (slow mode)
Platform down

GS-2032 and GS-2632

Platform up (fast mode)
Platform up (slow mode)
Platform down

Platform up (fast mode)
Platform up (slow mode)
Platform down

GS-3232 and GS-3246

Platform up (fast mode)
Platform up (slow mode)
Platform down

15 to 17 seconds
30 to 32 seconds
28 to 30 seconds

15 to 17 seconds
30 to 32 seconds
28 to 30 seconds

28 to 32 seconds
58 to 62 seconds
32 to 36 seconds

28 to 32 seconds
58 to 62 seconds
32 to 36 seconds

55 to 59 seconds

108 to 112 seconds

33 to 37 seconds

GS-4047

Platform up (fast mode)
Platform up (slow mode)
Platform down

71 to 76 seconds
83 to 87 seconds
41 to 46 seconds

Rated work load at full height, maximum

GS-1530 and GS-1532

GS-1930, GS-1932,
GS-2632 and GS-3232

GS-2032

GS-2046

GS-2646

GS-3246

GS-4047
(CE and AS models)

GS-4047
(ANSI and CSA models)

Side to side
Front to rear

600 lbs

272 kg

500 lbs

227 kg

800 lbs

363 kg

1200 lbs

544 kg

1000 lbs

454 kg

700 lbs

317 kg

770 lbs

350 kg

550 lbs

250 kg

5°
3°

4 GS

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October 2023 Service and Repair Manual

Drive speed, maximum

Airborne noise emissions

Specifications

Performance Specifications (models with proportional lift)

GS-1530, GS-1532, GS-1930, GS-1932

Platform stowed

12.2 m / 10,9 sec

Platform raised

GS-2032, GS-2632, GS-3232, GS-2046, GS-2646,
GS-3246

Platform stowed

o serial number

t
GS3216P-145830
GS4616P-139575

Platform stowed

from serial number

GS3216P-145831
GS4616P-139576

Platform raised

:

12.2 m / 12,4 sec

:

12.2 m / 12,4 sec

2.5 mph

40 ft / 10.9 sec

4 km/h

0.5 mph

40 ft / 55 sec

0,8 km/h

12.2 m / 55 sec

2.2 mph

40 ft / 12.4 sec

3,5 km/h

2.0 mph

40 ft / 12.4 sec

3,2 km/h

0.5 mph

40 ft / 55 sec

0,8 km/h

12.2 m / 55 sec

GS-4047

Platform stowed

Platform raised

Braking distance, maximum

High range on paved surface

Gradeability

GS-1930, GS-1932,
GS-2632, GS-3232, GS-3246,
GS-4047

GS-1530, GS-1532, GS-2032,
GS-2046, GS-2646

Sound pressure level at ground
workstation

Sound pressure level at platform
workstation

2.0 mph

40 ft / 13.6 sec

3,2 km/h

12.2 m / 13,6 sec

0.5 mph

40 ft / 55 sec

0,8 km/h

12.2 m / 55 sec

1 - 3 ft

0,3 - 0,9 m

25%

30%

< 70 dBA

< 70 dBA

Part No. 1272217GT GS

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Service and Repair Manual October 2023

GS-1530, GS-1532

GS-1930, 1930PAR, GS-1932

28 to 32 seconds

GS-2046, GS-2646

GS-4047

GS-3232 Outrigger leveling capacity, maximum

Specifications

Performance Specifications
(with proportional lift), continued

Function speed, maximum from platform
controls (with 1 person in platform)

Platform up
Platform down

Platform up
Platform down

GS-2032, GS-2632

Platform up
Platform down

Platform up
Platform down

GS-3232, GS-3246

Platform up
Platform down

Platform up
Platform down

15 to 17 seconds
18 to 25 seconds

15 to 17 seconds
18 to 25 seconds

24 to 28 seconds

28 to 32 seconds
28 to 32 seconds

55 to 59 seconds
28 to 32 seconds

71 to 76 seconds
41 to 46 seconds

Rated work load at full height, maximum

GS-1530, GS-1532

GS-1930, GS-1932,
GS-2632, GS-3232

GS-1930PAR

GS-2032

GS-2046

GS-2646

GS-3246

GS-4047
(CE and AS models)

Side to side
Front to rear

600 lbs

272 kg

500 lbs

227 kg

400 lbs

181 kg

800 lbs

363 kg

1200 lbs

544 kg

1000 lbs

454 kg

700 lbs

317 kg

770 lbs

350 kg

5°
3°

6 GS

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October 2023 Service and Repair Manual

Hydraulic Fluid Specifications

and may result in component

Specifications

Hydraulic Oil Specifications

Genie specifications require hydraulic oils which are
designed to give maximum protection to hydraulic
systems, have the ability to perform over a wide
temperature range, and the viscosity index should
exceed 140. They should provide excellent
antiwear, oxidation prevention, corrosion inhibition,
seal conditioning, and foam and aeration
suppression properties.

Cleanliness level,
minimum

Water content,
maximum

Recommended Hydraulic Fluid

Hydraulic oil type Chevron Rando HD Premium

ISO Grade 32

Viscosity index,
maximum

Optional Hydraulic Fluids

Mineral based

Shell Donax TG (Dexron III)

Biodegradable Petro Canada Environ MV 46

Fire resistant UCON Hydrolube HP-5046

Shell Tellus S2 V 32
Shell Tellus S2 V 46

Shell Tellus S4 VX 32

Note: Genie specifications require additional
equipment and special installation instructions
for the approved optional fluids. Consult Genie
Product Support before use.

Optional fluids may not have
the same hydraulic lifespan

damage.

ISO 15/13

250 ppm

200

Chevron 5606A

Note: Do not operate the machine when the
ambient air temperature is consistently above
120°F / 49°C.

Hydraulic Fluid Temperature
Range

1 Chevron hydraulic oil 5606A
2 Petro-Canada Environ MV 46
3 UCON Hydrolube HP-5046D
4 Chevron Rando HD premium oil MV

Do not top off with
incompatible hydraulic fluids.
Hydraulic fluids may be
incompatible due to the
differences in base additive
chemistry. When
incompatible fluids are
mixed, insoluble materials
may form and deposit in the
hydraulic system, plugging
hydraulic lines, filters, control
valves and may result in
component damage.

Ambient air temperature

Note: Extended machine operation can cause
the hydraulic fluid temperature to increase
beyond its maximum allowable range. If the
hydraulic fluid temperature consistently exceeds
200°F / 90°C an optional oil cooler may be
required.

Part No. 1272217GT GS

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Service and Repair Manual October 2023

Specifications

Chevron Rando HD Premium Oil
MV Fluid Properties

Chevron 5606A Hydraulic Oil
Fluid Properties

ISO Grade 32

Viscosity index, maximum 200

Kinematic Viscosity, maximum
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C

Brookfield Viscosity, maximum
cP @ -4°F / -20°C
cP @ -22°F / -30°C

Flash point 375°F / 190°C

Pour point -58°F / -50°C

Maximum continuous operating
temperature

171°F / 77°C

7.5

33.5

1040
3310

Note: A hydraulic oil heating system is
recommended when the ambient temperature is
consistently below 0°F / -18°C.

Note: Do not operate the machine when the
ambient temperature is below -20°F / -29°C with
Rando HD Premium MV.

ISO Grade 15

Viscosity index, maximum 300

Kinematic Viscosity, maximum
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
cSt @ -40°F / -40°C

Flash point 180°F / 82°C

Pour point -81°F / -63°C

Maximum continuous operating
temperature

124°F / 51°C

5.5

15.0
510

Note: Use of Chevron 5606A hydraulic fluid, or
equivalent, is required when ambient
temperatures are consistently below 0°F / -17°C
unless an oil heating system is used.

Continued use of Chevron
5606A hydraulic fluid, or
equivalent, when ambient
temperatures are
consistently above 32°F /
0°C may result in component
damage

8 GS

Petro-Canada Environ MV 46
Fluid Properties

ISO Grade 46

Viscosity index, maximum 154

Kinematic Viscosity, maximum
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C

Flash point 482°F / 250°C

Pour point -49°F / -45°C

Maximum continuous operating
temperature

180°F / 82°C

44.4

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8.0

October 2023 Service and Repair Manual

Specifications

Shell Tellus S4 VX Fluid
Properties

ISO Grade 32

Viscosity index, maximum 300

Kinematic Viscosity, maximum
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C

Brookfield Viscosity, maximum
cSt @ -4°F / -20°C
cSt @ -13°F / -25°C
cSt @ -40°F / -40°C

Flash point >100

Pour point -76°F / -60°C

Maximum continuous operating
temperature

103°F / 75°C

UCON Hydrolube HP-5046 Fluid
Properties

9

33.8

481

702.4
2624

ISO Grade 46

Viscosity index, maximum 192

Kinematic Viscosity, maximum
cSt @ 149°F / 65°C
cSt @ 104°F / 40°C
cSt @ 0°F / -18°C

Flash point None

Pour point -81°F / -63°C

Maximum continuous operating
temperature

189°F / 87°C

1300

22
46

Part No. 1272217GT GS

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Service and Repair Manual October 2023

GS-1932

ar

icron

Function manifold – All models except GS-4047

Lift pressure selector manifold - GS-4047

Specifications

Hydraulic Component Specifications

Function Pump – GS-1530, GS1532, GS-1930,

Type Gear

Displacement per revolution

Flow rate @ 2500 psi / 172 bar

Hydraulic tank return filter

Function Pump – GS-2032, GS-2632, GS-3232,
GS-2046, GS-2646, GS-3246, GS-4047

Type Gear

Displacement per revolution

Flow rate @ 2500 psi / 172 bar

Hydraulic tank return filter

0.244 cu in
4 cc

3 gpm

11,3 L/min

10 micron

25 psi / 1.7 b

bypass

0.355 cu in

5,5 cc

4 gpm

15 L/min

10 m

25 psi / 1,7 bar

bypass

Outrigger manifold

Relief valve pressure,
maximum

Check valve manifold -
GS-1530, GS-1532, GS-1930. GS-1932

Check valve pressure,
maximum

Platform relief valve pressure,
maximum

3500 psi

241 bar

200 psi

13,8 bar

2000 psi

138 bar

System relief valve pressure,
maximum

Lift relief valve pressure

Steer relief valve pressure

Function manifold – GS-4047

System relief valve pressure,
maximum

Platform relief valve pressure

Steer relief valve pressure

3700 psi

255 bar

1800 to 3700 psi

142 to 241 bar

1500 psi

103 bar

3500 psi

241 bar

3000 psi

206 bar

1500 psi

103 bar

10 GS

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October 2023 Service and Repair Manual

Plug torque

Specifications

Manifold Component Specifications

SAE No. 2 50 in-lbs / 6 Nm

SAE No. 4 13 ft-lbs / 18 Nm

SAE No. 6 18 ft-lbs / 24 Nm

SAE No. 8 50 ft-lbs / 68 Nm

SAE No. 10 55 ft-lbs / 75 Nm

SAE No. 12 75 ft-lbs / 102 Nm

Valve coil resistance

Note: The following coil resistance specifications
are at an ambient temperature of 68°F / 20°C. As
valve coil resistance is sensitive to change in air
temperature, the coil resistance will typically
increase or decrease by 4% of each 18°F / -7.7°C
that your air temperature increases or decreases
from 68°F / 20°C.

Description Specification

Solenoid valve, 3 position 4 way,

27.2Ω
20V DC with diode
(schematic items F, AC or DC)

Solenoid valve, 3 position 4 way,

19Ω
20V DC with diode
(schematic item E)

Solenoid valve, 2 position 4 way,

19Ω
20V DC with diode
(schematic items H, AI or DI)

Solenoid valve, 2 position 2 way,

25Ω
N.C. 20V DC with diode
(schematic item N)

Solenoid valve, 2 position 4 way,

19Ω
20V DC with diode
(schematic item AE or DE)

Solenoid valve, 3 position 5 way,

19Ω
20V DC with diode
(schematic item AG or DG)

Solenoid valve, 2 position 2 way,

27.2Ω
20V DC with diode
(schematic items CA, CB, CC
and CD)

Solenoid valve, 3 position 4 way,

19Ω
20V DC with diode
(schematic item BA)

Solenoid valve, 2 position 2 way,

23.9Ω
20V DC with diode
(schematic item DN)

Solenoid valve, 3 position 4 way

33.75Ω
24V DC with diode
(schematic item EA)

Solenoid valve, 2 position 4 way

33.75Ω
24V DC with diode
(schematic item EC)

Solenoid valve, 2 position 4 way,

24Ω
20V DC with diode
(schematic item GC)

Solenoid valve, 3 position 4 way,

24Ω
20V DC with diode
(schematic item GA)

Part No. 1272217GT GS

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Service and Repair Manual October 2023

SAE Dash Size

Torque

SAE Dash Size

Torque

SAE Dash Size

Torque

200 ft-lbs / 271.2

Specifications

Hydraulic Hose and Fitting Torque Specifications

Your machine is equipped with Parker Seal­Lok™ ORFS or 37° JIC 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.

Seal-Lok™ Fittings

(hose end - ORFS)

-4 18 ft-lbs / 25 Nm

-6 30 ft-lbs / 41 Nm

-8 40 ft-lbs / 55 Nm

-10 60 ft-lbs / 81 Nm

-12 85 ft-lbs / 115 Nm

-16 110 ft-lbs / 150 Nm

-20 150 ft-lbs / 205 Nm

-24 230 ft-lbs / 315 Nm

SAE O-ring Boss Port

(tube fitting - installed into Aluminum)

(all types)

-4 14 ft-lbs / 19 Nm

-6 23 ft-lbs / 31.2 Nm

-8 36 ft-lbs / 49 Nm

-10 62 ft-lbs / 84 Nm

-12 84 ft-lbs / 114 Nm

-16 125 ft-lbs / 169.5 Nm

-20 151 ft-lbs / 204.7 Nm

-24 184 ft-lbs / 249.5 Nm

Adjustable Fitting Non-adjustable fitting

1 jam nut

JIC 37° Fittings

(swivel nut or hose connection)

SAE Dash Size Thread Size Flats

-4 7/16-20 2

-6 9/16-18 1 1/2

-8 3/4-16 1 1/2

-10 7/8-14 1 1/2

-12 1 1/16-12 1 1/4

-16 1 5/16-12 1

-20 1 5/8-12 1

-24 1 7/8-12 1

SAE O-ring Boss Port

(tube fitting - installed into Steel)

-4 ORFS / 37° (Adj)
ORFS (Non-adj)
37° (Non-adj)

-6 ORFS (Adj / Non-adj)
37° (Adj / Non-adj)

-8 ORFS (Adj / Non-adj)
37° (Adj / Non-adj)

-10 ORFS (Adj / Non-adj)
37° (Adj / Non-adj)

-12 (All types) 135 ft-lbs / 183 Nm

-16
(All types)

-20 (All types) 250 ft-lbs / 339 Nm

-24
(All types)

15 ft-lbs / 20.3 Nm
26 ft-lbs / 35.3 Nm

22 ft-lbs / 30 Nm

35 ft-lbs / 47.5 Nm
29 ft-lbs / 39.3 Nm

60 ft-lbs / 81.3 Nm
52 ft-lbs / 70.5 Nm

100 ft-lbs / 135.6

Nm

85 ft-lbs / 115.3

Nm

Nm

305 ft-lbs / 413.5

Nm

12 GS

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October 2023 Service and Repair Manual

Specifications

Torque Procedure

Seal-Lok™ fittings

1 Replace the O-ring. The O-ring must be

replaced anytime the seal has been broken.
The O-ring cannot be re-used if the fitting or
hose end has been tightened beyond finger
tight.

Note: The O-ring in Parker Seal Lok™ fittings
and hose end are custom-size O-rings. They are
not standard size O-rings. They are available in
the O-ring field service kit (Genie part number

49612).

2 Lubricate the O-ring before installation.

3 Be sure the O-ring face seal is seated and

retained properly.

4 Position the tube and nut squarely on the

face seal end of the fitting, and tighten the
nut finger tight.

5 Tighten the nut or fitting to the appropriate

torque. Refer to the appropriate torque chart
in this section.

6 Operate all machine functions and inspect

the hose, fittings and related components to
confirm there are no leaks.

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 Using a permanent ink marker, make a

reference mark on one the flats of the hex
nut and continue the mark onto the body of
the hex fitting. Refer to Illustration 1.

Illustration 1

1 hex nut
2 reference mark
3 body hex fitting

Part No. 1272217GT GS

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Service and Repair Manual October 2023

Specifications

3 Working clockwise on the body hex fitting,

make a second mark with a permanent ink
marker to indicate the proper tightening
position. Refer to Illustration 2.

Note: Use the JIC 37° Fitting table in this section
to determine the correct number of flats, for the
proper tightening position.

Note: The marks indicate 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.

Illustration 2

1 body hex fitting
2 reference mark
3 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 hose, fittings and related components to
confirm there are no leaks.

14 GS

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October 2023 Service and Repair Manual

Repair Procedures

Section 3 Repair Proc edur es

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.

Machine Configuration:

 Unless otherwise specified, perform each

repair procedure with the machine in the
following configuration:

• Machine parked on a firm, level surface

• Key switch in the off position with the key

removed

• The red Emergency Stop button in the off
position at both the ground and platform
controls

• Wheels chocked

• All external AC power supply

disconnected from the machine

• Platform in the stowed position

 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.

Part No. 1272217GT GS

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Service and Repair Manual October 2023

Indicates a potentially

Repair Procedures

About This Section

Most of the procedures in this section should
only be performed by 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 re­assemble, 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 a 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.

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.

16 GS

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October 2023 Service and Repair Manual

Platform Controls

The platform controls are used to operate the
machine from the platform.

Activating a function button sends a signal to the
Electronic Control Module (ECM). When the
ECM is in the function mode, the platform
controls are used to operate the various
machine functions.

The platform controls consist of an Emergency
Stop button, electronic circuit board, proportional
control handle, drive/steer enable switch, alarm,
function buttons and LED display.

For further information or assistance, contact
Genie Product Support.

1 red Emergency Stop button P2
2 platform controls circuit board U3
3 proportional control handle and

drive/steer enable switch JC9

Part No. 1272217GT GS

4 alarm H1

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Service and Repair Manual October 2023

Code

Condition

Platform Controls

Operational Indicator Codes

These codes are generated by the electrical
system to indicate machine operating status.
During normal operation, a code will appear in
the platform controls LED readout if a condition
such as off-level, overload cutout, chassis mode
operation or pothole guard stuck occurs.

If the platform controls LED readout displays an
operational indicator code such as LL, the fault
condition must be repaired or removed before
resuming machine operation. Push in and pull
out the red Emergency Stop button to reset the
system.

Platform Controls LED Readout

Note: The Ld Operation Indicator Code will
appear when the outriggers are not fully
retracted, the machine is not auto leveled, an
outrigger has lost contact with the ground or
either level sensor detects the machine is no
longer level. When any of the above scenarios
occur, the lift function is disabled.

The lift function will also be disabled while
extending or retracting the outriggers and during
the outrigger auto level procedure. While
performing the above operations, the Ld
Operation Indicator Code will appear.

Note: A code and a description of a code can
also be viewed at the ground controls LCD
display.

LL Off-level

OL Platform Overload (CE and Australia)

CH Chassis Mode Operation

PHS Pothole Guard Stuck

nd No Drive (option)

Ld Lifting Disabled

br Brake Release

OHL Outdoor Height Restriction

18 GS

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October 2023 Service and Repair Manual

Platform Controls

1-1 Circuit Board

How to Remove the Platform
Controls Circuit Board

1 Push in the red Emergency Stop button to

the off position at both the ground and
platform controls.

2 Disconnect the platform controls from the

control cable at the platform.

3 Remove the fasteners securing the platform

control box to the platform control bracket.

4 Remove the fasteners securing the bottom

cover to the platform control box. Open the
control box.

5 Remove the ties securing the wire harness.

6 Disconnect the red and black wires from the

alarm.

7 Carefully remove the alarm from the

platform control box.

8 Carefully disconnect all wire harness

connectors from the platform controls circuit
board.

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.

9 Carefully remove the platform controls

circuit board fasteners.

10 Carefully remove the platform controls

circuit board from the platform control box.

11 Remove the transparent caps from the

platform controls circuit board and save.

Circuit board fastener torque specifications

Hand tighten until screws seat

< 5 in-lbs
< 0.6 Nm

Note: Before installing a circuit board, place the
transparent caps removed in step 11, over the
circuit board buttons.

Note: After installing the circuit board, check for
proper button operation. Excessive torque of the
circuit board fasteners will cause the buttons to
bind. Moderate torque of the circuit board
fasteners will not allow the buttons to engage.

Part No. 1272217GT GS

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Service and Repair Manual October 2023

Platform Controls

1-2 Joystick

7 Carefully remove the joystick fasteners.

8 Carefully remove the joystick from the

platform control box.

How to Remove the Joystick

1 Push in the red Emergency Stop button to

the off position at both the ground and
platform controls.

2 Disconnect the platform controls from the

control cable at the platform.

3 Remove the fasteners securing the platform

control box to the platform control bracket.

4 Remove the fasteners securing the bottom

cover to the platform control box. Open the
control box.

5 Remove the ties securing the joystick wire

harness.

6 Carefully disconnect the joystick wire

harness from the platform controls circuit
board.

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.

Torque specifications

Joystick fasteners

9 in-lbs

1 Nm

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Platform Controls

1-3
Platform Controls Alarm

How to Remove the Platform
Controls Alarm

1 Push in the red Emergency Stop button to

the off position at both the ground and
platform controls.

2 Disconnect the platform controls from the

control cable at the platform.

3 Remove the fasteners securing the platform

control box to the platform control bracket.

4 Remove the fasteners securing the bottom

cover to the platform control box. Open the
control box.

5 Disconnect the red and black wires from the

alarm.

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.

1-4 Platform Emergency Stop Button

How to Remove the Platform
Controls Emergency Stop
Button

1 Push in the red Emergency Stop button to

the off position at both the ground and
platform controls.

2 Disconnect the platform controls from the

control cable at the platform.

3 Remove the fasteners securing the platform

control box to the platform control bracket.

4 Remove the fasteners securing the bottom

cover to the platform control box. Open the
control box.

6 Carefully remove the alarm from the

platform control box.

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Platform Controls

5 Disconnect the white wires from the

Emergency Stop base.

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.

6 Carefully remove the Emergency Stop base

from the Emergency Stop button.

7 Carefully remove the retaining ring from the

Emergency Stop button.

8 Carefully remove the Emergency Stop

button from the platform control box.

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Ground Controls

The ground controls, used to operate the
machine from the ground, can also be used to
tune the performance of the machine.

The ground controls consist of an Electronic
Control Module (ECM), emergency stop button,
key switch and circuit breaker.

Activating the function enable button and the up
or down at the same time, sends a signal to the
(ECM). This allows the platform to be raised or
lowered at the ground controls.

Note: Steer and drive functions are not available
at the ground controls.

When the ECM is in the set up mode, the ground
controls are used to adjust the function speed
parameters, machine models, or machine
options.

For further information or assistance, contact
Genie Product Support.

1 machine setup escape button
2 machine setup scroll up button
3 LCD readout
4 machine setup scroll down button
5 machine setup enter button
6 Key switch KS1
7 red Emergency Stop P1
8 circuit breaker CB2
9 Diagnostic port (if equipped)
10 platform down button
11 lift function enable button
12 platform up button

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Service and Repair Manual October 2023

Ground Controls

2-1 Software Revision Level

How to Determine the Revision
Level

The machine software revision level is displayed
at the ground controls LCD display.

1 Turn the key switch to the ground controls

or platform controls position. Pull out the red
Emergency Stop button to the on position at
both ground and platform controls.

Result: The display at the platform controls

will show "CH". See example below.

2 Press the ground control scroll down button.

Result: The ground control LCD display will

indicate the software revision and hour
meter information. After 5 seconds, the
ground controls LCD display will display
machine model and hour meter information
again.

3 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.

Result: The display at the ground controls

will show the machine model and hour
meter information. After 3 seconds, the
machine model will not show on the display.
See example below.

a ground control LCD display
b ground control scroll down button

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Ground Controls

2-2 Machine Setup

How to Setup the Machine from
Ground Controls

The ground controls can be used to setup the
machine parameters from the ground. Features
that can be adjusted from the ground controls
include machine Model, Options and Speed
setup. This menu can only be entered from
ground controls with the key switch in the ground
controls position.

Tip-over hazard. Do not
adjust function speeds higher
than specified in this
procedure. Setting the
function speeds greater than
specifications could cause the
machine to tip over resulting
in death or serious injury.

Tip-over hazard. This
procedure must only be
performed by a trained
service professional.
Attempting this procedure
without the necessary skills
could result in death or
serious injury.

Note: Select a test area that is firm, level and
free of obstructions.

1 Turn the key switch to ground controls.

2 Press and hold the ground control scroll up

and scroll down buttons.

Ground Control Menu Buttons

1 scroll down button
2 enter button
3 scroll up button
4 escape button
5 LCD display

3 Pull out the red Emergency Stop button to

the on position at the ground controls.

Result: The ground controls LCD display

will show the following:

4 Use the ground control menu buttons to

select machine Model, Options and Speed
Setup parameters. Follow the menu
structure indicated on the ground control
LCD display.

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Service and Repair Manual October 2023

Ground Controls

2-3 Loading or Updating Machine Software

Note: Before updating the machine software,
open a web browser and navigate to the
following location for the Genie Machine
Software Download portal,
http://firmware.genielift.com. Perform a search
by applying the appropriate filters and download
the machine software.

Note: There are two procedures available to
update the machine software. These are

Bootloader Mode and Machine Application
Mode.

Bootloader Mode: The Bootloader mode is only

available with the key switch in the GCON
position. It allows the user to update or reinstall
the machine software by directing the system
into the Bootloader.

Choose this mode if the GCON ECM is not
opertaing correctly.

Machine Application Mode: The machine
Application mode is available with the key switch
in the GCON or PCON position. This mode of
machine software update requires the user to
enter the Machine Service Tool.

Choose this mode if the machine is operating
correctly and you are updating the machine
software.

Bootloader Mode

1 Open the GCON compartment.

Note: Some models will require opening the
ground control box to access the GCON.

2 Turn the key switch to the ground controls

position and pull out the red Emergency
Stop button to the on position at the
platform controls.

3 At the ground controls, press and hold the

Enter and Escape buttons.

1 LCD display
2 enter button

4 Pull out the red Emergency Stop button to

Result: The ground controls LCD display

3 escape button

the on position at the ground controls.

will show the following:

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October 2023 Service and Repair Manual

Ground Controls

5 Locate the diagnostic port on the side of the

GCON. Remove one of the fasteners
securing the cover and set aside. Loosen
the other fastener. Do not remove it.

8 Launch a web browser such as Internet

®

Explorer

, Chrome ® or Firefox ® on your
PC or laptop. Type the IP address from step
7 into the web browser address bar and
press enter.

Result: The following screen will be

displayed.

1 diagnostic port

6 Connect one end of a CAT5 Ethernet cable

into the diagnostic port. Connect the other
end into a PC or laptop.

Result: The ground controls LCD display

will show the following:

7 Read and record the IP address.

9 Select the Choose File button and navigate

to the downloaded Genie Flash file (.gff).

Note: Verify it is the correct flash file.

10 Select the Load Flash File button to verify

the file is a .gff file.

Result: The following screen will be

displayed.

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Ground Controls

11 Select the Reprogram Device(s) button to

start the ECM software update.

Result: The following screen will be

displayed after the software update is
complete.

Note: Do not turn off power while the ECM is
being reprogrammed.

15 Perform a function test. Refer to the

Operator's Manual on your machine.

16 Return the machine to service.

12 Select the Run Application button to exit

the software update mode.

13 Push in the red Emergency Stop button and

disconnect the CAT5 cable from the GCON.

14 Secure the diagnostic port cover using the

retaining fasteners removed in step 5. Do
not over tighten.

Note: Machines equipped with AGM batteries
will need to select the AGM battery type using
the GCON set parameters screen. Refer to the
Machine Setup procedure in the Service and
Repair manual that is appropriate for your
machine.

Tip over hazard. Updating the
SmartLink software may have
impacted the machines default
drive speeds. Tipping over the
machine will result in death or
serious injury.

Perform drive speed test.
Refer to the Maintenance
Manual that is appropriate for
your machine.

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October 2023 Service and Repair Manual

Ground Controls

Machine Application Mode

5 Read and record the IP address.

1 Open the GCON compartment.

Note: Some models will require opening the
ground control box to access the GCON.

2 Turn the key switch to ground controls or

platform controls and pull out the red
Emergency Stop button to the on position at
both ground and platform controls.

3 Locate the diagnostic port on the side of the

GCON. Remove one of the fasteners
securing the cover and set aside. Loosen
the other fastener. Do not remove it.

Note: The display will only show
the IP address for 3 seconds.
Press the scroll up button to
display the IP address for another
3 seconds.

6 Launch a web browser such as Internet

®

Explorer

, Chrome ® or Firefox ® on your
PC or laptop. Type the IP address from step
5 into the web browser address bar and
press enter.

Result: The following screen will be

displayed.

7 Enter the following username and password

then select OK.

Username: smart.link

Password: SL1000

Note: The username and password are case
sensitive.

1 diagnostic port

4 Connect one end of a CAT5 Ethernet cable

into the diagnostic port. Connect the other
end into a PC or laptop.

Result: The ground controls LCD display

will show the following:

Part No. 1272217GT GS

Result: The following screen will be

displayed.

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Service and Repair Manual October 2023

Ground Controls

8 Select the Software tab at the header bar.

Result: The following screen will be

displayed.

9 Select the Update Machine Software

button.

Result: The following screen will be

displayed.

11 Select the Load Flash File button to verify

the file is a .gff file.

Result: The following screen will be

displayed.

12 Select the Reprogram Device(s) button to

start the ECM software update.

Result: The following screen will be

displayed after the software update is
complete.

10 Select the Choose File button and navigate

to the downloaded Genie Flash file (.gff).

Note: Verify it is the correct flash file.

Note: Do not turn off power while the ECM is
being reprogrammed.

13 Select the Run Application button to exit

the software update mode.

14 Push in the red Emergency Stop button and

disconnect the CAT5 cable from the GCON.

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October 2023 Service and Repair Manual

Ground Controls

15 Secure the diagnostic port cover using the

retaining fasteners removed in step 5. Do
not over tighten.

Note: Machines equipped with AGM batteries
will need to select the AGM battery type using
the GCON set parameters screen. Refer to the
Machine Setup procedure in the Service and
Repair manual that is appropriate for your
machine.

Tip over hazard. Updating the
SmartLink software may have
impacted the machines default
drive speeds. Tipping over the
machine will result in death or
serious injury.

2-4 Using a Wi-Fi Router to Connect to the SmartLink Web Service Tool

Note: Before using a portable wireless router to
connect to the Smart Link Service Tool web site,
the router must be configured to the type of
connection desired. Refer to the portable
wireless router users manual for set-up and
configuration instructions.

1 Open the GCON compartment.

Note: Some models will require opening the
ground control box to access the GCON.

Perform drive speed test.
Refer to the Maintenance
Manual that is appropriate for
your machine.

16 Perform a function test. Refer to the

Operator's Manual on your machine.

17 Return the machine to service.

2 Turn the key switch to ground controls or

platform controls and pull out the red
Emergency Stop button to the on position at
both ground and platform controls.

Result: The display at the platform controls

will show "CH". See example below.

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Ground Controls

3 Locate the diagnostic port on the side of the

GCON. Remove one of the fasteners
securing the cover and set aside. Loosen
the other fastener. Do not remove it.

1 diagnostic port

4 Connect one end of a CAT5 Ethernet cable

into the diagnostic port. Connect the other
end into the ethernet port of the portable
wireless router.

Result: The ground controls LCD display

will show the following:

5 Read and record the IP address.

Note: The display will only show
the IP address for 3 seconds.
Press the scroll up button to
display the IP address for another
3 seconds.

6 On a PC, laptop or mobile device, set up a

wireless network for the portable router.

Note: Refer to the Operating System's procedure
for connecting to a wireless network.

7 After establishing a new wireless network,

select the appropriate network your portable
wireless router.

Note: Refer to the Operating System's procedure
for connecting to a wireless network.

8 Launch a web browser such as Internet

®

Explorer

, Chrome ® or Firefox ® on your
PC, laptop or mobile device. Type the IP
address from step 5 into the web browser
address bar and press enter.

Result: The following screen will be

displayed.

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October 2023 Service and Repair Manual

Tip over hazard. Updating the

Ground Controls

9 Enter the following username and password

then select OK.

Username: smart.link

Password: SL1000

Note: The username and password are case
sensitive.

Result: The following screen will be

displayed.

2-5 Service Override Mode

The Electronic Control Module (ECM) is
programmed with a Service Override mode.
Service Override mode is only indented for
certain circumstances and is not part of the
normal machine operation. Service Override
mode should only be accessed by trained
personal to repair faults and/ or a malfunctioning
machine.

Note: Service Override mode can only be
entered at the ground controls and is intended to
allow the platform to be raised or lowered. Once
the platform has reached the maximum
allowable height, the system will exit Service
Override mode. Repeat this procedure to lower
the platform.

10 After using the Smart Link Service Tool web

site, push in the red Emergency Stop button
and disconnect the CAT5 cable from the
GCON.

11 Secure the diagnostic port cover using the

retaining fasteners removed in step 3. Do
not over tighten.

Note: Machines equipped with AGM batteries
will need to select the AGM battery type using
the GCON set parameters screen. Refer to the
Machine Setup procedure in the Service and
Repair manual that is appropriate for your
machine.

SmartLink software may have
impacted the machines default
drive speeds. Tipping over the
machine will result in death or
serious injury.

Perform drive speed test.
Refer to the Maintenance
Manual that is appropriate for
your machine.

Note: When in Service Override mode, an
audible alarm will sound.

Note: Before entering Service Override mode,
fault codes or the malfunction affecting the
operation of the machine should be fully
understood to ensure Service Override mode is
required.

Operator's Manual on your machine.

Part No. 1272217GT GS

12 Perform a function test. Refer to the

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Service and Repair Manual October 2023

death or serious injury. Follow

Ground Controls

Note: Perform this operation on a firm, level
surface and if equipped, with the outriggers auto
leveled or fully retracted.

Tip-over hazard. Operating
the machine on a surface that
is not level while in Service
Override mode will result in

3 Pull out the red Emergency Stop button to

the on position at the ground controls.

Result: The ground controls LCD display

will show the following:

proper operating procedures
and safety precautions. Do
not use Service Override
mode if you are not trained
and familiar with the
operation of the machine.

1 Turn the key switch to the ground controls

position and pull out the red Emergency
Stop button to the on position at the
platform controls.

2 Press and hold the ground control scroll up

and scroll down buttons.

4 Release the Scroll Up and Scroll Down

buttons after the ground controller powers
up.

5 At the ground controls, use the Scroll Down

button to scroll to SVC Override.

Result: The ground controls LCD display

will show the following:

Ground Control Menu Buttons

1 scroll down button
2 enter button
3 scroll up button
4 escape button
5 LCD display

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October 2023 Service and Repair Manual

X

Y

1

2

Ground Controls

6 Press the enter button.

Result: The ground controls LCD display

will show an alternating message every

1.5 seconds.

2-6 Level Sensors

The Electronic Control Module (ECM) is
programmed to deactivate the lift and drive
functions and activate an alarm when a signal is
received from the level sensor.

The tilt alarm sounds when the incline of the
chassis exceeds 1.5° to the side and 3° to the
front or rear.

Use the illustrations to verify which type of level
sensor is installed and perform the procedure
that is appropriate for your machine.

7 Press the enter button.

Result: The ground controls LCD display

will show the following:

8 Press the enter button.

Result: The ground controls LCD display

will show the following:

Procedure 1

Procedure 2

Procedure 3

1 X axis
2 Y axis

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Service and Repair Manual October 2023

Ground Controls

How to Install and Calibrate the
Level Sensor - Procedure 1

Procedure 1

1 X axis
2 Y axis

Tip-over hazard. Failure to
install or calibrate the level
sensor as instructed will
compromise machine stability
and cause the machine to tip
over, resulting in death or
serious injury. Do not install
or calibrate the level sensor
other than specified in this
procedure.

6 Lower the platform onto the safety arm.

Crushing hazard. Keep hands
clear of the safety arm when
lowering the platform.

7 Turn the key switch to the off position and

push in the red Emergency Stop button to
the off position at the ground controls.

8 Tag and disconnect the level sensor wire

harness from the chassis wire harness.

Note: The wire harness connection is located
next to the level sensor, on top of the chassis at
the steer end of the machine.

9 Remove the level sensor retaining fasteners

and remove the level sensor from the
machine.

10 Tag and disconnect the level sensor wires

from the level sensor connector plug.

11 Securely install the wires of the new level

sensor into the level sensor connector plug.

Note: If you are not installing a new level sensor,
proceed to step 15.

1 Move the machine to an area that has a

firm, level surface and is free of
obstructions.

Note: The surface must be 0° +/- 0.5°.

2 Remove the platform controls from the

platform.

3 Turn the key switch to platform controls and

pull out the red Emergency Stop button to
the on position at both ground and platform
controls.

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

5 Lift the safety arm, move it to the center of

the scissor arm and rotate down to a
vertical position.

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October 2023 Service and Repair Manual

Tip-over hazard. Failure to

Ground Controls

12 Place the new level sensor onto the level

sensor mount bracket with the "X" on the
level 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 sensor mount.

install the level sensor as
instructed, could result in the
machine tipping over, causing
death or serious injury.

Steer End

13 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.

Result: The measurement should be

approximately 0.375 inch / 10 mm.

14 Connect the chassis wire harness to the

level sensor wire harness.

15 Turn the key switch to the ground control

and pull out the red Emergency Stop button
to the on position at the ground controls.

16 Adjust the level sensor retaining fasteners

until the bubble at the top of the level
sensor is centered in the circles.

Result: The tilt sensor alarm should not

sound.

Non-steer End

1 limit switch
2 level sensor mount bracket
3 level sensor S7
4 scissor chassis
5 alarm H5

17 Raise the platform slightly.

18 Return the safety arm to the stowed

position.

19 Lower the platform to the stowed position.

20 Center a lifting jack under the drive chassis

at the ground controls side of the machine.

21 Raise the machine approximately 2 inches /

5 cm. Place blocks under the chassis for
support.

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Service and Repair Manual October 2023

Ground Controls

22 GS-1530 and GS-1930: Place a 0.64 x 6 x

6 inch / 16.2 mm x 15 cm x 15 cm thick
steel block under both wheels at the ground
controls side of the machine.

GS-1532 and GS-1932: Place a 0.68 x 6 x
6 inch / 17.2 mm x 15 cm x 15 cm thick
steel block under both wheels at the ground
controls side of the machine.

GS-2032, GS-2632 and GS-3232: 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 the
ground controls side of the machine.

GS-2046, GS-2646, GS-3246 and GS­4047: Place a 1 x 6 x 6 inch / 25.4 mm x

15 cm x 15 cm thick steel block under both
wheels at the ground controls side of the
machine.

23 Lower the machine onto the blocks.

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

Result: The level sensor alarm should not

sound.

Result: The level sensor alarm does sound

and fault code LL appears in the diagnostic
display. Adjust the level sensor retaining
fasteners just until the level sensor alarm
does not sound.

25 Lower the platform to the stowed position.

29 Center a lifting jack under the drive chassis

at the battery pack side of the machine.

30 Raise the machine approximately 2 inches /

5 cm. Place blocks under the chassis for
support.

31 GS-1530 and GS-1930: Place a 0.77 x 6 x

6 inch / 19.6 mm x 15 cm x 15 cm thick
steel block under both wheels at the battery
pack side of the machine.

GS-1532 and GS-1932: Place a 0.83 x 6 x
6 inch / 21.1 mm x 15 cm x 15 cm thick
steel block under both wheels at the battery
pack side of the machine.

GS-2032, GS-2632 and GS-3232: 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
battery pack side of the machine.

GS-2046, GS-2646, GS-3246 and GS­4047: Place a 1.22 x 6 x 6 inch / 31 mm x

15 cm x 15 cm thick steel block under both
wheels at the battery pack side of the
machine.

32 Lower the machine onto the blocks.

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

Result: The platform should stop, an alarm

should sound and fault code LL appears in
the diagnostic display.

26 Raise the machine approximately 2 inches /

5 cm. Place blocks under the chassis for
support.

27 Remove the blocks from under both wheels.

28 Lower the machine and remove the jack.

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Result: The platform does not stop or the

level sensor alarm does not sound. Adjust
the level sensor until the alarm just begins
to sound OR the down limit switch may
need to be adjusted.

34 Lower the platform to the stowed position.

35 Raise the machine approximately 2 inches /

5 cm.

36 Remove the blocks from under both wheels.

37 Lower the machine and remove the jack.

October 2023 Service and Repair Manual

Ground Controls

How to Install and Calibrate the
Level Sensor - Procedure 2

Procedure 2

1 X axis

Note: If you are not installing a new level
sensor, proceed to step 14.

2 Y axis

Tip-over hazard. Failure to
install the level sensor as
instructed will compromise
machine stability and cause
the machine to tip over,
resulting in death or serious
injury. Do not install the level
sensor other than specified in
this procedure.

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

4 Lift the safety arm, move it to the center of

the scissor arm and rotate down to a
vertical position.

5 Lower the platform onto the safety arm.

Crushing hazard. Keep hands
clear of the safety arm when
lowering the platform.

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.

Note: The wire harness connection is located on
the level sensor, on top of the chassis at the
steer end of the machine.

8 Remove the level sensor retaining fasteners

and remove the level sensor from the
machine.

9 Securely install the wires of the new level

sensor into the level sensor connector plug.

1 Move the machine to an area that has a

firm, level surface and is free of
obstructions.

Note: Use a digital level to verify the surface is
level.

2 Turn the key switch to ground control and

pull out the red Emergency Stop button to
the on position at both ground and platform
controls.

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Ground Controls

10 Place the new level sensor on to the level

sensor bracket with the "Y" on the level
sensor closest to the ground controls of the
machine and the "X" on the level sensor
closest to the steer end of the machine.

Tip-over hazard. Failure to
install the level sensor as
instructed, could result in the
machine tipping over, causing
death or serious injury.

Steer End

11 Install the level sensor retaining fasteners

through the level sensor and into the mount
bracket.

12 Connect the chassis wire harness to the

level sensor.

13 Turn the key switch to ground control and

pull out the red Emergency Stop button to
the on position at both ground and platform
controls.

Result: GCON will display a ‘C051:

SYSTEMFAULT, TILT:NoCal fault.

14 Push in the red Emergency Stop button to

the off position at the ground controls.

15 Press and hold the ground control scroll up

and scroll down buttons.

Non-steer End

1 limit switch
2 level sensor mount bracket
3 level sensor S7
4 scissor chassis
5 alarm H5

40 GS

Ground Control Menu Buttons

1 scroll down button
2 enter button
3 scroll up button
4 escape button
5 LCD display

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October 2023 Service and Repair Manual

Ground Controls

16 Pull out the red Emergency Stop button to

the on position at the ground controls.

22 Press and hold the Enter button to start

calibration.

Result: The ground controls LCD display

will show the following:

17 Release the Scroll Up and Scroll Down

buttons after the ground controller powers
up.

18 Use the Scroll Up or Scroll Down buttons to

scroll to Select Option.

19 Press the enter button.

20 Use the Scroll Up or Scroll Down buttons to

scroll to Tilt Sensor.

Result: An audible alarm will sound when

calibration is complete.

Note: The machine will not calibrate if it is on a
slope of one degree or greater.

Note: If the level sensor has been replaced,
continue with step 23. If the level sensor was not
replaced skip to step 26.

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

24 Return the safety arm to the stowed

position.

25 Lower the platform to the stowed position.

21 Press the enter button.

26 Place a digital level on the ground control

side of the drive chassis. Zero out the digital
level.

27 Drive the steer end of the machine up a

ramp until it is just under 3°.

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Service and Repair Manual October 2023

Ground Controls

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

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

Result: No audible alarm is heard.

Result: The platform stops, an audible

alarm is heard and Fault LL is displayed.
Repeat this procedure starting at step 15 on
a firm level surface.

29 Lower the platform to the stowed position.

30 Continue driving the machine up the ramp

until it is just over 3°.

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

Result: The platform should stop, an alarm

should sound and fault code LL appears in
the diagnostic display.

Result: The platform does not stop or the

level sensor alarm does not sound. Repeat
this procedure starting at step 15 on a firm
level surface.

32 Lower the platform to the stowed position.

33 Drive the non-steer end of the machine up a

ramp until it is just under 3°.

Result: No audible alarm is heard.

Result: The platform stops, an audible

alarm is heard and Fault LL is displayed.
Repeat this procedure starting at step 15 on
a firm level surface.

35 Lower the platform to the stowed position.

36 Continue driving the machine up the ramp

until it is just over 3°.

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

Result: The platform should stop, an alarm

should sound and fault code LL appears in
the diagnostic display.

Result: The platform does not stop or the

level sensor alarm does not sound. Repeat
this procedure starting at step 15 on a firm
level surface.

38 Lower the platform to the stowed position.

39 Place a digital level on the steer end of the

drive chassis. Zero out the digital level.

40 Drive the ground control side of the

machine onto a ramp until it is just under

1.5°.

42 GS

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October 2023 Service and Repair Manual

Ground Controls

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

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

Result: No audible alarm is heard.

Result: The platform stops, an audible

alarm is heard and Fault LL is displayed.
Repeat this procedure starting at step 15 on
a firm level surface.

42 Lower the platform to the stowed position.

43 Continue driving the machine onto the ramp

until it is just over 1.5°.

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

Result: The platform should stop, an alarm

should sound and fault code LL appears in
the diagnostic display.

Result: The platform does not stop or the

level sensor alarm does not sound. Repeat
this procedure starting at step 15 on a firm
level surface.

45 Lower the platform to the stowed position.

46 Drive the battery compartment side of the

machine onto a ramp until it is just under

1.5°.

Result: No audible alarm is heard.

Result: The platform stops, an audible

alarm is heard and Fault LL is displayed.
Repeat this procedure starting at step 15 on
a firm level surface.

48 Lower the platform to the stowed position.

49 Continue driving the machine onto the ramp

until it is just over 1.5°.

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

Result: The platform should stop, an alarm

should sound and fault code LL appears in
the diagnostic display.

Result: The platform does not stop or the

level sensor alarm does not sound. Repeat
this procedure starting at step 15 on a firm
level surface.

51 Lower the platform to the stowed position.

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Service and Repair Manual October 2023

X

Y

1

2

Ground Controls

How to Install and Calibrate the
Level Sensor - Procedure 3

Procedure 3

1 X axis
2 Y axis

Tip-over hazard. Failure to
install the level sensor as
instructed will compromise
machine stability and cause
the machine to tip over,
resulting in death or serious
injury. Do not install the level
sensor other than specified in
this procedure.

5 Lower the platform onto the safety arm.

Crushing hazard. Keep hands
clear of the safety arm when
lowering the platform.

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.

Note: The wire harness connection is located on
the level sensor, on top of the chassis at the
steer end of the machine.

8 Remove the level sensor retaining fasteners

and remove the level sensor from the
machine.

9 Securely install the wires of the new level

sensor into the level sensor connector plug.

Note: If you are not installing a new level
sensor, proceed to step 14.

1 Move the machine to an area that has a

firm, level surface and is free of
obstructions.

Note: Use a digital level to verify the surface is
level.

2 Turn the key switch to ground control and

pull out the red Emergency Stop button to
the on position at both ground and platform
controls.

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

4 Lift the safety arm, move it to the center of

the scissor arm and rotate down to a
vertical position.

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Ground Controls

10 Place the new level sensor on to the level

sensor bracket with the "Y" on the level
sensor away from the ground controls of the
machine and the "X" on the level sensor
closest to the steer end of the machine.

Tip-over hazard. Failure to
install the level sensor as
instructed, could result in the
machine tipping over, causing
death or serious injury.

Steer End

11 Install the level sensor retaining fasteners

through the level sensor and into the mount
bracket.

12 Connect the chassis wire harness to the

level sensor.

13 Turn the key switch to ground control and

pull out the red Emergency Stop button to
the on position at both ground and platform
controls.

Result: GCON will display a ‘C051:

SYSTEMFAULT, TILT:NoCal fault.

14 Push in the red Emergency Stop button to

the off position at the ground controls.

15 Press and hold the ground control scroll up

and scroll down buttons.

Non-steer End

1 limit switch
2 level sensor mount bracket
3 level sensor S7
4 scissor chassis
5 alarm H5

Part No. 1272217GT GS

Ground Control Menu Buttons

1 scroll down button
2 enter button
3 scroll up button
4 escape button
5 LCD display

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Service and Repair Manual October 2023

Ground Controls

16 Pull out the red Emergency Stop button to

the on position at the ground controls.

22 Press and hold the Enter button to start

calibration.

Result: The ground controls LCD display

will show the following:

17 Release the Scroll Up and Scroll Down

buttons after the ground controller powers
up.

18 Use the Scroll Up or Scroll Down buttons to

scroll to Select Option.

19 Press the enter button.

20 Use the Scroll Up or Scroll Down buttons to

scroll to Tilt Sensor.

Result: An audible alarm will sound when

calibration is complete.

Note: The machine will not calibrate if it is on a
slope of one degree or greater.

Note: If the level sensor has been replaced,
continue with step 23. If the level sensor was not
replaced skip to step 26.

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

24 Return the safety arm to the stowed

position.

25 Lower the platform to the stowed position.

21 Press the enter button.

26 Place a digital level on the ground control

side of the drive chassis. Zero out the digital
level.

27 Drive the steer end of the machine up a

ramp until it is just under 3°

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October 2023 Service and Repair Manual

Ground Controls

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

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

Result: No audible alarm is heard.

Result: The platform stops, an audible

alarm is heard and Fault LL is displayed.
Repeat this procedure starting at step 15 on
a firm level surface.

29 Lower the platform to the stowed position.

30 Drive the steer end of the machine up a

ramp until it is just over 3°.

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

Result: The platform should stop, an alarm

should sound and fault code LL appears in
the diagnostic display.

Result: The platform does not stop or the

level sensor alarm does not sound. Repeat
this procedure starting at step 15 on a firm
level surface.

32 Lower the platform to the stowed position.

33 Drive the non-steer end of the machine up a

ramp until it is just under 3°.

Result: No audible alarm is heard.

Result: The platform stops, an audible

alarm is heard and Fault LL is displayed.
Repeat this procedure starting at step 15 on
a firm level surface.

35 Lower the platform to the stowed position.

Drive the non-steer end of the machine up a
ramp until it is just over 3°.

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

Result: The platform should stop, an alarm

should sound and fault code LL appears in
the diagnostic display.

Result: The platform does not stop or the

level sensor alarm does not sound. Repeat
this procedure starting at step 15 on a firm
level surface.

37 Lower the platform to the stowed position.

38 Place a digital level on the steer end of the

drive chassis. Zero out the digital level.

39 Drive the ground control side of the

machine onto a ramp until it is just under

1.5°.

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Service and Repair Manual October 2023

Ground Controls

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

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

Result: No audible alarm is heard.

Result: The platform stops, an audible

alarm is heard and Fault LL is displayed.
Repeat this procedure starting at step 15 on
a firm level surface.

41 Lower the platform to the stowed position.

42 Continue driving the machine onto the ramp

until it is just over 1.5°.

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

Result: The platform should stop, an alarm

should sound and fault code LL appears in
the diagnostic display.

Result: The platform does not stop or the

level sensor alarm does not sound. Repeat
this procedure starting at step 15 on a firm
level surface.

44 Lower the platform to the stowed position.

45 Drive the battery compartment side of the

machine onto a ramp until it is just under

1.5°.

Result: No audible alarm is heard.

Result: The platform stops, an audible

alarm is heard and Fault LL is displayed.
Repeat this procedure starting at step 15 on
a firm level surface.

47 Lower the platform to the stowed position.

48 Continue driving the machine onto the ramp

until it is just over 1.5°.

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

Result: The platform should stop, an alarm

should sound and fault code LL appears in
the diagnostic display.

Result: The platform does not stop or the

level sensor alarm does not sound. Repeat
this procedure starting at step 15 on a firm
level surface.

50 Lower the platform to the stowed position.

48 GS

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October 2023 Service and Repair Manual

Ground Controls

Outrigger Level Sensor -
GS-3232 Models

(from serial number GS3211A to GS3215A-141898)
(from serial number GS3212C-10000)

Tip-over hazard. Failure to
install the level sensor as
instructed will compromise
machine stability and cause
the machine to tip over,
resulting in death or serious
injury. Do not install the level
sensor other than specified in
this procedure.

1 Move the machine to an area that has a

firm, level surface and is free of
obstructions.

2 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.

3 Open the access door at the battery side of

the machine.

4 Tag and disconnect the outrigger level

sensor wire harness from the outrigger level
sensor.

5 Remove the outrigger level sensor retaining

fasteners and remove the outrigger level
sensor from the machine.

6 Place the new outrigger level sensor onto

the outrigger level sensor base with the flat
side of the outrigger level sensor closest to
the battery side access door. Refer to the
illustration below.

1 outrigger level sensor (GS-3232)

7 Secure the outrigger level sensor onto the

base with the retaining fasteners removed
in step 5.

8 Adjust the outrigger level sensor retaining

fasteners until the bubble at the top of the
level sensor is centered in the circles.

9 Connect the outrigger level sensor wire

harness to the new outrigger level sensor.

Part No. 1272217GT GS

10 Close the access door at the battery side of

the machine.

11 Calibrate the outrigger level sensor. Refer

to Repair Procedure, How to Calibrate the
Outrigger System.

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Service and Repair Manual October 2023

Platform manual lowering cable specification

Ground Controls

2-7 Manual Platform Lowering Cable

The manual platform lowering cable lowers the
platform in the event of a main power failure.
The manual platform lowering cable is attached
to the barrel end of the lift cylinder and is
activated at the drive chassis.

How to Adjust the Manual
Platform Lowering Cable

1 Raise the platform 7 to 8 feet / 2.1 to

2.4 m.:

2 Lift the safety arm, move it to the center of

the scissor arm and rotate down to a
vertical position.

3 Lower the platform onto the safety arm.

Crushing hazard. Keep hands
clear of the safety arm when
lowering the platform.

5 Measure the distance between the base of

the handle and cable mounting nut.

Result: The measurement should be no

greater than 0.125 inch / 3 mm.

Note: Proceed to step 8 if measurement is
correct.

Gap, lowering handle to mounting
nut

0 to 0.125 inch

0 to 3 mm

4 Pull the handle of the manual platform

lowering cable out until considerable
resistance is felt. Release the handle.

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October 2023 Service and Repair Manual

Ground Controls

6 To adjust, loosen the upper lock nut on the

cable mounting bracket at the cylinder. Turn
the lower lock nut clockwise to decrease the
distance or counterclockwise to increase
the distance. Tighten the upper lock nut.

1 manual lowering cable sheath
2 upper lock nut
3 cable mounting bracket
4 lower lock nut
5 cable mounting nut
6 end of lowering cable
7 manual lowering valve (hydraulic

schematic item N)

7 Repeat this procedure beginning with step

4.

8 Raise the platform and rotate the safety arm

to the stowed position.

9 Pull the manual lowering handle at the

ground controls 2 to 3 times to ensure it is
functioning correctly.

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Service and Repair Manual October 2023

Ground Controls

2-8 Outrigger Calibration

The Electronic Control Module (ECM) is
programmed to deactivate the drive and steer
functions while the outriggers are deployed and
activate an alarm when a signal is received from
the outrigger level sensor, indicating the
outriggers are not deployed or the machine is
out of level.

The ECM is also used to calibrate the outrigger
level sensor to achieve a levelness of 0° +/- 0.5°
front to back and side to side, while the
outriggers are deployed.

For further information or assistance, contact
Genie Product Support.

How to Calibrate the Outrigger
System

(GS-3232 - facility code C)
(GS-3232 - facility code A, to GS3215A-141898)

1 Move the machine to an area that has a

firm, level surface and is free of
obstructions. Use digital level to confirm.

2 Turn the key switch to ground controls.

3 At the ground controls, press and hold the

Menu Up and Menu Down buttons.

4 While pressing both buttons down, pull out

the red Emergency Stop Button.

5 Release the Menu Up and Menu Down

buttons after the ground controller powers
up.

6 Use the Menu Up or Menu Down buttons to

scroll to Machine Options.

8 Use the Menu Up or Menu Down buttons to

scroll to Outriggers.

9 Press the Enter button to select Outriggers.

10 Use the Menu Up or Menu Down buttons to

scroll to Calibrate Outriggers.

11 Press the Enter button to select Calibrate

Outriggers.

12 Press and hold the Enter button while the

system gathers data to calibrate the
outrigger level sensor.

Crushing hazard. Keep body
parts away from outriggers
during outrigger movement.

13 Continue holding the Enter button after the

outrigger level sensor is calibrated. The
outriggers will retract while the outrigger
system gathers and saves data.

14 Continue holding the Enter button after the

outriggers retract. The outriggers will now
extend and the system will gather and save
data to calibrate the outriggers.

15 Continue holding the Enter button after the

outriggers extend. The outriggers will now
retract while the outrigger system gathers
and saves data.

Result: The alarms at the ground and

platform controls should sound for
1 second. The outrigger system is
calibrated.

Note: After installing a new outrigger level
sensor, the new outrigger level sensor must be
calibrated following this procedure.

7 Press the Enter button to select Machine

Options.

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October 2023 Service and Repair Manual

Torque specifications

Hydraulic Tank

3-1 Hydraulic Tank

4 Remove the hydraulic tank retaining

fasteners and remove the hydraulic tank
from the machine.

The primary functions of the hydraulic tank are
to cool and deaerate the hydraulic fluid during
operation. It utilizes internal suction strainers for
the pump supply lines and has an external return
line filter.

How to Remove the Hydraulic
Tank

Component damage hazard.
The work area and surfaces
where this procedure will be
performed must be clean and
free of debris that could get
into the hydraulic system.

Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer
to Specifications, Hydraulic Hose and Fitting
Torque Specifications.

Perform this procedure with the platform in the
stowed position.

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.

5 Remove the hydraulic tank cap and drain

the tank into a suitable container.

Hydraulic retaining fasteners, dry

Hydraulic tank retaining fasteners,
lubricated

35 in-lbs

4 Nm

26 in-lbs

2,9 Nm

1 Disconnect the battery pack 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 Tag and disconnect the hydraulic tank

return hard line from the filter. Remove the
hard line from the machine. Cap the fitting
on the filter head.

3 Tag and disconnect the hydraulic tank hard

line from the pump. Remove the hard line
from the machine. Cap the fitting on the
pump.

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Service and Repair Manual October 2023

Hydraulic Pump

4-1
Function Pump

The hydraulic pump is attached to the motor
which makes up the hydraulic power unit.

How to Test the Hydraulic Pump

Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer
to Specifications, Hydraulic Hose and Fitting
Torque Specifications.

Component damage hazard.
The work area and surfaces
where this procedure will be
performed must be clean and
free of debris that could get
into the hydraulic system.

1 Tag, disconnect and plug the high pressure

hydraulic hose from the hydraulic pump.

2 Connect a 0 to 5000 psi / 0 to 350 bar

pressure gauge to the high pressure port on
the pump.

4 Activate the platform up function in one

second intervals from the ground controls
until the pressure gauge reaches 3200 psi /
221 bar.

Result: If the pressure gauge reads

3200 psi / 221 bar, immediately stop. The
pump is good.

Result: If the pressure gauge fails to reach

3200 psi / 221 bar, the pump is bad and will
need to be serviced or replaced.

Component damage hazard.
There is no relief valve in the
hydraulic pump and the pump
can be damaged if the
pressure is allowed to exceed
3200 psi / 221 bar. When
testing the pump, activate the
pump in one second intervals
until 3200 psi / 221 bar is
confirmed. Do not over­pressurize the pump.

5 Remove the pressure gauge and reconnect

the hydraulic hose. Torque to specifications.

3 Turn the key switch to ground control and

pull out the red Emergency Stop button to
the on position at both ground and platform
controls.

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October 2023 Service and Repair Manual

Hydraulic Pump

How to Remo ve t he Hydr auli c P ump

How to Remove the Hydraulic
Pump

Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer
to Specifications, Hydraulic Hose and Fitting
Torque Specifications.

1 Disconnect the battery pack from the

machine.

6 Tag, disconnect and plug the high pressure

hose from the pump. Cap the fitting on the
pump.

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.

Electrocution/burn hazard.
Contact with electrically
charged circuits could result
in death or serious injury.
Remove all rings, watches
and other jewelry.

2 Tag and disconnect the hydraulic power unit

cables at the motor controller.

3 Disconnect the filter head from the filter

head mounting bracket. Rotate the filter out
and away from the hydraulic power unit.

4 Remove the hydraulic power unit retaining

fasteners.

5 Tag, disconnect and plug the hydraulic tank

hard line from the pump. Cap the fitting on
the pump.

7 Remove the hydraulic power unit from the

machine.

8 Remove the pump mounting bolts. Carefully

remove the pump.

Tip-over hazard. After
replacing the hydraulic pump,
it is critical to return the
function speed settings to
original factory specifications.
Failure to restore the machine
to original factory
specifications could cause the
machine to tip over resulting
in death or serious injury.

Part No. 1272217GT GS

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Service and Repair Manual October 2023

Manifolds

5-1
Function Manifold Components –
GS-1530, GS-1532, GS-1930, GS-1932

The function manifold is mounted under the machine, between the module trays.

Index No. Description

— Coil nut (item F) — — 4-5 ft-lbs / 5-7 Nm

— Coil nut (items E and H) — — 5-7 ft-lbs / 7-9 Nm

1 Diagnostic port A Test port —

2 Check disc B Steer circuit 18 ft-lbs / 24 Nm

3

4 Check valve, 10 psi / 0.7 bar D Drive circuit 20 ft-lbs / 27 Nm

5 Solenoid valve, 3 position 4 way E

6 Solenoid valve, 3 position 4 way F Steer left/right 25 ft-lbs / 34 Nm

7 Flow regulator and relief valve,

8 Solenoid valve, 2 position 4 way H Platform up 25 ft-lbs / 34 Nm

9

Relief valve, 1800 - 3700 psi / 124 ­255 bar

0.75 gpm / 2.8 L/min
1500 psi / 130 bar

Relief valve, 3700 psi / 255 bar
maximum

Schematic

Item

C Lift relief 20 ft-lbs / 27 Nm

G Steer circuit 26 ft-lbs / 35 Nm

I System relief

Function Torque

Drive

forward/reverse

25 ft-lbs / 34 Nm

20 ft-lbs / 27 Nm

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 specifications.

3 If required, install the valve coil(s) onto the valve stem. Install the coil nut onto the valve stem and

torque to specifications.

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October 2023 Service and Repair Manual

Manifolds

Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic.

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

™

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Service and Repair Manual October 2023

Manifolds

5-2
Function Manifold Components –
GS-2032, GS-2632, GS-3232, GS-2046, GS-2646, GS-3246

The function manifold is mounted behind an inspection door, at the ground control side of the machine.

Index No. Description

— Coil nut (item AC) — — 4-5 ft-lbs / 5-7 Nm

— Coil nut (items AE, AG, AI) — — 5-7 ft-lbs / 7-9 Nm

1 Diagnostic port AA Test port —

2

3 Solenoid valve, 3 position 4 way AC Steer left/right 25 ft-lbs / 34 Nm

4

5 Check disc AD Steer circuit 18 ft-lbs / 24 Nm

6 Solenoid valve, 2 position 4 way AE

7 Relief valve, 50 psi / 3.4 bar AF Brake release 20 ft-lbs / 27 Nm

8 Solenoid valve, 3 position 5 way AG

9 Flow regulator and relief valve,

10 Solenoid valve, 2 position 4 way AI Platform up 25 ft-lbs / 34 Nm

11

Relief valve, 3700 psi / 255 bar
maximum

Check valve, (GS-3232, GS-3246
with load sense installed)

0.75 gpm / 2.8 L/min,
1500 psi / 103 bar

Relief valve, 1800 - 3700 psi / 124 ­255 bar

Schematic

Item

AB System relief 20 ft-lbs / 27 Nm

AK Lift circuit 23 ft-lbs / 31 Nm

AH Steer circuit 26 ft-lbs / 35 Nm

AJ Lift relief 20 ft-lbs / 27 Nm

Function Torque

Drive speed select

circuit

Drive

forward/reverse

25 ft-lbs / 34 Nm

25 ft-lbs / 34 Nm

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 specifications.

3 If required, install the valve coil(s) onto the valve stem. Install the coil nut onto the valve stem and

torque to specifications.

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October 2023 Service and Repair Manual

Manifolds

Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic.

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

™

Part No. 1272217GT GS

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Service and Repair Manual October 2023

Manifolds

5-3 Function Manifold Components – GS-4047

The function manifold is mounted behind an inspection door, at the ground control side of the machine.

Index No. Description

— Coil nut (item DC) — — 4-5 ft-lbs / 5-7 Nm

— Coil nut (items DE, DG, DI) — — 5-7 ft-lbs / 7-9 Nm

1 Diagnostic port DA Test port —

2

3 Solenoid valve, 3 position 4 way DC Steer left/right 25 ft-lbs / 34 Nm

4 Check disc DD Steer circuit 18 ft-lbs / 24 Nm

5 Solenoid valve, 2 position 4 way DE

6 Relief valve, 50 psi / 3.4 bar DF Brake release 20 ft-lbs / 27 Nm

7 Solenoid valve, 3 position 5 way DG

8 Flow regulator and relief valve,

9 Solenoid valve, 2 position 4 way DI Platform up 25 ft-lbs / 34 Nm

10 Relief valve, 3000 psi / 207 bar DJ Lift relief 20 ft-lbs / 27 Nm

Relief valve, 3500 psi / 241 bar
maximum

0.75 gpm / 2.8 L/min,
1500 psi / 103 bar

Schematic

Item

DB System relief 20 ft-lbs / 27 Nm

DH Steer circuit 26 ft-lbs / 35 Nm

Function Torque

Drive speed

select circuit

Drive

forward/reverse

25 ft-lbs / 34 Nm

25 ft-lbs / 34 Nm

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 specifications.

3 If required, install the valve coil(s) onto the valve stem. Install the coil nut onto the valve stem and

torque to specifications.

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Manifolds

Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic.

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

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Manifolds

5-4
Check Valve Manifold Components –
GS-1530, GS-1532, GS-1930, GS-1932

The check valve manifold is mounted on the function manifold.

Index No. Description Schematic Item Function Torque

1

Check valve, 200 psi /

13.8 bar

S Drive circuit 20 ft-lbs / 27 Nm

Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic.

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 specifications.

3 If required, install the valve coil(s) onto the valve stem. Install the coil nut onto the valve stem and

torque to specifications.

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October 2023 Service and Repair Manual

Item

Manifolds

5-5 Lift Pressure Selector Manifold Components – GS-4047

The lift pressure selector manifold is mounted behind an inspection door, at the ground control side of the
machine.

Index No. Description

— Coil nut (item DN) — — 4-5 ft-lbs / 5-7 Nm

— Plug — — 13 ft-lbs / 18 Nm

1

2 Solenoid valve, 2 position 2 way DN Lift circuit 20 ft-lbs / 27 Nm

Lift pressure selector valve, 200 psi /
138 bar

Schematic

DM Lift relief 20 ft-lbs / 27 Nm

Function Torque

Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic.

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

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 specifications.

3 If required, install the valve coil(s) onto the valve stem. Install the coil nut onto the valve stem and

torque to specifications.

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Manifolds

5-6 Outrigger Function Manifold Components – GS-3232

The outrigger function manifold is mounted behind an inspection door, at the battery side of the machine.

Index No. Description

— Coil nut (item BA) — — 4-5 ft-lbs / 5-7 Nm

1 Solenoid valve, 3 position 4 way BA

2

Relief valve, 3500 psi / 241 bar
maximum

Schematic

Item

BB Outrigger circuit 20 ft-lbs / 27 Nm

Function Torque

Outriggers extend /

retract

25 ft-lbs / 34 Nm

Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic.

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

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 specifications.

3 If required, install the valve coil(s) onto the valve stem. Install the coil nut onto the valve stem and

torque to specifications.

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October 2023 Service and Repair Manual

Index No.

Description

Schematic Item

Function

Torque

Manifolds

5-7 Outrigger Cylinder Manifold Components – GS-3232

The outrigger function manifold is mounted behind an inspection door, at the battery side of the machine.

— Coil nut (item CA, CB. CC, CD) — — 4-5 ft-lbs / 5-7 Nm

1 Solenoid valve, 2 position 2 way CA, CB, CC, CD

2

3 Check Valve, pilot operated CF Retract flow control 20 ft-lbs / 27.1 Nm

4 Pressure transducer CG Outrigger auto level 16 ft-lbs / 21.7 Nm

Orifice Plug, 0.037 inch /

0.94 mm

CE Outrigger retract —

Outriggers extend /

retract

25 ft-lbs / 34 Nm

Front Outriggers Rear Outriggers

Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic.

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

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 specifications.

3 If required, install the valve coil(s) onto the valve stem. Install the coil nut onto the valve stem and

torque to specifications.

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Manifolds

5-8
Valve Adjustments - Function
Manifold

Note: Perform this test from the ground with the
platform controls. Do not stand in the platform.

Note: Verify the hydraulic oil level is at the FULL
mark on the hydraulic tank.

How to Adjust the System Relief
Valve

1 Locate the system relief valve on the

function manifold (schematic item I, AB or
DB).

2 Connect a 0 to 5000 psi / 0 to 350 bar

pressure gauge to the test port on the
function manifold. (schematic item A, AA or
DA).

3 Chock both sides of the wheels at the steer

end of the machine.

4 Remove the platform controls from the

platform.

5 Turn the key switch to platform controls and

pull out the red Emergency Stop button to
the on position at both ground and platform
controls.

GS-1530/32 and GS-1930/32

1 test port
2 system relief valve

6 Move and hold the joystick fully in either

direction while observing the pressure
reading on the pressure gauge. Note the
pressure. Refer to Specifications, Hydraulic
Component Specifications.

66 GS

7 Turn the machine off. Hold the system relief

valve with a wrench and remove the cap. I,
AB or DB).

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Manifolds

8 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 result in
the machine tipping over,
causing death or serious
injury. Do not adjust the relief
valve pressures higher than
specifications.

9 Install the relief valve cap.

10 Repeat steps 5 and 6 to confirm the relief

valve pressure.

How to Adjust the Platform Lift
Relief Valve

Note: Perform this test from the ground with the
platform controls. Do not stand in the platform.

Note: Verify the hydraulic oil level is at the FULL
mark on the hydraulic tank.

1 Locate the system relief valve on the

function manifold (schematic item I, AB or
DB).

2 Connect a 0 to 5000 psi / 0 to 350 bar

pressure gauge to the test port on the
function manifold. (schematic item A, AA or
DA).

3 Chock both sides of the wheels at the steer

end of the machine.

4 Remove the platform controls from the

platform.

5 Turn the key switch to platform controls and

pull out the red Emergency Stop button to
the on position at both ground and platform
controls.

GS-32, GS-46 and GS-47

1 test port
2 system relief valve
3 steer relief valve
4 lift relief valve

GS-1530/32 and GS-1930/32

1 test port
2 system relief valve
3 lift relief valve

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Manifolds

6 Move and hold the joystick fully in either

direction while observing the pressure
reading on the pressure gauge. Note the
pressure. Refer to Specifications, Hydraulic
Component Specifications.

7 Turn the machine off. Hold the system relief

valve with a wrench and remove the cap. I,
AB or DB).

8 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 result in
the machine tipping over,
causing death or serious
injury. Do not adjust the relief
valve pressures higher than
specifications.

9 Install the relief valve cap.

10 Repeat steps 5 and 6 to confirm the relief

valve pressure.

11 Place maximum rated load into the platform.

Secure the load to the platform. Refer to
Specifications, Machine Specifications.

12 Turn the key switch to ground control and

pull out the red Emergency Stop button to
the on position at both ground and platform
controls.

13 Hold the lift relief valve with a wrench and

remove the cap (schematic item C, AJ or
DJ).

14 While activating the platform up function,

adjust the internal hex socket clockwise,
just until the platform fully rises.

15 Fully lower the platform to the stowed

position.

16 Add an additional 50 pounds / 22,7 kg to

the platform. Secure the additional weight.

17 Attempt to raise the platform.

Result: The power unit should not be able

to lift platform.

Result: If the power unit lifts the platform,

adjust the internal hex nut socket
counterclockwise until the platform will not
rise.

18 Install the relief valve cap.

19 Remove the weight from the platform.

20 Bleed the hydraulic system by raising the

platform to full height. If the pump cavitates
or the platform fails to reach full height, add
hydraulic oil until the pump is functioning
correctly. Do not overfill the hydraulic tank.

GS-32, GS-46 and GS-47

1 test port
2 system relief valve
3 steer relief valve
4 lift relief valve

68 GS

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Manifolds

How to Adjust the
Lift Pressure Selector Valve
(GS-4047 only)

Note: The System Relief Valve and Platform Lift
Relief Valve must be adjusted before making an
adjustment to the Lift Pressure Selector Valve.
Refer to Repair Procedures, How to Adjust the

System Relief Valve and How to Adjust the
Platform Lift Relief Valve.

Note: Perform this test from the ground with the
platform controls. Do not stand in the platform.

Note: Verify the hydraulic oil level is at the FULL
mark on the hydraulic tank.

1 Locate the pressure selector relief valve on

the pressure selector manifold (schematic
item DM).

2 Connect a 0 to 5000 psi / 0 to 350 bar

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

3 Using a suitable lifting device, place and

secure the maximum rated load in the
center of the platform deck.

Maximum load, GS-4047

GS-4047
(CE and AS models)

GS-4047
(ANSI and CSA models)

770 lbs

350 kg

550 lbs

250 kg

4 Remove the platform controls from the

platform.

5 Turn the key switch to platform controls and

pull out the red Emergency Stop button to
the on position at both ground and platform
controls.

6 Press and hold the lift function enable

button and the press the platform up button
to raise the platform 4 ft / 1.2 m above the
stowed position.

Result: The platform does not rise. Perform

steps 7 through 10 to increase the pressure
in small increments until the platform rises.
Then proceed to step 12.

GS-32, GS-46 and GS-47

1 test port
2 system relief valve
3 steer relief valve
4 lift relief valve

Result: The platform rises. Perform steps

7 through 10 to decrease the pressure in
small increments until the platform does not
rise. Then follow steps 7 through 10 again
to increase the pressure in small increments
until the platform is able to rise.

7 Turn the machine off. Hold the lift pressure

selector valve with a wrench and remove
the cap (schematic item DM).

GS-4047

1 lift pressure selector valve
2 solenoid valve

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Manifolds

8 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 result in
the machine tipping over,
causing death or serious
injury. Do not adjust the relief
valve pressures higher than
specifications.

9 Install the relief valve cap.

10 Fully lower the platform to the stowed

position.

11 Using a suitable lifting device, add and

secure an additional 150 lbs / 68 kg to the
platform deck.

12 Raise the platform.

Result: The platform does not rise. Proceed

to step 13.

How to Adjust the Steer Relief
Valve

Note: Perform this test from the ground with the
platform controls. Do not stand in the platform.

Note: Verify the hydraulic oil level is at the FULL
mark on the hydraulic tank.

1 Locate the steer relief valve on the function

manifold (schematic item G, AH or DH).

2 Connect a 0 to 5000 psi / 0 to 350 bar

pressure gauge to the test port on the
function manifold. (schematic item A, AA or
DA).

3 Remove the platform controls from the

platform.

4 Turn the key switch to platform controls and

pull out the red Emergency Stop button to
the on position at both ground and platform
controls.

Result: The platform rises. Perform steps

7 through 10 to decrease the pressure in
small increments until the platform does not
rise.

13 Fully lower the platform to the stowed

position.

14 Using a suitable lifting device, remove the

weight from the platform.

GS-1530/32 and GS-1930/32

1 test port
2 steer relief valve

70 GS

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Manifolds

5 Activate the function enable switch and

press and hold the steer thumb rocker
switch to the right. Allow the wheels to
completely turn to the right. Continue
holding the switch while observing the
pressure reading on the pressure gauge.
Note the pressure. Refer to Specifications,
Hydraulic Component Specifications..

6 Press and hold the steer thumb rocker

switch to the left. Allow the wheels to
completely turn to the left. Continue holding
the switch while observing the pressure
reading on the pressure gauge.

7 Turn the machine off. Hold the steer relief

valve with a wrench and remove the cap. G,
AH or DH).

8 Adjust the internal hex socket. Turn it

clockwise to increase the pressure or
counterclockwise to decrease the pressure.

Component damage hazard.
Do not adjust the relief valve
pressures higher than
specifications.

10 Repeat steps 5 and 6 to confirm the relief

valve pressure.

GS-32, GS-46 and GS-47

1 test port
2 system relief valve
3 steer relief valve
4 lift relief valve

9 Install the relief valve cap.

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Description

Specification

Manifolds

5-9 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 (W). 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.

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 / 10°C that your air temperature increases
or decreases from 68°F / 20°C.

Solenoid valve, 3 position 4 way,
20V DC with diode
(schematic item F, AC or DC)

Solenoid valve, 3 position 4 way,
20V DC with diode
(schematic item E)

Solenoid valve, 2 position 4 way,
20V DC with diode
(schematic item H, AI or DI)

Solenoid valve, 2 position 2 way,
N.C. 20V DC with diode
(schematic item N)

Solenoid valve, 2 position 4 way,
20V DC with diode
(schematic item AE or DE)

Solenoid valve, 3 position 5 way,
20V DC with diode
(schematic item AG or DG)

Solenoid valve, 2 position 2 way,
20V DC with diode
(schematic item CA, CB, CC, CD

Solenoid valve, 3 position 4 way,
20V DC with diode
(schematic item BA)

Proportional solenoid valve,
2 position 2 way, 20V DC with
diode
(schematic item DN)

27.2Ω

19Ω

19Ω

25Ω

19Ω

19Ω

27.2Ω

19Ω

23.9Ω

72 GS

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Manifolds

How to Test a Coil Diode

Genie incorporates spike suppressing diodes in
all of its coils. Properly functioning coil diodes
protect the electrical circuit by suppressing
voltage spikes. Voltage spikes naturally occur
within a function circuit following the interruption
of electrical current to a coil. Faulty diodes can
fail to protect the electrical system, resulting in a
tripped circuit breaker or component damage.

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 resistance. Refer to Repair

Procedure, 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.

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.

1 multimeter
2 9V DC battery
3 10Ω resistor
4 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 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 current readings are

greater than 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.

Part No. 1272217GT GS

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Steer Axle Components

6-1 Yoke and Drive Motor

How to Remove the Yoke and
Drive Motor

Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer
to Specifications, Hydraulic Hose and Fitting
Torque Specifications.

1 Block the non-steer tires.

2 Remove the cotter pin from the wheel castle

nut.

Note: Always replace the cotter pin with a new
one when removing the castle nut.

3 Loosen the wheel castle nut. Do not remove

it.

4 Center a lifting jack under the drive chassis

at the steer end of the machine.

5 Raise the machine approximately 6 inches /

15 cm. Place blocks under the chassis for
support.

Crushing hazard. The chassis
will fall if not properly
supported.

6 Remove the wheel castle nut. Remove the

wheel.

7 Tag, disconnect and plug the hydraulic

hoses on the drive motor. Cap the fittings
on the drive motor.

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.

Component damage
hazard. Hoses can be
damaged if they are
kinked or pinched.

8 Support and secure the yoke assembly to

an appropriate lifting device.

9 Remove the retaining fastener from the

steer link at the yoke assembly.

Note: While removing the retaining fasteners,
take note of the quantity and location of the
spacers when disconnecting the steer link from
the yoke assembly.

10 Remove the retaining fastener from the top

of the yoke pivot shaft.

Note: The pivot shaft retaining fastener is
located above the main deck.

11 Lower the yoke assembly out of the

chassis.

Bodily injury hazard. The
yoke/motor assembly may fall
if not properly supported
when it is removed from the
chassis.

74 GS

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October 2023 Service and Repair Manual

Steer Axle Components

How to Remove a Drive Motor

1 Block the non-steer tires.

2 Remove the cotter pin from the wheel castle

nut of the motor to be removed.

3 Note: Always replace the cotter pin with a

new one when removing the castle nut.

4 Loosen the wheel castle nut. Do not remove

it.

5 Raise the machine approximately 2 inches /

5 cm. Place blocks under the chassis for
support.

Crushing hazard. The chassis
will fall if not properly
supported.

6-2 Steer Cylinder

How to Remove the Steer
Cylinder

Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer
to Specifications, Hydraulic Hose and Fitting
Torque Specifications.

1 Block the non-steer tires.

2 Remove the pin retaining fasteners from the

rod-end pivot pin. Remove the pivot pin.

6 Remove the wheel castle nut. Remove the

wheel.

7 Tag, disconnect and plug the hydraulic

hoses on the drive motor. Cap the fittings
on the drive motor.

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.

Component damage
hazard. Hoses can be
damaged if they are
kinked or pinched.

8 Remove the drive motor mounting

fasteners. Remove the motor.

Torque specifications

Drive motor mounting
fasteners, dry

Drive motor mounting
fasteners, lubricated

75 ft-lbs

101.7 Nm

56 ft-lbs

76.3 Nm

Note: While removing the pin retaining fasteners,
take note of the quantity and location of the
spacers when removing the pivot pin.

3 Remove the pin retaining fasteners from the

barrel-end pivot pin. Remove the pin.

Note: While removing the pin retaining fasteners,
take note of the quantity and location of the
spacers when removing the pivot pin.

4 Remove the steer cylinder from the

machine.

5 Tag, disconnect and plug the hydraulic

hoses from the steer cylinder. Cap the
fittings on the cylinder.

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.

Component damage
hazard. Hoses can be
damaged if they are
kinked or pinched.

Part No. 1272217GT GS

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Steer Axle Components

6-3 Steer Bellcrank

How to Remove the Steer
Bellcrank

1 Remove the steer cylinder. Refer to Repair

Procedure, How to Remove the Steer
Cylinder.

2 Remove the retaining fasteners from the

steer links at each end of the bellcrank.

Note: While removing the retaining fasteners,
take note of the quantity and location of the
spacers between the bellcrank and the steer
links.

3 Center a lifting jack under the drive chassis

at the steer end of the machine.

4 Raise the machine approximately 14 inches

/ 36 cm. Place blocks under the chassis for
support.

Crushing hazard. The chassis
will fall if not properly
supported.

5 Turn the yokes to the side so the bellcrank

can be removed.

6 Remove the bellcrank from the machine.

1 apply removable thread lock to fastener

threads

Note: While removing the bellcrank from the
machine, take note of the quantity and location
of the spacers between the bellcrank and the
steer links.

Note: Before re-installing the steer bellcrank
onto the machine, apply a small amount of
removable thread lock onto the threads of the
fasteners. Torque the fasteners to 31 ft-lbs / 42
Nm.

76 GS

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October 2023 Service and Repair Manual

Crushing hazard. The entry

Torque specifications

56 ft-lbs

Non-Steer Axle Components

7-1 Drive Brake

How to Remove the Drive Brake

Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer
to Specifications, Hydraulic Hose and Fitting
Torque Specifications.

1 Support and secure the entry ladder to an

appropriate lifting device.

2 Remove the entry ladder mounting

fasteners. Remove the entry ladder from the
machine.

ladder will fall if not properly
supported and secured to the
lifting device.

3 Block the steer wheels.

4 Remove the cotter pin from the wheel castle

nut.

Note: Always replace the cotter pin with a new
one when removing the castle nut.

5 Loosen the wheel castle nut. Do not remove

it.

6 Center a lifting jack under the drive chassis

at the non-steer end of the machine.

7 Raise the machine approximately 2 inches /

5 cm. Place blocks under the chassis for
support.

Crushing hazard. The chassis
will fall if not properly
supported.

8 Remove the wheel castle nut. Remove the

wheel.

9 Tag, disconnect and plug the hydraulic hose

from the brake. Cap the fitting on the brake.

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.

10 Place a lifting jack under the brake for

support.

11 Remove the fasteners that attach the brake

to the drive chassis. Remove the brake.

Crushing hazard. The brake
will fall if not properly
supported when the mounting
fasteners are removed.

Brake mounting fasteners, dry

Brake mounting fasteners, lubricated

75 ft-lbs

102 Nm

76 Nm

Part No. 1272217GT GS

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Brake Release Hand Pump Components

8-1 Brake Release Hand Pump Components

The brake release hand pump manifold is mounted behind the entry ladder.

Index No. Description Schematic Item Function Torque

1 Hand

pump

2 Needle

valve

L Manual brake release 30 ft-lbs / 41 Nm

M

Manual brake release

enable

45-50 in-lbs / 5 Nm

Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic.

™

78 GS

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October 2023 Service and Repair Manual

Scissor Components

Steer End

1 - Number 4 pivot pin 10 - Number 3 inner arm

2 - Number 3 center pivot pin (Qty. 2) 11 - Number 3 outer arm

3 - Lift cylinder rod-end pivot pin 12 - Number 3 pivot pin (non-steer end)

4 - Number 3 pivot pin (steer end) 13 - Number 2 inner arm

5 - Number 2 center pivot pin (Qty. 2) 14 - Number 2 outer arm

6 - Number 2 pivot pin (steer end) 15 - Number 2 pivot pin (non-steer end)

7 - Number 1 center pivot pin (Qty. 2) 16 - Lift cylinder barrel-end pivot pin

8 - Number 1 inner arm 17 - Number 1 outer arm

9 - Number 1 pivot pin

Non-steer End

Part No. 1272217GT GS

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Service and Repair Manual October 2023

Scissor Components

9-1 Scissor Assembly, GS-1530 and GS-1532

How to Disassemble the Scissor
Assembly

Bodily injury hazard. The
procedures in this section
require specific repair skills,
lifting equipment and a
suitable workshop.
Attempting this procedure
without these skills and tools
could result in death or
serious injury and significant
component damage. Dealer
service is required.

Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer
to Specifications, Hydraulic Hose and Fitting
Torque Specifications.

4 Lower the platform onto the safety arm.

Crushing hazard. Keep hands
clear of the safety arm when
lowering the platform.

5 At the ground controls, turn the key switch

to the off position and push in the red
Emergency Stop button to the off position.

6 Disconnect the battery pack 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.

7 Remove the fasteners securing the large

platform height sensor cover to the large
platform height sensor bracket.

8 Remove the platform height sensor cover.

9 Tag and disconnect the platform height

sensor from the platform height sensor
harness.

Note: Machines equipped with a Platform Height
Sensor, begin the Scissor Disassembly
procedure at step 1. Machines without a
Platform Height Sensor, begin the Scissor
Disassembly procedure at step 24.

1 Turn the key switch to ground controls and

pull out the red Emergency Stop button to
the on position at both ground and platform
controls.

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

3 Lift the safety arm, move it to the center of

the scissor arm and rotate down to a
vertical position.

10 Remove the fastener securing the platform

height sensor assembly to the number
1 inner arm.

11 Remove the platform height sensor

assembly from the number 1 pivot pin.

12 Remove the plastic nut securing the

squeeze connector to the large platform
height sensor bracket.

13 Remove the squeeze connector from the

large platform height sensor bracket.

14 Remove the fasteners securing the large

platform height sensor bracket to the
number 1 inner arm pivot bracket.

15 Remove the large platform height sensor

bracket from the number 1 inner arm pivot
bracket.

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October 2023 Service and Repair Manual

Component damage hazard.

1

3

2

4

Scissor Components

16 Install the fasteners removed in 14 to the

number 1 inner arm pivot bracket and
chassis.

17 Connect the battery pack to the machine.

18 Turn the key switch to ground controls.

19 Press and hold the ground control scroll up

and scroll down buttons.

24 Remove the platform. Refer to Repair

Procedure, How to Remove the Platform.

25 Remove the cables from the number 3 outer

arm (index #11) at the ground controls side.

Cables can be damaged if
they are kinked or pinched.

20 Pull out the red Emergency Stop button to

the on position at the ground controls.

21 Using the ground control menu buttons,

navigate to Service Override Mode. Select
Service Override Mode.

Note: The machine must be in Service Override
Mode to raise the platform. While in Service
Override Mode, only the GCON will operate with
limited functionality. The platform will raise a
predetermined amount of time and stop.

22 Raise the platform and rotate the safety arm

to the stowed position.

23 Fully lower the platform to the stowed

position.

26 Remove the cables from the number

3 cable bridge and lay them off to the side.

Component damage hazard.
Cables can be damaged if
they are kinked or pinched.

27 Attach a lifting strap from an overhead

crane to the number 3 outer arm (index
#11).

28 Remove the external snap rings and

retaining fasteners from the number
3 center pivot pins (index #2).

29 Use a soft metal drift to remove the number

3 center pivot pins (index #2).

30 Remove the retaining fasteners from the

number 3 pivot pin (index #12) at the non­steer end of the machine.

31 Use a soft metal drift to remove the number

3 pivot pin (index #12) from the non-steer
end of the machine. Remove the number
3 outer arm (index #11) from the machine.

Crushing hazard. The number
3 outer arm may become
unbalanced and fall if not
properly supported when
removed from the machine.

Cable bridge and platform height sensor

1 cable bridge 3
2 cable bridge 2
3 cable bridge 1
4 platform height sensor

Part No. 1272217GT GS

32 Remove the number 3 cable bridge

mounting fasteners and remove the cable
bridge from the machine.

33 Attach a lifting strap from an overhead

crane to the lug on the rod end of the lift

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cylinder for support. Do not apply any lifting
pressure.

Service and Repair Manual October 2023

become unbalanced and fall if

Scissor Components

34 Remove the pin retaining fasteners from the

lift cylinder rod-end pivot pin (index #3). Use
a soft metal drift to remove the pin.

42 Attach a lifting strap from an overhead

crane to the number 2 outer arm (index
#14) at the ground controls side.

Bodily injury hazard. The
cylinder may fall when the
rod-end pivot pin is removed
if not properly supported.

35 Lower the cylinder onto the number 1 inner

arm (index #8).

Component damage hazard.
Cables can be damaged if
they are kinked or pinched.

36 Attach a lifting strap from an overhead

crane to the number 3 inner arm (index
#10).

37 Remove the retaining fasteners from the

number 3 pivot pin (index #4) at the steer
end.

38 Use a soft metal drift to remove the number

3 pivot pin (index #4). Remove the number
3 inner arm (index #10) from the machine.

Bodily injury hazard. The
number 3 inner arm may

not properly supported when
removed from the machine.

39 Remove the cables from the number

2 cable bridge and lay them off to the side.

Component damage hazard.
Cables can be damaged if
they are kinked or pinched.

40 Remove the external snap rings and

retaining fasteners from the number
2 center pivot pin (index #5) at the ground
controls side.

43 Use a soft metal drift to remove the number

2 center pivot pin (index #5) at the ground
controls side.

44 Remove the retaining fasteners from the

number 2 pivot pin (index #15) at the non­steer end of the machine.

45 Use a soft metal drift to tap the number

2 pivot pin (index #15) halfway out at the
non-steer end of the machine. Remove the
number 2 outer arm (index #14) from the
ground controls side of the machine.

Bodily injury hazard. The
number 2 outer arm at the
ground controls side may
become unbalanced and fall if
not properly supported when
removed from the machine.

46 Attach a lifting strap from an overhead

crane to the number 2 outer arm (index
#14) at the battery pack side.

47 Remove the external snap rings and

retaining fasteners from the number
2 center pivot pin (index #5) at the battery
pack side.

48 Use a soft metal drift to remove the number

2 center pivot pin (index #5) at the battery
pack side.

Bodily injury hazard. The
number 2 outer arm at the
battery pack side may
become unbalanced and fall if
not properly supported when
removed from the machine.

41 Remove the number 2 cable bridge

mounting fasteners and remove the cable
bridge from the machine.

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October 2023 Service and Repair Manual

become unbalanced and fall if

become unbalanced and fall if

Scissor Components

49 Use a soft metal drift to tap the number

2 pivot pin (index #15) in the other direction
at the non-steer end. Remove the number
2 outer arm (index #14) from the battery
pack side of the machine.

Bodily injury hazard. The
number 2 outer arm at the
battery pack side may

not properly supported when
removed from the machine.

50 Attach a lifting strap from an overhead

crane to the number 2 inner arm (index
#13).

51 Remove the retaining fasteners from the

number 2 pivot pin (index #6) at the steer
end of the machine.

52 Use a soft metal drift to remove the number

2 pivot pin (index #6). Remove the number
2 inner arm (index #13) from the machine.

Bodily injury hazard. The
number 2 inner arm may

not properly supported when
removed from the machine.

56 Attach a lifting strap from an overhead

crane to the lug on the rod end of the lift
cylinder (index #3). Raise the lift cylinder
approximately 3 ft / 1 m.

57 Tag, disconnect and plug the hydraulic

hoses on the lift cylinder. Cap the fittings on
the cylinder.

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.

58 Tag and disconnect the wires and manual

lowering cable from the solenoid valve on
the cylinder.

59 Models with platform overload option:

Tag and disconnect the wire harness from
the platform overload pressure transducer.

Note: After replacing the scissor assembly, the
platform overload system must be calibrated.
Refer to Repair Procedure, How to Calibrate the
Platform Overload System (if equipped).

53 Remove the safety arm from the number

2 inner arm (index #13) that was just
removed.

54 Attach a lifting strap from an overhead

crane to the number 1 inner arm (index #8).

55 Raise the number 1 inner arm (index #8)

approximately 2 feet / 60 cm and install the
safety arm between the number 1 inner arm
(index #8) and the number 1 outer arm
(index #17). Lower the scissor arms onto
the safety arm.

Part No. 1272217GT GS

Bodily injury hazard. Keep
hands clear of moving parts
when lowering the scissor
arms onto the safety arm.

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60 Raise the lift cylinder to a vertical position.

61 Remove the pin retaining fasteners from the

lift cylinder barrel-end pin (index #16). Use
a soft metal drift to remove the pin. Remove
the lift cylinder from the machine.

Crushing hazard. The lift
cylinder will become
unbalanced and fall if not
properly supported and
secured to the lifting device.

Component damage hazard.
Be careful not to damage the
valve or fittings on the
cylinder while removing it
from the machine.

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Service and Repair Manual October 2023

Scissor Components

62 Place a 4 x 4 x 48 inch / 10 cm x 10 cm x

1.2 m long block across both sides of the
chassis under the number 1 center pivot pin
(index #7).

63 Attach a lifting strap from an overhead

crane to the number 1 inner arm (index #8)
at the non-steer end. Raise the number
1 inner arm and remove the safety arm.
Lower the number 1 inner arm (index #8)
onto the block that was placed across the
chassis.

70 Use a soft metal drift to remove the number

1 center pivot pins (index #7).

Bodily injury hazard. The
number 1 outer arm may
become unbalanced and fall if
not properly supported when
the pin is removed.

71 Slide the number 1 outer arm (index #17) to

the non-steer end and remove it from the
machine.

Bodily injury hazard. Keep
hands clear of moving parts
when lowering the scissor
arms.

64 Remove the cables from the number

1 cable bridge and lay them off to the side.

Component damage hazard.
Cables can be damaged if
they are kinked or pinched.

65 Support and secure the entry ladder to an

appropriate lifting device.

66 Remove the fasteners from the entry ladder

and remove the entry ladder from the
machine.

Crushing hazard. The entry
ladder will fall if not properly
supported and secured to the
lifting device.

67 Attach a lifting strap from an overhead

crane to the number 1 outer arm (index
#17). Do not apply any lifting pressure.

68 Remove the external snap rings and

retaining fasteners from the number
1 center pivot pins (index #7).

69 Remove the number 1 cable bridge from the

machine.

Bodily injury hazard. The
number 1 outer arm may
become unbalanced and fall if
not properly supported when
removed from the machine.

72 Attach the strap from an overhead crane to

the number 1 inner arm (index #8). Do not
lift it.

73 Remove the upper fasteners securing the

number 1 inner arm pivot bracket to the end
of the chassis. Loosen the lower fasteners.

74 Remove the number 1 inner arm (index #8)

from the machine.

Bodily injury hazard. The
number 1 inner arm may
become unbalanced and fall if
not properly supported when
removed from the machine.

Component damage hazard.
Be sure not to damage the
limit switch or level sensor
components when the
number 1 inner arm is
removed from the machine.

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