Genie GS-2646AV Installation and operating manual

Service and Repair Manual
Serial Number Range
GS-2646AV
from GS4612A-110000
from GS4616P-
138362 to
GS4616P-
141799
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics
GS-2646AV 35
from GS46P-141800
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
Part No. 1272218
Rev A2
September 2016

Service and Repair Manual September 2016
Introduction
ii GS-2646 AV • GS-2646 AV35 Part No. 1272218
Intr oduct io n Intr oduct io n
Important
Read, understand and obey the safety rules and
operating instructions in the appropriate Operator's
Manual on your machine before attempting any
procedure.
This manual provides troubleshooting and repair
procedures for qualified service professionals.
Basic mechanical, hydraulic and electrical skills are
required to perform most procedures. However,
several procedures require specialized skills, tools,
lifting equipment and a suitable workshop. In these
instances, we strongly recommend that
maintenance and repair be performed at an
authorized Genie dealer service center.
Compliance
Machine Classification
Group A/Type 3 as defined by ISO 16368
Machine Design Life
Unrestricted with proper operation, inspection and
scheduled maintenance.
Technical Publications
Genie has endeavored to deliver the highest
degree of accuracy possible. However, continuous
improvement of our products is a Genie policy.
Therefore, product specifications are subject to
change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.
Contact Us:
Internet: www.genielift.com
E-mail: [e-mail]
Find a Manual for this Model
Go to http://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
1272218 Rev A, March 2016
First Edition, First 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..

September 2016 Service and Repair Manual
Introduction
Part No. 1272218 GS-2646 AV • GS-2646 AV35 iii
Revision History
Revision Date Section Procedure / Page / Description
A 3/2016 Initial Release
A1 5/2016 Repair Procedures 2-3, 2-4, 2-5, 2-6
Diagnostics H067 fault
A2 9/2016 Introduction Serial Number Legend
Reference Examples: Electronic Version
Click on any content or procedure in the Table of Contents to view
the update.
Section – Repair Procedure, 4-2
Section – Fault Codes, All charts
Section – Schematics, Legends and schematics

Service and Repair Manual September 2016
Introduction
iv GS-2646 AV • GS-2646 AV35 Part No. 1272218
Serial Number Legend
To August 31, 2016
1 Model
2 Model year
3 Facility code
4 Sequence number
5 Serial label (located on chassis)
6 Serial number (stamped on chassis)
From September 1, 2016
1 Model
2 Facility code
3 Sequence number
4 Serial label (located on chassis)
5 Serial number (stamped on chassis)

September 2016 Service and Repair Manual
Safety Rules
Part No. 1272218 GS-2646 AV • GS-2646 AV35 v
Section 1 Safet y Rul es
Danger
Failure to obey the instructions and safety rules in
this manual and the appropriate Operator's Manual
on your machine will result in death or serious
injury.
Many of the hazards identified in the operator's
manual are also safety hazards when maintenance
and repair procedures are performed.
Do Not Perform Maintenance
Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
•manufacturer's instructions and safety rules
•employer's safety rules and worksite
regulations
•applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.

Service and Repair Manual September 2016
Safety Rules
vi GS-2646 AV • GS-2646 AV35 Part No. 1272218
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 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.
Indicates a potentially hazardous
situation
which, if not avoided,
may cause minor or moderate
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may result in property damage.
Be sure to wear protective eye wear and
other protective clothing if the situation
warrants i
t.
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.
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. Alwa
ys 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.
Be sure that fasteners intended for on
e
time use (i.e., cotter pins and self
-locking
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.

September 2016
Table of Contents
Part No. 1272218 GS-2646 AV • GS-2646 AV35 vii
Introduction Introduction...........................................................................................................ii
Important Information .............................................................................................ii
Find a Manual for this Model..................................................................................ii
Revision History..................................................................................................... iii
Serial Number Legend ..........................................................................................iv
Section 1 Safety Rules..........................................................................................................v
General Safety Rules .............................................................................................v
Section 2Specifications.......................................................................................................1
Machine Specifications...........................................................................................1
Performance Specifications....................................................................................2
Hydraulic Specification...........................................................................................3
Hydraulic Component and Manifold Specifications................................................6
Hydraulic Hose and Fitting Torque Specifications .................................................6
Torque Procedure ..................................................................................................7
Section 3 Repair Procedures ...............................................................................................9
Introduction.............................................................................................................9
Platform Controls...............................................................................................11
1-1 Circuit Board...................................................................................................12
1-2 Joystick...........................................................................................................13
1-3 Platfrom Controls Alarm.................................................................................13
1-4 Platform Emergency Stop Button...................................................................14
Ground Controls.................................................................................................15
2-1 Software Revision Level.................................................................................16
2-2 Machine Setup ...............................................................................................17
2-3 Loading or Updating Machine Software.........................................................18
2-4 Using a Wi-Fi Router to Connect to the SmartLink Web Service Tool ..........23
2-5 Service Override Mode ..................................................................................25
2-6 Level Sensors ................................................................................................27
2-7 Manual Platform Lowering Cable...................................................................41

September 2016
Table of Contents
viii GS-2646 AV • GS-2646 AV35 Part No. 1272218
Hydraulic Tank ...................................................................................................43
3-1 Hydraulic Tank...............................................................................................43
Hydraulic Pump.................................................................................................. 44
4-1 Hydraulic Pump .............................................................................................44
How to Remove the Hydraulic Pump..............................................................45
Manifolds ............................................................................................................46
5-1 Function Manifold Components.....................................................................46
5-2 Powered Extension Deck Function Manifold Components ...........................48
5-3 Valve Adjustments – Function Manifold ........................................................49
5-4 Valve Coils.....................................................................................................52
Steer Axle Components ....................................................................................55
6-1 Yoke and Drive Motor....................................................................................55
6-2 Steer Cylinder................................................................................................56
6-3 Steer Bellcrank ..............................................................................................57
Non-Steer Axle Components............................................................................ 58
7-1 Drive Brake....................................................................................................58
Brake Release Hand Pump Components ........................................................59
8-1 Brake Release Hand Pump Components......................................................59
Scissor Components.........................................................................................60
9-1 Scissor Assembly ..........................................................................................61
How to Replace the Scissor Arm Wear Pads.................................................66
9-2 Lift Cylinder....................................................................................................67
Platform Components .......................................................................................69
10-1 Platform........................................................................................................69
10-2 Platform Extension.......................................................................................71
How to Remove the Manual Extension Deck .................................................71
How to Remove the Powered Extension Deck (if equipped)..........................72
10-3 Extension Deck Cylinder..............................................................................73

September 2016
Table of Contents
Part No. 1272218 GS-2646 AV • GS-2646 AV35 ix
Section 4 Diagnostics.........................................................................................................77
Introduction...........................................................................................................77
GCON I/O Map (with manual extension deck).....................................................79
GCON I/O Map (with powered extension deck)...................................................80
Operation Indicator Codes (OIC)..........................................................................82
Diagnostic Trouble Codes (DTC).........................................................................82
Troubleshooting "HXXX" and "PXXX" Faults.......................................................83
Fault Inspection Procedure ..................................................................................84
Type "HXXX" Faults .............................................................................................86
Type "PXXX" Faults..............................................................................................88
Type "UXXX" Faults .............................................................................................89
Type "FXXX" Faults..............................................................................................91
Type "CXXX" Faults .............................................................................................92
Section 5 Schematics..........................................................................................................93
Introduction...........................................................................................................93
Electrical Component and Wire Color Legends ...................................................94
Wiring Diagram Ground Controls.........................................................................96
Wiring Diagram Platform Controls........................................................................97
Limit Switch Legend .............................................................................................98
Electrical Symbol Legend...................................................................................100
Hydraulic Symbols Legend.................................................................................101
Hydraulic Component Reference.......................................................................102
Electrical Schematics – ANSI and CSA Models............................................103
Electrical Schematic • GS-2646 AV and GS-2646 AV35 (with manual extension
deck) (from GS4612A-110000) ..................................................................104
Electrical Schematic • GS-2646 AV and GS-2646 AV35 (with powered extension
deck) (from serial number GS4612A-110000) ...........................................108
Electrical Schematic • GS-2646 AV and GS-2646 AV35 (foot switch option) (from
serial number GS4612A-110000)...............................................................112
Section 6 Hydraulic Schematics......................................................................................113
Hydraulic Schematic...........................................................................................113
Hydraulic Schematic, Powered Extension Deck Manifold..................................114

September 2016 Service and Repair Manual
Specifications
Part No. 1272218 GS-2646 AV • GS-2646 AV35 1
Section 2 Speci fic ati ons
Machine Specifications
Batteries, Standard
Voltage
6V DC
Group
GC2
Type
T-
105
Quantity
4
Battery capacity,
maximum
C20 = 225AH
Reserve capacity @ 25A rate
447 m
inutes
Weight, each
62
lbs
28
kg
Batteries, Maintenance
-free (option)
Voltage
6V
DC
Group
GC2
Type
6V-
AGM
Quantity
4
Battery capacity, maximum
C20 = 200AH
Reserve capacity @ 25A rate
380 m
inutes
Weight, each
62
lbs
28
kg
Fluid capacities
Hydraulic tank
3.75 g
allons
14.2 l
iters
Hydraulic system (including tank)
5 g
allons
19 l
iters
Tires and Wheels
Tire size (solid rubber)
15 x 5 i
n
38.1 x 12.7 c
m
Tire contact area
15 s
q in
96.7 cm
2
Castle nut torque, dry
300 ft-
lbs
406.7 Nm
Castle nut torque, lubricated
225 ft-
lbs
305 Nm

Service and Repair Manual September 2016
Specifications
2 GS-2646 AV • GS-2646 AV35 Part No. 1272218
Performance Specifications
Drive speed, maximum
Platform stowed, fast
2.2 m
ph
40 ft / 12.4 s
ec
3.5 k
m/h
12.2 m / 12.4 s
ec
Platform
stowed, slow 1.1 m
ph
40 ft / 24.8 s
ec
1.8 k
m/h
12.2 m / 24.8 s
ec
Platform raised
0.5 m
ph
40 ft / 55 s
ec
0.8 k
m/h
12.2 m / 55 s
ec
Braking distance, maximum
High range on paved surface
24 in ± 12 i
n
61 cm ± 30 c
m
Gradeability
GS
-2646 AV
25%
GS
-2646 AV35
20%
Airborne noise emissions
Sound pressure level at ground
workstation
< 70 d
BA
Sound pressure level at platform
workstation
< 70 d
BA
Function speed, maximum from platform controls
(with
1 person in platform)
Platform up (fast mode)
Platform up (slow mode)
Platform down
28 to 32 s
econds
58 to 62 s
econds
32 to 36 s
econds
Function speed, powered extension deck from
platform controls or ground controls (if equipped)
Extend
Retract 28 to 32 s
econds
31 to 35 s
econds
Rated work load at full height, maximum
Platform Capacity
900 lbs
408
kg
For operational specifications, refer to the
Operator's Manual.

September 2016 Service and Repair Manual
Specifications
Part No. 1272218 GS-2646 AV • GS-2646 AV35 3
Hydraulic Oil Specifications
Hydraulic Fluid 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
conditi
oning, and foam and aeration suppression
properties.
Cleanliness level,
minimum
ISO 15/13
Water content,
maximum
250 p
pm
Recommended Hydraulic Fluid
Hydraulic oil type
Chevron Rando HD Premium
Viscosity grade
32
Viscosity index
200
Optional
Hydraulic Fluids
Mineral based
Shell Tellus S2 V 32
Shell Tellus S2 V 46
Shell Tellus S4 VX 32 Shell
Shell Donax TG (Dexron III)
Chevron 5606A
Biodegradable
Petro Canada Environ MV
46
Fire resistant
UCON Hydrolube HP-
5046
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 and
may result in component
damage.
Note: Extended machine operation can cause the
hydraulic fluid temperature to increase beyond it's
maximum allowable range. If the hydraulic fluid
temperature consistently exceeds 200°F / 90°C an
optional oil cooler may be required.
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 valve
s and may result in
component damage.
Note: Do not operate the machine when the
ambient air temperature is consistently above
120°F / 49°C.
Hydraulic Fluid Temperature
Range
Ambient air temperature
1 Chevron hydraulic oil 5606A
2 Petro-Canada Environ MV 46
3 UCON Hydrolube HP-5046D
4 Chevron Rando HD premium oil MV

Service and Repair Manual September 2016
Specifications
4 GS-2646 AV • GS-2646 AV35 Part No. 1272218
Chevron Rando HD Premium Oil
MV Fluid Properties
ISO Grade
32
Viscosity index
200
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
7.5
33.5
Brookfield Viscosity
cP @
-4°F / -20°C
cP @
-22°F / -30°C
1040
3310
Flash point
375°F / 190°C
Pour point
-58°F / -
50°C
Maximum continuous operating
temperature
171°F / 77°C
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.
Chevron 5606A Hydraulic Oil
Fluid Properties
ISO Grade
15
Viscosity index
300
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
cSt @
-40°F / -40°C
5.5
15.0
510
Flash point
180°F / 82°C
Pour point
-81°F / -
63°C
Maximum continuous operating
temperature
124°F / 51°C
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

September 2016 Service and Repair Manual
Specifications
Part No. 1272218 GS-2646 AV • GS-2646 AV35 5
Petro-Canada Environ MV 46
Fluid Properties
ISO Grade
46
Viscosity index
154
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
8.0
44.4
Flash point
482°F / 250°C
Pour point
-49°F / -
45°C
Maximum continuous operating
temperature
180°F / 82°C
Shell Tellus S4 VX Fluid
Properties
ISO
Grade
32
Viscosity index
300
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
9
33.8
Brookfield Viscosity
cSt @
-4°F / -20°C
cSt @
-13°F / -25°C
cSt @
-40°F / -40°C
481
702.4
2624
Flash point
>100
Pour point
-76°F / -
60°C
Maximum
continuous operating
temperature
103°F / 75°C
UCON Hydrolube HP-5046 Fluid
Properties
ISO Grade
46
Viscosity index
192
Kinematic Viscosity
cSt @ 149°F / 65°C
cSt @ 104°F / 40°C
cSt @ 0°F /
-18°C
22
46
1300
Flash point
None
Pour point
-81°F / -
63°C
Maximum continuous operating
temperature
189°F / 87°C

Service and Repair Manual September 2016
Specifications
6 GS-2646 AV • GS-2646 AV35 Part No. 1272218
Hydraulic Component
Specifications
Function pump
Type
Gear
Displacement per revolution
0.244 c
u in
4 c
c
Flow rate @ 250
0 psi / 172 bar 3 g
pm
11.3
L/min
Hydraulic tank return filter
10 m
icron with
25 psi / 1.7 b
ar
bypass
Function manifold
System relief valve pressure,
maximum
3700 p
si
255 b
ar
Lift relief valve pressure
1800 to 3700 p
si
142 to 241 b
ar
Steer relief valve pressure
1500 p
si
103 b
ar
Powered extension deck manifold
Relief valve pressure, maximum
750 p
si
52 b
ar
Manifold Component
Specifications
Plug torque
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
Hydraulic Hose and Fitting
Torque Specifications
Your machine is equipped with Parker Seal-Lok™
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)
SAE Dash Size
Torque
-4 10 ft-lbs / 13.6 Nm
-6 30 ft-lbs / 40.7 Nm
-8 40 ft-lbs / 54.2 Nm
-10 60 ft-lbs / 81.3 Nm
-12 85 ft-lbs / 115 Nm
-16 110 ft-lbs / 150 Nm
-20 140 ft-lbs / 190 Nm
-24 180 ft-lbs / 245 Nm
JIC 37° Fittings
(swivel nut or hose connection)
SAE Dash Size Thread Size Flats
-4 7/16-20 2
-6 9/16-18 1 ¼
-8 3/4-16 1
-10 7/8-14 1
-12 1 1/16-12 1
-16 1 5/16-12 1
-20 1 5/8-12 1
-24 1 7/8-12 1

September 2016 Service and Repair Manual
Specifications
Part No. 1272218 GS-2646 AV • GS-2646 AV35 7
SAE O-ring Boss Port
(tube fitting - installed into Aluminum)
(all types)
SAE Dash Size Torque
-4 14 ft-lbs / 19 Nm
-6 23 ft-lbs / 31.2 Nm
-8 36 ft-lbs / 54.2 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
SAE O-ring Boss Port
(tube fitting - installed into Steel)
SAE Dash Size
Torque
-4 ORFS / 37° (Adj)
ORFS (Non-adj)
37° (Non-adj)
15 ft-lbs / 20.3 Nm
26 ft-lbs / 35.3 Nm
22 ft-lbs / 30 Nm
-6 ORFS (Adj / Non-adj)
37° (Adj / Non-adj) 35 ft-lbs / 47.5 Nm
29 ft-lbs / 39.3 Nm
-8 ORFS (Adj / Non-adj)
37° (Adj / Non-adj) 60 ft-lbs / 81.3 Nm 52 ft-lbs / 70.5 Nm
-10 ORFS (Adj / Non-adj)
37° (Adj / Non-adj) 100 ft-lbs / 135.6 Nm 85 ft-lbs / 115.3 Nm
-12 (All types) 135 ft-lbs / 183 Nm
-16 (All types) 200 ft-lbs / 271.2 Nm
-20 (All types) 250 ft-lbs / 339 Nm
-24 (All types) 305 ft-lbs / 413.5 Nm
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.

Service and Repair Manual September 2016
Specifications
8 GS-2646 AV • GS-2646 AV35 Part No. 1272218
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
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.

September 2016 Service and Repair Manual
Repair Procedures
Part No. 1272218 GS-2646 AV • GS-2646 AV35 9
Section 3 Repai r Pr oc ed ures
Observe and Obey:
Repair procedures shall be completed by a
person trained and qualified on the repair of
this machine.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating the machine.
Before Repairs Start:
Read, understand and obey the safety rules
and operating instructions in the appropriate
operator's manual on your machine.
Be sure that all necessary tools and parts are
available and ready for use.
Use only Genie approved replacement parts.
Read each procedure completely and adhere
to the instructions. Attempting shortcuts may
produce hazardous conditions.
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

Service and Repair Manual September 2016
Repair Procedures
10 GS-2646 AV • GS-2646 AV35 Part No. 1272218
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
re-assemble, perform the disassembly steps in
reverse order.
Symbols Legend
Safety alert symbol
—
used to alert
personnel to potential
personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicates a imminently hazardous
situation which, if not avoided, will
result in death or serious injury.
Indicates a potentially hazardous
s
ituation which, if not avoided,
could result in death or serious
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may cause minor or moderate
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may
result in property damage.
Indicates that a specific result is expected
after performing a series of steps.
Indicates that an incorrect result has occurred
after performing a series of steps.