Genie GS-2032 Service Manual Download Page 160

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Genie GS-2046 and GS-2646 and GS-3246

Part No. 72972

Section 6 • Schematics

June 2003

REV B

ECM Pin-out Legend

ECM PIN-OUT LEGEND

From serial number 17408 to 21064

Item

Description

Spare

Ground from platform controls (input)
(White wire at platform)

Spare

Power from platform controls to ECM (input)
(Red wire at platform)

Level sensor power S7 (output)

Platform up coil Y8 (output)

Drive reverse coil Y5 (output)

Motor controller U6, terminal 1 (output)

Motor controller U6, terminal 3 (output)

A10

Overload sensor PS2 (input)

A11

Key switch to platform control (input)

A12

Platform down TS66

Platform data link + (input)
(Blue wire at platform)

Power to platform controls (output)
(Black wire at platform)

ECM ground (output)

Spare

Platform down coil Y7 (output)

Steer left coil Y4 (output)

Automotive-style horn H2 (option) (output)

Multifunction alarm H5 (output)

B10

Pothole limit switch (input)

B11

Drive enable power (input)

B12

Platform up at ground controls TS66 (input)

Platform data link – (input)
(yellow or orange wire at platform)

Key switch to ground controls (input)

Spare

Drive forward coil Y6 (output)

Steer right coil Y3 (output)

Spare

Brake release coil Y2 (output)

C10

Spare

C11

Level sensor signal S7 (input)

C12

Down limit switch LS6 (input)

ECM PIN-OUT LEGEND

From serial number 21065 to 25141

Item

Description

Flashing beacon FB1 (output)

Ground from platform controls (input)
(White wire at platform)

Spare

Power from platform controls to ECM (input)
(Red wire at platform)

Level sensor power S7 (output)

Platform up coil Y8 (output)

Drive reverse coil Y5 (output)

Motor controller U6, terminal 1 (output)

Motor controller U6, terminal 3 (output)

A10

Overload sensor PS2 (input)

A11

Key switch to platform control (input)

A12

Platform down TS66

Platform data link + (input)
(Blue wire at platform)

Power to platform controls (output)
(Black wire at platform)

ECM ground (output)

Spare

Platform down coil Y7 (output)

Steer left coil Y4 (output)

Automotive-style horn H2 (option) (output)

Multifunction alarm H5 (output)

B10

Pothole limit switch (input)

B11

Drive enable power (input)

B12

Platform up at ground controls TS66 (input)

Platform data link – (input)
(yellow or orange wire at platform)

Power to ECM (input)

Spare

Drive forward coil Y6 (output)

Steer right coil Y3 (output)

Spare

Brake release coil Y2 (output)

C10

Spare

C11

Level sensor signal S7 (input)

C12

Down limit switch LS6 (input)

Summary of Contents for GS-2032

Page 1: ...Service Manual Part No 72972 September 2006 Rev B2 ...

Page 2: ...Technical Publications Genie Industries has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in suggestions for improvement All communications will be carefully considered for future printings o...

Page 3: ...ious 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 regul...

Page 4: ...amage Green used to indicate operation or maintenance information iv Be sure to wear protective eye wear and other protective clothing if the situation warrants it 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 Be sure to keep sparks flames and lighted tobacco awa...

Page 5: ...manceSpecifications 2 2 Hydraulic Specifications 2 3 ManifoldComponentSpecifications 2 4 Hydraulic Hose and Fitting Torque Specifications 2 6 SectionThree ScheduledMaintenanceProcedures Introduction 3 1 Pre deliveryPreparationReport 3 3 MaintenanceInspectionReport 3 5 Checklist A Procedures Rev B A 1 PerformPre operationInspection 3 6 A 2 Perform Function Tests 3 6 A 3 Perform 30 Day Service 3 7 A...

Page 6: ... 10 B 4 Test the Key Switch 3 10 B 5 Test the Automotive style Horn if equipped 3 11 B 6 Test the Drive Brakes 3 12 B 7 Test the Drive Speed Stowed Position 3 14 B 8 Test the Drive Speed Raised Position 3 15 B 9 Perform Hydraulic Oil Analysis 3 16 B 10 Replace the Hydraulic Tank Return Filter 3 16 B 11 Check the Module Tray Latch Components 3 17 Checklist C Procedure Rev C C 1 Check the Scissor Ar...

Page 7: ...ents Rev A 2 1 Platform 4 16 2 2 Platform Extension 4 17 Scissor Components Rev A 3 1 Scissor Assembly GS 2046 4 18 3 2 Scissor Assembly GS 2646 4 24 3 3 Scissor Assembly GS 3246 4 32 3 4 Lift Cylinder 4 42 Ground Controls Rev B 4 1 ManualPlatformLoweringCable GS 2046andGS 2646 4 46 4 2 ManualPlatformLowering GS 3246 4 47 4 3 Toggle Switches 4 48 4 4 ControlRelays 4 49 4 5 Tilt Level Sensor before...

Page 8: ...tion Manifold Components Models with Traction Control 4 66 6 5 Valve Adjustments Function Manifold 4 68 6 6 Platform Lift Relief Valve Manifold Components GS 3246 Models beforeserialnumber36045 4 75 6 7 Valve Adjustments Lift Relief Manifold GS 3246 Models beforeserialnumber36045 4 76 6 8 Valve Coils 4 78 Hydraulic Tank Rev A 7 1 HydraulicTank 4 80 Steer Axle Components Rev A 8 1 Yoke and Drive Mo...

Page 9: ...mally Rev A 5 10 6 Platform Up Function Inoperative Rev A 5 11 7 Platform Down Function Inoperative Rev A 5 12 8 Steer Left Function Inoperative Rev A 5 14 9 Steer Right Function Inoperative Rev A 5 16 10 All Drive Functions Inoperative All Other Functions Operate Normally Rev A 5 18 10A Brake Release Function Inoperative Rev A 5 19 11 Drive Forward Function Inoperative Rev A 5 20 12 Drive Reverse...

Page 10: ...Rev B 6 9 Level Sensor Box Wiring Diagram Rev A 6 10 Electrical Symbols Legend Rev B 6 12 Electrical Schematic from serial number 17408 to 21064 Rev B 6 13 Electrical Schematic from serial number 21065 to 21262 Rev B 6 15 Electrical Schematic from serial number 21263 to 24438 Rev B 6 17 Electrical Schematic from serial number 24439 to 25141 Rev B 6 19 Electrical Schematic from serial number 25142 ...

Page 11: ...aulic Schematic GS 2046 and GS 2646 from serial number 17408 to 36044 Rev A 6 38 Hydraulic Schematic GS 2046 and GS 2646 after serial number 36044 Rev A 6 39 Hydraulic Schematic GS 2046 and GS 2646 Models with Traction Control Rev A 6 40 Hydraulic Schematic GS 3246 from serial number 17408 to 22446 Rev A 6 41 Hydraulic Schematic GS 3246 from serial number 22447 to 27181 Rev A 6 42 Hydraulic Schema...

Page 12: ...GenieGS 2046andGS 2646andGS 3246 Part No 72972 June2003 This page intentionally left blank ...

Page 13: ...number 26566 20 8 liters Hydraulic system capacity including tank 6 gallons before serial number 26566 22 7 liters Hydraulic tank capacity 7 gallons after serial number 26565 26 5 liters Hydraulic system including tank 7 gallons after serial number 26565 26 5 liters Tires and wheels Tire size solid rubber 15 x 5 in 38 1 x 12 7 cm Tire contact area 10 sq in 64 5 cm2 Castle nut torque dry 300 ft lbs...

Page 14: ...s 700 lbs before serial number 24439 318 kg GS 3246 CSA models 500 lbs before serial number 24439 227 kg GS 3246 700 lbs after serial number 24438 318 kg Extension deck load capacity maximum 250 lbs 113 4 kg Function speed maximum from platform controls with 1 person in platform GS 2046 Platform up 28 to 32 seconds Platform down 26 to 30 seconds GS 2646 Platform up 28 to 32 seconds Platform down 2...

Page 15: ...remium ECO 46 Statoil Hydra Way Bio Pa 32 BP Biohyd SE S Fire resistant UCON Hydrolube HP 5046 Quintolubric 822 Mineral based Shell Tellus T32 Shell Tellus T46 Chevron Aviation A Genie specifications require additional equipment and special installation instructions for the approved optional fluids Consult the Genie Industries Service Department before use Function pump Type gear Displacement per ...

Page 16: ...oid valve N C 23 25Ω 2 position 2 way 20V DC schematic item D before serial number 28937 Solenoid valve N C 23 25Ω 2 position 2 way 20V DC with diode schematic item D after serial number 28936 Solenoid valve 2 position 2 way N O 25 to 27Ω 20V DC with diode schematic items AI BK CI and CL Solenoid valve 2 position 4 way 18 to 20Ω 20V DC with diode schematic items AH AJ BI BL CJ and CN Solenoid valv...

Page 17: ...Part No 72972 Genie GS 2046 and GS 2646 and GS 3246 2 5 Section 2 Specifications May 2003 REV B This page intentionally left blank SPECIFICATIONS ...

Page 18: ...t lbs 93 6 Nm 12 93 ft lbs 126 1 Nm 16 139 ft lbs 188 5 Nm 20 172 ft lbs 233 2 Nm 24 208 ft lbs 282 Nm SAE O ring Boss Port tube fitting installed into Steel SAE Dash size Torque 4 16 ft lbs 21 7 Nm 6 35 ft lbs 47 5 Nm 8 60 ft lbs 81 3 Nm 10 105 ft lbs 142 4 Nm 12 140 ft lbs 190 Nm 16 210 ft lbs 284 7 Nm 20 260 ft lbs 352 5 Nm 24 315 ft lbs 427 1 Nm Seal Lok Fittings hose end SAE Dash size Torque ...

Page 19: ... body hex fitting make a second mark with a permanent ink marker to indicate the proper tightening position Use the JIC 37 Fittings table on the previous page to determine the correct number of flats for the proper tightening position The marks indicate that the correct tightening positions have been determined Use the second mark on the body hex fitting to properly tighten the joint after it has ...

Page 20: ... custom size O rings They are not standard SAE size O rings They are available in the O ring field service kit 2 Lubricate the O ring before installation 3 Be sure that the face seal O ring is seated and retained properly 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight 5 Tighten the nut or fitting to the appropriate torque per given size as...

Page 21: ...presence of a potentially hazardous situation which if not avoided may result in property damage Green used to indicate operation or maintenance information Indicates that a specific result is expected after performing a series of steps Scheduled Maintenance Procedures Observe and Obey Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine S...

Page 22: ... scheduled inspection Make copies of the Pre delivery Preparation report to use for each inspection Store completed forms as required Maintenance Schedule There are four types of maintenance inspections that must be performed according to a schedule daily quarterly annual and two year The Scheduled Maintenance Procedures and the Maintenance Inspection Report have been divided into four subsections...

Page 23: ...ests Use this form to record the results Place a check in the appropriate box after each part is completed Follow the instructions in the operator s manual If any inspection receives an N remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes completed N no unable to complete R repaired Comments Fundamentals It is the responsibility of the dea...

Page 24: ...3 4 Genie GS 2046 and GS 2646 and GS 3246 Part No 72972 June 2003 Section 3 Scheduled Maintenance Procedures This page intentionally left blank ...

Page 25: ...tion receives an N tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable N no remove from service R repaired Comments Model Serial number Date Hour meter Machine owner Inspected by print Inspector signature Inspector title Inspector company Checklist B Rev C Y N R B 1 Batteries B 2 Electrical wiring B 3 Tires and wheels B 4...

Page 26: ...termine if routine maintenance procedures are required Complete information to perform this procedure is available in the Genie GS 1530 and GS 1532 and GS 1930 and GS 1932 Operator s Manual Refer to the Operator s Manual on your machine A 2 Perform Function Tests Completing the function tests is essential to safe machine operation Function tests are designed to discover any malfunctions before the...

Page 27: ...eels including castle nut torque B 10 Replace the Hydraulic Tank Return Filter A 4 Grease the Steer Yokes Genie specifications require that this procedure be performed every 100 hours of operation Regular application of lubrication to the steer yokes is essential to good machine performance and service life Continued use of an insufficiently greased steer yoke will result in component damage 1 Loc...

Page 28: ...y charging the batteries 1 Put on protective clothing and eye wear 2 Disconnect the battery pack from the machine 3 Be sure that the battery cable connections are free of corrosion 4 Be sure that the battery hold downs and cable connections are tight Models without maintenance free or sealed batteries 5 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrome...

Page 29: ... Platform controls 3 Inspect for a liberal coating of dielectric grease in all connections between the ECM and the platform controls 4 Turn the key switch to ground control and pull out the Emergency Stop button to the on position at both the ground and platform controls 5 Raise the platform approximately 8 feet 2 4 m from the ground 6 Rotate the safety arm away from the machine and let it hang do...

Page 30: ...otter pin Bend the cotter pin to lock it in place CHECKLIST B PROCEDURES B 4 Test the Key Switch Proper key switch action and response is essential to safe machine operation The machine can be operated from the ground or platform controls and the activation of one or the other is accomplished with the key switch Failure of the key switch to activate the appropriate control panel could cause a haza...

Page 31: ... at the platform controls and sounds at the ground as a warning to ground personnel An improperly functioning horn will prevent the operator from alerting ground personnel of hazards or unsafe conditions 1 Turn the key switch to platform control and pull out the Emergency Stop button to the on position at both the ground and platform controls 2 Push down the horn button at the platform controls Re...

Page 32: ...ion 1 a drive function select button BN8 5 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the test line 6 Bring the machine to full drive speed before reaching the test line Release the function enable switch or the joystick on the platform controls when your reference point on the machine crosses the test line 7 Measure the distance between t...

Page 33: ...eed to step 18 13 Install the drive forward reverse valve removed in step 11 into the function manifold and securely tighten Torque to 25 ft lbs 34 Nm 14 In order install the reverse valve coil with white black and brown wires spacer washer and the forward valve coil with white and brown wires onto the valve For the machine to function correctly the reverse valve coil must be closest to the manifo...

Page 34: ...lines by marking two lines on the ground 40 feet 12 2 m apart 2 Turn the key switch to platform control and pull out the Emergency Stop button to the on position at both the ground and platform controls 3 Lower the platform to the stowed position 4 Models with drive function select button Press the drive function select button a drive function select button BN8 5 Choose a point on the machine i e ...

Page 35: ...controls 3 Models with lift function enable button Press and hold the lift function enable button Models with drive function select button Press the lift function select button a lift function enable button BN9 b lift function select button BN9 c drive function select button BN8 4 Press and hold the function enable switch on the joystick 5 Raise the platform approximately 4 feet 1 2 m from the gro...

Page 36: ...turn filter is essential for good machine performance and service life A dirty or clogged filter may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter be replaced more often Beware of hot oil Contact with hot oil may cause severe burns The hydraulic filter is mounted on the function manifold next to the hydraulic...

Page 37: ...dule tray latch Using light oil apply a few drops to the side of the latch pin 2 Inspect each module tray latch pad if equipped Replace any worn pad before the latch fails to securely hold the module tray closed The module tray latch pad is attached to the drive chassis and located above the module tray latch when the module tray is closed Models after serial number 36044 1 Lubricate each module t...

Page 38: ...3 18 Genie GS 2046 and GS 2646 and GS 3246 Part No 72972 June 2003 Section 3 Scheduled Maintenance Procedures This page intentionally left blank ...

Page 39: ...nt damage and unsafe operating conditions Perform this procedure with the platform in the stowed position 1 Measure the thickness of each scissor arm wear pad at the non steer end of the machine 2 Replace both wear pads if either one is less than 1 07 inch 27 2 mm thick Refer to Repair Procedure 3 1 or 3 2 How to Replace the Scissor Arm Wear Pads 3 Apply a thin layer of dry film lubricant to the a...

Page 40: ...owly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Tag disconnect and cap the hydraulic hoses from the hydraulic tank 4 Remove the hydraulic tank mounting fasteners Remove the hydraulic tank from the machine Checklist D Procedure 5 Remove the suction strainer and clean it using a mild solvent 6 Clean the inside of the hydraulic tank using a mild solvent 7 I...

Page 41: ... This Section Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop Select the appropriate repair procedure after troubleshooting the problem Perform disassembly procedures to the point where repairs can be completed Then to re assemble perform the disassembly steps in reverse order Symbols Legend Safety alert symbol used ...

Page 42: ...tronic circuit board joystick membrane decal buttons switches and LEDs Potentiometer equipped joysticks can be adjusted to maintain performance For further information or assistance consult the Genie Industries Service Department P2 EMERGENCY STOP BUTTON JC1 JOYSTICK CONTROLLER H1 ALARM 2 1 U3 PLATFORM CONTROLS CIRCUIT BOARD h g f e a b c d 1 9F 2 3 4 5 6 7 8 ON ALCO ADF085 P2 EMERGENCY STOP BUTTO...

Page 43: ...s connectors from the platform controls circuit board 5 Carefully remove the platform controls circuit board retaining fasteners 6 Carefully remove the platform controls circuit board from the platform control box lid 1 2 Joystick Controller Maintaining the joystick at the proper setting is essential to safe machine operation The joystick should operate smoothly over its entire range of motion A H...

Page 44: ...st enough to let the shaft rotate 6 With the joystick in the neutral position adjust the potentiometer to 2 05V DC at the potentiometer shaft Tighten the set screw 7 Move the joystick full stroke in both directions several times Return the joystick to the neutral position Result The volt meter should read 2 05V DC Result If the volt meter does not read 2 05V DC repeat steps 5 through 7 8 Turn the ...

Page 45: ...led by the ECM and located in the hydraulic module tray are adjustable to compensate for wear in the hydraulic pump and drive motors The raised drive speed and lift speed are determined by the percentage of total controller output For further information or assistance consult the Genie Industries Service Department Tip over hazard Do not adjust the lift and or drive speed higher than specified in ...

Page 46: ...mergency Stop button to the on position at the ground and platform controls 3 Press and hold the lift function enable and horn buttons and turn the key switch to platform controls Result The diagnostic display will show PS a function enable switch SW5 b joystick controller JC1 with thumb steering rocker SW6 c horn button BN5 d machine on incline button BN6 e lift function enable button BN9 f red E...

Page 47: ...The diagnostic display will show PS a function enable switch SW5 b joystick controller JC1 with thumb steering rocker SW6 c horn button BN5 d machine on incline button e lift function select button BN9 f drive function select BN8 g red Emergency Stop button P2 4 Release the lift function select and horn buttons Result The diagnostic display will show the maximum lift speed percentage 5 Press the l...

Page 48: ...tton to the on position at the ground and platform controls 3 Press and hold the lift function select and horn buttons and turn the key switch to platform controls Result The diagnostic display will show PS 4 Release the lift function select and horn buttons Result The diagnostic display will show the maximum lift speed percentage 5 Press the drive function select button Result The diagnostic disp...

Page 49: ... hold the lift function select and horn buttons and turn the key switch to platform controls Result The diagnostic display will show PS 4 Release the lift function select and horn buttons Result The diagnostic display will show the maximum lift speed percentage 5 Press the drive function select button Result The diagnostic display will show the stowed drive speed percentage a function enable switc...

Page 50: ...he off position 2 Pull out the red Emergency Stop button to the on position at the ground and platform controls 3 Press and hold the lift function enable and horn buttons and turn the key switch to platform controls Result The diagnostic display will show PS a function enable switch SW5 b joystick controller JC1 with thumb steering rocker SW6 c horn button BN5 d machine on incline button e lift fu...

Page 51: ...rocker SW6 c horn button BN5 d machine on incline button e lift function select button BN9 f drive function select BN8 g red Emergency Stop button P2 4 Release the lift function select and horn buttons Result The diagnostic display will show the maximum lift speed percentage 5 Press the drive function select button Result The diagnostic display will show PS 6 Press and hold the horn button Result ...

Page 52: ...5 b joystick controller JC1 with thumb steering rocker SW6 c horn button BN5 d machine on incline button e lift function select button BN9 f drive function select BN8 g red Emergency Stop button P2 4 Release the lift function select and horn buttons Result The diagnostic display will show the maximum lift speed percentage 5 Press and hold the horn button Result The diagnostic display will show the...

Page 53: ... PLATFORM CONTROLS CIRCUIT BOARD JC1 JOYSTICK CONTROLLER c d a 1 9F 2 3 4 5 6 7 8 ON ALCO ADF085 P2 EMERGENCY STOP BUTTON H1 ALARM U3 PLATFORM CONTROLS CIRCUIT BOARD 1 4 2 5 2 1 NC 1 9F 2 3 4 5 6 7 8 ON ALCO ADF085 P N 000000 Date 0000 S N Al 00000000 JC1 JOYSTICK CONTROLLER c a d before serial number 48055 after serial number 48054 How to Determine the DIP Switch Configuration 1 Remove the platfo...

Page 54: ... the DIP switch on the circuit board Move the DIP switch settings to correspond with the configuration of the machine options indicated in the DIP Switch Code Chart a platform controls circuit board U3 b enlarged view of DIP switch SW25 c joystick controller JC1 d DIP switch SW25 5 Close the lid and install the fasteners 6 Confirm the settings See 1 3 How to Determine the DIP Switch Configuration ...

Page 55: ...is cuts out all functions when the pressure sensor is overloaded The Emergency Stop button must be cycled before any function can be resumed Required for France Descent Delay This option halts descent at approximately 7 feet 2 1 m All controls must be released for 4 to 6 seconds before descent is re enabled Required for Europe Battery Drain Alarm When the machine is turned on and no function is ac...

Page 56: ...th a forklift at the non steer end Do not lift it Platform Components 8 Attach a strap from the platform railings to the carriage on the forklift to help support the platform 9 Remove the platform pivot pin retaining fasteners from the platform pivot pins at the steer end of the machine 10 Use a slide hammer to remove the pins Crushing hazard The platform will fall if it is not properly supported ...

Page 57: ...h platform extension roller bracket assembly Remove each assembly from the machine Do not remove the platform roller bolt a roller bracket assembly b assembly retaining fastener c platform roller bolt 7 Remove the platform roller wheels from the machine 8 Carefully slide the platform extension out from the platform and place it on a structure capable of supporting it Crushing hazard The platform e...

Page 58: ...center pivot pin 2pins 6 Number 2 pivot pin steer end 7 Number 1 center pivot pin 8 Number 1 inner arm 9 Number 1 pivot pin steer end 2pins 10 Number 4 pivot pin non steer end 11 Number 3 inner arm 12 Number 3 outer arm 13 Number 3 pivot pin non steer end 14 Number 2 inner arm 15 Number 2 outer arm 16 Number 2 pivot pin non steer end 17 Lift cylinder barrel end pivot pin 18 Number 1 outer arm Scis...

Page 59: ...kinked or pinched 3 Attach a lifting strap from an overhead crane to the number 3 outer arm index 12 4 Remove the external snap rings from the number 3 center pivot pin index 2 5 Use a soft metal drift to remove the number 3 center pivot pin index 2 6 Remove the external snap rings from the number 3 pivot pin index 13 7 Use a soft metal drift to remove the number 3 pivot pin index 13 from the non ...

Page 60: ...ove the number 2 center pivot pin index 5 at the ground controls side 20 Remove the external snap rings from the number 2 pivot pin index 16 at the non steer end 21 Use a soft metal drift to remove the number 2 pivot pin index 16 at the non steer end Remove the number 2 outer arm index 15 from the ground controls side of the machine Bodily injury hazard The number 2 outer arm index 15 at the groun...

Page 61: ...t or spray 32 Tag and disconnect the wires from the solenoid valve on the cylinder 33 Attach a lifting strap from an overhead crane to the lug on the rod end of the lift cylinder Raise the lift cylinder to a vertical position 34 Remove the pin retaining fasteners from the lift cylinder barrel end pivot pin index 17 Use a soft metal drift to remove the pin Remove the cylinder from the machine Crush...

Page 62: ...to remove the pins 46 Remove the number 1 inner arm index 8 from the machine Bodily injury hazard The number 1 inner arm index 8 may become unbalanced and fall if not properly supported when removed from the machine SCISSOR COMPONENTS How to Replace the Scissor Arm Wear Pads 1 Remove the platform See 2 1 How to Remove the Platform 2 Remove the mounting fasteners from the stationary wear pads on th...

Page 63: ...e moving the scissor assembly 18 Move the scissor assembly towards the non steer end of the machine slightly and to one side of the machine until one of the scissor arm wear pads is accessible Do not allow both wear pads to slide out of the drive chassis Crushing hazard The scissor assembly will fall if both wear pads are allowed to slide out of the drive chassis 19 Remove the old wear pad Note th...

Page 64: ...ins 8 Number 2 pivot pin steer end 9 Number 1 center pivot pin 10 Number 1 inner arm 11 Number 1 pivot pin steer end 2 pins 12 Number 5 pivot pin non steer end 13 Number 4 inner arm 14 Number 4 outer arm 15 Number 4 pivot pin non steer end 16 Number 3 inner arm 17 Number 3 center pivot pin 18 Number 3 pivot pin non steer end 19 Number 2 inner arm 20 Number 2 outer arm 21 Number 2 pivot pin non ste...

Page 65: ...ed if they are kinked or pinched 3 Attach a lifting strap from an overhead crane to the number 4 outer arm index 14 4 Remove the external snap rings from the number 4 center pivot pin index 2 5 Use a soft metal drift to remove the number 4 center pivot pin index 2 6 Remove the external snap ring from the number 4 pivot pin index 2 7 Use a soft metal drift to remove the number 4 pivot pin index 15 ...

Page 66: ...nd fall if not properly supported when it is removed from the machine 19 Attach a lifting strap from an overhead crane to the number 3 outer arm index 4 at the battery pack side 20 Use a soft metal drift to tap the number 3 pivot pin index 18 in the other direction Remove the number 3 outer arm index 4 from the battery pack side of the machine Bodily injury hazard The number 3 outer arm index 4 at...

Page 67: ...ter arm index 20 at the ground controls side 34 Remove the external snap rings from the number 2 center pivot pin index 7 at the ground controls side 35 Use a soft metal drift to remove the number 2 center pivot pin index 7 at the ground controls side 36 Use a soft metal drift to tap the number 2 pivot pin index 21 halfway out at the non steer end of the machine Remove the number 2 outer arm index...

Page 68: ...operly supported when it is removed from the machine 44 Remove the safety arm from the number 2 inner arm index 19 that was just removed 45 Attach a lifting strap from an overhead crane to the number 1 inner arm index 10 46 Raise the number 1 inner arm index 10 approximately 2 feet 60 cm and install the safety arm between the number 1 inner arm index 10 and the number 1 outer arm index 23 Lower th...

Page 69: ...ables and hydraulic hoses from the number 1 inner arm index 10 and lay them to the side Component damage hazard Cables and hoses can be damaged if they are kinked or pinched 54 Support and secure the entry ladder to an appropriate lifting device 55 Remove the entry ladder mounting fasteners Remove the entry ladder from the machine Crushing hazard The entry ladder may become unbalanced and fall if ...

Page 70: ...Scissor Arm Wear Pads 1 Remove the platform See 2 1 How to Remove the Platform 2 Remove the mounting fasteners from the stationary wear pads on the platform Note the position of the wear pads before they are removed so when the new ones are installed they will be in the correct position 3 Support and secure the entry ladder to an appropriate lifting device 4 Remove the entry ladder mounting fasten...

Page 71: ...x Component damage hazard Be careful not to damage the level sensor box limit switch or level sensor while moving the scissor assembly SCISSOR COMPONENTS 18 Move the scissor assembly towards the non steer end of the machine slightly and to one side of the machine until one of the scissor arm wear pads is accessible Do not allow both wear pads to slide out of the drive chassis Crushing hazard The s...

Page 72: ...center pivot pin 2 pins 12 Number 2 pivot pin steer end 13 Number 1 center pivot pin 14 Number 1 inner arm 15 Number 1 pivot pin steer end 2 pins 16 Number 6 pivot pin non steer end 17 Number 5 inner arm 18 Number 5 outer arm 19 Number 5 pivot pin non steer end 20 Number 4 inner arm 21 Number 4 outer arm 22 Number 4 pivot pin non steer end 23 Upper lift cylinder barrel end pivot pin 24 Number 3 in...

Page 73: ...ched 3 Attach a lifting strap from an overhead crane to the number 5 outer arm index 18 4 Remove the external snap rings from the number 5 center pivot pin index 2 5 Use a soft metal drift to remove the number 5 center pivot pin index 2 6 Remove the external snap rings from the number 5 pivot pin index 19 7 Use a soft metal drift to remove the number 5 pivot pin index 19 from the non steer end of ...

Page 74: ... pivot pin index 5 at the ground controls side 19 Remove the external snap rings from the number 4 center pivot pin index 5 at the battery pack side 20 Use a soft metal drift to remove both of the number 4 center pivot pins index 5 21 Remove the external snap rings from the number 4 pivot pin index 22 at the non steer end of the machine 22 Use a soft metal drift to remove the number 4 pivot pin in...

Page 75: ...lear of moving parts when inserting the safety arm 32 Activate the down function to lower the scissor assembly onto the safety arm Push in the Emergency Stop buttons and turn the key to the OFF position Bodily injury hazard The scissor assembly may become unbalanced and fall if not properly supported by the safety arm Bodily injury hazard Keep hands clear of moving parts when inserting the safety ...

Page 76: ...e Do not remove the pin 42 Use a soft metal drift to tap the number 3 pivot pin index 25 halfway out at the non steer end of the machine Remove the number 3 outer arm index 7 at the ground controls side from the machine Bodily injury hazard The number 3 outer arm index 7 at the ground controls side may become unbalanced and fall if not properly supported when removed from the machine 43 Attach a l...

Page 77: ...x 24 54 Remove the external snap rings from the number 3 pivot pin index 10 55 Use a soft metal drift to remove the number 3 pivot pin index 10 Remove the number 3 inner arm index 24 from the machine Bodily injury hazard The number 3 inner arm index 24 may become unbalanced and fall if not properly supported when it is removed from the machine 56 Attach a lifting strap from an overhead crane to th...

Page 78: ...ift to remove the number 2 pivot pin index 12 Remove the number 2 inner arm index 26 from the machine Bodily injury hazard The number 2 inner arm index 26 may become unbalanced and fall if not properly supported when it is removed from the machine 68 Attach the strap from the overhead crane to the number 1 inner arm index 14 69 Using the overhead crane lift the number 1 inner arm index 14 approxim...

Page 79: ... pinched 77 Attach a lifting strap from an overhead crane to the number 1 outer arm index 30 Do not lift it 78 Remove the external snap rings from the number 1 center pivot pin index 13 79 Use a soft metal drift to remove the number 1 center pivot pin index 13 Crushing hazard The number 1 outer arm index 30 may become unbalanced and fall if not properly supported when the pin is removed 80 Slide t...

Page 80: ...ion of the level sensor box on the drive chassis 9 Remove the level sensor box cover 10 Mark the mounting position of the level sensor on the level sensor box 11 Remove the level sensor mounting fasteners 12 Remove the fasteners from the level sensor box and slide the box towards the non steer end of the machine as far as it can go Component damage hazard Be careful not to damage the level sensor ...

Page 81: ...en the new one is installed it will be in the correct position 20 Move the scissor assembly towards the other side of the machine until the other scissor arm wear pad is accessible Crushing hazard The scissor assembly will fall if both wear pads are allowed to slide out of the drive chassis 21 Install the new wear pad Note the position of the wear pad before it is removed so when the new one is in...

Page 82: ...a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 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 SCISSOR COMPONENTS GS 2046 GS 2646 models ...

Page 83: ...ead crane or similar lifting device to the rod end of the lift cylinder for support 10 Remove the external snap ring from the lift cylinder rod end pivot pin Use a soft metal drift to remove the pin Crushing hazard The lift cylinder will fall if not properly supported 11 Lower the cylinder Component damage hazard Be careful not to damage the level sensor box limit switch or level sensor while lowe...

Page 84: ...and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Raise the platform approximately 10 feet 3 m 2 Lift ...

Page 85: ...se a soft metal drift to remove the pin Crushing hazard The lift cylinder could become unbalanced and fall if not properly supported 8 Lower the cylinder to a horizontal position Skip to step 11 if removing the upper cylinder 9 Support and secure the entry ladder to an appropriate lifting device 10 Remove the entry ladder mounting fasteners Remove the entry ladder from the machine Crushing hazard ...

Page 86: ...valve at the barrel end of the lift cylinder 6 Pull the cable tight and measure the distance between the end of the lowering cable and the end of the lowering valve Result The measurement should be 3 16 to 1 4 inch 4 7 to 6 4 mm a Manual lowering cable sheath b Upper lock nut c cable mounting bracket d Lower lock nut e Cable mounting nut f End of the lowering cable g Manual lowering valve schemati...

Page 87: ...ere is no adjustment required Before serial number 49200 two 12V batteries are wired in series supplying 24V to the manual platform lowering button The batteries are located inside the ground control panel How to Replace the Manual Platform Lowering Batteries before serial number 49200 1 Remove the ground control cover retaining fasteners Remove the cover 2 Tag and disconnect the wires from the ba...

Page 88: ...switch testing and does not specifically apply to all varieties of toggle switches 1 Turn the key switch to the OFF position Tag and disconnect all wiring from the toggle switch to be tested Disconnect the wires from the toggle switch before testing 2 Connect the leads of an ohmmeter to the switch terminals in the combinations listed below to check for continuity Test Desired result Left position ...

Page 89: ... or continuity tester to each terminal combination and check for continuity Terminals 85 and 86 represent the coil and should not be tested in any other combination Test Desired result terminal 85 to 86 with resistor 310 to 330 Ω terminal 87 to 87a 30 no continuity infinite Ω terminal 87a to 30 continuity zero Ω 3 Connect 24V DC and a ground wire to terminals 85 and 86 then test the following term...

Page 90: ...he steer end of the machine 5 Raise the machine approximately 2 inches 5 cm 6 Place a 1 27 x 6 x 6 inch 23 1 mm x 15 cm x 15 cm thick steel block under both wheels at the steer end of the machine 7 Lower the machine onto the blocks 8 Raise the platform 7 to 8 feet 2 1 to 2 4 m 9 Lift the safety arm move it to the center of the scissor arm and rotate down to a vertical position 10 Lower the scissor...

Page 91: ...ning fasteners 18 Connect the wiring harness to the level sensor limit switch and alarm 19 Turn the key switch to the ground control and pull out the red Emergency Stop button to the ON position at the ground controls 20 Tighten the level sensor adjusting fasteners until the bubble in the top of the level sensor is centered in the circles Be sure there are threads showing through the top of the ad...

Page 92: ...or the tilt sensor alarm does not sound adjust the tilt 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 5 inches 13 cm 36 Remove the blocks from under both wheels 37 Lower the machine and remove the jack 38 Remove the blocks from the wheels at the steer end of the mach...

Page 93: ...ould not operate Models after serial number 48816 Raise the platform 7 to 8 feet 2 1 to 2 4 m Result The platform should stop and an alarm should sound Result If the platform does not stop or the tilt sensor alarm does not sound adjust the tilt level sensor until the alarm just begins to sound OR the down limit switch may need to be adjusted 54 Lift the safety arm move it to the center of the scis...

Page 94: ...position at both the 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 5 Lower the platform onto the safety arm Crushing hazard Keep hands clear of the safety arm when lowering the platform 6 Remove the tilt level sensor box cover retaining fasteners Remove the cover The t...

Page 95: ...evel sensor as instructed could cause the machine to tip over resulting in death or serious injury 12 Install the level sensor box onto the machine Install the level sensor box retaining fasteners 13 Connect the wiring harness to the level sensor limit switch and alarm 14 Turn the key switch to the ground control and pull out the red Emergency Stop button to the ON position at the ground controls ...

Page 96: ...lace a 1 57 x 6 x 6 inch 24 9 mm x 15 cm x 15 cm thick steel block under both wheels at the ground controls side of the machine 31 Lower the machine onto the blocks 32 Models before serial number 48817 Raise the platform 7 to 8 feet 2 1 to 2 4 m Result The tilt sensor alarm should sound Result The tilt sensor alarm does not sound Adjust the tilt level sensor until the alarm just begins to sound OR...

Page 97: ...ion 4 Repair Procedures REV B GROUND CONTROLS 37 Return the safety arm to the stowed position 38 Lower the platform to the stowed position 39 Raise the machine approximately 2 inches 5 cm 40 Remove the blocks from under both wheels 41 Lower the machine and remove the jack ...

Page 98: ...bar pressure gauge to the high pressure port on the pump 3 Turn the key switch to ground control and pull out the Emergency Stop button to the ON position at both the ground and platform controls 4 Activate the platform up function from the ground controls Result If the pressure gauge reads 3200 psi 221 bar immediately stop The pump is good Result If pressure fails to reach 3200 psi 221 bar the pu...

Page 99: ...Hose and Fitting Torque Specifications 1 Remove the mounting fasteners from the hydraulic filter bracket at the function manifold Move the filter off to the side 2 Tag disconnect and plug the hydraulic hoses on the pump Cap the fittings on the pump Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate...

Page 100: ...circuit 5 Relief valve 1500 psi 103 4 bar AE Steering relief 20 ft lbs 27 Nm 6 Relief valve 3500 psi 241 3 bar AF System relief 20 ft lbs 27 Nm 7 Solenoid valve 3 position 4 way AG Steer left right 20 ft lbs 27 Nm 8 Solenoid valve 2 position 4 way AH Platform up 25 ft lbs 34 Nm 9 Solenoid valve 2 position 2 way N O AI Brake circuit 20 ft lbs 27 Nm 10 Solenoid valve 2 position 4 way AJ Drive speed ...

Page 101: ...Part No 72972 Genie GS 2046 and GS 2646 and GS 3246 4 61 June 2003 Section 4 Repair Procedures REV B MANIFOLDS ...

Page 102: ... lbs 27 Nm 6 Relief valve 3500 psi 241 3 bar AF System relief 20 ft lbs 27 Nm 7 Solenoid valve 3 position 4 way AG Steer left right 20 ft lbs 27 Nm 8 Solenoid valve 2 position 4 way AH Platform up 25 ft lbs 34 Nm 9 Solenoid valve 2 position 2 way N O AI Brake circuit 20 ft lbs 27 Nm 10 Solenoid valve 2 position 4 way AJ Drive speed select circuit 25 ft lbs 34 Nm 11 Solenoid valve 3 position 4 way ...

Page 103: ...Part No 72972 Genie GS 2046 and GS 2646 and GS 3246 4 63 June 2003 Section 4 Repair Procedures REV B MANIFOLDS ...

Page 104: ...500 psi 103 4 bar BF Steering relief 20 ft lbs 27 Nm 7 Relief valve 130 psi 9 bar BG Brake relief 20 ft lbs 27 Nm 8 Solenoid valve 3 position 4 way BH Steer left right 20 ft lbs 27 Nm 9 Solenoid valve 2 position 4 way BI Drive speed select circuit 25 ft lbs 34 Nm 10 Solenoid valve 3 position 4 way BJ Drive forward reverse 25 ft lbs 34 Nm 11 Solenoid valve 2 position 2 way N O BK Brake circuit 20 f...

Page 105: ...Part No 72972 Genie GS 2046 and GS 2646 and GS 3246 4 65 June 2003 Section 4 Repair Procedures REV B MANIFOLDS ...

Page 106: ...si 2 bar CG Brake circuit 20 ft lbs 27 Nm 8 Solenoid valve 3 position 4 way CH Steer left right 20 ft lbs 27 Nm 9 Solenoid valve 2 position 2 way N O CI Brake circuit 20 ft lbs 27 Nm 10 Solenoid valve 2 position 4 way CJ Drive speed select circuit 25 ft lbs 34 Nm 11 Solenoid valve 3 position 4 way CK Drive forward reverse 25 ft lbs 34 Nm 12 Solenoid valve 2 position 2 way CL High speed bypass 20 f...

Page 107: ...Part No 72972 Genie GS 2046 and GS 2646 and GS 3246 4 67 June 2003 Section 4 Repair Procedures REV B MANIFOLDS ...

Page 108: ... to decrease lift capacity Adjust the relief valve until the platform just begins to raise 6 Fully lower the platform 7 Add an additional 100 pounds 45 4 kg to the platform Secure the additional weight 8 Activate the platform up function Result The power unit should not be able to lift the platform Result If the power unit lifts the platform adjust the internal hex socket counterclockwise until th...

Page 109: ...ef valve on the function manifold item BD or CD Models without traction control a system relief valve b function manifold c test port 2 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the test port on the function manifold item BA or CA Models with traction control a system relief valve b function manifold c test port 3 Chock both sides of the wheels at the steer end of the machine 4 Remove...

Page 110: ...ssure gauge Note the pressure Refer to Section 2 Specifications 8 Turn the machine off Hold the system relief valve with a wrench and remove the cap item BD or CD 9 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Tip over hazard Failure to adjust the relief valves to specification could cause the machine to tip over resulting i...

Page 111: ...essure reading on the pressure gauge Note the pressure 4 Press and hold the steer thumb rocker switch to the left Allow the wheels to completely turn to the left then continue holding the switch while observing the pressure reading on the pressure gauge Note the pressure Refer to Section 2 Specifications 5 Turn the machine off Hold the steering relief valve with a wrench and remove the cap item AE...

Page 112: ...sure gauge Note the pressure 4 Press and hold the steer thumb rocker switch to the left Allow the wheels to completely turn to the left then continue holding the switch while observing the pressure reading on the pressure gauge Note the pressure Refer to Section 2 Specifications 5 Turn the machine off Hold the steering relief valve with a wrench and remove the cap item BF or CF Models with tractio...

Page 113: ...hock both sides of the wheels at the steer end of the machine 4 Remove the platform controls from the platform Perform this test from the ground with the platform controls Do not stand in the platform MANIFOLDS Models with traction control a lift relief valve b system relief valve c function manifold d test port Confirm the System Relief Valve Pressure 5 Turn the key switch to platform control and...

Page 114: ...position at both the ground and platform controls 14 Hold the lift relief valve with a wrench and remove the cap item BC or CC 15 While activating the platform up function adjust the internal hex socket clockwise just until the platform begins to raise 16 Fully lower the platform 17 Add an additional 100 pounds 45 4 kg to the platform Secure the additional weight 18 Raise the platform slightly Res...

Page 115: ... Schematic No Description Item Function Torque 1 Relief valve 2000 psi 137 9 bar G Platform up 25 30 ft lbs 34 41 Nm 6 6 Platform Lift Relief Valve Manifold Components GS 3246 Models before serial number 36045 The platform lift relief manifold is mounted inside the hydraulic power unit module tray MANIFOLDS ...

Page 116: ...nd locate the lift relief valve located next to the function manifold item G a relief valve b manifold 2 Place maximum rated load in the platform Secure the load to the platform Refer to Section 2 Specifications 3 Turn the key switch to ground control and pull out the Emergency Stop button to the on position at both the ground and platform controls 4 Hold the function relief valve item G with a wr...

Page 117: ...power unit to lift more than maximum rated load Component damage hazard If the pump cavitates or platform fails to reach full height add hydraulic oil until the pump is functioning correctly Do not overfill the hydraulic reservoir 10 Remove the weight from the platform 11 Bleed the hydraulic system Raise the platform to full height and then lower it to the stowed position through two complete cycl...

Page 118: ...e resistance should be within specification plus or minus 30 Result If the resistance is not within specification plus or minus 30 replace the coil Valve Coil Resistance Specifications Description Specification Solenoid valve N C 23 25Ω 2 position 2 way 20V DC schematic item D before serial number 28937 Solenoid valve N C 23 25Ω 2 position 2 way 20V DC with diode schematic item D after serial numb...

Page 119: ...ore when measured across the terminals Resistor 10Ω Ω Ω Ω Ω Genie part number 27287 a multimeter b 9V DC battery c 10Ω resistor d coil 3 Set a multimeter to read DC voltage The multimeter when set to read DC voltage should be capable of reading up to 800 mA 4 Connect the negative lead to the other terminal on the coil If testing a single terminal coil connect the negative lead to the internal meta...

Page 120: ... machine Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 2 Open the power unit module tray 3 Remove the drain plug from the hydraulic tank and allow all of the oil from the tank to drain into a suitable container Refer to Section 2 Specifications Bodily injury hazard Spraying hydraulic oil can penetr...

Page 121: ...rd The chassis will fall if it is not properly supported 6 Remove the wheel castle nut Remove the wheel 7 Tag disconnect and cap the hydraulic hoses 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 ...

Page 122: ...der the chassis for support Crushing hazard The chassis will fall if it is 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 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 allo...

Page 123: ...ylinder 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 3 Remove the pin retaining fasteners from the barrel end pivot pin Remove the pivot pi...

Page 124: ...g fastener from the center pivot pin of the bellcrank Remove the pin Note the quantity and the location of the spacers on the bellcrank 3 Remove the retaining fasteners from the steer links at each end of the bellcrank Note the quantity and the location of the spacers in between the bellcrank and the steer links 4 Raise the machine approximately 14 inches 36 cm Place blocks under the chassis for s...

Page 125: ...om the wheel castle nut Always replace the cotter pin with a new one when removing the castle nut 6 Loosen the wheel castle nut Do not remove it 7 Raise the machine approximately 2 inches 5 cm Place blocks under the chassis for support Crushing hazard The chassis will fall if it is not properly supported 8 Remove the wheel castle nut Remove the wheel 9 Disconnect and plug the hydraulic hose from t...

Page 126: ...Check valve pilot operated A Manual brake release 25 30 ft lbs 34 41 Nm 2 Shuttle valve B Brake release 8 10 ft lbs 11 14 Nm 3 Hand pump C Manual brake release 25 30 ft lbs 34 41 Nm 10 1 Brake Release Hand Pump Components The brake release hand pump manifold is mounted behind the entry ladder next to the battery charger Brake Release Hand Pump Components ...

Page 127: ...lt in death or serious injury Remove all rings watches and other jewelry 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 Two persons will be required to safely perform some troubleshootingprocedures Troubleshooting Flow Charts Observe and Obey Troubl...

Page 128: ...icular function loss may occur selecting the appropriate flow chart may be troublesome When a function will not operate with the same speed or power as a machine in good working condition refer to the flow chart which most closely describes the problem Malfunction discovered Identify symptoms Troubleshoot Perform repair Return to service problem solved problem still exists Inspect and test LED Dia...

Page 129: ... right microswitch 46 See Chart 5 Platform drive enable switch fault Malfunctioning drive enable switch Troubleshoot drive enable switch 47 Platform joystick fault Joystick potentiometer not centered Verify potentiometer setting 52 See Chart 11 Forward coil fault Malfunctioning coil OR wire disconnected from coil Troubleshoot coil OR inspect wire connection 53 See Chart 12 Reverse coil fault Malfu...

Page 130: ...open in the 24V cable circuit from F6 to QD1 OR replace or repair QD1 OR repair open in 24V cable circuit from QD1 through terminal B at U6 to terminal D1 at M6 20V or more Check continuity from the B terminal on the motor controller U6 to the negative battery cable at QD1 no continuity continuity Repair open in the negative battery cable from the B terminal at motor controller U6 to QD1 With the ...

Page 131: ...ound Controls Inoperative Chart 5 OR consult the Genie Industries Service Department 20V or more 0V 0V Turn KS1 to the ground control position and check output side of each contact Replace contact OR refer to Platform Controls Inoperative Chart 6 OR consult the Genie Industries Service Department 20V or more Refer to Chart 2 Pump Motor Will Not Operate OR repair open in wht wire C2 estop chassis O...

Page 132: ...at motor controller U6 20V or more Replace positive battery cable from the B terminal at U6 to D1 at M5 0V Replace the cable from the B terminal at U6 to QD1 OR repair or replace QD1 OR replace the cable from QD1 to F6 OR replace F6 OR replace the cable from F6 to B5 Check for continuity in the positive cable circuit from the B terminal at U6 through battery quick disconnect QD1 through the 275A f...

Page 133: ...o B5 Check for continuity in the ground cable circuit from the B terminal at U6 through QD1 to the battery B5 no continuity Repair open in the WH A8 motor contr enable wire from terminal 1 at U6 to pin A8 of the AMP connector at ECM U5 Activate the lift function and check voltage on terminal 3 at U6 Repair open in the WH A9 motor cont enable wire from pin A9 at U5 to terminal 3 at U6 OR replace U5...

Page 134: ...sure the circuit breaker and fuse are not tripped or blown Be sure the batteries are fully charged and properly connected Be sure the hydraulic tank is filled to the correct level Check for a positive connection between electric motor and pump by removing pump from motor M5 leaving all hoses connected Visually check the coupling connection bad Replace pump coupling OR replace the pump OR replace t...

Page 135: ...ct at the input side of the key switch KS1 0V Repair open in WH wire from KS1 to Emergency Stop button P1 OR repair or replace P1 OR repair open in WH wire from P1 to circuit breaker CB2 20V or more Check voltage on output side of ground control contact at KS1 Check if internal cam at KS1 is activating the ground control contact yes Replace contact for ground controls at KS1 no Replace KS1 20V or ...

Page 136: ...gency Stop button P1 OR repair open in the WH wire from P1 to circuit breaker CB2 20V or more Check voltage on output side of platform control contact at KS1 0V Check if internal cam at KS1 is activating platform control contact yes Replace contact for platform controls at KS1 no Replace KS1 20V or more Repair or replace P2 OR replace control cable from U5 to the platform controls Check voltage at...

Page 137: ...nd point on the manifold Activate the controller in the UP direction and check the voltage Disconnect the wire from the platform up directional valve coil on the function manifold item AG or BG and check the resistance See Repair Section 0V Repair open in the WH A6 up coil wire from the platform up directional valve coil item AG or BG to the ECM U5 see Repair Section OR replace U5 OR consult the G...

Page 138: ... circuit from the coil to the battery module tray OR replace U5 OR consult the Genie Industries Service Department 20V or more 0 or infinite ohms 23 to 25 ohms Replace platform lowering valve coil item D Repair or replace the platform lowering valve cartridge item D Are there mechanical restrictions keeping the platform from lowering With the platform raised and the safety arm removed pull the man...

Page 139: ...Part No 72972 GenieGS 2046andGS 2646andGS 3246 5 13 June2003 Section 5 Troubleshooting Flow Charts REV A This page intentionally left blank ...

Page 140: ...alve coil See Repair Section 0V Repair open in the WH B7 left coil wire from the coil on the steer left directional valve item AF or BI to the ECM U5 OR repair open in the brown ground wire circuit from the coil to the wire harness OR replace U5 OR consult the Genie Industries Service Department 20V or more 25 to 27 ohms 0 or infinite ohms Replace the steer left directional valve coil item AF or B...

Page 141: ...the steer cylinder OR replace the steer left right valve cartridge item AF or BI OR the function manifold could have an internal defect Consult the Genie Industries Service Department Are there mechanical restrictions keeping the steer left function from moving Reset the steer relief valve pressure item AE or BF See Repair Section less than 1500 PSI Remove the mechanical restrictions Repair or rep...

Page 142: ...lve coil See Repair Section 0V Repair open in the WH C7 rt coil wire from the coil on the steer right directional valve item AF or BI to the ECM U5 OR repair open in the brown ground wire circuit from the coil to the wire harness OR replace U5 OR consult the Genie Industries Service Department 20V or more 25 to 27 ohms Repair or replace the steer directional valve cartridge item AF or BI OR consul...

Page 143: ...ce the steer left right valve cartridge item AF or BI OR the function manifold could have an internal defect Consult the Genie Industries Service Department Are there mechanical restrictions keeping the steer left function from moving Reset the steer relief valve pressure item AE or BF See Repair Section Remove the mechanical restrictions Repair or replace the steer cylinder OR consult the Genie I...

Page 144: ... drive reverse functions Check to see if the error indicator light is on at the platform controls light is on light is not on Reset the ECM U5 by pushing in Emergency Stop button P2 to the OFF position Pull the Emergency Stop button P2 up to the ON position Check to see if the error indicator light is on at the platform controls Refer to the chart s that are related to the error code that is displ...

Page 145: ...nt try to rotate the non steer wheels This will require 2 people wheels turn If machine still does not drive at full speed with the platform in the stowed position replace the platform controls OR replace the platform controls circuit board U3 OR replace the ECM U5 OR consult the Genie Industries Service Department wheels do not turn Plumb a 0 to 500 psi 35 bar gauge into the hose from the functio...

Page 146: ... the wire and the negative lead of the volt meter to the brown ground wire on the coil Activate drive in the forward direction and check the voltage Disconnect the wires from the drive forward directional valve coil item AI or BJ and check resistance of the coil See Repair Section 0V Repair open in the WH C6 fwd coil wire from the drive forward directional valve coil item AI or BJ to the ECM U5 OR...

Page 147: ... the wire and the negative lead of the volt meter to the brown ground wire on the coil Activate drive in the REVERSE direction and check the voltage Disconnect the wires from the drive reverse directional valve coil item AI or BJ and check resistance of the coil See Repair Section 0V Repair open in the WH A7 rev coil wire from the drive reverse directional valve coil item AI or BJ to the ECM U5 OR...

Page 148: ...5 Check voltage at the WH 21B pothole sw wire on the input side of limit switch LS8 Repair open in the WH 21B pothole jumper wire from the output side of LS7 to the input side of LS8 Check voltage on the output side of LS8 Adjust LS8 so the pothole arm activates the switch OR replace the limit switch contact OR replace the LS8 no yes Raise the platform to more than 6 feet 1 8 m and drive the machi...

Page 149: ... the Genie Industries Service Department Check limit switch LS7 and LS8 for correct adjustment With the key switch turned to platform controls and both Emergency Stop buttons pulled out to the ON position and the platform in the stowed position drive the machine in either direction Is the error indicator light on at the platform controls Check the controller adjustments See Repair Section OR repla...

Page 150: ... B10 pothole sw wire at the ECM U5 20V or more 0V Check voltage on the other terminal at LS6 With the platform raised to 6 feet 1 8 m check for 20V or more on one side of LS8 0V 0V Adjust LS6 OR replace the LS6 contacts 20V or more Repair or replace the 44D wire from alarm H5 to LS6 Repair or replace the wire circuit between LS7 and the positive terminal at alarm H5 20V or more Repair or replace t...

Page 151: ...Part No 72972 GenieGS 2046andGS 2646andGS 3246 5 25 June2003 Section 5 Troubleshooting Flow Charts REV A This page intentionally left blank ...

Page 152: ... 30 at relay CR48 Disconnect the control cable quick disconnect plug at the ECM and check for voltage at terminal C of the quick disconnect plug 20V or more Connect the control cable quick disconnect plug at the ECM Disconnect the control cable quick disconnect plug at the platform and check for voltage at terminal C of the quick disconnect plug 0V Repair or replace the quick disconnect plug OR re...

Page 153: ...andGS 3246 5 27 June2003 Section 5 Troubleshooting Flow Charts REV A CHART 16 a Platform controls circuit board b voltage regulator terminal 2 c voltage regulator terminal 1 d circuit board voltage regulator e voltage regulator terminal 3 ...

Page 154: ... of the platform controls quick disconnect to terminal B1 at U5 no continuity continuity Replace the coil cord assembly OR replace the control cable from the platform to U5 Check for continuity in the green data line or the yellow data line from pin E of the platform controls quick disconnect to terminal C1 at U5 continuity Consult the Genie Industries Service Department no continuity Replace the ...

Page 155: ...ity in the WH C 8 prll coil wire from the ECM U5 to the drive speed select coil item AJ or BI or CJ 20V or more Check for continuity in the brown ground wire circuit from the drive speed select valve coil item AJ or BI or CJ to ground no continuity 0 or infinite ohms Repair or replace the ground wire circuit from the drive speed select coil to ground Consult the Genie Industries Service Department...

Page 156: ...5 30 GenieGS 2046andGS 2646andGS 3246 Part No 72972 REV A Section 5 Troubleshooting Flow Charts June2003 This page intentionally left blank ...

Page 157: ...anual Be sure that all necessary tools and test equipment are available and ready for use About This Section There are two groups of schematics in this section An illustration legend precedes each group of drawings Electrical Schematics Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Hydraulic Schema...

Page 158: ... Section 6 Schematics June 2003 REV A Control Relay Layout a electronic control module ECM U5 b CR48 power relay to U5 not used before serial number 25142 c hydraulic tank d motor controller U6 e hydraulic power unit M5 f hydraulic pump g function manifold ...

Page 159: ...Part No 72972 Genie GS 2046 and GS 2646 and GS 3246 6 3 Section 6 Schematics June 2003 REV A CONTROL RELAY LAYOUT a automotive style horn H2 option b CR5 horn relay c tilt level sensor S7 ...

Page 160: ...6 output C7 Steer right coil Y3 output C8 Spare C9 Brake release coil Y2 output C10 Spare C11 Level sensor signal S7 input C12 Down limit switch LS6 input ECM PIN OUT LEGEND From serial number 21065 to 25141 Item Description A1 Flashing beacon FB1 output A2 Ground from platform controls input White wire at platform A3 Spare A4 Power from platform controls to ECM input Red wire at platform A5 Level...

Page 161: ...coil Y6 output C7 Steer right coil Y3 output C8 Spare C9 Brake release coil Y2 output C10 Spare C11 Level sensor signal S7 input C12 Down limit switch LS6 input ECM PIN OUT LEGEND After serial number 36044 Item Description A1 Flashing beacon FB1 output A2 Ground from platform controls input Blue wire at platform A3 Spare A4 Power from platform controls to ECM input White wire at platform A5 Level ...

Page 162: ... CORD ASSEMBLY WH BN WH BK WH RD WH BL SW25 DIP SWITCH OR PP U3 PLATFORM CONTROLS CIRCUIT BOARD 1 2 3 4 5 6 7 8 ON ALCO ADFO8S OE ABBREVIATION LEGEND Item Description H1 Alarm JC1 Joystick controller P2 Emergency Stop button at platform controls SW25 DIP switch U3 Platform controls circuit board WIRE COLOR LEGEND Color Description BL Blue BK Black BN Brown GN Green OR Orange PP Purple RD Red WH Wh...

Page 163: ...ROLS CIRCUIT BOARD 1 4 2 5 2 1 NC 1 9F 2 3 4 5 6 7 8 ON ALCO ADF085 P N 000000 Date 0000 S N Al 00000000 BN YL BL BK WH RD JC1 JOYSTICK CONTROLLER RD BK OR WH GN PP BL GY BN WIRE COLOR LEGEND Color Description BL Blue BK Black BN Brown GN Green GY Gray OR Orange PP Purple RD Red WH White YL Yellow ABBREVIATION LEGEND Item Description H1 Alarm JC1 Joystick controller P2 Emergency Stop button at pla...

Page 164: ...8F A11 52F A11 KEY SWITCH G6 NC P1 NO NO TS66 CB2 NO NO KS1 PLATFORM KS1 GROUND 25F 3 2 1 29F 41F 24F A12 UP B12 DOWN 76F 53F 51F 54F 45F 50F 49F 48F A11 52F A11 KEY SWITCH NC P1 NO NO TS66 CB2 NO NO KS1 PLATFORM KS1 GROUND A12 UP B12 DOWN 76F G6 25F 29F 41F 53F 51F 45F 50F 49F 23F A11 52F A11 KEY SWITCH 42F 24F G6 NC P1 TS66 CB2 25F 29F 41F 24F A12 UP B12 DOWN 53F 51F A11 KEY SWITCH KS1 51F 76F A...

Page 165: ...O NO TS66 BN23 CB2 NO NO KS1 PLATFORM KS1 GROUND UP DOWN G6 53F 51F 24F A12 B12 42F 76F 45F 50F 49F 23F A11 52F A11 KEY SWITCH EMERGENCY DOWN BATTERY BK RD 60E B7 25F 29F 41F 60E NC P1 TS66 BN23 CB2 KS1 UP DOWN G6 51F 25F 24F A12 B12 76F A11 B B1 3 1 4 2 52F A11 KEY SWITCH EMERGENCY DOWN BATTERY 29F 41F 60E BK RD 60E B7 53F after serial number 48717 from serial number 40926 to 48717 from serial nu...

Page 166: ...K BK WH WH RD RD 44D 44D 44D 44D 23F 75D 23D C12 C12 C11 C11 70D 70D 27D 27D 29F 75D 29F A5 A5 39C 39C Level Sensor Box Wiring Diagram after serial number 21064 before serial number 21065 ABBREVIATION LEGEND Item Description H5 Multi function alarm LS6 Down limit switch S7 Level sensor WIRE COLOR LEGEND Color Description BK Black RD Red WH White ...

Page 167: ...Part No 72972 Genie GS 2046 and GS 2646 and GS 3246 6 11 Section 6 Schematics June 2003 This page intentionally left blank ...

Page 168: ...SW6 STEER LEFT RIGHT SW5 FUNCTION ENABLE JC1 JOYSTICK CONTROLLER HALL GENERATOR SW6 STEER LEFT RIGHT LEFT RIGHT SW5 FUNCTION ENABLE Wire with description Circuits crossing no connection Diode Connection no terminal Connector Hour meter Flashing beacons FB1 Pressure switch normally closed Limit switch Switch Toggle switch Emergency Stop button Normally closed Circuit breaker Relay Fuse Horn or alar...

Page 169: ......

Page 170: ...1 2 3 4 5 6 7 8 A B C D E F G H I J K L M N Electrical Schematic from serial number 17408 to 21064 REV B Section 6 Schematics June 2003 6 13 Genie GS 2046 and GS 2646 and GS 3246 Part No 72972 QD1 QD1 ...

Page 171: ... C H O Normally closed held open N O Normally open Power switch P P1 Emergency Stop button at ground controls P2 Emergency Stop button at platform controls PS2 Platform overload pressure switch option QD Quick disconnect QD1 Battery quick disconnect QD3 Control cable to ground QD4 Control cable to platform Resistor R R15 5000 ohm potentiometer R21 75 ohm resistor S7 Tilt level sensor Switch SW SW5...

Page 172: ...Electrical Schematic from serial number 17408 to 21064 June 2003 Section 6 Schematics ...

Page 173: ......

Page 174: ...Electrical Schematic from serial number 21065 to 21262 1 2 3 4 5 6 7 8 A B C D E F G H I J K L M N Section 6 Schematics June 2003 6 15 Genie GS 2046 and GS 2646 and GS 3246 Part No 72972 QD1 QD1 REV B ...

Page 175: ...N O Normally open Power switch P P1 Emergency Stop button at ground controls P2 Emergency Stop button at platform controls PS2 Platform overload pressure switch option QD Quick disconnect QD1 Battery quick disconnect QD3 Control cable to ground QD4 Control cable to platform Resistor R R15 5000 ohm potentiometer R21 75 ohm resistor S7 Tilt level sensor Switch SW SW5 Function enable SW6 Steer left r...

Page 176: ...Electrical Schematic from serial number 21065 to 21262 June 2003 Section 6 Schematics ...

Page 177: ......

Page 178: ...Electrical Schematic from serial number 21263 to 24438 1 2 3 4 5 6 7 8 A B C D E F G H I J K L M N Section 6 Schematics June 2003 6 17 Genie GS 2046 and GS 2646 and GS 3246 Part No 72972 QD1 QD1 REV B ...

Page 179: ... Normally closed held open N O Normally open Power switch P P1 Emergency Stop button at ground controls P2 Emergency Stop button at platform controls PS2 Platform overload pressure switch option QD Quick disconnect QD1 Battery quick disconnect QD3 Control cable to ground QD4 Control cable to platform Resistor R R15 5000 ohm potentiometer R21 75 ohm resistor S7 Tilt level sensor Switch SW SW5 Funct...

Page 180: ...Electrical Schematic from serial number 21263 to 24438 June 2003 Section 6 Schematics ...

Page 181: ......

Page 182: ...Electrical Schematic from serial number 24439 to 25141 1 2 3 4 5 6 7 8 A B C D E F G H I J K L M N Section 6 Schematics June 2003 6 19 Genie GS 2046 and GS 2646 and GS 3246 Part No 72972 QD1 QD1 REV B ...

Page 183: ... Normally closed held open N O Normally open Power switch P P1 Emergency Stop button at ground controls P2 Emergency Stop button at platform controls PS2 Platform overload pressure switch option QD Quick disconnect QD1 Battery quick disconnect QD3 Control cable to ground QD4 Control cable to platform Resistor R R15 5000 ohm potentiometer R21 75 ohm resistor S7 Tilt level sensor Switch SW SW5 Funct...

Page 184: ...Electrical Schematic from serial number 24439 to 25141 June 2003 Section 6 Schematics ...

Page 185: ......

Page 186: ...Electrical Schematic from serial number 25142 to 27181 1 2 3 4 5 6 7 8 A B C D E F G H I J K L M N Section 6 Schematics June 2003 6 21 Genie GS 2046 and GS 2646 and GS 3246 Part No 72972 QD1 QD1 REV B ...

Page 187: ... Normally closed held open N O Normally open Power switch P P1 Emergency Stop button at ground controls P2 Emergency Stop button at platform controls PS2 Platform overload pressure switch option QD Quick disconnect QD1 Battery quick disconnect QD3 Control cable to ground QD4 Control cable to platform Resistor R R15 5000 ohm potentiometer R21 75 ohm resistor S7 Tilt level sensor Switch SW SW5 Funct...

Page 188: ...Electrical Schematic from serial number 25142 to 27181 June 2003 Section 6 Schematics ...

Page 189: ......

Page 190: ...Electrical Schematic from serial number 27182 to 28936 1 2 3 4 5 6 7 8 A B C D E F G H I J K L M N Section 6 Schematics June 2003 6 23 Genie GS 2046 and GS 2646 and GS 3246 Part No 72972 QD1 QD1 REV B ...

Page 191: ... Normally closed held open N O Normally open Power switch P P1 Emergency Stop button at ground controls P2 Emergency Stop button at platform controls PS2 Platform overload pressure switch option QD Quick disconnect QD1 Battery quick disconnect QD3 Control cable to ground QD4 Control cable to platform Resistor R R15 5000 ohm potentiometer R21 75 ohm resistor S7 Tilt level sensor Switch SW SW5 Funct...

Page 192: ...Electrical Schematic from serial number 27182 to 28936 June 2003 Section 6 Schematics ...

Page 193: ......

Page 194: ...Electrical Schematic from serial number 28937 to 33721 1 2 3 4 5 6 7 8 A B C D E F G H I J K L M N Section 6 Schematics June 2003 6 25 Genie GS 2046 and GS 2646 and GS 3246 Part No 72972 QD1 QD1 REV B ...

Page 195: ... Normally closed held open N O Normally open Power switch P P1 Emergency Stop button at ground controls P2 Emergency Stop button at platform controls PS2 Platform overload pressure switch option QD Quick disconnect QD1 Battery quick disconnect QD3 Control cable to ground QD4 Control cable to platform Resistor R R15 5000 ohm potentiometer R21 75 ohm resistor S7 Tilt level sensor Switch SW SW5 Funct...

Page 196: ...Electrical Schematic from serial number 28937 to 33721 June 2003 Section 6 Schematics ...

Page 197: ......

Page 198: ...Electrical Schematic from serial number 33722 to 40925 1 2 3 4 5 6 7 8 A B C D E F G H I J K L M N Section 6 Schematics June 2003 6 27 Genie GS 2046 and GS 2646 and GS 3246 Part No 72972 QD1 QD1 REV B ...

Page 199: ... Normally closed held open N O Normally open Power switch P P1 Emergency Stop button at ground controls P2 Emergency Stop button at platform controls PS2 Platform overload pressure switch option QD Quick disconnect QD1 Battery quick disconnect QD3 Control cable to ground QD4 Control cable to platform Resistor R R15 5000 ohm potentiometer R21 75 ohm resistor S7 Tilt level sensor Switch SW SW5 Funct...

Page 200: ...Electrical Schematic from serial number 33722 to 40925 June 2003 Section 6 Schematics ...

Page 201: ......

Page 202: ...Electrical Schematic from serial number 40926 to 48054 1 2 3 4 5 6 7 8 A B C D E F G H I J K L M N Section 6 Schematics June 2003 6 29 Genie GS 2046 and GS 2646 and GS 3246 Part No 72972 QD1 QD1 REV B ...

Page 203: ... Normally closed held open N O Normally open Power switch P P1 Emergency Stop button at ground controls P2 Emergency Stop button at platform controls PS2 Platform overload pressure switch option QD Quick disconnect QD1 Battery quick disconnect QD3 Control cable to ground QD4 Control cable to platform Resistor R R15 5000 ohm potentiometer R21 75 ohm resistor S7 Tilt level sensor Switch SW SW5 Funct...

Page 204: ...Electrical Schematic from serial number 40926 to 48054 June 2003 Section 6 Schematics ...

Page 205: ......

Page 206: ...Electrical Schematic from serial number 48055 to 48717 1 2 3 4 5 6 7 8 A B C D E F G H I J K L M N Section 6 Schematics June 2003 6 31 Genie GS 2046 and GS 2646 and GS 3246 Part No 72972 QD1 QD1 REV A ...

Page 207: ... Normally closed held open N O Normally open Power switch P P1 Emergency Stop button at ground controls P2 Emergency Stop button at platform controls PS2 Platform overload pressure switch option QD Quick disconnect QD1 Battery quick disconnect QD3 Control cable to ground QD4 Control cable to platform Resistor R R15 5000 ohm potentiometer R21 75 ohm resistor S7 Tilt level sensor Switch SW SW5 Funct...

Page 208: ...Electrical Schematic from serial number 48055 to 48717 June 2003 Section 6 Schematics ...

Page 209: ......

Page 210: ...Electrical Schematic from serial number 48718 to 49199 1 2 3 4 5 6 7 8 A B C D E F G H I J K L M N Section 6 Schematics June 2003 6 33 Genie GS 2046 and GS 2646 and GS 3246 Part No 72972 QD1 QD1 REV A ...

Page 211: ... Normally closed held open N O Normally open Power switch P P1 Emergency Stop button at ground controls P2 Emergency Stop button at platform controls PS2 Platform overload pressure switch option QD Quick disconnect QD1 Battery quick disconnect QD3 Control cable to ground QD4 Control cable to platform Resistor R R15 5000 ohm potentiometer R21 75 ohm resistor S7 Tilt level sensor Switch SW SW5 Funct...

Page 212: ...Electrical Schematic from serial number 48718 to 49199 June 2003 Section 6 Schematics ...

Page 213: ......

Page 214: ...Electrical Schematic after serial number 49199 1 2 3 4 5 6 7 8 A B C D E F G H I J K L M N Section 6 Schematics June 2003 6 35 Genie GS 2046 and GS 2646 and GS 3246 Part No 72972 QD1 QD1 REV A ...

Page 215: ...mally closed held open N O Normally open Power switch P P1 Emergency Stop button at ground controls P2 Emergency Stop button at platform controls PS2 Platform overload pressure switch option QD Quick disconnect QD1 Battery quick disconnect QD3 Control cable to ground QD4 Control cable to platform Resistor R R15 5000 ohm potentiometer R21 75 ohm resistor S7 Tilt level sensor Switch SW SW5 Function ...

Page 216: ...Electrical Schematic after serial number 49199 June 2003 Section 6 Schematics ...

Page 217: ...Hydraulic Symbols Legend and Component Reference Section 6 Schematics June 2003 ...

Page 218: ...ld components GS 3246 from serial number 22447 to 36044 Lift cylinder components GS 2046 and GS 2646 before serial number 23567 Lift cylinder components GS 3246 after serial number 27181 Lift cylinder components GS 3246 from s n 23568 to 27181 Lift cylinder components GS 3246 before serial number 23568 Filter Fixed displacement pump Bi directional motor Variable speed motor Check valve Solenoid op...

Page 219: ... number 17481 ABBREVIATION LEGEND Item Description A Check valve manual brake release circuit B Shuttle valve brake release C Hand pump manual brake release circuit D Platform lowering valve E Orifice platform down circuit F Accumulator ABBREVIATION LEGEND Item Description AA Check valve steer circuit AB Test port AC Flow regulator steer circuit AD Orifice washer steer circuit AE Relief valve stee...

Page 220: ...Hydraulic Schematic GS 2046 and GS 2646 from serial number 17408 to 36044 April 2003 Section 6 Schematics ...

Page 221: ...lief valve lift BD Relief valve system BE Orifice washer steer circuit BF Relief valve steer BG Relief valve brake circuit BH Steer left right BI Drive speed select BJ Drive forward reverse BK Brake circuit BL Platform up BM Check valve steer circuit ABBREVIATION LEGEND Item Description A Check valve manual brake release circuit B Shuttle valve brake release C Hand pump manual brake release circui...

Page 222: ...Hydraulic Schematic GS 2046 and GS 2646 after serial number 36044 June 2003 Section 6 Schematics ...

Page 223: ...tor steer circuit CC Relief valve lift CD Relief valve system CE Orifice washer steer circuit CF Relief valve steer CG Check valve brake circuit CH Steer left right CI Brake circuit CJ Drive speed select CK Drive forward reverse CL High speed bypass CM Flow divider combiner CN Platform up CO Check valve steer circuit ABBREVIATION LEGEND Item Description A Check valve manual brake release circuit B...

Page 224: ...Hydraulic Schematic GS 2046 and GS 2646 Models with Traction Control June 2003 Section 6 Schematics ...

Page 225: ...r 17481 ABBREVIATION LEGEND Item Description AA Check valve steer circuit AB Test port AC Flow regulator steer circuit AD Orifice washer steer circuit AE Relief valve steer AF Relief valve system AG Steer left right AH Platform up AI Brake circuit AJ Drive speed select AK Drive forward reverse AL Check valve OR relief valve brake circuit ABBREVIATION LEGEND Item Description A Check valve manual br...

Page 226: ...Hydraulic Schematic GS 3246 from serial number 17408 to 22446 June 2003 Section 6 Schematics ...

Page 227: ...A Check valve steer circuit AB Test port AC Flow regulator steer circuit AD Orifice washer steer circuit AE Relief valve steer AF Relief valve system AG Steer left right AH Platform up AI Brake circuit AJ Drive speed select AK Drive forward reverse AL Relief valve brake circuit ABBREVIATION LEGEND Item Description A Check valve manual brake release circuit B Shuttle valve brake release C Hand pump...

Page 228: ...Hydraulic Schematic GS 3246 from serial number 22447 to 27181 June 2003 Section 6 Schematics ...

Page 229: ...k valve steer circuit AB Test port AC Flow regulator steer circuit AD Orifice washer steer circuit AE Relief valve steer AF Relief valve system AG Steer left right AH Platform up AI Brake circuit AJ Drive speed select AK Drive forward reverse AL Relief valve brake circuit ABBREVIATION LEGEND Item Description A Check valve manual brake release circuit B Shuttle valve brake release C Hand pump manua...

Page 230: ...Hydraulic Schematic GS 3246 from serial number 27182 to 36044 June 2003 Section 6 Schematics ...

Page 231: ...alve lift BD Relief valve system BE Orifice washer steer circuit BF Relief valve steer BG Relief valve brake circuit BH Steer left right BI Drive speed select BJ Drive forward reverse BK Brake circuit BL Platform up BM Check valve steer circuit ABBREVIATION LEGEND Item Description A Check valve manual brake release circuit B Shuttle valve brake release C Hand pump manual brake release circuit D Pl...

Page 232: ...Hydraulic Schematic GS 3246 after serial number 36044 June 2003 Section 6 Schematics ...

Page 233: ...tor steer circuit CC Relief valve lift CD Relief valve system CE Orifice washer steer circuit CF Relief valve steer CG Check valve brake circuit CH Steer left right CI Brake circuit CJ Drive speed select CK Drive forward reverse CL High speed bypass CM Flow divider combiner CN Platform up CO Check valve steer circuit ABBREVIATION LEGEND Item Description A Check valve manual brake release circuit B...

Page 234: ...Hydraulic Schematic GS 3246 Models with Traction Control June 2003 Section 6 Schematics ...

Page 235: ...Service Manual GS 2046 GS 2646 GS 3246 Part No 72972 Rev B2 ...

Page 236: ... 544 Phone 81 3 3453 6082 Fax 81 3 3453 6083 Phone 82 25 587 267 Fax 82 25 583 910 Phone 55 11 41 665 755 Fax 55 11 41 665 754 Phone 31 183 581 102 Fax 31 183 581 566 Genie Scandinavia Genie France Genie Iberica Genie Germany Genie U K Genie Mexico City Phone 46 31 575100 Fax Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Phone 34 93 579 5042 Fax 34 93 579 5059 Phone 0800 180 9017 Fax 49 422 149 ...

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