Genie GS-2668 RT Service Manual Download

Page: 11 / 184

November 2008

Part No. 112657

GS-2668 RT • GS-3268 RT

Section 4

Rev

Repair Procedures,

continued

Perkins 403D-11 and 403C-11 Engines

6-1

Engine RPM ..................................................................................... 4 - 29

6-2

Timing Adjustment ............................................................................ 4 - 29

6-3

Flex Plate ......................................................................................... 4 - 30

6-4

Coolant Temperature and Oil Pressure Switches .............................. 4 - 30

Ground Controls

7-1

Auxiliary Platform Lowering .............................................................. 4 - 32

7-2

Function Speed Tuning ..................................................................... 4 - 32

7-3

Software Configuration ...................................................................... 4 - 37

7-4

Level Sensor - Models without Outriggers ......................................... 4 - 43

7-5

Level Sensor - Models with Outriggers .............................................. 4 - 46

Hydraulic Pump

8-1

Function Pump ................................................................................. 4 - 50

Manifolds

9-1

Function Manifold Components ........................................................ 4 - 52

9-2

Valve Adjustments - Function Manifold ............................................ 4 - 56

9-3

Outrigger Manifold Components ........................................................ 4 - 59

9-4

Valve Adjustments - Outrigger Manifold ............................................ 4 - 60

9-5

Generator Manifold Components ....................................................... 4 - 62

9-6

Valve Adjustments - Generator Manifold ........................................... 4 - 63

9-7

Valve Coils ....................................................................................... 4 - 64

TABLE OF CONTENTS

Summary of Contents for GS-2668 RT

Page 1: ...Parts Manual Serial Number Range Service Manual Part No 112657 Rev C2 July 2011 Serial Number Range GS 2668 RT from GS6805 44771 GS 3268 RT from GS6805 44771 ...

Page 2: ...stries 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 Copy...

Page 3: ...USA This machine complies with Serial number Rated work load including occupants Genie Industries 18340 NE 76th Street Redmond WA 98052 USA Electrical schematic number Gradeability Maximum allowable side force Maximum number of platform occupants Machine unladen weight ANSI A92 6 1999 B354 2 01 GS 1930 GS3005A 12345 04 12 05 ES0141 2 714 lb 1 231 kg 500 lb 227 kg N A N A 100 lb 445 N 2 2005 Model ...

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Page 5: ...or 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 ...

Page 6: ...ve 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 away from flammable and combustible materials like battery gases and engine fuels Always have an approved fire extinguisher wi...

Page 7: ...ns 2 2 HydraulicComponentsSpecifications 2 3 ManifoldComponentSpecifications 2 4 Valve Coil Resistance Specifications 2 4 Kubota D1105 Engine Tier 4 2 5 Kubota D905 Engine Tier 2 2 6 KubotaDF752Engine 2 7 Perkins403D 11Engine 2 8 Perkins403C 11Engine 2 9 Hydraulic Hose and Fitting Torque Specifications 2 10 SAE and Metric Fasteners Torque Charts 2 11 Section 3 Rev ScheduledMaintenanceProcedures In...

Page 8: ...11 A 9 Perform Engine Maintenance Kubota Models 3 12 A 10 Perform Engine Maintenance Kubota Models 3 12 A 11 Drain the Fuel Filter Water Separator Diesel Models 3 13 A 12 Perform Engine Maintenance Kubota Models 3 14 B ChecklistBProcedures B 1 Inspect the Battery 3 15 B 2 Inspect the Electrical Wiring 3 16 B 3 Inspect the Tires Wheels and Lug Bolt Torque 3 17 B 4 Perform Engine Maintenance Perkins...

Page 9: ...dels with Optional Hydraulic Oil 3 27 C 4 Perform Engine Maintenance Diesel Models 3 27 C 5 Perform Engine Maintenance Kubota Models 3 28 B Checklist D Procedures D 1 Check the Scissor Arm Wear Pads 3 29 D 2 Replace the Hydraulic Tank Return Filter 3 30 D 3 Perform Engine Maintenance Perkins Models 3 31 D 4 Perform Engine Maintenance Kubota Models 3 31 D 5 Perform Engine Maintenance Kubota Models ...

Page 10: ...3268 RT 4 12 3 3 Wear Pads 4 19 3 4 Lift Cylinder s 4 20 C Kubota D1105 and D905 Engines 4 1 Timing Adjustment 4 23 4 2 Glow Plugs 4 23 4 3 Engine RPM 4 24 4 4 Flex Plate 4 24 4 5 Coolant Temperature and Oil Pressure Switches 4 25 A Kubota DF752 Engine 5 1 Timing Adjustment 4 27 5 2 Carburetor Adjustment Gasoline LPG Models 4 27 5 3 Choke Adjustment Gasoline LPG Models 4 27 5 4 Flex Plate 4 27 5 5...

Page 11: ... 32 7 2 FunctionSpeedTuning 4 32 7 3 SoftwareConfiguration 4 37 7 4 Level Sensor Models without Outriggers 4 43 7 5 Level Sensor Models with Outriggers 4 46 A Hydraulic Pump 8 1 Function Pump 4 50 B Manifolds 9 1 FunctionManifoldComponents 4 52 9 2 Valve Adjustments Function Manifold 4 56 9 3 OutriggerManifoldComponents 4 59 9 4 Valve Adjustments Outrigger Manifold 4 60 9 5 GeneratorManifoldCompon...

Page 12: ...1 Yoke and Drive Motor 4 68 11 2 SteerCylinder 4 70 11 3 Tie Rod 4 70 A Non steerAxleComponents 12 1 Drive Motor and Brake 4 71 A OutriggerComponents 13 1 OutriggerCylinder 4 72 A BrakeReleaseHandPumpComponents 14 1 Brake Release Hand Pump Components 4 73 A PlatformOverloadComponents 15 1 Platform Overload System 4 74 Section 5 Rev FaultCodes Introduction 5 1 B FaultCodeChart fromserialnumberGS680...

Page 13: ...s with Gasoline LPG Power from serial number GS6805 44771 6 8 C Electrical Schematic CE Models with Gasoline LPG Power from serial number GS6805 44771 6 12 C Electrical Schematic ANSI Models with Diesel Power from serial number GS6805 44771 to GS6806 45204 6 16 C Electrical Schematic ANSI Models with Diesel Power from serial number GS6806 45205 6 20 C Electrical Schematic CE Models with Diesel Pow...

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Page 15: ...liters For operational specifications refer to the Operator s Manual Tire and wheels Wheel lugs 6 1 2 20 Lug bolt torque dry 90 ft lbs 122 Nm Lug bolt torque lubricated 67 5 ft lbs 91 5 Nm Castle nut torque dry 300 ft lbs 406 7 Nm Castle nut torque lubricated 225 ft lbs 305 Nm Rough Terrain foam filled Tire size 26 x 12D380 Tire ply rating 8 Tire diameter 26 in 66 cm Tire width 12 in 30 cm Tire we...

Page 16: ...ppm Chevron Rykon MV oil is fully compatible and mixable with Shell Donax TG Dexron III oils 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 corrosion inhibition seal conditioning and foam...

Page 17: ...nction manifold System relief valve pressure 3500 psi pump 1 241 3 bar System relief valve pressure 3000 psi pump 2 207 bar Lift relief valve pressure GS 2668 RT 3600 psi 248 2 bar Lift relief valve pressure GS 3268 RT 2800 psi 193 bar Steer relief valve pressure 2800 psi 193 bar Steer flow regulator 2 gpm 7 5 L min Outriggermanifold Relief valve pressure 2000 psi 137 8 bar Generator manifold Reli...

Page 18: ... 12V DC with diode schematic item AI Solenoid valve 2 position 2 way 7 5Ω 12V DC schematic item BB Solenoid valve 3 position 4 way 7 5Ω 12V DC schematic item BD Solenoid valve 2 position 2 way 8 2Ω 10V DC schematic items CA CB CC and CD Solenoid valve 2 position 3 way 6Ω 12V DC schematic item DA Solenoid valve 2 position 2 way 8 8Ω 12V DC with diode schematic items FB and FK Solenoid valve 2 posit...

Page 19: ...4 41bar Oil capacity including filter 5 4 quarts 5 1 liters Oilviscosityrequirements Units ship with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Handbook on your machine Injection system Injectionpumpmake Bosch MD Injectiontiming 16 25 to 17 75 BTDC Injectionpumppressure 1992 to 2133 psi 137 to 147 bar Fuelr...

Page 20: ...2 48 to 4 41 bar Oil capacity including filter 5 4 quarts 5 1 liters Oil viscosity requirements Units ship with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Handbook on your machine Injection system Injectionpumpmake Bosch MD Injectiontiming 18 to 21 BTDC Injectionpumppressure 1991 psi 137 bar Fuelrequirement...

Page 21: ...ernative engine oils For oil requirements refer to the Engine Operator Handbook on your machine Fuel pump Fuel pressure static 2 84 psi 0 19bar Fuel flow rate 0 125gpm 0 47L min Starter motor Brush length new 0 669in 17 mm Brush length wear limit 0 453in 11 5mm Brush spring tension 50 to 91 ounces 13 7 to 25 5 N Battery Type 12V DC Group 34 78 Quantity 1 Amperehour 75AH Cold cranking ampere 900A R...

Page 22: ...with 50 anti freeze concentration ethylene glycol to BS 6580 1992 or ASTMD 3306 89 or AS 2108 1977 Lubricationsystem Oil pressure 40 to 60 psi hot 2000 rpm 2 76 to 4 14bar Oil capacity including filter 4 6 quarts 4 4 liters Oilviscosityrequirements Units ship with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator ...

Page 23: ... soft water with 50 anti freeze concentration ethylene glycol to BS 6580 1992 or ASTMD 3306 89 or AS 2108 1977 Lubrication system Oil pressure 40 to 60 psi hot 2000 rpm 2 76 to 4 14 bar Oil capacity including filter 4 3 quarts 4 07 liters Oil viscosity requirements Units ship with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the...

Page 24: ...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 rings used in the Parker Seal Lok fittings and hose ends are custom size O rings They are not standard SAE size O rings They are available in the O ring field service kit Genie part number 49612...

Page 25: ...60 4826 3000 4067 LUBED DRY LUBED SAE FASTENER TORQUE CHART Grade 5 DRY LUBED This chart is to be used as a guide only unless noted elsewhere in this manual A574 High Strength Black Oxide Bolts Grade 8 LUBED 1 4 LUBED DRY LUBED DRY 1 1 2 9 16 5 8 3 4 7 8 1 1 1 8 1 1 4 5 16 3 8 7 16 1 2 Size mm in lbs N m in lbs N m in lbs N m in lbs N m in lbs N m in lbs N m in lbs N m in lbs N m 5 16 1 8 21 2 4 4...

Page 26: ...Section 2 Specifications November 200 2 12 GS 2668 RT GS 3268 RT Part No 112657 This page intentionally left blank ...

Page 27: ...urface Platform in the stowed position Key switch in the off position with the key removed The red Emergency Stop button in the off position at both ground and platform controls Wheels chocked All external AC power supply disconnected from the machine About This Section This section contains detailed procedures for each scheduled maintenance inspection Each procedure includes a description safety ...

Page 28: ...aration report to use for each inspection Store completed forms as required Maintenance Schedule There are five types of maintenance inspections that must be performed according to a schedule daily quarterly semi annually annually and two year The Scheduled Maintenance Procedures Section and the Maintenance Inspection Report have been divided into five subsections A B C D and E Use the following c...

Page 29: ...s 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 dealer...

Page 30: ...Section 3 Scheduled Maintenance Procedures November 2008 3 4 GS 2668 RT GS 3268 RT Part No 112657 This page intentionally left blank ...

Page 31: ...Perform every 100 hours A 9 Engine maintenance Kubota models Perform every 200 hours A 10 Engine maintenance Kubota models A 11 Drain filter separator Diesel models Perform every 1 2 months A 12 Engine maintenance Kubota models Model Serial number Date Hour meter Machine owner Inspected by print Inspector signature Inspector title Inspector company Instructions Make copies of this report to use fo...

Page 32: ...bota models Perform every 1500 hours D 5 Engine maintenance Kubota models MAINTENANCE INSPECTION REPORT Model Serial number Date Hour meter Machine owner Inspected by print Inspector signature Inspector title Inspector company Instructions Make copies of this report to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hours Inspection ...

Page 33: ...rd and could result in unsafe operating conditions 1 Check to make sure that the operator s and safety manuals are present and complete in the storage container on the platform 2 Examine the pages of each manual to be sure that they are legible and in good condition Result The operator s manual is appropriate for the machine and all manuals are legible and in good condition Result The operator s m...

Page 34: ...ves to determine if routine maintenance procedures are required Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine A 3 Perform Function Tests Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Completing the function tests is essential to safe machine...

Page 35: ...Genie part number 131661 Perkins 403C 11 User s Handbook Genie part number 97360 A 5 Inspect the Engine Air Filter Genie specifications require that this procedure be performed every 40 hours or weekly whichever comes first Maintaining the engine air filter in good condition is essential to good engine performance and service life Failure to perform this procedure can lead to poor engine performan...

Page 36: ...models Swing the engine pivot tray back to its original position and make sure the engine tray locking pin locks into place CHECKLIST A PROCEDURES A 6 Perform 30 Day Service The 30 day maintenance procedure is a one time sequence of procedures to be performed after the first 30 days or 40 hours of usage After this interval refer to the maintenance checklists for continued scheduled maintenance 1 P...

Page 37: ... Genie part number 131379 Kubota D905 Operator s Manual Genie part number 84240 A 8 Perform Engine Maintenance Kubota Models Engine specifications require that this procedure be performed every 50 hours or weekly whichever comes first Required maintenance procedures and additional engine information is available in the Kubota D1105 Operator s Manual Kubota part number 16622 89166 OR the Kubota D90...

Page 38: ... Manual Genie part number 131379 Kubota D905 Operator s Manual Genie part number 84240 Kubota DF752 Operator s Manual Genie part number 84250 A 10 Perform Engine Maintenance Kubota Models Engine specifications require that this procedure be performed every 200 hours Required maintenance procedures and additional engine information is available in the Kubota D1105 Operator s Manual Kubota part numb...

Page 39: ...ug located on the fuel filter water separator head 2 Loosen the drain plug located at the bottom of the bowl Allow the water to drain into a suitable container until fuel starts to come out Immediately tighten the drain plug a head bolt b vent plug c separator head d filter bowl e drain plug 3 Tighten the vent plug and clean up any spills or wet surfaces Note If the fuel bowl is completely drained...

Page 40: ...Operator s Manual Kubota part number 16622 89166 OR the Kubota D905 Operator s Manual Kubota part number 16622 8916 5 OR the Perkins 403D 11 User s Handbook Perkins part number SEBU8311 01 OR the Perkins 403C 11 User s Handbook Perkins part number 100816460 Kubota D1105 Operator s Manual Genie part number 131379 Kubota D905 Operator s Manual Genie part number 84240 Perkins 403D 11 User s Handbook ...

Page 41: ...Note the results 6 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows Add 0 004 to the reading of each cell for every 10 5 5 C above 80 F 26 7 C Subtract 0 004 from the reading of each cell for every 10 5 5 C below 80 F 26 7 C Result All battery cells display an adjusted specific gravity of 1 277 or higher The battery is fully charged Proceed to step...

Page 42: ... arms Platform controls 2 Inspect for a liberal coating of dielectric grease in the following locations Between the ECM and platform controls All wire harness connectors Level sensor 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 Start the engine and raise the platform approximately 10 feet 3 m from the g...

Page 43: ...ck plate or cotter pin and check each castle nut for proper torque Refer to Section 2 Specifications Note Always replace the cotter pin with a new one when removing the castle nut or checking the torque of the castle nut 4 Check each lug bolt for proper torque 5 Install the castle nut lock plate using a new lock washer OR install a new cotter pin and secure B 4 Perform Engine Maintenance Perkins M...

Page 44: ...ould not operate 6 Turn the key switch to the OFF position Result The engine should stop and no functions should operate B 6 Test the Emergency Stop Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first A properly functioning Emergency Stop is essential for safe machine operation An improperly operating red Emergency Stop button will fail to shut off po...

Page 45: ... the Fuel Select Operation Gasoline LPG Models Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first The ability to select and switch between gasoline and LPG fuels as needed is essential to safe machine operation A fuel selection can be made whether the engine is running or not Switching malfunctions and or the failure of the engine to start and run pr...

Page 46: ... if the fuel source is switched while the engine is running B 9 Test the Drive Brakes Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Proper brake action is essential to safe machine operation The drive brake function should operate smoothly free of hesitation jerking and unusual noise Hydraulically released individual wheel brakes can appear to o...

Page 47: ... drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 2 Turn the key switch to platform controls and pull out the red Emergency Stop button to the on position at ...

Page 48: ...ime when your reference point on the machine crosses the finish line Refer to Section 2 Specifications Note If the raised drive speed does not meet specifications refer to the Repair procedure 7 2 Function Speed Tuning B 12 Inspect the Fuel and Hydraulic Tank Cap Venting Systems Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Perform this procedur...

Page 49: ...ng low pressure compressed air Repeat this procedure beginning with step 6 8 Install the breather cap onto the hydraulic tank B 13 Perform Hydraulic Oil Analysis Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil and a clogged suction stra...

Page 50: ...trol and pull out the red Emergency Stop button to the on position at both the ground and platform controls Result The beacons should flash 2 Turn the key switch to platform controls Result The beacons should flash B 15 Perform Engine Maintenance Kubota Models Engine specifications require that this procedure be performed every 400 hours Required maintenance procedures and additional engine inform...

Page 51: ...Emergency Stop button to the on position at both the ground and platform controls 10 Fully raise the platform Release the joystick Result The engine should stop and an alarm should sound and fault code 99 PLATFORM OVERLOAD should be present in the ECM diagnostic display window at the ground controls Result The engine does not stop OR an alarm doesn t sound OR fault code 99 is not present in the EC...

Page 52: ...3 Using an approved hand operated pump drain the fuel tank into a suitable container Refer to Section 2 Specifications for tank capacity Explosion and fire hazard When transferring fuel connect a grounding wire between the machine and pump or container Note Be sure to only use a hand operated pump suitable for use with gasoline and or diesel fuel 4 Remove the tank retaining fasteners from the bott...

Page 53: ...e cap be inspected more often 1 Remove and discard the hydraulic tank breather cap 2 Install and new cap onto the tank C 4 Perform Engine Maintenance Diesel Models Engine specifications require that this procedure be performed every 500 hours Required maintenance procedures and additional engine information is available in the Kubota D1105 Operator s Manual Kubota part number 16622 89166 OR the Ku...

Page 54: ...s procedure be performed every 800 hours Required maintenance procedures and additional engine information is available in the Kubota D1105 Operator s Manual Kubota part number 16622 89166 OR the Kubota D905 Operator s Manual Kubota part number 16622 8916 5 Kubota D1105 Operator s Manual Genie part number 131379 Kubota D905 Operator s Manual Genie part number 84240 CHECKLIST C PROCEDURES ...

Page 55: ...or more Proceed to step 2 Result The measurement is less than 5 16 inch 8 mm Replace both wear pads 2 Measure the thickness of each chassis wear pad at the non steer end of the machine Result The measurement is 5 16 inch 8 mm or more Proceed to step 3 Result The measurement is less than 5 16 inch 8 mm Replace both wear pads 3 Measure the thickness of each platform scissor arm wear pad at the steer...

Page 56: ...an the area where the hydraulic oil filter meets the filter head 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 Note The hydraulic filter is mounted on the hydraulic tank 2 Apply a thin layer of fresh oil to the new oil filter gasket 3 Install the n...

Page 57: ...kins 403D 11 User s Handbook Genie part number 131661 Perkins 403C 11 User s Handbook Genie part number 97360 D 4 Perform Engine Maintenance Kubota Models Engine specifications require that this procedure be performed annually Required maintenance procedures and additional engine information is available in the Kubota D1105 Operator s Manual Kubota part number 16622 89166 OR the Kubota D905 Operat...

Page 58: ...tions require that this procedure be performed every 1500 hours Required maintenance procedures and additional engine information is available in the Kubota D1105 Operator s Manual Kubota part number 16622 89166 OR the Kubota D905 Operator s Manual Kubota part number 16622 8916 5 Kubota D1105 Operator s Manual Genie part number 131379 Kubota D905 Operator s Manual Genie part number 84240 ...

Page 59: ...ing hazard Keep hands clear of the safety arm when lowering the platform 4 Push in the red Emergency Stop button to the off position 5 Locate the hose cover plate in the center of the drive chassis Remove the hose cover plate mounting fasteners and remove the cover 6 If equipped close the two hydraulic shutoff valves located at the hydraulic tank Component damage hazard The engine must not be star...

Page 60: ...ntil the fluid is within the top 2 inches 5 cm of the sight gauge Do not overfill 21 Clean up any oil that may have spilled Properly discard the oil 22 If equipped open the two hydraulic shutoff valves located at the hydraulic tank 23 Operate all machine functions through a full cycle and check for leaks 24 Install the hose cover plate and install the hose cover plate mounting fasteners E 2 Perfor...

Page 61: ...part number EG261 8916 1 OR the Kubota DF752 Operator s Manual Kubota part number EG601 8916 1 Kubota DF750 Operator s Manual Genie part number 97359 Kubota DF752 Operator s Manual Genie part number 84250 E 4 Perform Engine Maintenance Kubota D1105 Models Engine specifications require that this procedure be performed every two years Required maintenance procedures and additional engine information...

Page 62: ...rt number SEBU8311 01 OR the Perkins 403C 11 User s Handbook Perkins part number 100816460 Perkins 403D 11 User s Handbook Genie part number 131661 Perkins 403C 11 User s Handbook Genie part number 97360 E 6 Perform Engine Maintenance Kubota D1105 Models Engine specifications require that this procedure be performed every 3000 hours Required maintenance procedures and additional engine information...

Page 63: ...y 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 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 mach...

Page 64: ...board mounted to the inside of the platform control box lid 4 Tag and disconnect the wire connections from the red Emergency Stop button 5 Tag and disconnect the wire harness connectors from the platform controls circuit board Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Component damage hazard El...

Page 65: ...nd return the safety arm to the stowed position 6 Lower the platform to the stowed position and turn the machine off 7 Remove the mounting fasteners that secure the platform controls quick disconnect plug to the platform 8 Twist the connector to disconnect the platform controls from the plug 9 Remove the platform control box from the platform and lay it off to the side Component damage hazard The ...

Page 66: ...cured to the forklift Note Note the position of the wear pads before the platform is removed so that when the platform is installed they will be in the correct position 2 2 Platform Extension Deck How to Remove the Platform Extension Deck 1 Remove the fasteners from the access cover on the side of the platform at the non steer end of the machine 2 Remove the fasteners from the roller wheel mount 3...

Page 67: ... forklift 12 Attach a lifting strap from the platform extension railings to the carriage on the forklift to support the platform extension 13 Carefully slide the platform extension out and away from the platform and place it on a structure capable of supporting it Crushing hazard The platform extension will become unbalanced and fall when removed from the machine if not properly supported and secu...

Page 68: ...t pin steer end 7 Number 2 center pivot pins 2 each 8 Number 2 pivot pin steer end 9 Number 1 center pivot pin 10 Number 1 inner arm 11 Number 1 pivot pin s steer end 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 Numbe...

Page 69: ...ched 5 Remove the mounting fasteners from the upper cable tray supports 6 Remove the upper cable tray from the scissor assembly Component damage hazard Cables can be damaged if they are kinked or pinched 7 Connect the platform controls to the quick disconnect plug to allow the machine to operate 8 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position a...

Page 70: ...r 3 inner arm index 16 with a second overhead crane at the non steer end 26 Remove the external snap rings from the number 3 center pivot pin index 17 at the ground controls side 27 Use a soft metal drift to tap the number 3 center pivot pin index 17 halfway out at the ground controls side 28 Remove the external snap rings from the number 3 pivot pin index 18 at the non steer end 29 Use a soft met...

Page 71: ...dex 16 from the machine Crushing hazard The number 3 inner arm index 16 could become unbalanced and fall if not properly supported when removed from the machine 43 Attach a lifting strap from an overhead crane to the number 2 outer arm index 20 at the ground controls side 44 Support the number 2 inner arm index 19 with a second overhead crane at the non steer end 45 Remove the external snap rings ...

Page 72: ...y 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 57 Tag and disconnect the wiring from the solenoid valve on the lift cylinder 58 Remove the cables from the number 1 inner arm index 10 Lay the cables off to the side of the machine Component damage hazard C...

Page 73: ...Remove the straps securing the scissor arms together 70 Attach a lifting strap from an overhead crane to the lug on the rod end of the lift cylinder Raise the rod end of the cylinder to a vertical position 71 Remove the pin retaining fasteners from the cylinder barrel end pivot pin index 22 Use a soft metal drift to remove the pin Remove the cylinder from the scissor assembly Crushing hazard The c...

Page 74: ... cylinder rod end pivot pin 10 Number 3 pivot pin steer end 11 Number 2 center pivot pins 2 each 12 Number 2 pivot pin steer end 13 Number 1 center pivot pin 14 Number 1 inner arm 15 Number 1 pivot pin s steer end 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 ...

Page 75: ...l 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 at the non steer end 7 Use a soft metal drift to remove the number 5 pivot pin index 19 from the non steer end of the machine Remove the number 5 outer arm index 18 from the machine Crushing hazard The number 5 outer arm index 18 could become unbalanced and fall if not prop...

Page 76: ... ground control and pull out the red Emergency Stop buttons to the on position at both the ground and platform controls Start the engine 24 Raise the platform approximately 10 feet 3 m 25 Lift the safety arm move it to the center of the scissor arm and rotate down to a vertical position Lower the scissor assembly onto the safety arm Crushing hazard Keep hands clear of the safety arm when lowering ...

Page 77: ...t cylinder Raise the rod end of the cylinder to a vertical position 40 Remove the pin retaining fasteners from the upper cylinder barrel end pivot pin index 23 Use a soft metal drift to remove the pin Remove the cylinder from the machine Crushing hazard The cylinder could become unbalanced and fall when removed from the machine if not properly supported Component damage hazard Be careful not to da...

Page 78: ...er cable tray 55 Remove the lower cable tray from the machine Component damage hazard Cables can be damaged if they are kinked or pinched 56 Attach a lifting strap from an overhead crane to the lug on the rod end of the lower lift cylinder 57 Remove the pin retaining fasteners from the lower cylinder rod end pivot pin index 9 Use a soft metal drift to remove the pin Crushing hazard The cylinder co...

Page 79: ...x 30 with a second overhead crane at the steer end 72 Remove the external snap rings from the number 2 pivot pin index 12 at the steer end 73 Use a soft metal drift to remove the number 2 pivot pin index 12 at the steer end Remove the number 2 inner arm index 26 from the machine Crushing hazard The number 2 inner arm index 26 could become unbalanced and fall if not properly supported when it is re...

Page 80: ...balanced and fall if not properly supported and secured to the overhead crane Note During removal the lifting strap connected to the overhead crane will need to be carefully adjusted for proper balancing 87 Remove the straps securing the scissor arms together 88 Attach a lifting strap from an overhead crane to the lug on the rod end of the lower lift cylinder Raise the rod end of the cylinder to a...

Page 81: ...ENTS Chassis Scissor Arm Wear Pads 1 Attach a lifting strap from an overhead crane to the ladder at the non steer end of the machine Support the ladder Do not apply any lifting pressure 2 Remove the fasteners securing the ladder to the chassis Remove the ladder from the machine Crushing hazard The ladder could fall if not properly supported when the fasteners are removed from the machine 3 Secure ...

Page 82: ... during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Raise the platform approximately 10 feet 3 m 2 Lift the safety arm move to the center of the scissor arm and rotate down to a vertical position GS 2668 RT a platform down solenoid valve b lift cylinder c pressure switch CE models 3 Lower the platform onto the safety arm Crushing hazard Keep hands clear of th...

Page 83: ...11 Carefully pull the lift cylinder out the non steer end of the machine through the scissor arms Crushing hazard The lift cylinder could become unbalanced and fall if not properly supported when removed from the machine Component damage hazard Be careful not to damage the valve or fittings on the cylinder while removing it from the machine GS 3268 RT Bodily injury hazard This procedure requires s...

Page 84: ...linder disregard step 9 9 To remove the lower cylinder support and secure the entry ladder to an appropriate lifting device Remove the entry ladder mounting fasteners Remove the entry ladder from the machine Crushing hazard The entry ladder could become unbalanced and fall if not properly supported and secured to the lifting device when removed from the machine 10 Support and secure the lift cylin...

Page 85: ...left glow plug and ground Result The resistance should be approximately 1Ω 2 If the ohm reading is different than 1Ω remove the wire and connector plate from the three individual glow plugs Then one glow plug at a time measure the resistance between the glow plug and ground Result The resistance should be approximately 1 8Ω for each individual glow plug 3 Install the connector plate and wires to a...

Page 86: ...switch to the start position and check the engine RPM on the diagnostic display Refer to Section 2 Specifications 6 To correct the high idle speed loosen the lock nut on the solenoid then turn the solenoid boot counterclockwise to increase the rpm or clockwise to decrease the rpm Tighten the lock nut and recheck the rpm b a d c KUBOTA D1105 and D905 ENGINES 4 4 Flex Plate The flex plate couples th...

Page 87: ...tacts close at approximately 225 F 107 C If the coolant temperature rises above the switch point the switch contacts close and the engine will shut off to prevent damage The engine will not start until the temperature drops below the switch point An over temperature indicator light at the ground controls should turn on when the switch closes The engine oil pressure switch is a normally closed swit...

Page 88: ...nt temperature switch b oil pressure switch How to Repair the Kubota D1105 and D905 Engines Repair procedures and additional engine information are available in the Kubota D1105 Operator s Manual Kubota part number 16622 89166 OR the Kubota D905 Operator s Manual Kubota part number 16622 8916 5 OR the Kubota D1105 Workshop Manual Kubota part number 9Y111 00123 Kubota D905 Workshop Manual Kubota pa...

Page 89: ...a dealer 5 2 Carburetor Adjustment Gasoline LPG Models Note The carburetor cannot be adjusted The carburetor mixture screws are factory sealed with tamper resistant caps installed by the manufacturer If service or repair is needed contact your local Kubota dealer 5 3 Choke Adjustment Gasoline LPG Models The choke is solenoid operated and functions only in the gasoline mode The choke will not opera...

Page 90: ... on the carburetor clockwise to increase rpm or counterclockwise to decrease rpm a solenoid boot b threaded rod c yoke locknut d yoke 4 Move the engine idle control switch to high idle rabbit symbol from the ground controls 5 Hold the start toggle switch to the start position and check the engine RPM on the diagnostic display Refer to Section 2 Specifications 6 To correct the high idle speed loose...

Page 91: ...e ground controls 5 Hold the start toggle switch to the start position and check the engine RPM on the diagnostic display Refer to Section 2 Specifications 6 To correct the high idle speed loosen the yoke lock nut on the high idle solenoid then turn the high idle adjustment nut and solenoid boot counterclockwise to increase the rpm or clockwise to decrease the rpm Tighten the yoke lock nut and rec...

Page 92: ...ow at the ground controls when either switch closes How to Replace the Coolant Temperature and Oil Pressure Switches 1 Open the engine side cover and pull up on the lock pin on the engine pivot tray located under the radiator Swing the engine pivot tray out and away from the machine to access both switches 2 Coolant temperature switch Tag and disconnect the wiring from the switch located at the en...

Page 93: ...s Handbook Perkins part number SEBU8311 01 OR the Perkins 403D 11 Workshop Manual Perkins part number KENR6942 OR the Perkins 403C 11 User s Handbook Perkins part number 100816460 OR the Perkins 403C 11 Workshop Manual Perkins part number TPD1458 Perkins 403D 11 Operator s Manual Genie part number 131661 Perkins 403D 11 Workshop Manual Genie part number 131662 Perkins 403C 11 Operator s Manual Gen...

Page 94: ...cause the machine to tip over resulting in death or serious injury Tip over hazard This procedure must only be performed by a trained service professional Attempting this procedure without the necessary skills will result in death or serious injury How to Determine the Revision Level 1 Turn the key switch to ground controls and pull out the red Emergency Stop buttons to the on position at both pla...

Page 95: ...ng in the diagnostic display window 7 Press the lift function enable button 8 Press the yellow platform down button to decrease the drive speed or press the blue platform up button to increase the drive speed Refer to Section 2 Specifications a diagnostic display b blue platform up button c lift function enable button d yellow platform down button 9 Press the lift function enable button Result TUN...

Page 96: ...ll to max fwd high torque drive Result MAX FWD HIGH TORQUE DRIVE is showing in the diagnostic display window 7 Press the lift function enable button 8 Press the yellow platform down button to decrease the drive speed or press the blue platform up button to increase the drive speed Refer to Section 2 Specifications a diagnostic display b blue platform up button c lift function enable button d yello...

Page 97: ...ng in the diagnostic display window 7 Press the lift function enable button 8 Press the yellow platform down button to decrease the drive speed or press the blue platform up button to increase the drive speed Refer to Section 2 Specifications a diagnostic display b blue platform up button c lift function enable button d yellow platform down button 9 Press the lift function enable button Result TUN...

Page 98: ...ndow The ECM is now in programming mode 5 Press the lift function enable button 6 Use the yellow platform down arrow to scroll to lift speed Result MAX LIFT SPEED is showing in the diagnostic display window 7 Press the lift function enable button a diagnostic display b blue platform up button c lift function enable button d yellow platform down button 8 Press the yellow platform down button to dec...

Page 99: ...ndow a diagnostic display b blue platform up button c lift function enable button d yellow platform down button Machine Option Definitions Descent Delay This option halts descent at approximately 12 feet 3 6 m All controls must be released for 4 to 6 seconds before descent is re enabled Required for Europe Lift Drive Cut Out Lift and drive functions are disabled when the down limit switch is activ...

Page 100: ... the diagnostic display window 9 Press the lift function enable button to activate or deactivate the motion beacon option Note For this option to function correctly the machine must be equipped with flashing beacons 10 Models with platform overload option Use the yellow platform down arrow to scroll to overload Result OVERLOAD ON is showing in the diagnostic display window Result OVERLOAD OFF is s...

Page 101: ... lift function enable button to activate or deactivate the beacons option Note For this option to function the machine must be equipped with flashing beacons GROUND CONTROLS 16 Use the yellow platform down arrow to scroll to generator option Result GENERATOR OFF is showing in the diagnostic display window Press the lift function enable button to activate or deactivate the generator option Note For...

Page 102: ...dels the descent delay option should be activated or in the ON position 6 Models with software revisions F0 E0 D0 and lower Use the yellow platform down arrow to scroll to lift drive cutout Result LFT DRV CUTOUT ON is showing in the diagnostic display window Result LFT DRV CUTOUT OFF is showing in the diagnostic display window Press the lift function enable button to activate the lift drive cutout...

Page 103: ... to step 12 Models with software revisions F0 and higher proceed to step 15 GROUND CONTROLS 12 Use the yellow platform down arrow to scroll to beacons option Result BEACONS AUTO is showing in the diagnostic display window Press the lift function enable button to activate or deactivate the beacons option Note For this option to function the machine must be equipped with flashing beacons and the sof...

Page 104: ...ption to function correctly the machine must be equipped with the required generator components 17 Use the yellow platform down arrow to scroll to outriggers option Result OUTRIGGERS OFF is showing in the diagnostic display window Press the lift function enable button to activate or deactivate the outrigger option Note For this option to function correctly the machine must be equipped with the req...

Page 105: ...a firm level surface that is free of obstructions Use a digital level to confirm 1 Remove the platform controls from the platform If you are not installing a new level sensor proceed to step 13 2 Raise the platform approximately 10 feet 3 m 3 Lift the safety arm move to the center of the scissor arm and rotate to a vertical position GROUND CONTROLS 4 Lower the platform onto the safety arm Crushing...

Page 106: ...ith the Y on the level sensor base closest to the steer end of the machine Failure to install the tilt level sensor as instructed will cause the machine to tip over resulting in death or serious injury 9 Connect the wire harness to the level sensor 10 Turn the key switch to platform control and pull out the red Emergency Stop buttons to the on position at both the ground and platform controls 11 T...

Page 107: ... under both wheels at the ground controls side of the machine Models with non marking tires Place a 2 25 x 10 x 10 inch 5 72 x 25 x 25 cm thick steel block under both wheels at the ground controls side of the machine 27 Lower the machine onto the blocks GROUND CONTROLS 28 Raise the platform at least 12 feet 3 6 m Result The drive function and the lift function will not operate and the tilt alarm w...

Page 108: ... tilt alarm sounds when the incline of the chassis exceeds 2 to the side When the outriggers are deployed the tilt alarm sounds when the incline of the chassis exceeds 0 8 to the side At all times the tilt alarm sounds when the incline of the chassis exceeds 3 to the front or rear How to Install and Calibrate the Level Sensor Tip over hazard Failure to install or calibrate the level sensor as inst...

Page 109: ...the negative lead of the multimeter to the black wire at the level sensor 13 Without disconnecting the wire harness from the level sensor connect the positive lead of the multimeter to the yellow wire at the level sensor 14 Adjust the Y axis side to side to 2 5V DC Tap the top of the level sensor lightly with fingers after each turn of an adjusting nut Tip over hazard Do not adjust the potentiomet...

Page 110: ...inches 15 cm 25 Models with RT tires Place a 2 15 x 10 x 10 inch 5 46 x 25 x 25 cm thick steel block under both wheels at the ground controls side of the machine All other models Place a 2 25 x 10 x 10 inch 5 72 x 25 x 25 cm thick steel block under both wheels at the ground controls side of the machine 26 Lower the machine onto the blocks 27 Pull out the red Emergency Stop button to the on positio...

Page 111: ...s not sound The level sensor must be replaced Repeat this procedure beginning with step 2 Note For reference only the output of the level sensor should be approximately 1 5V DC To confirm connect the positive lead of a multimeter to the blue wire at the level sensor and the negative lead to the black wire 46 Lower the platform to the stowed position 47 Raise the machine slightly 48 Remove the bloc...

Page 112: ... connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 2 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the high pressure port on each section of the pump 3 Gasoline LPG models Disconnect the ignition coil wire from the center of the ignition coil Diesel models Hold the manual fuel shutoff lever clockwise in the closed position 4 Turn ...

Page 113: ...hutoff valves in the closed position or component damage will occur 1 Connect a 0 to 600 psi 0 to 50 bar pressure gauge to either diagnostic test port on the function manifold 2 Turn the key switch to ground controls and pull out the red Emergency Stop buttons to the on position at both the ground and platform controls 3 Gasoline LPG models Close the valve on the LPG tank then disconnect the hose ...

Page 114: ... 30 ft lbs 34 41 Nm 5 Solenoid valve 3 position 4 way FE Controls flow to the non steer end drive motors in forward and reverse 25 30 ft lbs 34 41 Nm 6 Solenoid valve 3 position 4 way FF Steer left right 25 30 ft lbs 34 41 Nm 7 Check valve FG Proportional circuit 25 30 ft lbs 34 41 Nm 8 Check valve FH Proportional circuit 25 30 ft lbs 34 41 Nm 9 Orifice plug 0 030 in 0 76 mm FI Balances flow from ...

Page 115: ...10 14 13 12 9 2 3 16 FA FB FC FD FE FF FG FH F I FJ FK FL FM FN FO FP FQ FR FS FT FU FV FW FX FY FZ FAA FAB FAC FAD FAE FD Y1A Y5 Y6 Y3 Y4 Y9 Y2 Y8 Y6A Y5A Y1 Y1 1 Y1A Y6 Y5 Y4 Y3 Y9 Y8 Y2 Y5A Y6A Y1B Note alpha callouts refer to corresponding notes on the hydraulic schematic Note alphanumeric callouts refer to corresponding notes on the electrical schematic ...

Page 116: ...up 25 30 ft lbs 34 41 Nm 21 Proportional solenoid valve N O FU Drive lift circuit 25 30 ft lbs 34 41 Nm 22 Relief valve 2800 psi 193 bar FV Steer left right 25 30 ft lbs 34 41 Nm 23 Counterbalance valve 1000 psi 68 9 bar FW Improves braking performance 30 35 ft lbs 41 47 Nm 24 Diagnostic nipple Test port 2 FX Testing 25 Relief valve 3000 psi 207 bar FY Relief valve for number two section of pump 1...

Page 117: ...10 14 13 12 9 2 3 16 FA FB FC FD FE FF FG FH F I FJ FK FL FM FN FO FP FQ FR FS FT FU FV FW FX FY FZ FAA FAB FAC FAD FAE FD Y1A Y5 Y6 Y3 Y4 Y9 Y2 Y8 Y6A Y5A Y1 Y1 1 Y1A Y6 Y5 Y4 Y3 Y9 Y8 Y2 Y5A Y6A Y1B Note alpha callouts refer to corresponding notes on the hydraulic schematic Note alphanumeric callouts refer to corresponding notes on the electrical schematic ...

Page 118: ...orque button BN6 5 Move the joystick full stroke in the forward direction Note the pressure readings on both pressure gauges Refer to Section 2 Specifications 6 Turn the engine off Use a wrench to hold the P2 system relief valve item FY or P1 system relief valve item FAC and remove the cap MANIFOLDS a P1 system relief valve b test port 1 c test port 2 d P2 system relief valve a FAA b FAC FX d c FY...

Page 119: ...mb rocker switch in the right direction Allow the wheels to completely turn to the right then continue holding the switch while observing the pressure reading on the pressure gauge Note the pressure Refer to Section 2 Specifications 5 Turn the engine off Use a wrench to hold the steer relief valve and remove the cap item FV 6 Adjust the internal hex socket Turn it clockwise to increase the pressur...

Page 120: ...unction enable button and move the platform up down toggle switch in the up direction Allow the platform to raise completely then continue activating the lift function while observing the pressure reading on the pressure gauge Note the pressure Refer to Section 2 Specifications 6 Turn the engine off Hold the lift relief valve with a wrench and remove the cap item FS 7 Adjust the internal hex socke...

Page 121: ...e 1 Relief valve 2000 psi 137 8 bar BA Outrigger circuit 20 ft lbs 27 1 Nm 2 Solenoid valve 2 position 2 way BB Outrigger slow extend 25 ft lbs 34 Nm 3 Orifice plug 0 063 inch 1 6 mm BC Outrigger retract 4 Solenoid valve 3 position 4 way BD Outrigger extend retract 25 ft lbs 34 Nm BA BB BD Y44 Y40 Y39 3 4 1 2 BC Note alpha callouts refer to corresponding notes on the hydraulic schematic Note alpha...

Page 122: ...he platform controls to the quick disconnect plug above the hydraulic tank 4 Turn the key switch to platform control and pull out the red Emergency Stop buttons to the ON position at both the ground and platform controls 5 Start the engine and raise the platform approximately 10 feet 3 m 6 Lift the safety arm move to the center of the scissor arm and rotate down to a vertical position 7 Lower the ...

Page 123: ... tee from the manifold and install the outrigger manifold supply line into the outrigger manifold Torque to specification Refer to Section 2 Specifications 17 Raise the platform and return the safety arm to the stowed position 18 Lower the platform the stowed position and turn the machine off 19 Disconnect the platform controls from the quick disconnect plug above the hydraulic tank and connect th...

Page 124: ...tion Item Function Torque 1 Solenoid valve 2 position 3 way DA Generator on off 25 ft lbs 34 Nm 2 Flow regulator 4 3 gpm 16 3 L min DB Generator speed 20 ft lbs 27 1 Nm 3 Relief valve 3000 psi 206 8 bar DC Generator circuit 20 ft lbs 27 1 Nm 1 2 3 DC Y29 DA DB Note alpha callouts refer to corresponding notes on the hydraulic schematic Note alphanumeric callouts refer to corresponding notes on the ...

Page 125: ...n electrical tool which does not draw more than 15A to the electrical outlet at the platform controls and run the tool at full speed 5 Connect the positive and negative leads from a multimeter of sufficient capacity to the electrical outlet at the generator Result The reading on the multimeter should be 112V to 118V AC Result If the reading on the multimeter is not 112V to 118V AC proceed to step ...

Page 126: ...esistance using a multimeter set to resistance Ω Refer to the Valve Coil Resistance Specification table Result If the resistance is not within the adjusted specification plus or minus 10 replace the coil Valve Coil Resistance Specification Note The following coil resistance specifications are at an ambient temperature of 68 F 20 C As valve coil resistance is sensitive to changes in air temperature...

Page 127: ... or more when measured across the terminals Resistor 10 Genie part number 27287 3 Set a multimeter to read DC current Note The multimeter when set to read DC current should be capable of reading up to 800 mA a multimeter b 9V DC battery c 10 resistor d coil Note Dotted lines in illustration indicate a reversed connection as specified in step 6 9V BATTERY 10 RESISTOR W MULTI METER COIL d b b a c c ...

Page 128: ... from the tank 2 Using an approved hand operated pump drain the fuel tank into a suitable container See capacity specifications Note Be sure to only use a hand operated pump suitable for use with gasoline and or diesel fuel 3 Models with fuel shutoff valves Close the fuel tank shutoff valves 4 Tag disconnect and plug the fuel supply and return hoses from the fuel tank 5 Clean up any fuel that may ...

Page 129: ...r the platform onto the safety arm Crushing hazard Keep hands clear of the safety arm when lowering the platform 4 Remove the hose cover plate mounting fasteners Remove the cover 5 Close the two hydraulic shutoff valves located at the hydraulic tank Component damage hazard The engine must not be started with the hydraulic tank shutoff valves in the closed position or component damage will occur If...

Page 130: ...g bolts Remove the tire and wheel assembly 5 Tag disconnect and plug the hoses from the drive motor Cap the fittings on the drive motor Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 6 Support and secure the yoke and drive motor assembly to a liftin...

Page 131: ...tion Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Loosen the wheel lug bolts Do not remove them 2 Block the non steer end wheels and center a lifting jack under the steer end of the machine 3 Raise the machine approximately 2 inches 5 cm Place blocks under the chassis for support Crushing hazard The chassis will fall if not properly supported 4 Remove the wheel lug bolts...

Page 132: ...n 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 2 Remove the pin retaining fasteners from the barrel end pivot pin Use a soft metal drift to remove the pivot pin 3 Remove the pin retaining fasteners from the rod end pivot pin Use a sof...

Page 133: ...fting jack under the drive chassis at the non steer end of the machine 2 Loosen the wheel lug bolts Do not remove them 3 Raise the machine approximately 2 inches 5 cm and place blocks under the drive chassis for support 4 Remove the wheel lug bolts Remove the tire and wheel assembly 5 Tag disconnect and plug the hydraulic hoses from the drive motor and brake Cap the fittings on the drive motor and...

Page 134: ...connect the wiring from the outrigger cylinder solenoid valve 5 Tag disconnect and plug the hydraulic hoses from the outrigger cylinder Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 6 Attach a lifting strap from an ...

Page 135: ...ted at the non steer end of the chassis on the ground controls side of the machine Index Schematic No Description Item Function Torque 1 Hand pump AG Manual brake release 30 ft lbs 41 Nm 2 Needle valve AH Manual brake release enable 45 50 in lbs 5 Nm Brake Release Hand Pump Components Note alpha callouts refer to corresponding notes on the hydraulic schematic AG AH 3 4 ...

Page 136: ...c tank 5 Tag and disconnect the platform controls wire harness from the ECM wire harness 6 Securely connect the platform controls to the ECM wire harness 7 Using a suitable lifting device place a test weight corresponding to the maximum load as indicated on the capacity indicator decal in the center of the platform floor Secure the weight to the platform Refer to the chart below GS 2668 975 kg GS ...

Page 137: ... position indicator corresponds to the maximum load position of the capacity indicator decal Tip over hazard Raising the platform with maximum load above the maximum load position as shown on the capacity indicator decal on the side of the platform could result in the machine tipping over resulting in death or serious injury Do not raise the platform above the maximum load position of the capacity...

Page 138: ...ure beginning with step 17 Note The red Emergency Stop button must be cycled after each quarter turn of the nut to allow the platform overload system to reset Note Wait a minimum of 3 seconds between each quarter turn of the nut to allow the platform overload system to reset 20 Return the safety arm to the stowed position Lower the platform to the stowed position Note After returning the safety ar...

Page 139: ...Do not over tighten 28 Use the auxiliary down function to lower the platform approximately 15 cm 29 Start the engine and fully raise the platform Result The engine continues to run Proceed to step 30 Result An alarm sounds and the engine stops running Repeat this procedure beginning with step 24 30 Lower the platform to approximately 4 m 31 Return the safety arm to the stowed position Disable the ...

Page 140: ...atform to approximately 4 m 43 Rotate the safety arm away from the machine and let it hang down 44 Loosen the fasteners securing the load sense delay limit switch just enough to allow movement of the limit switch 45 Move the roller head of the load sense delay limit switch 1 mm upwards Tighten the fasteners Do not over tighten 46 Return the safety arm to the stowed position 47 Raise the platform a...

Page 141: ...on at the ground controls 56 Pull out the red Emergency Stop button to the on position at the ground controls Calibrate the down limit switch 57 Turn the key switch to platform control Start the engine 58 Raise the platform approximately 1 m 59 Lower the platform until the down limit switch activates and the platform stops lowering Quickly release the controls and then immediately attempt to lower...

Page 142: ...78 Calibrate the lift relief valve See 9 2 How to Adjust the Lift Relief Valve CONDITION POSSIBLE CAUSE SOLUTION CANNOT LIFT RATED LOAD RELIEF VALVE SET TOO LOW INCREASE RELIEF VALVE PRESSURE AT MAXIMUM HEIGHT WITH RATED LOAD IN PLATFORM THE PRESSURE SWITCH ALARM CONTINUES TO SOUND SYSTEM NEEDS TO BE RESET TURN OFF RED EMERGENCY STOP BUTTON WAIT THREE SECONDS AND TURN BACK ON MAXIMUM HEIGHT LIMIT ...

Page 143: ...lry 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 Observe and Obey Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service a damaged or malfunc...

Page 144: ...eter pressure gauges Malfunction discovered Identify symptoms Troubleshoot Perform repair Return to service problem solved problem still exists Inspect and test LED Diagnostic Readout FAULT CODES The diagnostic readout displays numerical codes that provide information about the machine operating status and about malfunctions The dot to the right of the numbers remain on when a fault code is displa...

Page 145: ...T Red Right turn switch fault Malfunctioning steer right microswitch Troubleshoot steer right microswitch 27 DRIVE ENABLE SW FLT Red Function enable switch on joystick is activated when machine is turned on Machine functions disabled Release function enable switch on joystick before power up OR replace joystick 28 OFF NEUTRAL DRIVE JOYSTICK Red Drive joystick off neutral when machine is turned on ...

Page 146: ...eed drive function will not operate Troubleshoot coil OR wiring 51 DRIVE COIL 3 FAULT Red Drive coil 3 Y1B fault High speed drive function will not operate Troubleshoot coil OR wiring 52 FUNC PROP COIL FAULT Red Proportional coil Y9 fault Lift and outrigger functions are disabled Troubleshoot coil OR wiring 54 UP COIL FAULT Red Up coil Y8 fault Platform will not raise Troubleshoot coil OR wiring 5...

Page 147: ...ft front outrigger disabled Troubleshoot coil OR wiring 81 LEFT REAR OTRG COIL FLT Red Left rear outrigger coil Y33 fault Left rear outrigger disabled Troubleshoot coil OR wiring 82 RIGHT FRONT OTRG COIL FLT Red Right front outrigger coil Y36 fault Right front outrigger disabled Troubleshoot coil OR wiring 83 RIGHT REAR OTRG COIL FLT Red Right rear outrigger coil Y34 fault Right rear outrigger dis...

Page 148: ...Section 5 Fault Codes June 2007 5 6 GS 2668 RT GS 3268 RT Part No 112657 This page intentionally left blank ...

Page 149: ...y 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 burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Hydraulic Schematics Bodily injury hazard ...

Page 150: ... Electronic Control Module Layout from serial number GS6805 44771 Engine Down limit switch Flashing beacons Platform controls To outriggers Electronic Control Module Generator Outriggers and manifold Function manifold Level sensor Horn Ground controls and ECM J2 J1 00009 9 STOP ...

Page 151: ...ght front outrigger limit switch LS13 input Right rear outrigger limit switch LS12 input Left front outrigger limit switch LS12 input Left rear outrigger limit switch LS14 input Alternator input Engine oil pressure SW2 input Engine water temp SW1 OR oil temp SW3 input Plug Fuel coil output Plug GS 68 GS 68 GS 68 GS 68 GS 68 J2 Connector 36 pin A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 B1 B2 B3 B4 B5 ...

Page 152: ...2 J1 5 1 4 1 1 14 1 6 1 2 NC P2 EMERGENCY STOP H1 ALARM JC1 JOYSTICK CONTROLLER U3 PLATFORM CONTROLS CIRCUIT BOARD OR WH WH BL PP GY BN YL WH RD BK BL OR RD BK BK YL BL RD RD BK BL GY TS20 TS21 OR COIL CORD ASSEMBLY TS20 PLATFORM UP DOWN TOGGLE SWITCH MODELS WITHOUT OUTRIGGERS TS21 PLATFORM UP DOWN OUTRIGGER UP DOWN TOGGLE SWITCH MODELS WITH OUTRIGGERS ...

Page 153: ...Section 6 Schematics June 2007 Part No 112657 GS 2668 RT GS 3268 RT 6 5 This page intentionally left blank ...

Page 154: ...Driving lights L41 Coolant temperature L42 Oil pressure Limit switch LS LS1 Extension deck LS5 Platform up LS6 Platform down LS12 Left front outrigger LS13 Right front outrigger LS14 Left rear outrigger LS15 Right rear outrigger Motor or pump M M1 Hydraulic oil cooling fan M3 Engine starter ELECTRICAL SCHEMATIC LEGEND Item Description N Note N C Normally closed N O Normally open Power P P1 Emergen...

Page 155: ... breaker LED 12V DC Battery Key switch Control relay Button Pressure switch Temperature switch Capacitor Limit switch Work lights Solenoid valve with spike supression diode Solenoid valve no diode Solenoid valve with redundant coils Electro mechanical solenoid Alternator Ignition coil Distributor Motor or pump Spark plugs Glow plug s Starter motor DIP switch Hour meter Level sensor models without ...

Page 156: ...DLE Q3 HIGH IDLE SOLENOID LS6 PLAT DOWN LIMIT SWITCH J2 A2 N C L30 WORK LIGHTS OPTION BAT STA G6 ENGINE HOURMETER Y8 PLATFORM UP Y7 PLATFORM DOWN J1 A3 Y7 Y10 AUX PLATFORM DOWN Y7A PLATFORM DOWN GS 3268 ONLY Y10A AUX PLATFORM DOWN GS 3268 ONLY Y10 Y7A Y10A U5 ECM ES7161F J1 A9 J2 C12 Y8 U20 SPARK PLUG S U26 DISTRIBUTOR U19 IGNITION COIL G U26 U19 Q7 CHOKE SOLENOID AB3 AB4 L30 WORK LIGHTS AB1 85 86...

Page 157: ...UTRIGGERS S7 LEVEL SENSOR J2 B2 J2 A6 J2 B10 AB29 AB1 AB23 CR17 SW4 M1 N O F9A 20A 85 86 30 87 HYDRAULIC OIL COOLER OPTION BATTERY BATTERY CR8 TERMINAL 30 AB2 AB11 AB22 S7 LEVEL SENSOR ECM GROUND J2 C7 Y2 J1 A4 Y4 STEER LEFT Y2 BRAKE RELEASE Y3 STEER RIGHT J1 A2 Y3 Y4 J1 A10 J1 A11 Y1 J1 A12 Y1B J1 A1 Y1A J1 A5 Y5 Y6 J1 A7 J1 A8 Y6A J1 B3 Y9 J1 A6 Y5A Y6 DRIVE FORWARD 1 Y6A DRIVE FORWARD 2 Y5 DRIV...

Page 158: ...2 PIN7 J2 PIN4 J2 PIN5 BK RD OR PP WH BN HALL EFFECT GENERATOR GY J2 PIN1 J2 PIN12 J2 PIN13 YL J2 PIN2 J2 PIN3 BL WH BL J2 PIN8 H1 ALARM J3 PIN2 J3 PIN1 RD BK POUT1 PIN14 HORN BN5 ENGINE START BN2 PIN2 PIN3 PIN4 STARTING AID BN3 ORGR AUTOLEVEL ENABLE BN20 PIN7 LPG SELECT BN14 PIN6 GENERATOR BN7 PIN9 LF OUTRIGGER ENABLE BN85 PIN8 HIGH IDLE BN4 PIN11 LR OUTRIGGER ENABLE BN87 PIN10 RF OUTRIGGER ENABL...

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Page 160: ...9 Q7 CHOKE SOLENOID AB1 AB4 AB28 AB1 J2 B9 Q3 HIGH IDLE SOLENOID CR4 HIGH IDLE Q3 HIGH IDLE SOLENOID C5 4700 uF L30 WORK LIGHTS L30 WORK LIGHTS OPTION G6 ENGINE HOURMETER J1 A9 J1 A3 Y8 PLATFORM UP Y8 Y7 PLATFORM DOWN LS25 LOAD SENSE DELAY LIMIT SW N C CR77 DOWN ENABLE 87A 85 86 30 87 9 LS24 MAXIMUM HEIGHT LIMIT SW N C Y7 Y10 AUX PLATFORM DOWN Y7A PLATFORM DOWN GS 3268 ONLY Y10A AUX PLATFORM DOWN ...

Page 161: ...RELEASE Y3 STEER RIGHT J1 A2 Y3 Y4 J1 A10 J1 A11 Y1 J1 A12 Y1B J1 A1 Y1A J1 A5 Y5 Y6 J1 A7 J1 A8 Y6A J1 B3 Y9 J1 A6 Y5A Y6 DRIVE FORWARD 1 Y6A DRIVE FORWARD 2 Y5 DRIVE REVERSE 1 Y5A DRIVE REVERSE 2 Y9 PROPORTIONAL FLOW CONTROL ES7183G BK RD WH N C LEVEL SENSOR CIRCUIT BOARD MODELS WITHOUT OUTRIGGERS S7 LEVEL SENSOR J2 B2 J2 A6 J2 B10 AB29 AB1 AB23 CR17 SW4 M1 N O F9A 20A 85 86 30 87 HYDRAULIC OIL ...

Page 162: ... PIN7 J2 PIN4 J2 PIN5 BK RD OR PP WH BN HALL EFFECT GENERATOR GY J2 PIN1 J2 PIN12 J2 PIN13 YL J2 PIN2 J2 PIN3 BL WH BL J2 PIN8 H1 ALARM J3 PIN2 J3 PIN1 RD BK POUT1 PIN14 HORN BN5 ENGINE START BN2 PIN2 PIN3 PIN4 STARTING AID BN3 ORGR AUTOLEVEL ENABLE BN20 PIN7 LPG SELECT BN14 PIN6 GENERATOR BN7 PIN9 LF OUTRIGGER ENABLE BN85 PIN8 HIGH IDLE BN4 PIN11 LR OUTRIGGER ENABLE BN87 PIN10 RF OUTRIGGER ENABLE...

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Page 164: ...23 AUXILIARY DOWN J2 A4 J2 C4 J2 B9 J1 C7 J2 C1 C3 J2 A3 BN23 AUXILIARY DOWN BN91 AUXILIARY DOWN ENABLE J2 A5 LS6 PLAT DOWN LIMIT SWITCH J2 A2 N C PULL HOLD 30A F9 KUBOTA DIESEL ONLY BAT STA G6 ENGINE HOURMETER Y8 PLATFORM UP Y8 Y7 PLATFORM DOWN J1 A3 Y7 Y10 AUX PLATFORM DOWN Y7A PLATFORM DOWN GS 3268 ONLY Y10A AUX PLATFORM DOWN GS 3268 ONLY Y10 Y7A Y10A U5 ECM J1 A9 J2 C12 AB3 AB1 AB1 AB3 AB3 AB7...

Page 165: ...BK RD WH N C LEVEL SENSOR CIRCUIT BOARD MODELS WITHOUT OUTRIGGERS S7 LEVEL SENSOR J2 B2 J2 A6 J2 B10 AB29 AB1 AB23 CR17 SW4 M1 N O F9A 20A 85 86 30 87 HYDRAULIC OIL COOLER OPTION BATTERY BATTERY CR8 TERMINAL 30 AB2 AB11 AB22 Y29 GENERATOR OPTION J1 B1 ECM GROUND J2 C7 Y1B J1 A4 Y4 STEER LEFT Y1 DRIVE HIGH SPEED 10A Y2 BRAKE RELEASE Y3 STEER RIGHT J1 A2 Y3 Y4 J1 A10 Y1 J1 A12 Y1A J1 A1 Y1 1 J1 A5 Y...

Page 166: ...IN7 J2 PIN4 J2 PIN5 BK RD OR PP WH BN HALL EFFECT GENERATOR GY J2 PIN1 J2 PIN12 J2 PIN13 YL J2 PIN2 J2 PIN3 BL WH BL J2 PIN8 H1 ALARM J3 PIN2 J3 PIN1 RD BK POUT1 PIN14 HORN BN5 ENGINE START BN2 PIN2 PIN3 PIN4 STARTING AID BN3 ORGR AUTOLEVEL ENABLE BN20 PIN7 LPG SELECT BN14 PIN6 GENERATOR BN7 PIN9 LF OUTRIGGER ENABLE BN85 PIN8 HIGH IDLE BN4 PIN11 LR OUTRIGGER ENABLE BN87 PIN10 RF OUTRIGGER ENABLE B...

Page 167: ...Section 6 Schematics June 2007 Part No 112657 GS 2668 RT GS 3268 RT 6 19 This page intentionally left blank ...

Page 168: ...H J2 A2 N C PULL HOLD 30A F9 KUBOTA DIESEL ONLY BAT STA G6 ENGINE HOURMETER Y8 PLATFORM UP Y8 Y7 PLATFORM DOWN J1 A3 Y7 Y10 AUX PLATFORM DOWN Y7A PLATFORM DOWN GS 3268 ONLY Y10A AUX PLATFORM DOWN GS 3268 ONLY Y10 Y7A Y10A U5 ECM J1 A9 J2 C12 AB3 AB1 AB1 AB3 AB3 AB7 Q3 HIGH IDLE SOLENOID CR4 HIGH IDLE Q3 HIGH IDLE SOLENOID L30 WORK LIGHTS L30 WORK LIGHTS OPTION C5 4700 uF P1EMERGENCY STOP F9 5A FUS...

Page 169: ... N C LEVEL SENSOR CIRCUIT BOARD MODELS WITHOUT OUTRIGGERS S7 LEVEL SENSOR J2 B2 J2 A6 J2 B10 AB29 AB1 AB23 CR17 SW4 M1 N O F9A 20A 85 86 30 87 HYDRAULIC OIL COOLER OPTION BATTERY BATTERY CR8 TERMINAL 30 AB2 AB11 AB22 Y29 GENERATOR OPTION J1 B1 ECM GROUND J2 C7 Y1B J1 A4 Y4 STEER LEFT Y2 BRAKE RELEASE Y3 STEER RIGHT J1 A2 Y3 Y4 J1 A10 Y1 J1 A12 Y1A J1 A1 Y1 1 J1 A5 Y6 Y2 J1 A7 J1 A8 Y5 Y5A J1 A6 Y6...

Page 170: ...IN4 J2 PIN5 BK RD OR PP WH BN HALL EFFECT GENERATOR GY J2 PIN1 J2 PIN12 J2 PIN13 YL J2 PIN2 J2 PIN3 BL WH BL J2 PIN8 H1 ALARM J3 PIN2 J3 PIN1 RD BK POUT1 PIN14 HORN BN5 ENGINE START BN2 PIN2 PIN3 PIN4 STARTING AID BN3 ORGR AUTOLEVEL ENABLE BN20 PIN7 LPG SELECT BN14 PIN6 GENERATOR BN7 PIN9 LF OUTRIGGER ENABLE BN85 PIN8 HIGH IDLE BN4 PIN11 LR OUTRIGGER ENABLE BN87 PIN10 RF OUTRIGGER ENABLE BN86 PIN1...

Page 171: ...Section 6 Schematics June 2007 Part No 112657 GS 2668 RT GS 3268 RT 6 23 This page intentionally left blank ...

Page 172: ...A5 C5 4700 uF LS6 PLAT DOWN LIMIT SWITCH J2 A2 N C PULL HOLD 30A F9 KUBOTA DIESEL ONLY BAT STA G6 ENGINE HOURMETER G6 HOUR METER Y8 PLATFORM UP Y8 Y7 PLATFORM DOWN LS25 LOAD SENSE DELAY LIMIT SW N C J1 A9 CR77 DOWN ENABLE 87A 85 86 30 87 9 LS24 MAXIMUM HEIGHT LIMIT SW N C J1 A3 Y7 Y10 AUX PLATFORM DOWN Y7A PLATFORM DOWN GS 3268 ONLY Y10A AUX PLATFORM DOWN GS 3268 ONLY Y10 Y7A Y10A U5 ECM J2 C12 AB...

Page 173: ...ION J1 B1 S7 LEVEL SENSOR ECM GROUND J2 C7 Y1B J1 A4 Y4 STEER LEFT Y2 BRAKE RELEASE Y3 STEER RIGHT J1 A2 Y3 Y4 J1 A10 Y1 J1 A12 Y1A J1 A1 Y1 1 CR17 SW4 M1 N O F9A 20A 85 86 30 87 HYDRAULIC OIL COOLER OPTION BATTERY BATTERY CR8 TERMINAL 30 J1 A5 Y6 Y2 J1 A7 J1 A8 Y5 Y5A J1 A6 Y6A Y6 DRIVE FORWARD 1 Y6A DRIVE FORWARD 2 Y5 DRIVE REVERSE 1 Y5A DRIVE REVERSE 2 Y29 BK RD WH N C LEVEL SENSOR CIRCUIT BOAR...

Page 174: ...N7 J2 PIN4 J2 PIN5 BK RD OR PP WH BN HALL EFFECT GENERATOR GY J2 PIN1 J2 PIN12 J2 PIN13 YL J2 PIN2 J2 PIN3 BL WH BL J2 PIN8 H1 ALARM J3 PIN2 J3 PIN1 RD BK POUT1 PIN14 HORN BN5 ENGINE START BN2 PIN2 PIN3 PIN4 STARTING AID BN3 ORGR AUTOLEVEL ENABLE BN20 PIN7 LPG SELECT BN14 PIN6 GENERATOR BN7 PIN9 LF OUTRIGGER ENABLE BN85 PIN8 HIGH IDLE BN4 PIN11 LR OUTRIGGER ENABLE BN87 PIN10 RF OUTRIGGER ENABLE BN...

Page 175: ...Section 6 Schematics June 2007 Part No 112657 GS 2668 RT GS 3268 RT 6 27 This page intentionally left blank ...

Page 176: ...ORK LIGHTS OPTION PULL HOLD 30A F9 KUBOTA DIESEL ONLY BAT STA G6 ENGINE HOURMETER G6 HOUR METER Y8 PLATFORM UP Y8 Y7 PLATFORM DOWN LS25 LOAD SENSE DELAY LIMIT SW N C J1 A9 CR77 DOWN ENABLE 87A 85 86 30 87 9 LS24 MAXIMUM HEIGHT LIMIT SW N C J1 A3 Y7 Y10 AUX PLATFORM DOWN Y7A PLATFORM DOWN GS 3268 ONLY Y10A AUX PLATFORM DOWN GS 3268 ONLY Y10 Y7A Y10A U5 ECM J2 C12 AB1 AB1 AB4 AB12 AB28 AB3 85 86 30 ...

Page 177: ...1 S7 LEVEL SENSOR ECM GROUND J2 C7 Y1B J1 A4 Y4 STEER LEFT Y2 BRAKE RELEASE Y3 STEER RIGHT J1 A2 Y3 Y4 J1 A10 Y1 J1 A12 Y1A J1 A1 Y1 1 CR17 SW4 M1 N O F9A 20A 85 86 30 87 HYDRAULIC OIL COOLER OPTION BATTERY BATTERY CR8 TERMINAL 30 J1 A5 Y6 Y2 J1 A7 J1 A8 Y5 Y5A J1 A6 Y6A Y6 DRIVE FORWARD 1 Y6A DRIVE FORWARD 2 Y5 DRIVE REVERSE 1 Y5A DRIVE REVERSE 2 Y29 BK RD WH N C LEVEL SENSOR CIRCUIT BOARD MODELS...

Page 178: ...N4 J2 PIN5 BK RD OR PP WH BN HALL EFFECT GENERATOR GY J2 PIN1 J2 PIN12 J2 PIN13 YL J2 PIN2 J2 PIN3 BL WH BL J2 PIN8 H1 ALARM J3 PIN2 J3 PIN1 RD BK POUT1 PIN14 HORN BN5 ENGINE START BN2 PIN2 PIN3 PIN4 STARTING AID BN3 ORGR AUTOLEVEL ENABLE BN20 PIN7 LPG SELECT BN14 PIN6 GENERATOR BN7 PIN9 LF OUTRIGGER ENABLE BN85 PIN8 HIGH IDLE BN4 PIN11 LR OUTRIGGER ENABLE BN87 PIN10 RF OUTRIGGER ENABLE BN86 PIN13...

Page 179: ...alance valve Solenoid operated 2 position 2 way directional valve Relief valve Solenoid operated 3 position 4 way directional valve Single direction variable speed motor Priority flow regulator Solenoid operated 2 position 3 way directional valve Platform overload pressure switch Pilot operated check valve with needle valve Hand pump Bi directional variable speed motor Brake Solenoid operated 2 po...

Page 180: ...BRAKE AG AH BRAKE RELEASE MANIFOLD MANUAL RELEASE FU FG FH FO FJ FP FX FAA FV FZ FF OPTION GENERATOR FAC 3500 psi 241 3 bar 200 psi 13 8 bar 5 psi 0 3 bar 10 psi 0 7 bar HS0032D RIGHT FRONT OUTRIGGER LEFT FRONT OUTRIGGER Y36 Y35 CB CA OUTRIGGERS OPTION IN OUT 2000 psi 137 8 bar BA IN B OUT B IN R OUT R Y39 Y40 BD 0 063 in 1 6 mm Y44 BB BC Y34 CC Y33 CD RIGHT REAR OUTRIGGER LEFT REAR OUTRIGGER OUTR...

Page 181: ...Section 6 Schematics REV C November 2008 Part No 112657 GS 2668 RT GS 3268 RT 6 33 Hydraulic Schematic from serial number GS6805 44771 Part 2 of 2 ...

Page 182: ...Section 6 Schematics June 2007 6 34 GS 2668 RT GS 3268 RT Part No 112657 This page intentionally left blank ...

Page 183: ...ne 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 1820 Phone 44 0 1476 584333 Fax 44 0 1476 584334 Phone 52 55 5666 5242 Fax 52 55 5666 ...

Page 184: ... from serial number GS6805 44771 Part No 112657 Rev C2 Service Manual GS 2668 RT GS 3268 RT ...

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