Genie GS-2046 Manuale utente

Service Manual Part No. 72972

September 2006

Rev B2

800-610-4101

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Genie GS-2046 and GS-2646 and GS-3246 Part No.72972

June 2003

Introduction

Important

Read, understand and obey the safety rules and

operating instructions in the

Genie GS-2032 and

GS-2632 and GS-2046 and GS-2646 and GS-3246

Operator's Manual

before attempting any

maintenance or repair procedure.

This manual provides detailed scheduled

maintenance information for the machine owner

and user. It also provides troubleshooting and

repair procedures for qualified service

professionals.

Basic mechanical, hydraulic and electrical

skills are required to perform most procedures.

However, several procedures require specialized

skills, tools, lifting equipment and a suitable

workshop. In these instances, we strongly

recommend that maintenance and repair be

performed at an authorized Genie dealer

service center.

Technical Publications

Genie Industries has endeavored to deliver the

highest degree of accuracy possible. However,

continuous improvement of our products is a Genie

policy. Therefore, product specifications

are subject to change without notice.

Readers are encouraged to notify Genie of errors

and send in suggestions for improvement. All

communications will be carefully considered for

future printings of this and all other manuals.

PO Box 97030

Redmond, WA 98073-9730 USA

www.genieindustries.com

e-mail: [email protected]

72972 Rev B June 2003

Second Edition, Second Printing

"Genie" is a registered trademark of Genie

Industries in the USA and many other countries.

"GS" is a trademark of Genie Industries.

Printed on recycled paper

Printed in U.S.A.

Serial Number Information

Genie Industries offers the following Service

Manuals for these models:

Title Part No.

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

Service Manual (before serial number 17408) .... 48339

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Part No. 72972 Genie GS-2046 and GS-2646 and GS-3246

June 2003

iii

Safety Rules

Section 1 • Safety Rules

Danger

Failure to obey the instructions and safety rules

in this manual and the

Genie GS-2032 and

GS-2632 and GS-2046 and GS-2646 and GS-3246

Operator's Manual

will result in death or serious

injury.

Many of the hazards identified in the

operator’s manual are also safety hazards

when maintenance and repair procedures

are performed.

Do Not Perform Maintenance

Unless:

You are trained and qualified to perform

maintenance on this machine.

You read, understand and obey:

- manufacturer’s instructions and safety rules

- employer’s safety rules and worksite

regulations

- applicable governmental regulations

You have the appropriate tools, lifting

equipment and a suitable workshop.

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Genie GS-2046 and GS-2646 and GS-3246 Part No.72972

June 2003

SAFETY RULES

Personal Safety

Any person working on or around a machine must

be aware of all known safety hazards. Personal

safety and the continued safe operation of the

machine should be your top priority.

Read each procedure thoroughly. This

manual and the decals on the machine,

use signal words to identify the following:

Safety alert symbol—used to alert

personnel to potential personal

injury hazards. Obey all safety

messages that follow this symbol

to avoid possible injury or death.

Red—used to indicate the

presence of an imminently

hazardous situation which, if not

avoided, will result in death or

serious injury.

Orange—used to indicate the

presence of a potentially

hazardous situation which, if not

avoided, could result in death or

serious injury.

Yellow with safety alert symbol—

used to indicate the presence of a

potentially hazardous situation

which, if not avoided, may cause

minor or moderate injury.

Yellow without safety alert

symbol—used to indicate the

presence of a potentially

hazardous situation which, if not

avoided, may result in property

damage.

Green—used to indicate operation

or maintenance information.

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 away from flammable and

combustible materials like battery gases

and engine fuels. Always have an approved fire

extinguisher within easy reach.

Be sure that all tools and working areas

are properly maintained and ready for

use. Keep work surfaces clean and free of

debris that could get into machine components and

cause damage.

Be sure any forklift, overhead crane or

other lifting or supporting device is fully

capable of supporting and stabilizing the

weight to be lifted. Use only chains or straps that

are in good condition and of ample capacity.

Be sure that fasteners intended for one

time use (i.e., cotter pins and self-locking

nuts) are not reused. These components

may fail if they are used a second time.

Be sure to properly dispose of old oil or

other fluids. Use an approved container.

Please be environmentally safe .

Be sure that your workshop or work area

is properly ventilated and well lit.

Section 1 • Safety Rules

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Part No. 72972 Genie GS-2046 and GS-2646 and GS-3246

June 2003

Table of Contents

Introduction

Important Information ......................................................................................................

Section One Safety Rules

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

iii

Section Two Specifications - Rev B

Machine Specifications ............................................................................................. 2 - 1

Performance Specifications ...................................................................................... 2 - 2

Hydraulic Specifications ............................................................................................ 2 - 3

Manifold Component Specifications .......................................................................... 2 - 4

Hydraulic Hose and Fitting Torque Specifications ..................................................... 2 - 6

Section Three Scheduled Maintenance Procedures

Introduction ............................................................................................................... 3 - 1

Pre-delivery Preparation Report ................................................................................. 3 - 3

Maintenance Inspection Report ................................................................................. 3 - 5

Checklist A Procedures - Rev B

A-1 Perform Pre-operation Inspection .................................................................... 3 - 6

A-2 Perform Function Tests ................................................................................... 3 - 6

A-3 Perform 30 Day Service .................................................................................. 3 - 7

A-4 Grease the Steer Yokes .................................................................................. 3 - 7

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Genie GS-2046 and GS-2646 and GS-3246 Part No.72972

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TABLE OF CONTENTS

Section Three Maintenance Procedures, continued

Checklist B Procedures - Rev C

B-1 Inspect the Batteries ....................................................................................... 3 - 8

B-2 Inspect the Electrical Wiring ............................................................................ 3 - 9

B-3 Inspect the Tires and Wheels (including castle nut torque) ............................ 3 - 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 Arm Wear Pads ............................................................... 3 - 19

Checklist D Procedure - Rev A

D-1 Test or Replace the Hydraulic Oil .................................................................. 3 - 20

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June 2003

TABLE OF CONTENTS

vii

Section Four Repair Procedures

Introduction ............................................................................................................... 4 - 1

Platform Controls - Rev B

1-1 Circuit Boards .................................................................................................. 4 - 2

1-2 Joystick Controller ........................................................................................... 4 - 3

1-3 Controller Adjustments .................................................................................... 4 - 5

1-4 Software Configuration .................................................................................. 4 - 13

Platform Components - 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 Manual Platform Lowering Cable, GS-2046 and GS-2646 .............................. 4 - 46

4-2 Manual Platform Lowering, GS-3246 .............................................................. 4 - 47

4-3 Toggle Switches ............................................................................................ 4 - 48

4-4 Control Relays ............................................................................................... 4 - 49

4-5 Tilt Level Sensor (before serial number 50444) .............................................. 4 - 50

4-6 Tilt Level Sensor (after serial number 50443) ................................................. 4 - 54

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TABLE OF CONTENTS

viii

Section Four Repair Procedures, continued

Hydraulic Pump - Rev A

5-1 Function Pump .............................................................................................. 4 - 58

Function Manifold - Rev B

6-1 Function Manifold Components

(from serial number 17408 to 17481) .............................................................. 4 - 60

6-2 Function Manifold Components

(from serial number 17482 to 36044) .............................................................. 4 - 62

6-3 Function Manifold Components

(after serial number 36044) ............................................................................ 4 - 64

6-4 Function 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

(before serial number 36045) ......................................................................... 4 - 75

6-7 Valve Adjustments - Lift Relief Manifold, GS-3246 Models

(before serial number 36045) ......................................................................... 4 - 76

6-8 Valve Coils .................................................................................................... 4 - 78

Hydraulic Tank - Rev A

7-1 Hydraulic Tank .............................................................................................. 4 - 80

Steer Axle Components - Rev A

8-1 Yoke and Drive Motor .................................................................................... 4 - 81

8-2 Steer Cylinder ................................................................................................ 4 - 83

8-3 Steer Bellcrank .............................................................................................. 4 - 84

Non-steer Axle Components - Rev A

9-1 Drive Brake ................................................................................................... 4 - 85

Brake Release Hand Pump Components - Rev A

10-1 Brake Release Hand Pump Components ....................................................... 4 - 86

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Part No. 72972 Genie GS-2046 and GS-2646 and GS-3246

June 2003

TABLE OF CONTENTS

Section Five Troubleshooting Flow Charts and Fault Codes

Introduction ............................................................................................................... 5 - 1

Fault Code Chart (after serial number 17407) - Rev A................................................ 5 - 3

Chart

Number Chart Title

1 All Functions Will Not Operate - Rev A ..................................................................... 5 - 4

2 Pump Motor Will Not Operate - Rev A ....................................................................... 5 - 6

3 All Functions Inoperative, Power Unit Starts and Runs - Rev A................................. 5 - 8

4 Ground Controls Inoperative,

Platform Controls Operate Normally - Rev A ............................................................ 5 - 9

5 Platform Controls Inoperative,

Ground Controls Operate Normally - 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 Function Inoperative - Rev A ............................................................ 5 - 21

13 Machine Will Not Drive At Full Speed - Rev A ......................................................... 5 - 22

14 Machine Drives At Full Speed With Platform Raised - Rev A .................................. 5 - 23

15 Limit Switch Function Inoperative - Rev A ............................................................... 5 - 24

16 Fault Code 02 - ECM / Platform Communication Error - Rev A ................................ 5 - 26

17 Fault Code 59 - Parallel/Series Coil Fault - Rev B ................................................... 5 - 29

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Genie GS-2046 and GS-2646 and GS-3246 Part No.72972

June 2003

TABLE OF CONTENTS

Section Six Schematics

Introduction ............................................................................................................... 6 - 1

Control Relay Layout - Rev A .................................................................................... 6 - 2

ECM Pin-out Legend - Rev B .................................................................................... 6 - 4

Platform Controls Wiring Diagram

(from serial number 17408 to 48054) - Rev B ............................................................ 6 - 6

Platform Controls Wiring Diagram

(after serial number 48054) - Rev A ........................................................................... 6 - 7

Ground Controls Wiring Diagram, GS-2046 and GS-2646 - Rev B ............................. 6 - 8

Ground Controls Wiring Diagram, GS-3246 - 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 to 27181) - Rev B .......................................................... 6 - 21

Electrical Schematic

(from serial number 27182 to 28936) - Rev B .......................................................... 6 - 23

Electrical Schematic

(from serial number 28937 to 33721) - Rev B .......................................................... 6 - 25

Electrical Schematic

(from serial number 33722 to 40925) - Rev B .......................................................... 6 - 27

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