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Genie GS-2668 DC GS-3268 DC Service Manual 65248 – PDF DOWNLOAD
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Genie GS-2668 DC GS-3268 DC Service Manual 65248 – PDF DOWNLOAD
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Description
Genie GS-2668 DC GS-3268 DC Service Manual 65248 – PDF DOWNLOAD
Language : English
Pages : 280
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie GS-2668 DC GS-3268 DC Service Manual 65248 – PDF DOWNLOAD
Table of Contents.................................................................................................................... 7 Section One • Safety Rules........................................................................................................... 5 Safety Rules..................................................................................................................... 5 Section Two • Specifications - Rev D................................................................................................. 17 Machine Specifications........................................................................................................... 17 Performance Specifications....................................................................................................... 18 Hydraulic Specifications......................................................................................................... 19 Hydraulic Components Specifications.............................................................................................. 20 Manifold Component Specifications................................................................................................ 21 Valve Coil Resistance Specifications............................................................................................. 21 Hydraulic Hose and Fitting Torque Specifications................................................................................. 22 SAE and Metric Fastener Torque Charts............................................................................................ 24 Section Three • Scheduled Maintenance Procedures..................................................................................... 25 Introduction..................................................................................................................... 25 Pre-delivery Preparation Report.................................................................................................. 27 Maintenance Inspection Report.................................................................................................... 29 Checklist A Procedures - Rev E................................................................................................... 30 A-1 Inspect the Manuals and Decals.......................................................................................... 30 A-2 Perform Pre-operation Inspection........................................................................................ 31 A-3 Perform Function Tests.................................................................................................. 31 A-4 Perform 30 Day Service.................................................................................................. 31 Checklist B Procedures - Rev F................................................................................................... 32 B-1 Inspect the Batteries.................................................................................................... 32 B-2 Inspect the Electrical Wiring............................................................................................ 34 B-3 Inspect the Tires, Wheels and Castle Nut Torque.......................................................................... 35 B-4 Test the Emergency Stop.................................................................................................. 35 B-5 Test the Key Switch...................................................................................................... 36 B-6 Test the Automotive-style Horn (if equipped)............................................................................. 36 B-7 Test the Drive Brakes.................................................................................................... 37 B-8 Test the Drive Speed - Stowed Position................................................................................... 37 B-9 Test the Drive Speed - Raised Position................................................................................... 38 B-10 Check the Module Tray Latch Components................................................................................. 38 B-11 Perform Hydraulic Oil Analysis......................................................................................... 39 Checklist C Procedure - Rev A.................................................................................................... 40 C-1 Test the Platform Overload System (if equipped)......................................................................... 40 Checklist D Procedures - Rev D................................................................................................... 42 D-1 Check the Scissor Arm Wear Pads......................................................................................... 42 D-2 Replace the Hydraulic Tank Return Filter................................................................................ 43 Checklist E Procedures - Rev C................................................................................................... 44 E-1 Test or Replace the Hydraulic Oil....................................................................................... 44 E-2 Grease the Steer Axle Wheel Bearings..................................................................................... 46 Section Four • Repair Procedures..................................................................................................... 49 Introduction..................................................................................................................... 49 Platform Controls - Rev E........................................................................................................ 50 1-1 Circuit Boards........................................................................................................... 50 1-2 Joystick Controller...................................................................................................... 51 1-3 Controller Adjustments................................................................................................... 53 1-4 Software Configuration (before serial number GS6805-44699)............................................................... 61 1-5 Software Configuration (after serial number GS6805-44698)................................................................ 66 1-6 Toggle Switches.......................................................................................................... 70 Platform Components - Rev B...................................................................................................... 71 2-1 Platform................................................................................................................. 71 2-2 Platform Extension....................................................................................................... 72 Scissor Components - Rev B....................................................................................................... 74 3-1 Scissor Assembly, GS-2668 DC............................................................................................. 74 3-2 Scissor Assembly, GS-3268 DC............................................................................................. 82 3-3 Lift Cylinder............................................................................................................ 89 3-4 Platform Overload System (if equipped)................................................................................... 92 Ground Controls - Rev C.......................................................................................................... 97 4-1 Manual Platform Lowering................................................................................................. 97 4-2 Toggle Switches.......................................................................................................... 98 4-3 Control Relays........................................................................................................... 99 4-4 Tilt Level Sensor........................................................................................................100 Hydraulic Pump - Rev B...........................................................................................................107 5-1 Function Pump............................................................................................................107 Function Manifold - Rev C........................................................................................................110 6-1 Function Manifold Components (before serial number 40594)................................................................110 6-2 Function Manifold Components (from serial number 40594 to 41199).........................................................112 6-3 Function Manifold Components (after serial number 41199).................................................................116 6-4 Valve Adjustments - Function Manifold....................................................................................118 6-5 Valve Coils..............................................................................................................124 Hydraulic Tank - Rev B...........................................................................................................126 7-1 Hydraulic Tank...........................................................................................................126 Steer Axle Components - Rev C....................................................................................................128 8-1 Yoke and Drive Motor.....................................................................................................128 8-2 Yoke and Spindle.........................................................................................................131 8-3 Steer Cylinder...........................................................................................................133 8-4 Tie Rod..................................................................................................................134 Non-steer Axle Components - Rev C................................................................................................135 9-1 Brake Motor..............................................................................................................135 9-2 Drive/Brake Motor........................................................................................................136 Brake Release Hand Pump Components - Rev C.......................................................................................137 10-1 Brake Release Hand Pump Components......................................................................................137 Section Five • Troubleshooting Flow Charts and Fault Codes...........................................................................139 Introduction.....................................................................................................................139 Fault Code Chart (before serial number 41200) - Rev C............................................................................141 Fault Code Chart (from serial number 41200 to GS6805-44698) - Rev C..............................................................145 Fault Code Chart (after serial number GS6805-44698) - Rev A......................................................................146 Chart 1 All Functions Will Not Operate (before serial number 41200) - Rev D...................................................147 Chart 1A All Functions Will Not Operate (after serial number 41199) - Rev C.....................................................149 Chart 2 Pump Motor Will Not Operate (before serial number 41200) - Rev D......................................................151 Chart 2A Pump Motor Will Not Operate (after serial number 41199) - Rev C........................................................152 Chart 3 All Functions Inoperative, Power Unit Starts and Runs (before serial number 41200) - Rev D............................154 Chart 3A All Functions Inoperative, Power Unit Starts and Runs (after serial number 41199) - Rev C..............................155 Chart 4 Ground Controls Inoperative, Platform Controls Operate Normally (before serial number 41200) - Rev D..................156 Chart 4A Ground Controls Inoperative, Platform Controls Operate Normally (after serial number 41199) - Rev C....................157 Chart 5 Platform Controls Inoperative, Ground Controls Operate Normally (before serial number 41200) - Rev D..................158 Chart 5A Platform Controls Inoperative, Ground Controls Operate Normally (after serial number 41199) - Rev C....................159 Chart 6 Platform Up Function Inoperative (before serial number 41200) - Rev D.................................................160 Chart 6A Platform Up Function Inoperative (after serial number 41199) - Rev C...................................................161 Chart 7 Platform Down Function Inoperative, GS-2668 DC (before serial number 41200) - Rev D...................................162 Chart 8 Platform Down Function Inoperative, GS-2668 DC (after serial number 41199) and GS-3268 DC (all) - Rev D...............163 Chart 9 Steer Left Function Inoperative (before serial number 41200) - Rev D..................................................165 Chart 9A Steer Left Function Inoperative (after serial number 41199) - Rev C....................................................166 Chart 10 Steer Right Function Inoperative (before serial number 41200) - Rev D................................................168 Chart 10A Steer Right Function Inoperative (after serial number 41199) - Rev C..................................................169 Chart 11 All Drive Functions Inoperative, All Other Functions Operate Normally (before serial number 41200) - Rev D...........171 Chart 11A All Drive Functions Inoperative, All Other Functions Operate Normally (after serial number 41199) - Rev C.............172 Chart 12 Brake Release Function Inoperative (before serial number 41200) - Rev D..............................................173 Chart 12A Brake Release Function Inoperative (after serial number 41199) - Rev C................................................174 Chart 13 Drive Forward Function Inoperative (before serial number 41200) - Rev D..............................................175 Chart 13A Drive Forward Function Inoperative (after serial number 41199) - Rev C................................................176 Chart 14 Drive Reverse Function Inoperative (before serial number 41200) - Rev D..............................................177 Chart 14A Drive Reverse Function Inoperative (after serial number 41199) - Rev C................................................178 Chart 15 Machine Will Not Drive At Full Speed (before serial number 41200) - Rev D............................................179 Chart 15A Machine Will Not Drive At Full Speed (after serial number 41199) - Rev C..............................................180 Chart 16 Machine Drives At Full Speed With Platform Raised (before serial number 41200) - Rev D...............................181 Chart 16A Machine Drives At Full Speed With Platform Raised (after serial number 41199) - Rev C.................................182 Chart 17 Manual Platform Lowering Function Inoperative, GS-2668 DC (before serial number 41200) - Rev C.......................183 Chart 18 Manual Platform Lowering Function Inoperative, GS-2668 DC (after serial number 41199) and GS-3268 DC (all) -Rev D....184 Chart 19 Limit Switch Function Inoperative (after serial number 41199) - Rev C................................................186 Chart 20 Fault Code 02 - ECM / Platform Communication Error (after serial number 41199) - Rev C...............................187 Chart 21 Fault Code 59 - Parallel / Series Coil Fault (after serial number 41199) - Rev C.....................................188 Section Six • Schematics.............................................................................................................189 Introduction.....................................................................................................................189 Electrical.......................................................................................................................190 Electronic Control Module Pin-out (before serial number 41200) - Rev C.......................................................190 Electronic Control Module Pin-out (after serial number 41199) - Rev C........................................................191 Platform Controls Wiring Diagram (before serial number 41200) - Rev D........................................................192 Platform Controls Wiring Diagram (from serial number 41200 to GS6805-44698) - Rev C..........................................193 Platform Controls Wiring Diagram (after serial number GS6805-44698) - Rev A..................................................194 Ground Controls Wiring Diagram (before serial number 21161) - Rev A..........................................................195 Ground Controls Wiring Diagram (from serial number 21161 to 26562) - Rev A...................................................196 Ground Controls Wiring Diagram (from serial number 26563 to 33850) - Rev A...................................................197 Ground Controls Wiring Diagram (from serial number 33851 to 40463) - Rev A...................................................198 Ground Controls Wiring Diagram (from serial number 40464 to 40751) - Rev A...................................................199 Ground Controls Wiring Diagram (from serial number 40752 to 41199) - Rev A...................................................200 Ground Controls Wiring Diagram (from serial number 41200 to 41829) - Rev B...................................................201 Ground Controls Wiring Diagram (from serial number 41830 to GS6805-43529) - Rev B............................................202 Ground Controls Wiring Diagram (after serial number GS6805-43529) - Rev A....................................................203 Electrical Symbols Legend - Rev B............................................................................................204 Electrical Schematic (from serial number 101 to 21516) - Rev C...............................................................206 Electrical Schematic (from serial number 21517 to 21570) - Rev B.............................................................210 Electrical Schematic (from serial number 21571 to 26562) - Rev B.............................................................214 Electrical Schematic (from serial number 26563 to 28475) - Rev B.............................................................218 Electrical Schematic (from serial number 28476 to 33850) - Rev B.............................................................222 Electrical Schematic (from serial number 33851 to 38464) - Rev B.............................................................226 Electrical Schematic (from serial number 38465 to 40463) - Rev B.............................................................230 Electrical Schematic (from serial number 40464 to 41199) - Rev B.............................................................234 Electrical Schematic (from serial number 41200 to 41803) - Rev C.............................................................238 Electrical Schematic (from serial number 41804 to GS6804-42449) - Rev B......................................................242 Electrical Schematic (from serial number GS6804-42450 to GS6805-43529) - Rev B...............................................246 Electrical Schematic - ANSI, CSA and Australia Models (from serial number GS6805-43530 to GS6805-44698) - Rev B..............250 Electrical Schematic - ANSI, CSA and Australia Models(after serial number GS6805-44698) - Rev B..............................254 Electrical Schematic - CE Models (from serial number GS6805-43530 to GS6805-44698) - Rev B...................................258 Electrical Schematic - CE Models (after serial number GS6805-44698) - Rev B..................................................262 Hydraulic........................................................................................................................266 Hydraulic Symbols Legend and Component Reference - Rev C.....................................................................266 Hydraulic Schematic (before serial number 40594) - Rev B.....................................................................267 Hydraulic Schematic (from serial number 40594 to 41199) - Rev A..............................................................270 Hydraulic Schematic (from serial number 41200 to 41317) - Rev B..............................................................271 Hydraulic Schematic (from serial number 41318 to GS6804-43183) - Rev B.......................................................274 Hydraulic Schematic (from serial number GS6804-43184 to GS6806-45257) - Rev B................................................275 Hydraulic Schematic (after serial number GS6806-45257) - Rev B...............................................................277
S.S 04/24
