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Genie GS-2646AV User Manual

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

Table of Contents

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Genie GS-2646AV Specifications

General IconGeneral
Platform Height26 ft
Gradeability25%
Fuel TypeElectric
Drive Speed2.2 mph
Turning Radius (Inside)0 in
Machine Width46 in
Machine Length95 in
Drive Speed - Lowered3.5 km/h
Turning Radius (Outside)2.29 m
BatteriesFour 6 V batteries
Platform Width46 in
Platform Length8 ft
Tire TypeSolid non-marking
Overall Width1.17 m
Overall Length24 ft
Overall Height8 ft
Turning Radius2.29 m

Summary

Introduction

Important Information

Guidance on safety rules and operating instructions.

Technical Publications

Information on accuracy and product specifications.

Contact Us

Contact details for Genie.

Find a Manual for this Model

Instructions to find manuals on Genie's website.

Revision History

Revision History

Records of manual revisions.

Serial Number Legend

Explanation of serial number components.

Serial Number Legend

Serial Number Legend

Serial number explanation for different date ranges.

Safety Rules

General Safety Rules

Safety warnings before performing maintenance.

Safety Rules

Personal Safety

Safety awareness for individuals working near machinery.

Workplace Safety

Safety practices for the work environment.

Specifications

Machine Specifications

Details on batteries, fluid capacities, and tires.

Specifications

Performance Specifications

Drive speed, braking distance, gradeability, and noise emissions.

Specifications

Hydraulic Oil Specifications

Requirements for hydraulic fluids and temperature range.

Specifications

Chevron Rando HD Premium Oil MV Fluid Properties

Fluid properties and operating temperature limits.

Chevron 5606A Hydraulic Oil Fluid Properties

Fluid properties and operating temperature limits.

Specifications

Petro-Canada Environ MV 46 Fluid Properties

Fluid properties and operating temperature limits.

Shell Tellus S4 VX Fluid Properties

Fluid properties and operating temperature limits.

UCON Hydrolube HP-5046 Fluid Properties

Fluid properties and operating temperature limits.

Specifications

Hydraulic Component Specifications

Details on function pump, manifolds, and powered extension deck.

Hydraulic Hose and Fitting Torque Specifications

Torque values for Seal-Lok™ and JIC fittings.

Specifications

Torque Procedure

Steps for torquing Seal-Lok™ fittings.

Specifications

Torque Procedure

Steps for torquing JIC 37° fittings.

Repair Procedures

Observe and Obey

General safety and preparation for repairs.

Before Repairs Start

Pre-repair checks and safety guidelines.

Machine Configuration

Required machine setup for repairs.

Repair Procedures

About This Section

Overview of repair procedures and symbols.

Symbols Legend

Explanation of safety and procedural symbols.

Platform Controls

Platform Controls

Description of platform control components.

Operational Indicator Codes

Codes displayed on the platform control readout.

Platform Controls

1-1 Circuit Board

Procedure to remove the platform controls circuit board.

Platform Controls

1-2 Joystick

Procedure to remove the joystick.

1-3 Platform Controls Alarm

Procedure to remove the platform controls alarm.

Platform Controls

1-4 Platform Emergency Stop Button

Procedure to remove the emergency stop button.

Ground Controls

Ground Controls

Description of ground control components and functions.

Ground Controls

2-1 Software Revision Level

Procedure to determine the software revision level.

Ground Controls

2-2 Machine Setup

Procedure for setting up the machine from ground controls.

Ground Controls

2-3 Loading or Updating Machine Software

Procedure for updating machine software.

Ground Controls

Bootloader Mode

Procedure for updating software via bootloader mode.

Ground Controls

Bootloader Mode

Continuation of software update procedure.

Ground Controls

Machine Application Mode

Procedure for updating software via machine application mode.

Ground Controls

Machine Application Mode

Continuation of software update procedure.

Ground Controls

Ground Controls

Ground Controls

2-5 Service Override Mode

Procedure for entering and using service override mode.

Ground Controls

Service Override Mode

Continuation of service override mode procedure.

Ground Controls

2-6 Level Sensors

Information about level sensors and their function.

Ground Controls

How to Install and Calibrate the Level Sensor - Procedure 1

Step-by-step guide for sensor calibration.

Ground Controls

How to Install and Calibrate the Level Sensor - Procedure 1

Continuation of sensor calibration procedure.

Ground Controls

Ground Controls

How to Install and Calibrate the Level Sensor - Procedure 2

Alternative procedure for sensor calibration.

Ground Controls

How to Install and Calibrate the Level Sensor - Procedure 2

Continuation of alternative sensor calibration.

Ground Controls

Ground Controls

How to Install and Calibrate the Level Sensor - Procedure 3

Continuation of third sensor calibration.

Ground Controls

How to Install and Calibrate the Level Sensor - Procedure 3

Further steps for third sensor calibration.

Ground Controls

How to Install and Calibrate the Level Sensor - Procedure 3

Final steps for third sensor calibration.

Ground Controls

How to Install and Calibrate the Level Sensor - Procedure 3

Continuation of third sensor calibration procedure.

Ground Controls

How to Install and Calibrate the Level Sensor - Procedure 3

Further steps for third sensor calibration.

Ground Controls

How to Install and Calibrate the Level Sensor - Procedure 3

Final steps for third sensor calibration.

Ground Controls

How to Install and Calibrate the Level Sensor - Procedure 3

Additional steps for third sensor calibration.

Ground Controls

2-7 Manual Platform Lowering Cable

Information on the manual lowering cable.

How to Adjust the Manual Platform Lowering Cable

Procedure to adjust the lowering cable.

Ground Controls

How to Adjust the Manual Platform Lowering Cable

Continuation of lowering cable adjustment.

Hydraulic Tank

3-1 Hydraulic Tank

Description of the hydraulic tank's functions.

How to Remove the Hydraulic Tank

Procedure for removing the hydraulic tank.

Hydraulic Pump

4-1 Function Pump

Description of the hydraulic pump.

How to Test the Hydraulic Pump

Procedure to test the hydraulic pump.

Hydraulic Pump

How to Remove the Hydraulic Pump

Procedure for removing the hydraulic pump.

Manifolds

5-1 Function Manifold Components

Components of the function manifold.

Manifolds

Function manifold

Illustration of the function manifold components.

Manifolds

5-2 Powered Extension Deck Function Manifold Components

Components of the powered extension deck manifold.

Manifolds

5-3 Valve Adjustments – Function Manifold

Adjusting valves on the function manifold.

How to Adjust the System Relief Valve

Procedure to adjust the system relief valve.

Manifolds

How to Adjust the Platform Lift Relief Valve

Procedure to adjust the platform lift relief valve.

Manifolds

How to Adjust the Steer Relief Valve

Procedure to adjust the steer relief valve.

Manifolds

5-4 Valve Coils

Information on testing valve coils.

How to Test a Coil

Procedure for testing valve coil resistance.

Manifolds

Valve Coil Resistance Specifications

Specifications for valve coil resistance.

How to Test a Coil Diode

Procedure for testing coil diodes.

Manifolds

How to Test a Coil Diode

Continuation of coil diode testing procedure.

Steer Axle Components

6-1 Yoke and Drive Motor

Information on yoke and drive motor components.

How to Remove the Yoke and Drive Motor Assembly

Procedure to remove the yoke and drive motor.

Steer Axle Components

6-2 Steer Cylinder

Information on the steer cylinder.

How to Remove the Steer Cylinder

Procedure to remove the steer cylinder.

Steer Axle Components

6-3 Steer Bellcrank

Information on the steer bellcrank.

How to Remove the Steer Bellcrank

Procedure to remove the steer bellcrank.

Non-Steer Axle Components

7-1 Drive Brake

Information on the drive brake.

How to Remove the Drive Brake

Procedure to remove the drive brake.

Brake Release Hand Pump Components

8-1 Brake Release Hand Pump Components

Components of the brake release hand pump.

Scissor Components

Scissor Components

Diagram of scissor components.

Scissor Components

9-1 Scissor Assembly

Information on the scissor assembly.

How to Disassemble the Scissor Assembly

Procedure to disassemble the scissor assembly.

Scissor Components

How to Replace the Scissor Arm Wear Pads

Procedure to replace scissor arm wear pads.

Scissor Components

9-2 Lift Cylinder

Information on the lift cylinder.

How to Remove the Lift Cylinder

Procedure to remove the lift cylinder.

Scissor Components

How to Remove the Lift Cylinder

Continuation of lift cylinder removal.

Scissor Components

How to Remove the Lift Cylinder

Further steps for lift cylinder removal.

Scissor Components

How to Replace the Scissor Arm Wear Pads

Continuation of wear pad replacement.

Platform Components

10-1 Platform

Information on the platform.

How to Remove the Platform

Procedure to remove the platform.

Platform Components

How to Remove the Platform

Continuation of platform removal.

Platform Components

How to Remove the Platform

Further steps for platform removal.

Platform Components

How to Remove the Platform

Final steps for platform removal.

Platform Components

10-2 Platform Extension

Information on platform extension.

How to Remove the Manual Extension Deck

Procedure to remove the manual extension deck.

Platform Components

How to Remove the Powered Extension Deck (if equipped)

Procedure to remove the powered extension deck.

Platform Components

10-3 Extension Deck Cylinder

Information on the extension deck cylinder.

How to Remove the Extension Deck Cylinder (if equipped)

Procedure to remove the extension deck cylinder.

Platform Components

Platform Components

Diagnostics

Observe and Obey

Safety and preparation for diagnostics.

Before Troubleshooting

Pre-diagnostic checks and guidelines.

About This Section

Overview of diagnostic fault codes and tools.

Diagnostics

Definitions

Glossary of diagnostic terms.

GCON LCD Diagnostic Readout

Explanation of diagnostic display codes.

Genie SmartLink Diagnostic System

Overview of the diagnostic system.

GCON I/O Map (with manual extension deck)

GCON I/O Map (with manual extension deck)

Pinout and wire color for GCON with manual extension.

GCON I/O Map (with powered extension deck)

GCON I/O Map (with powered extension deck)

Pinout and wire color for GCON with powered extension.

GCON I/O Map (with powered extension deck)

GCON I/O Map (with powered extension deck)

Continuation of GCON I/O map for powered extension.

Operation Indicator Codes (OIC)

Operation Indicator Codes (OIC)

Codes for machine status and non-malfunction events.

Diagnostic Trouble Codes (DTC)

Types of diagnostic trouble codes.

Troubleshooting "HXXX" and "PXXX" Faults

Troubleshooting "HXXX" and "PXXX" Faults

Typical steps for diagnosing HXXX and PXXX faults.

Fault Inspection Procedure

Fault Inspection Procedure

Step-by-step procedure for fault inspection.

Fault Inspection Procedure

Check the GCON ECM

Procedure for checking the GCON ECM.

Type "HXXX" Faults

Type "HXXX" Faults

Fault codes related to hydraulic functions.

Type "HXXX" Faults

Type "HXXX" Faults

More fault codes related to hydraulic functions.

Type "PXXX" Faults

Type "PXXX" Faults

Fault codes related to power devices.

Type "UXXX" Faults

Type "UXXX" Faults

Fault codes related to user interface devices.

Type "UXXX" Faults

Type "UXXX" Faults

More fault codes related to user interface devices.

Type "FXXX" Faults

Type "FXXX" Faults

Fault codes related to machine feedback devices.

Type "CXXX" Faults

Type "CXXX" Faults

Fault codes related to control devices.

Schematics

About This Section

Overview of electrical and hydraulic schematics.

Electrical Schematics

Introduction to electrical schematics.

Hydraulic Schematics

Introduction to hydraulic schematics.

Electrical Component and Wire Color Legends

Electrical Component Legend

Legend for electrical components.

Electrical Component and Wire Color Legends

Electrical Component Legend cont.

Continuation of electrical component legend.

Wire Color Legend

Legend for wire colors.

Wiring Diagram Ground Controls

Wiring Diagram Ground Controls

Wiring diagram for ground controls.

Wiring Diagram Platform Controls

Wiring Diagram Platform Controls

Wiring diagram for platform controls.

Limit Switch Legend

Limit Switch Legend

Legend for limit switches.

Limit Switch Legend

Limit Switch Legend

Continuation of limit switch legend.

Electrical Symbol Legend

Electrical Symbol Legend

Legend for electrical symbols.

Hydraulic Symbols Legend

Hydraulic Symbols Legend

Legend for hydraulic symbols.

Hydraulic Component Reference

Hydraulic Component Reference

Reference illustrations for hydraulic components.

Electrical Schematic (with manual extension deck)

Electrical Schematic (with manual extension deck)

Electrical schematic for manual extension deck.

Electrical Schematic (with manual extension deck)

Electrical Schematic (with manual extension deck)

Continuation of electrical schematic for manual extension.

Electrical Schematic (with manual extension deck)

Electrical Schematic (with manual extension deck)

Further continuation of electrical schematic for manual extension.

Electrical Schematic (with manual extension deck)

Electrical Schematic (with manual extension deck)

Final part of electrical schematic for manual extension.

Electrical Schematic (with powered extension deck)

Electrical Schematic (with powered extension deck)

Electrical schematic for powered extension deck.

Electrical Schematic (with powered extension deck)

Electrical Schematic (with powered extension deck)

Continuation of electrical schematic for powered extension.

Electrical Schematic (with powered extension deck)

Electrical Schematic (with powered extension deck)

Further continuation of electrical schematic for powered extension.

Electrical Schematic (with powered extension deck)

Electrical Schematic (with powered extension deck)

Final part of electrical schematic for powered extension.

Electrical Schematic (foot switch option)

Electrical Schematic (foot switch option)

Electrical schematic for foot switch option.

Electrical Schematic (foot switch option)

Electrical Schematic (foot switch option)

Continuation of electrical schematic for foot switch option.

Hydraulic Schematics

Hydraulic Schematic

Main hydraulic schematic diagram.

Hydraulic Schematics

Hydraulic Schematic, Powered Extension Deck Manifold

Hydraulic schematic for powered extension deck manifold.

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