Genie GS-2046 Bedienungsanleitung

First Edition, Third Printing

Rev C2

Part No. 48339

GS-3246

GS-2646

GS-2046

Technical

Publications

Service

Manual

(before serial number 17408)

Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339

Service Manual - First Edition

Introduction

Genie North America

Telephone (425) 881-1800

Toll Free 800 536-1800 in U.S.A.

Toll Free 800 426-8089 in Canada

Fax (425) 882-9260

http://www.genielift.com

E-mail: [email protected]

Genie Europe

Telephone (44) 01636-605030

Fax (44) 01636-611090

http://www.genielift.com

E-mail: [email protected]

Important

Read, understand and obey the safety rules and

operating instructions in the

Genie GS-2032 &

Genie GS-2046 & Genie GS-2646 & Genie

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.

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 other manuals. Please

write to the technical publications team in care of

Genie Industries, PO Box 97030, Redmond WA

98073-9730 USA.

If you have any questions, please call Genie

Industries.

First Edition: First Printing, December 1997

Second Printing, April 1999

Third Printing,October 1999

"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.

GS-324

GS-2646

GS-204

Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246

Service Manual - First Edition

iii

Danger

Failure to obey the instructions and safety rules

in this manual and the

Genie GS-2032 & Genie

GS-2046 & Genie GS-2646 & Genie 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.

Safety Rules

Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339

Service Manual - First Edition

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 that your workshop or work area

is properly ventilated and well lit.

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.

Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246

Service Manual - First Edition

Theory of Operation

Power Source

The Genie GS-2046 & Genie GS-2646 & Genie

GS-3246 machines are powered by four six-volt

(225 AH) batteries. The four batteries are wired in

series to produce 24 volts.

Hydraulic System

All machine functions are performed by the

hydraulic system. The hydraulic system is

pump is activated, it supplies hydraulic fluid under

pressure to the function manifold, where the

control valves are located. To protect from over-

pressurization of the hydraulic system, the pump

is provided with a pressure relief valve.

Activating a machine function is accomplished by

actuating or moving a switch and/or control

handle, which sends voltage to the ECM. The

ECM then sends the signal to the appropriate

directional control valve. The directional valve

determines which direction the hydraulic fluid will

travel. Computer software determines the volume

of fluid in relation to the proportional valve input

voltage.

Electrical System

Limit switches are found in various locations on

the machine. The function of a limit switch is to

communicate the operating position of the

machine to the ECM (Electronic Control Module).

When a change in signal is received from a limit

switch, the ECM responds by limiting the drive

speed to 0.5 miles per hour (0.8 km/h), according

to the default settings in the ECM software.

Machine Controls

The GS-2046 & GS-2646 & GS-3246 machines

are equipped with operational controls which are

found in two locations: the ground controls,

located on the hydraulic tank side of the machine,

and the platform controls, located in the platform.

All lift and drive functions are available at the

platform controls. Only platform up/down functions

are available at the ground controls.

The ECM uses input from the ground or platform

controls to activate the various machine functions.

The ECM has predetermined settings for the

various machine functions.

The joystick is fitted with a 5000 ohm

potentiometer. With the joystick in the neutral

position, the potentiometer will measure 2730

ohms. These signals are sent to the multiplex

card, then down to the ECM to control the voltage

supplied to the proportional valve. Two

microswitches mounted on the joystick tell the

ECM the drive direction desired. A thumb rocker

switch on the top of the joystick is used for

steering.

Mounted on the platform control box lid of

machines before serial number 17408 are buttons

and a switch that, when activated, sends a signal

to the ECM through the multiplex card. On

machines after serial number 17407, the platform

control box lid has a decal/membrane pad. This is

a touch-activated pad incorporating wiring,

switches and LEDs that are resistant to the

environment. Activating any of the buttons on the

Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339

Service Manual - First Edition

THEORY OF OPERATION

pad will send a signal to the ECM through the

multiplex card.

A diagnostic display is located at the battery pack

side of the machine to aid in troubleshooting. If the

machine malfunctions, a fault code will be shown

in the display window.

Washing electronic components is not suggested.

Instead, use compressed air to remove debris

from these components.

Component damage hazard.

Avoid shock or impact to the

ECM. Internal damage may not be

visible from the outside.

Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246

Service Manual - First Edition

Table of Contents

vii

Introduction

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

Section One Safety Rules

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

iii

Section Two Specifications

Machine Specifications, GS-2046 ............................................................................ 2 - 1

Machine Specifications, GS-2646 ............................................................................ 2 - 2

Machine Specifications, GS-3246 ............................................................................ 2 - 3

Performance Specifications, All Models ................................................................... 2 - 4

Hydraulic Specifications, All Models ......................................................................... 2 - 4

Hydraulic Hose and Fitting Torque Specifications .................................................... 2 - 5

Section Three Scheduled Maintenance Inspections

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

Table A ..................................................................................................................... 3 - 2

Table B ..................................................................................................................... 3 - 2

Table C ..................................................................................................................... 3 - 3

Table D ..................................................................................................................... 3 - 3

Maintenance Inspection Report ................................................................................ 3 - 4

Section Four Scheduled Maintenance Procedures

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

A-1 Inspect the Operator’s and Safety Manuals .................................................... 4 - 2

A-2 Inspect the Decals and Placards .................................................................... 4 - 2

A-3 Inspect for Damage, and Loose or Missing Parts ........................................... 4 - 3

A-4 Check the Hydraulic Oil Level ......................................................................... 4 - 4

A-5 Check for Hydraulic Leaks .............................................................................. 4 - 4

Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339

Service Manual - First Edition

TABLE OF CONTENTS

viii

Section Four Scheduled Maintenance Procedures, continued

A-6 Test the Platform and Ground Controls .......................................................... 4 - 5

A-7 Test the Manual Platform Lowering Operation ............................................... 4 - 6

A-8 Test the Tilt Sensor ........................................................................................ 4 - 6

A-9 Test the Pothole Guards ................................................................................. 4 - 7

A-10 Test the Lift/Drive Select Switch ..................................................................... 4 - 7

A-11 Perform 30 Day Service .................................................................................. 4 - 8

B-1 Check the Batteries ........................................................................................ 4 - 9

B-2 Inspect the Electrical Wiring .......................................................................... 4 - 10

B-3 Inspect the Tires and Wheels (including castle nut torque) ............................ 4 - 11

B-4 Test the Key Switch ...................................................................................... 4 - 11

B-5 Test the Emergency Stop Buttons................................................................. 4 - 12

B-6 Test the Service Horn.................................................................................... 4 - 12

B-7 Test the Drive Brakes.................................................................................... 4 - 13

B-8 Test the Drive Speed - Stowed Position ........................................................ 4 - 15

B-9 Test the Drive Speed - Raised Position ......................................................... 4 - 15

B-10 Perform Hydraulic Oil Analysis ...................................................................... 4 - 16

B-11 Check the Electrical Contactor ...................................................................... 4 - 16

B-12 Replace the Hydraulic Return Filter ............................................................... 4 - 17

C-1 Check the Module Tray Latch Components ................................................... 4 - 18

D-1 Test or Replace the Hydraulic Oil .................................................................. 4 - 19

Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246

Service Manual - First Edition

TABLE OF CONTENTS

Section Five Troubleshooting Flow Charts and Fault Codes

Chart

Number Chart Title Page

Fault Code Chart (Before Serial Number 17408) ..................................................... 5 - 3

Normal Operation Code Chart (Before Serial Number 17408) ................................. 5 - 6

Fault Code Chart (After Serial Number 17407) ........................................................ 5 - 8

1 All Functions Will Not Operate ................................................................................. 5 - 9

2 Pump Motor Will Not Operate ................................................................................ 5 - 12

3 Pump Motor Will Not Operate

After serial number 6900 ........................................................................................ 5 - 14

4 All Functions Inoperative, Power Unit Starts and Runs

(No applicable code) ............................................................................................... 5 - 16

5 Ground Controls Inoperative, Platform Controls Operate Normally

(No applicable code) ............................................................................................... 5 - 17

6 Platform Controls Inoperative, Ground Controls Operate Normally

(No applicable code) ............................................................................................... 5 - 18

7 Platform Up Function Inoperative ........................................................................... 5 - 20

8 Platform Down Function Inoperative

GS-2046 & GS-2646 Models .................................................................................. 5 - 21

9 Platform Down Function Inoperative

GS-3246 Models .................................................................................................... 5 - 23

10 Steer Left Function Inoperative .............................................................................. 5 - 25

11 Steer Right Function Inoperative ............................................................................ 5 - 27

12 All Drive Functions Inoperative, All Other Functions Operate Normally ................. 5 - 29

13 Brake Release Function Inoperative ...................................................................... 5 - 31

14 Drive Forward Function Inoperatmive .................................................................... 5 - 32

Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339

Service Manual - First Edition

TABLE OF CONTENTS

Section Five Troubleshooting Flow Charts and Fault Codes, continued

15 Drive Reverse Function Inoperative ....................................................................... 5 - 33

16 Machine Will Not Drive At Full Speed..................................................................... 5 - 34

17 Machine Drives At Full Speed With Platform Raised ............................................. 5 - 36

18 Manual Platform Lowering Function Inoperative

GS-2046 & GS-2646 (No applicable code)............................................................ 5 - 37

19 Manual Platform Lowering Function Inoperative

GS-3246 (No applicable code) ............................................................................... 5 - 38

20 Drive Function Overspeeds While Driving Down an Incline

GS-3246 Models (No applicable code) ................................................................... 5 - 39

21 Drive Function Hesitates While Steering

GS-3246 Models (No applicable code) ................................................................... 5 - 40

Section Six Schematics

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

Electrical Components.............................................................................................. 6 - 2

Module Tray Legend (Before serial number 6901) ................................................... 6 - 4

Module Tray Legend (After serial number 6900) ...................................................... 6 - 5

Electrical Symbols Legend ....................................................................................... 6 - 6

Electrical Schematic (Before serial number 6901) .................................................... 6 - 7

Electrical Schematic (From serial number 6901 to 8931) ......................................... 6 - 9

Electrical Schematic (From serial number 8932 to 17407) ..................................... 6 - 11

Electrical Schematic (After serial number 17407)................................................... 6 - 13

Ground Controls and Level Sensor Box Legend .................................................... 6 - 15

Platform Controls Legend (Before serial number 17408) ....................................... 6 - 16

Platform Controls Legend (After serial number 17407) .......................................... 6 - 17

Hydraulic Symbols Legend ..................................................................................... 6 - 18

Hydraulic Schematic (Before serial number 17482) ............................................... 6 - 19

Hydraulic Schematic (After serial number 17481) .................................................. 6 - 20

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