Genie GS-2046 Service Manual
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Genie GS-2046 Service Manual

Scissor lifts
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See also: Service & Repair Manual , Service Manual
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Technical
Publications
GS-2046
GS-2646
GS-3246
Service
Manual
(before serial number 17408)
First Edition, Third Printing
Rev C2
Part No. 48339

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Summary of Contents for Genie GS-2046

  • Page 1 ® Technical Publications GS-2046 GS-2646 GS-3246 Service Manual (before serial number 17408) First Edition, Third Printing Rev C2 Part No. 48339...

  • Page 2: Introduction

    However, "Genie" is a Registered Trademark continuous improvement of our products is a of Genie Industries in the USA and many other Genie policy. Therefore, product specifications countries. "GS" is a Trademark of are subject to change without notice.
  • Page 3 Service Manual - First Edition Safety Rules 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.
  • Page 4 Be sure to properly dispose of old oil or other fluids. Use an approved container. Please be environmentally safe. Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...
  • Page 5 Power Source to the default settings in the ECM software. Machine Controls The Genie GS-2046 & Genie GS-2646 & Genie GS-3246 machines are powered by four six-volt The GS-2046 & GS-2646 & GS-3246 machines (225 AH) batteries. The four batteries are wired in are equipped with operational controls which are series to produce 24 volts.
  • Page 6 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. Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...

  • Page 7: Table Of Contents

    Inspect for Damage, and Loose or Missing Parts ........... 4 - 3 Check the Hydraulic Oil Level ................. 4 - 4 Check for Hydraulic Leaks ................4 - 4 Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246...
  • Page 8 B-12 Replace the Hydraulic Return Filter ............... 4 - 17 Check the Module Tray Latch Components ........... 4 - 18 Test or Replace the Hydraulic Oil ..............4 - 19 viii Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...
  • Page 9 (No applicable code) ....................5 - 18 Platform Up Function Inoperative ................5 - 20 Platform Down Function Inoperative GS-2046 & GS-2646 Models .................. 5 - 21 Platform Down Function Inoperative GS-3246 Models ....................5 - 23 Steer Left Function Inoperative ................5 - 25 Steer Right Function Inoperative ................
  • Page 10 Machine Drives At Full Speed With Platform Raised ..........5 - 36 Manual Platform Lowering Function Inoperative GS-2046 & GS-2646 (No applicable code) ............5 - 37 Manual Platform Lowering Function Inoperative GS-3246 (No applicable code) ................5 - 38 Drive Function Overspeeds While Driving Down an Incline GS-3246 Models (No applicable code) ..............
  • Page 11 Scissor Assembly, GS-3246 ................. 7 - 25 Lift Cylinder ....................7 - 32 Ground Controls Manual Platform Lowering Cable, GS-2046 & GS-2646 ....... 7 - 35 Manual Platfrom Lowering, GS-3246 ............7 - 36 Toggle Switches, See 1-2, Toggle Switches ..........7 - 36 Hydraulic Pump Hydraulic Pump ....................
  • Page 12 Steering Cylinder ..................7 - 48 Steering Bellcrank ..................7 - 48 Non-steering Axle Components Drive Brake ....................7 - 49 Brake Release Hand Pump Components Brake Release Hand Pump ................7 - 50 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...

  • Page 13: Specifications

    20 ft 6.1 m Maximum platform extension 39 in 99 cm Wheelbase 185.1 cm Turning radius, outside 233.1 cm Turning radius, inside 0 in 0 cm Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 2 - 1...

  • Page 14: Machine Specifications, Gs-2646

    32 ft 9.8 m Maximum platform extension 39 in 99 cm Wheelbase 185.1 cm Turning radius, outside 233.1 cm Turning radius, inside 0 in 0 cm 2 - 2 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...

  • Page 15: Machine Specifications, Gs-3246

    233.1 cm Continuous improvement of our products is a Turning radius, inside 0 in 0 cm Genie policy. Product specifications are subject to change without notice. Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 2 - 3...

  • Page 16: Performance Specifications, All Models

    (GS-3246 models) 2000 psi 137.9 bar GS-3246 Steer relief valve pressure 1500 psi 103.4 bar Platform up 55 to 59 seconds Platform down 38 to 40 seconds 2 - 4 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...

  • Page 17: Hydraulic Hose And Fitting Torque Specifications

    (Genie pn. 6 Operate all machine functions and inspect the 49612). hoses and fittings and related components to be sure that there are no leaks. Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 2 - 5...
  • Page 18 Section 2 - Specifications Service Manual - First Edition This page intentionally left blank. 2 - 6 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...

  • Page 19: Scheduled Maintenance Inspections

    The maintenance inspection report contains checklists for each type of scheduled inspection. Make copies of the Maintenance Inspection Report to use for each inspection. Store completed forms for three years. Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 3 - 1...
  • Page 20 Perform 30 Day Service Table B Check the Batteries Inspect the Electrical Wiring Inspect the Tires and Wheels (including castle nut torque) Test the Key Switch 3 - 2 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...
  • Page 21 Every 250 hours, perform the following engine maintenance procedure. B-12 Replace the Hydraulic Return Filter Table C Check the Module Tray latch Components Table D Test or Replace the Hydraulic Oil Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 3 - 3...

  • Page 22: Maintenance Inspection Report

    “R” box. B-12 Hydraulic Return Filter Legend Y = yes, acceptable N = no, remove from service R = repaired Comments 3 - 4 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...

  • Page 23: Scheduled Maintenance Procedures

    Green—used to indicate operation · Wheels chocked or maintenance information. Indicates that a specific result is expected after performing a series of steps. Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 4 - 1...

  • Page 24: Inspect The Operator's And Safety Manuals

    Contact your authorized Genie distributor or Genie Industries if Contact your authorized Genie replacement decals are needed. distributor or Genie Industries if replacement manuals are needed. 4 - 2 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...

  • Page 25: Inspect For Damage And Loose Or Missing Parts

    · Brake release components · Safety arm · Pothole guards · Platform extension · Scissor pins and retaining fasteners · Platform control joystick · Inverter (if equipped) Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 4 - 3...

  • Page 26: Check The Hydraulic Oil Level

    Hydraulic Oil Specifications GS-3246 After Serial Number 21919 Hydraulic oil type Dexron equivalent Hydrailic tank capacity 7 gallons 26.5 liters Hydraulic system 7 gallons (including tank) 26.5 liters 4 - 4 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...

  • Page 27: Test The Platform And Ground Controls

    OR press the lift function selector As a safety feature, selecting button. and operating the ground controls will override the platform controls, except the Emergency Stop button. Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 4 - 5...

  • Page 28: Test The Manual Platform Lowering Operation

    Result: The platform should lower. The descent should not operate. alarm will not sound. 4 Lower the platform and drive the machine off the blocks. 4 - 6 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...

  • Page 29: Test The Pothole Guards

    6 feet (1.8 meters), an alarm operate. should sound and the drive function should not work. 5 Lower the platform and remove the block of wood. Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 4 - 7...

  • Page 30: Perform 30 Day Service

    1 Perform the following maintenance procedures: · B-3 Inspect Tires and Wheels · B-12 Replace the Hydraulic Filter 4 - 8 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...

  • Page 31: Check The Batteries

    Result: If any battery cell displays a specific gravity of less than 1.098, the battery must be replaced. Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 4 - 9...

  • Page 32: Inspect The Electrical Wiring

    5 Lower the platform onto the safety arm. Crushing hazard. Keep hands clear of the safety arm when lowering the platform. 4 - 10 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...

  • Page 33: Inspect The Tires And Wheels (Including Castle Nut Torque)

    300 ft-lbs 405 Nm 6 Turn the key switch to the position. Castle nut torque, lubricated 225 ft-lbs 305 Nm Result: No machine functions should operate. Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 4 - 11...

  • Page 34: Test The Emergency Stop Buttons

    Result: No machine functions should operate. The ground control Emergency Stop button will stop all machine operation, even if the key switch is switched to platform control. 4 - 12 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...

  • Page 35: Test The Drive Brakes

    Release the function enable switch or the joystick on the platform controls when your reference point on the machine crosses the test line. drive forward/reserve valve Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 4 - 13...
  • Page 36 (with white and brown wires) onto the valve. For the machine to function correctly, the reverse valve coil must be closest to the manifold. 4 - 14 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...

  • Page 37: Test The Drive Speed - Stowed Position

    Drive speed (maximum): Stowed position 40 ft / 12.4 sec 12.2 m / 12.4 sec Platform raised 40 ft / 54.5 sec 12.2 m / 54.5 sec Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 4 - 15...

  • Page 38: Perform Hydraulic Oil Analysis

    2 Visually inspect the contact points of each contactor for the following items: · Excessive burns · Excessive arcs · Excessive pitting Replace the contactor if any damage is found. 4 - 16 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...

  • Page 39: Replace The Hydraulic Return Filter

    2 Apply a thin layer of oil to the new oil filter gasket. 3 Install the new filter (Genie part number 55616) and tighten it securely by hand. Clean up any oil that may have spilled during the replacement procedure.

  • Page 40: Check The Module Tray Latch Components

    2 Inspect each module tray latch pad (if equipped). Replace any worn pad before the latch will fail to securely hold the module tray closed. 4 - 18 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...

  • Page 41: Test Or Replace The Hydraulic Oil

    12 Fill the tank with hydraulic oil until the fluid is hydraulic tank. within the marks on the oil level FULL indicator decal. Do not overfill. Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 4 - 19...
  • Page 42 Hydraulic Oil Specifications After Serial Number 21919 Hydraulic oil type Dexron equivalent Hydrailic tank capacity 7 gallons 26.5 liters Hydraulic system 7 gallons (including tank) 26.5 liters 4 - 20 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...
  • Page 43 Do not allow oil to squirt or spray. Perform all troubleshooting on a firm level surface. Two persons will be required to safely perform some troubleshooting procedures. Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 5 - 1...
  • Page 44 The codes listed in the Fault Code Chart describe malfunctions and can aid in troubleshooting the machine by pinpointing the area or component affected. 5 - 2 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...

  • Page 45: Fault Code Chart Before Serial Number 17408

    ECM pin A9, controls when the function ckt A9-Curtis terminal 3. enable switch is engaged. Notes Continued on next page Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 5 - 3...
  • Page 46 OR check wiring and platform will still raise. the brake orifice coil. terminal at ECM pin C9, C9 orifice coil OR replace Coil. Notes Continued on next page 5 - 4 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...
  • Page 47 Charge batteries. flashing LED at the platform supply voltage is 18.5V DC or available controls while function enable less. switch is activated. Notes Continued on next page Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 5 - 5...

  • Page 48: Normal Operation Code Chart Before Serial Number 17408

    5 - 6 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...
  • Page 49 Service Manual - First Edition Section 5 - Troubleshooting Flow Charts Continued on next page Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 5 - 7...

  • Page 50: Fault Code Chart (After Serial Number 17407)

    Malfunctioning coil OR wire Troubleshoot coil OR inspect Brake coil error disconnected from coil wire connection Low Voltage Batteries discharged Charge batteries 5 - 8 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...

  • Page 51: All Functions Will Not Operate

    Anderson plug OR repair open in 24V supply cable from Anderson plug to the B+ Continued on the next terminal on the motor page. controller. Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 5 - 9...
  • Page 52 Replace contact OR refer to Ground Controls Inoperative, Chart 6 OR consult Genie Industries Service Department. Continued on the next page. 5 - 10 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...
  • Page 53 Service Department. Refer to Chart 2, Pump Motor Will Not Operate OR repair open in white wire (C2 estop chassis) OR consult Genie Industries Service Department. Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 5 - 11...
  • Page 54 Genie Industries Service controller. Department. Replace pump motor OR consult Genie Industries Service Department. Continued on the next page. 5 - 12 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...
  • Page 55 275A fuse to the Anderson plug OR replace positive battery cables from Anderson plug to K1 OR consult Genie Industries Service Department. Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 5 - 13...

  • Page 56: Pump Motor Will Not Operate

    M- OR consult Genie terminal on motor Industries Service controller. Department. Replace pump motor OR consult Genie Industries Service Department. Continued on the next page. 5 - 14 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...
  • Page 57 275A fuse to Anderson plug OR replace positive battery cables from Anderson plug to the B+ terminal on the motor controller OR consult Genie Industries Service Department. Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 5 - 15...

  • Page 58: All Functions Inoperative, Power Unit Starts And Runs (No Applicable Code)

    Visually check coupling connection. good no good Test hydraulic pump. Replace the pump. See Repair section. good Consult Genie Industries Service Department. 5 - 16 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...

  • Page 59: Ground Controls Inoperative, Platform Controls Operate Normally

    ECM (B12-up switch) OR repair open in white wire from toggle switch to ECM (A12-down switch) OR consult Genie Industries Service Department. Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 5 - 17...

  • Page 60: Platform Controls Inoperative, Ground Controls Operate Normally

    A11 at the wire (A11-key switch) ECM. from keyswitch to A11 at ECM. Check voltage at Replace ECM. terminal B2 at the ECM. Continued on the next page. 5 - 18 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...
  • Page 61 OR replace joystick controller OR replace main circuit board OR replace ECM OR consult Genie Industries Service Department. Replace ECM OR consult Genie Industries Service Department. Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 5 - 19...

  • Page 62: Platform Up Function Inoperative

    OR platform lowering valve(s) may be stuck open OR function manifold could have an internal defect. Consult Genie Industries Service Department. 5 - 20 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...

  • Page 63: Platform Down Function Inoperative

    (item Q) OR 0.059" orifice inside the cylinder is plugged OR repair or replace lift cylinder OR consult Genie Industries Service Department. Continued on the next page. Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 5 - 21...
  • Page 64 0.059" orifice inside the cylinder is plugged OR repair or replace lift cylinder OR replace platform controls OR replace ECM OR consult Genie Industries Service Department. 5 - 22 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...

  • Page 65: Platform Down Function Inoperative Gs-3246 Models

    OR repair or replace the platform lowering valve cartridge (item Q) OR replace ECM OR consult Genie Industries Service Department. Continued on the next page. Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 5 - 23...
  • Page 66 0.059" orifice inside the cylinder(s) is plugged OR repair or replace lift cylinder(s) OR replace platform controls OR replace ECM OR consult Genie Industries Service Department. 5 - 24 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...

  • Page 67: Steer Left Function Inoperative

    Check for wire continuity from the steer microswitch to the terminal strip OR replace main circuit board at the platform controls. Continued on the next page. Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 5 - 25...
  • Page 68 Section) OR repair or replace steer cylinder OR replace steer left/ right valve cartridge (item G) OR function manifold could have an internal defect. Consult Genie Industries Service Department. 5 - 26 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...

  • Page 69: Steer Right Function Inoperative

    Check for wire continuity from the steer microswitch to the terminal strip OR replace main circuit board at the platform controls. Continued on the next page. Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 5 - 27...
  • Page 70 Section) OR repair or replace steer cylinder OR replace steer left/ right valve cartridge (item G) OR function manifold could have an internal defect. Consult Genie Industries Service Department. 5 - 28 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...

  • Page 71: All Drive Functions Inoperative, All Other Functions Operate Normally

    OR replace function. Does the main circuit board OR hydraulic power unit turn replace ECM OR consult Genie Industries Service Department. Continued on the next page. Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 5 - 29...
  • Page 72 Repair or replace drive forward/reverse valve cartridge (item K) OR rebuild or replace drive motors OR function manifold may have an internal defect. Consult Genie Industries Service Department. 5 - 30 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...

  • Page 73: Brake Release Function Inoperative

    (item O) OR replace brake release valve (item N) OR function manifold or brake release manifold may have an internal defect OR consult Genie Industries Service Department. Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 5 - 31...
  • Page 74 OR consult Replace the drive Genie Industries Service forward/reverse valve Department. cartridge (item K) OR consult the Genie Industries Service Department.. 5 - 32 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...

  • Page 75: Drive Reverse Function Inoperative

    OR consult Replace the drive Genie Industries Service forward/reverse valve Department. cartridge (item K) OR consult the Genie Industries Service Department. Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 5 - 33...

  • Page 76: Machine Will Not Drive At Full Speed

    (B10-pothole sw) from the output side of S6 to the ECM OR replace ECM OR consult Genie Industries Service Department. Continued on the next page. 5 - 34 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...
  • Page 77 Repair open in white wire (B10-pothole switch) from output side of S6 to ECM OR replace ECM OR see Chart 13, Brake Release Function Inoperative. Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 5 - 35...

  • Page 78: Machine Drives At Full Speed With Platform Raised

    Remove obstruction from pothole guard or from pothole guard limit switches OR consult Genie Industries Service Department. 5 - 36 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...
  • Page 79 OR see or pinched. OR consult Genie Industries Service Be sure the Department. platform lowers using the platform up/down toggle switch at the ground controls. Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 5 - 37...
  • Page 80 Repair open in ground wire circuit from the blk wire at the manual platform lowering batteries through the brown wire to the hour meter then to ground. 5 - 38 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...
  • Page 81 Be sure the circuit breaker and fuse are not tripped or blown. Be sure the batteries are properly connected. Be sure the batteries are fully charged. Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 5 - 39...
  • Page 82 Be sure the circuit breaker and fuse are not tripped or blown. Be sure the batteries are properly connected. Be sure the batteries are fully charged. 5 - 40 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...
  • Page 83 Be sure that all necessary tools and test Identify Malfunction Troubleshoot equipment are available and ready for use. discovered symptoms problem still exists Return to Inspect Perform service and test repair problem solved Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 6 - 1...

  • Page 84: Electrical Components

    (size10) with diode ....44176 ..... Hydra Power Systems ..6359752 ......4 Y7 ....Coil, 20V DC ......44787 ..... Hydra Power Systems ..10166-25 ......3 6 - 2 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...
  • Page 85 Service Manual - First Edition Section 6 - Schematics This page intentionally left blank. Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 6 - 3...

  • Page 86: Module Tray Legend (Before Serial Number 6901)

    Section 6 - Schematics Service Manual - First Edition Module Tray Legend (before serial number 6901) 6 - 4 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...

  • Page 87: Module Tray Legend (After Serial Number 6900)

    Service Manual - First Edition Section 6 - Schematics Module Tray Legend (after serial number 6900) Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 6 - 5...

  • Page 88: Electrical Symbols Legend

    Section 6 - Schematics Service Manual - First Edition Electrical Symbols Legend 6 - 6 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...

  • Page 90: Electrical Schematic (Before Serial Number 6901)

    Section 6 - Schematics Service Manual Electrical Schematic (before serial number 6901) 6 - 7 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...
  • Page 91 Service Manual Section 6 - Schematics Electrical Schematic (before serial number 6901) Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 6 - 8...
  • Page 92 Service Manual Section 6 - Schematics Electrical Schematic (before serial number 6901)

  • Page 94: Electrical Schematic (From Serial Number 6901 To 8931)

    Section 6 - Schematics Service Manual Electrical Schematic (from serial number 6901 to 8931) 6 - 9 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48399...
  • Page 95 Service Manual Section 6 - Schematics Electrical Schematic (from serial number 6901 to 8931) Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 6 - 10...
  • Page 96 Service Manual Section 6 - Schematics Electrical Schematic (from serial number 6901 to 8931)

  • Page 98: Electrical Schematic (From Serial Number 8932 To 17407)

    Section 6 - Schematics Service Manual Electrical Schematic (from serial number 8932 to 17407) 6 - 11 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...
  • Page 99 Service Manual Section 6 - Schematics Electrical Schematic (from serial number 8932 to 17407) Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 6 - 12...
  • Page 100 Service Manual Section 6 - Schematics Electrical Schematic (from serial number 8932 to 17407)

  • Page 102: Electrical Schematic (After Serial Number 17407)

    Section 6 - Schematics Service Manual Electrical Schematic (after serial number 17407) 6 - 13 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...
  • Page 103 Service Manual Section 6 - Schematics Electrical Schematic (after serial number 17407) Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 6 - 14...
  • Page 104 Service Manual Section 6 - Schematics Electrical Schematic (after serial number 17407)

  • Page 105: Ground Controls And Level Sensor Box Legend

    Service Manual - First Edition Section 6 - Schematics Ground Controls and Level Sensor Box Legend Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 6 - 15...

  • Page 106: Platform Controls Legend (Before Serial Number 17408)

    Section 6 - Schematics Service Manual - First Edition Platform Controls Legend (before serial number 17408) 6 - 16 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...

  • Page 107: Platform Controls Legend (After Serial Number 17407)

    Service Manual - First Edition Section 6 - Schematics Platform Controls Legend (after serial number 17407) Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 6 - 17...

  • Page 108: Hydraulic Symbols Legend

    Section 6 - Schematics Service Manual - First Edition Hydraulic Symbols Legend 6 - 18 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...

  • Page 109: Hydraulic Schematic (Before Serial Number 17482)

    Service Manual Section 6 - Schematics Hydraulic Schematic (before serial number 17482) Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 6 - 19...
  • Page 110 Service Manual Section 6 - Schematics Hydraulic Schematic (before serial number 17482)

  • Page 111: Hydraulic Schematic (After Serial Number 17481)

    Service Manual Section 6 - Schematics Hydraulic Schematic (after serial number 17481) Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 6 - 20...
  • Page 112 Service Manual Section 6 - Schematics Hydraulic Schematic (after serial number 17481)
  • Page 113 Read, understand and obey the safety rules presence of an imminently and operating instructions in the Genie GS-2032 hazardous situation which, if not & Genie GS-2046 & Genie GS-2646 & Genie avoided, will result in death or GS-3246 Operator's Manual . serious injury.

  • Page 114: Platform Controls

    Main circuit board Lift/drive selector toggle switch Main circuit board Horn button Emergency stop button Emergency stop button Joystick controller LED circuit board Alarm Joystick controller 7 - 2 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...

  • Page 115: Software Configuration

    1 Remove the platform controls from the platform. 2 Turn the key switch to platform control and pull out the Emergency Stop buttons to the position at both the ground and platform controls. Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 7 - 3...

  • Page 116: How To Set The Dip Switch Codes

    2 Remove the fasteners securing the top of the controller to the controller case. DIP switch Emergency stop button Circuit boards Joystick controller Controller box Enlarged view of DIP switch 7 - 4 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...
  • Page 117 11011000 • • • 11101000 • • • 11111000 • • • • 10110000 • • 11010000 • • 11110000 • • • 11100000 • • Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 7 - 5...

  • Page 118: Toggle Switches

    4 to 6 no continuity Right Left Center terminal 5 to 6 no continuity Single pole double throw (SPDT) Double pole double throw (DPDT) 7 - 6 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...

  • Page 119: Platform Components

    Do not lift it. 7 Attach a strap from the platform railings to the carriage on the forklift to help support the platform. Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 7 - 7...

  • Page 120: Platform Extension

    Remove the roller supports. 7 Carefully slide the platform extension out from the platform and place it on a stucture capable of supporting it. 7 - 8 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...
  • Page 121 Service Manual - First Edition Section 7 - Repair Procedures This page intentionally left blank. Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 7 - 9...

  • Page 122: Scissor Components

    16 Number 2 pivot pin (non-steer end) 8 Number 1 inner arm 17 Lift cylinder barrel-end pivot pin 9 Number 1 pivot pin (steer end) (2pins) 18 Number 1 outer arm 7 - 10 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...

  • Page 123: Scissor Assembly, Gs-2046

    4 Remove the external snap rings from the when the pin is removed. number 3 center pivot pin (index #2). Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 7 - 11...
  • Page 124 28 Remove the safety arm from the number 2 inner supported when it is removed from arm (index #14) that was just removed. the machine. 7 - 12 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...
  • Page 125 37 Remove the cables from the number 1 inner arm (index #8)and lay them off to the side. Component damage hazard. Cables can be damaged if they are kinked or pinched. Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 7 - 13...
  • Page 126 Bodily injury hazard. The number 1 inner arm (index #8) may become unbalanced and fall if not properly supported when removed from the machine. 7 - 14 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...
  • Page 127 Crushing hazard. The scissor assembly will fall if both wear pads are allowed to slide out of the drive chassis. Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 7 - 15...
  • Page 128 22 Lift cylinder barrel-end pivot pin 11 Number 1 pivot pin (steer end) (2 pins) 23 Number 1 outer arm 12 Number 5 pivot pin (non-steer end) 7 - 16 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...

  • Page 129: Scissor Assembly, Gs-2646

    15 Remove the external snap rings from the number 3 center pivot pin (index #17). 6 Remove the external snap ring from the number 4 pivot pin (index #2). Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 7 - 17...
  • Page 130 2 support. Do not lift it. center pivot pin (index #7) at the ground controls side of the machine. 7 - 18 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...
  • Page 131 Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 7 - 19...
  • Page 132 57 Remove the external snap rings from the number 1 center pivot pin (index #9). number 1 center pivot pin (index #9). 7 - 20 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...
  • Page 133 Crushing hazard. The entry ladder may become unbalanced and fall if not properly supported and secured to the lifting device. Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 7 - 21...
  • Page 134 16 Remove the pin retaining fasteners from the number 1 inner arm pivot pins (item #11) at the steer end of the machine. Use a slide hammer to remove the pins. 7 - 22 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...
  • Page 135 Component damage hazard. Be careful not to damage the level sensor box, limit switch or level sensor while installing the scissor assembly. Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 7 - 23...
  • Page 136 14 Number 1 inner arm 29 Lower lift cylinder barrel-end pivot pin 15 Number 1 pivot pin (steer end) (2 pins) 30 Number 1 outer arm 7 - 24 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...

  • Page 137: Scissor Assembly, Gs-3246

    14 Lower the cylinder onto the number 3 center pivot pin (index #8). 5 Use a soft metal drift to remove the number 5 center pivot pin (index #2). Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 7 - 25...
  • Page 138 24 Remove the external snap rings from the number 4 pivot pin (index #6) from the steer end of the machine. 7 - 26 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...
  • Page 139 Bodily injury hazard. The number controls. 3 outer arm (index #7) at the ground controls side may become unbalanced and fall if not properly supported when removed from the machine. Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 7 - 27...
  • Page 140 7 - 28 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...
  • Page 141 Component damage hazard. Be careful not to damage the valve or fittings on the cylinder while removing it from the machine. Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 7 - 29...
  • Page 142 Note the position of the wear pads before the arm is removed so when the scissor is assembled they will be in the correct position. 7 - 30 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...
  • Page 143 Component damage hazard. Be assembly. careful not to damage the level sensor box, limit switch or level sensor while moving the scissor assembly. Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 7 - 31...

  • Page 144: Lift Cylinder

    10 Lower the cylinder to a horizontal position. the platform. If removing the lower lift cylinder, remove the entry ladder from the non-steer end of the machine. 7 - 32 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...
  • Page 145 Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 7 - 33...
  • Page 146 Crushing hazard. The cylinder may become unbalanced and fall when it is removed from the machine if it is not properly attached and secured to the lifting device. 7 - 34 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...

  • Page 147: Ground Controls

    Result: The measurement should be inch (4.7 to 6.4 mm). 7 To adjust, loosen the upper lock nut on the Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 7 - 35...
  • Page 148 2 Tag and disconnect the wires from the battery to be removed. 3 Remove the battery from the machine. 4 Install the new battery and connect the wires. 5 Install the ground control cover. 7 - 36 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...

  • Page 149: Hydraulic Pump

    Result: If pressure fails to reach 3700 psi (255 bar), the pump is bad and will need to be serviced or replaced. 5 Remove the pressure gauge and reconnect the hydraulic hose. Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 7 - 37...

  • Page 150: Function Manifold Components (Before Serial Number 11501)

    55 ft-lbs / 75 Nm SAE No. 4 13 ft-lbs / 18 Nm SAE No. 12 75 ft-lbs / 102 Nm SAE No. 6 18 ft-lbs / 24 Nm 7 - 38 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...
  • Page 151 Service Manual - First Edition Section 7 - Repair Procedures MANIFOLDS Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 7 - 39...

  • Page 152: Function Manifold Components (After Serial Number 11500)

    13 ft-lbs / 18 Nm SAE No. 10 55 ft-lbs / 75 Nm SAE No. 6 18 ft-lbs / 24 Nm SAE No. 12 75 ft-lbs / 102 Nm 7 - 40 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...
  • Page 153 Service Manual - First Edition Section 7 - Repair Procedures MANIFOLDS Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 7 - 41...

  • Page 154: Valve Adjustments - Function Manifold

    8 Activate the platform up function. forward position and observe the pressure reading on the pressure gauge. Return control handle to center. 7 - 42 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...
  • Page 155 5 Turn the machine off. Hold the steering relief valve with a wrench and remove the cap (item Coil, 20V (function manifold items H, J, K) 18 - 20W #5, function manifold). Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 7 - 43...
  • Page 156 227 kg 3 Turn the key switch to ground control and pull out the Emergency Stop button to the position at both the ground and platform controls. 7 - 44 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...
  • Page 157 Lift Relief Valve Manifold, GS-3246 Models Description ....Relief valve, 2000 psi (241 bar) Schematic Item ............M Function ............Platform up Torque ........25-30 ft-lbs (34-41 Nm) Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 7 - 45...

  • Page 158: Steering Axle Components

    Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 7 - 46 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...
  • Page 159 7 Support and secure the drive motor to an appropriate lifting device. 8 Remove the drive motor mounting fasteners, then remove the motor. Torque specifications Castle nut 300 ft-lbs 406.7 Nm Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 7 - 47...

  • Page 160: Steering Cylinder

    4 Remove the pin retaining fasteners from the rod- end pivot pin. Use a soft metal drift to remove the pin. 5 Remove the steering cylinder from the machine. 7 - 48 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...

  • Page 161: Non-Steering Axle Components

    Always replace the cotter pin with Castle nut 300 ft-lbs 406.7 Nm a new one when removing the castle nut. 4 Loosen the wheel castle nut. Do not remove it. Part No. 48339 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 7 - 49...

  • Page 162: Brake Release Hand Pump Components

    55 ft-lbs / 75 Nm SAE No. 4 13 ft-lbs / 18 Nm SAE No. 12 75 ft-lbs / 102 Nm SAE No. 6 18 ft-lbs / 24 Nm 7 - 50 Genie GS-2046 & Genie GS-2646 & Genie GS-3246 Part No. 48339...
  • Page 163 Genie UK Limited Fax: 81 3 3453 6083 Fax: 31 7051 13993 Phone: 44 1636 605030 Fax: 44 1636 611090 Genie Australia Pty Ltd. Genie Latin America Phone: 61 07 3375 1660 Phone: 561-994-0380 Fax: 61 07 3375 1002 Fax:...

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