Genie GS-2646AV Service And Repair Manual
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Genie GS-2646AV Service And Repair Manual

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Service and Repair Manual
GS-2646AV
GS-2646AV 35
Serial Number Range
from GS4612A-110000
from GS4616P-138362 to
GS4616P-141799
from GS46P-141800
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
Part No. 1272218
Rev A2
September 2016

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Summary of Contents for Genie GS-2646AV

  • Page 1 Service and Repair Manual Serial Number Range GS-2646AV from GS4612A-110000 This manual includes: from GS4616P-138362 to Repair procedures GS4616P-141799 GS-2646AV 35 Fault Codes Electrical and from GS46P-141800 Hydraulic Schematics For detailed maintenance procedures, refer to the appropriate Maintenance Manual for your machine.

  • Page 2: Find A Manual For This Model

    Copyright © 2016 by Terex Corporation 1272218 Rev A, March 2016 First Edition, First Printing Genie is a registered trademark of Terex South Dakota, Inc. in the U.S.A. and many other countries. “GS” is a trademark of Terex South Dakota, Inc..

  • Page 3: Revision History

    September 2016 Service and Repair Manual Introduction Revision History Revision Date Section Procedure / Page / Description 3/2016 Initial Release 5/2016 Repair Procedures 2-3, 2-4, 2-5, 2-6 Diagnostics H067 fault 9/2016 Introduction Serial Number Legend Reference Examples: Electronic Version Section – Repair Procedure, 4-2 Click on any content or procedure in the Table of Contents to view Section –...

  • Page 4: Serial Number Legend

    Service and Repair Manual September 2016 Introduction Serial Number Legend To August 31, 2016 1 Model 4 Sequence number 2 Model year 5 Serial label (located on chassis) 3 Facility code 6 Serial number (stamped on chassis) From September 1, 2016 1 Model 4 Serial label (located on chassis) 2 Facility code...

  • Page 5: Safety Rules

    September 2016 Service and Repair Manual Safety Rules Section 1 Safety R ules Danger Failure to obey the instructions and safety rules in this manual and the appropriate Operator's Manual on your machine 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.
  • Page 6 Service and Repair Manual September 2016 Safety Rules Personal Safety Workplace Safety Any person working on or around a machine must Any person working on or around a machine must be aware of all known safety hazards. Personal be aware of all known safety hazards. Personal safety and the continued safe operation of the safety and the continued safe operation of the machine should be your top priority.

  • Page 7: Table Of Contents

    September 2016 Table of Contents Introduction Introduction ......................ii Important Information ..................... ii Find a Manual for this Model .................. ii Revision History..................... iii Serial Number Legend ..................iv Section 1 Safety Rules ......................v General Safety Rules ..................... v Section 2 Specifications .......................
  • Page 8 September 2016 Table of Contents Hydraulic Tank ....................43 3-1 Hydraulic Tank ....................43 Hydraulic Pump ....................44 4-1 Hydraulic Pump ..................... 44 How to Remove the Hydraulic Pump .............. 45 Manifolds ......................46 5-1 Function Manifold Components ..............46 5-2 Powered Extension Deck Function Manifold Components ......
  • Page 9 September 2016 Table of Contents Section 4 Diagnostics ......................77 Introduction ......................77 GCON I/O Map (with manual extension deck) ............. 79 GCON I/O Map (with powered extension deck) ........... 80 Operation Indicator Codes (OIC)................82 Diagnostic Trouble Codes (DTC) ................. 82 Troubleshooting "HXXX"...

  • Page 11: Specifications

    September 2016 Service and Repair Manual Specifications Section 2 Specific ati ons Machine Specifications Fluid capacities Hydraulic tank 3.75 gallons Batteries, Standard 14.2 liters Hydraulic system (including tank) 5 gallons Voltage 6V DC 19 liters Group Tires and Wheels Type T-105 Tire size (solid rubber) 15 x 5 in...

  • Page 12: Performance Specifications

    Service and Repair Manual September 2016 Specifications Performance Specifications Function speed, maximum from platform controls (with 1 person in platform) Drive speed, maximum Platform up (fast mode) 28 to 32 seconds Platform up (slow mode) 58 to 62 seconds Platform stowed, fast 2.2 mph Platform down 32 to 36 seconds...

  • Page 13: Hydraulic Specification

    Hydraulic fluids may be incompatible due to the Hydraulic Fluid Specifications differences in base additive Genie specifications require hydraulic oils which are chemistry. When incompatible designed to give maximum protection to hydraulic fluids are mixed, insoluble systems, have the ability to perform over a wide...
  • Page 14 Service and Repair Manual September 2016 Specifications Chevron Rando HD Premium Oil Chevron 5606A Hydraulic Oil MV Fluid Properties Fluid Properties ISO Grade ISO Grade Viscosity index Viscosity index Kinematic Viscosity Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 200°F / 100°C cSt @ 104°F / 40°C 33.5 cSt @ 104°F / 40°C...
  • Page 15 September 2016 Service and Repair Manual Specifications Petro-Canada Environ MV 46 UCON Hydrolube HP-5046 Fluid Fluid Properties Properties ISO Grade ISO Grade Viscosity index Viscosity index Kinematic Viscosity Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 149°F / 65°C cSt @ 104°F / 40°C 44.4 cSt @ 104°F / 40°C...

  • Page 16: Hydraulic Component And Manifold Specifications

    Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with Parker Seal-Lok™ ORFS or 37° JIC fittings and hose ends. Genie specifications require that fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed.

  • Page 17: Torque Procedure

    O-rings. They are not 125 ft-lbs / 169.5 Nm standard size O-rings. They are available in the O-ring field service kit (Genie part number 49612). 151 ft-lbs / 204.7 Nm 184 ft-lbs / 249.5 Nm Lubricate the O-ring before installation.
  • Page 18 Service and Repair Manual September 2016 Specifications JIC 37° fittings Working clockwise on the body hex fitting, make a second mark with a permanent ink Align the tube flare (hex nut) against the nose marker to indicate the proper tightening of the fitting body (body hex fitting) and tighten position.

  • Page 19: Repair Procedures

     Be sure that all necessary tools and parts are available and ready for use.  Use only Genie approved replacement parts.  Read each procedure completely and adhere to the instructions. Attempting shortcuts may produce hazardous conditions.
  • Page 20 Service and Repair Manual September 2016 Repair Procedures Symbols Legend About This Section Safety alert symbol—used to alert Most of the procedures in this section should only personnel to potential personal be performed by trained service professional in a injury hazards. Obey all safety suitably equipped workshop.

  • Page 21: Platform Controls

    Push in and pull out function buttons and LED display. the red Emergency Stop button to reset the system. For further information or assistance, contact Genie Product Support. Platform Controls LED Readout Code Condition Off-level Platform Overload (CE and Australia)

  • Page 22: Circuit Board

    Service and Repair Manual September 2016 Platform Controls Carefully disconnect all wire harness connectors from the platform controls circuit Circuit Board board. Electrocution/burn hazard. How to Remove the Platform Contact with electrically charged Controls Circuit Board circuits could result in death or serious injury.

  • Page 23: Joystick

    September 2016 Service and Repair Manual Platform Controls Joystick Platform Controls Alarm How to Remove the Joystick How to Remove the Platform Controls Alarm Push in the red Emergency Stop button to the off position at both the ground and platform Push in the red Emergency Stop button to the controls.

  • Page 24: Platform Emergency Stop Button

    Service and Repair Manual September 2016 Platform Controls Disconnect the white wires from the Emergency Stop base. Platform Emergency Stop Button Electrocution/burn hazard. Contact with electrically charged How to Remove the Platform circuits could result in death or Controls Emergency Stop Button serious injury.

  • Page 25: Ground Controls

    2 machine setup, scroll up button 3 LCD readout For further information or assistance, contact 4 machine setup, scroll down button Genie Product Support. 5 machine setup, enter button 6 selector switch KS1 7 red Emergency Stop P1 8 circuit breaker CB2...

  • Page 26: Software Revision Level

    Service and Repair Manual September 2016 Ground Controls Software Revision Level How to Determine the Software Revision Level The machine software revision level is displayed at the ground controls LCD display. Turn the selector/key switch to the ground controls or platform controls position. Pull out the red Emergency Stop button to the on position at both ground and platform controls.

  • Page 27: Machine Setup

    September 2016 Service and Repair Manual Ground Controls Press the ground control scroll down button. Machine Setup Result: The ground control LCD display will indicate the software revision and hour meter information. After 5 seconds, the ground How to Setup the Machine from controls LCD display will display machine model and hour meter information again.

  • Page 28: Loading Or Updating Machine Software

    Loading or Updating Machine Software Note: Before updating the machine software, open a web browser and navigate to the following location for the Genie Machine Software Download portal, http://firmware.genielift.com. Perform a search by applying the appropriate filters and download the machine software.
  • Page 29 September 2016 Service and Repair Manual Ground Controls Bootloader Mode Locate the diagnostic port on the side of the GCON. Remove one of the fasteners securing Open the GCON compartment. the cover and set aside. Loosen the other fastener. Do not remove it. Note: Some models will require opening the ground control box to access the GCON.
  • Page 30 Note: Do not turn off power while the ECM is being reprogrammed. Select the Choose File button and navigate to the downloaded Genie Flash file (.gff). 12 Select the Run Application button to exit the Note: Verify it is the correct flash file.
  • Page 31 September 2016 Service and Repair Manual Ground Controls Machine Application Mode Read and record the IP address. Open the GCON compartment. Note: The display wil only show the IP address for 3 seconds. Press the Note: Some models will require opening the ground scroll up button to display the IP control box to access the GCON.
  • Page 32 Note: Do not turn off power while the ECM is being reprogrammed. 10 Select the Choose File button and navigate to the downloaded Genie Flash file (.gff). Note: Verify it is the correct flash file. 13 Select the Run Application button to exit the software update mode.

  • Page 33: Using A Wi-Fi Router To Connect To The Smartlink Web Service Tool

    September 2016 Service and Repair Manual Ground Controls 15 Secure the diagnostic port cover using the retaining fasteners removed in step 5. Do not Using a Wi-Fi Router to Connect over tighten. to the SmartLink Web Service Note: Machines equipped with AGM batteries will Tool need to select the AGM battery type using the GCON set parameters screen.
  • Page 34 Service and Repair Manual September 2016 Ground Controls Locate the diagnostic port on the side of the Read and record the IP address. GCON. Remove one of the fasteners securing Note: The display wil only show the the cover and set aside. Loosen the other IP address for 3 seconds.

  • Page 35: Service Override Mode

    September 2016 Service and Repair Manual Ground Controls Enter the following username and password then select OK. Service Override Mode Username: smart.link The Electronic Control Module (ECM) is Password: SL1000 programmed with a Service Override mode. Note: The username and password are case Service Override mode is only indented for certain sensitive.
  • Page 36 Service and Repair Manual September 2016 Ground Controls Press and hold the ground control scroll up Press the Enter button. and scroll down buttons. Result: The ground controls LCD display will show an alternating message every 1.5 seconds. Ground Control Menu Buttons a scroll down button b enter button c scroll up button...

  • Page 37: Level Sensors

    September 2016 Service and Repair Manual Ground Controls Level Sensors The Electronic Control Module (ECM) is programmed to deactivate the lift and drive functions and activate an alarm when a signal is received from the level sensor. The tilt alarm sounds when the incline of the chassis exceeds 1.5°...
  • Page 38 Service and Repair Manual September 2016 Ground Controls How to Install and Calibrate the Turn the key switch to the off position and push in the red Emergency Stop button to the Level Sensor - Procedure 1 off position at the ground controls. Tip-over hazard.
  • Page 39 September 2016 Service and Repair Manual Ground Controls 12 Place the new level sensor onto the level 13 Install the level sensor retaining fasteners sensor mount bracket with the "X" on the level through the level sensor and springs, and into sensor base closest to the long side of the the mount bracket.
  • Page 40 Service and Repair Manual September 2016 Ground Controls 22 GS-1530 and GS-1930: Place a 0.64 x 6 x 29 Center a lifting jack under the drive chassis at 6 inch / 16.2 mm x 15 cm x 15 cm thick steel the battery pack side of the machine.
  • Page 41 September 2016 Service and Repair Manual Ground Controls How to Install and Calibrate the Raise the platform 7 to 8 feet / 2.1 to 2.4 m. Level Sensor - Procedure 2 Lift the safety arm, move it to the center of the scissor arm and rotate down to a vertical Tip-over hazard.
  • Page 42 Service and Repair Manual September 2016 Ground Controls 11 Place the new level sensor on to the level 12 Install the level sensor retaining fasteners sensor bracket with the "Y" on the level sensor through the level sensor and into the mount closest to the ground controls of the machine bracket.
  • Page 43 September 2016 Service and Repair Manual Ground Controls 17 Pull out the red Emergency Stop button to the 23 Press and hold the Enter button to start on position at the ground controls. calibration. Result: The ground controls LCD display will Result: An audible alarm will sound when show the following: calibration is complete.
  • Page 44 Service and Repair Manual September 2016 Ground Controls 29 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. 35 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. Result: No audible alarm is heard. Result: No audible alarm is heard.
  • Page 45 September 2016 Service and Repair Manual Ground Controls 42 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. 48 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. Result: No audible alarm is heard. Result: No audible alarm is heard.
  • Page 46 Service and Repair Manual September 2016 Ground Controls How to Install and Calibrate the Lower the platform onto the safety arm. Level Sensor - Procedure 3 Crushing hazard. Keep hands clear of the safety arm when Tip-over hazard. Failure to install lowering the platform.
  • Page 47 September 2016 Service and Repair Manual Ground Controls 11 Place the new level sensor on to the level 12 Install the level sensor retaining fasteners sensor bracket with the "Y" on the level sensor through the level sensor and into the mount away from the ground controls of the machine bracket.
  • Page 48 Service and Repair Manual September 2016 Ground Controls 17 Pull out the red Emergency Stop button to the 23 Press and hold the Enter button to start on position at the ground controls. calibration. Result: The ground controls LCD display will Result: An audible alarm will sound when show the following: calibration is complete.
  • Page 49 September 2016 Service and Repair Manual Ground Controls 29 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. 35 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. Result: No audible alarm is heard. Result: No audible alarm is heard.
  • Page 50 Service and Repair Manual September 2016 Ground Controls 42 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. 48 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. Result: No audible alarm is heard. Result: No audible alarm is heard.

  • Page 51: Manual Platform Lowering Cable

    September 2016 Service and Repair Manual Ground Controls Measure the distance between the base of the handle and cable mounting nut. Manual Platform Lowering Cable Result: The measurement should be no The manual platform lowering cable lowers the greater than 0.125 inch / 3 mm. platform in the event of a main power failure.
  • Page 52 Service and Repair Manual September 2016 Ground Controls Skip to step 8 if the measurement is Repeat this procedure beginning with step 4. correct. Raise the platform and rotate the safety arm to To adjust, loosen the upper lock nut on the the stowed position.

  • Page 53: Hydraulic Tank

    September 2016 Service and Repair Manual Hydraulic Tank Tag and disconnect the hydraulic tank hard line from the pump. Remove the hard line from Hydraulic Tank the machine. Cap the fitting on the pump. The primary functions of the hydraulic tank are to Remove the hydraulic tank retaining fasteners cool and deaerate the hydraulic fluid during and remove the hydraulic tank from the...

  • Page 54: Hydraulic Pump

    Service and Repair Manual September 2016 Hydraulic Pump Activate the platform up function from the ground controls. Function Pump Result: If the pressure gauge reads 3200 psi / The hydraulic pump is attached to the motor which 221 bar, immediately stop. The pump is good. makes up the hydraulic power unit.

  • Page 55: How To Remove The Hydraulic Pump

    September 2016 Service and Repair Manual Hydraulic Pump How to R emove the Hydr aulic Pump How to Remove the Hydraulic Tag, disconnect and plug the high pressure hose from the pump. Cap the fitting on the Pump pump. Note: When removing a hose assembly or fitting, Bodily injury hazard.

  • Page 56: Manifolds

    Service and Repair Manual September 2016 Manifolds Function Manifold Components The function manifold is mounted behind an inspection door, at the ground control side of the machine. Schematic Index No. Description Function Torque Item — Coil Nut (item AC) — —...
  • Page 57 September 2016 Service and Repair Manual Manifolds Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic. Note: 'alpha-numeric' callouts refer to corresponding notes on the electrical schematic. Part No. 1272218 GS-2646 AV • GS-2646 AV35...

  • Page 58: Powered Extension Deck Function Manifold Components

    Service and Repair Manual September 2016 Manifolds Powered Extension Deck Function Manifold Components The powered extension deck function manifold is mounted behind an inspection door, at the battery side of the machine. Index No. Description Schematic Item Function Torque — Coil nut (item EA and EC) 4-5 ft-lbs / 5-7 Nm Solenoid valve, 3 position 4 way...

  • Page 59: Valve Adjustments - Function Manifold

    September 2016 Service and Repair Manual Manifolds Adjust the internal hex socket. Turn it clockwise to increase the pressure or Valve Adjustments – counterclockwise to decrease the pressure. Function Manifold Tip-over hazard. Failure to adjust the relief valves to specification Note: Perform this test from the ground with the could result in the machine platform controls.
  • Page 60 Service and Repair Manual September 2016 Manifolds How to Adjust the Adjust the internal hex socket. Turn it clockwise to increase the pressure or Platform Lift Relief Valve counterclockwise to decrease the pressure. Note: Perform this test from the ground with the Tip-over hazard.
  • Page 61 September 2016 Service and Repair Manual Manifolds How to Adjust the 12 Turn the selector/key switch to ground control and pull out the red Emergency Stop button to Steer Relief Valve the on position at both ground and platform controls. Note: Perform this test from the ground with the platform controls.

  • Page 62: Valve Coils

    Service and Repair Manual September 2016 Manifolds Turn the machine off. Hold the steer relief valve with a wrench and remove the cap Valve Coils (schematic item AH). Adjust the internal hex socket. Turn it How to Test a Coil clockwise to increase the pressure or counterclockwise to decrease the pressure.
  • Page 63 Manifolds Valve Coil Resistance How to Test a Coil Diode Specifications Genie incorporates spike suppressing diodes in all of its coils. Properly functioning coil diodes protect Note: The following coil resistance specifications the electrical circuit by suppressing voltage spikes. are at an ambient temperature of 68°F / 20°C. As...
  • Page 64 Service and Repair Manual September 2016 Manifolds Note: If testing a single terminal coil, connect the negative lead to the internal metallic ring at either end of the coil. 1 multimeter 2 9V DC battery 3 10Ω resistor 4 coil Note: Dotted lines in illustration indicate a reversed connection as specified in step 6.

  • Page 65: Steer Axle Components

    September 2016 Service and Repair Manual Steer Axle Components Tag, disconnect and plug the hydraulic hoses on the drive motor. Cap the fittings on the Yoke and Drive Motor drive motor. Bodily injury hazard. Spraying How to Remove the Yoke hydraulic oil can penetrate and and Drive Motor Assembly burn skin.

  • Page 66: Steer Cylinder

    Service and Repair Manual September 2016 Steer Axle Components How to Remove a Drive Motor Steer Cylinder Block the non-steer tires. Remove the cotter pin from the wheel castle How to Remove the Steer nut of the motor to be removed. Cylinder Note: Always replace the cotter pin with a new one when removing the castle nut.

  • Page 67: Steer Bellcrank

    September 2016 Service and Repair Manual Steer Axle Components Remove the bellcrank from the machine. Steer Bellcrank How to Remove the Steer Bellcrank Remove the steer cylinder. Refer to Repair Procedure, How to Remove the Steer Cylinder. Remove the retaining fasteners from the steer links at each end of the bellcrank.

  • Page 68: Non-Steer Axle Components

    Service and Repair Manual September 2016 Non-Steer Axle Components Raise the machine approximately 2 inches / 5 cm. Place blocks under the chassis for Drive Brake support. Crushing hazard. The chassis How to Remove the Drive Brake will fall if not properly supported. Note: When removing a hose assembly or fitting, Remove the wheel castle nut.

  • Page 69: Brake Release Hand Pump Components

    September 2016 Service and Repair Manual Brake Release Hand Pump Components Brake Release Hand Pump Components The brake release hand pump manifold is mounted behind the entry ladder. Index No. Description Schematic Item Function Torque Hand pump Manual brake release 30 ft-lbs / 41 Nm Needle valve Manual brake release enable...

  • Page 70: Scissor Components

    Service and Repair Manual September 2016 Scissor Components Steer End Non-steer End 1 - Number 5 pivot pin 12 - Number 4 inner arm 2 - Number 4 center pivot pin (2 pins) 13 - Number 4 outer arm 3 - Number 4 pivot pin (steer end) 14 - Number 4 pivot pin (non-steer end) 4 - Number 3 center pivot pin (2 pins) 15 - Number 3 inner arm...

  • Page 71: Scissor Assembly

    September 2016 Service and Repair Manual Scissor Components Scissor Assembly How to Disassemble the Scissor Assembly Bodily injury hazard. The procedures in this section require specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage.
  • Page 72 Service and Repair Manual September 2016 Scissor Components Use a soft metal drift to remove the number 16 Remove the number 4 outer arm (index #13) 5 pivot pin (index #1). Remove the platform from the machine. mount bracket from the machine. Crushing hazard.
  • Page 73 September 2016 Service and Repair Manual Scissor Components 24 Place a rod through the number 3 center pivot 32 Remove the retaining fasteners from the lift pin at the ground control side (index #4) and cylinder rod end pivot pin (index #5). twist to remove the pin.
  • Page 74 Service and Repair Manual September 2016 Scissor Components 40 Disconnect the number 2A and 2B cable 48 Place a rod through the number 2 center pivot bridges from the scissor linkset and remove pin at the battery side (index #7) and twist to both cable bridges from the machine.
  • Page 75 September 2016 Service and Repair Manual Scissor Components 56 Lower the scissor arms onto the block that 63 Remove the cables from the number 1 cable was placed across the chassis. bridge and lay them off to the side. Bodily injury hazard. Keep hands Component damage hazard.

  • Page 76: How To Replace The Scissor Arm Wear Pads

    Service and Repair Manual September 2016 Scissor Components How to R eplac e the Sciss or Arm W ear Pads How to Replace the Scissor Arm Raise the scissor arm assembly at the steer end with the overhead crane until the chassis Wear Pads mount bracket will clear the level sensor.

  • Page 77: Lift Cylinder

    September 2016 Service and Repair Manual Scissor Components At the ground controls, turn the selector/key switch to the off position and push in the red Lift Cylinder Emergency Stop button to the off position. How to Remove the Lift Cylinder Bodily injury hazard.
  • Page 78 Service and Repair Manual September 2016 Scissor Components Tag and disconnect the wiring from the 15 Attach a lifting strap from an overhead crane solenoid valve coil at the barrel end of the lift or similar lifting device to the barrel end of the cylinder.

  • Page 79: Platform Components

    September 2016 Service and Repair Manual Platform Components 10-1 Disconnect the battery pack from the machine. Platform Electrocution/burn hazard. Contact with electrically charged circuits could result in death or How to Remove the Platform serious injury. Remove all rings, watches and other jewelry. Bodily injury hazard.
  • Page 80 Service and Repair Manual September 2016 Platform Components 16 Remove the zip tie that secures the power to 22 Carefully lift the platform enough to clear the platform wiring to the bottom of the platform. platform pivot. 23 Slide the platform towards the non-steer end Component damage hazard.

  • Page 81: Platform Extension

    September 2016 Service and Repair Manual Platform Components 10-2 Repeat steps 3 and 4 at the opposite side of the extension deck. Platform Extension How to R emove the M anual Extension D eck How to Remove the Manual Extension Deck Remove the platform controls from the platform and set the platform controls to the side.

  • Page 82: How To Remove The Powered Extension Deck (If Equipped)

    Service and Repair Manual September 2016 Platform Components How to R emove the Power ed Ex tensi on Dec k (if equi pped) How to Remove the Powered At the steer end of the extension deck, locate, tag and disconnect the front gate proximity Extension Deck (if equipped) switch from the limit switch harness.

  • Page 83: Extension Deck Cylinder

    September 2016 Service and Repair Manual Platform Components 10-3 Locate the cable track at the steer end of the extension deck and remove the fasteners. Set Extension Deck Cylinder the fasteners to the side. Carefully slide the cable track and the cable How to Remove the Extension track mounting bracket into the main deck.
  • Page 84 Service and Repair Manual September 2016 Platform Components Working with the PED limit switch, loosen the 10 Remove the fasteners securing the banjo bolt nut from the carriage bolt. Do not remove. to the extension deck cylinder pin. Set the banjo bolt and fasteners to the side.
  • Page 85 September 2016 Service and Repair Manual Platform Components 17 Raise the platform and return the safety arm to the stowed position. 18 Fully lower the platform to the stowed position. 19 Fully extend the extension deck. 20 Carefully remove the extension deck cylinder from the main deck.
  • Page 86 Service and Repair Manual September 2016 This page intentionally left blank. GS-2646 AV • GS-2646 AV35 Part No. 1272218...

  • Page 87: Diagnostics

    September 2016 Service and Repair Manual Diagnostics Section 4 Diagnostics Before Troubleshooting:  Read, understand and obey the safety rules and operating instructions in the appropriate operator's manual on your machine.  Be sure that all necessary tools and test Observe and Obey: equipment are available and ready for use.
  • Page 88 Models are listed below each code to assist in the troubleshooting codes for a specific model. Genie SmartLink Diagnostic System This machine is equipped with the Genie SmartLink™ Diagnostic System (GSDS). The GSDS indicates a machine malfunction has happened by displaying Operational Indicator Codes (OIC) and Diagnostic Trouble Codes (DTC).

  • Page 89: Gcon I/O Map (With Manual Extension Deck)

    September 2016 Service and Repair Manual GCON I/O Map (with manual extension deck) GCON Pin Wire Gauge and Circuit Function I/O Type Number Color J1 Connector – Gray J1-01 ECM Power Power Input 14 RD J1-02 PCON, E-Stop Power Power Output 18 RD J1-03 PCON, E-Stop Return...

  • Page 90: Gcon I/O Map (With Powered Extension Deck)

    Service and Repair Manual September 2016 GCON I/O Map (with powered extension deck) GCON Pin Wire Gauge and Circuit Function I/O Type Number Color J1 Connector – Gray J1-01 ECM Power Power Input 14 RD J1-02 PCON, E-Stop Power Power Output 18 RD J1-03 PCON, E-Stop Return...
  • Page 91 September 2016 Service and Repair Manual GCON I/O Map (with powered extension deck) GCON Pin Circuit Function I/O Type Wire Gauge and Number Color J-3 Connector – Green J3-01 No Circuit J3-02 GCON — Alarm Digital Output 18 BL J3-03 Switch/Sensor Power Digital Output 14 RD...

  • Page 92: Operation Indicator Codes (Oic)

    Service and Repair Manual September 2016 Operation Indicator Codes (OIC) Operation Indicator Codes (OIC) Diagnostic Trouble Codes (DTC) These codes are generated by the electrical These codes are generated by the system to system to indicate machine operating status such indicate that a device or circuit malfunction has as Off-level, Overload Cutout, Chassis Mode been detected in the electrical system.

  • Page 93: Troubleshooting "Hxxx" And "Pxxx" Faults

    September 2016 Service and Repair Manual Troubleshooting "HXXX" and "PXXX" Faults Troubleshooting "HXXX" and "PXXX" Faults The procedure below illustrates typical steps for diagnosing and fixing faults of type "HXXX" and "PXXX". Diagnostic Chart Good 1 Check the faulted device for a short or open circuit. Replace faulted device.

  • Page 94: Fault Inspection Procedure

    Service and Repair Manual September 2016 Fault Inspection Procedure Fault Inspection Procedure Check the device associated with the faulted circuit Disconnect the faulted device connector. Using a multi-meter, measure resistance between the two terminals of the faulted device. Resistance should be as follows. Device Typical Resistance 27.2 Ω...
  • Page 95 September 2016 Service and Repair Manual Fault Inspection Procedure Check the GCON ECM Disconnect the GCON ECM connectors, J1, J2 and J3. For short to B- type faults, measure resistance between pins J1-7 (ground) and the GCON pin associated with the fault code.

  • Page 96: Type "Hxxx" Faults

    Service and Repair Manual September 2016 Type "HXXX" Faults Message on Problem Possible Failure Number GCON LCD Description Causes Mode • Short circuit in platform up #1 harness H001:COILFAULT Short circuit of the platform up #1 Platform up function • Platform up #1 coil short circuit H001 PLAT UP1:BAT- circuit to battery negative.
  • Page 97 September 2016 Service and Repair Manual Type "HXXX" Faults Message on Problem Possible Failure Number GCON LCD Description Causes Mode • Short circuit in motor controller enable wire All functions H067:FAULT Short circuit of the motor controller • Motor Controller H067 inhibited except MC ENABLE:BAT-...

  • Page 98: Type "Pxxx" Faults

    Service and Repair Manual September 2016 Type "PXXX" Faults Message on Problem Possible Failure Number GCON LCD Description Causes Mode • Short circuit in switched power #1, down limit P001:PWR FAULT Short circuit of the switched power #1 switch, pothole limit switch, digital tilt switch All functions P001 SW PWR1:BAT-...

  • Page 99: Type "Uxxx" Faults

    September 2016 Service and Repair Manual Type "UXXX" Faults Message on Problem Possible Failure Number GCON LCD Description Causes Mode • Short circuit of the GCON main function enable U001:SWITCHFAULT Short circuit of the GCON main function All GCON functions switch U001 GCON MAIN FTN EN...
  • Page 100 Service and Repair Manual September 2016 Type "UXXX" Faults Message on Problem Possible Failure Number GCON LCD Description Causes Mode PCON platform up & U020:SWITCHFAULT Short circuit of the PCON high lift speed • Short circuit of the PCON hi lift speed switch U020 down functions PCON HI LIFT SPD...

  • Page 101: Type "Fxxx" Faults

    September 2016 Service and Repair Manual Type "FXXX" Faults Message on Problem Possible Failure Number GCON LCD Description Causes Mode • Short circuit of the down limit switch circuit. All functions F003:SWITCHFAULT Short circuit of the down limit #1 switch at •...

  • Page 102: Type "Cxxx" Faults

    Service and Repair Manual September 2016 Type "CXXX" Faults Message on Problem Possible Failure Number GCON LCD Description Causes Mode C001:GCON ECM • Incorrect software file All functions GCON ECM CRC check error. C001 FAULT TYPE 1 • GCON ECM internal failure inhibited.

  • Page 103: Schematics

    September 2016 Service and Repair Manual Schematics Section 5 Schem atics About This Section There are two groups of schematics in this section. Electrical Schematics Electrocution/burn hazard. Contact with electrically charged Observe and Obey: circuits could result in death or serious injury.

  • Page 104: Electrical Component And Wire Color Legends

    Service and Repair Manual September 2016 Electrical Component and Wire Color Legends ELECTRICAL COMPONENT LEGEND ELECTRICAL COMPONENT LEGEND cont. Item Description Item Description Batteries Circuit Breaker, 7A B5 = Battery Pack 24V DC, 4 each @ 6V DC Diode Connector D1 = Motor Controller Enable -, 3A D2 = Motor Controller Enable +, 3A C1 = Anderson Connector...
  • Page 105 September 2016 Service and Repair Manual Electrical Component and Wire Color Legends ELECTRICAL COMPONENT LEGEND cont. WIRE COLOR LEGEND Item Description Color Description Joystick Controller Black Contactor, Motor Controller Power, N.O.H.C. BK/RD Black/Red KS1 = Key Switch Blue KS2 = Keyless Selector Switch BL/BK Blue/Black Limit Switch...

  • Page 106: Wiring Diagram Ground Controls

    Service and Repair Manual September 2016 Wiring Diagram Ground Controls GS-2646 AV • GS-2646 AV35 Part No. 1272218...

  • Page 107: Wiring Diagram Platform Controls

    September 2016 Service and Repair Manual Wiring Diagram Platform Controls Part No. 1272218 GS-2646 AV • GS-2646 AV35...

  • Page 108: Limit Switch Legend

    Service and Repair Manual September 2016 Limit Switch Legend Limit Switch Legend 1 pothole switches LS7, LS8 2 down limit switch LS6 3 quick disconnect limit switch LS30 (no charger option) 4 powered extension deck LS29 (option) 5 front gate PX3 (steer end) 6 rear gate PX4 (non-steer end) GS-2646 AV •...
  • Page 109 September 2016 Service and Repair Manual Limit Switch Legend Part No. 1272218 GS-2646 AV • GS-2646 AV35...

  • Page 110: Electrical Symbol Legend

    Service and Repair Manual September 2016 Electrical Symbol Legend Wire with description or color Limit Switch Motor controller Key switch Circuits crossing no connection Emergency Stop button Motor Solenoid valve with diode Diode Circuit breaker Battery charger Level sensor Circuit connection Fuse 6V or 12V DC battery Deutsch connector...

  • Page 111: Hydraulic Symbols Legend

    September 2016 Service and Repair Manual Hydraulic Symbols Legend Hydraulic cylinder Variable speed motor Pressure transducer Solenoid operated 2 position 4 way directional valve Relief valve Bi-directional motor Solenoid operated Solenoid operated 2 position 2 way 2 position 4 way blocking valve directional valve normally open...

  • Page 112: Hydraulic Component Reference

    Service and Repair Manual September 2016 Hydraulic Component Reference Powered extension deck manifold Brake release manifold Function manifold GS-2646 AV • GS-2646 AV35 Part No. 1272218...

  • Page 113: Electrical Schematics - Ansi And Csa Models

    September 2016 Service and Repair Manual Electrical Schematic • GS-2646 AV and GS-2646 AV35 (with manual extension deck) (from GS4612A-110000)

  • Page 114: Electrical Schematic • Gs-2646 Av And Gs-2646 Av35 (With Manual Extension Deck) (From Gs4612A-110000)

    Service and Repair Manual September 2016 Electrical Schematic • GS-2646 AV and GS-2646 AV35 (with manual extension deck) (from GS4612A-110000) GS-2646 AV • GS-2646 AV35 Part No. 1272218...
  • Page 115 September 2016 Service and Repair Manual Electrical Schematic • GS-2646 AV and GS-2646 AV35 (with manual extension deck) (from GS4612A-110000) Part No. 1272218 GS-2646 AV • GS-2646 AV35...
  • Page 116 Service and Repair Manual September 2016 Electrical Schematic • GS-2646 AV and GS-2646 AV35 (with manual extension deck) (from GS4612A-110000)
  • Page 117 September 2016 Service and Repair Manual Electrical Schematic • GS-2646 AV and GS-2646 AV35 (with powered extension deck) (from serial number GS4612A-110000)

  • Page 118: Electrical Schematic • Gs-2646 Av And Gs-2646 Av35 (With Powered Extension Deck) (From Serial Number Gs4612A-110000)

    Service and Repair Manual September 2016 Electrical Schematic • GS-2646 AV and GS-2646 AV35 (with powered extension deck) (from serial number GS4612A-110000) GS-2646 AV • GS-2646 AV35 Part No. 1272218...
  • Page 119 September 2016 Service and Repair Manual Electrical Schematic • GS-2646 AV and GS-2646 AV35 (with powered extension deck) (from serial number GS4612A-110000) Part No. 1272218 GS-2646 AV • GS-2646 AV35...
  • Page 120 Service and Repair Manual September 2016 Electrical Schematic • GS-2646 AV and GS-2646 AV35 (with powered extension deck) (from serial number GS4612A-110000)
  • Page 121 September 2016 Service and Repair Manual Electrical Schematic • GS-2646 AV and GS-2646 AV35 (foot switch option) (from serial number GS4612A-110000)

  • Page 122: Electrical Schematic • Gs-2646 Av And Gs-2646 Av35 (Foot Switch Option) (From Serial Number Gs4612A-110000)

    Service and Repair Manual September 2016 Electrical Schematic • GS-2646 AV and GS-2646 AV35 (foot switch option) (from serial number GS4612A-110000) GS-2646 AV • GS-2646 AV35 Part No. 1272218...

  • Page 123: Hydraulic Schematics

    September 2016 Service and Repair Manual Hydraulic Schematics Section 6 Hydraulic Schem atics Hydraulic Schematic Part No. 1272218 GS-2646 AV • GS-2646 AV35...

  • Page 124: Hydraulic Schematic, Powered Extension Deck Manifold

    Service and Repair Manual September 2016 Hydraulic Schematics Hydraulic Schematic, Powered Extension Deck Manifold GS-2646 AV • GS- 2646 AV35 Part No. 1272218 Servic e and R epair M anual September 2016 GS-2646 AV • GS-2646 AV35 Part No. 1272218...

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