Terex GS6805-44771 Service Manual
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Terex GS6805-44771 Service Manual

Terex GS6805-44771 Service Manual

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Service Manual
Par ts Manual
GS-2668 RT
GS-3268 RT
All manuals and user guides at all-guides.com
Serial Number Range
Serial Number Range
from GS6805-44771
from GS6805-44771
Part No. 112657
Rev C2
July 2011

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  • Page 1 All manuals and user guides at all-guides.com Par ts Manual Service Manual Serial Number Range Serial Number Range GS-2668 RT from GS6805-44771 GS-3268 RT from GS6805-44771 Part No. 112657 Rev C2 July 2011...

  • Page 2: Introduction

    Copyright © 1998 by Genie Industries www.genieindustries.com 112657 Rev C June 2007 Second Edition, Third Printing e-mail: techpub@terex.com "Genie" is a registered trademark of Genie Industries in the USA and many other countries. "GS" is a trademark of Genie Industries.

  • Page 3: Serial Number Legend

    All manuals and user guides at all-guides.com June 2007 INTRODUCTION Serial Number Legend Model: GS-1930 Serial number: GS3005A-12345 Model year: 2005 Manufacture date: 04/12/05 Electrical schematic number: ES0141 Machine unladen weight: 2,714 lb / 1,231 kg GS30 05 A - 12345 Rated work load (including occupants): 500 lb / 227 kg Maximum allowable inclination of the chassis:...
  • Page 4 All manuals and user guides at all-guides.com June 2007 This page intentionally left blank. GS-2668 RT • GS-3268 RT Part No. 112657...

  • Page 5: Safety Rules

    All manuals and user guides at all-guides.com June 2007 Section 1 • Safety Rules Safety Rules 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.

  • Page 6: Personal Safety

    All manuals and user guides at all-guides.com Section 1 • Safety Rules June 2007 SAFETY RULES Personal Safety Workplace Safety Any person working on or around a machine must Be sure to keep sparks, flames and be aware of all known safety hazards. Personal lighted tobacco away from flammable and safety and the continued safe operation of the combustible materials like battery gases...

  • Page 7: Table Of Contents

    All manuals and user guides at all-guides.com November 2008 Table of Contents Introduction Important Information ..................ii Serial Number Information .................. ii Serial Number Legend ..................iii Section 1 Safety Rules General Safety Rules ..................v Section 2 Specifications Machine Specifications ................2 - 1 Performance Specifications .................
  • Page 8 All manuals and user guides at all-guides.com November 2008 TABLE OF CONTENTS Section 3 Scheduled Maintenance Procedures, continued Checklist A Procedures Inspect the Manuals and Decals ............3 - 7 Perform Pre-operation Inspection ............3 - 8 Perform Function Tests ..............3 - 8 Perform Engine Maintenance ..............
  • Page 9 All manuals and user guides at all-guides.com November 2008 TABLE OF CONTENTS Section 3 Scheduled Maintenance Procedures, continued B-11 Test the Drive Speed - Raised Position ..........3 - 22 B-12 Inspect the Fuel and Hydraulic Tank Cap Venting Systems ....3 - 22 B-13 Perform Hydraulic Oil Analysis ............
  • Page 10 All manuals and user guides at all-guides.com November 2008 TABLE OF CONTENTS Section 4 Repair Procedures Introduction ....................4 - 1 Platform Controls Circuit Boards ..................4 - 2 Platform Components Platform ..................... 4 - 3 Platform Extension ................4 - 4 Scissor Components Scissor Assembly, GS-2668 RT ............
  • Page 11 All manuals and user guides at all-guides.com November 2008 TABLE OF CONTENTS Section 4 Repair Procedures, continued Perkins 403D-11 and 403C-11 Engines Engine RPM ..................4 - 29 Timing Adjustment ................4 - 29 Flex Plate ..................4 - 30 Coolant Temperature and Oil Pressure Switches ......
  • Page 12 14-1 Brake Release Hand Pump Components .......... 4 - 73 Platform Overload Components 15-1 Platform Overload System ............... 4 - 74 Section 5 Fault Codes Introduction ....................5 - 1 Fault Code Chart (from serial number GS6805-44771) ........5 - 3 GS-2668 RT • GS-3268 RT Part No. 112657...
  • Page 13 (from serial number GS6805-44771) ............6 - 12 Electrical Schematic - ANSI Models with Diesel Power (from serial number GS6805-44771 to GS6806-45204) ......6 - 16 Electrical Schematic - ANSI Models with Diesel Power (from serial number GS6806-45205) ............6 - 20 Electrical Schematic - CE Models with Diesel Power (from serial number GS6805-44771 to GS6806-45204) ......
  • Page 14 All manuals and user guides at all-guides.com June 2007 This page intentionally left blank. GS-2668 RT • GS-3268 RT Part No. 112657...

  • Page 15: Machine Specifications

    All manuals and user guides at all-guides.com July 2011 Section 2 • Specifications Specifications REV D Machine Specifications Tire and wheels Wheel lugs Fluid capacities Lug bolt torque, dry 90 ft-lbs Hydraulic tank 15 gallons 122 Nm 56.8 liters Lug bolt torque, lubricated 67.5 ft-lbs Hydraulic system with outriggers 15.75 gallons...

  • Page 16: Performance Specifications

    All manuals and user guides at all-guides.com Section 2 • Specifications July 2011 SPECIFICATIONS REV D Performance Specifications Hydraulic Specifications Drive speed, maximum Hydraulic Oil Specifications Platform stowed 3.8 mph Hydraulic oil type Chevron Rykon MV equivalent 6.1 km/h Viscosity grade Multi-viscosity 40 ft / 7.2 sec Viscosity index...

  • Page 17: Hydraulic Components Specifications

    All manuals and user guides at all-guides.com July 2011 Section 2 • Specifications REV D SPECIFICATIONS Hydraulic Components Outrigger manifold Specifications Relief valve pressure 2000 psi 137.8 bar Function pump Generator manifold Type: 2 section pressure balanced gear pump Relief valve pressure 3000 psi Displacement 0.488 cu in...

  • Page 18: Manifold Component Specifications

    All manuals and user guides at all-guides.com Section 2 • Specifications July 2011 SPECIFICATIONS REV D Manifold Component Valve Coil Resistance Specifications Specifications Note: The following coil resistance specifications Plug torque are at an ambient temperature of 68°F / 20°C. As SAE No.

  • Page 19: Kubota D1105 Engine Tier 4

    All manuals and user guides at all-guides.com July 2011 Section 2 • Specifications REV D SPECIFICATIONS Kubota D1105 Engine Tier 4 Injection system Displacement 68.53 cu in Injection pump make Bosch MD 1.123 liters Injection timing 16.25° to 17.75° BTDC Number of cylinders Injection pump pressure 1992 to 2133 psi...

  • Page 20: Kubota D905 Engine Tier 2

    All manuals and user guides at all-guides.com Section 2 • Specifications July 2011 SPECIFICATIONS REV D Kubota D905 Engine Tier 2 Injection system Displacement 54.86 cu in Injection pump make Bosch MD 0.898 liters Injection timing 18° to 21° BTDC Number of cylinders Injection pump pressure 1991 psi...

  • Page 21: Kubota Df752 Engine

    All manuals and user guides at all-guides.com July 2011 Section 2 • Specifications REV D SPECIFICATIONS Kubota DF752 Engine Starter motor Displacement 45.21 cu in Brush length, new 0.669 in 0.74 liters 17 mm Number of cylinders Brush length wear limit 0.453 in 11.5 mm Bore &...

  • Page 22: Perkins 403D-11 Engine

    All manuals and user guides at all-guides.com Section 2 • Specifications July 2011 SPECIFICATIONS REV D Perkins 403D-11 Engine Injection system Displacement 68.9 cu in Injection pump make Bosch 1.13 liters Injection timing 23° BTDC @ 3000 rpm Number of cylinders Injection pump pressure 2133 psi Bore and stroke...

  • Page 23: Perkins 403C-11 Engine

    All manuals and user guides at all-guides.com July 2011 Section 2 • Specifications REV D SPECIFICATIONS Perkins 403C-11 Engine Injection system Displacement 68.9 cu in Injection pump make Bosch 1.13 liters Injection timing 23° BTDC @ 3000 rpm Number of cylinders Injection pump pressure 2133 psi Bore and stroke...

  • Page 24: Hydraulic Hose And Fitting Torque Specifications

    All manuals and user guides at all-guides.com Section 2 • Specifications July 2011 SPECIFICATIONS REV D Seal-Lok® fittings Hydraulic Hose and Fitting Torque Specifications 1 Replace the O-ring. The O-ring must be replaced anytime the seal has been broken. Your machine is equipped with Parker Seal-Lok ®...

  • Page 25: Sae Fastener Torque Chart

    All manuals and user guides at all-guides.com July 2011 Section 2 • Specifications REV D SPECIFICATIONS SAE FASTENER TORQUE CHART • This chart is to be used as a guide only unless noted elsewhere in this manual • A574 High Strength Grade 5 Grade 8 SIZE THREAD...
  • Page 26 All manuals and user guides at all-guides.com Section 2 • Specifications November 200 This page intentionally left blank. 2 - 12 GS-2668 RT • GS-3268 RT Part No. 112657...

  • Page 27: Scheduled Maintenance Procedures

    All manuals and user guides at all-guides.com November 2008 Section 3 • Scheduled Maintenance Procedures Scheduled Maintenance Procedures About This Section This section contains detailed procedures for each scheduled maintenance inspection. Each procedure includes a description, safety warnings and step-by-step instructions. Observe and Obey: Symbols Legend Safety alert symbol—used to alert...

  • Page 28: Pre-Delivery Preparation Report

    All manuals and user guides at all-guides.com Section 3 • Scheduled Maintenance Procedures November 2008 SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend Pre-delivery Preparation Report Note: The following symbols have been used in The pre-delivery preparation report contains this manual to help communicate the intent of the checklists for each type of scheduled inspection.
  • Page 29 All manuals and user guides at all-guides.com Pre-Deliver Pre-Deliver y Preparation y Preparation Pre-Deliver y Preparation y Preparation Pre-Deliver Pre-Deliver y Preparation November 2008 Section 3 • Scheduled Maintenance Procedures Fundamentals Instructions It is the responsibility of the dealer to perform the Use the operator’s manual on your machine.
  • Page 30 All manuals and user guides at all-guides.com Section 3 • Scheduled Maintenance Procedures November 2008 This page intentionally left blank. 3 - 4 GS-2668 RT • GS-3268 RT Part No. 112657...

  • Page 31: Maintenance Inspection Report

    All manuals and user guides at all-guides.com November 2008 Section 3 • Scheduled Maintenance Procedures Maintenance Inspection Report Model Checklist A - Rev B Y N R Checklist B - Rev B Y N R A-1 Manuals and decals B-1 Battery Serial number A-2 Pre-operation inspect B-2 Electrical wiring...
  • Page 32 All manuals and user guides at all-guides.com Section 3 • Scheduled Maintenance Procedures November 2008 MAINTENANCE INSPECTION REPORT Model Checklist C - Rev B Y N R Checklist E - Rev B Y N R C-1 Platform overload E-1 Test or replace Serial number (if equipped) hydraulic oil...

  • Page 33: Checklist A Procedures

    All manuals and user guides at all-guides.com November 2008 Section 3 • Scheduled Maintenance Procedures Checklist A Procedures REV B 3 Open the operator's manual to the decals inspection section. Carefully and thoroughly Inspect the Manuals and Decals inspect all decals on the machine for legibility and damage.

  • Page 34: Perform Pre-Operation Inspection

    All manuals and user guides at all-guides.com Section 3 • Scheduled Maintenance Procedures November 2008 CHECKLIST A PROCEDURES REV B Perform Pre-operation Inspection Perform Function Tests Genie specifications require that this procedure be Genie specifications require that this procedure be performed every 8 hours or daily, whichever performed every 8 hours or daily, whichever comes first.

  • Page 35: Perform Engine Maintenance

    All manuals and user guides at all-guides.com November 2008 Section 3 • Scheduled Maintenance Procedures REV B CHECKLIST A PROCEDURES Perform Engine Maintenance Inspect the Engine Air Filter Engine specifications require that this procedure Genie specifications require that this procedure be be performed every 8 hours or daily, whichever performed every 40 hours or weekly, whichever comes first.

  • Page 36: Perform 30 Day Service

    All manuals and user guides at all-guides.com Section 3 • Scheduled Maintenance Procedures November 2008 CHECKLIST A PROCEDURES REV B 6 Inspect the air filter element. If needed, blow from the inside out using low pressure dry Perform 30 Day Service compressed air, or carefully tap out dust.

  • Page 37: Perform Engine Maintenance - Kubota Models

    All manuals and user guides at all-guides.com November 2008 Section 3 • Scheduled Maintenance Procedures REV B CHECKLIST A PROCEDURES Perform Engine Maintenance - Perform Engine Maintenance - Kubota Models Kubota Models Engine specifications require that this one time Engine specifications require that this procedure procedure be performed after the first 50 hours of be performed every 50 hours or weekly, whichever operation.

  • Page 38: Perform Engine Maintenance - Kubota Models

    All manuals and user guides at all-guides.com Section 3 • Scheduled Maintenance Procedures November 2008 CHECKLIST A PROCEDURES REV B A-10 Perform Engine Maintenance - Perform Engine Maintenance - Kubota Models Kubota Models Engine specifications require that this procedure Engine specifications require that this procedure be performed every 100 hours.

  • Page 39: Drain The Fuel Filter/Water Separator - Diesel Models

    All manuals and user guides at all-guides.com November 2008 Section 3 • Scheduled Maintenance Procedures REV B CHECKLIST A PROCEDURES A-11 Drain the Fuel Filter/ Water Separator - Diesel Models Genie specifications require that this procedure be performed every 200 hours or monthly, whichever comes first.

  • Page 40: Perform Engine Maintenance - Kubota Models

    All manuals and user guides at all-guides.com Section 3 • Scheduled Maintenance Procedures November 2008 CHECKLIST A PROCEDURES REV B 8 Operate the hand primer until fuel, free of air, A-12 flows from the vent plug/screw. Tighten the vent Perform Engine Maintenance - plug/screw on the injection pump.

  • Page 41: Checklist B Procedures

    All manuals and user guides at all-guides.com November 2008 Section 3 • Scheduled Maintenance Procedures Checklist B Procedures REV B 6 Check the ambient air temperature and adjust the specific gravity reading for each cell as Inspect the Battery follows: •...

  • Page 42: Inspect The Electrical Wiring

    All manuals and user guides at all-guides.com Section 3 • Scheduled Maintenance Procedures November 2008 CHECKLIST B PROCEDURES REV B 3 Turn the key switch to ground control and pull out the Emergency Stop button to the Inspect the Electrical Wiring position at both the ground and platform controls.

  • Page 43: Inspect The Tires, Wheels And Lug Bolt Torque

    All manuals and user guides at all-guides.com November 2008 Section 3 • Scheduled Maintenance Procedures REV B CHECKLIST B PROCEDURES Inspect the Tires, Wheels and Perform Engine Maintenance - Lug Bolt Torque Perkins Models Engine specifications require that this procedure Genie requires that this procedure be performed be performed every 250 hours or six months, every 250 hours or quarterly, whichever comes...

  • Page 44: Test The Key Switch

    All manuals and user guides at all-guides.com Section 3 • Scheduled Maintenance Procedures November 2008 CHECKLIST B PROCEDURES REV B Test the Key Switch Test the Emergency Stop Genie requires that this procedure be performed Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes every 250 hours or quarterly, whichever comes first.

  • Page 45: Test The Automotive-Style Horn

    All manuals and user guides at all-guides.com November 2008 Section 3 • Scheduled Maintenance Procedures REV B CHECKLIST B PROCEDURES Test the Automotive-style Horn Test the Fuel Select Operation - Gasoline/LPG Models Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first.

  • Page 46: Test The Drive Brakes

    All manuals and user guides at all-guides.com Section 3 • Scheduled Maintenance Procedures November 2008 CHECKLIST B PROCEDURES REV B 4 Press the high idle button again to return the engine to low idle. Test the Drive Brakes Result: The high idle indicator light should turn and the engine should return to low idle.

  • Page 47: Test The Drive Speed - Stowed Position

    All manuals and user guides at all-guides.com November 2008 Section 3 • Scheduled Maintenance Procedures REV B CHECKLIST B PROCEDURES 5 Slowly move the joystick in the direction B-10 indicated by the yellow arrow on the control Test the Drive Speed - panel until the machine begins to move, then Stowed Position return the joystick to the center position.

  • Page 48: Test The Drive Speed - Raised Position

    All manuals and user guides at all-guides.com Section 3 • Scheduled Maintenance Procedures November 2008 CHECKLIST B PROCEDURES REV B B-11 B-12 Test the Drive Speed - Inspect the Fuel and Hydraulic Raised Position Tank Cap Venting Systems Genie requires that this procedure be performed Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes every 250 hours or quarterly, whichever comes...

  • Page 49: Perform Hydraulic Oil Analysis

    All manuals and user guides at all-guides.com November 2008 Section 3 • Scheduled Maintenance Procedures REV B CHECKLIST B PROCEDURES 3 Using a mild solvent, carefully wash the cap B-13 venting system. Dry using low pressure Perform Hydraulic Oil Analysis compressed air.

  • Page 50: Test The Flashing Beacons (If Equipped)

    All manuals and user guides at all-guides.com Section 3 • Scheduled Maintenance Procedures November 2008 CHECKLIST B PROCEDURES REV B B-14 B-15 Test the Flashing Beacons Perform Engine Maintenance - (if equipped) Kubota Models Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first.

  • Page 51: Checklist C Procedures

    All manuals and user guides at all-guides.com November 2008 Section 3 • Scheduled Maintenance Procedures Checklist C Procedures REV B 10 Fully raise the platform. Release the joystick. Test the Result: The engine should stop and an alarm should sound and fault code 99 PLATFORM Platform Overload System should be present in the ECM...

  • Page 52: Clean The Fuel Tank - Diesel Models

    All manuals and user guides at all-guides.com Section 3 • Scheduled Maintenance Procedures November 2008 CHECKLIST C PROCEDURES REV B 4 Remove the tank retaining fasteners from the bottom of the fuel tank and remove the tank Clean the Fuel Tank - from the machine.

  • Page 53: Replace The Hydraulic Tank Breather Cap - Models With Optional Hydraulic Oil

    All manuals and user guides at all-guides.com November 2008 Section 3 • Scheduled Maintenance Procedures REV B CHECKLIST C PROCEDURES Replace the Hydraulic Tank Perform Engine Maintenance - Breather Cap - Models with Diesel Models Optional Hydraulic Oil Engine specifications require that this procedure be performed every 500 hours.

  • Page 54: Perform Engine Maintenance - Kubota Models

    All manuals and user guides at all-guides.com Section 3 • Scheduled Maintenance Procedures November 2008 CHECKLIST C PROCEDURES REV B Perform Engine Maintenance - Kubota Models Engine specifications require that this procedure be performed every 800 hours. Required maintenance procedures and additional engine information is available in the Kubota D1105 Operator's Manual (Kubota part number 16622-89166) OR the...

  • Page 55: Checklist D Procedures

    All manuals and user guides at all-guides.com November 2008 Section 3 • Scheduled Maintenance Procedures Checklist D Procedures REV B 3 Measure the thickness of each platform scissor arm wear pad at the steer end of the machine. Check the Scissor Arm Wear Result: The measurement is inch / 8 mm or Pads...

  • Page 56: Replace The Hydraulic Tank Return Filter

    All manuals and user guides at all-guides.com Section 3 • Scheduled Maintenance Procedures November 2008 CHECKLIST D PROCEDURES REV B 2 Apply a thin layer of fresh oil to the new oil filter gasket. Replace the Hydraulic Tank 3 Install the new filter and tighten it securely by Return Filter hand.

  • Page 57: Perform Engine Maintenance - Perkins Models

    All manuals and user guides at all-guides.com November 2008 Section 3 • Scheduled Maintenance Procedures REV B CHECKLIST D PROCEDURES Perform Engine Maintenance - Perform Engine Maintenance - Perkins Models Kubota Models Engine specifications require that this procedure Engine specifications require that this procedure be performed every 1000 hours.

  • Page 58: Perform Engine Maintenance - Kubota Models

    All manuals and user guides at all-guides.com Section 3 • Scheduled Maintenance Procedures November 2008 CHECKLIST D PROCEDURES REV B Perform Engine Maintenance - Kubota Models Engine specifications require that this procedure be performed every 1500 hours. Required maintenance procedures and additional engine information is available in the Kubota D1105 Operator's Manual (Kubota part number 16622-89166) OR the...

  • Page 59: Checklist E Procedures

    All manuals and user guides at all-guides.com November 2008 Section 3 • Scheduled Maintenance Procedures Checklist E Procedures REV B 5 Locate the hose cover plate in the center of the drive chassis. Remove the hose cover plate Test or Replace the Hydraulic Oil mounting fasteners and remove the cover.

  • Page 60: Perform Engine Maintenance - Perkins Models

    All manuals and user guides at all-guides.com Section 3 • Scheduled Maintenance Procedures November 2008 CHECKLIST E PROCEDURES REV B 12 Remove the hydraulic tank from the machine. Perform Engine Maintenance - 13 Remove the suction strainers and clean them using a mild solvent.

  • Page 61: Perform Engine Maintenance - Gasoline/Lpg Models

    All manuals and user guides at all-guides.com November 2008 Section 3 • Scheduled Maintenance Procedures REV B CHECKLIST E PROCEDURES Perform Engine Maintenance - Perform Engine Maintenance - Gasoline/LPG Models Kubota D1105 Models Engine specifications require that this procedure Engine specifications require that this procedure be performed every two years.

  • Page 62: Perform Engine Maintenance - Perkins Models

    All manuals and user guides at all-guides.com Section 3 • Scheduled Maintenance Procedures November 2008 CHECKLIST E PROCEDURES REV B Perform Engine Maintenance - Perform Engine Maintenance - Perkins Models Kubota D1105 Models Engine specifications require that this procedure Engine specifications require that this procedure be performed every 3000 hours.

  • Page 63: Repair Procedures

    All manuals and user guides at all-guides.com June 2007 Section 4 • Repair Procedures Repair Procedures About This Section Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop. Select the appropriate repair procedure after troubleshooting the problem.

  • Page 64: Platform Controls

    All manuals and user guides at all-guides.com Section 4 • Repair Procedures June 2007 Platform Controls REV A The platform controls, used to activate machine functions from the platform or while standing on the Circuit Boards ground, contain a printed circuit board, joystick, decal membrane pad, buttons and/or toggle How to Remove the Platform switches, and LEDs.

  • Page 65: Platform Components

    All manuals and user guides at all-guides.com June 2007 Section 4 • Repair Procedures Platform Components REV A 6 Lower the platform to the stowed position and turn the machine off. Platform 7 Remove the mounting fasteners that secure the platform controls quick disconnect plug to the How to Remove the Platform platform.

  • Page 66: Platform Extension

    All manuals and user guides at all-guides.com Section 4 • Repair Procedures June 2007 PLATFORM COMPONENTS REV A 13 Attach a strap from the platform railings to the carriage on the forklift to support the platform. Platform Extension Deck 14 Remove the retaining fasteners from the platform pivot pins at the steer end of the How to Remove the Platform machine.
  • Page 67 All manuals and user guides at all-guides.com June 2007 Section 4 • Repair Procedures REV A PLATFORM COMPONENTS 11 Carefully slide the platform extension out until the platform extension makes contact with the carriage on the forklift. 12 Attach a lifting strap from the platform extension railings to the carriage on the forklift to support the platform extension.

  • Page 68: Scissor Components

    All manuals and user guides at all-guides.com Section 4 • Repair Procedures June 2007 Scissor Components REV B GS-2668 Steer End Non-steer End Number 5 pivot pin (steer end) 13 Number 4 inner arm Number 4 center pivot pin 14 Number 4 outer arm Number 4 pivot pin (steer end) 15 Number 4 pivot pin (non-steer end) Number 3 outer arm...

  • Page 69: Scissor Assembly, Gs-2668 Rt

    All manuals and user guides at all-guides.com June 2007 Section 4 • Repair Procedures REV B SCISSOR COMPONENTS 6 Remove the upper cable tray from the scissor assembly. Scissor Assembly, GS-2668 RT Component damage hazard. Cables can be damaged if they How to Disassemble the are kinked or pinched.
  • Page 70 All manuals and user guides at all-guides.com Section 4 • Repair Procedures June 2007 SCISSOR COMPONENTS REV B 17 Remove the external snap rings from the 26 Remove the external snap rings from the number 4 center pivot pin (index #2). number 3 center pivot pin (index #17) at the ground controls side.
  • Page 71 All manuals and user guides at all-guides.com June 2007 Section 4 • Repair Procedures REV B SCISSOR COMPONENTS 34 Remove the cables from the lower cable tray. 43 Attach a lifting strap from an overhead crane to Lay the cables off to the side of the machine. the number 2 outer arm (index #20) at the ground controls side.
  • Page 72 All manuals and user guides at all-guides.com Section 4 • Repair Procedures June 2007 SCISSOR COMPONENTS REV B 52 Use a soft metal drift to tap the number 2 pivot 57 Tag and disconnect the wiring from the solenoid pin (index #21) at the non steer end in the other valve on the lift cylinder.
  • Page 73 All manuals and user guides at all-guides.com June 2007 Section 4 • Repair Procedures REV B SCISSOR COMPONENTS 64 Attach each end of a lifting strap to each end of 71 Remove the pin retaining fasteners from the the scissor assembly. cylinder barrel-end pivot pin (index #22).
  • Page 74 All manuals and user guides at all-guides.com Section 4 • Repair Procedures June 2007 SCISSOR COMPONENTS REV B GS-3268 Non-steer End Steer End Number 6 pivot pin (steer end) 15 Number 1 pivot pin(s) (steer end) Number 5 center pivot pin 16 Number 6 pivot pin (non-steer end) 17 Number 5 inner arm Upper lift cylinder rod-end pivot pin...

  • Page 75: Scissor Assembly, Gs-3268 Rt

    All manuals and user guides at all-guides.com June 2007 Section 4 • Repair Procedures REV B SCISSOR COMPONENTS 6 Remove the external snap rings from the number 5 pivot pin (index #19) at the non-steer Scissor Assembly, GS-3268 RT end. 7 Use a soft metal drift to remove the number 5 How to Disassemble the pivot pin (index #19) from the non-steer end of...
  • Page 76 All manuals and user guides at all-guides.com Section 4 • Repair Procedures June 2007 SCISSOR COMPONENTS REV B 12 Lower the cylinder onto the number 3 center 24 Raise the platform approximately 10 feet / 3 m. pivot pin (index #8). 25 Lift the safety arm, move it to the center of the 13 Attach a lifting strap from an overhead crane to scissor arm and rotate down to a vertical...
  • Page 77 All manuals and user guides at all-guides.com June 2007 Section 4 • Repair Procedures REV B SCISSOR COMPONENTS 33 Attach a lifting strap from an overhead crane to 40 Remove the pin retaining fasteners from the the number 4 outer arm (index #21) at the upper cylinder barrel-end pivot pin (index #23).
  • Page 78 All manuals and user guides at all-guides.com Section 4 • Repair Procedures June 2007 SCISSOR COMPONENTS REV B 47 Attach a lifting strap from an overhead crane to 57 Remove the pin retaining fasteners from the the number 3 outer arm (index #7) at the engine lower cylinder rod-end pivot pin (index #9).
  • Page 79 All manuals and user guides at all-guides.com June 2007 Section 4 • Repair Procedures REV B SCISSOR COMPONENTS 66 Use a soft metal drift to tap the number 2 pivot 73 Use a soft metal drift to remove the number 2 pin (index #28) halfway out at the non-steer end pivot pin (index #12) at the steer end.
  • Page 80 All manuals and user guides at all-guides.com Section 4 • Repair Procedures June 2007 SCISSOR COMPONENTS REV B 80 Raise the scissor assembly slightly and return 87 Remove the straps securing the scissor arms the safety arm to the stowed position. Lower together.

  • Page 81: Wear Pads

    All manuals and user guides at all-guides.com June 2007 Section 4 • Repair Procedures REV B SCISSOR COMPONENTS Chassis Scissor Arm Wear Pads: Wear Pads 1 Attach a lifting strap from an overhead crane to the ladder at the non-steer end of the machine. Support the ladder.

  • Page 82: Lift Cylinder(S)

    All manuals and user guides at all-guides.com Section 4 • Repair Procedures June 2007 SCISSOR COMPONENTS REV B Note: 'alpha' callouts refer to corresponding notes on Lift Cylinder(s) the hydraulic schematic The lift cylinders are single acting hydraulic cylinders. The GS-2668 RT uses one lift cylinder; the GS-3268 RT uses two.
  • Page 83 All manuals and user guides at all-guides.com June 2007 Section 4 • Repair Procedures REV B SCISSOR COMPONENTS 6 Attach a strap from an overhead crane or GS-3268 RT: similar lifting device to the rod end of the lift Bodily injury hazard. This cylinder for support.
  • Page 84 All manuals and user guides at all-guides.com Section 4 • Repair Procedures June 2007 SCISSOR COMPONENTS REV B 6 Attach a lifting strap from an overhead crane or similar lifting device to the rod end of the lift cylinder for support. Note: 'alpha' callouts refer to corresponding notes on 7 Remove the external snap ring from the lift...

  • Page 85: Kubota D1105 And D905 Engines

    All manuals and user guides at all-guides.com November 2008 Section 4 • Repair Procedures Kubota D1105 and D905 Engines REV C Timing Adjustment Glow Plugs Complete information to perform this procedure is How to Check the Glow Plugs available in the 1 Connect the leads from an ohmmeter between Kubota D1105 Workshop Manual (Kubota part the far left glow plug and ground.

  • Page 86: Engine Rpm

    All manuals and user guides at all-guides.com Section 4 • Repair Procedures November 2008 KUBOTA D1105 and D905 ENGINES REV C Engine RPM Flex Plate How to Adjust the RPM The flex plate couples the engine to the pump. The flex plate is bolted to the engine flywheel and has a 1 Start the engine from the ground controls.

  • Page 87: How To Install The Flex Plate

    All manuals and user guides at all-guides.com November 2008 Section 4 • Repair Procedures REV C KUBOTA D1105 and D905 ENGINES How to Install the Flex Plate Coolant Temperature and Oil 1 Install the flex plate onto the flywheel with the Pressure Switches raised spline toward the pump.
  • Page 88 All manuals and user guides at all-guides.com Section 4 • Repair Procedures November 2008 KUBOTA D1105 and D905 ENGINES REV C 2 Tag and disconnect the wiring from the switch. How to Repair the Kubota Remove the switch from the engine. D1105 and D905 Engines Bodily injury hazard.

  • Page 89: Kubota Df752 Engine

    All manuals and user guides at all-guides.com June 2007 Section 4 • Repair Procedures Kubota DF752 Engine REV A Timing Adjustment - Choke Adjustment - Gasoline/LPG Models Gasoline/LPG Models Note: The ignition timing cannot be adjusted. The The choke is solenoid-operated and functions only timing adjustment screw is factory sealed with a in the gasoline mode.

  • Page 90: Engine Rpm

    All manuals and user guides at all-guides.com Section 4 • Repair Procedures June 2007 KUBOTA DF752 ENGINE REV A Engine RPM How to Adjust the RPM Note: The on-board self diagnostics incorporate a built-in engine tachometer. The first two digits of the engine rpm are displayed on the diagnostic solenoid boot display when the start toggle switch is moved to...

  • Page 91: Timing Adjustment

    All manuals and user guides at all-guides.com November 2008 Section 4 • Repair Procedures Perkins 403D-11 and 403C-11 Engines REV B Engine RPM Timing Adjustment How to Adjust the RPM Complete information to perform this procedure is available in the 1 Start the engine from the ground controls.

  • Page 92: Flex Plate

    All manuals and user guides at all-guides.com Section 4 • Repair Procedures November 2008 PERKINS 403D-11 and 403C-11 ENGINES REV B How to Replace the Coolant Flex Plate Temperature and Oil Pressure Switches See 4-4, Flex Plate . 1 Open the engine side cover and pull up on the lock pin on the engine pivot tray located under the radiator.
  • Page 93 All manuals and user guides at all-guides.com November 2008 Section 4 • Repair Procedures REV B PERKINS 403D-11 and 403C-11 ENGINES How to Repair the Perkins 403D-11 and 403C-11 Engines Repair procedures and additional engine information are available in the Perkins 403D-11 User's Handbook (Perkins part number SEBU8311-01) OR the Perkins 403D-11 Workshop Manual...

  • Page 94: Ground Controls

    All manuals and user guides at all-guides.com Section 4 • Repair Procedures June 2007 Ground Controls REV B Auxiliary Platform Lowering Function Speed Tuning Auxiliary Platform Lowering All machine function speeds are determined by the percentage of total ECM voltage output. The In the event of a main power failure, activating the speeds of the following machine functions may be function enable and manual platform lowering...

  • Page 95: How To Adjust The Stowed Drive Speed

    All manuals and user guides at all-guides.com June 2007 Section 4 • Repair Procedures REV B GROUND CONTROLS How to Adjust the Stowed Drive Speed Tip-over hazard. Do not adjust the lift and/or drive speed higher than specified in this procedure. Setting drive speed greater than specifications could cause the diagnostic display...

  • Page 96: How To Adjust The High Torque Drive Speed

    All manuals and user guides at all-guides.com Section 4 • Repair Procedures June 2007 REV B GROUND CONTROLS How to Adjust the High Torque Drive Speed Tip-over hazard. Do not adjust the lift and/or drive speed higher than specified in this procedure. Setting drive speed greater than diagnostic display specifications could cause the...

  • Page 97: How To Adjust The Raised Drive Speed

    All manuals and user guides at all-guides.com June 2007 Section 4 • Repair Procedures REV B GROUND CONTROLS How to Adjust the Raised Drive Speed Tip-over hazard. Do not adjust the lift and/or drive speed higher than specified in this procedure. Setting drive speed greater than specifications could cause the diagnostic display...

  • Page 98: How To Adjust The Lift Speed

    All manuals and user guides at all-guides.com Section 4 • Repair Procedures June 2007 GROUND CONTROLS REV B How to Adjust the Lift Speed 1 Pull out the red Emergency Stop button to the on position at the platform controls. 2 Push in the red Emergency Stop button to the off position at the ground controls.

  • Page 99: Software Configuration

    All manuals and user guides at all-guides.com June 2007 Section 4 • Repair Procedures REV B GROUND CONTROLS Machine Option Definitions Software Configuration Descent Delay: This option halts descent at approximately 12 feet / 3.6 m. All controls must How to Configure the Software be released for 4 to 6 seconds before descent is re-enabled.
  • Page 100 All manuals and user guides at all-guides.com Section 4 • Repair Procedures June 2007 GROUND CONTROLS REV B 4 Use the yellow platform down arrow to scroll to 10 Models with platform overload (option): Use select options. the yellow platform down arrow to scroll to overload.
  • Page 101 All manuals and user guides at all-guides.com June 2007 Section 4 • Repair Procedures REV B GROUND CONTROLS 13 Use the yellow platform down arrow to scroll to 16 Use the yellow platform down arrow to scroll to generator option. generator option.
  • Page 102 All manuals and user guides at all-guides.com Section 4 • Repair Procedures June 2007 GROUND CONTROLS REV B CE models with all software revisions: 5 Press the lift function enable button. Result: is showing in the 1 Turn the key switch to ground controls and pull DESCENT DELAY ON diagnostic display window.
  • Page 103 All manuals and user guides at all-guides.com June 2007 Section 4 • Repair Procedures REV B GROUND CONTROLS 9 Press the lift function enable button to activate 12 Use the yellow platform down arrow to scroll to or deactivate the motion beacon option. beacons option.
  • Page 104 All manuals and user guides at all-guides.com Section 4 • Repair Procedures June 2007 GROUND CONTROLS REV B 15 Use the yellow platform down arrow to scroll to CE models with all software revisions: beacons option. 18 Use the yellow platform down arrow to scroll to Result: is showing in the diagnostic return to the main menu.

  • Page 105: Level Sensor - Models Without Outriggers

    All manuals and user guides at all-guides.com June 2007 Section 4 • Repair Procedures REV B GROUND CONTROLS 4 Lower the platform onto the safety arm. Level Sensor - Crushing hazard. Keep hands clear of the safety arm when Models without Outriggers lowering the platform.
  • Page 106 All manuals and user guides at all-guides.com Section 4 • Repair Procedures June 2007 REV B GROUND CONTROLS 8 Install the new level sensor onto the machine with the "Y" on the level sensor base closest to the steer end of the machine. Install and tighten the level sensor retaining fasteners.
  • Page 107 All manuals and user guides at all-guides.com June 2007 Section 4 • Repair Procedures REV B GROUND CONTROLS 18 Raise the platform at least 12 feet / 3.6 m. 28 Raise the platform at least 12 feet / 3.6 m. Result: The tilt alarm does not sound and all Result - The drive function and the lift function functions will operate.

  • Page 108: Level Sensor - Models With Outriggers

    All manuals and user guides at all-guides.com Section 4 • Repair Procedures June 2007 REV B GROUND CONTROLS 3 Lift the safety arm, move to the center of the scissor arm and rotate to a vertical position. Level Sensor - 4 Lower the platform onto the safety arm.
  • Page 109 All manuals and user guides at all-guides.com June 2007 Section 4 • Repair Procedures REV B GROUND CONTROLS 8 Install the new level sensor onto the machine with the "X" on the level sensor base closest to the steer end of the machine. Install and tighten the level sensor retaining fasteners.
  • Page 110 All manuals and user guides at all-guides.com Section 4 • Repair Procedures June 2007 GROUND CONTROLS REV B 17 Adjust the "X" axis (front-to-back) to 2.43V DC. 26 Lower the machine onto the blocks. Tap the top of the level sensor lightly with 27 Pull out the red Emergency Stop button to the fingers after each turn of an adjusting nut.
  • Page 111 All manuals and user guides at all-guides.com June 2007 Section 4 • Repair Procedures REV B GROUND CONTROLS 36 Raise the platform at least 12 feet / 3.6 m. 46 Lower the platform to the stowed position. Result: The platform stops raising and the tilt 47 Raise the machine slightly.

  • Page 112: Hydraulic Pump

    All manuals and user guides at all-guides.com Section 4 • Repair Procedures June 2007 Hydraulic Pump REV A 2 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to the high pressure port on each section Hydraulic Pump of the pump.

  • Page 113: How To Remove The Hydraulic Pump

    All manuals and user guides at all-guides.com June 2007 Section 4 • Repair Procedures REV A HYDRAULIC PUMP How to Remove the How to Prime the Pump Hydraulic Pump Component damage hazard. Be sure that the hydraulic tank shutoff 1 Tag, disconnect and plug the hydraulic hoses valves (if equipped) are in the on the pump.

  • Page 114: Function Manifold Components

    All manuals and user guides at all-guides.com Section 4 • Repair Procedures June 2007 Manifolds REV B Function Manifold Components The function manifold is located inside the hydraulic tray. Index Schematic Description Item Function Torque Relief valve, 3500 psi / 241.3 bar ..FA ..Anti-cavitation for rear drive circuit ... 15-25 ft-lbs / 20-34 Nm Solenoid valve, 2 position 2 way N.C.
  • Page 115 All manuals and user guides at all-guides.com June 2007 Section 4 • Repair Procedures REV B MANIFOLDS Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic Note: 'alphanumeric' callouts refer to corresponding notes on the electrical schematic Y1.1 Part No.
  • Page 116 All manuals and user guides at all-guides.com Section 4 • Repair Procedures June 2007 MANIFOLDS REV B Function Manifold Components, continued Index Schematic Description Item Function Torque Priority flow regulator, 2 gpm / 7.6 L/min ......... FO ..Steer circuit ........25-30 ft-lbs / 34-41 Nm Solenoid valve, 2 position 3 way ..
  • Page 117 All manuals and user guides at all-guides.com June 2007 Section 4 • Repair Procedures REV B MANIFOLDS Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic Note: 'alphanumeric' callouts refer to corresponding notes on the electrical schematic Y1.1 Part No.

  • Page 118: Valve Adjustments - Function Manifold

    All manuals and user guides at all-guides.com Section 4 • Repair Procedures June 2007 MANIFOLDS REV B 7 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to Valve Adjustments - decrease the pressure. Install the relief valve Function Manifold cap.

  • Page 119: How To Adjust The Steer Relief Valve

    All manuals and user guides at all-guides.com June 2007 Section 4 • Repair Procedures REV B MANIFOLDS How to Adjust the Steer Relief Valve 1 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to test port #1 (item FAA) on the function manifold.
  • Page 120 All manuals and user guides at all-guides.com Section 4 • Repair Procedures June 2007 MANIFOLDS REV B How to Adjust the Lift Relief Valve Note: Be sure that the hydraulic oil level is within the top 2 inches / 5 cm of the sight gauge. 1 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to test port #2 (item FX) on the function manifold.

  • Page 121: Outrigger Manifold Components

    All manuals and user guides at all-guides.com June 2007 Section 4 • Repair Procedures REV B MANIFOLDS Outrigger Manifold Components The outrigger manifold is located beneath the hose cover panel on top of the drive chassis Index Schematic Description Item Function Torque Relief valve, 2000 psi / 137.8 bar ..

  • Page 122: Valve Adjustments - Outrigger Manifold

    All manuals and user guides at all-guides.com Section 4 • Repair Procedures June 2007 MANIFOLDS REV B 4 Turn the key switch to platform control and pull out the red Emergency Stop buttons to the Valve Adjustments - position at both the ground and platform Outrigger Manifold controls.
  • Page 123 All manuals and user guides at all-guides.com June 2007 Section 4 • Repair Procedures REV B MANIFOLDS 13 Turn the engine off. Use a wrench to hold the outrigger relief valve (item BA) and remove the cap. 14 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure.

  • Page 124: Generator Manifold Components

    All manuals and user guides at all-guides.com Section 4 • Repair Procedures June 2007 MANIFOLDS REV B Generator Manifold Components The generator manifold is located above the function manifold. Index Schematic Description Item Function Torque Solenoid valve, 2 position 3 way ..DA ..Generator on/off ........25 ft-lbs / 34 Nm Flow regulator, 4.3 gpm / 16.3 L/min ...

  • Page 125: Valve Adjustments - Generator Manifold

    All manuals and user guides at all-guides.com June 2007 Section 4 • Repair Procedures REV B MANIFOLDS 5 Connect the positive and negative leads from a multimeter of sufficient capacity to the electrical Valve Adjustments - outlet at the generator. Generator Manifold Result: The reading on the multimeter should be 112V to 118V AC.

  • Page 126: Valve Coils

    All manuals and user guides at all-guides.com Section 4 • Repair Procedures June 2007 MANIFOLDS REV B Valve Coil Resistance Valve Coils Specification Note: The following coil resistance specifications How to Test a Coil are at an ambient temperature of 68°F / 20°C. As valve coil resistance is sensitive to changes in air A properly functioning coil provides an temperature, the coil resistance will typically...
  • Page 127 All manuals and user guides at all-guides.com June 2007 Section 4 • Repair Procedures REV B MANIFOLDS How to Test a Coil Diode Genie incorporates spike suppressing diodes in COIL many valve coils. Properly functioning coil diodes MULTI METER protect the electrical circuit by suppressing voltage spikes.

  • Page 128: Fuel And Hydraulic Tanks

    All manuals and user guides at all-guides.com Section 4 • Repair Procedures June 2007 Fuel and Hydraulic Tanks REV A 4 Tag, disconnect and plug the fuel supply and 10-1 return hoses from the fuel tank. Fuel Tank 5 Clean up any fuel that may have spilled. How to Remove the Fuel Tank 6 Remove the fuel tank mounting fasteners.

  • Page 129: Hydraulic Tank

    All manuals and user guides at all-guides.com June 2007 Section 4 • Repair Procedures REV A FUEL AND HYDRAULIC TANKS 5 Close the two hydraulic shutoff valves located 10-2 at the hydraulic tank. Hydraulic Tank Component damage hazard. The engine must not be started with The primary functions of the hydraulic tank are to the hydraulic tank shutoff valves in cool, clean and deaerate the hydraulic fluid during...

  • Page 130: Steer Axle Components

    All manuals and user guides at all-guides.com Section 4 • Repair Procedures June 2007 Steer Axle Components REV A 7 Remove the cotter pin from the tie rod clevis 11-1 pin. Yoke and Drive Motor Note: Always use a new cotter pin when installing a clevis pin.

  • Page 131: How To Remove A Drive Motor

    All manuals and user guides at all-guides.com June 2007 Section 4 • Repair Procedures REV A STEER AXLE COMPONENTS 4 Remove the wheel lug bolts. Remove the tire How to Remove a Drive Motor and wheel assembly. Component damage hazard. 5 Tag, disconnect and plug the hoses from the Repairs to the motor should only drive motor.

  • Page 132: Steer Cylinder

    All manuals and user guides at all-guides.com Section 4 • Repair Procedures June 2007 STEER AXLE COMPONENTS REV A 11-2 11-3 Steer Cylinder Tie Rod How to Remove the How to Remove the Tie Rod Steer Cylinder 1 Remove the cotter pin from each tie rod clevis pin.

  • Page 133: Non-Steer Axle Components

    All manuals and user guides at all-guides.com June 2007 Section 4 • Repair Procedures Non-steer Axle Components REV A 4 Remove the wheel lug bolts. Remove the tire 12-1 and wheel assembly. Drive Motor and Brake 5 Tag, disconnect and plug the hydraulic hoses from the drive motor and brake.

  • Page 134: Outrigger Components

    All manuals and user guides at all-guides.com Section 4 • Repair Procedures June 2007 Outrigger Components REV A 6 Attach a lifting strap from an overhead crane to 13-1 the barrel end of the outrigger cylinder for Outrigger Cylinder support. Do not apply any lifting pressure. 7 Remove the outrigger mounting fasteners.

  • Page 135: Brake Release Hand Pump Components

    All manuals and user guides at all-guides.com June 2007 Section 4 • Repair Procedures Brake Release Hand Pump Components REV A 14-1 Brake Release Hand Pump Components The brake release hand pump manifold is mounted at the non-steer end of the chassis on the ground controls side of the machine.

  • Page 136: Platform Overload Components

    All manuals and user guides at all-guides.com Section 4 • Repair Procedures June 2007 Platform Overload Components REV A 7 Using a suitable lifting device, place a test 15-1 weight, corresponding to the maximum load as Platform Overload System indicated on the capacity indicator decal, in the center of the platform floor.
  • Page 137 All manuals and user guides at all-guides.com June 2007 Section 4 • Repair Procedures REV A PLATFORM OVERLOAD COMPONENTS 14 Pull out the red Emergency Stop button to the 15 Raise the platform until the position indicator on position at the ground controls. Wait 3 corresponds to the maximum load position of seconds and start the engine.
  • Page 138 All manuals and user guides at all-guides.com Section 4 • Repair Procedures June 2007 PLATFORM OVERLOAD COMPONENTS REV A Set the pressure switch: 20 Return the safety arm to the stowed position. Lower the platform to the stowed position. 16 Using a wrench, turn the nut of the platform Note: After returning the safety arm to the stowed overload pressure switch out of the hydraulic position, use the auxiliary down function to lower...
  • Page 139 All manuals and user guides at all-guides.com June 2007 Section 4 • Repair Procedures REV A PLATFORM OVERLOAD COMPONENTS 26 Raise the platform in 5 cm increments until the 27 Install and adjust the maximum height limit overload alarm sounds and the engine stops switch until it activates just before the point running.
  • Page 140 All manuals and user guides at all-guides.com Section 4 • Repair Procedures June 2007 PLATFORM OVERLOAD COMPONENTS REV A 34 Press and hold both the blue platform up and 39 Pull out the red Emergency Stop button to the yellow platform down buttons. Pull out the red on position at the ground controls.
  • Page 141 All manuals and user guides at all-guides.com June 2007 Section 4 • Repair Procedures REV A PLATFORM OVERLOAD COMPONENTS Enable the descent delay function: Calibrate the down limit switch: 49 Push in the red Emergency Stop button to the 57 Turn the key switch to platform control. Start the off position at the ground controls.
  • Page 142 All manuals and user guides at all-guides.com Section 4 • Repair Procedures June 2007 PLATFORM OVERLOAD COMPONENTS REV A 67 Lower the platform to the stowed position and 72 Raise the platform to approximately 4 m. remove the weight from the platform. 73 Rotate the safety arm away from the machine and let it hang down.

  • Page 143: Hydraulic Oil Can Penetrate And Burn Skin. Loosen Hydraulic

    All manuals and user guides at all-guides.com June 2007 Section 5 • Fault Codes Fault Codes 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 equipment are available and ready for use.

  • Page 144: About This Section

    All manuals and user guides at all-guides.com Section 5 • Fault Codes June 2007 FAULT CODES About This Section LED Diagnostic Readout When a malfunction is discovered, the fault code charts in this section will help a service professional pinpoint the cause of the problem. To use this section, basic hand tools and certain pieces of test equipment are required—voltmeter, ohmmeter, pressure gauges.

  • Page 145: Fault Code Chart (From Serial Number Gs6805-44771)

    All manuals and user guides at all-guides.com June 2007 Section 5 • Fault Codes Fault Code Chart REV B (from serial number GS6805-44771) Fault Code Condition Result Solution SYSTEM READY Green Normal operation Internal ECM error. System shutdown. Replace ECM.
  • Page 146 All manuals and user guides at all-guides.com Section 5 • Fault Codes June 2007 FAULT CODE CHART REV B (FROM SERIAL NUMBER GS6805-44771) Fault Code Condition Result Solution Right front outrigger enable Troubleshoot button OR replace printed button fault at platform Outriggers disabled.
  • Page 147 All manuals and user guides at all-guides.com June 2007 Section 5 • Fault Codes REV B FAULT CODE CHART (FROM SERIAL NUMBER GS6805-44771) Fault Code Condition Result Solution Check the engine oil level OR check wiring from the oil pressure switch to Low oil pressure.
  • Page 148 All manuals and user guides at all-guides.com Section 5 • Fault Codes June 2007 This page intentionally left blank. 5 - 6 GS-2668 RT • GS-3268 RT Part No. 112657...
  • Page 149 All manuals and user guides at all-guides.com June 2007 Section 6 • Schematics Schematics About This Section There are two groups of schematics in this section. An illustration legend precedes each group of drawings. Electrical Schematics Observe and Obey: Electrocution/burn hazard. Contact with electrically charged Troubleshooting and repair procedures shall be circuits could result in death or...

  • Page 150: Electronic Control Module Layout (From Serial Number Gs6805-44771)

    All manuals and user guides at all-guides.com Section 6 • Schematics June 2007 Electronic Control Module Layout (from serial number GS6805-44771) REV A Platform controls Engine To outriggers Down limit Flashing beacons switch Electronic Control Module Level sensor Generator Horn...

  • Page 151: Electronic Control Module Pin-Out Legend (From Serial Number Gs6805-44771)

    All manuals and user guides at all-guides.com June 2007 Section 6 • Schematics Electronic Control Module Pin-Out Legend (from serial number GS6805-44771) REV A J1 Connector J2 Connector (36 pin) (36 pin) Right turn - Y3 (output) Up limit switch LS5 (input)

  • Page 152: Wiring Diagram - Platform Control Box (From Serial Number Gs6805-44771)

    All manuals and user guides at all-guides.com Section 6 • Schematics June 2007 Wiring Diagram - Platform Control Box (from serial number GS6805-44771) REV A COIL CORD ASSEMBLY ALARM EMERGENCY STOP JOYSTICK CONTROLLER PLATFORM CONTROLS CIRCUIT BOARD WH/BL TS20 TS21...
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  • Page 154: Electrical Schematics Abbreviation And Wire Color Legends

    All manuals and user guides at all-guides.com Section 6 • Schematics June 2007 Electrical Schematics Abbreviation and Wire Color Legends REV B ELECTRICAL SCHEMATIC LEGEND ELECTRICAL SCHEMATIC LEGEND WIRE COLOR Item Description Item Description LEGEND Battery Note Item Description B1 = Engine start N.C.

  • Page 155: Electrical Symbols Legend

    All manuals and user guides at all-guides.com June 2007 Section 6 • Schematics Electrical Symbols Legend REV A PLATFORM GROUND Solenoid valve with Motor or pump Emergency Stop spike supression Flashing beacon GROUND button diode Key switch Wire connection Spark plugs Solenoid valve Control relay Horn or alarm...

  • Page 156: C Electrical Schematic - Ansi Models With Gasoline/Lpg Power

    All manuals and user guides at all-guides.com Section 6 • Schematics June 2007 Electrical Schematic ANSI Models with Gasoline/LPG Power REV C (from serial number GS6805-44771) Part 1 of 3 5A FUSE EMERGENCY STOP KEY SWITCH PLATFORM CONTROL GROUND CONTROL...

  • Page 157: (From Serial Number Gs6805-44771)

    All manuals and user guides at all-guides.com June 2007 Section 6 • Schematics Electrical Schematic ANSI Models with Gasoline/LPG Power REV C (from serial number GS6805-44771) Part 2 of 3 CR8 TERMINAL 30 BATTERY (+) N.O. CR17 N.C. LEVEL SENSOR...
  • Page 158 All manuals and user guides at all-guides.com Section 6 • Schematics June 2007 Electrical Schematic ANSI Models with Gasoline/LPG Power REV C (from serial number GS6805-44771) Part 3 of 3 EMERGENCY POWER TO PLATFORM STOP WH/RD POWER TO GROUND RD/WH...
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  • Page 160 All manuals and user guides at all-guides.com Section 6 • Schematics June 2007 Electrical Schematic CE Models with Gasoline/LPG Power REV C (from serial number GS6805-44771) Part 1 of 3 5A FUSE EMERGENCY STOP KEY SWITCH PLATFORM CONTROL PS2A PLATFORM OVERLOAD PRESSURE SWITCH...
  • Page 161 All manuals and user guides at all-guides.com June 2007 Section 6 • Schematics Electrical Schematic CE Models with Gasoline/LPG Power REV C (from serial number GS6805-44771) Part 2 of 3 CR8 TERMINAL 30 BATTERY (+) N.O. CR17 N.C. LEVEL SENSOR...
  • Page 162 All manuals and user guides at all-guides.com Section 6 • Schematics June 2007 Electrical Schematic CE Models with Gasoline/LPG Power REV C (from serial number GS6805-44771) Part 3 of 3 EMERGENCY POWER TO PLATFORM STOP WH/RD POWER TO GROUND RD/WH...
  • Page 163 All manuals and user guides at all-guides.com June 2007 Section 6 • Schematics This page intentionally left blank. Part No. 112657 GS-2668 RT • GS-3268 RT 6 - 15...

  • Page 164: C Electrical Schematic - Ansi Models With Diesel Power

    All manuals and user guides at all-guides.com Section 6 • Schematics June 2007 Electrical Schematic ANSI Models with Diesel Power REV C (from serial number GS6805-44771 to GS6806-45204) Part 1 of 3 5A FUSE EMERGENCY STOP KEY SWITCH PLATFORM CONTROL...
  • Page 165 All manuals and user guides at all-guides.com June 2007 Section 6 • Schematics Electrical Schematic ANSI Models with Diesel Power REV C (from serial number GS6805-44771 to GS6806-45204) Part 2 of 3 CR8 TERMINAL 30 BATTERY (+) N.O. CR17 N.C.
  • Page 166 All manuals and user guides at all-guides.com Section 6 • Schematics June 2007 Electrical Schematic ANSI Models with Diesel Power REV C (from serial number GS6805-44771 to GS6806-45204) Part 3 of 3 EMERGENCY POWER TO PLATFORM STOP WH/RD POWER TO GROUND...
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  • Page 168: (From Serial Number Gs6806-45205)

    All manuals and user guides at all-guides.com Section 6 • Schematics June 2007 Electrical Schematic ANSI Models with Diesel Power REV C (from serial number GS6806-45205) Part 1 of 3 5A FUSE EMERGENCY STOP KEY SWITCH PLATFORM CONTROL GROUND CONTROL CR41 CR42 CR23...
  • Page 169 All manuals and user guides at all-guides.com June 2007 Section 6 • Schematics Electrical Schematic ANSI Models with Diesel Power REV C (from serial number GS6806-45205) Part 2 of 3 CR8 TERMINAL 30 BATTERY (+) N.O. CR17 N.C. LEVEL SENSOR CIRCUIT BOARD HYDRAULIC OIL COOLER...
  • Page 170 All manuals and user guides at all-guides.com Section 6 • Schematics June 2007 Electrical Schematic ANSI Models with Diesel Power REV C (from serial number GS6806-45205) Part 3 of 3 EMERGENCY POWER TO PLATFORM STOP WH/RD POWER TO GROUND RD/WH GROUND J5 PIN1 DATA LINK (HIGH)
  • Page 171 All manuals and user guides at all-guides.com June 2007 Section 6 • Schematics This page intentionally left blank. Part No. 112657 GS-2668 RT • GS-3268 RT 6 - 23...

  • Page 172: C Electrical Schematic - Ce Models With Diesel Power

    All manuals and user guides at all-guides.com Section 6 • Schematics June 2007 Electrical Schematic CE Models with Diesel Power REV C (from serial number GS6805-44771 to GS6806-45204) Part 1 of 3 5A FUSE EMERGENCY STOP KEY SWITCH PLATFORM CONTROL...
  • Page 173 All manuals and user guides at all-guides.com June 2007 Section 6 • Schematics Electrical Schematic CE Models with Diesel Power REV C (from serial number GS6805-44771 to GS6806-45204) Part 2 of 3 CR8 TERMINAL 30 BATTERY (+) N.O. CR17 N.C.
  • Page 174 All manuals and user guides at all-guides.com Section 6 • Schematics June 2007 Electrical Schematic CE Models with Diesel Power REV C (from serial number GS6805-44771 to GS6806-45204) Part 3 of 3 EMERGENCY POWER TO PLATFORM STOP WH/RD POWER TO GROUND...
  • Page 175 All manuals and user guides at all-guides.com June 2007 Section 6 • Schematics This page intentionally left blank. Part No. 112657 GS-2668 RT • GS-3268 RT 6 - 27...

  • Page 176: (From Serial Number Gs6806-45205)

    All manuals and user guides at all-guides.com Section 6 • Schematics June 2007 Electrical Schematic CE Models with Diesel Power REV C (from serial number GS6806-45205) Part 1 of 3 5A FUSE EMERGENCY STOP KEY SWITCH PLATFORM CONTROL PS2A PLATFORM OVERLOAD PRESSURE SWITCH 5 OHM GROUND CONTROL...
  • Page 177 All manuals and user guides at all-guides.com June 2007 Section 6 • Schematics Electrical Schematic CE Models with Diesel Power REV C (from serial number GS6806-45205) Part 2 of 3 CR8 TERMINAL 30 BATTERY (+) N.O. CR17 N.C. LEVEL SENSOR CIRCUIT BOARD HYDRAULIC OIL COOLER...
  • Page 178 All manuals and user guides at all-guides.com Section 6 • Schematics June 2007 Electrical Schematic CE Models with Diesel Power REV C (from serial number GS6806-45205) Part 3 of 3 EMERGENCY POWER TO PLATFORM STOP WH/RD POWER TO GROUND RD/WH GROUND J5 PIN1 DATA LINK (HIGH)

  • Page 179: Hydraulic Symbols Legend

    All manuals and user guides at all-guides.com June 2007 Section 6 • Schematics Hydraulic Symbols Legend REV A Filter Bi-directional Single direction variable speed motor variable speed motor Counterbalance valve Check valve Brake Priority flow regulator Solenoid operated 2 position 2 way Engine directional valve Solenoid operated...

  • Page 180: Hydraulic Schematic (From Serial Number Gs6805-44771)

    All manuals and user guides at all-guides.com Section 6 • Schematics November 2008 Hydraulic Schematic (from serial number GS6805-44771) REV C Part 1 of 2 BRAKE GENERATOR MANIFOLD BRAKE 4.5 gpm RELEASE 17 L/min 3000 psi 206.8 bar MANIFOLD GENERATOR...
  • Page 181 All manuals and user guides at all-guides.com November 2008 Section 6 • Schematics Hydraulic Schematic (from serial number GS6805-44771) REV C Part 2 of 2 Part No. 112657 GS-2668 RT • GS-3268 RT 6 - 33...
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  • Page 183 All manuals and user guides at all-guides.com California Proposition 65 Warning The exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. Genie North America Phone 425.881.1800 Toll Free USA and Canada 800.536.1800 Fax 425.883.3475 Genie Australia Pty Ltd.
  • Page 184 All manuals and user guides at all-guides.com Part No. 112657 Rev C2...

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