Genie GS 2668 RT, GS 3268 RT scissor lift Service Manual

Service Manual
Part No. 52302
Rev D
March 2005
March 2005
Important
Read, understand and obey the safety rules and
operating instructions in the appropriate Operator's
Manual on your machine before attempting any
maintenance procedure.
Basic mechanical, hydraulic and electrical
skills are required to perform most procedures.
However, several procedures require specialized
skills, tools, lifting equipment and a suitable
workshop. In these instances, we strongly
recommend that maintenance and repair be
performed at an authorized Genie dealer
service center.
Technical Publications
Genie Industries has endeavored to deliver the
highest degree of accuracy possible. However,
continuous improvement of our products is a Genie
policy. Therefore, product specifications
are subject to change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.
Contact Us:
Copyright © 1998 by Genie Industries
www.genieindustries.com
e-mail: [email protected]
52302 Rev D March 2005
First Edition, Fourth Printing
"Genie" is a registered trademark of Genie
Industries in the USA and many other countries.
"GS" is a trademark of Genie Industries.
Printed on recycled paper
Printed in U.S.A.
ii
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
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.
Many of the hazards identified in the
operator’s manual are also safety hazards
when maintenance and repair procedures
are performed.
Do Not Perform Maintenance
Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
- manufacturer’s instructions and safety rules
- employer’s safety rules and worksite
regulations
- applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.
Part No. 52302
GS-2668 RT • GS-3268 RT
iii
Section 1 • Safety Rules
March 2005
SAFETY RULES
Personal Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Read each procedure thoroughly. This
manual and the decals on the machine,
use signal words to identify the following:
Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Red—used to indicate the
presence of an imminently
hazardous situation which, if not
avoided, will result in death or
serious injury.
Orange—used to indicate the
presence of a potentially
hazardous situation which, if not
avoided, could result in death or
serious injury.
Yellow with safety alert symbol—
used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause
minor or moderate injury.
Yellow without safety alert
symbol—used to indicate the
presence of a potentially
hazardous situation which, if not
avoided, may result in property
damage.
Green—used to indicate operation
or maintenance information.
Be sure to wear protective eye wear and
other protective clothing if the situation
warrants it.
Be aware of potential crushing hazards
such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved steel-toed
shoes.
Workplace Safety
Be sure to keep sparks, flames and
lighted tobacco away from flammable and
combustible materials like battery gases
and engine fuels. Always have an approved fire
extinguisher within easy reach.
Be sure that all tools and working areas
are properly maintained and ready for
use. Keep work surfaces clean and free of
debris that could get into machine components and
cause damage.
Be sure that your workshop or work area
is properly ventilated and well lit.
Be sure any forklift, overhead crane or
other lifting or supporting device is fully
capable of supporting and stabilizing the
weight to be lifted. Use only chains or straps that
are in good condition and of ample capacity.
Be sure that fasteners intended for one
time use (i.e., cotter pins and self-locking
nuts) are not reused. These components
may fail if they are used a second time.
Be sure to properly dispose of old oil or other
fluids. Use an approved container. Please be
environmentally safe .
iv
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Table of Contents
Introduction
Important Information ......................................................................................... ii
Section 1
Safety Rules
General Safety Rules ........................................................................................ iii
Section 2
Section 3
Rev
Specifications
B
Machine Specifications ................................................................................ 2 - 1
B
Performance Specifications ......................................................................... 2 - 2
B
Hydraulic Specifications ............................................................................... 2 - 2
B
Manifold Component Specifications ............................................................. 2 - 3
B
Kubota D905 Engine .................................................................................... 2 - 4
B
Perkins 403C-11 Engine .............................................................................. 2 - 5
B
Kubota DF750 Engine ................................................................................. 2 - 6
B
Kubota DF752 Engine ................................................................................. 2 - 7
B
Hydraulic Hose and Fitting Torque Specifications ........................................ 2 - 8
Rev
Scheduled Maintenance Procedures
Introduction .................................................................................................. 3 - 1
Pre-delivery Preparation Report .................................................................. 3 - 3
Maintenance Inspection Report ................................................................... 3 - 5
B
Part No. 52302
Checklist A Procedures
A-1
Perform Pre-operation Inspection ....................................................... 3 - 7
A-2
Perform Function Tests ...................................................................... 3 - 7
A-3
Perform Engine Maintenance ............................................................. 3 - 8
A-4
Inspect the Engine Air Filter ................................................................ 3 - 8
A-5
Perform 30 Day Service ..................................................................... 3 - 9
GS-2668 RT • GS-3268 RT
v
March 2005
TABLE OF CONTENTS
Section 3
Rev
B
Scheduled Maintenance Procedures, continued
Checklist A Procedures, continued
A-6
Perform Engine Maintenance - Kubota D905 Models ....................... 3 - 10
A-7
Perform Engine Maintenance - Kubota Models ................................ 3 - 10
A-8
Perform Engine Maintenance - Kubota Models ................................ 3 - 11
A-9
Perform Engine Maintenance - Kubota Models ................................ 3 - 11
A-10 Drain the Fuel Filter/Water Separator - Diesel Models ...................... 3 - 12
A-11 Perform Engine Maintenance - Kubota D905 Models ....................... 3 - 13
B
Checklist B Procedures
B-1
Inspect the Battery ........................................................................... 3 - 14
B-2
Inspect the Electrical Wiring ............................................................. 3 - 15
B-3
Inspect the Tires and Wheels
(including castle nut and lug bolt torque) .......................................... 3 - 16
B-4
Perform Engine Maintenance - Perkins 403C-11 Models ................. 3 - 16
B-5
Test the Key Switch .......................................................................... 3 - 17
B-6
Test the Emergency Stop ................................................................. 3 - 17
B-7
Test the Automotive-style Horn ........................................................ 3 - 18
B-8
Test the Fuel Select Operation - Gasoline/LPG Models ................... 3 - 19
B-9
Test the Drive Brakes ....................................................................... 3 - 20
B-10 Test the Drive Speed - Stowed Position ........................................... 3 - 21
B-11 Test the Drive Speed - Raised Position ............................................ 3 - 22
B-12 Inspect the Fuel and Hydraulic Tank Cap Venting Systems ............. 3 - 23
B-13 Perform Hydraulic Oil Analysis ......................................................... 3 - 24
B-14 Test the Flashing Beacons (if equipped) .......................................... 3 - 24
B-15 Perform Engine Maintenance - Kubota D905 Models ....................... 3 - 24
vi
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
TABLE OF CONTENTS
Section 3
Rev
B
Scheduled Maintenance Procedures, continued
Checklist C Procedures
C-1 Grease the Platform Overload Mechanism (if equipped) .................. 3 - 25
C-2 Clean the Fuel Tank - Diesel Models ............................................... 3 - 26
C-3 Replace the Hydraulic Tank Breather Cap - Models with
Optional Hydraulic Oil ....................................................................... 3 - 27
C-4 Perform Engine Maintenance - Diesel Models .................................. 3 - 27
C-5 Perform Engine Maintenance - Kubota D905 and DF750 Models .... 3 - 27
B
Checklist D Procedures
D-1 Check the Scissor Arm Wear Pads .................................................. 3 - 28
D-2 Calibrate the Platform Overload System (if equipped) ...................... 3 - 29
D-3 Replace the Hydraulic Tank Return Filter ......................................... 3 - 36
D-4 Perform Engine Maintenance - Perkins 403C-11 Models ................. 3 - 37
D-5 Perform Engine Maintenance - Kubota DF752 Models ..................... 3 - 37
D-6 Perform Engine Maintenance - Kubota Models ................................ 3 - 37
D-7 Perform Engine Maintenance - Kubota D905 Models ....................... 3 - 37
B
Part No. 52302
Checklist E Procedures
E-1
Test or Replace the Hydraulic Oil ..................................................... 3 - 38
E-2
Perform Engine Maintenance - Perkins 403C-11 Models ................. 3 - 39
E-3
Perform Engine Maintenance - Gasoline/LPG Models ...................... 3 - 40
E-4
Perform Engine Maintenance - Perkins 403C-11 Models ................. 3 - 40
GS-2668 RT • GS-3268 RT
vii
March 2005
TABLE OF CONTENTS
Section 4
Rev
Repair Procedures
Introduction .................................................................................................. 4 - 1
B
A
B
B
viii
Platform Controls
1-1
Circuit Boards .................................................................................... 4 - 2
1-2
Joystick Controller .............................................................................. 4 - 3
1-3
Function Speed Tuning (before serial number GS6803-42382) ......... 4 - 5
1-3
Software Configuration (before serial number GS6803-42382) ........ 4 - 10
Platform Components
2-1
Platform ........................................................................................... 4 - 14
2-2
Platform Extension ........................................................................... 4 - 15
Scissor Components
3-1
Scissor Assembly, GS-2668 RT ....................................................... 4 - 18
3-2
Scissor Assembly, GS-3268 RT ....................................................... 4 - 24
3-3
Wear Pads ....................................................................................... 4 - 31
3-4
Lift Cylinder(s) .................................................................................. 4 - 32
Kubota D905 Engine
4-1
Timing Adjustment ........................................................................... 4 - 35
4-2
Glow Plugs ....................................................................................... 4 - 35
4-3
Engine RPM ..................................................................................... 4 - 35
4-4
Flex Plate ......................................................................................... 4 - 36
4-5
Coolant Temperature and Oil Pressure Switches ............................. 4 - 37
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
TABLE OF CONTENTS
Section 4
Rev
Repair Procedures, continued
B
Kubota DF750 / DF752 Engine
A
B
A
5-1
Timing Adjustment ........................................................................... 4 - 38
5-2
Carburetor Adjustment - Gasoline/LPG Models ............................... 4 - 38
5-3
Choke Adjustment - Gasoline/LPG Models ...................................... 4 - 38
5-4
Flex Plate ......................................................................................... 4 - 38
5-5
Coolant Temperature and Oil Pressure Switches ............................. 4 - 38
5-6
Engine RPM ..................................................................................... 4 - 39
Perkins 403C-11 Engine
6-1
Engine RPM ..................................................................................... 4 - 40
6-2
Timing Adjustment ........................................................................... 4 - 40
6-3
Flex Plate ......................................................................................... 4 - 41
6-4
Coolant Temperature and Oil Pressure Switches ............................. 4 - 41
Ground Controls
7-1
Auxiliary Platform Lowering .............................................................. 4 - 42
7-2
Function Speed Tuning (after serial number GS6803-42381) .......... 4 - 43
7-3
Software Configuration (after serial number GS6803-42381) ........... 4 - 51
7-4
Level Sensor - Models without Outriggers
(before serial number 41754) ........................................................... 4 - 55
7-5
Level Sensor - Models without Outriggers
(after serial number 41753) .............................................................. 4 - 60
7-6
Level Sensor - Models with Outriggers ............................................. 4 - 63
Hydraulic Pump
8-1
Part No. 52302
Function Pump ................................................................................. 4 - 68
GS-2668 RT • GS-3268 RT
ix
March 2005
TABLE OF CONTENTS
Section 4
Rev
B
B
Repair Procedures, continued
Manifolds
9-1
Function Manifold Components ........................................................ 4 - 70
9-2
Valve Adjustments - Function Manifold ............................................ 4 - 74
9-3
Outrigger Manifold Components ....................................................... 4 - 77
9-4
Valve Adjustments - Outrigger Manifold ........................................... 4 - 78
9-5
Generator Manifold Components ..................................................... 4 - 80
9-6
Valve Adjustments - Generator Manifold .......................................... 4 - 81
9-7
Valve Coils ....................................................................................... 4 - 82
Fuel and Hydraulic Tanks
10-1 Fuel Tank ......................................................................................... 4 - 84
10-2 Hydraulic Tank ................................................................................. 4 - 85
A
Steer Axle Components
11-1 Yoke and Drive Motor ...................................................................... 4 - 86
11-2 Steer Cylinder .................................................................................. 4 - 87
11-3 Tie Rod ............................................................................................ 4 - 88
A
Non-steer Axle Components
12-1 Drive Motor and Brake ..................................................................... 4 - 89
A
Outrigger Components
13-1 Outrigger Cylinder ............................................................................ 4 - 90
B
Brake Release Hand Pump Components
14-1 Brake Release Hand Pump Components ......................................... 4 - 91
x
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
TABLE OF CONTENTS
Section 5
Rev
Fault Codes
Introduction .................................................................................................. 5 - 1
Section 6
B
Fault Code Chart (before serial number GS6803-42382) ............................ 5 - 3
A
Fault Code Chart (after serial number GS6803-42381) ............................... 5 - 9
Rev
Schematics
Introduction .................................................................................................. 6 - 1
Part No. 52302
A
Electronic Control Module Layout (before serial number GS6803-42382) ... 6 - 2
A
Electronic Control Module Pin-Out Legend
(before serial number GS6803-42382) ........................................................ 6 - 3
A
Electronic Control Module Layout (after serial number GS6803-42381) ...... 6 - 4
A
Electronic Control Module Pin-Out Legend
(after serial number GS6803-42381) ........................................................... 6 - 5
A
Wiring Diagram - Platform Control Box
(before serial number GS6803-42382) ........................................................ 6 - 6
A
Wiring Diagram - Platform Control Box
(after serial number GS6803-42381) ........................................................... 6 - 7
A
Electrical Schematics Abbreviation and Wire Color Legends ....................... 6 - 8
A
Electrical Symbols Legend ........................................................................... 6 - 9
B
Electrical Schematic - Gasoline/LPG Models
(before serial number 21161) ..................................................................... 6 - 10
B
Electrical Schematic - Gasoline/LPG Models
(from serial number 21161 to 21837) ......................................................... 6 - 12
B
Electrical Schematic - Gasoline/LPG Models
(from serial number 21838 to 38464) ......................................................... 6 - 14
B
Electrical Schematic - Gasoline/LPG Models
(from serial number 38465 to 41199) ......................................................... 6 - 18
B
Electrical Schematic - Gasoline/LPG Models
(from serial number 41200 to 41823) ......................................................... 6 - 22
A
Electrical Schematic - Gasoline/LPG Models
(from serial number 41824 to GS6803-42381) ........................................... 6 - 26
A
Electrical Schematic - ANSI Models with Gasoline/LPG Power
(from serial number GS6803-42382 to GS6805-43594) ............................ 6 - 30
A
Electrical Schematic - ANSI Models with Gasoline/LPG Power
(after serial number GS6805-43594) ......................................................... 6 - 34
GS-2668 RT • GS-3268 RT
xi
March 2005
TABLE OF CONTENTS
Section 6
xii
Rev
Schematics, continued
A
Electrical Schematic - CE Models with Gasoline/LPG Power
(from serial number GS6803-42382 to GS6805-43594) ............................ 6 - 38
A
Electrical Schematic - CE Models with Gasoline/LPG Power
(after serial number GS6805-43594) ......................................................... 6 - 42
B
Electrical Schematic - Diesel Models
(before serial number 21161) ..................................................................... 6 - 46
B
Electrical Schematic - Diesel Models
(from serial number 21161 to 21837) ......................................................... 6 - 48
B
Electrical Schematic - Diesel Models
(from serial number 21838 to 38464) ......................................................... 6 - 50
B
Electrical Schematic - Diesel Models
(from serial number 38465 to 40173) ......................................................... 6 - 54
B
Electrical Schematic - Diesel Models
(from serial number 40174 to 40939) ......................................................... 6 - 58
B
Electrical Schematic - Diesel Models
(from serial number 40940 to 41199) ......................................................... 6 - 62
B
Electrical Schematic - Diesel Models
(from serial number 41200 to 41823) ......................................................... 6 - 66
A
Electrical Schematic - Diesel Models
(from serial number 41824 to GS6803-42381) ........................................... 6 - 70
A
Electrical Schematic - ANSI Models with Diesel Power
(from serial number GS6803-42382 to GS6805-43594) ............................ 6 - 74
A
Electrical Schematic - ANSI Models with Diesel Power
(after serial number GS6805-43594) ......................................................... 6 - 78
A
Electrical Schematic - CE Models with Diesel Power
(from serial number GS6803-42382 to GS6805-43594) ............................ 6 - 82
A
Electrical Schematic - CE Models with Diesel Power
(after serial number GS6805-43594) ......................................................... 6 - 86
A
Hydraulic Schematics Component Call-out Legend ................................... 6 - 90
A
Hydraulic Symbols Legend ........................................................................ 6 - 91
B
Hydraulic Schematic (before serial number 35557) ................................... 6 - 92
A
Hydraulic Schematic (from serial number 35557 to 40484) ....................... 6 - 94
A
Hydraulic Schematic (from serial number 40485 to GS6804-43183) ......... 6 - 96
A
Hydraulic Schematic (after serial number GS6804-43183 ......................... 6 - 98
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 2 • Specifications
Specifications
REV B
Machine Specifications
Rough Terrain, foam-filled
Fluid Capacities (before serial number 42000)
Tire size
(before serial number 41200)
(after serial number 41199)
Hydraulic tank
21.5 gallons
81.4 liters
26 x 12 x 12
26 x 12D380
Tire ply rating
8
Hydraulic system (including tank)
25 gallons
94.6 liters
Tire diameter
26 in
66 cm
Fuel tank
15 gallons
56.8 liters
Tire width
12 in
30 cm
Fluid Capacities (after serial number 41999)
Weight
Hydraulic tank
15 gallons
56.8 liters
Hydraulic system (including tank)
17 gallons
64.4 liters
Fuel tank
14.5 gallons
54.9 liters
Wheel alignment specification
Toe-in Measurement
0 ± 0.125 inch
0 ± 3.2 mm
Non-marking, solid rubber
Tire size
Lug bolt torque, dry
Lug bolt torque, lubricated
Castle nut torque, dry
Castle nut torque, lubricated
6 @ 1/2 -20
90 ft-lbs
122 Nm
22 in
55.9 cm
Tire width
9 in
22.9 cm
Weight
120 lbs (+/- 1 lbs)
54.4 kg (+/- 2.2 kg)
Industrial, foam-filled (before serial number 41200)
Tire size
24-12.00 x 12 in
Tire ply rating
8
67.5 ft-lbs
91.5 Nm
Tire diameter
24 in
61 cm
300 ft-lbs
406.7 Nm
Tire width
12 in
30 cm
225 ft-lbs
305 Nm
Weight
For operational specifications, refer to the
Operator's Manual.
Part No. 52302
22 x 16 x 9 in
55.9 x 40.6 x 22.9 cm
Tire diameter
Tire and wheels
Wheel lugs
178 lbs (+/- 7 lbs)
80.7 kg (+/- 3.4 kg)
165 lbs (+/- 7 lbs)
74.8 kg (+/- 4.5 kg)
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.
GS-2668 RT • GS-3268 RT
2-1
Section 2 • Specifications
March 2005
SPECIFICATIONS
REV B
Performance Specifications
Hydraulic Specifications
Drive speed, maximum
Hydraulic Oil Specifications
Platform stowed
3.8 mph
6.1 km/h
40 ft / 7.2 sec
12.2 m / 7.2 sec
Platform raised
0.5 mph
0.8 km/h
40 ft / 54.6 sec
12.2 m / 54.6 sec
Function speed, maximum from platform controls
(with maximum rated load in platform)
GS-2668 RT
Platform up
Platform down
28 to 32 seconds
33 to 37 seconds
GS-3268 RT
Platform up
Platform down
Hydraulic oil type
ISO viscosity grade
Viscosity index
Cleanliness level, minimum
Water content, maximum
200 ppm
Optional fluids
38 to 42 seconds
35 to 39 seconds
6.6°
10.6°
Biodegradable
Fire resistant
Mineral based
Gradeability
GS-2668 RT
GS-3268 RT
15/13
Chevron Rykon MV oil is fully compatible and
mixable with Shell Donax TG (Dexron III) oils.
Genie specifications require hydraulic oils which are
designed to give maximum protection to hydraulic
systems, have the ability to perform over a wide
temperature range, and have a minimum viscosity index
of 150. They should provide excellent antiwear,
oxidation, corrosion inhibition, seal conditioning, and
foam and aeration suppression properties.
Outrigger leveling, maximum
Front to back
Side to side
Chevron Rykon MV equivalent
Multi-viscosity
200
40%
35%
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.
Petro Canada Premium ECO 46
Statoil Hydra Way Bio Pa 32
BP Biohyd SE-S
UCON Hydrolube HP-5046
Quintolubric 822
Shell Tellus T32
Shell Tellus T46
Chevron Aviation A
Use Chevron Aviation A hydraulic
oil when in ambient temperatures
consistently below 32°F / 0°C.
Use Shell Tellus T46 hydraulic oil
when oil temperatures consistently
exceed 205°F / 96°C.
Genie specifications require
additional equipment and special
installation instructions for the
approved optional fluids. Consult
the Genie Industries Service
Department before use.
2-2
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 2 • Specifications
REV B
SPECIFICATIONS
Function pump
Type:
2 section pressure balanced gear pump
Displacement
per revolution (pump #1)
0.488 cu in
8 cc
Flow rate @ 3600 rpm
(pump #1)
6.5 gpm
24.6 L/min
Displacement
per revolution (pump #2)
0.488 cu in
8 cc
Flow rate @ 3600 rpm
(pump #2)
6.5 gpm
24.6 L/min
Hydraulic tank
return filter
10 micron with
25 psi / 1.7 bar bypass
Function manifold
3500 psi
241.3 bar
System relief valve pressure
(pump #2)
3500 psi
241.3 bar
Lift relief valve pressure, GS-2668 RT
3500 psi
241.3 bar
Lift relief valve pressure, GS-3268 RT
2000 psi
137.8 bar
Steer relief valve pressure
1500 psi
103.4 bar
Steer flow regulator
2 gpm
7.5 L/min
2000 psi
137.8 bar
Generator manifold
Flow rate
3000 psi
206.8 bar
4.5 gpm
17 L/min
Drive motors
Displacement
Part No. 52302
SAE No. 2
50 in-lbs / 6 Nm
SAE No. 4
13 ft-lbs / 18 Nm
SAE No. 6
18 ft-lbs / 24 Nm
SAE No. 8
50 ft-lbs / 68 Nm
SAE No. 10
55 ft-lbs / 75 Nm
SAE No. 12
75 ft-lbs / 102 Nm
Description
28.3 cu in
464 cc
Specification
DO3 valve, 3 position 4 way
3.5 - 4.5Ω
12V DC with diode (schematic items A and B)
Solenoid valve, 2 position 4 way
12V DC with diode (schematic item P)
7 to 8Ω
Solenoid valve, 3 position 4 way
12V DC with diode (schematic item R)
7 to 8Ω
Proportional valve,
12V DC (schematic item T)
4 to 6Ω
Solenoid valve, 2 position 2 way
9 to 10Ω
12V DC with diode (schematic items U, W, X and Y)
Solenoid valve, 2 position 3 way
12V DC (schematic item AB)
Outrigger manifold
Relief valve pressure
Plug torque
Valve Coil Resistance
System relief valve pressure
(pump #1)
Relief valve pressure
Manifold Component
Specifications
Solenoid valve, 2 position 2 way
12V DC with diode (schematic item AI)
5.5 to 6.5Ω
8 to 10Ω
Solenoid valve, 2 position 2 way
12V DC (schematic item BB)
7 to 8Ω
Solenoid valve, 3 position 4 way
12V DC (schematic item BD)
7 to 8Ω
Solenoid valve, 2 position 2 way
7.2 to 9.2Ω
10V DC (schematic items CA, CB, CC and CD)
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.
GS-2668 RT • GS-3268 RT
2-3
Section 2 • Specifications
March 2005
SPECIFICATIONS
REV B
Kubota D905 Engine
Displacement
Injection system
54.86 cu in
0.90 liters
Number of cylinders
Bore and stroke
Horsepower, gross intermittent
Firing order
Compression ratio
Compression pressure
3
2.83 x 2.90 inches
72 x 73.6 mm
26 @ 3600 rpm
19.3 kW
1-2-3
23:1
412 to 469 psi
28.4 to 32.3 bar
Low idle
1500 rpm
300 hz
High idle
3000 rpm
600 hz
Injection pump make
Injection timing
Valve clearance, cold
Engine coolant capacity
centrifugal mechanical
0.0057 to 0.0072 in
0.145 to 0.185 mm
3.3 quarts
3.1 liters
Lubrication system
Oil pressure
Oil capacity (including filter)
Oil viscosity requirements
36 to 64 psi
2.48 to 4.41 bar
5.4 quarts
5.1 liters
10W-30
13° to 25° BTDC
Injection pump pressure
Fuel requirement
1991 psi
137 bar
diesel number 2-D
Battery
Type
12V DC
Group
34/78
Quantity
1
Ampere hour
75AH
Cold cranking ampere
900A
Reserve capacity @ 25A rate
Governor
Bosch MD
125 minutes
Starter motor
Brush length, new
0.5188 in
13 mm
Brush length, minimum
0.3346 in
8.5 mm
Alternator
Output
30A, 14V DC
Fan belt deflection
1 /4
to 3/8 inch
7 to 9 mm
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.
Engine oil should have properties of API classification
CD or higher.
2-4
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 2 • Specifications
REV B
SPECIFICATIONS
Perkins 403C-11 Engine
Displacement
Injection system
68.9 cu in
1.13 liters
Number of cylinders
3
Bore and stroke
3.03 x 3.19 inches
77 x 81 mm
Horsepower, gross intermittent
26.1 @ 3000 rpm
19.5 kW
Firing order
1-2-3
Compression ratio
23:1
Compression pressure
425 psi
29.3 bar
Pressure of the lowest cylinder must be within
50 psi / 3.45 bar of the highest cylinder, though
at no time less than 360 psi / 24.8 bar
Injection timing
Injection pump pressure
Fuel requirement
1500 rpm
300 hz
High idle
3000 rpm
600 hz
Type
Group
Engine coolant capacity
0.0078 in
0.2 mm
3.28 quarts
3.1 liters
23° BTDC @ 3000 rpm
2133 psi
150 bar
diesel number 2-D
12V DC
34/78
Quantity
1
Ampere hour
75AH
Cold cranking ampere
900A
125 minutes
Alternator
Output
Fan belt deflection
all-speed mechanical
Valve clearance, cold
Bosch
Battery
Reserve capacity @ 25A rate
Low idle
Governor
Injection pump make
40A, 12V DC
3/16
inch
5 mm
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.
Engine coolant should be clean soft water with 50% anti
freeze concentration ethylene glycol to BS 6580:1992 or
ASTMD 3306-89 or AS 2108-1977
Lubrication system
Oil pressure
(hot @ 2000 rpm)
Oil capacity (including filter)
Oil viscosity requirements
Below 14°F / -10°C
From 14°F to 104°F / -10°C to 40°C
Above 104°F / 40°C
40 to 60 psi
2.76 to 4.14 bar
4.3 quarts
4.07 liters
0W
15W-40
20W-50
Engine oil should have properties of API classification
CH4 or ACEA classification E5.
Part No. 52302
GS-2668 RT • GS-3268 RT
2-5
Section 2 • Specifications
March 2005
SPECIFICATIONS
REV B
Kubota DF750 Engine
Displacement
Starter motor
45.21 cu in
0.74 liters
Number of cylinders
3
Bore & stroke
2.68 x 2.68 inches
68 x 68 mm
Horsepower, Gross intermittent
23.8 @ 3600 rpm
17.7 kW @ 3600 rpm
Firing order
1-2-3
Low idle
1500 rpm
300 hz
High idle
3300 rpm
660 hz
Governor
centrifugal ball mechanical
Compression ratio
9:1
Compression pressure
Valve clearances, cold
128 to 185 psi
8.8 to 12.7 bar
0.0057 to 0.0072 inches
0.145 to 0.085 mm
Lubrication system
Oil pressure
(operating temperature @ 3850 rpm)
Oil capacity (including filter)
Oil viscosity requirements
Brush length, new
Brush length wear limit
Brush spring tension
3.9 quarts
3.7 liters
50 to 91 ounces
13.7 to 25.5 N
Type
12V DC
Group
34/78
Quantity
1
Ampere hour
75AH
Cold cranking ampere
900A
Reserve capacity at 25A rate
125 minutes
Ignition System
Ignition spark advance
Ignition coil primary resistance
Spark plug wire resistance
18° BTDC
1.3 to 1.6Ω
@ 75°F / 24°C
10.7 to 14.5 kΩ
@ 75°F / 24°C
10 to 22kΩ
Spark plug type
NGK BCP4ES-11
Spark plug gap
0.039 to 0.043 inches
1.0 to 1.1 mm
10W-30
Engine oil should have properties of API classification
SH.
0.453 in
11.5 mm
Battery
Ignition coil secondary resistance
28 to 64 psi
1.9 to 4.4 bar
0.669 in
17 mm
Engine coolant
Capacity
3.1 quarts
2.9 liters
Fuel pump
Fuel pressure, static
Fuel flow rate
2.84 psi
0.19 bar
0.125 gpm
0.47 L/min
Alternator
Output
30A, 14V DC
Fan belt deflection
1 /4
to 3/8 inch
7 to 9 mm
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.
2-6
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 2 • Specifications
SPECIFICATIONS
REV B
Kubota DF752 Engine
Displacement
Starter motor
45.21 cu in
0.74 liters
Number of cylinders
3
Bore & stroke
2.68 x 2.68 inches
68 x 68 mm
Horsepower, Gross intermittent
24.8 @ 3600 rpm
18.5 kW @ 3600 rpm
Firing order
1-2-3
Brush length, new
0.669 in
17 mm
Brush length wear limit
Brush spring tension
0.453 in
11.5 mm
50 to 91 ounces
13.7 to 25.5 N
Battery
Type
12V DC
1500 rpm
300 hz
Group
High idle
3200 rpm
640 hz
Ampere hour
75AH
Governor
centrifugal ball mechanical
Cold cranking ampere
900A
Low idle
Compression ratio
9.2:1
Compression pressure
Valve clearances, cold
128 to 185 psi
8.8 to 12.7 bar
0.0057 to 0.0072 inches
0.145 to 0.185 mm
Lubrication system
Oil pressure
(operating temperature @ 3850 rpm)
Oil capacity (including filter)
Oil viscosity requirements
28 to 64 psi
1.9 to 4.4 bar
3.4 quarts
3.25 liters
34/78
Quantity
Reserve capacity at 25A rate
1
125 minutes
Ignition System
Ignition spark advance
Ignition coil primary resistance
18° BTDC
1.3 to 1.6Ω
@ 75°F / 24°C
Ignition coil secondary resistance
10.7 to 14.5 kΩ
@ 75°F / 24°C
#1 Spark plug wire resistance
2.81 to 4.79kΩ
#2 Spark plug wire resistance
3.4 to 5.8kΩ
#3 Spark plug wire resistance
3.57 to 6.09kΩ
10W30
Engine oil should have properties of API classification
SH.
Spark plug type
NGK BKR4E-11
Spark plug gap
0.039 to 0.043 inches
1 to 1.1 mm
Fuel pump
Engine coolant
Fuel pressure, static
Fuel flow rate
2.84 psi
0.19 bar
0.125 gpm
0.47 L/min
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.
Part No. 52302
Capacity
3.1 quarts
2.9 liters
Alternator
Output
30A, 14V DC
Fan belt deflection
1 /4
GS-2668 RT • GS-3268 RT
to 3/8 inch
7 to 9 mm
2-7
Section 2 • Specifications
March 2005
SPECIFICATIONS
REV B
Hydraulic Hose and Fitting
Torque Specifications
Your machine is equipped with Parker Seal-Lok®
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.
Seal-Lok® fittings
1 Replace the O-ring. The O-ring must be
replaced anytime the seal has been broken.
The O-ring cannot be re-used if the fitting or
hose end has been tightened beyond finger
tight.
The O-rings used in the Parker
Seal Lok® fittings and hose ends
are custom-size O-rings. They are
not standard SAE size O-rings.
They are available in the O-ring
field service kit (Genie part
number 49612).
SAE O-ring Boss Port
(tube fitting - installed into Aluminum)
SAE Dash size
Torque
-4
11 ft-lbs / 14.9 Nm
2 Lubricate the O-ring before installation.
-6
23 ft-lbs / 31.2 Nm
-8
40 ft-lbs / 54.2 Nm
3 Be sure that the face seal O-ring is seated and
retained properly.
-10
69 ft-lbs / 93.6 Nm
-12
93 ft-lbs / 126.1 Nm
-16
139 ft-lbs / 188.5 Nm
-20
172 ft-lbs / 233.2 Nm
-24
208 ft-lbs / 282 Nm
4 Position the tube and nut squarely on the face
seal end of the fitting and tighten the nut finger
tight.
5 Tighten the nut or fitting to the appropriate
torque per given size as shown in the table.
6 Operate all machine functions and inspect the
hoses and fittings and related components to
confirm that there are no leaks.
SAE O-ring Boss Port
Seal-Lok Fittings
(tube fitting - installed into Steel)
(hose end)
®
SAE Dash size
Torque
SAE Dash size
Torque
-4
16 ft-lbs / 21.7 Nm
-4
18 ft-lbs / 24.4 Nm
-6
35 ft-lbs / 47.5 Nm
-6
27 ft-lbs / 36.6 Nm
-8
60 ft-lbs / 81.3 Nm
-8
40 ft-lbs / 54.2 Nm
-10
105 ft-lbs / 142.4 Nm
-10
63 ft-lbs / 85.4 Nm
-12
140 ft-lbs / 190 Nm
-12
90 ft-lbs / 122 Nm
-16
210 ft-lbs / 284.7 Nm
-16
120 ft-lbs / 162.7 Nm
-20
260 ft-lbs / 352.5 Nm
-20
140 ft-lbs / 190 Nm
-24
315 ft-lbs / 427.1 Nm
-24
165 ft-lbs / 223.7 Nm
2-8
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
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
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Maintenance inspections shall be completed by
a person trained and qualified on the
maintenance of this machine.
Scheduled maintenance inspections shall be
completed daily, quarterly, semi-annually,
annually and every 2 years as specified on the
Maintenance Inspection Report.
Used to indicate the presence of
an imminently hazardous situation
which, if not avoided, will result in
death or serious injury.
Failure to perform each procedure
as presented and scheduled could
result in death, serious injury or
substantial damage.
Used to indicate the presence of a
potentially hazardous situation
which, if not avoided, could result
in death or serious injury.
Immediately tag and remove from service a
damaged or malfunctioning machine.
With safety alert symbol—used to
indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause
minor or moderate injury.
Repair any machine damage or malfunction
before operating the machine.
Keep records on all inspections for three years.
Machines that have been out of service for a
period longer than 3 months must complete the
quarterly inspection.
Without safety alert symbol—used
to indicate the presence of a
potentially hazardous situation
which, if not avoided, may result in
property damage.
Unless otherwise specified, perform each
maintenance procedure with the machine in the
following configuration:
Used to indicate operation or
maintenance information.
· Machine parked on a firm, level surface
· Platform in the stowed position
· Key switch in the off position with the key
removed
· The red Emergency Stop button in the off
position at both ground and platform controls
Indicates that a specific result is expected after
performing a series of steps.
Indicates that an incorrect result has occurred
after performing a series of steps.
· Wheels chocked
· All external AC power supply disconnected
from the machine
Part No. 52302
GS-2668 RT • GS-3268 RT
3-1
Section 3 • Scheduled Maintenance Procedures
March 2005
SCHEDULED MAINTENANCE PROCEDURES
Pre-delivery Preparation Report
Maintenance Symbols Legend
The following symbols have been
used in this manual to help
communicate the intent of the
instructions. When one or more of
the symbols appear at the
beginning of a maintenance
procedure, it conveys the meaning
below.
Indicates that tools will be required to
perform this procedure.
Indicates that new parts will be required
to perform this procedure.
Indicates that a cold engine will be
required to perform this procedure.
The pre-delivery preparation report contains
checklists for each type of scheduled inspection.
Make copies of the Pre-delivery Preparation report
to use for each inspection. Store completed forms
as required.
Maintenance Schedule
There are five types of maintenance inspections
that must be performed according to a schedule—
daily, quarterly, semi-annually, annually, and
two year. The Scheduled Maintenance Procedures
Section and the Maintenance Inspection Report
have been divided into five subsections—A, B, C,
D, and E. Use the following chart to determine
which group(s) of procedures are required to
perform a scheduled inspection.
Inspection
Daily or every 8 hours
Quarterly or every 250 hours
Indicates that a warm engine will be
required to perform this procedure.
Indicates that dealer service will be
required to perform this procedure.
Checklist
Semi-annually or every 500 hours
A
A+B
A+B+C
Annually or every 1000 hours
A+B+C+D
Two year or every 2000 hours
A+B+C+D+E
Maintenance Inspection Report
The maintenance inspection report contains
checklists for each type of scheduled inspection.
Make copies of the Maintenance Inspection Report
to use for each inspection. Store completed forms
for three years.
3-2
GS-2668 RT • GS-3268 RT
Part No. 52302
Pre-Delivery Preparation
March 2005
Section 3 • Scheduled Maintenance Procedures
Fundamentals
Instructions
It is the responsibility of the dealer to perform the
Pre-delivery Preparation.
Use the operator’s manual on your machine.
The Pre-delivery Preparation is performed prior to
each delivery. The inspection is designed to discover if
anything is apparently wrong with a machine before it
is put into service.
A damaged or modified machine must never be used.
If damage or any variation from factory delivered
condition is discovered, the machine must be tagged
and removed from service.
Repairs to the machine may only be made by a
qualified service technician, according to the
manufacturer's specifications.
Scheduled maintenance inspections shall be
performed by qualified service technicians, according
to the manufacturer's specifications and the
requirements listed in the responsibilities manual.
The Pre-delivery Preparation consists of completing
the Pre-operation Inspection, the Maintenance items
and the Function Tests.
Use this form to record the results. Place a check in
the appropriate box after each part is completed.
Follow the instructions in the operator’s manual.
If any inspection receives an N, remove the machine
from service, repair and re-inspect it. After repair,
place a check in the R box.
Legend
Y = yes, completed
N = no, unable to complete
R = repaired
Comments
Pre-Delivery Preparation
Y
N
R
Pre-operation inspection
completed
Maintenance items completed
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Genie Industries USA
18340 NE 76th Street
PO Box 97030
Redmond, WA 98073-9730
(425) 881-1800
Genie UK
The Maltings, Wharf Road
Grantham, Lincolnshire
NG31- 6BH England
(44) 1476-584333
Copyright © 2002 by Genie Industries. Genie® is a registered trademark of Genie
Industries. Rev B
Part No. 52302
GS-2668 RT • GS-3268 RT
3-3
Section 3 • Scheduled Maintenance Procedures
March 2005
This page intentionally left blank.
3-4
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 3 • Scheduled Maintenance Procedures
Maintenance Inspection Report
Model
Checklist A - Rev B
Y N R
Checklist B - Rev B
A-1 Pre-operation inspect
B-1 Battery
A-2 Function tests
B-2 Electrical wiring
A-3 Engine maintenance
B-3 Tires and wheels
Perform every 40 hours:
A-4 Engine air filter
B-4 Engine maintenance Perkins 403C models
Perform after 40 hours:
B-5 Key switch
A-5 Perform 30 day service
B-6 Emergency Stop
Inspected by (print)
Perform after 50 hours:
B-7 Horn
Inspector signature
A-6 Engine maintenance Kubota D905 models
B-8 Fuel select Gasoline/LPG models
Inspector title
Perform every 50 hours:
B-9 Drive brakes
A-7 Engine maintenance Kubota models
B-10 Drive speed - stowed
Inspector company
Perform every 100 hours:
B-12 Tank venting systems
Instructions
· Make copies of this report to use for
each inspection.
A-8 Engine maintenance Kubota models
B-13 Hydraulic oil analysis
· Select the appropriate checklist(s) for
the type of inspection to be
performed.
A-9 Engine maintenance Kubota models
Serial number
Date
Hour meter
Machine owner
A-10 Drain filter/separator Diesel models
Daily or 8 hours
Inspection:
Quarterly or 250 hours
Inspection:
Perform every 200 hours:
A
A+B
Semi-annually or 500 hours
Inspection:
A+B+C
Y N R
B-11 Drive speed - raised
B-14 Flashing beacons
(if equipped)
Perform every 400 hours:
B-15 Engine maintenance Kubota D905 models
Perform every 1-2 months:
A-11 Engine maintenance Kubota D905 models
Comments
Annually or 1000 hours
Inspection:
A+B+C+D
Two year or 2000 hours
Inspection:
A+B+C+D+E
· Place a check in the appropriate box
after each inspection procedure is
completed.
· Use the step-by-step procedures in
this section to learn how to perform
these inspections.
· If any inspection receives an “N”, tag
and remove the machine from service,
repair and re-inspect it. After repair,
place a check in the “R” box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
Part No. 52302
GS-2668 RT • GS-3268 RT
3-5
Section 3 • Scheduled Maintenance Procedures
March 2005
MAINTENANCE INSPECTION REPORT
Model
Checklist C - Rev B
Serial number
C-1 Platform overload
(if equipped)
E-1 Test or replace
hydraulic oil
Date
C-2 Fuel tank Diesel models
E-2 Engine maintenance Perkins 403C models
Hour meter
C-3 Breather cap - models
with optional oil
E-3 Engine maintenance Gasoline/LPG models
Machine owner
C-4 Engine maintenance Diesel models
Perform every 3000 hours:
Inspected by (print)
Perform every 800 hours:
Inspector signature
C-5 Engine maintenance Kubota D905, DF750
Y N R
Checklist E - Rev B
Y N R
E-4 Engine maintenance Perkins 403C models
Inspector title
Checklist D - Rev B
Inspector company
D-1 Scissor arm wear pads
Instructions
· Make copies of this report to use for
each inspection.
D-2 Platform overload
(if equipped)
· Select the appropriate checklist(s) for
the type of inspection to be performed.
D-4 Engine maintenance Perkins 403C models
D-3 Hydraulic filter
D-5 Engine maintenance Kubota DF752 models
Daily or 8 hours
Inspection:
Quarterly or 250 hours
Inspection:
Y N R
A
A+B
Semi-annually or 500 hours
Inspection:
A+B+C
Annually or 1000 hours
Inspection:
A+B+C+D
Two year or 2000 hours
Inspection:
A+B+C+D+E
Perform annually:
D-6 Engine maintenance Kubota models
Perform every 1500 hours:
D-7 Engine maintenance Kubota D905
Comments
· Place a check in the appropriate box
after each inspection procedure is
completed.
· Use the step-by-step procedures in
this section to learn how to perform
these inspections.
· If any inspection receives an “N”, tag
and remove the machine from service,
repair and re-inspect it. After repair,
place a check in the “R” box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
3-6
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
REV B
Section 3 • Scheduled Maintenance Procedures
Checklist A Procedures
A-1
Perform Pre-operation Inspection
A-2
Perform Function Tests
Completing a Pre-operation Inspection is essential
to safe machine operation. The Pre-operation
Inspection is a visual inspection performed by the
operator prior to each work shift. The inspection is
designed to discover if anything is apparently
wrong with a machine before the operator performs
the function tests. The Pre-operation Inspection
also serves to determine if routine maintenance
procedures are required.
Completing the function tests is essential to safe
machine operation. Function tests are designed to
discover any malfunctions before the machine is
put into service. A malfunctioning machine must
never be used. If malfunctions are discovered, the
machine must be tagged and removed from
service.
Complete information to perform this procedure is
available in the appropriate operator's manual.
Refer to the Operator's Manual on your machine.
Part No. 52302
Complete information to perform this procedure is
available in the appropriate operator's manual.
Refer to the Operator's Manual on your machine.
GS-2668 RT • GS-3268 RT
3-7
March 2005
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A
REV B
PROCEDURES
A-3
Perform Engine Maintenance
A-4
Inspect the Engine Air Filter
Engine specifications require that
this procedure be performed every
8 hours or daily, whichever comes
first.
Genie specifications require that
this procedure be performed every
40 hours or weekly, whichever
comes first.
Required maintenance procedures and additional
engine information is available in the
Kubota DF750 Operator's Manual
(Kubota part number EG261-8916-1) OR the
Kubota DF752 Operator's Manual
(Kubota part number EG601-8916-1) OR the
Kubota D905 Operator's Manual
(Kubota part number 16622-8916-5) OR the
Perkins 403C-11 User's Handbook
(Perkins part number 100816460).
Maintaining the engine air filter in good condition is
essential to good engine performance and service
life. Failure to perform this procedure can lead to
poor engine performance and component damage.
Kubota DF750 Operator's Manual
Genie part number
97359
Kubota DF752 Operator's Manual
Genie part number
2 Kubota D905 models: Remove the wingnut
securing the end cap to the air cleaner canister.
Remove the end cap.
84250
Kubota D905 Operator's Manual
Genie part number
84240
Perkins 403C-11 User's Handbook
Genie part number
97360
Perform this procedure with the
engine off.
1 Kubota D905 models: Pull up on the engine
tray locking pin, located under the radiator on
the engine pivot tray. Swing the engine pivot
tray out and away from the machine for access.
All other models: Disconnect the retaining
clamps securing the end cap to the air cleaner
canister. Remove the end cap.
3 Remove the air filter element.
4 Clean the inside of the air filter canister and the
canister gasket with a damp cloth.
5 Inspect for and remove any blockage or debris
from the intake air passages.
3-8
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 3 • Scheduled Maintenance Procedures
REV B
CHECKLIST A
6 Inspect the air filter element. If needed, blow
from the inside out using low pressure dry
compressed air, or carefully tap out dust.
PROCEDURES
A-5
Perform 30 Day Service
7 Securely install the filter element into the
canister.
Be sure the dust discharge valve
is facing down when installed.
The 30 day maintenance procedure is a one-time
sequence of procedures to be performed after the
first 30 days or 40 hours of usage. After this
interval, refer to the maintenance checklists for
continued scheduled maintenance.
9 Secure the end cap to the air cleaner cannister
with the retaining clamps.
1 Perform the following maintenance procedures:
Kubota DF750 and DF752 models:
8 Install the gasket and baffle (if equipped), and
end cap onto the air cleaner canister.
10 Kubota D905 models: Swing the engine pivot
tray back to its original position and make sure
the engine tray locking pin locks into place.
· A-10
Perform Engine Maintenance Gasoline/LPG Models
· B-3
Inspect the Tires and Wheels
(including lug nut torque)
· D-3
Replace the Hydraulic Tank
Return Filter
Kubota D905 models:
· A-9
Perform Engine Maintenance Kubota D905 Models
· B-3
Inspect the Tires and Wheels
(including lug nut torque)
· D-3
Replace the Hydraulic Tank
Return Filter
Perkins 403C-11 models:
Part No. 52302
· B-3
Inspect the Tires and Wheels
(including lug nut torque)
· B-4
Perform Engine Maintenance Perkins 403C-11 Models
· C-3
Perform Engine Maintenance Diesel Models
· D-3
Replace the Hydraulic Tank
Return Filter
GS-2668 RT • GS-3268 RT
3-9
March 2005
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A
PROCEDURES
REV B
A-6
Perform Engine Maintenance Kubota D905 Models
A-7
Perform Engine Maintenance Kubota Models
Engine specifications require that
this one time procedure be
performed after the first 50 hours
of operation.
Required maintenance procedures and additional
engine information is available in the
Kubota D905 Operator's Manual
(Kubota part number 16622-8916-5).
Kubota D905 Operator's Manual
Genie part number
3 - 10
84240
Engine specifications require that
this procedure be performed every
50 hours or weekly, whichever
comes first.
Required maintenance procedures and additional
engine information is available in the
Kubota D905 Operator's Manual
(Kubota part number 16622-8916-5) OR the
Kubota DF750 Operator's Manual
(Kubota part number EG261-8916-1) OR the
Kubota DF752 Operator's Manual
(Kubota part number EG601-8916-1).
Kubota D905 Operator's Manual
Genie part number
84240
Kubota DF750 Operator's Manual
Genie part number
97359
Kubota DF752 Operator's Manual
Genie part number
84250
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 3 • Scheduled Maintenance Procedures
REV B
CHECKLIST A
A-8
Perform Engine Maintenance Kubota Models
PROCEDURES
A-9
Perform Engine Maintenance Kubota Models
Engine specifications require that
this procedure be performed every
100 hours.
Engine specifications require that
this procedure be performed every
200 hours.
Required maintenance procedures and additional
engine information is available in the
Kubota D905 Operator's Manual
(Kubota part number 16622-8916-5) OR the
Kubota DF750 Operator's Manual
(Kubota part number EG261-8916-1) OR the
Kubota DF752 Operator's Manual
(Kubota part number EG601-8916-1).
Required maintenance procedures and additional
engine information is available in the
Kubota D905 Operator's Manual
(Kubota part number 16622-8916-5) OR the
Kubota DF750 Operator's Manual
(Kubota part number EG261-8916-1) OR the
Kubota DF752 Operator's Manual
(Kubota part number EG601-8916-1).
Kubota D905 Operator's Manual
Genie part number
84240
Kubota D905 Operator's Manual
Genie part number
84240
Kubota DF750 Operator's Manual
Genie part number
97359
Kubota DF750 Operator's Manual
Genie part number
97359
Kubota DF752 Operator's Manual
Genie part number
84250
Kubota DF752 Operator's Manual
Genie part number
84250
Part No. 52302
GS-2668 RT • GS-3268 RT
3 - 11
March 2005
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A
PROCEDURES
REV B
A-10
Drain the Fuel Filter/ Water
Separator - Diesel Models
a
b
c
Genie specifications require that
this procedure be performed every
200 hours or monthly, whichever
comes first.
Proper maintenance of the fuel filter/water
separator is essential for good engine
performance. Failure to perform this procedure can
lead to poor engine performance and component
damage.
d
e
Explosion and fire hazard. Engine
fuels are combustible. Perform this
procedure in an open, wellventilated area away from heaters,
sparks, flames and lighted
tobacco. Always have an
approved fire extinguisher within
easy reach.
Perform this procedure with the
engine off.
1 Locate the fuel filter/water separator and loosen
the vent plug located on the fuel filter/water
separator head.
2 Loosen the drain plug located at the bottom of
the bowl. Allow the water to drain into a suitable
container until fuel starts to come out.
Immediately tighten the drain plug.
3 - 12
a
b
c
d
e
head bolt
vent plug
separator head
filter bowl
drain plug
3 Tighten the vent plug and clean up any spills or
wet surfaces.
If the fuel bowl is completely
drained, you must prime, or bleed,
the fuel filter/water separator
before starting the engine. See
step 5.
4 Start the engine from the ground controls and
check the fuel filter/water separator for leaks.
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 3 • Scheduled Maintenance Procedures
REV B
CHECKLIST A
Bleed the fuel system:
Before bleeding the system, fill the
fuel tank.
PROCEDURES
A-11
Perform Engine Maintenance Kubota D905 Models
5 Loosen the vent plug/screw located on the filter
head.
6 Operate the hand primer until fuel, free of air,
flows from the vent plug/screw. Tighten the vent
plug/screw on the filter head.
7 Loosen the vent screw, located on top of the
fuel injection pump.
8 Operate the hand primer until fuel, free of air,
flows from the vent plug/screw. Tighten the vent
plug/screw on the injection pump.
Engine specifications require that
this procedure be performed every
one or two months.
Required maintenance procedures and additional
engine information is available in the
Kubota D905 Operator's Manual
(Kubota part number 16622-8916-5).
Kubota D905 Operator's Manual
Genie part number
9 Clean up any fuel that may have spilled.
84240
10 Attempt to start the engine using the starter
motor for a maximum of 15 seconds, resting the
starter for 30 seconds before trying again.
11 Inspect the fuel filter/water separator for leaks.
Explosion and fire hazard. If a fuel
leak is discovered, keep any
additional personnel from entering
the area and do not operate the
machine. Repair the leak
immediately.
Information to perform this
procedure is also available in the
Kubota D905 Operator's Manual,
(Kubota part number
16622-8916-5) OR the Perkins
403C-11 User's Handbook
(Perkins part number 100816460).
Kubota D905 Operator's Manual
Genie part number
84240
Perkins 403C-11 User's Handbook
Genie part number
97360
Part No. 52302
GS-2668 RT • GS-3268 RT
3 - 13
March 2005
Section 3 • Scheduled Maintenance Procedures
Checklist B Procedures
REV B
3 Be sure that the battery hold downs and cable
connections are tight.
B-1
Inspect the Battery
Models without maintenance-free or sealed
batteries:
Proper battery condition is essential to good
engine performance and operational safety.
Improper fluid levels or damaged cables and
connections can result in engine component
damage and hazardous conditions.
Electrocution hazard. Contact with
hot or live circuits could result in
death or serious injury. Remove all
rings, watches and other jewelry.
Bodily injury hazard. Batteries
contain acid. Avoid spilling or
contacting battery acid. Neutralize
battery acid spills with baking soda
and water.
4 Remove the battery vent caps and check the
specific gravity of each battery cell with a
hydrometer.
Result: If any battery cell displays a specific
gravity of less than 1.026, the battery must be
replaced.
5 Check the battery acid level of each battery cell.
If needed, replenish with distilled water to the
bottom of the battery fill tube. Do not overfill.
6 Install the battery vent caps.
Perform this test after fully
charging the battery.
For a more accurate determination
of battery condition, fully charge
the battery and allow the battery to
rest 24 hours before performing
this procedure to allow the battery
cells to equalize.
1 Put on protective clothing and eye wear.
2 Be sure that the battery cable connections are
free of corrosion.
Adding terminal protectors and a
corrosion preventative sealant will
help eliminate corrosion on the
battery terminals and cables.
3 - 14
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 3 • Scheduled Maintenance Procedures
REV B
CHECKLIST B
B-2
Inspect the Electrical Wiring
Maintaining electrical wiring in good condition is
essential to safe operation and good machine
performance. Failure to find and replace burnt,
chafed, corroded or pinched wires could result in
unsafe operating conditions and may cause
component damage.
Electrocution hazard. Contact
with hot or live circuits may
result in death or serious injury.
Remove all rings, watches and
other jewelry.
1 Inspect the following areas for burnt, chafed,
corroded and loose wires:
PROCEDURES
3 Turn the key switch to ground control and pull
out the Emergency Stop button to the ON
position at both the ground and platform
controls.
4 Start the engine and raise the platform
approximately 10 feet / 3 m from the ground.
5 Lift the safety arm, move to the center of the
scissor arm and rotate down to a vertical
position.
6 Lower the platform onto the safety arm.
Crushing hazard. Keep hands
clear of the safety arm when
lowering the platform.
7 Inspect the center chassis area and scissor
arms for burnt, chafed and pinched cables.
8 Inspect the following areas for burnt, chafed,
corroded, pinched and loose wires:
· Ground control panel
·
ECM to platform controls
· Hydraulic tray
·
Power to platform wiring
9 Raise the platform and return the safety arm to
the stowed position.
· Engine tray
· Scissor arms
· Platform controls
2 Inspect for a liberal coating of dielectric grease
in the following locations:
10 Lower the platform to the stowed position and
turn the machine off.
· Between the ECM and platform controls
· All wire harness connectors
· Level sensor
Part No. 52302
GS-2668 RT • GS-3268 RT
3 - 15
March 2005
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
PROCEDURES
REV B
B-3
Inspect the Tires and Wheels
(including castle nut and lug bolt
torque)
Maintaining the tires and wheels in good
condition is essential to safe operation and good
performance. Tire and/or wheel failure could result
in a machine tip-over. Component damage may
also result if problems are not discovered and
repaired in a timely fashion.
1 Check the tire tread and sidewalls for cuts,
cracks, punctures and unusual wear.
2 Check each wheel for damage, bends and
cracked welds.
B-4
Perform Engine Maintenance Perkins 403C-11 Models
Engine specifications require that
this procedure be performed every
250 hours or six months,
whichever comes first.
Required maintenance procedures and additional
engine information is available in the
Perkins 403C-11 User's Handbook
(Perkins part number 100816460).
Perkins 403C-11 User's Handbook
Genie part number
97360
3 Remove the castle nut lock plate or cotter pin
and check each castle nut for proper torque.
Refer to Section 2, Specifications.
Always replace the cotter pin with
a new one when removing the
castle nut or checking the torque
of the castle nut.
4 Check each lug bolt for proper torque.
5 Install the castle nut lock plate using a new lock
washer OR install a new cotter pin and secure.
3 - 16
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 3 • Scheduled Maintenance Procedures
REV B
CHECKLIST B
PROCEDURES
B-5
Test the Key Switch
B-6
Test the Emergency Stop
Proper key switch action and response is essential
to safe machine operation. The machine can be
operated from the ground or platform controls and
the activation of one or the other is accomplished
with the key switch. Failure of the key switch to
activate the appropriate control panel could cause
a hazardous operating situation.
A properly functioning Emergency Stop is essential
for safe machine operation. An improperly
operating red Emergency Stop button
will fail to shut off power and stop all machine
functions, resulting in a hazardous situation.
As a safety feature, selecting
and operating the ground controls
will override the platform controls,
except the platform red
Emergency Stop button.
1 Pull out the red Emergency Stop button to the
ON position at both the ground and platform
controls.
2 Turn the key switch to platform control.
1 Start the engine from ground controls.
3 Check the platform up/down function from the
ground controls.
2 Push in the red Emergency Stop button to the
off position.
Result: The machine functions should not
operate.
Result: The engine should shut off and no
machine functions should operate.
4 Turn the key switch to ground control.
3 Start the engine from platform controls.
5 Check the machine functions from the platform
controls.
4 Push in the red Emergency Stop button to the
off position.
Result: The machine functions should not
operate.
Result: The engine should shut off and no
machine functions should operate.
6 Turn the key switch to the OFF position.
Result: The engine should stop and no
functions should operate.
Part No. 52302
GS-2668 RT • GS-3268 RT
The red Emergency Stop button at
the ground controls should stop all
machine operation, even if the key
switch is switched to platform
control.
3 - 17
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
March 2005
REV B
PROCEDURES
B-7
Test the Automotive-style Horn
A functioning horn is essential to safe machine
operation. The horn is activated at the platform
controls and sounds at the ground as a warning to
ground personnel. An improperly functioning horn
will prevent the operator from alerting ground
personnel of hazards or unsafe conditions.
1 Turn the key switch to platform control and
pull out the red Emergency Stop button to the
ON position at both the ground and platform
controls.
2 Push down the horn button at the platform
controls.
Result: The horn should sound.
If necessary, the horn can be
adjusted to obtain the loudest
volume by turning the adjustment
screw near the wire terminals on
the horn.
3 - 18
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 3 • Scheduled Maintenance Procedures
REV B
CHECKLIST B
B-8
Test the Fuel Select Operation Gasoline/LPG Models
PROCEDURES
4 Press the high idle button again to return the
engine to low idle.
Result: The high idle indicator light should turn
OFF and the engine should return to low idle.
5 Press the engine stop button.
The ability to select and switch between
gasoline and LPG fuels as needed is essential to
safe machine operation. A fuel selection can be
made whether the engine is running or not.
Switching malfunctions and/or the failure of the
engine to start and run properly in both fuel
modes and through all idle speeds can indicate
fuel system problems that could develop into a
hazardous situation.
Perform this test after checking
the gasoline and LPG fuel levels,
and warming the engine to normal
operating temperature.
Result: The engine should stop.
6 Press the LPG operation button.
Result: The LPG indicator light should be ON.
7 Start the engine and allow it to run at low idle.
8 Press the high idle button to allow the engine to
run at high idle.
Result: The high idle indicator light should be ON
and the engine should start promptly and
operate smoothly in low and high idle.
Be sure that the valve on the LPG
tank is in the OPEN position.
The engine may hesitate
momentarily and then continue
to run on the selected fuel if the
fuel source is switched while
the engine is running.
1 Move the fuel select toggle switch to the
gasoline position at the ground controls.
2 Start the engine from the platform controls and
allow the engine to run at low idle.
3 Press the high idle button at the platform
controls to allow the engine to run at high idle.
Result: The high idle indicator light should be ON
and the engine should start promptly and
operate smoothly in low and high idle.
Part No. 52302
GS-2668 RT • GS-3268 RT
3 - 19
March 2005
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
PROCEDURES
REV B
5 Slowly move the joystick in the direction
indicated by the yellow arrow on the control
panel until the machine begins to move, then
return the joystick to the center position.
B-9
Test the Drive Brakes
Proper brake action is essential to safe machine
operation. The drive brake function should operate
smoothly, free of hesitation, jerking and unusual
noise. Hydraulically-released individual wheel
brakes can appear to operate normally when they
are actually not fully operational.
Select a test area that is firm, level
and free of obstructions.
Be sure the extend deck is fully
retracted and the platform is in the
stowed position.
Result: The machine should move in the
direction that the yellow arrow points on the
control panel, then come to an abrupt stop.
6 Bring the machine to maximum drive speed
before reaching the start line. Release the
function enable switch on the joystick or release
the joystick when your reference point on the
machine crosses the test line.
7 Measure the distance between the test line and
your machine reference point.
1 Mark a test line on the ground for reference.
The brakes must be able to hold
the machine on any slope it is able
to climb.
2 Start the engine from platform controls.
3 Choose a point on the machine; i.e., contact
patch of a tire, as a visual reference for use
when crossing the test line.
4 Slowly move the joystick in the direction
indicated by the blue arrow on the control panel
until the machine begins to move, then return
the joystick to the center position.
Result: The machine should move in the
direction that the blue arrow points on the
control panel, then come to an abrupt stop.
3 - 20
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 3 • Scheduled Maintenance Procedures
REV B
CHECKLIST B
PROCEDURES
Models before serial number GS6803-42382,
and after serial number GS6803-42381 with
software revision B1 or lower:
B-10
Test the Drive Speed Stowed Position
6 Bring the machine to maximum drive speed
before reaching the start line. Begin timing
when your reference point on the machine
crosses the start line.
Proper drive function movement is essential to
safe machine operation. The drive function should
respond quickly and smoothly to operator control.
Drive performance should also be free of
hesitation, jerking and unusual noise over the
entire proportionally controlled speed range.
Select a test area that is firm, level
and free of obstructions.
Be sure the platform is fully
retracted and lowered to the
stowed position.
7 Continue at full speed and note the time when
the machine reference point passes over the
finish line. Refer to Section 2, Specifications.
Models after serial number GS6803-42381 with
software revision C0 or higher:
6 Bring the machine to maximum forward drive
speed before reaching the start line. Begin
timing when your reference point on the
machine crosses the start line.
1 Create start and finish lines by marking two
lines on the ground 40 feet / 12.2 m apart.
7 Continue at full speed and note the time when
the machine reference point passes over the
finish line. Refer to Section 2, Specifications.
2 Turn the key switch to platform controls and pull
out the red Emergency Stop button to the on
position at both the ground and platform
controls.
8 Bring the machine to maximum reverse drive
speed before reaching the start line. Begin
timing when your reference point on the
machine crosses the start line.
3 Start the engine from the platform controls.
9 Continue at full speed and note the time when
the machine reference point passes over the
finish line. Refer to Section 2, Specifications.
4 Lower the platform to the stowed position.
5 Choose a point on the machine; i.e., contact
patch of a tire, as a visual reference for use
when crossing the start and finish lines.
Part No. 52302
GS-2668 RT • GS-3268 RT
3 - 21
March 2005
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
PROCEDURES
REV B
6 Continue at maximum speed and note the time
when your reference point on the machine
crosses the finish line. Refer to Section 2,
Specifications.
B-11
Test the Drive Speed Raised Position
Proper drive function movement is essential to
safe machine operation. The drive function should
respond quickly and smoothly to operator control.
Drive performance should also be free of
hesitation, jerking and unusual noise over the
entire proportionally controlled speed range.
Select a test area that is firm, level
and free of obstructions.
1 Create start and finish lines by marking two
lines on the ground 40 feet / 12.2 m apart.
2 Start the engine from the platform controls.
If the raised drive speed does not
meet specifications, refer to the
Repair procedure, 1-3, Controller
Adjustments.
GS-2668 RT before serial number 26563 and
GS-3268 RT before serial number 42000:
7 Raise the platform to full height.
8 Fully extend the platform extension.
9 Slowly move the joystick to the full drive
position.
Result: The drive function should not operate.
10 Lower the platform or retract the platform
extension to drive.
3 Raise the platform to approximately
6 feet / 2 m.
4 Choose a point on the machine; i.e., contact
patch of a tire, as a visual reference for use
when crossing the start and finish lines.
5 Bring the machine to maximum drive speed
before reaching the start line. Begin timing
when your reference point on the machine
crosses the start line.
3 - 22
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 3 • Scheduled Maintenance Procedures
REV B
CHECKLIST B
B-12
Inspect the Fuel and Hydraulic
Tank Cap Venting Systems
Genie requires that this procedure
be performed quarterly or every
250 hours, whichever comes first.
Perform this procedure more often
if dusty conditions exist.
A free-breathing fuel tank cap is essential for good
engine performance and service life. A dirty or
clogged fuel tank cap may cause the engine to
perform poorly and continued use may cause
component damage. Extremely dirty conditions
may require that the cap be inspected more often.
Explosion and fire hazard. Engine
fuels are combustible. Perform this
procedure in an open, wellventilated area away from heaters,
sparks, flames and lighted
tobacco. Always have an
approved fire extinguisher within
easy reach.
Perform this procedure with the
engine off.
PROCEDURES
2 Check for proper venting.
Result: Air passes through the fuel tank cap.
Result: If air does not pass through the cap,
clean or replace the cap. Proceed to step 3.
When checking for positive fuel
tank cap venting, air should pass
freely through the cap.
3 Using a mild solvent, carefully wash the cap
venting system. Dry using low pressure
compressed air. Repeat step 2.
4 Install the fuel tank cap onto the fuel tank.
5 Remove the breather cap from the hydraulic
tank.
6 Check for proper venting.
Result: Air passes through the breather cap.
Result: If air does not pass through the cap,
clean or replace the cap. Proceed to step 3.
When checking for positive fuel
tank cap venting, air should pass
freely through the cap.
7 Using a mild solvent, carefully wash the cap
venting system. Dry using low pressure
compressed air. Repeat step 2.
8 Install the breather cap onto the fuel tank.
1 Remove the cap from the fuel tank.
Part No. 52302
GS-2668 RT • GS-3268 RT
3 - 23
March 2005
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
PROCEDURES
REV B
B-13
Perform Hydraulic Oil Analysis
Replacement or testing of the hydraulic oil is
essential for good machine performance and
service life. Dirty oil and a clogged suction strainer
may cause the machine to perform poorly and
continued use may cause component damage.
Extremely dirty conditions may require oil changes
to be performed more often.
Before replacing the hydraulic oil,
the oil may be tested by an oil
distributor for specific levels of
contamination to verify that
changing the oil is necessary. If
the hydraulic oil is not replaced
at the two year inspection, test
the oil quarterly. Replace the oil
when it fails the test. See E-1,
Test or Replace the Hydraulic Oil.
B-14
Test the Flashing Beacons
(if equipped)
Flashing beacons are used to alert operators and
ground personnel of machine proximity and
motion. The flashing beacons are located on both
sides of the machine.
1 Turn the key switch to ground control and pull
out the red Emergency Stop button to the on
position at both the ground and platform
controls.
Result: The beacons should flash.
2 Turn the key switch to platform controls.
Result: The beacons should flash.
B-15
Perform Engine Maintenance Kubota D905 Models
Engine specifications require that
this procedure be performed every
400 hours.
Required maintenance procedures and additional
engine information is available in the
Kubota D905 Operator's Manual
(Kubota part number 16622-8916-5).
Kubota D905 Operator's Manual
Genie part number
3 - 24
GS-2668 RT • GS-3268 RT
84240
Part No. 52302
March 2005
Section 3 • Scheduled Maintenance Procedures
Checklist C Procedures
REV B
C-1
Test the
Platform Overload System
(if equipped)
8 Securely connect a jumper wire from terminal
A10 of the terminal strip to terminal B9 of the
terminal strip.
9 Turn the key switch to platform control and pull
out the red Emergency Stop button to the on
position at both the ground and platform
controls.
10 Fully raise the platform. Release the joystick.
Genie specifications require that
this procedure be performed every
500 hours or six months,
whichever comes first OR when
the machine fails to lift the
maximum rated load.
Testing the platform overload system regularly is
essential to safe machine operation. Continued
use of an improperly operating platform overload
system could result in the system not sensing an
overloaded platform condition. Machine stability
could be compromised resulting in the machine
tipping over.
Perform this procedure with the
machine on a firm, level surface
that is free of obstructions.
Result: The engine should stop and an alarm
should sound and fault code 99 PLATFORM
OVERLOAD should be present in the ECM
diagnostic display window at the ground
controls.
11 Activate the auxiliary lowering function and
lower the platform approximately 4.5 m.
12 Turn the key switch to the off position.
13 Disconnect the jumper wire from terminal A10
of the terminal strip to terminal B9 of the
terminal strip.
14 Securely connect the black wire of the
maximum height limit switch wire harness to
terminal A10 of the terminal strip.
1 Disconnect the platform controls from the
machine at the platform.
15 Securely connect the white wire of the
maximum height limit switch wire harness to
terminal B9 of the terminal strip.
2 Open the ground control panel and locate the
Electronic Control Module (ECM).
16 Turn the key switch to platform control.
3 Tag and disconnect the platform controls wire
harness from the ECM wire harness.
4 Securely connect the platform controls to the
ECM wire harness.
5 Locate the terminal strip behind the ground
control panel.
6 Tag and disconnect the black wire of the
maximum height limit switch wire harness from
the A10 terminal of the terminal strip.
7 Tag and disconnect the white wire of the
maximum height limit switch wire harness from
the B9 terminal of the terminal strip.
Part No. 52302
17 Fully raise the platform. Release the joystick.
Result: The platform should stop raising at
maximum height. The engine should continue
to run and an alarm should not sound.
18 Lower the platform to the stowed position.
19 Disconnect the platform controls from the ECM
wire harness.
20 Securely connect the platform controls wire
harness to the ECM wire harness.
21 Securely connect the platform controls to the
platform controls wire harness at the platform.
GS-2668 RT • GS-3268 RT
3 - 25
March 2005
Section 3 • Scheduled Maintenance Procedures
CHECKLIST
C
PROCEDURES
REV B
3 Using an approved hand-operated pump, drain
the fuel tank into a suitable container. Refer to
Section 2, Specifications, for tank capacity.
C-2
Clean the Fuel Tank Diesel Models
Explosion and fire hazard. When
transferring fuel, connect a
grounding wire between the
machine and pump or container.
Removing sediment from the fuel tank is essential
to good engine performance and service life. A
dirty fuel tank may cause the fuel filter to clog
prematurely resulting in poor engine performance
and possible component damage.
Explosion and fire hazard. Engine
fuels are combustible. Clean the
fuel tank in an open, wellventilated area away from heater,
sparks, flames and lighted
tobacco. Always have an
approved fire extinguisher within
easy reach.
Immediately clean up any fuel that
may have spilled during this
procedure.
Perform this procedure with the
engine off.
1 Models with fuel shutoff valve: Turn the
manual fuel shutoff valve, located above the
fuel filter, to the closed position.
2 Tag, disconnect and plug the fuel supply and
return hoses at the filter head and the fuel
return pipe at the injectors. Clean up any fuel
that may have spilled.
Be sure to only use a hand
operated pump suitable for use
with gasoline and/or diesel fuel.
4 Remove the tank retaining fasteners from the
bottom of the fuel tank and remove the tank
from the machine.
Component damage hazard. The
fuel tank is plastic and may
become damaged if allowed to fall.
5 Tag and remove the hoses and fittings from the
top of the tank.
6 Rinse out the inside of the tank using a mild
solvent.
7 Install the hoses and fittings (removed in step 5)
into the top of the tank.
8 Install the tank into the machine as you route
the hoses through the bulkhead. Install and
tighten the tank retaining fasteners to
specification.
Torque specifications
Fuel tank retaining fasteners, dry
175 in-lbs
19.8 Nm
Fuel tank retaining fasteners, lubricated
131 in-lbs
14.8 Nm
9 Install the fuel supply and return hoses onto the
filter head and the fuel return pipe at the
injectors. Tighten the clamps.
10 Models with fuel shutoff valve: Turn the
manual fuel shutoff valve, located above the
fuel filter, to the open position.
3 - 26
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 3 • Scheduled Maintenance Procedures
REV B
CHECKLIST
C-3
Replace the
Hydraulic Tank Breather Cap Models with Optional Hydraulic Oil
The hydraulic tank is a vented-type tank. The
breather cap has an internal air filter that can
become clogged or, over time, can deteriorate. If
the breather cap is faulty or improperly installed,
impurities can enter the hydraulic system which
may cause component damage. Extremely dirty
conditions may require that the cap be inspected
more often.
1 Remove and discard the hydraulic tank breather
cap.
C PROCEDURES
C-5
Perform Engine Maintenance Kubota D905 and DF750 Models
Engine specifications require that
this procedure be performed every
800 hours.
Required maintenance procedures and additional
engine information is available in the
Kubota D905 Operator's Manual
(Kubota part number 16622-8916-5) OR the
Kubota DF750 Operator's Manual
(Kubota part number EG261-8916-1).
Kubota D905 Operator's Manual
Genie part number
84240
Kubota DF750 Operator's Manual
Genie part number
97359
2 Install and new cap onto the tank.
C-4
Perform Engine Maintenance Diesel Models
Engine specifications require that
this procedure be performed every
500 hours.
Required maintenance procedures and additional
engine information is available in the
Kubota D905 Operator's Manual
(Kubota part number 16622-8916-5) OR the
Perkins 403C-11 User's Handbook
(Perkins part number 100816460).
Kubota D905 Operator's Manual
Genie part number
84240
Perkins 403C-11 User's Handbook
Genie part number
97360
Part No. 52302
GS-2668 RT • GS-3268 RT
3 - 27
March 2005
Section 3 • Scheduled Maintenance Procedures
Checklist D Procedures
D-1
Check the Scissor Arm Wear
Pads
REV B
3 Measure the thickness of each platform scissor
arm wear pad at the steer end of the machine.
Result: The measurement is 5/16 inch / 8 mm or
more. Proceed to step 4.
Result: The measurement is less than
5/16 inch / 8 mm. Replace both wear pads.
Maintaining the scissor arm wear pads in good
condition is essential to safe machine operation.
Continued use of worn out wear pads may result in
component damage and unsafe operating
conditions.
Perform this procedure on a firm,
level surface with the platform in
the stowed position.
4 Measure the thickness of each platform scissor
arm wear pad at the non-steer end of the
machine.
Result: The measurement is 5/16 inch / 8 mm or
more.
Result: The measurement is less than
5/16 inch / 8 mm. Replace both wear pads.
1 Measure the thickness of each chassis wear
pad at the steer end of the machine.
Result: The measurement is 5/16 inch / 8 mm or
more. Proceed to step 2.
Result: The measurement is less than
5/16 inch / 8 mm. Replace both wear pads.
2 Measure the thickness of each chassis wear
pad at the non-steer end of the machine.
Result: The measurement is 5/16 inch / 8 mm or
more. Proceed to step 3.
Result: The measurement is less than
5/16 inch / 8 mm. Replace both wear pads.
3 - 28
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 3 • Scheduled Maintenance Procedures
REV B
CHECKLIST
D-2
Calibrate the
Platform Overload System
(if equipped)
D PROCEDURES
4 Open the side cover at the ground controls side
of the machine and locate the Electronic
Control Module (ECM) wire harness to platform
controls wire harness connection above the
hydraulic tank.
5 Tag and disconnect the platform controls wire
harness from the ECM wire harness.
Genie specifications require that
this procedure be performed every
1000 hours or annually, whichever
comes first.
On machines with platform overload systems,
proper calibration is essential to safe machine
operation. An improperly calibrated platform
overload system could result in the system failing
to sense an overloaded platform. The stability of
the machine is compromised and it could tip over.
Be sure the hydraulic oil level is
between the full and add marks on
the oil level indicator.
Perform this procedure with the
machine on a firm, level surface
that is free of obstructions.
1 Models with outriggers: Deploy the outriggers
and level the machine.
2 Apply a thin layer of dry film lubricant to the
area of the chassis where the scissor arm wear
pads make contact.
3 Disconnect the platform controls from the
machine at the platform.
Part No. 52302
6 Securely connect the platform controls to the
ECM wire harness.
7 Using a suitable lifting device, place a test
weight, corresponding to the maximum load as
indicated on the capacity indicator decal, in the
center of the platform floor. Secure the weight
to the platform. Refer to the chart below.
GS-2668
975 kg
GS-3268
919 kg
8 Turn the key switch to platform control and pull
out the red Emergency Stop button to the on
position at both the ground and platform
controls. Start the engine.
9 Raise the platform to approximately 4 m.
10 Rotate the safety arm away from the machine
and let it hang down.
11 Remove the cover from the pressure switch.
The pressure switch is located on
the lift cylinder.
12 Slowly turn the nut of the platform overload
pressure switch one-quarter turn into the
hydraulic line.
GS-2668 RT • GS-3268 RT
3 - 29
March 2005
Section 3 • Scheduled Maintenance Procedures
CHECKLIST
D
PROCEDURES
REV B
13 Push in the red Emergency Stop button to the
off position at the ground controls.
14 Pull out the red Emergency Stop button to the
on position at the ground controls. Wait 3
seconds and start the engine.
15 Raise the platform until the position indicator
corresponds to the maximum load position of
the capacity indicator decal.
Tip-over hazard. Raising the
platform with maximum load
above the maximum load position,
as shown on the capacity indicator
decal on the side of the platform,
could result in the machine tipping
over, resulting in death or serious
injury. Do not raise the platform
above the maximum load position
of the capacity indicator decal.
Result: The alarm doesn't sound and the engine
will start and run. Proceed to step 15.
Result: The engine will not start and an alarm is
sounding. Repeat this procedure beginning with
step 12.
The red Emergency Stop button
must be cycled after each quarter
turn of the nut to allow the platform
overload system to reset.
To perform this step, the lift relief
valve will need to be adjusted.
Before raising the platform,
applying a piece of tape onto the
underside of the platform, at a
point which corresponds to the
maximum load position of the
capacity indicator decal, may help
complete this part of the
procedure.
Wait a minimum of 3 seconds
between each quarter turn of the
nut to allow the platform overload
system to reset.
Result: The engine continues to run. Proceed to
step 16.
Result: The engine has stopped and an alarm is
sounding. Proceed to step 17.
3 - 30
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 3 • Scheduled Maintenance Procedures
REV B
CHECKLIST
Set the pressure switch:
16 Using a wrench, turn the nut of the platform
overload pressure switch out of the hydraulic
line until the overload alarm sounds and the
engine stops running.
Turning the nut out of the
hydraulic line will activate the
alarm; turning the nut into the
hydraulic line will deactivate the
alarm.
17 Slowly turn the nut of the platform overload
pressure switch one-quarter turn into the
hydraulic line.
D PROCEDURES
20 Return the safety arm to the stowed position.
Lower the platform to the stowed position.
After returning the safety arm to
the stowed position, use the
auxiliary down function to lower
the platform.
Set the maximum height limit switch:
21 Using a suitable lifting device, place a test
weight in the center of the platform floor.
Secure the weight to the platform. Refer to the
chart below.
GS-2668 RT
567 kg
18 Push in the red Emergency Stop button to the
off position at the ground controls.
GS-3268 RT
454 kg
19 Pull out the red Emergency Stop button to the
on position at the ground controls. Wait 3
seconds and start the engine.
22 Raise the platform to approximately 4 m.
Result: The alarm doesn't sound and the engine
will start and run. Proceed to step 20.
Result: The engine will not start and an alarm is
sounding. Repeat this procedure beginning with
step 17.
The red Emergency Stop button
must be cycled after each quarter
turn of the nut to allow the platform
overload system to reset.
23 Rotate the safety arm away from the machine
and let it hang down.
24 Remove the maximum height limit switch
fasteners. Remove the maximum height limit
switch and set it to the side so that the limit
switch will not be activated.
25 Raise the platform until it is approximately
65 cm less than full height.
Wait a minimum of 3 seconds
between each quarter turn of the
nut to allow the platform overload
system to reset.
Part No. 52302
GS-2668 RT • GS-3268 RT
3 - 31
March 2005
Section 3 • Scheduled Maintenance Procedures
CHECKLIST
D
PROCEDURES
REV B
26 Raise the platform in 5 cm increments until the
overload alarm sounds and the engine stops
running. Proceed to step 27.
Result: The alarm does not sound and the
engine continues to run when the platform
reaches full height. Repeat this procedure
beginning with step 7.
a
b
c
27 Install and adjust the maximum height limit
switch until it activates just before the point
reached in step 26. Securely tighten the
fasteners. Do not over tighten.
28 Use the auxiliary down function to lower the
platform approximately 15 cm.
29 Start the engine and fully raise the platform.
Result: The engine continues to run. Proceed to
step 30.
Result: An alarm sounds and the engine stops
running. Repeat this procedure beginning with
step 24.
30 Lower the platform to approximately 4 m.
31 Return the safety arm to the stowed position.
Disable the descent delay function:
32 Push in the red Emergency Stop button to the
off position at the ground controls.
GS-2668
GS-3268
33 Turn the key switch to ground control.
Limit switch legend
a
b
c
3 - 32
maximum height limit switch
down limit switch
load sense delay limit switch
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 3 • Scheduled Maintenance Procedures
REV B
CHECKLIST
34 Press and hold both the blue platform up and
yellow platform down buttons. Pull out the red
Emergency Stop button to the on position at the
ground controls.
Result: TUNE SPEEDS is showing in the diagnostic
display window.
a
41 Lower the platform until the load sense delay
limit switch activates and the platform stops
lowering. Release the joystick.
Result: SELECT OPTIONS is showing in the
diagnostic display window. The ECM is now in
programming mode.
37 Press the lift function enable button to
deactivate the descent delay option.
Calibrate the load sense delay limit switch:
c
35 Use the yellow platform down arrow to scroll to
SELECT OPTIONS.
Result: DESCENT DELAY ON is showing in the
diagnostic display window.
For more information on
programming, refer to Section 4,
Repair.
40 Turn the key switch to platform control. Start the
engine.
diagnostic display
blue platform up button
lift function enable button
yellow platform down button
36 Press the lift function enable button.
39 Pull out the red Emergency Stop button to the
on position at the ground controls.
b
d
a
b
c
d
D PROCEDURES
Result: The alarm does not sound and the
engine continues to run. Proceed to step 49.
Result: The alarm sounds and the engines
stops running. The load sense delay limit switch
needs to be calibrated. Proceed to step 42.
42 Raise the platform to approximately 4 m.
43 Rotate the safety arm away from the machine
and let it hang down.
44 Loosen the fasteners securing the load sense
delay limit switch just enough to allow
movement of the limit switch.
45 Move the roller head of the load sense delay
limit switch 1 mm upwards. Tighten the
fasteners. Do not over tighten.
Result: DESCENT DELAY OFF is showing in the
diagnostic display window.
46 Return the safety arm to the stowed position.
38 Push in the red Emergency Stop button to the
off position at the ground controls.
48 Repeat this procedure beginning with step 41.
Part No. 52302
47 Raise the platform approximately 1 m.
GS-2668 RT • GS-3268 RT
3 - 33
March 2005
Section 3 • Scheduled Maintenance Procedures
CHECKLIST
D
REV B
PROCEDURES
Enable the descent delay function:
Calibrate the down limit switch:
49 Push in the red Emergency Stop button to the
off position at the ground controls.
57 Turn the key switch to platform control. Start the
engine.
50 Turn the key switch to ground control.
58 Raise the platform approximately 1 m.
51 Press and hold both the blue platform up and
yellow platform down buttons. Pull out the red
Emergency Stop button to the on position at the
ground controls.
59 Lower the platform until the down limit switch
activates and the platform stops lowering.
Quickly release the controls and then
immediately attempt to lower the platform to
the stowed position.
Result: TUNE SPEEDS is showing in the diagnostic
display window.
52 Use the yellow platform down arrow to scroll to
select options.
Result: SELECT OPTIONS is showing in the
diagnostic display window. The ECM is now in
programming mode.
Result: The platform stops for 4 to six seconds.
Release the joystick and proceed to step 67.
Result: The platform stops and then will
immediately begin to lower again. The down
limit switch needs to be calibrated. Proceed to
step 60.
60 Raise the platform to approximately 4 m.
53 Press the lift function enable button.
Result: DESCENT DELAY OFF is showing in the
diagnostic display window.
61 Rotate the safety arm away from the machine
and let it hang down.
54 Press the lift function enable button to activate
the descent delay option.
62 Loosen the fasteners securing the down limit
switch just enough to allow movement of the
limit switch.
Result: DESCENT DELAY ON is showing in the
diagnostic display window.
55 Push in the red Emergency Stop button to the
off position at the ground controls.
56 Pull out the red Emergency Stop button to the
on position at the ground controls.
63 Move the roller head of the down limit switch
1 mm upwards. Tighten the fasteners. Do not
over tighten.
64 Raise the platform approximately 1 m.
65 Return the safety arm to the stowed position.
66 Repeat this procedure beginning with step 59.
3 - 34
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 3 • Scheduled Maintenance Procedures
REV B
CHECKLIST
67 Lower the platform to the stowed position and
remove the weight from the platform.
Result: The platform lowers to the stowed
position. Proceed to step 72.
Result: The platform stops lowering. The down
limit switch needs to be calibrated. Proceed to
step 68.
68 Raise the platform to approximately 4 m.
69 Rotate the safety arm away from the machine
and let it hang down..
70 Loosen the fasteners securing the down limit
switch just enough to allow movement of the
limit switch.
D PROCEDURES
72 Raise the platform to approximately 4 m.
73 Rotate the safety arm away from the machine
and let it hang down.
74 Install the cover onto the platform overload
pressure switch box and securely tighten the
cover retaining fasteners. Do not over tighten.
75 Apply Sentry Seal to one of the cover retaining
fasteners where it contacts the platform
overload pressure switch box.
76 Return the safety arm to the stowed position.
77 Lower the platform to the stowed position.
78 Calibrate the lift relief valve.
71 Move the roller head of the down limit switch
1 mm downwards. Tighten the fasteners. Do
not over tighten.
TROUBLESHOOTING THE PLATFORM OVERLOAD SYSTEM
CONDITION
CANNOT LIFT RATED LOAD
POSSIBLE CAUSE
RELIEF VALVE SET TOO LOW
AT MAXIMUM HEIGHT WITH RATED LOAD IN
PLATFORM, THE PRESSURE SWITCH
ALARM CONTINUES TO SOUND
SYSTEM NEEDS TO BE RESET
MAXIMUM HEIGHT LIMIT SWITCH OUT OF
ADJUSTMENT -OR- FAULTY
TOO MUCH WEIGHT IN PLATFORM
PRESSURE SWITCH OUT OF ADJUSTMENT
BATTERIES ARE NOT FULLY CHARGED
OVERLOAD SYSTEM NOT ADJUSTED
PROPERLY
SLIDER CHANNEL NOT LUBRICATED
AT DOWN LIMIT WITH RATED LOAD IN
PLATFORM, THE PRESSURE SWITCH
ALARM CONTINUES TO SOUND
SYSTEM NEEDS TO BE RESET
DOWN LIMIT SWITCH OUT OF ADJUSTMENT
TOO MUCH WEIGHT IN PLATFORM
OVERLOAD SYSTEM NOT ADJUSTED
PROPERLY
Part No. 52302
GS-2668 RT • GS-3268 RT
SOLUTION
INCREASE RELIEF VALVE PRESSURE
TURN OFF RED EMERGENCY STOP
BUTTON, WAIT THREE SECONDS AND TURN
BACK ON
LOWER THE UP LIMIT SWITCH SLIGHTLY
-OR- REPLACE CONTACTS
PUT CORRECT RATED LOAD IN PLATFORM
TURN THE PRESSURE SWITCH NUT 1/4
TURN INTO THE HYDRAULIC LINE
CHARGE BATTERIES
REPEAT CALIBRATION PROCEDURE
LUBRICATE SLIDER CHANNELS
TURN OFF RED EMERGENCY STOP
BUTTON, WAIT THREE SECONDS AND TURN
BACK ON
RAISE THE DOWN LIMIT SWITCH
PUT CORRECT RATED LOAD IN PLATFORM
TURN THE PRESSURE SWITCH NUT 1/4
TURN INTO THE HYDRAULIC LINE -ORREPEAT CALIBRATION PROCEDURE
3 - 35
March 2005
Section 3 • Scheduled Maintenance Procedures
CHECKLIST
D
PROCEDURES
REV B
D-3
Replace the Hydraulic Tank
Return Filter
Replacement of the hydraulic tank return filter is
essential for good machine performance and
service life. A dirty or clogged filter may cause the
machine to perform poorly and continued use may
cause component damage. Extremely dirty
conditions may require that the filter be replaced
more often.
4 Use a permanent ink marker to write the date
and number of hours from the hour meter on
the filter.
5 Clean up any oil that may have spilled during
the replacement procedure.
6 Turn the key switch to ground controls and pull
out the red Emergency Stop button to the on
position at both the ground and platform
controls. Start the engine.
7 Raise the platform approximately 3 feet / 1 m.
8 Inspect the filter and related components to
be sure that there are no leaks.
Bodily injury hazard. Beware of
hot oil. Contact with hot oil may
cause severe burns.
The hydraulic filter is mounted on
the hydraulic tank.
1 Remove the filter with an oil filter wrench. Clean
the area where the hydraulic oil filter meets the
filter head.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
2 Apply a thin layer of fresh oil to the new oil filter
gasket.
3 Install the new filter and tighten it securely by
hand.
3 - 36
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 3 • Scheduled Maintenance Procedures
REV B
CHECKLIST
D-4
Perform Engine Maintenance Perkins 403C-11 Models
D-6
Perform Engine Maintenance Kubota Models
Engine specifications require that
this procedure be performed every
1000 hours.
Required maintenance procedures and additional
engine information is available in the
Perkins 403C-11 User's Handbook
(Perkins part number 100816460).
Perkins 403C-11 User's Handbook
Genie part number
97360
D-5
Perform Engine Maintenance Kubota DF752 Models
Engine specifications require that
this procedure be performed every
1000 hours.
Required maintenance procedures and additional
engine information is available in the
Kubota DF752 Operator's Manual
(Kubota part number EG601-8916-1).
Kubota DF752 Operator's Manual
Genie part number
D PROCEDURES
Engine specifications require that
this procedure be performed
annually.
Required maintenance procedures and additional
engine information is available in the
Kubota D905 Operator's Manual
(Kubota part number 16622-8916-5) OR the
Kubota DF750 Operator's Manual
(Kubota part number EG261-8916-1) OR the
Kubota DF752 Operator's Manual
(Kubota part number EG601-8916-1).
Kubota D905 Operator's Manual
Genie part number
84240
Kubota DF750 Operator's Manual
Genie part number
97359
Kubota DF752 Operator's Manual
Genie part number
84250
D-7
Perform Engine Maintenance Kubota D905 Models
Engine specifications require that
this procedure be performed every
1500 hours.
84250
Required maintenance procedures and additional
engine information is available in the
Kubota D905 Operator's Manual
(Kubota part number 16622-8916-5).
Kubota D905 Operator's Manual
Genie part number
Part No. 52302
GS-2668 RT • GS-3268 RT
84240
3 - 37
March 2005
Section 3 • Scheduled Maintenance Procedures
Checklist E Procedures
E-1
Test or Replace the Hydraulic Oil
REV B
5 Locate the hose cover plate in the center of the
drive chassis. Remove the hose cover plate
mounting fasteners and remove the cover.
6 If equipped, close the two hydraulic shutoff
valves located at the hydraulic tank.
Replacement or testing of the hydraulic oil is
essential for good machine performance and
service life. Dirty oil and suction strainers may
cause the machine to perform poorly and
continued use may cause component damage.
Extremely dirty conditions may require oil changes
to be performed more often.
Before replacing the hydraulic oil,
the oil may be tested by an oil
distributor for specific levels of
contamination to verify that
changing the oil is necessary. If
the hydraulic oil is not replaced
at the two year inspection, test
the oil quarterly. Replace the oil
when it fails the test.
Component damage hazard. The
engine must not be started with
the hydraulic tank shutoff valves in
the closed position or component
damage will occur. If the tank
valves are closed, remove the key
from the key switch and tag the
machine to inform personnel of the
condition.
7 Place a drain pan or other suitable container
under the hydraulic tank. Refer to Section 2,
Specifications.
8 Remove the drain plug from the hydraulic tank
and completely drain the tank.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
1 Raise the platform approximately 10 feet / 3 m.
2 Lift the safety arm, move to the center of the
scissor arm and rotate down to a vertical
position.
3 Lower the platform onto the safety arm.
Crushing hazard. Keep hands
clear of the safety arm when
lowering the platform.
4 Push in the red Emergency Stop button to the
off position.
9 Tag and disconnect the two suction hoses from
the hydraulic tank.
10 Disconnect and plug the hydraulic hose at the
return filter. Cap the fitting on the filter.
11 Remove the tank strap retaining fasteners and
remove the tank strap from the machine.
12 Remove the hydraulic tank from the machine.
3 - 38
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 3 • Scheduled Maintenance Procedures
REV B
CHECKLIST E
13 Remove the suction strainers and clean them
using a mild solvent.
14 Clean the inside of the hydraulic tank using a
mild solvent.
PROCEDURES
E-2
Perform Engine Maintenance Perkins 403C-11 Models
15 Install the suction strainers using thread sealer
on the threads.
Engine specifications require that
this procedure be performed every
2000 hours.
16 Install the drain plug using thread sealer on the
threads.
17 Install the hydraulic tank, tank strap and tank
strap retaining fasteners.
18 Install the return filter hose onto the filter head.
19 Install the suction hoses onto the tank.
20 Fill the tank with hydraulic oil until the fluid is
within the top 2 inches / 5 cm of the sight
gauge. Do not overfill.
Required maintenance procedures and additional
engine information is available in the
Perkins 403C-11 User's Handbook
(Perkins part number 100816460).
Perkins 403C-11 User's Handbook
Genie part number
97360
21 Clean up any oil that may have spilled. Properly
discard the oil.
22 If equipped, open the two hydraulic shutoff
valves located at the hydraulic tank.
23 Operate all machine functions through a full
cycle and check for leaks.
24 Install the hose cover plate and install the hose
cover plate mounting fasteners.
Part No. 52302
GS-2668 RT • GS-3268 RT
3 - 39
March 2005
Section 3 • Scheduled Maintenance Procedures
CHECKLIST E
PROCEDURES
REV B
E-3
Perform Engine Maintenance Gasoline/LPG Models
E-4
Perform Engine Maintenance Perkins 403C-11 Models
Engine specifications require that
this procedure be performed every
two years.
Required maintenance procedures and additional
engine information is available in the Kubota
DF750 Operator's Manual (Kubota part number
EG261-8916-1) OR the Kubota DF752 Operator's
Manual (Kubota part number EG601-8916-1).
Required maintenance procedures and additional
engine information is available in the
Perkins 403C-11 User's Handbook
(Perkins part number 100816460).
Perkins 403C-11 User's Handbook
Genie part number
Kubota DF750 Operator's Manual
Genie part number
97359
Kubota DF752 Operator's Manual
Genie part number
84250
3 - 40
Engine specifications require that
this procedure be performed every
3000 hours.
GS-2668 RT • GS-3268 RT
97360
Part No. 52302
March 2005
Section 4 • Repair Procedures
Repair Procedures
About This Section
Observe and Obey:
Repair procedures shall be completed by a
person trained and qualified on the repair of this
machine.
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. Perform disassembly procedures to
the point where repairs can be completed. To
re-assemble, perform the disassembly steps in
reverse order.
Symbols Legend
Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating the machine.
Used to indicate the presence of
an imminently hazardous situation
which, if not avoided, will result in
death or serious injury.
Before Repairs Start:
Read, understand and obey the safety rules
and operating instructions in the appropriate
operator’s manual on your machine.
Used to indicate the presence of a
potentially hazardous situation
which, if not avoided, could result
in death or serious injury.
Be sure that all necessary tools and parts are
available and ready for use.
Read each procedure completely and adhere
to the instructions. Attempting shortcuts may
produce hazardous conditions.
With safety alert symbol—used to
indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause
minor or moderate injury.
Unless otherwise specified, perform each
repair procedure with the machine in the
following configuration:
Without safety alert symbol—used
to indicate the presence of a
potentially hazardous situation
which, if not avoided, may result in
property damage.
· Machine parked on a firm, level surface
· Platform in the stowed position
· Key switch in the off position with the key
removed
Used to indicate operation or
maintenance information.
· The red Emergency Stop button in the off
position at both ground and platform controls
· Wheels chocked
· All external AC power supply disconnected
from the machine
Part No. 52302
Indicates that a specific result is expected after
performing a series of steps.
Indicates that an incorrect result has occurred
after performing a series of steps.
GS-2668 RT • GS-3268 RT
4-1
Section 4 • Repair Procedures
March 2005
Platform Controls
The platform controls, used to activate machine
functions from the platform or while standing on the
ground, contain a printed circuit board, joystick,
decal membrane pad, buttons and/or toggle
switches, and LEDs. All of these components are
replaceable though only the potentiometerequipped joystick, used before serial number
GS6803-42382, is serviceable.
On models before serial number GS6803-42382,
the platform controls are also used to tune the
performance of the machine.
The function speed parameters in the Electronic
Control Module are easily adjusted by moving the
joystick, pressing a button or activating a toggle
switch in a specific order when the ECM is in the
programming mode (PS showing in the diagnostic
display window).
For further information or assistance, consult the
Genie Industries Service Department.
REV B
a
b
c
d
e
f
g
h
i
Platform controls before serial number GS6803-42382
a
NC 1
i
2
g
e
d
Platform controls after serial number GS6803-42381
a
b
c
d
e
f
g
h
i
4-2
GS-2668 RT • GS-3268 RT
alarm H1
function enable/high speed select button for
platform up/down function BN12
function enable/low speed select button for
platform up/down function BN13
platform up/down toggle switch TS20 OR
platform up/down and outrigger up/down
toggle switch TS21
circuit board U3
DIP switch SW25
joystick controller JC1
potentiometer
red Emergency Stop button P2
Part No. 52302
March 2005
Section 4 • Repair Procedures
REV B
PLATFORM CONTROLS
1-1
Circuit Boards
1-2
Joystick Controller
How to Remove the Platform
Controls Circuit Board
Maintaining the joystick at the proper setting is
essential to safe machine operation. The joystick
should operate smoothly over its entire range of
motion.
1 Push in the red Emergency Stop button to the
off position at both the ground and platform
controls.
2 Loosen the platform control box lid retaining
fasteners. Open the control box and secure the
control box lid in a level position.
3 Visually locate the circuit board mounted to the
inside of the platform control box lid.
Machines after serial number GS6803-42381 are
equipped with Hall-effect joysticks, which do not
require calibration.
How to Calibrate the Joystick
(before serial number GS6803-42382)
If the joystick is out of calibration,
fault code 30 will be present on the
diagnostic display and the error
indicator light will be illuminated at
the platform controls.
4 Tag and disconnect the wire connections from
the red Emergency Stop button.
5 Tag and disconnect the wire harness
connectors from the platform controls circuit
board.
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
1 Turn the key switch to platform control and pull
out the red Emergency Stop button to the ON
position at both the ground and platform
controls.
2 Remove the platform control box lid retaining
fasteners. Open the control box lid.
Component damage hazard.
Electrostatic discharge (ESD) can
damage printed circuit board
components. Maintain firm contact
with a metal part of the machine
that is grounded at all times when
handling printed circuit boards OR
use a grounded wrist strap.
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
6 Remove the platform controls circuit board
retaining fasteners.
7 Remove the platform controls circuit board from
the platform control box lid.
Part No. 52302
GS-2668 RT • GS-3268 RT
4-3
Section 4 • Repair Procedures
March 2005
PLATFORM CONTROLS
REV B
3 Locate the potentiometer on the base of the
joystick.
5 Loosen the set screw on the potentiometer
shaft just enough to allow the shaft to rotate.
6 With the joystick in the center or neutral
position, adjust the potentiometer shaft until
2.05V DC is displayed on the voltmeter. Tighten
the set screw.
7 Move the joystick full stroke in both directions
several times. Return the joystick to the center
position.
Result: The voltmeter should read 2.05V DC.
Result: If the voltmeter does not read
2.05V DC, repeat steps 5 through 8.
8 Turn the key switch to the off position.
9 Wait a few seconds and then turn the key
switch to platform control.
a
b
c
d
e
f
g
joystick controller JC1
potentiometer shaft slot
potentiometer shaft set screw
platform controls circuit board U3
potentiometer
brown wire
purple wire
4 Using a volt meter set to read DC voltage, place
the voltmeter negative lead on the purple wire.
Place the volt meter positive lead on the brown
wire.
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
4-4
Result: The error indicator light on the top of the
platform control box should not be illuminated
and code 30 should not be present on the
diagnostic display.
Result: If the error indicator light is illuminated
or if code 30 is present on the diagnostic
display, repeat this procedure beginning with
step 5.
10 Turn the key switch to the off position.
11 Close the lid and install the fasteners.
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 4 • Repair Procedures
REV B
PLATFORM CONTROLS
1-3
Function Speed Tuning
How to Determine the Revision
Level
(before serial number GS6803-42382)
Models before serial number
13154 were not adjustable when
they were shipped from the
factory. If the ECM has been
updated to revision "BO" or later,
or if the machine serial number is
after 13153, you can access the
revision level of the ECM by using
the following procedure.
The raised drive speed and platform lift speeds are
determined by the percentage of total ECM voltage
output. The speeds of the these functions may be
adjusted to compensate for wear in the hydraulic
pump and drive motors.
To adjust the function speeds on machines after
serial number GS6803-42382, see 7-2,
Function Speed Tuning (after serial number
GS6803-42381).
For further information or assistance, consult the
Genie Industries Service Department.
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
machine to tip over resulting in
death or serious injury.
1 Turn the key switch to ground control and pull
out the red Emergency Stop button to the ON
position at both platform and ground controls.
2 Move and hold the function enable toggle switch
and the platform up/down toggle switch in the
down direction.
Result: The revision level of the ECM will
appear in the diagnostic display window.
a
SYSTEM
20 AMP
Tip-over hazard. This procedure
must only be performed by a
trained service professional.
Attempting this procedure without
the necessary skills will result in
death or serious injury.
Refer to the appropriate
Genie service manual
for code descriptions.
HOUR METER
b
Stop
Function
Enable
Select a test area that is firm, level
and free of obstructions.
d
a
b
c
c
Part No. 52302
GS-2668 RT • GS-3268 RT
c
diagnostic display window
red Emergency Stop Button P1
platform up/down toggle switch TS66
function enable toggle switch TS67
4-5
Section 4 • Repair Procedures
March 2005
PLATFORM CONTROLS
REV B
How to Adjust the Raised Drive
Speed
Tip-over hazard. Setting drive
speed greater than specifications
will cause the machine to tip over
resulting in death or serious injury.
Do not adjust the drive speed
higher than specified in this
procedure.
The drive function of the
GS-2668 RT before serial number
26563 is disabled when the
platform is 20 feet / 6.1 m or
higher while the platform is
extended. The GS-2668 RT after
serial number 26562 is able to
drive at full height due to additional
counterweight being added to the
machine.
The drive function of the
GS-3268 RT before serial number
42000 is disabled when the
platform is 26 feet / 7.9 m or
higher while the platform is
extended. The GS-3268 RT after
serial number 41999 is able to
drive at full height due to additional
counterweight being added to the
machine.
1 Remove the platform controls from the platform
and place the controls near the diagnostic
display window at the ground control panel.
®
Stop
c
a
b
®
STOP
Stop
c
AUTO
LEVEL
a
b
STOP
a
b
c
3 Models without outriggers: Press and hold
the horn button and platform extend/retract
enable button, then turn the key switch to
platform controls.
Models with outriggers: Press and hold the
horn button and the outrigger enable button,
then turn the key switch to platform controls.
Result: The diagnostic display window at the
ground controls will show PS.
2 Turn the key switch to the off position.
4-6
steer rocker switch SW6
horn button BN5
platform extend/retract enable BN16
OR outrigger enable button BN16
GS-2668 RT • GS-3268 RT
The PS showing in the diagnostic
display window indicates that the
ECM is in the programming mode.
Part No. 52302
March 2005
Section 4 • Repair Procedures
REV B
PLATFORM CONTROLS
4 Release the horn button and the platform
extend/retract enable button or outrigger enable
button.
5 Press the horn button to show the maximum
raised drive speed percentage.
6 To increase or decrease the raised drive speed,
press and hold the horn button while using the
steering rocker switch to adjust the percentage.
The percentage will be seen in the diagnostic
display window.
Factory percentage settings
Raised drive speed
Gasoline/LPG models
Diesel models
39
42
7 Release the horn button.
8 Turn the key switch to the off position to save
the settings.
9 Confirm the raised drive speed of the machine.
Refer to Maintenance Procedure B-11, Test the
Drive Speed - Raised Position.
Part No. 52302
GS-2668 RT • GS-3268 RT
4-7
Section 4 • Repair Procedures
March 2005
PLATFORM CONTROLS
REV B
How to Adjust the Fast Lift Speed
®
1 Remove the platform controls from the platform
and place the controls near the diagnostic
display at the ground control panel.
d
2 Turn the key switch to the off position.
c
3 Models without outriggers: Press and hold
the horn button and platform extend/retract
enable button, then turn the key switch to
platform controls.
Stop
a
®
STOP
Stop
AUTO
LEVEL
a
Models with outriggers: Press and hold the
horn button and the outrigger enable button,
then turn the key switch to platform controls.
Result: The diagnostic display window at the
ground controls will show PS.
STOP
The PS showing in the diagnostic
display window indicates that the
ECM is in the programming mode.
b
a
b
4 Release the horn button and the platform
extend/retract enable button or outrigger enable
button.
5 Press and hold the function enable/high speed
select button to show the fast platform lift speed
percentage in the diagnostic display window.
d
c
d
c
b
steer rocker switch SW6
function enable/high speed
select button BN12
horn button BN 5
platform extend/retract enable BN16
OR outrigger enable button BN16
8 Turn the key switch to the off position to save
the settings.
6 To increase or decrease the fast platform lift
speed, press and hold the function enable/high
speed select button while using the steering
rocker switch to adjust the percentage.
9 Confirm the lift speed of the machine. Refer to
Section 2, Specifications.
7 Release the function enable/high speed select
button.
Fast lift speed
Gasoline/LPG models
Diesel models
4-8
Factory percentage settings
GS-2668 RT • GS-3268 RT
39
42
Part No. 52302
March 2005
Section 4 • Repair Procedures
REV B
PLATFORM CONTROLS
How to Adjust the Slow Lift
Speed
1 Remove the platform controls from the platform
and place the controls near the diagnostic
display at the ground control panel.
®
Stop
d
a
c
2 Turn the key switch to the off position.
®
3 Models without outriggers: Press and hold
the horn button and platform extend/retract
enable button, then turn the key switch to
platform controls.
STOP
Stop
AUTO
LEVEL
a
Models with outriggers: Press and hold the
horn button and the outrigger enable button,
then turn the key switch to platform controls.
Result: The diagnostic display window at the
ground controls will show PS.
STOP
b
The PS showing in the diagnostic
display window indicates that the
ECM is in the programming mode.
a
b
c
d
4 Release the horn button and the platform
extend/retract enable button or outrigger enable
button.
5 Press and hold the function enable/high speed
select button to show the fast platform lift speed
percentage in the diagnostic display window.
Note this number.
d
c
b
steer rocker switch SW6
function enable/low speed
select button BN13
horn button BN5
platform extend/retract enable BN16
OR outrigger enable button BN16
7 To increase or decrease the platform lift speed,
press and hold the function enable/slow speed
select button while using the steering rocker
switch to adjust the percentage.
The Slow Lift Speed percentage
should be set 4 to 6 points less
than the Fast Lift Speed
percentage.
6 Press and hold the function enable/low speed
select button to show the platform lift slow
speed percentage in the diagnostic display
window.
8 Release the function enable/slow speed select
button.
9 Turn the key switch to the off position to save
the settings.
Factory percentage settings
Slow lift speed
Gasoline/LPG models
Diesel models
Part No. 52302
GS-2668 RT • GS-3268 RT
34
38
4-9
Section 4 • Repair Procedures
March 2005
PLATFORM CONTROLS
REV B
1-4
Software Configuration
How to Configure the Software
If replacing the circuit board, note
the position of each of the 8 toggle
switches on the DIP switch block.
Set the DIP switch on the new
circuit board to the same
configuration of the old one.
(before serial number GS6803-42382)
The Electronic Control Module (ECM) contains
programming for all configurations of the GS68 RT.
Models before serial number GS6803-42382 can
be adjusted to a different configuration by changing
the combination of the DIP switch settings, located
on the circuit board inside the platform control box.
DIP switches have two positions - on or off. When
reading the DIP switch code in the DIP Switch
Codes Chart on the next page, the on and off are
represented by the numbers 1 (on) and 0 (off).
How to Determine the DIP Switch
Configuration
If replacing the circuit board, use
dielectric grease on the DIP switch
and all plug-in connectors.
1 Push in the red Emergency Stop button to the
off position at both the ground and platform
controls. Turn the key switch to the off position.
2 Remove the fasteners securing the lid of the
platform controls and open the platform control
box.
1 Turn the key switch to ground control and pull
out the red Emergency Stop buttons to the on
position at both the ground and platform
controls.
2 Move and hold the platform up/down toggle
switch in the up direction and activate the
function enable toggle switch from the ground
controls.
Result: The diagnostic display window located
on the ground control panel, will display a
configuration number without the dot
illuminated. This configuration number indicates
the current configuration of the machine.
Configuration code that is less
than 100 will be shown as a
constant display. Configuration
code that is greater than 99 will be
shown as a flashing display.
4 - 10
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 4 • Repair Procedures
REV B
PLATFORM CONTROLS
3 Rotate the platform control box in the position
shown to correctly identify the configuration of
the DIP switch settings.
a
7 To confirm the settings, pull out the red
Emergency Stop button to the on position at
both the ground and platform controls and turn
the key switch to ground control. Do not start
the engine.
8 Move and hold the platform up/down toggle
switch in the up direction and activate the
function enable toggle switch from the ground
controls.
f
e
b
Result: The diagnostic display window located
on the ground control panel, will display a
configuration number without the dot
illuminated. This configuration number indicates
the current configuration of the machine.
Configuration code that is less
than 100 will be shown as a
constant display. Configuration
code that is greater than 99 will be
shown as a flashing display.
c
a
SYSTEM
20 AMP
Refer to the appropriate
Genie service manual
for code descriptions.
HOUR METER
ON
DIP
ON (1)
d
b
OFF (0)
1
a
b
c
d
e
f
2
3
4
5
6
7
red Emergency Stop button P2
DIP switch SW25
control box
enlarged view of DIP switch SW25
circuit board U3
joystick controller JC4
4 Locate the DIP switch on the printed circuit
board. Move the DIP switch settings to
correspond with the configuration of the
machine options indicated in the chart.
See 1-4, Software Configuration.
5 Apply dielectric grease to the DIP switch after
setting the configuration.
Stop
Function
Enable
8
d
a
b
c
c
c
diagnostic display window
red Emergency Stop Button P1
platform up/down toggle switch TS66
function enable toggle switch TS67
9 Release the toggle switches, push in the red
Emergency Stop button to the off position at
both the ground and platform controls and turn
the key switch to the off position.
6 Close the lid and install the platform control box
lid fasteners.
Part No. 52302
GS-2668 RT • GS-3268 RT
4 - 11
Section 4 • Repair Procedures
March 2005
01
01011010
02
00111010
04
01010001
05
10100110
07
01011011
08
00111011
10
01010000
11
10100111
13
01010100
14
00110000
16
00100100
17
10100100
19
01011000
20
00111000
22
00101100
23
10101100
25
01010011
26
00110011
28
00100101
29
10100101
31
01010111
32
00110111
34
00101001
35
10101001
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01011100
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00111100
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00101101
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10101101
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01011111
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00111111
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00101111
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10101111
4 - 12
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10000000
52
01110001
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10000001
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01110010
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10000010
58
10011111
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01111111
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01110111
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01111000
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10011000
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10011001
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01110011
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10001011
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10001101
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01111100
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10011011
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10000111
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01110100
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10010011
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01110110
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00011010
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10000100
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10001100
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01110101
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10000110
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10000101
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10011110
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10001000
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00011100
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01111011
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10011100
GS-2668 RT • GS-3268 RT
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No Simultaneous
Operation
01110000
50
Descent Delay
49
Overload Sensor
DIP
Switch
Code
Motion Alarm
Diagnostic
Display
Code
Diesel
No Simultaneous
Operation
Descent Delay
Overload Sensor
Motion Beacon
Lift/Drive Cut Out
Diesel
DIP
Switch
Code
Motion Alarm
Diagnostic
Display
Code
Gasoline/LPG
A • in the column indicate that the machine
configuration includes this option.
Gasoline/LPG
DIP Switch Codes Chart
Motion Beacon
REV B
Lift/Drive Cut Out
PLATFORM CONTROLS
•
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Part No. 52302
March 2005
Section 4 • Repair Procedures
01111010
109
00101000
110
00011101
112
00011111
113
00000000
115
00000010
116
00000011
118
00000101
119
00000110
121
00001000
122
00001001
124
00001011
125
00001100
127
00001110
128
00001111
130
00100001
131
00100010
133
00100110
134
00100111
136
00101011
137
00101110
139
00110010
140
00110100
142
00110110
143
00111001
Part No. 52302
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151
01000101
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01000110
154
01001000
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01001001
157
01001011
158
01001100
160
01001110
161
01001111
163
01010101
164
01010110
166
01011101
167
01011110
169
01100001
170
01100010
172
01100110
173
01100111
175
01101110
176
10100000
178
10100010
179
10100011
181
10101010
182
10101011
184
10110000
185
10110001
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10110011
188
10110100
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10110110
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10110111
GS-2668 RT • GS-3268 RT
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No Simultaneous
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149
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Descent Delay
00011001
•
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Overload Sensor
106
•
01000000
Motion Beacon
00010111
•
•
00111110
146
Lift/Drive Cut Out
00010110
104
•
145
Motion Alarm
103
•
DIP
Switch
Code
Diesel
00010100
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Diagnostic
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Code
Gasoline/LPG
00010011
101
•
No Simultaneous
Operation
100
•
Descent Delay
00010001
Overload Sensor
00010000
98
Motion Beacon
97
Lift/Drive Cut Out
DIP
Switch
Code
Motion Alarm
Diagnostic
Display
Code
Diesel
PLATFORM CONTROLS
Gasoline/LPG
REV B
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4 - 13
Section 4 • Repair Procedures
March 2005
Platform Components
2-1
Platform
How to Remove the Platform
Bodily injury hazard. This
procedure requires 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. Dealer
service is required.
Perform this procedure with the
platform in the stowed position
and the platform extension deck
fully retracted and locked in
position.
5 GS-2668 RT before serial number 26563 and
GS-3268 RT before serial number 41200:
Remove the platform extension limit switch
mounting fasteners and remove the limit switch.
Do not disconnect the wiring.
6 Raise the platform and return the safety arm to
the stowed position.
7 Lower the platform to the stowed position and
turn the machine off.
8 Remove the mounting fasteners that secure the
platform controls quick disconnect plug to the
platform.
9 Twist the connector to disconnect the platform
controls from the plug.
10 Remove the platform control box from the
platform and lay it off to the side.
Component damage hazard. The
platform controls wiring can be
damaged if it is kinked or pinched.
1 Start the engine from the ground controls and
raise the platform 9 to 10 feet / 2.7 to 3 m.
2 Lift the safety arm, move it to the center of the
scissor arm and rotate down to a vertical
position.
11 Remove the cover to the AC power to platform
outlet. Tag and disconnect the wiring from the
outlet.
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
3 Lower the platform onto the safety arm. Turn
the machine off.
Crushing hazard. Keep hands
clear of the safety arm when
lowering the platform.
12 Pull the wiring down through the platform tube.
4 Remove the hose clamps or zip ties that secure
the power to platform wiring to the bottom of the
platform.
Component damage hazard. Be
sure not to cut the power to
platform wiring.
4 - 14
REV A
GS-2668 RT • GS-3268 RT
Component damage hazard. The
AC power to platform wiring can
be damaged if it is kinked or
pinched.
If your machine is equipped with
an air line to platform option, the
air line must be disconnected from
the platform before removal.
Part No. 52302
March 2005
Section 4 • Repair Procedures
REV A
PLATFORM COMPONENTS
13 Support the platform with a forklift at the
steer end of the machine. Do not apply any
lifting pressure.
2-2
Platform Extension Deck
14 Attach a strap from the platform railings to the
carriage on the forklift to support the platform.
How to Remove the Platform
Extension Deck
15 Remove the retaining fasteners from the
platform pivot pins at the steer end of the
machine.
Perform this procedure with the
platform in the stowed position
and the platform extension deck
fully retracted and locked in
position.
16 Use a slide hammer to remove the pins.
Crushing hazard. The platform will
fall when the pivot pins are
removed if not properly supported
by the forklift.
1 Remove the fasteners from the access cover on
the side of the platform at the non-steer end of
the machine.
17 Remove the retaining fasteners from the
platform pivot pins at the non-steer end of the
machine.
2 Remove the fasteners from the roller wheel
mount.
18 Use a slide hammer to remove the pins.
3 Remove the wheel roller bolt, then remove the
roller wheel from the platform.
Crushing hazard. The platform will
fall when the pivot pins are
removed if not properly supported
by the forklift.
19 Carefully lift the platform off of the machine and
place it on a structure capable of supporting it.
Crushing hazard. The platform will
become unbalanced and fall when
removed from the machine if not
properly supported and secured to
the forklift.
Note the position of the wear pads
before the platform is removed so
that when the platform is installed
they will be in the correct position.
Part No. 52302
4 Repeat steps 2 through 4 for the other side of
the platform.
5 Lift the platform extension lock handle.
6 Remove the two bolts that attach the platform
extension lock handle assembly to the platform
extension railing.
7 Remove the two bolts that attach the extension
lock pin bracket to the railing. Lay the lock
handle assembly off to the side.
8 Remove the platform extension limit switch
mounting fasteners and remove the limit switch.
Do not disconnect the wiring.
GS-2668 RT • GS-3268 RT
4 - 15
Section 4 • Repair Procedures
March 2005
PLATFORM COMPONENTS
REV A
9 GS-2668 RT before serial number 26563 and
GS-3268 RT before serial number 41200:
Remove the platform extension limit switch
mounting fasteners and remove the limit switch.
Do not disconnect the wiring.
10 Remove the platform controls from the platform
and lay them off to the side.
11 Position a forklift at the steer end of the
machine with the forks even with the bottom of
the platform extension.
12 Carefully slide the platform extension out until
the platform extension makes contact with the
carriage on the forklift.
13 Attach a lifting strap from the platform extension
railings to the carriage on the forklift to support
the platform extension.
14 Carefully slide the platform extension out and
away from the platform and place it on a
structure capable of supporting it.
Crushing hazard. The platform
extension will become unbalanced
and fall when removed from the
machine if not properly supported
and secured to the forklift.
4 - 16
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 4 • Repair Procedures
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Part No. 52302
GS-2668 RT • GS-3268 RT
4 - 17
Section 4 • Repair Procedures
March 2005
Scissor Components
REV B
1
12
13
2
14
3
15
4
16
17
5
18
6
19
7
20
8
21
22
9
23
10
11
GS-2668
Steer End
1
2
3
4
5
6
7
8
9
10
11
12
Non-steer End
Number 5 pivot pin (steer end)
Number 4 center pivot pin
Number 4 pivot pin (steer end)
Number 3 outer arm
Lift cylinder rod-end pivot pin
Number 3 pivot pin (steer end)
Number 2 center pivot pins (2 each)
Number 2 pivot pin (steer end)
Number 1 center pivot pin
Number 1 inner arm
Number 1 pivot pin(s) (steer end)
Number 5 pivot pin (non-steer end)
4 - 18
13
14
15
16
17
18
19
20
21
22
23
Number 4 inner arm
Number 4 outer arm
Number 4 pivot pin (non-steer end)
Number 3 inner arm
Number 3 center pivot pin
Number 3 pivot pin (non-steer end)
Number 2 inner arm
Number 2 outer arm
Number 2 pivot pin (non-steer end)
Lift cylinder barrel-end pivot pin
Number 1 outer arm
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 4 • Repair Procedures
REV B
SCISSOR COMPONENTS
3-1
Scissor Assembly, GS-2668 RT
How to Disassemble the
Scissor Assembly, GS-2668 RT
Bodily injury hazard. This
procedure requires 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. Dealer
service is required.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose must be replaced and
then torqued to specification
during installation. Refer to
Section Two, Hydraulic Hose and
Fitting Torque Specifications.
1 Remove the platform. See 2-1, How to Remove
the Platform.
6 Remove the upper cable tray from the scissor
assembly.
Component damage hazard.
Cables can be damaged if they
are kinked or pinched.
7 Connect the platform controls to the quick
disconnect plug to allow the machine to
operate.
8 Turn the key switch to ground control and pull
out the red Emergency Stop button to the on
position at both the ground and platform
controls. Start the engine.
9 Raise the platform approximately 10 feet / 3 m.
10 Remove the safety arm from the number 3 inner
arm (index #16).
11 Install the safety arm on the number 2 inner arm
(index #19) at the steer end of the machine.
12 Lift the safety arm, move to the center of the
scissor arm and rotate down to a vertical
position.
13 Lower the scissor assembly onto the safety
arm.
2 Remove the cables from the number 4 outer
arm (index #14).
3 Remove the cables from the upper cable tray
support.
4 Remove the cables from the number 3 inner
arm (index #16) and lay the cables off to the
side.
Component damage hazard.
Cables can be damaged if they
are kinked or pinched.
5 Remove the mounting fasteners from the upper
cable tray supports.
Part No. 52302
Crushing hazard. Keep hands
clear of the safety arm when
lowering the platform.
14 Turn the key switch to the off position and push
in the red Emergency Stop button to the off
position at both the ground and platform
controls.
15 Attach a lifting strap from an overhead crane to
the number 4 outer arm (index #14).
16 Support the number 4 inner arm (index #13)
with a second overhead crane at the non-steer
end.
GS-2668 RT • GS-3268 RT
4 - 19
Section 4 • Repair Procedures
March 2005
SCISSOR COMPONENTS
REV B
17 Remove the external snap rings from the
number 4 center pivot pin (index #2).
18 Use a soft metal drift to remove the number 4
center pivot pin (index #2).
19 Remove the external snap rings from the
number 4 pivot pin (index #15) at the non-steer
end of the machine.
20 Use a soft metal drift to remove the number 4
pivot pin (index #15) from the non-steer end.
Remove the number 4 outer arm (index #14)
from the machine.
Crushing hazard. The number 4
outer arm (index #14) could
become unbalanced and fall if not
properly supported when removed
from the machine.
26 Remove the external snap rings from the
number 3 center pivot pin (index #17) at the
ground controls side.
27 Use a soft metal drift to tap the number 3 center
pivot pin (index #17) halfway out at the ground
controls side.
28 Remove the external snap rings from the
number 3 pivot pin (index #18) at the non-steer
end.
29 Use a soft metal drift to tap the number 3 pivot
pin (index #18) halfway out at the non-steer end
of the machine. Remove the number 3 outer
arm (index #4) at the ground controls side from
the machine.
Crushing hazard. The number 3
outer arm (index #4) at the ground
controls side could become
unbalanced and fall if not properly
supported when removed from the
machine.
21 Attach a lifting strap from an overhead crane to
the number 4 inner arm (index #13).
22 Remove the external snap rings from the
number 4 pivot pin (index #3).
23 Use a soft metal drift to remove the number 4
pivot pin (index #3). Remove the number 4
inner arm (index #13) from the machine.
Crushing hazard. The number 4
inner arm (index #13) could
become unbalanced and fall if not
properly supported when removed
from the machine.
24 Attach a lifting strap from an overhead crane to
the number 3 outer arm (index #4) at the
ground controls side.
25 Support the number 3 inner arm (index #16)
with a second overhead crane at the non-steer
end.
4 - 20
30 Attach a lifting strap from an overhead crane to
the number 3 outer arm (index #4) at the engine
side.
31 Remove the external snap rings from the
number 3 center pivot pin (index #17) at the
engine side.
32 Use a soft metal drift to tap the number 3 center
pivot pin (index #17) at the engine side in the
other direction.
33 Use a soft metal drift to tap the number 3 pivot
pin (index #18) at the non-steer end in the other
direction. Remove the number 3 outer arm
(index #4) from the engine side of the machine.
GS-2668 RT • GS-3268 RT
Crushing hazard. The number 3
outer arm (index #4) at the engine
side could become unbalanced
and fall if not properly supported
when removed from the machine.
Part No. 52302
March 2005
Section 4 • Repair Procedures
REV B
SCISSOR COMPONENTS
34 Remove the cables from the lower cable tray.
Lay the cables off to the side of the machine.
35 Remove the mounting fasteners from the lower
cable tray mounting bracket on the number 2
center pivot pin (index #7) at the engine side of
the machine.
43 Attach a lifting strap from an overhead crane to
the number 2 outer arm (index #20) at the
ground controls side.
44 Support the number 2 inner arm (index #19)
with a second overhead crane at the non-steer
end.
36 Remove the mounting fasteners from the lower
cable tray supports at both ends of the lower
cable tray.
45 Remove the external snap rings from the
number 2 center pivot pin (index #7) at the
ground controls side.
37 Remove the lower cable tray from the machine.
46 Use a soft metal drift to remove the number 2
center pivot pin (index #7) at the ground
controls side.
Component damage hazard.
Cables can be damaged if they
are kinked or pinched.
38 Attach a lifting strap from an overhead crane to
the lug on the rod end of the lift cylinder.
39 Remove the pin retaining fasteners from the
cylinder rod-end pivot pin (index #5). Use a soft
metal drift to remove the pin.
Crushing hazard. The cylinder
could fall if not properly supported
when the pin is removed.
47 Remove the external snap rings from the
number 2 pivot pin (index #21) at the non steer
end.
48 Use a soft metal drift to tap the number 2 pivot
pin (index #21) halfway out at the non-steer end
of the machine. Remove the number 2 outer
arm (index #20) at the ground controls side
from the machine.
Crushing hazard. The number 2
outer arm (index #20) at the
ground controls side could
become unbalanced and fall if not
properly supported when removed
from the machine.
40 Lower the cylinder onto the number 1 center
pivot pin (index #9).
41 Remove the external snap rings from the
number 3 pivot pin (index #6) at the steer end.
42 Use a soft metal drift to remove the number 3
pivot pin (index #6) at the steer end. Remove
the number 3 inner arm (index #16) from the
machine.
Crushing hazard. The number 3
inner arm (index #16) could
become unbalanced and fall if not
properly supported when removed
from the machine.
Part No. 52302
49 Attach a lifting strap from an overhead crane to
the number 2 outer arm (index #20) at the
engine side.
50 Remove the external snap rings from the
number 2 center pivot pin (index #7) at the
engine side.
51 Use a soft metal drift to remove the number 2
center pivot pin (index #7) at the engine side.
GS-2668 RT • GS-3268 RT
4 - 21
Section 4 • Repair Procedures
March 2005
SCISSOR COMPONENTS
REV B
52 Use a soft metal drift to tap the number 2 pivot
pin (index #21) at the non steer end in the other
direction. Remove the number 2 outer arm
(index #20) from the engine side of the
machine.
Crushing hazard. The number 2
outer arm (index #20) at the
engine side could become
unbalanced and fall if not properly
supported when removed from the
machine.
53 Support the number 1 outer arm (index #23)
with a second overhead crane at the steer end.
54 Remove the external snap rings from the
number 2 pivot pin (index #8) at the steer end.
55 Use a soft metal drift to remove the number 2
pivot pin (index #8) at the steer end. Remove
the number 2 inner arm (index #19) from the
machine.
Crushing hazard. The number 2
inner arm (index #19) could
become unbalanced and fall if not
properly supported when removed
from the machine.
56 Tag, disconnect and plug the hydraulic hose on
the lift cylinder. Cap the fitting on the cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
4 - 22
57 Tag and disconnect the wiring from the solenoid
valve on the lift cylinder.
58 Remove the cables from the number 1 inner
arm (index #10). Lay the cables off to the side
of the machine.
Component damage hazard.
Cables can be damaged if they
are kinked or pinched.
59 Remove the LPG tank.
60 Remove the LPG tank bracket mounting
fasteners. Remove the LPG tank bracket from
the machine.
61 Raise the scissor assembly slightly and return
the safety arm to the stowed position. Lower
the scissor assembly.
Crushing hazard. The scissor
assembly could become
unbalanced and fall if not properly
supported when the safety arm is
returned to the stowed position.
62 Support and secure the entry ladder to an
appropriate lifting device. Remove the entry
ladder mounting fasteners. Remove the entry
ladder from the machine.
Crushing hazard. The entry ladder
could become unbalanced and fall
if not properly supported and
secured to the lifting device.
63 Secure both ends of the scissor arms together
with a strap or other suitable device.
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 4 • Repair Procedures
REV B
SCISSOR COMPONENTS
64 Attach each end of a lifting strap to each end of
the scissor assembly.
65 Attach an overhead crane to the center of the
strap.
71 Remove the pin retaining fasteners from the
cylinder barrel-end pivot pin (index #22). Use a
soft metal drift to remove the pin. Remove the
cylinder from the scissor assembly.
Crushing hazard. The cylinder
could become unbalanced and fall
if not properly supported when
removed from the assembly.
66 Remove the pin retaining fasteners from the
number 1 pivot pin(s) (index #11). Use a soft
metal drift to remove the pin(s).
Crushing hazard. The scissor
assembly could fall if not properly
supported by the overhead crane.
67 Lift the scissor assembly slightly and slide the
scissor assembly towards the non-steer end of
the machine to allow the wear pads to slide out
of the channel.
68 Remove the scissor assembly from the
machine and place it on a structure capable of
supporting it.
Crushing hazard. The scissor
assembly could become
unbalanced and fall if not properly
supported and secured to the
overhead crane.
During removal, the lifting strap
connected to the overhead crane
will need to be carefully adjusted
for proper balancing.
72 Attach a lifting strap from an overhead crane to
the number 1 outer arm (index #23).
73 Support the number 1 inner arm (index #10)
with a second overhead crane.
74 Remove the external snap rings from the
number 1 center pivot pin (index #9).
75 Use a soft metal drift to remove the number 1
center pivot pin (index #9).
Crushing hazard. The scissor
assembly could become
unbalanced and fall if not properly
supported when the center pivot
pin is removed.
76 Remove the number 1 outer arm (index #23)
from the assembly.
69 Remove the straps securing the scissor arms
together.
Crushing hazard. The number 1
inner arm (index #10) could
become unbalanced and fall if not
properly supported when removed
from the machine.
70 Attach a lifting strap from an overhead crane to
the lug on the rod end of the lift cylinder. Raise
the rod end of the cylinder to a vertical position.
Part No. 52302
GS-2668 RT • GS-3268 RT
4 - 23
Section 4 • Repair Procedures
March 2005
SCISSOR COMPONENTS
REV B
1
16
2
17
3
18
4
19
20
5
21
6
22
7
8
23
9
24
10
25
26
11
27
12
28
13
29
14
30
15
GS-3268
Non-steer End
Steer End
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Number 6 pivot pin (steer end)
Number 5 center pivot pin
Upper lift cylinder rod-end pivot pin
Number 5 pivot pin (steer end)
Number 4 center pivot pins (2 each)
Number 4 pivot pin (steer end)
Number 3 outer arm
Number 3 center pivot pin
Lower lift cylinder rod-end pivot pin
Number 3 pivot pin (steer end)
Number 2 center pivot pins (2 each)
Number 2 pivot pin (steer end)
Number 1 center pivot pin
Number 1 inner arm
Number 1 pivot pin(s) (steer end)
4 - 24
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Number 6 pivot pin (non-steer end)
Number 5 inner arm
Number 5 outer arm
Number 5 pivot pin (non-steer end)
Number 4 inner arm
Number 4 outer arm
Number 4 pivot pin (non-steer end)
Upper lift cylinder barrel-end pivot pin
Number 3 inner arm
Number 3 pivot pin (non-steer end)
Number 2 inner arm
Number 2 outer arm
Number 2 pivot pin (non-steer end)
Lower lift cylinder barrel-end pivot pin
Number 1 outer arm
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 4 • Repair Procedures
REV B
SCISSOR COMPONENTS
3-2
Scissor Assembly, GS-3268 RT
6 Remove the external snap rings from the
number 5 pivot pin (index #19) at the non-steer
end.
How to Disassemble the
Scissor Assembly, GS-3268 RT
7 Use a soft metal drift to remove the number 5
pivot pin (index #19) from the non-steer end of
the machine. Remove the number 5 outer arm
(index #18) from the machine.
Bodily injury hazard. This
procedure requires 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. Dealer
service is required.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose must be replaced and
then torqued to specification
during installation. Refer to
Section Two, Hydraulic Hose and
Fitting Torque Specifications.
Crushing hazard. The number 5
outer arm (index #18) could
become unbalanced and fall if not
properly supported when removed
from the machine.
8 Remove the cable clamps from the number 5
inner arm (index #17) and the upper cable tray.
Lay the cables off to the side of the machine.
Component damage hazard.
Cables can be damaged if they
are kinked or pinched.
9 Tag, disconnect and plug the hydraulic hose on
the upper lift cylinder. Cap the fitting on the
cylinder.
1 Remove the platform. See 2-1, How to Remove
the Platform.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
2 Remove the cables from the side of the number
5 outer arm (index #18) at the engine side.
Component damage hazard.
Cables can be damaged if they
are kinked or pinched.
3 Attach a lifting strap from an overhead crane to
the number 5 outer arm (index #18).
4 Remove the external snap rings from the
number 5 center pivot pin (index #2).
10 Attach a lifting strap from an overhead crane to
the lug on the rod end of the upper lift cylinder.
11 Remove the pin retaining fasteners from the
upper cylinder rod-end pivot pin (index #3). Use
a soft metal drift to remove the pin.
5 Use a soft metal drift to remove the number 5
center pivot pin (index #2).
Part No. 52302
GS-2668 RT • GS-3268 RT
Crushing hazard. The cylinder
could fall if not properly supported
when the pin is removed.
4 - 25
Section 4 • Repair Procedures
March 2005
SCISSOR COMPONENTS
REV B
12 Lower the cylinder onto the number 3 center
pivot pin (index #8).
13 Attach a lifting strap from an overhead crane to
the number 5 inner arm (index #17).
14 Remove the external snap rings from the
number 5 pivot pin (index #4).
15 Use a soft metal drift to remove the number 5
pivot pin (index #4). Remove the number 5
inner arm (index #17) from the machine.
Crushing hazard. The number 5
inner arm (index #17) could
become unbalanced and fall if not
properly supported when removed
from the machine.
16 Remove the mounting fasteners from the upper
cable tray mounting bracket on the number 4
center pivot pin (index #5) at the engine side of
the machine.
24 Raise the platform approximately 10 feet / 3 m.
25 Lift the safety arm, move it to the center of the
scissor arm and rotate down to a vertical
position. Lower the scissor assembly onto the
safety arm.
Crushing hazard. Keep hands
clear of the safety arm when
lowering the platform.
26 Turn the key switch to the off position and push
in the red Emergency Stop buttons to the off
position at both the ground and platform
controls.
27 Attach a lifting strap from an overhead crane to
the number 4 outer arm (index #21) at the
ground controls side.
28 Support the number 4 inner arm (index #20)
with a second overhead crane at the non-steer
end.
17 Remove the mounting fasteners from the upper
cable tray supports at both ends of the upper
cable tray.
29 Remove the external snap rings from the
number 4 center pivot pin (index #5) at the
ground controls side.
18 Remove the upper cable tray.
30 Use a soft metal drift to remove the number 4
center pivot pin (index #5) at the ground
controls side.
19 Tag and disconnect the wiring from the solenoid
valve on the lift cylinder.
20 Remove the safety arm from the number 4 inner
arm (index #20).
21 Install the safety arm on the number 2 inner arm
(index #26) at the steer end of the machine.
22 Connect the platform controls to the quick
disconnect plug to allow the machine to
operate.
31 Remove the external snap rings from the
number 4 pivot pin (index #22) at the non-steer
end.
32 Use a soft metal drift to tap the number 4 pivot
pin (index #22) halfway out at the non-steer end
of the machine. Remove the number 4 outer
arm (index #21) at the ground controls side
from the machine.
23 Turn the key switch to ground control and pull
out the red Emergency Stop buttons to the on
position at both the ground and platform
controls. Start the engine.
4 - 26
GS-2668 RT • GS-3268 RT
Crushing hazard. The number 4
outer arm (index #21) at the
ground controls side could
become unbalanced and fall if not
properly supported when removed
from the machine.
Part No. 52302
March 2005
Section 4 • Repair Procedures
REV B
SCISSOR COMPONENTS
33 Attach a lifting strap from an overhead crane to
the number 4 outer arm (index #21) at the
engine side.
34 Remove the external snap rings from the
number 4 center pivot pin (index #5) at the
engine side.
40 Remove the pin retaining fasteners from the
upper cylinder barrel-end pivot pin (index #23).
Use a soft metal drift to remove the pin.
Remove the cylinder from the machine.
Crushing hazard. The cylinder
could become unbalanced and fall
when removed from the machine if
not properly supported.
35 Use a soft metal drift to remove the number 4
center pivot pin (index #5) at the engine side.
Component damage hazard. Be
careful not to damage the valve or
fittings on the cylinder while
removing it from the machine.
36 Use a soft metal drift to tap the number 4 pivot
pin (index #22) in the other direction. Remove
the number 4 outer arm (index #21) from the
engine side of the machine.
Crushing hazard. The number 4
outer arm at the engine side
(index #21) could become
unbalanced and fall if not properly
supported when removed from the
machine.
41 Attach a lifting strap from an overhead crane to
the number 3 outer arm (index #7) at the
ground controls side.
42 Support the number 3 inner arm (index #24)
with a second overhead crane at the non-steer
end.
37 Remove the external snap rings from the
number 4 pivot pin (index #6) at the steer end
of the machine.
43 Remove the external snap rings from the
number 3 center pivot pin (index #8) at the
ground controls side.
38 Use a soft metal drift to remove the number 4
pivot pin (index #6) at the steer end. Remove
the number 4 inner arm (index #20) from the
machine.
44 Use a soft metal drift to tap the number 3 center
pivot pin (index #8) halfway out at the ground
controls side.
Crushing hazard. The number 4
inner arm (index #20) could
become unbalanced and fall if not
properly supported when removed
from the machine.
39 Attach a lifting strap from an overhead crane to
the lug on the rod end of the upper lift cylinder.
Raise the rod end of the cylinder to a vertical
position.
Part No. 52302
45 Remove the external snap rings from the
number 3 pivot pin (index #25) at the non steer
end.
46 Use a soft metal drift to tap the number 3 pivot
pin (index #25) halfway out at the non-steer end
of the machine. Remove the number 3 outer
arm (index #7) at the ground controls side from
the machine.
GS-2668 RT • GS-3268 RT
Crushing hazard. The number 3
outer arm (index #7) at the ground
controls side could become
unbalanced and fall if not properly
supported when removed from the
machine.
4 - 27
Section 4 • Repair Procedures
March 2005
SCISSOR COMPONENTS
REV B
47 Attach a lifting strap from an overhead crane to
the number 3 outer arm (index #7) at the engine
side.
57 Remove the pin retaining fasteners from the
lower cylinder rod-end pivot pin (index #9). Use
a soft metal drift to remove the pin.
48 Remove the external snap rings from the
number 3 center pivot pin (index #8) at the
engine side.
49 Use a soft metal drift to tap the number 3 center
pivot pin (index #8) at the engine side in the
other direction.
50 Use a soft metal drift to tap the number 3 pivot
pin (index #25) at the non-steer end in the other
direction. Remove the number 3 outer arm
(index #7) from the engine side of the machine.
Crushing hazard. The number 3
outer arm (index #7) at the engine
side could become unbalanced
and fall if not properly supported
when removed from the machine.
51 Remove the cables from the number 3 inner
arm (index #24). Lay the cables off to the side
of the machine.
52 Remove the cables from the lower cable tray.
Lay the cables off to the side of the machine.
53 Remove the mounting fasteners from the lower
cable tray mounting bracket on the number 2
center pivot pin (index #11) at the engine side
of the machine.
54 Remove the mounting fasteners from the lower
cable tray supports at both ends of the lower
cable tray.
55 Remove the lower cable tray from the machine.
Component damage hazard.
Cables can be damaged if they
are kinked or pinched.
Crushing hazard. The cylinder
could fall if not properly supported
when the pin is removed.
58 Lower the cylinder onto the number 1 center
pivot pin (index #13).
59 Remove the external snap rings from the
number 3 pivot pin (index #10) at the steer end.
60 Use a soft metal drift to remove the number 3
pivot pin (index #10) at the steer end. Remove
the number 3 inner arm (index #24) from the
machine.
Crushing hazard. The number 3
inner arm (index #24) could
become unbalanced and fall if not
properly supported when removed
from the machine.
61 Attach a lifting strap from an overhead crane to
the number 2 outer arm (index #27) at the
ground controls side.
62 Support the number 2 inner arm (index #26)
with a second overhead crane at the non-steer
end.
63 Remove the external snap rings from the
number 2 center pivot pin (index #11) at the
ground controls side.
64 Use a soft metal drift to remove the number 2
center pivot pin (index #11) at the ground
controls side.
65 Remove the external snap rings from the
number 2 pivot pin (index #28) at the non steer
end.
56 Attach a lifting strap from an overhead crane to
the lug on the rod end of the lower lift cylinder.
4 - 28
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 4 • Repair Procedures
REV B
SCISSOR COMPONENTS
66 Use a soft metal drift to tap the number 2 pivot
pin (index #28) halfway out at the non-steer end
of the machine. Remove the number 2 outer
arm (index #27) at the ground controls side
from the machine.
Crushing hazard. The number 2
outer arm (index #27) at the
ground controls side could
become unbalanced and fall if not
properly supported when removed
from the machine.
67 Attach a lifting strap from an overhead crane to
the number 2 outer arm (index #27) at the
engine side.
73 Use a soft metal drift to remove the number 2
pivot pin (index #12) at the steer end. Remove
the number 2 inner arm (index #26) from the
machine.
Crushing hazard. The number 2
inner arm (index #26) could
become unbalanced and fall if not
properly supported when it is
removed from the machine.
74 Support and secure the entry ladder to an
appropriate lifting device. Then remove the
entry ladder mounting fasteners. Remove the
entry ladder from the machine.
Crushing hazard. The entry ladder
could become unbalanced and fall
if not properly supported and
secured to the lifting device.
68 Remove the external snap rings from the
number 2 center pivot pin (index #11) at the
engine side.
69 Use a soft metal drift to remove the number 2
center pivot pin (index #11) at the engine side.
75 Disconnect and plug the hydraulic hose on the
lift cylinder. Cap the fitting on the cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
70 Use a soft metal drift to tap the number 2 pivot
pin (index #28) at the non-steer end in the other
direction. Remove the number 2 outer arm
(index #27) from the engine side of the
machine.
Crushing hazard. The number 2
outer arm (index #27) at the
engine side could become
unbalanced and fall if not properly
supported when removed from the
machine.
71 Support the number 1 outer arm (index #30)
with a second overhead crane at the steer end.
72 Remove the external snap rings from the
number 2 pivot pin (index #12) at the steer end.
Part No. 52302
76 Tag and disconnect the wiring from the solenoid
valve on the lift cylinder.
77 Remove the cables from the number 1 inner
arm (index #14). Lay the cables off to the side
of the machine.
78 Remove the LPG tank.
79 Remove the LPG tank bracket mounting
fasteners. Remove the LPG tank bracket from
the machine.
GS-2668 RT • GS-3268 RT
4 - 29
Section 4 • Repair Procedures
March 2005
SCISSOR COMPONENTS
REV B
80 Raise the scissor assembly slightly and return
the safety arm to the stowed position. Lower
the scissor assembly. Remove the straps.
Crushing hazard. The scissor
assembly could become
unbalanced and fall if not properly
supported when the safety arm is
returned to the stowed position.
81 Secure both ends of the scissor arms together
with a strap or suitable device.
82 Attach each end of a lifting strap of ample
capacity to each end of the scissor assembly.
87 Remove the straps securing the scissor arms
together.
88 Attach a lifting strap from an overhead crane to
the lug on the rod end of the lower lift cylinder.
Raise the rod end of the cylinder to a vertical
position.
89 Remove the pin retaining fasteners from the
lower cylinder barrel-end pivot pin (index #29).
Use a soft metal drift to remove the pin.
Remove the cylinder from the scissor
assembly.
Crushing hazard. The cylinder
could become unbalanced and fall
if not properly supported when
removed from the assembly.
83 Attach an overhead crane to the center of the
strap.
84 Remove the pin retaining fasteners from the
number 1 pivot pin(s) (index #15). Use a soft
metal drift to remove the pin(s).
Crushing hazard. The scissor
assembly could fall if not properly
supported by the overhead crane.
85 Lift the scissor assembly slightly and slide the
scissor assembly towards the non-steer end of
the machine to allow the wear pads to slide out
of the channel.
90 Attach a lifting strap from an overhead crane to
the number 1 outer arm (index #30).
91 Support the number 1 inner arm (index #14)
with a second overhead crane.
92 Remove the external snap rings from the
number 1 center pivot pin (index #13).
93 Use a soft metal drift to remove the number 1
center pivot pin (index #13).
Crushing hazard. The scissor
assembly could become
unbalanced and fall if not properly
supported when removed from the
machine.
86 Remove the scissor assembly from the
machine and place it on a structure capable of
supporting it.
Crushing hazard. The scissor
assembly could become
unbalanced and fall if not properly
supported and secured to the
overhead crane.
94 Remove the number 1 outer arm (index #30)
from the assembly.
During removal, the lifting strap
connected to the overhead crane
will need to be carefully adjusted
for proper balancing.
4 - 30
GS-2668 RT • GS-3268 RT
Crushing hazard. The number 1
outer arm (index #30) could
become unbalanced and fall if not
properly supported when removed
from the machine.
Part No. 52302
March 2005
Section 4 • Repair Procedures
REV B
SCISSOR COMPONENTS
8 Turn the key switch to the off position and push
in the red Emergency Stop buttons to the off
position at both the ground and platform
controls.
3-3
Wear Pads
How to Replace the Scissor Arm
Wear Pads
9 Secure both ends of the scissor arms together
with a strap or other suitable device.
1 Remove the platform. See 2-1, How to Remove
the Platform.
10 Attach a strap from an overhead crane to the
non-steer end of the scissor arms.
2 Remove the mounting fasteners from the
stationary wear pads on the platform.
11 Raise the scissor arms slightly at the non-steer
end with the overhead crane just enough to
take the pressure off of the non-steer end slide
blocks.
Note the position of the wear pads
before they are removed so when
the new ones are installed they
will be in the correct position.
3 Connect the platform controls to the quick
disconnect plug to allow the machine to
operate.
12 Remove the pin retaining fasteners from the
slide block pivot pin.
13 Place a rod through the pin and twist to remove
the pin.
4 Turn the key switch to ground control and pull
out the red Emergency Stop button to the on
position at both the ground and platform
controls. Start the engine.
5 Raise the platform approximately 10 feet / 3 m.
6 Lift the safety arm, move it to the center of the
scissor arm and rotate down to a vertical
position.
7 Lower the scissor arms onto the safety arm.
Crushing hazard. Keep hands
clear of the safety arm when
lowering the scissor arms.
14 Remove the slide block and remove the wear
pad mounting fasteners.
15 Install the new wear pad.
16 Repeat steps 12 through 15 for the other wear
pad slide block.
17 Install the wear pad slide blocks into the drive
chassis and install the slide block pivot pins and
pin retaining fasteners.
Part No. 52302
GS-2668 RT • GS-3268 RT
4 - 31
Section 4 • Repair Procedures
March 2005
SCISSOR COMPONENTS
REV B
3 Lower the platform onto the safety arm.
3-4
Lift Cylinder(s)
The lift cylinders are single acting hydraulic
cylinders. The GS-2668 RT uses one lift cylinder;
the GS-3268 RT uses two. Each lift cylinder is
equipped with a check valve to prevent movement
in the event of a hydraulic line failure.
How to Remove the Lift Cylinder
Crushing hazard. Keep hands
clear of the safety arm when
lowering the platform.
4 Tag and disconnect the wiring from the solenoid
valve at the barrel end of the lift cylinder.
5 Before serial number 40207: Tag and
disconnect the manual lowering cable from the
solenoid.
During assembly, the manual
platform lowering cable needs to
be properly adjusted. See 6-1,
How to Adjust the Manual Platform
Lowering Cable.
GS-2668 RT:
Bodily injury hazard. This
procedure requires 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. Dealer
service is strongly recommended.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose must be replaced and
then torqued to specification
during installation. Refer to
Section Two, Hydraulic Hose and
Fitting Torque Specifications.
6 Tag, disconnect and plug the hydraulic hose
from the lift cylinder. Cap the fitting on the
cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
1 Raise the platform approximately 10 feet / 3 m.
7 Attach a strap from an overhead crane or
similar lifting device to the rod end of the lift
cylinder for support.
2 Lift the safety arm, move to the center of the
scissor arm and rotate down to a vertical
position.
8 Remove the lift cylinder rod-end pivot pin
retaining fastener. Use a soft metal drift to
remove the pin.
Crushing hazard. The lift cylinder
will fall if not properly supported.
4 - 32
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 4 • Repair Procedures
REV B
SCISSOR COMPONENTS
9 Lower the cylinder onto the number 1 center
pivot pin.
GS-3268 RT:
Bodily injury hazard. This
procedure requires 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. Dealer
service is strongly recommended.
10 Support and secure the entry ladder to an
appropriate lifting device. Remove the entry
ladder mounting fasteners. Remove the entry
ladder from the machine.
Crushing hazard. The entry ladder
could become unbalanced and fall
if not properly supported and
secured to the lifting device when
removed from the machine.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose must be replaced and
then torqued to specification
during installation. Refer to
Section Two, Hydraulic Hose and
Fitting Torque Specifications.
11 Remove the lift cylinder barrel-end pivot pin
retaining fastener. Use a soft metal drift to
remove the pin.
Crushing hazard. The lift cylinder
will fall if not properly supported.
12 Carefully pull the lift cylinder out the non-steer
end of the machine through the scissor arms.
Crushing hazard. The lift cylinder
could become unbalanced and fall
if not properly supported when
removed from the machine.
1 Start the engine and raise the platform
approximately 10 feet / 3 m.
2 Lift the safety arm, move to the center of the
scissor arm and rotate down to a vertical
position.
3 Lower the platform onto the safety arm.
Component damage hazard. Be
careful not to damage the valve or
fittings on the cylinder while
removing it from the machine.
Crushing hazard. Keep hands
clear of the safety arm when
lowering the platform.
4 Tag and disconnect the wiring from the solenoid
valve at the barrel end of the lift cylinder.
Part No. 52302
GS-2668 RT • GS-3268 RT
4 - 33
Section 4 • Repair Procedures
March 2005
SCISSOR COMPONENTS
REV B
5 Tag, disconnect and plug the hydraulic hose
from the lift cylinder. Cap the fitting on the
cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
10 Support and secure the lift cylinder to an
appropriate lifting device.
11 Remove the external snap ring from the lift
cylinder barrel-end pivot pin. Use a soft metal
drift to remove the pin.
Crushing hazard. The lift cylinder
will fall if not properly supported.
12 Carefully pull the lift cylinder out the non-steer
end of the machine through the scissor arms.
6 Attach a lifting strap from an overhead crane or
similar lifting device to the rod end of the lift
cylinder for support.
7 Remove the external snap ring from the lift
cylinder rod-end pivot pin. Use a soft metal drift
to remove the pin.
Crushing hazard. The lift cylinder
will fall if not properly supported.
Crushing hazard. The lift cylinder
could become unbalanced and fall
if not properly supported when
removed from the machine.
Component damage hazard. Be
careful not to damage the valve or
fittings on the cylinder while
removing it from the machine.
8 Lower the cylinder to a horizontal position.
If removing the upper lift cylinder, disregard
step 9.
9 To remove the lower cylinder, support and
secure the entry ladder to an appropriate lifting
device. Remove the entry ladder mounting
fasteners. Remove the entry ladder from the
machine.
Crushing hazard. The entry ladder
could become unbalanced and fall
if not properly supported and
secured to the lifting device when
removed from the machine.
4 - 34
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 4 • Repair Procedures
Kubota D905 Engine
REV B
4-1
Timing Adjustment
4-3
Engine RPM
Complete information to perform this procedure is
available in the Kubota D905 Workshop Manual
(Kubota part number 97897-00870).
How to Adjust the RPM
Kubota D905 Workshop Manual
Genie part number
52229
1 Start the engine from the ground controls.
2 Hold the start toggle switch to the start position
and check the engine RPM on the diagnostic
display. Refer to Section 2, Specifications.
Proceed to step 4 if the low idle is correct.
3 To correct the low idle speed, loosen the lock
nut, then turn the low idle adjustment screw
clockwise to increase the rpm or
counterclockwise to decrease the rpm. Tighten
the lock nut and recheck the rpm.
4-2
Glow Plugs
How to Check the Glow Plugs
a
b
Perform this procedure with the
engine turned off.
1 Connect the leads from an ohmmeter between
the far left glow plug and ground.
Result: The resistance should be approximately
1Ω.
2 If the ohm reading is different than 1Ω, remove
the wire and connector plate from the three
individual glow plugs. Then, one glow plug at a
time, measure the resistance between the glow
plug and ground.
d
a
b
c
d
Result: The resistance should be approximately
1.8Ω for each individual glow plug.
3 Install the connector plate and wires to all three
glow plugs.
4 Turn the key switch to ground control and pull
out the red Emergency Stop button to the on
position.
5 Connect the red positive (+) lead from a volt
meter to the number three glow plug. Connect
the black negative (-) lead to ground.
6 Hold the glow plug switch in the on position.
Result: The volt meter should read 12V DC or
more.
Part No. 52302
c
high idle solenoid
low idle adjustment screw
lock nut
high idle adjustment nut
4 Move the engine idle control switch to high idle
(rabbit symbol) from the ground controls.
5 Hold the start toggle switch to the start position
and check the engine RPM on the diagnostic
display. Refer to Section 2, Specifications.
6 To correct the high idle speed, loosen the lock
nut on the solenoid, then turn the solenoid boot
counterclockwise to increase the rpm or
clockwise to decrease the rpm. Tighten the lock
nut and recheck the rpm.
GS-2668 RT • GS-3268 RT
4 - 35
Section 4 • Repair Procedures
March 2005
KUBOTA D905 ENGINE
REV B
4-4
Flex Plate
How to Install the Flex Plate
1 Install the flex plate onto the flywheel with the
raised spline toward the pump.
The flex plate couples the engine to the pump. The
flex plate is bolted to the engine flywheel and has a
splined cut-out in the center to engage the pump
coupler.
Install the coupler onto the pump
shaft with the set screw towards
the pump. Leave a
1/32 inch / 0.8 mm gap between
the coupler and pump end plate.
Apply Loctite® removable thread
locker to the coupler set screw
and torque the set screw to
65-70 ft-lbs / 88-95 Nm.
How to Remove the Flex Plate
1 Attach a lifting strap from an overhead crane to
the pump assembly for support. Do not lift it.
2 Remove all of the pump mounting plate to
engine fasteners.
3 Carefully pull the pump assembly away from the
engine and secure it from moving.
2 Apply Loctite® removable thread locker to the
flex plate mounting fasteners. Torque the flex
plate mounting fasteners to 36 ft-lbs / 49 Nm.
Component damage hazard.
Hoses can be damaged if they are
kinked or pinched.
4 Remove the flex plate mounting fasteners.
Remove the flex plate from the flywheel.
Component damage hazard. Do
not force the drive pump during
installation or the flex plate splines
may become damaged.
a
b
c
d
e
f
a
b
c
d
e
f
4 - 36
GS-2668 RT • GS-3268 RT
pump
pump shaft
pump coupler
flex plate
flywheel
1/32 inch / 0.8 mm gap
Part No. 52302
March 2005
Section 4 • Repair Procedures
REV B
KUBOTA D905 ENGINE
4-5
Coolant Temperature and Oil
Pressure Switches
a
b
The engine coolant temperature switch is a
normally open switch. The switch contacts close at
approximately 225°F / 107°C. If the coolant
temperature rises above the switch point, the
switch contacts close and the engine will shut off to
prevent damage. The engine will not start until the
temperature drops below the switch point. An overtemperature indicator light at the ground controls
should turn on when the switch closes.
The engine oil pressure switch is a normally closed
switch. The switch contacts open at approximately
7 psi / 0.48 bar. If the oil pressure drops below the
switch point, the contacts open and the engine will
shut off to prevent damage. A low oil pressure
indicator light at the ground controls should turn on
when the switch opens.
How to Replace the Coolant
Temperature and Oil Pressure
Switches
Perform this procedure with the
engine off.
1 Open the engine side cover and pull up on the
lock pin on the engine pivot tray located under
the radiator. Swing the engine pivot tray out and
away from the machine to access both
switches.
Part No. 52302
a
b
coolant temperature switch
oil pressure switch
2 Tag and disconnect the wiring from the switch.
Remove the switch from the engine.
Bodily injury hazard. Contact with
hot engine fluids or components
may cause severe burns.
3 Install the new switch and tighten. Torque
to 8-18 ft-lbs / 11-24 Nm.
GS-2668 RT • GS-3268 RT
Always use pipe thread sealant
when installing a new switch.
4 - 37
Section 4 • Repair Procedures
March 2005
Kubota DF750 / DF752 Engine
5-1
Timing Adjustment Gasoline/LPG Models
REV B
5-3
Choke Adjustment Gasoline/LPG Models
The ignition timing cannot be
adjusted. The timing adjustment
screw is factory sealed with a
tamper resistant cap installed by
the manufacturer. If service or
repair is needed, contact your
local Kubota dealer.
The choke is solenoid-operated and functions only
in the gasoline mode. The choke will not operate in
LPG mode.
5-4
Flex Plate
See 4-4, Flex Plate.
5-2
Carburetor Adjustment Gasoline/LPG Models
The carburetor cannot be
adjusted. The carburetor mixture
screws are factory sealed with
tamper resistant caps installed by
the manufacturer. If service or
repair is needed, contact your
local Kubota dealer.
5-5
Coolant Temperature and Oil
Pressure Switches
See 4-5, Coolant Temperature and Oil Pressure
Switches.
Complete repair information for the Kubota DF750
engine is available in the
Kubota DF750 Workshop Manual
(Kubota part number 97897-00643).
Complete repair information for the Kubota DF752
engine is available in the
Kubota DF752 Workshop Manual
(Kubota part number 97897-02100).
Kubota DF750 Workshop Manual
Genie part number
Kubota DF752 Workshop Manual
Genie part number
4 - 38
52492
GS-2668 RT • GS-3268 RT
84249
Part No. 52302
March 2005
Section 4 • Repair Procedures
REV B
KUBOTA DF750 / DF752 ENGINE
5-6
Engine RPM
a
b
c
d
How to Adjust the RPM
The on-board self diagnostics
incorporate a built-in engine
tachometer. The first two digits of
the engine rpm are displayed on
the diagnostic display when the
start toggle switch is moved to the
start position with the engine
running. Engine rpm equals the
first two digits multiplied by 100.
Perform this procedure in gasoline
mode with the engine at normal
operating temperature.
1 Start the engine from the ground controls.
2 Hold the start toggle switch to the start position
and check the engine RPM on the diagnostic
display. Refer to Section 2, Specifications.
Proceed to step 4 if the low idle is correct.
a
b
c
d
4 Move the engine idle control switch to high idle
(rabbit symbol) from the ground controls.
5 Hold the start toggle switch to the start position
and check the engine RPM on the diagnostic
display. Refer to Section 2, Specifications.
6 To correct the high idle speed, loosen the yoke
lock nut on the high idle solenoid, then turn the
high idle adjustment nut and solenoid boot
counterclockwise to increase the rpm or
clockwise to decrease the rpm. Tighten the
yoke lock nut and recheck the rpm.
3 To correct the low idle speed, turn the low idle
adjustment screw on the carburetor clockwise
to increase rpm or counterclockwise to
decrease rpm.
Part No. 52302
solenoid boot
threaded rod
yoke locknut
yoke
GS-2668 RT • GS-3268 RT
Be sure the solenoid fully retracts
when activating high idle.
4 - 39
Section 4 • Repair Procedures
March 2005
Perkins 403C-11 Engine
REV A
6-1
Engine RPM
6-2
Timing Adjustment
How to Adjust the RPM
Complete information to perform this procedure is
available in the Perkins 403C-11 Workshop
Manual (Perkins part number TPD1458).
1 Start the engine from the ground controls.
2 Hold the start toggle switch to the start position
and check the engine RPM on the diagnostic
display. Refer to Section 2, Specifications.
Proceed to step 4 if the low idle is correct.
Perkins 403C-11 Workshop Manual
Genie part number
84817
3 To correct the low idle speed, loosen the
locknut on the low idle adjustment screw. Turn
the low idle adjustment screw on the linkage
clockwise to increase rpm or counterclockwise
to decrease rpm. Tighten the lock nut and
recheck the rpm. See the illustration.
4 Move the engine idle control switch to high idle
(rabbit symbol) from the ground controls.
5 Hold the start toggle switch to the start position
and check the engine RPM on the diagnostic
display. Refer to Section 2, Specifications.
6 To correct the high idle speed, loosen the yoke
lock nut on the high idle solenoid, then turn the
high idle adjustment nut and solenoid boot
counterclockwise to increase the rpm or
clockwise to decrease the rpm. Tighten the
yoke lock nut and recheck the rpm. See the
illustration.
Be sure the solenoid fully retracts
when activating high idle.
a
b
a
b
c
d
e
4 - 40
GS-2668 RT • GS-3268 RT
c
d
e
solenoid
yoke locknut
yoke
low idle lock nut
low idle adjustment screw
Part No. 52302
March 2005
Section 4 • Repair Procedures
REV A
PERKINS 403C-11 ENGINE
6-3
Flex Plate
How to Replace the Coolant
Temperature and Oil Pressure
Switches
See 4-4, Flex Plate.
Perform this procedure with the
engine off.
6-4
Coolant Temperature and Oil
Pressure Switches
1 Open the engine side cover and pull up on the
lock pin on the engine pivot tray located under
the radiator. Swing the engine pivot tray out and
away from the machine to access both
switches.
The engine coolant temperature switch is a
normally open switch. The switch contacts close at
approximately 221°F / 105°C. If the coolant
temperature rises above the switch point, the
switch contacts close and the engine will shut off to
prevent damage. The engine will not start until the
temperature drops below the switch point.
2 Coolant temperature switch: Tag and
disconnect the wiring from the switch, located
at the engine coolant outlet just above the
alternator. Remove the switch from the engine.
The engine oil pressure switch is a normally open
switch. The switch contacts close at approximately
4.27 psi / 0.3 bar. If the oil pressure drops below
the switch point, the contacts close and the engine
will shut off to prevent damage.
Before serial number GS6803-42382: A fault
indicator light at the ground controls should turn on
when either switch closes.
After serial number GS6803-42381: A fault code
will be shown in the diagnostic display window at
the ground controls when either switch closes.
Part No. 52302
Oil pressure switch: Tag and disconnect the
wiring from the switch, located at the top of the
engine just in front of the valve rocker cover.
Remove the switch from the engine.
Bodily injury hazard. Contact with
hot engine fluids or components
may cause severe burns.
3 Coolant temperature switch: Install the new
switch. Torque to 20 ft-lbs / 27 Nm.
Oil pressure switch: Install the new switch.
Torque to 88 in-lbs / 10 Nm.
GS-2668 RT • GS-3268 RT
Always use pipe thread sealant
when installing a new switch.
4 - 41
Section 4 • Repair Procedures
March 2005
Ground Controls
7-1
Auxiliary Platform Lowering
REV B
8 Tighten the upper lock nut and repeat step 6 to
confirm the distance between the end of the
lowering cable and the end of the lowering
valve.
Auxiliary Platform Lowering,
GS-2668 RT
(before serial number 40207)
9 Install the cable mounting nut onto the lowering
valve.
The manual platform lowering system lowers the
platform in the event of a main power failure. The
manual platform lowering cable is attached to the
barrel end of the lift cylinder and is activated next
to the ground controls.
11 Pull the manual lowering handle at the ground
controls 2 to 3 times to ensure it is functioning
correctly.
10 Raise the platform and rotate the safety arm to
the stowed position.
How to Adjust the Manual
Platform Lowering Cable
a
1 Raise the platform approximately 10 feet / 3 m.
2 Lift the safety arm, move to the center of the
scissor arm and rotate to a vertical position.
b
3 Lower the platform onto the safety arm.
Crushing hazard. Keep hands
clear of the safety arm when
lowering the platform.
c
d
4 Push the handle on the manual platform
lowering cable all the way in.
5 Disconnect the cable mounting nut from the
lowering valve at the barrel end of the lift
cylinder.
e
6 Pull the cable tight and measure the distance
between the end of the lowering cable and the
end of the lowering valve.
f
Result: The measurement should be 3/16 to
1/4 inch / 4.7 to 6.4 mm.
7 To adjust, loosen the upper lock nut on the
cable mounting bracket. Turn the lower lock nut
clockwise to decrease the distance or
counterclockwise to increase the distance.
4 - 42
GS-2668 RT • GS-3268 RT
g
AE
a
b
c
d
e
f
g
manual lowering cable sheath
upper lock nut
cable mounting bracket
lower lock nut
cable mounting nut
end of the lowering cable
manual lowering valve
(hydraulic schematic item AE)
Part No. 52302
March 2005
Section 4 • Repair Procedures
REV B
GROUND CONTROLS
Auxiliary Platform Lowering,
GS-3268 RT, and
GS-2668 RT (after serial
number 40206)
In the event of a main power failure, activating the
function enable and manual platform lowering
buttons at the ground controls will lower the
platform. There is no adjustment required.
Before serial number 41824, two 6V DC batteries
wired in series supply power for the manual
platform lowering function. These batteries are
located behind the ground control panel.
After serial number 41823, the auxiliary platform
lowering circuit uses the main 12V battery for its
power source.
How to Replace a Manual
Platform Lowering Battery
(before serial number 41824)
7-2
Function Speed Tuning
(after serial number GS6803-42381)
All machine function speeds are determined by the
percentage of total ECM voltage output. The
speeds of the following machine functions may be
adjusted to compensate for wear in the hydraulic
pump and drive motors.
· Stowed drive speed
· High torque drive speed
· Raised drive speed
· Platform lift speed
To adjust the function speeds on machines before
serial number GS6803-42382, see 1-3,
Function Speed Tuning (before serial number
GS6803-42382).
For further information or assistance, consult the
Genie Industries Service Department.
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
machine to tip over resulting in
death or serious injury.
1 Open the ground controls cover.
2 Remove the ground control panel fasteners and
open the panel.
3 Tag and disconnect the wires from the battery
to be removed.
4 Remove the battery from the machine.
Tip-over hazard. This procedure
must only be performed by a
trained service professional.
Attempting this procedure without
the necessary skills will result in
death or serious injury.
5 Install the new battery and connect the wires.
6 Close the ground control panel and install the
fasteners.
7 Close the ground controls cover.
How to
Determine the Revision Level
1 Turn the key switch to ground controls and pull
out the red Emergency Stop buttons to the on
position at both platform and ground controls.
Result: The revision level of the ECM will
appear in the LED display window.
Part No. 52302
GS-2668 RT • GS-3268 RT
4 - 43
Section 4 • Repair Procedures
March 2005
GROUND CONTROLS
REV B
How to
Adjust the Stowed Drive Speed
b
a
c
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
machine to tip over resulting in
death or serious injury.
On machines with software
revision B1 or lower, stowed drive
speeds in forward and reverse are
simultaneously adjusted, resulting
in both directions of travel
operating at the same speed.
On machines with software
revision C0 or higher, the stowed
forward drive speed and the
stowed reverse drive speed may
be adjusted independent of one
another. See 7-2, How to
Determine the Revision Level.
Models with software revision B1 or lower:
1 Pull out the red Emergency Stop button to the
on position at the platform controls.
d
a
b
c
d
Result: TUNE SPEEDS is showing in the diagnostic
display window. The ECM is now in
programming mode.
5 Press the lift function enable button.
6 Use the yellow platform down arrow to scroll to
max high speed drive.
Result: MAX HIGH SPEED DRIVE is showing in the
diagnostic display window.
7 Press the lift function enable button.
8 Press the yellow platform down button to
decrease the drive speed or press the blue
platform up button to increase the drive speed.
Refer to Section 2, Specifications.
The performance achieved should
always be within specifications.
2 Push in the red Emergency Stop button to the
off position at the ground controls.
3 Turn the key switch to ground control.
4 Press and hold both the blue platform up and
yellow platform down buttons. Pull out the red
Emergency Stop button to the on position at the
ground controls.
4 - 44
diagnostic display
blue platform up button
lift function enable button
yellow platform down button
9 Press the lift function enable button.
10 Push in the red Emergency Stop button to the
off position at the ground controls.
11 Check the stowed drive speed of the machine.
Refer to the Maintenance procedure B-10, Test
the Drive Speed - Stowed Position.
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 4 • Repair Procedures
REV B
GROUND CONTROLS
Models with software revision C0 or higher:
b
a
1 Pull out the red Emergency Stop button to the
on position at the platform controls.
c
2 Push in the red Emergency Stop button to the
off position at the ground controls.
d
3 Turn the key switch to ground control.
4 Press and hold both the blue platform up and
yellow platform down buttons. Pull out the red
Emergency Stop button to the on position at the
ground controls.
Result: TUNE SPEEDS is showing in the diagnostic
display window. The ECM is now in
programming mode.
diagnostic display
blue platform up button
lift function enable button
yellow platform down button
10 Press the lift function enable button.
11 Use the yellow platform down arrow to scroll to
max rev high speed drive.
Result: MAX REV HIGH SPEED DRIVE is showing in
the diagnostic display window.
5 Press the lift function enable button.
6 Use the yellow platform down arrow to scroll to
max fwd high speed drive.
Result: MAX FWD HIGH SPEED DRIVE is showing in
the diagnostic display window.
7 Press the lift function enable button.
8 Press the yellow platform down button to
decrease the drive speed or press the blue
platform up button to increase the drive speed.
Refer to Section 2, Specifications.
The performance achieved should
always be within specifications.
9 Press the lift function enable button.
Result: TUNE SPEEDS is showing in the diagnostic
display window. The ECM is now in
programming mode.
Part No. 52302
a
b
c
d
12 Press the lift function enable button.
13 Press the yellow platform down button to
decrease the drive speed or press the blue
platform up button to increase the drive speed.
Refer to Section 2, Specifications.
The performance achieved should
always be within specifications.
14 Press the lift function enable button.
15 Push in the red Emergency Stop button to the
off position at the ground controls.
16 Check the stowed drive speed of the machine.
Refer to the Maintenance procedure B-10, Test
the Drive Speed - Stowed Position.
GS-2668 RT • GS-3268 RT
4 - 45
Section 4 • Repair Procedures
March 2005
GROUND CONTROLS
REV B
How to Adjust the
High Torque Drive Speed
b
a
c
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
machine to tip over resulting in
death or serious injury.
On machines with software
revision B1 or lower, high torque
drive speeds in forward and
reverse are simultaneously
adjusted, resulting in both
directions of travel operating at the
same speed.
On machines with software
revision C0 or higher, the high
torque forward drive speed and
the high torque reverse drive
speed may be adjusted
independent of one another. See
7-2, How to Determine the
Revision Level.
d
a
b
c
d
diagnostic display
blue platform up button
lift function enable button
yellow platform down button
4 Press and hold both the blue platform up and
yellow platform down buttons. Pull out the red
Emergency Stop button to the on position at the
ground controls.
Result: TUNE SPEEDS is showing in the diagnostic
display window. The ECM is now in
programming mode.
5 Press the lift function enable button.
6 Use the yellow platform down arrow to scroll to
max high torque drive.
Result: MAX HIGH TORQUE DRIVE is showing in the
diagnostic display window.
Models with software revision B1 or lower:
7 Press the lift function enable button.
1 Pull out the red Emergency Stop button to the
on position at the platform controls.
8 Press the yellow platform down button to
decrease the drive speed or press the blue
platform up button to increase the drive speed.
Refer to Section 2, Specifications.
2 Push in the red Emergency Stop button to the
off position at the ground controls.
The performance achieved should
always be within specifications.
3 Turn the key switch to ground control.
9 Press the lift function enable button.
10 Push in the red Emergency Stop button to the
off position at the ground controls.
4 - 46
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 4 • Repair Procedures
REV B
GROUND CONTROLS
Models with software revision C0 or higher:
b
a
1 Pull out the red Emergency Stop button to the
on position at the platform controls.
c
2 Push in the red Emergency Stop button to the
off position at the ground controls.
d
3 Turn the key switch to ground control.
4 Press and hold both the blue platform up and
yellow platform down buttons. Pull out the red
Emergency Stop button to the on position at the
ground controls.
Result: TUNE SPEEDS is showing in the diagnostic
display window. The ECM is now in
programming mode.
5 Press the lift function enable button.
6 Use the yellow platform down arrow to scroll to
max fwd high torque drive.
Result: MAX FWD HIGH TORQUE DRIVE is showing in
the diagnostic display window.
7 Press the lift function enable button.
8 Press the yellow platform down button to
decrease the drive speed or press the blue
platform up button to increase the drive speed.
Refer to Section 2, Specifications.
The performance achieved should
always be within specifications.
a
b
c
d
diagnostic display
blue platform up button
lift function enable button
yellow platform down button
10 Press the lift function enable button.
11 Use the yellow platform down arrow to scroll to
max rev high speed drive.
Result: MAX REV HIGH TORQUE DRIVE is showing in
the diagnostic display window.
12 Press the lift function enable button.
13 Press the yellow platform down button to
decrease the drive speed or press the blue
platform up button to increase the drive speed.
Refer to Section 2, Specifications.
The performance achieved should
always be within specifications.
14 Press the lift function enable button.
15 Push in the red Emergency Stop button to the
off position at the ground controls.
9 Press the lift function enable button.
Result: TUNE SPEEDS is showing in the diagnostic
display window. The ECM is now in
programming mode.
Part No. 52302
GS-2668 RT • GS-3268 RT
4 - 47
Section 4 • Repair Procedures
March 2005
GROUND CONTROLS
REV B
How to
Adjust the Raised Drive Speed
b
a
c
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
machine to tip over resulting in
death or serious injury.
On machines with software
revision B1 or lower, raised drive
speeds in forward and reverse are
simultaneously adjusted, resulting
in both directions of travel
operating at the same speed.
On machines with software
revision C0 or higher, the raised
forward drive speed and the raised
reverse drive speed may be
adjusted independent of one
another. See 7-2, How to
Determine the Revision Level.
d
a
b
c
d
diagnostic display
blue platform up button
lift function enable button
yellow platform down button
5 Press the lift function enable button.
6 Use the yellow platform down arrow to scroll to
raised drive speed.
Result: MAX RAISED DRIVE SPEED is showing in the
diagnostic display window.
7 Press the lift function enable button.
8 Press the yellow platform down button to
decrease the raised drive speed or press the
blue platform up button to increase the raised
drive speed. Refer to Section 2, Specifications.
The performance achieved should
always be within specifications.
Models with software revision B1 or lower:
1 Pull out the red Emergency Stop button to the
on position at the platform controls.
9 Press the lift function enable button.
2 Push in the red Emergency Stop button to the
off position at the ground controls.
10 Push in the red Emergency Stop button to the
off position at the ground controls.
3 Turn the key switch to ground control.
11 Check the raised drive speed of the machine.
Refer to the Maintenance procedure B-11, Test
the Drive Speed - Raised Position.
4 Press and hold both the blue platform up and
yellow platform down buttons. Pull out the red
Emergency Stop button to the on position at the
ground controls.
Result: TUNE SPEEDS is showing in the diagnostic
display window. The ECM is now in
programming mode.
4 - 48
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 4 • Repair Procedures
REV B
GROUND CONTROLS
Models with software revision C0 or higher:
b
a
1 Pull out the red Emergency Stop button to the
on position at the platform controls.
c
2 Push in the red Emergency Stop button to the
off position at the ground controls.
d
3 Turn the key switch to ground control.
4 Press and hold both the blue platform up and
yellow platform down buttons. Pull out the red
Emergency Stop button to the on position at the
ground controls.
Result: TUNE SPEEDS is showing in the diagnostic
display window. The ECM is now in
programming mode.
diagnostic display
blue platform up button
lift function enable button
yellow platform down button
10 Press the lift function enable button.
11 Use the yellow platform down arrow to scroll to
max rev high speed drive.
Result: MAX REV RAISED DRIVE SPEED is showing in
the diagnostic display window.
5 Press the lift function enable button.
6 Use the yellow platform down arrow to scroll to
max fwd high torque drive.
Result: MAX FWD RAISED DRIVE SPEED is showing in
the diagnostic display window.
7 Press the lift function enable button.
8 Press the yellow platform down button to
decrease the drive speed or press the blue
platform up button to increase the drive speed.
Refer to Section 2, Specifications.
The performance achieved should
always be within specifications.
9 Press the lift function enable button.
Result: TUNE SPEEDS is showing in the diagnostic
display window. The ECM is now in
programming mode.
Part No. 52302
a
b
c
d
12 Press the lift function enable button.
13 Press the yellow platform down button to
decrease the drive speed or press the blue
platform up button to increase the drive speed.
Refer to Section 2, Specifications.
The performance achieved should
always be within specifications.
14 Press the lift function enable button.
15 Push in the red Emergency Stop button to the
off position at the ground controls.
16 Check the raised drive speed of the machine.
Refer to the Maintenance procedure B-11, Test
the Drive Speed - Raised Position.
GS-2668 RT • GS-3268 RT
4 - 49
Section 4 • Repair Procedures
March 2005
REV B
GROUND CONTROLS
How to
Adjust the Lift Speed
b
a
c
1 Pull out the red Emergency Stop button to the
on position at the platform controls.
d
2 Push in the red Emergency Stop button to the
off position at the ground controls.
a
b
c
d
3 Turn the key switch to ground control.
4 Press and hold both the blue platform up and
yellow platform down buttons. Pull out the red
Emergency Stop button to the on position at the
ground controls.
Result: TUNE SPEEDS is showing in the diagnostic
display window. The ECM is now in
programming mode.
8 Press the yellow platform down button to
decrease the maximum lift speed or press the
blue platform up button to increase the
maximum lift speed. Refer to Section 2,
Specifications.
The performance achieved should
always be within specifications.
5 Press the lift function enable button.
6 Use the yellow platform down arrow to scroll to
lift speed.
Result: MAX LIFT SPEED is showing in the
diagnostic display window.
7 Press the lift function enable button.
4 - 50
diagnostic display
blue platform up button
lift function enable button
yellow platform down button
9 Press the lift function enable button.
10 Push in the red Emergency Stop button to the
off position at the ground controls.
11 Check the lift speed of the machine. Refer to
Section 2, Specifications.
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 4 • Repair Procedures
REV B
GROUND CONTROLS
7-3
Software Configuration
(after serial number GS6803-42381)
Machine Option Definitions
How to Configure the Software
Descent Delay: This option halts descent at
approximately 12 feet / 3.6 m. All controls must
be released for 4 to 6 seconds before descent
is re-enabled. Required for Europe.
The Electronic Control Module (ECM) contains
programming for all configurations of the GS-68.
Models after serial number GS6803-42381 can be
adjusted to a different configuration using the
buttons at the ground controls.
Lift/Drive Cut Out: Lift and drive functions are
disabled when the down limit switch is
activated and the machine is on a slope
exceeding the rating on the serial plate.
Activated for all machines.
ANSI and CSA models:
Motion Alarm: The motion alarm will sound
when activating a function.
1 Pull out the red Emergency Stop button to the
on position at the platform controls.
Motion Beacons: The flashing beacons
operate only when activating a function.
2 Push in the red Emergency Stop button to the
off position at the ground controls.
3 Turn the key switch to ground control.
4 Press and hold both the blue platform up and
yellow platform down buttons. Pull out the red
Emergency Stop button to the on position at the
ground controls.
Result: TUNE SPEEDS is showing in the diagnostic
display window.
b
a
c
d
a
b
c
d
Part No. 52302
Overload: This cuts out all functions when the
platform overload pressure switch is tripped.
The red Emergency Stop button must be
cycled before any function can be resumed.
Required for Europe.
Sim Operation: When enabled, this allows
some machine functions to be activated
simultaneously. Required to be disabled for
European models.
Beacons: When installed on the machine, the
flashing beacons operate continuously when
the key switch is turned to ground or platform
controls and both red Emergency Stop buttons
are pulled out to the on position.
diagnostic display
blue platform up button
lift function enable button
yellow platform down button
GS-2668 RT • GS-3268 RT
4 - 51
Section 4 • Repair Procedures
March 2005
REV B
GROUND CONTROLS
5 Use the yellow platform down arrow to scroll to
select options.
9 Press the lift function enable button to activate
or deactivate the motion beacons option.
Result: SELECT OPTIONS is showing in the
diagnostic display window. The ECM is now in
programming mode.
6 Press the lift function enable button.
Result: DESCENT DELAY is showing in the
diagnostic display window. Press the lift
function enable button to activate or deactivate
the descent delay option OR use the yellow
platform down arrow to scroll to lift/drive cutout.
Result: LFT/DRV CUTOUT ON is showing in the
diagnostic display window.
Result: LFT/DRV CUTOUT OFF is showing in the
diagnostic display window. Press the lift
function enable button to activate the lift/drive
cutout option.
The lift/drive cutout option should
be activated or in the ON position.
7 Use the yellow platform down arrow to scroll to
motion alarm.
Result: MOTION ALARM is showing in the
diagnostic display window.
8 Press the lift function enable button to activate
or deactivate the motion alarm option OR use
the yellow platform down arrow to scroll to
motion beacons.
Result: MOTION BEACONS is showing in the
diagnostic display window.
4 - 52
For this option to function
correctly, the machine must be
equipped with flashing beacons.
10 Models with platform overload (option): Use
the yellow platform down arrow to scroll to
overload.
Result: OVERLOAD ON is showing in the diagnostic
display window.
Result: OVERLOAD OFF is showing in the
diagnostic display window. Press the lift
function enable button to activate the overload
option.
11 Use the yellow platform down arrow to scroll to
sim operation.
Result: SIM OPERATION ON is showing in the
diagnostic display window.
Result: SIM OPERATION OFF is showing in the
diagnostic display window. Press the lift
function enable button to activate the sim
operation option.
For all models except CE, the sim
operation option should be
activated or in the ON position.
12 Use the yellow platform down arrow to scroll to
return to the main menu.
Result: RETURN TO MAIN MENU is showing in the
diagnostic display window.
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 4 • Repair Procedures
REV B
GROUND CONTROLS
5 Use the yellow platform down arrow to scroll to
select options.
13 Press the lift function enable button.
Result: SELECT OPTIONS is showing in the
diagnostic display window.
Result: SELECT OPTIONS is showing in the
diagnostic display window. The ECM is now in
programming mode.
14 Push in the red Emergency Stop button to the
off position at the ground controls.
6 Press the lift function enable button.
CE models:
Result: DESCENT DELAY ON is showing in the
diagnostic display window.
1 Pull out the red Emergency Stop button to the
on position at the platform controls.
Result: DESCENT DELAY OFF is showing in the
diagnostic display window. Press the lift
function enable button to activate the descent
delay option.
2 Push in the red Emergency Stop button to the
off position at the ground controls.
3 Turn the key switch to ground control.
4 Press and hold both the blue platform up and
yellow platform down buttons. Pull out the red
Emergency Stop button to the on position at the
ground controls.
Result: TUNE SPEEDS is showing in the diagnostic
display window.
For CE models, the descent delay
option should be activated or in
the ON position.
7 Use the yellow platform down arrow to scroll to
lift/drive cutout.
Result: LFT/DRV CUTOUT ON is showing in the
diagnostic display window.
b
a
c
Result: LFT/DRV CUTOUT OFF is showing in the
diagnostic display window. Press the lift
function enable button to activate the lift/drive
cutout option.
d
a
b
c
d
diagnostic display
blue platform up button
lift function enable button
yellow platform down button
The lift/drive cutout option should
be activated or in the ON position.
8 Use the yellow platform down arrow to scroll to
motion alarm.
Result: MOTION ALARM is showing in the
diagnostic display window.
Part No. 52302
GS-2668 RT • GS-3268 RT
4 - 53
Section 4 • Repair Procedures
March 2005
REV B
GROUND CONTROLS
9 Press the lift function enable button to activate
or deactivate the motion alarm option OR use
the yellow platform down arrow to scroll to
motion beacons.
Result: MOTION BEACONS is showing in the
diagnostic display window.
10 Press the lift function enable button to activate
or deactivate the motion beacons option OR
use the yellow platform down arrow to scroll to
overload.
12 Use the yellow platform down arrow to scroll to
return to the main menu.
Result: RETURN TO MAIN MENU is showing in the
diagnostic display window.
13 Press the lift function enable button.
Result: SELECT OPTIONS is showing in the
diagnostic display window.
14 Push in the red Emergency Stop button to the
off position at the ground controls.
For this option to function
correctly, the machine must be
equipped with flashing beacons.
Result: OVERLOAD ON is showing in the diagnostic
display window.
Result: OVERLOAD OFF is showing in the
diagnostic display window. Press the lift
function enable button to activate the overload
option.
For CE models, the overload
option should be activated or in
the ON position.
11 Use the yellow platform down arrow to scroll to
sim operation.
Result: SIM OPERATION OFF is showing in the
diagnostic display window.
Result: SIM OPERATION ON is showing in the
diagnostic display window. Press the lift
function enable button to deactivate the sim
operation option.
For CE models, the sim operation
option should be deactivated or in
the OFF position.
4 - 54
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 4 • Repair Procedures
REV B
GROUND CONTROLS
7-4
Level Sensor Models without Outriggers
(before serial number 41754)
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 2° to the side, 3° to the front or 5°
to the rear.
How to Install and Calibrate the
Level Sensor
Tip-over hazard. Failure to install
or calibrate the level sensor as
instructed could result in the
machine tipping over causing
death or serious injury. Do not
install or calibrate the level sensor
other than specified in this
procedure.
Perform this procedure with the
machine on a firm, level surface
that is free of obstructions. Use a
digital level to confirm.
1 Remove the platform controls from the platform.
5 Place a 1.27 x 10 x 10 inch / 3.23 x 25 x 25 cm
thick steel block under both wheels at the steer
end of the machine.
6 Lower the machine onto the blocks.
7 Turn the key switch to platform control and pull
out the red Emergency Stop buttons to the on
position at both the ground and platform
controls.
8 Before serial number 41137: Raise the
platform at least 12 feet / 3.6 m.
Result - ANSI and CSA models: The tilt alarm
will sound at 180 beeps per minute.
Result - CE and Australian models: The drive
function and the lift function will not operate and
the tilt alarm will sound at 180 beeps per
minute.
After serial number 41136: Raise the platform
at least 12 feet / 3.6 m.
Result - The drive function and the lift function
will not operate and the tilt alarm will sound at
180 beeps per minute.
If you are not installing a new level sensor,
proceed to step 21.
9 Push in the red Emergency Stop button to the
off position at the platform controls.
Before serial number 41200:
2 Block the wheels at the non-steer end of the
machine.
10 Remove the ground control panel retaining
fasteners and open the panel. Locate the level
sensor behind the ground control panel.
3 Center a lifting jack under the drive chassis at
the steer end of the machine.
After serial number 41199:
4 Raise the machine approximately
4 inches / 10 cm.
11 Lift the safety arm, move to the center of the
scissor arm and rotate to a vertical position.
12 Lower the platform onto the safety arm.
Crushing hazard. Keep hands
clear of the safety arm when
lowering the platform.
Part No. 52302
GS-2668 RT • GS-3268 RT
4 - 55
Section 4 • Repair Procedures
March 2005
GROUND CONTROLS
REV B
13 Locate the level sensor enclosure on the
chassis under the limit switches at the steer
end of the machine. Remove the enclosure
cover retaining fasteners and the cover.
a
b
c
d
MODELS
WITHOUT
OUTRIGGERS
a
d
Y
b
c
X
BEFORE
SERIAL NUMBER
41200
Level sensor - models without outriggers
a
b
c
d
Level sensor (after serial number 41199)
a
b
c
d
level sensor
max height limit switch (CE models)
down limit switch
load sense delay limit switch (CE models)
All models:
chassis
level sensor
"X" indicator
"Y" indicator
d
a
Y
14 Tag and disconnect the wire harness from the
level sensor.
X
b
15 Remove the fasteners securing the level sensor
to the chassis. Remove the level sensor from
the machine.
16 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.
Tip-over hazard. The tilt level
sensor must be installed with the
"Y" on the level sensor base
closest to the steer end of the
machine. Failure to install the tilt
level sensor as instructed will
cause the machine to tip over
resulting in death or serious injury.
4 - 56
c
GS-2668 RT • GS-3268 RT
MODELS
WITHOUT
OUTRIGGERS
AFTER
SERIAL NUMBER
41199
Part No. 52302
March 2005
Section 4 • Repair Procedures
REV B
GROUND CONTROLS
17 Connect the wire harness to the level sensor.
18 Pull out the red Emergency Stop button to the
on position at the platform controls.
19 Tighten the level sensor adjusting fasteners
until the bubble in the top of the level sensor is
centered in the circles.
Be sure there are threads showing
through the top of the adjusting
fasteners.
Result: The tilt sensor alarm should not sound.
20 After serial number 41199: Raise the platform
and rotate the safety arm to the stowed
position.
21 Lower the platform to the stowed position.
22 Raise the machine slightly.
23 Remove the blocks from under both wheels.
24 Lower the machine and remove the jack.
25 Remove the blocks from the wheels at the
non-steer end of the machine.
31 Before serial number 41137: Raise the
platform at least 12 feet / 3.6 m.
Result - ANSI and CSA models: The tilt alarm
will sound at 180 beeps per minute.
Result - CE and Australian models: The drive
function and the lift function will not operate and
the tilt alarm will sound at 180 beeps per
minute.
Result: If the tilt sensor alarm does not sound,
adjust the tilt level sensor until the alarm just
begins to sound OR the down limit switch may
need to be adjusted.
After serial number 41136: Raise the platform
at least 12 feet / 3.6 m.
Result - The drive function and the lift function
will not operate and the tilt alarm will sound at
180 beeps per minute.
Result: If the tilt sensor alarm does not sound,
adjust the tilt level sensor until the alarm just
begins to sound OR the down limit switch may
need to be adjusted.
26 Block the wheels at the steer end of the
machine.
32 Lower the platform to the stowed position.
27 Center a lifting jack under the drive chassis at
the non-steer end of the machine.
34 Remove the blocks from under both wheels.
35 Lower the machine and remove the jack.
28 Raise the machine approximately
12 inches / 0.3 m.
29 Place a 6.64 x 10 x 10 inch / 16.87 x 25 x 25 cm
thick steel block under both wheels at the
non-steer end of the machine.
30 Lower the machine onto the blocks.
Part No. 52302
33 Raise the machine slightly.
36 Remove the blocks from the wheels at the steer
end of the machine.
37 Center a lifting jack under the drive chassis at
the ground controls side of the machine.
38 Raise the machine approximately
4 inches / 10 cm.
GS-2668 RT • GS-3268 RT
4 - 57
Section 4 • Repair Procedures
March 2005
REV B
GROUND CONTROLS
39 Models with RT tires: Place a
1.85 x 10 x 10 inch / 4.7 x 25 x 25 cm thick
steel block under both wheels at the ground
controls side of the machine.
Models with non-marking tires: Place a
1.94 x 10 x 10 inch / 4.93 x 25 x 25 cm thick
steel block under both wheels at the ground
controls side of the machine.
Models with industrial tires: Place a
1.95 x 10 x 10 inch / 4.95 x 25 x 25 cm thick
steel block under both wheels at the ground
controls side of the machine.
40 Lower the machine onto the blocks.
41 Before serial number 41137: Raise the
platform at least 12 feet / 3.6 m.
Result: The tilt alarm does not sound and all
functions will operate. Proceed to step 43.
Result - ANSI and CSA models: The tilt alarm
sounds at 180 beeps per minute. Proceed to
step 42.
Result - CE and Australian models: The drive
function and the lift function will not operate and
the tilt alarm sounds at 180 beeps per minute.
Proceed to step 42.
42 Turn the level sensor adjusting nuts just until
the level sensor alarm does not sound.
43 Lower the platform to the stowed position.
44 Raise the machine slightly.
45 Remove the blocks from under both wheels.
46 Lower the machine and remove the jack.
47 Center a lifting jack under the drive chassis at
the engine side of the machine.
48 Raise the machine approximately
4 inches / 10 cm.
49 Models with RT tires: Place a
2.15 x 10 x 10 inch / 5.46 x 25 x 25 cm thick
steel block under both wheels at the ground
controls side of the machine.
All other models: Place a
2.25 x 10 x 10 inch / 5.72 x 25 x 25 cm thick
steel block under both wheels at the ground
controls side of the machine.
50 Lower the machine onto the blocks.
After serial number 41136: Raise the platform
at least 12 feet / 3.6 m.
Result: The tilt alarm does not sound and all
functions will operate. Proceed to step 43.
Result - The drive function and the lift function
will not operate and the tilt alarm sounds at 180
beeps per minute. Proceed to step 42.
4 - 58
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 4 • Repair Procedures
REV B
GROUND CONTROLS
51 Before serial number 41137: Raise the
platform at least 12 feet / 3.6 m.
Result - ANSI and CSA models: The tilt alarm
will sound at 180 beeps per minute.
52 Lower the platform to the stowed position.
53 Push in the red Emergency Stop button to the
off position at both the ground and platform
controls.
Result - CE and Australian models: The drive
function and the lift function will not operate and
the tilt alarm will sound at 180 beeps per
minute.
54 Turn the key switch to the off position.
Result: If the tilt sensor alarm does not sound,
adjust the tilt level sensor until the alarm just
begins to sound OR the down limit switch may
need to be adjusted.
57 Lower the machine and remove the jack.
After serial number 41136: Raise the platform
at least 12 feet / 3.6 m.
Result - The drive function and the lift function
will not operate and the tilt alarm will sound at
180 beeps per minute.
55 Raise the machine slightly.
56 Remove the blocks from under both wheels.
58 Before serial number 41200: Close the ground
control panel. Install and securely tighten the
retaining fasteners. Do not over tighten.
After serial number 41199: Install the cover
onto the level sensor enclosure. Install and
securely tighten the retaining fasteners. Do not
over tighten.
Result: If the tilt sensor alarm does not sound,
adjust the tilt level sensor until the alarm just
begins to sound OR the down limit switch may
need to be adjusted.
Part No. 52302
GS-2668 RT • GS-3268 RT
4 - 59
Section 4 • Repair Procedures
March 2005
REV B
GROUND CONTROLS
7-5
Level Sensor Models without Outriggers
(after serial number 41753)
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.
4 Lower the platform onto the safety arm.
Crushing hazard. Keep hands
clear of the safety arm when
lowering the platform.
5 Locate the level sensor enclosure on the
chassis under the limit switches at the steer
end of the machine. Remove the enclosure
cover retaining fasteners and the cover.
a
b
c
d
The tilt alarm sounds when the incline of the
chassis exceeds 2° to the side and 3° to the front
or rear.
How to Install and Calibrate the
Level Sensor
Tip-over hazard. Failure to install
or calibrate the level sensor as
instructed could result in the
machine tipping over causing
death or serious injury. Do not
install or calibrate the level sensor
other than specified in this
procedure.
Perform this procedure with the
machine on a firm, level surface
that is free of obstructions. Use a
digital level to confirm.
Level sensor (after serial number 41199)
a
b
c
d
1 Remove the platform controls from the platform.
If you are not installing a new level sensor,
proceed to step 13.
2 Raise the platform approximately 10 feet / 3 m.
3 Lift the safety arm, move to the center of the
scissor arm and rotate to a vertical position.
4 - 60
level sensor
max height limit switch (CE models)
down limit switch
load sense delay limit switch (CE models)
6 Tag and disconnect the wire harness from the
level sensor.
7 Remove the fasteners securing the level sensor
to the chassis. Remove the level sensor from
the machine.
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 4 • Repair Procedures
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.
Tip-over hazard. The tilt level
sensor must be installed with the
"Y" on the level sensor base
closest to the steer end of the
machine. Failure to install the tilt
level sensor as instructed will
cause the machine to tip over
resulting in death or serious injury.
d
a
Y
c
X
b
MODELS
WITHOUT
OUTRIGGERS
9 Connect the wire harness to the level sensor.
10 Turn the key switch to platform control and pull
out the red Emergency Stop buttons to the on
position at both the ground and platform
controls.
11 Tighten the level sensor adjusting fasteners
until the bubble in the top of the level sensor is
centered in the circles.
Level sensor - models without outriggers
Be sure there are threads showing
through the top of the adjusting
fasteners.
a
b
c
d
Result: The tilt sensor alarm should not sound.
12 Raise the platform and rotate the safety arm to
the stowed position.
13 Lower the platform to the stowed position.
14 Center a lifting jack under the drive chassis at
the ground controls side of the machine.
15 Raise the machine approximately
4 inches / 10 cm.
Part No. 52302
chassis
level sensor
"X" indicator
"Y" indicator
16 Models with RT tires: Place a
1.85 x 10 x 10 inch / 4.7 x 25 x 25 cm thick
steel block under both wheels at the ground
controls side of the machine.
Models with non-marking tires: Place a
1.94 x 10 x 10 inch / 4.93 x 25 x 25 cm thick
steel block under both wheels at the ground
controls side of the machine.
17 Lower the machine onto the blocks.
GS-2668 RT • GS-3268 RT
4 - 61
Section 4 • Repair Procedures
March 2005
REV B
GROUND CONTROLS
18 Raise the platform at least 12 feet / 3.6 m.
Result: The tilt alarm does not sound and all
functions will operate. Proceed to step 20.
Result - The drive function and the lift function
will not operate and the tilt alarm will sound at
180 beeps per minute. Proceed to step 19.
19 Turn the level sensor adjusting nuts just until
the level sensor alarm does not sound.
20 Lower the platform to the stowed position.
28 Raise the platform at least 12 feet / 3.6 m.
Result - The drive function and the lift function
will not operate and the tilt alarm will sound at
180 beeps per minute.
Result: If the tilt sensor alarm does not sound,
adjust the tilt level sensor until the alarm just
begins to sound OR the down limit switch may
need to be adjusted.
29 Lower the platform to the stowed position.
22 Remove the blocks from under both wheels.
30 Push in the red Emergency Stop button to the
off position at both the ground and platform
controls.
23 Lower the machine and remove the jack.
31 Turn the key switch to the off position.
24 Center a lifting jack under the drive chassis at
the engine side of the machine.
32 Raise the machine slightly.
21 Raise the machine slightly.
25 Raise the machine approximately
4 inches / 10 cm.
33 Remove the blocks from under both wheels.
34 Lower the machine and remove the jack.
26 Models with RT tires: Place a
2.15 x 10 x 10 inch / 5.46 x 25 x 25 cm thick
steel block under both wheels at the ground
controls side of the machine.
Models with non-marking tires: Place a
2.25 x 10 x 10 inch / 5.72 x 25 x 25 cm thick
steel block under both wheels at the ground
controls side of the machine.
35 Install the cover onto the level sensor
enclosure. Install and securely tighten the
retaining fasteners. Do not over tighten.
27 Lower the machine onto the blocks.
4 - 62
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 4 • Repair Procedures
REV B
GROUND CONTROLS
After serial number 41199:
7-6
Level Sensor Models with Outriggers
3 Raise the platform approximately 10 feet / 3 m.
4 Lift the safety arm, move to the center of the
scissor arm and rotate to a vertical position.
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.
When the outriggers are stowed, the tilt alarm
sounds when the incline of the chassis exceeds 2°
to the side.
When the outriggers are deployed, the tilt alarm
sounds when the incline of the chassis exceeds
0.8° to the side.
5 Lower the platform onto the safety arm.
Crushing hazard. Keep hands
clear of the safety arm when
lowering the platform.
6 Locate the level sensor enclosure on the
chassis under the limit switches at the steer
end of the machine. Remove the enclosure
cover retaining fasteners and the cover.
a
b
c
d
At all times, the tilt alarm sounds when the incline
of the chassis exceeds 3° to the front or rear.
How to Install and Calibrate the
Level Sensor
Tip-over hazard. Failure to install
or calibrate the level sensor as
instructed could result in the
machine tipping over causing
death or serious injury. Do not
install or calibrate the level sensor
other than specified in this
procedure.
Perform this procedure with the
machine on a firm, level surface
that is free of obstructions. Use a
digital level to confirm.
1 Remove the platform controls from the platform.
Level sensor (after serial number 41199)
If you are not installing a new level sensor,
proceed to step 8.
a
b
c
d
2 Before serial number 41200: Remove the
ground control panel retaining fasteners and
open the panel. Locate the level sensor behind
the ground control panel.
Part No. 52302
GS-2668 RT • GS-3268 RT
level sensor
max height limit switch (CE models)
down limit switch
load sense delay limit switch (CE models)
4 - 63
Section 4 • Repair Procedures
March 2005
REV B
GROUND CONTROLS
Install the level sensor:
7 Tag and disconnect the wire harness from the
level sensor.
8 Remove the fasteners securing the level sensor
to the chassis. Remove the level sensor from
the machine.
9 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.
Tip-over hazard. The tilt level
sensor must be installed with the
"X" on the level sensor base
closest to the steer end of the
machine. Failure to install the tilt
level sensor as instructed could
result in the machine tipping over
causing death or serious injury.
MODELS
WITH
OUTRIGGERS
d
a
X
c
b
Y
BEFORE
SERIAL NUMBER
41200
10 Connect the wire harness to the level sensor.
Level sensor - models without outriggers
11 Turn the key switch to platform control and pull
out the red Emergency Stop buttons to the on
position at both the ground and platform
controls.
a
b
c
d
chassis
level sensor
"Y" indicator
"X" indicator
12 Set a multimeter to read DC voltage.
d
Adjust the side-to-side axis:
X
13 Without disconnecting the wire harness from
the level sensor, connect the negative lead of
the multimeter to the black wire at the level
sensor.
14 Without disconnecting the wire harness from
the level sensor, connect the positive lead of
the multimeter to the yellow wire at the level
sensor.
a
b
Y
c
MODELS
WITH
OUTRIGGERS
AFTER
SERIAL NUMBER
41199
4 - 64
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 4 • Repair Procedures
REV B
GROUND CONTROLS
15 Adjust the "Y" axis (side-to-side) to 2.5V DC.
Tap the top of the level sensor lightly with
fingers after each turn of an adjusting nut.
Tip-over hazard. Do not adjust the
potentiometers on the bottom of
the level sensor or calibrate the
level sensor other than specified in
this procedure. Failure to calibrate
the tilt level sensor as instructed
will cause the machine to tip over
resulting in death or serious injury.
Be sure there are threads showing
through the top of each adjusting
nut.
16 Disconnect the positive lead.
Adjust the front-to-back axis:
17 Without disconnecting the wire harness from
the level sensor, connect the positive lead of
the multimeter to the blue wire at the level
sensor.
18 Adjust the "X" axis (front-to-back) to 2.43V DC.
Tap the top of the level sensor lightly with
fingers after each turn of an adjusting nut.
19 Disconnect the positive and negative leads.
20 Apply Sentry Seal to the adjusting nuts.
21 Push in the red Emergency Stop button to the
off position at the platform controls.
22 Before serial number GS6803-42382: Press
and hold the outrigger enable button and press
and hold the auto level button and pull out the
red Emergency Stop button to the on position at
the platform controls. Continue to hold the
outrigger enable button and the auto level
button for approximately 3 seconds or until a
beep is heard. Release the buttons.
After serial number GS6803-42381: Press
and hold the auto level button and press and
hold the left front outrigger button. Pull out the
red Emergency Stop button to the on position at
the platform controls. Continue to hold the auto
level button and left front outrigger button for
approximately 3 seconds or until a beep is
heard. Release the buttons.
23 Push in the red Emergency Stop button to the
off position at the platform controls.
Tip-over hazard. Do not adjust the
potentiometers on the bottom of
the level sensor or calibrate the
level sensor other than specified in
this procedure. Failure to calibrate
the tilt level sensor as instructed
will cause the machine to tip over
resulting in death or serious injury.
Be sure there are threads showing
through the top of each adjusting
nut.
Part No. 52302
GS-2668 RT • GS-3268 RT
4 - 65
Section 4 • Repair Procedures
March 2005
REV B
GROUND CONTROLS
Confirm the side-to-side level sensor setting:
32 Lower the machine and remove the jack.
24 Center a lifting jack under the drive chassis at
the ground control side of the machine.
33 Center a lifting jack under the drive chassis at
the tank side of the machine.
25 Raise the machine approximately
6 inches / 15 cm.
34 Raise the machine approximately
6 inches / 15 cm.
26 Models with RT tires: Place a
2.15 x 10 x 10 inch / 5.46 x 25 x 25 cm thick
steel block under both wheels at the ground
controls side of the machine.
All other models: Place a
2.25 x 10 x 10 inch / 5.72 x 25 x 25 cm thick
steel block under both wheels at the ground
controls side of the machine.
35 Models with RT tires: Place a
2.15 x 10 x 10 inch / 5.46 x 25 x 25 cm thick
steel block under both wheels at the ground
controls side of the machine.
All other models: Place a
2.25 x 10 x 10 inch / 5.72 x 25 x 25 cm thick
steel block under both wheels at the ground
controls side of the machine.
27 Lower the machine onto the blocks.
36 Lower the machine onto the blocks.
28 Pull out the red Emergency Stop button to the
on position at platform controls. Start the
engine.
37 Raise the platform at least 12 feet / 3.6 m.
29 Raise the platform at least 12 feet / 3.6 m.
Result: The platform stops raising and the tilt
alarm will sound at 180 beeps per minute.
Result: The platform does not stop raising and
the tilt alarm does not sound. The level sensor
must be replaced. Repeat this procedure
beginning with step 2.
For reference only, the output of
the level sensor should be
approximately 1.7V DC. To
confirm, connect the positive lead
of a multimeter to the yellow wire
at the level sensor, and the
negative lead to the black wire.
Result: The platform does not stop raising and
the tilt alarm does not sound. The level sensor
must be replaced. Repeat this procedure
beginning with step 2.
For reference only, the output of
the level sensor should be
approximately 3.3V DC. To
confirm, connect the positive lead
of a multimeter to the yellow wire
at the level sensor, and the
negative lead to the black wire.
38 Lower the platform to the stowed position.
39 Raise the machine slightly.
40 Remove the blocks from under both wheels.
30 Raise the machine slightly.
31 Remove the blocks from under both wheels.
4 - 66
Result: The platform stops raising and the tilt
alarm will sound at 180 beeps per minute.
41 Lower the machine and remove the jack.
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 4 • Repair Procedures
REV B
GROUND CONTROLS
Confirm the front-to-back level sensor setting:
42 Center a lifting jack under the drive chassis at
the steer end of the machine.
43 Raise the machine approximately
6 inches / 15 cm.
44 Place a 4.08 x 10 x 10 inch / 10.36 x 25 x 25 cm
thick steel block under both wheels at the steer
end of the machine.
45 Lower the machine onto the blocks.
46 Raise the platform at least 12 feet / 3.6 m.
Result: The platform stops raising and the tilt
alarm will sound at 180 beeps per minute.
52 Raise the machine approximately
6 inches / 15 cm.
53 Place a 4.08 x 10 x 10 inch / 10.36 x 25 x 25 cm
thick steel block under both wheels at the
non-steer end of the machine.
54 Lower the machine onto the blocks.
55 Raise the platform at least 12 feet / 3.6 m.
Result: The platform stops raising and the tilt
alarm will sound at 180 beeps per minute.
Result: The platform does not stop raising and
the tilt alarm does not sound. The level sensor
must be replaced. Repeat this procedure
beginning with step 2.
Result: The platform does not stop raising and
the tilt alarm does not sound. The level sensor
must be replaced. Repeat this procedure
beginning with step 2.
For reference only, the output of
the level sensor should be
approximately 1.5V DC. To
confirm, connect the positive lead
of a multimeter to the blue wire at
the level sensor, and the negative
lead to the black wire.
47 Lower the platform to the stowed position.
48 Raise the machine slightly.
For reference only, the output of
the level sensor should be
approximately 3.4V DC. To
confirm, connect the positive lead
of a multimeter to the blue wire at
the level sensor, and the negative
lead to the black wire.
56 Lower the platform to the stowed position.
57 Raise the machine slightly.
58 Remove the blocks from under both wheels.
59 Lower the machine and remove the jack.
60 Turn the key switch to the off position.
49 Remove the blocks from under both wheels.
50 Lower the machine and remove the jack.
51 Center a lifting jack under the drive chassis at
the non-steer end of the machine.
Part No. 52302
GS-2668 RT • GS-3268 RT
4 - 67
Section 4 • Repair Procedures
March 2005
Hydraulic Pump
REV A
8-1
Hydraulic Pump
2 Connect a 0 to 5000 psi / 0 to 350 bar pressure
gauge to the high pressure port on each section
of the pump.
The hydraulic pump is a 2-section, gear-type
pump. Pump number 1 is the pump section which
is closer to the engine and pump number 2 is the
pump section that is farther from the engine. Each
section of the pump has its own relief valve in the
function manifold.
3 Gasoline/LPG models: Disconnect the ignition
coil wire from the center of the ignition coil.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose must be replaced and
then torqued to specification
during installation. Refer to
Section Two, Hydraulic Hose and
Fitting Torque Specifications.
How to Test the Hydraulic Pump
1 Tag, disconnect and plug the high pressure
hydraulic hoses from both sections of the
hydraulic pump.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
4 - 68
Diesel models: Hold the manual fuel shutoff
lever clockwise in the closed position.
4 Turn the key switch to ground control and pull
out the red Emergency Stop button to the on
position at both the ground and platform
controls.
5 Observe the pressure gauge while cranking the
engine. Immediately stop if the pressure
reaches or exceeds 3000 psi / 206 bar in either
one of the gauges.
Result: If both of the pressure gauges read
3000 psi / 206 bar, immediately stop. The pump
is good.
Result: If pressure fails to reach
3000 psi / 206 bar in one or both sections of the
pump, one of the pump sections or the pump
coupling is bad and will need to be serviced or
replaced.
6 Remove the pressure gauges and connect the
hydraulic hoses.
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 4 • Repair Procedures
REV A
HYDRAULIC PUMP
How to Remove the
Hydraulic Pump
How to Prime the Pump
Component damage hazard. Be
sure that the hydraulic tank shutoff
valves (if equipped) are in the
open position before priming the
pump. The engine must not be
started with the hydraulic tank
shutoff valves in the closed
position or component damage will
occur.
1 Tag, disconnect and plug the hydraulic hoses
on the pump.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
2 Remove the pump mounting bolts. Carefully
remove the pump.
After replacing the hydraulic
pump, it is critical to return the lift
speed and raised drive speed
settings to original factory
specifications. Refer to
Maintenance Procedure B-11 Test
the Drive Speed - Raised Position
to check the speeds, and see
Repair Procedure 1-3 Controller
Adjustments to correct the raised
drive speed percentage settings.
1 Connect a 0 to 600 psi / 0 to 50 bar pressure
gauge to either diagnostic test port on the
function manifold.
2 Turn the key switch to ground controls and pull
out the red Emergency Stop buttons to the on
position at both the ground and platform
controls.
3 Gasoline/LPG models: Close the valve on the
LPG tank, then disconnect the hose from the
tank (if equipped). Move the fuel select toggle
switch at the ground controls to the LPG
position.
Diesel models: Disconnect the wiring from the
fuel shutoff solenoid.
4 Crank the engine with the starter motor for
15 seconds, wait 15 seconds, then crank the
engine an additional 15 seconds or until the
pressure reaches 300 psi / 20.7 bar.
5 Gasoline/LPG models: Connect the hose to
the LPG tank and open the valve (if equipped).
Move the fuel select toggle switch at the ground
controls to the gasoline position.
Diesel models: Connect the wiring to the fuel
shutoff solenoid.
6 Start the engine from the ground controls and
check for hydraulic leaks.
Part No. 52302
GS-2668 RT • GS-3268 RT
4 - 69
Section 4 • Repair Procedures
March 2005
Manifolds
REV B
9-1
Function Manifold Components
The function manifold is located inside the hydraulic tray.
Index
No.
Description
Schematic
Item
Function
Torque
1
DO3 valve, 3 position 4 way ................ A ......... Controls flow to the steer end
ground controls side drive motor
and the non-steer end engine side
drive motor in forward and reverse ....... 30-35 in-lbs / 3-4 Nm
2
DO3 valve, 3 position 4 way ................ B ......... Controls flow to the steer end
engine side drive motor and
the non-steer end ground
controls side drive motor in
forward and reverse .............................. 30-35 in-lbs / 3-4 Nm
3
Check valve ......................................... C ......... Drive speed select circuit .................. 25-30 ft-lbs / 34-41 Nm
4
Check valve ......................................... D ......... Prevents engine from running
backwards when on an incline
and reversing direction of travel ........ 25-30 ft-lbs / 34-41 Nm
5
Check valve ......................................... E ......... Steer circuit ....................................... 25-30 ft-lbs / 34-41 Nm
6
Check valve ......................................... F ......... Proportional circuit ............................ 25-30 ft-lbs / 34-41 Nm
7
Relief valve, 3500 psi / 241.3 bar ........ G ......... Relief valve for number
one section of pump .......................... 15-25 ft-lbs / 34-41 Nm
8
Check valve ......................................... H ......... Proportional circuit ................................ 30-35 in-lbs / 3-4 Nm
9
Diagnostic nipple - Test port #1 ........... I ........... Testing
10
Diagnostic nipple - Test port #2 ........... J .......... Testing
11
Relief valve,
GS-2668 RT, 3500 psi / 241.3 bar
GS-3268 RT, 2000 psi / 37.8 bar ........ K ......... Platform up ........................................ 15-25 ft-lbs / 34-41 Nm
12
Check valve ........................................ L .......... Drive circuit anti-cavitation ................ 20-25 ft-lbs / 27-54 Nm
13
Shuttle valve ........................................ M ......... Brake circuit ...................................... 20-25 ft-lbs / 27-54 Nm
This list continues. Please turn the page.
4 - 70
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 4 • Repair Procedures
REV B
MANIFOLDS
1
Y5A
A
B
2
Y6A
Y5
Y6
AA
27
3
C
Z
26
4
D
5
E
F
Y
25
6
G
7
Y1
X
24
H
Y1B
W
23
8
Y1A
V
22
U
21
Y2
I
9
S
Y3
Y9
Y4
J
P
R
T
K
Y8
Q
10
O
N
L
M
20
Part No. 52302
19
18
17
16
15
14
GS-2668 RT • GS-3268 RT
13
12
11
4 - 71
Section 4 • Repair Procedures
March 2005
MANIFOLDS
REV B
Function Manifold Components, continued
Index
No.
Description
14
Check valve ......................................... N ......... Drive circuit anti-cavitation ................ 20-25 ft-lbs / 27-34 Nm
15
Relief valve, 3500 psi / 241.3 bar ........ O ......... Relief valve for number
two section of pump ............................ 5-25 ft-lbs / 34-41 Nm
16
Solenoid valve, 2 position 4 way ......... P ......... Platform up ........................................ 25-30 ft-lbs / 34-41 Nm
17
Priority flow regulator,
2 gpm / 7.6 L/min ................................. Q ......... Steer circuit ....................................... 25-30 ft-lbs / 34-41 Nm
18
Solenoid valve, 3 position 4 way ......... R ......... Steer left/right ...................................... 5-30 ft-lbs / 34-41 Nm
19
Orifice - plug, 0.035 in / 0.89 mm ........ S ......... Brake circuit
20
Proportional solenoid valve N.O. ........ T ......... Drive/lift circuit ................................... 25-30 ft-lbs / 34-41 Nm
21
Solenoid valve, 2 position 2 way
N.O. ..................................................... U ......... Brake circuit ...................................... 20-25 ft-lbs / 27-54 Nm
22
Relief valve, 1500 psi / 103.4 bar ........ V ......... Steer left/right .................................... 25-30 ft-lbs / 34-41 Nm
23
Solenoid valve, 2 position 2 way
N.O. poppet ......................................... W ........ Drive speed select circuit .................. 25-30 ft-lbs / 34-41 Nm
24
Solenoid valve, 2 position 2 way
N.O. poppet ......................................... X ......... Drive speed select circuit .................. 25-30 ft-lbs / 34-41 Nm
25
Solenoid valve, 2 position 2 way
N.C. ..................................................... Y ......... Drive speed select circuit .................. 25-30 ft-lbs / 34-41 Nm
26
Check valve ......................................... Z ......... Prevents overflowing the drive
motors when in high drive speed ...... 20-25 ft-lbs / 27-54 Nm
27
Check valve ......................................... AA ....... Prevents engine from running
backwards when on an incline
and reversing direction of travel ........ 25-30 ft-lbs / 34-41 Nm
4 - 72
Schematic
Item
Function
GS-2668 RT • GS-3268 RT
Torque
Part No. 52302
March 2005
Section 4 • Repair Procedures
REV B
MANIFOLDS
1
Y5A
A
B
2
Y6A
Y5
Y6
AA
27
3
C
Z
26
4
D
5
E
F
Y
25
6
G
7
Y1
X
24
H
Y1B
W
23
8
Y1A
V
22
U
21
Y2
I
9
S
Y3
Y9
Y4
J
P
R
T
K
Y8
Q
10
O
N
L
M
20
Part No. 52302
19
18
17
16
15
14
GS-2668 RT • GS-3268 RT
13
12
11
4 - 73
Section 4 • Repair Procedures
March 2005
REV B
MANIFOLDS
A
9-2
Valve Adjustments Function Manifold
B
Y5
Y5A
Y6
Y6A
AA
How to
Adjust the System Relief Valves
C
Z
Y
Y1
D
E
The function manifold contains two system relief
valves, one for each section of the pump.
Perform this procedure with the
machine on level ground.
F
X
Y1B
G
a
W
H
Y1A
V
1 Connect a 0 to 5000 psi / 0 to 350 bar pressure
gauge to test port #2 (item J) and test port #1
(item I) on the function manifold.
U
Y2
S
2 Place wheel chocks in front of all four wheels.
T
Y9
3 Remove the platform controls from the platform
and place the controls near the function
manifold on the tank side of the machine.
R
I
Y3
Y4
K
Y8
Q
J
P
O
L
M
d
Models with outriggers: Start the engine from
platform controls and press the high torque/left
front outrigger button (BN17).
6 Turn the engine off. Use a wrench to hold the
P2 system relief valve (item O) or P1 system
relief valve (item G) and remove the cap .
c
N
4 Models without outriggers: Start the engine
from platform controls and press the high
torque button (BN6).
5 Move the joystick full stroke in the forward
direction. Note the pressure readings on both
pressure gauges. Refer to Section 2,
Specifications.
b
a
b
c
d
P1 system relief valve
test port #1
test port #2
P2 system relief valve
7 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Install the relief valve
cap.
Tip-over hazard. Failure to adjust
the relief valve as instructed will
cause the machine to tip over
resulting in death or serious injury.
Do not adjust the relief valve
higher than specified.
8 Repeat steps 4 through 5 to confirm the relief
valve pressures.
4 - 74
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 4 • Repair Procedures
REV B
MANIFOLDS
A
How to Adjust the Steer Relief
Valve
B
Y5
Y5A
Y6
Perform this procedure with the
platform in the stowed position.
Y6A
AA
C
Z
1 Connect a 0 to 5000 psi / 0 to 350 bar pressure
gauge to test port #2 (item J) on the function
manifold.
Y
Y1
D
E
F
X
Y1B
G
2 Turn the key switch to platform control and pull
out the red Emergency Stop button to the on
position at both the ground and platform
controls.
W
H
Y1A
V
3 Start the engine from the platform controls.
U
Y2
4 Press and hold the function enable toggle
switch and hold the steer thumb rocker switch
in the right direction. Allow the wheels to
completely turn to the right, then continue
holding the switch while observing the pressure
reading on the pressure gauge. Note the
pressure. Refer to Section 2, Specifications.
5 Turn the engine off. Use a wrench to hold the
steer relief valve and remove the cap (item V).
S
T
Y9
I
R
Y3
Y4
K
Y8
Q
J
P
O
b
N
L
a
6 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Install the relief valve
cap.
M
a
b
test port #2
steer relief valve
Component damage hazard. Do
not adjust the relief valve higher
than specified.
7 Repeat steps 3 through 4 to confirm the relief
valve pressure.
Part No. 52302
GS-2668 RT • GS-3268 RT
4 - 75
Section 4 • Repair Procedures
March 2005
REV B
MANIFOLDS
A
How to Adjust the Platform Up
Relief Valve
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 #1 (item I) on the function
manifold.
B
Y5
Y5A
Y6
Y6A
AA
C
Z
Y
Y1
D
E
F
X
Y1B
G
2 Place the maximum rated load in the platform.
Secure the load to the platform. Refer to
Section 2, Specifications.
3 Turn the key switch to ground control and pull
out the red Emergency Stop button to the on
position at both the ground and platform
controls.
W
V
U
Y2
S
T
4 Start the engine from the ground controls.
5 Press and hold the function enable switch and
hold the platform up/down toggle switch in the
up direction. Allow the platform to raise
completely, then continue holding the switch
while observing the pressure reading on the
pressure gauge. Note the pressure. Refer to
Section 2, Specifications.
H
Y1A
Y9
R
I
a
Y3
Y4
K
Y8
Q
b
J
P
O
N
L
M
a
b
test port #1
platform up relief valve
6 Turn the engine off. Hold the platform up relief
valve with a wrench and remove the cap
(item K).
7 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Install the relief valve
cap.
Tip-over hazard. Failure to adjust
the relief valve as instructed will
cause the machine to tip over
resulting in death or serious injury.
Do not adjust the relief valve
higher than specified.
8 Repeat steps 4 through 5 to confirm the relief
valve pressure.
4 - 76
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 4 • Repair Procedures
REV B
MANIFOLDS
9-3
Outrigger Manifold Components
The outrigger manifold is located beneath the hose cover panel on top of the drive chassis
Index
No.
Description
Schematic
Item
1
Relief valve, 2000 psi / 137.8 bar ......... BA ......... Outrigger circuit ..................................... 20 ft-lbs / 27.1 Nm
2
Solenoid valve, 2 position 2 way .......... BB ......... Outrigger slow extend .............................. 25 ft-lbs / 34 Nm
3
Orifice - plug,
0.063 inch / 1.6 mm .............................. BC ......... Outrigger retract
4
Solenoid valve, 3 position 4 way .......... BD ......... Outrigger extend/retract ........................... 25 ft-lbs / 34 Nm
5
Counterbalance valve
(not used after serial number 40484) ... BE ......... Outrigger retract circuit .................. 30-35 ft-lbs / 41-47 Nm
Function
Torque
BA
1
BE
5
BE
5
Y39
BD
Y40
4
Y44
BC
2
3
BB
Part No. 52302
GS-2668 RT • GS-3268 RT
4 - 77
Section 4 • Repair Procedures
March 2005
MANIFOLDS
REV B
3 Connect the platform controls to the quick
disconnect plug above the hydraulic tank.
9-4
Valve Adjustments Outrigger Manifold
How to Adjust the Outrigger
Relief Valve
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose must be replaced and
then torqued to specification
during installation. Refer to
Section Two, Hydraulic Hose and
Fitting Torque Specifications.
4 Turn the key switch to platform control and pull
out the red Emergency Stop buttons to the ON
position at both the ground and platform
controls.
5 Start the engine and raise the platform
approximately 10 feet / 3 m.
6 Lift the safety arm, move to the center of the
scissor arm and rotate down to a vertical
position.
7 Lower the platform onto the safety arm.
Crushing hazard. Keep hands
clear of the safety arm when
lowering the platform.
8 Stop the engine.
9 Disconnect the hydraulic supply hose from the
IN port of the outrigger manifold.
The IN port of the outrigger
manifold is located next to the
outrigger extend/retract valve
(item BD) and is labeled as IN.
Perform this procedure with the
machine on a firm, level surface.
1 Disconnect the platform controls from the quick
disconnect plug at the bottom of the platform.
Remove the platform controls from the platform.
Component damage hazard. The
platform controls wiring can be
damaged if it is kinked or pinched.
2 Open the hydraulic tank cover at the ground
controls side of the machine and disconnect the
platform controls harness at the quick
disconnect plug above the hydraulic tank.
4 - 78
10 Install a tee into the in port and install the
outrigger manifold supply hose into the tee.
Connect a 0 to 5000 psi / 0 to 350 bar pressure
gauge to the tee of the outrigger manifold.
Torque to specification. Refer to Section 2,
Specifications.
11 Start the engine from the platform controls.
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 4 • Repair Procedures
REV B
MANIFOLDS
12 Push and hold the auto level button and activate
the outrigger extend/retract toggle switch in the
down direction and note the pressure reading
on the pressure gauge. Refer to Section 2,
Specifications.
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. Install the relief valve
cap.
15 Repeat steps 11 through 12 to confirm the relief
valve pressure.
16 Remove the pressure gauge and tee from the
manifold and install the outrigger manifold
supply line into the outrigger manifold. Torque
to specification. Refer to Section 2,
Specifications.
17 Raise the platform and return the safety arm to
the stowed position.
18 Lower the platform the stowed position and turn
the machine off.
19 Disconnect the platform controls from the quick
disconnect plug above the hydraulic tank and
connect the platform controls harness to the
quick disconnect plug above the hydraulic tank.
20 Install the platform controls into the platform and
connect the platform controls to the quick
disconnect plug at the bottom of the platform.
Part No. 52302
GS-2668 RT • GS-3268 RT
4 - 79
Section 4 • Repair Procedures
March 2005
MANIFOLDS
REV B
9-5
Generator Manifold Components
The generator manifold is located above the function manifold.
Index
No.
Description
Schematic
Item
1
Solenoid valve, 2 position 3 way ......... AB .......... Generator on/off .................................. 25 ft-lbs / 34 Nm
2
Flow regulator, 4.3 gpm / 16.3 L/min ... AC .......... Generator speed ................................. 20 ft-lbs / 27.1 Nm
3
Relief valve, 3000 psi / 206.8 bar ........ AD .......... Generator circuit .................................. 20 ft-lbs / 27.1 Nm
Function
Torque
1
AB
2
AC
3
AD
4 - 80
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 4 • Repair Procedures
REV B
MANIFOLDS
4 Connect an electrical tool, which does not draw
more than 15A, to the electrical outlet at the
platform controls and run the tool at full speed.
9-6
Valve Adjustments Generator Manifold
How to Adjust the Generator
Voltage
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
5 Connect the positive and negative leads from a
multimeter of sufficient capacity to the electrical
outlet at the generator.
Result: The reading on the multimeter should be
112V to 118V AC.
Result: If the reading on the multimeter is not
112V to 118V AC, proceed to step 6.
6 Turn the key switch to the off position.
7 Use a wrench to hold the generator flow
regulator valve (item AC) and remove the cap.
8 Adjust the internal hex socket. Turn it clockwise
to increase the AC voltage or counterclockwise
to decrease the AC voltage. Install the flow
regulator valve cap.
Component damage hazard.
Failure to adjust the generator as
instructed may result in damage to
the generator or other electrical
equipment. Do not adjust the
generator to other than specified.
Be sure that the hydraulic oil level
is within the top 2 inches / 5 cm of
the sight gauge.
Perform this procedure with the
machine on a firm, level surface.
1 Disconnect all electrical tools from the machine.
2 Start the engine from the platform controls.
9 Repeat steps 2 through 5 to confirm the
generator AC voltage.
3 Press the generator select switch.
Result: The generator should activate and the
engine should go to high rpm.
Part No. 52302
GS-2668 RT • GS-3268 RT
4 - 81
Section 4 • Repair Procedures
March 2005
MANIFOLDS
REV B
9-7
Valve Coils
Valve Coil Resistance Specifications
Description
How to Test a Coil
A properly functioning coil provides an
electromotive force which operates the solenoid
valve. Critical to normal operation is continuity
within the coil that provides this force field.
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
Not all solenoid valve coils utilize
an integrated diode; review the
electrical schematic for your
machine to confirm. Refer to
Section 7, Schematics.
Specification
DO3 valve, 3 position 4 way
3.5 - 4.5Ω
12V DC with diode (schematic items A and B)
Solenoid valve, 2 position 4 way
12V DC with diode (schematic item P)
7 to 8Ω
Solenoid valve, 3 position 4 way
12V DC with diode (schematic item R)
7 to 8Ω
Proportional valve,
12V DC (schematic item T)
4 to 6Ω
Solenoid valve, 2 position 2 way
9 to 10Ω
12V DC with diode (schematic items U, W, X and Y)
Solenoid valve, 2 position 3 way
12V DC (schematic item AB)
5.5 to 6.5Ω
1 Tag and disconnect the wire harness from the
coil to be tested.
Solenoid valve, 2 position 2 way
12V DC with diode (schematic item AI)
2 Test the coil resistance.
Solenoid valve, 2 position 2 way
12V DC (schematic item BB)
7 to 8Ω
Solenoid valve, 3 position 4 way
12V DC (schematic item BD)
7 to 8Ω
Result: The resistance should be within
specification, plus or minus 30%.
Result: If the resistance is not within
specification, plus or minus 30%, replace the
coil.
4 - 82
8 to 10Ω
Solenoid valve, 2 position 2 way
7.2 to 9.2Ω
10V DC (schematic items CA, CB, CC and CD)
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 4 • Repair Procedures
REV B
MANIFOLDS
How to Test a Coil Diode
-
c
10 W
RESISTOR
c
a
b
c
d
27287
b
multimeter
9V DC battery
10W resistor
coil
Note: Dotted lines in illustration indicate a
reversed connection as specified in step 6
4 Connect the negative lead to the other terminal
on the coil.
If testing a single-terminal coil,
connect the negative lead to the
internal metallic ring at either end
of the coil.
The battery should read 9V DC or
more when measured across the
terminals.
Resistor, 10W
Genie part number
b
9V
BATTERY
-
1 Test the coil for resistance. See 9-3, How to
Test a Coil.
2 Connect a 10W resistor to the negative terminal
of a known good 9V DC battery. Connect the
other end of the resistor to a terminal on the
coil.
a
MULTI
METER
d
+
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
COIL
+
Genie incorporates spike suppressing diodes in
many valve coils. Properly functioning coil diodes
protect the electrical circuit by suppressing voltage
spikes. Voltage spikes naturally occur within a
function circuit following the interruption of
electrical current to a coil. Faulty diodes can fail to
protect the electrical system, resulting in a tripped
circuit breaker or component damage.
5 Momentarily connect the positive lead from the
multimeter to the positive terminal on the 9V DC
battery. Note the current reading.
6 At the battery or coil terminals, reverse the
connections. Note the current reading.
3 Set a multimeter to read DC current.
The multimeter, when set to read
DC current, should be capable of
reading up to 800 mA.
Result: Both current readings are greater than
0 mA and are different by a minimum of 20%.
The coil is good.
Result: If one or both of the current readings are
0 mA, or if the two current readings do not differ
by a minimum of 20%, the coil and/or its
internal diode are faulty and the coil should be
replaced.
Part No. 52302
GS-2668 RT • GS-3268 RT
4 - 83
Section 4 • Repair Procedures
March 2005
Fuel and Hydraulic Tanks
REV B
4 Tag, disconnect and plug the fuel supply and
return hoses from the fuel tank.
10-1
Fuel Tank
5 Clean up any fuel that may have spilled.
How to Remove the Fuel Tank
Explosion and fire hazard. Engine
fuels are combustible. Remove the
fuel tank in an open, wellventilated area away from heaters,
sparks, flames and lighted
tobacco. Always have an
approved fire extinguisher within
easy reach.
6 Remove the fuel tank mounting fasteners.
7 Remove the fuel tank from the machine.
Explosion and fire hazard. When
transferring fuel, connect a
grounding wire between the
machine and pump or container.
Explosion and fire hazard. Never
drain or store fuel in an open
container due to the possibility of
fire.
Component damage hazard. The
fuel tank is plastic and may
become damaged if allowed to fall.
Component damage hazard.
During installation, do not
overtighten the fuel tank mounting
fasteners. Torque the fuel tank
mounting fasteners to
54 in-lbs / 6.1 Nm.
Clean the fuel tank and inspect
for cracks or other damage before
installing.
1 Remove the fuel filler cap from the tank.
2 Using an approved hand-operated pump, drain
the fuel tank into a suitable container. See
capacity specifications.
Be sure to only use a hand
operated pump suitable for use
with gasoline and/or diesel fuel.
3 Models with fuel shutoff valves: Close the
fuel tank shutoff valves.
4 - 84
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 4 • Repair Procedures
REV B
FUEL AND HYDRAULIC TANKS
5 Close the two hydraulic shutoff valves located
at the hydraulic tank.
10-2
Hydraulic Tank
Component damage hazard. The
engine must not be started with
the hydraulic tank shutoff valves in
the closed position or component
damage will occur. If the tank
valves are closed, remove the key
from the key switch and tag the
machine to inform personnel of the
condition.
The primary functions of the hydraulic tank are to
cool, clean and deaerate the hydraulic fluid during
operation. It utilizes internal suction strainers for
the pump supply lines and has an external return
line filter.
How to Remove the
Hydraulic Tank
Component damage hazard. The
work area and surfaces where this
procedure will be performed must
be clean and free of debris that
could get into the hydraulic system
and cause severe component
damage. Dealer service is
recommended.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose must be replaced and
then torqued to specification
during installation. Refer to
Section Two, Hydraulic Hose and
Fitting Torque Specifications.
open
6 Open the hydraulic tank side cover.
7 Remove the drain plug from the hydraulic tank
and completely drain the tank into a container
of suitable capacity. Refer to Section 2,
Specifications.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
1 Raise the platform approximately 10 feet / 3 m.
2 Lift the safety arm, move it to the center of the
scissor arm and rotate down to a vertical
position.
3 Lower the platform onto the safety arm.
Crushing hazard. Keep hands
clear of the safety arm when
lowering the platform.
4 Remove the hose cover plate mounting
fasteners. Remove the cover.
closed
8 Tag and disconnect the two suction hoses from
the hydraulic tank.
9 Disconnect and plug the hydraulic hose at the
return filter. Cap the fitting on the filter.
10 Remove the tank strap retaining fasteners.
Remove the tank strap.
11 Remove the hydraulic tank from the machine.
Part No. 52302
GS-2668 RT • GS-3268 RT
4 - 85
Section 4 • Repair Procedures
March 2005
Steer Axle Components
REV A
6 Support and secure the yoke and drive motor
assembly to a lifting jack.
11-1
Yoke and Drive Motor
7 Remove the cotter pin from the tie rod clevis
pin.
How to Remove the Yoke
and Drive Motor
Always use a new cotter pin when
installing a clevis pin.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose must be replaced and
then torqued to specification
during installation. Refer to
Section Two, Hydraulic Hose and
Fitting Torque Specifications.
8 Remove the retaining fastener from the lower
yoke pivot pin.
9 Place a rod through the pin and twist to remove
the pin.
1 Block the non-steer wheels and center a lifting
jack under the drive chassis at the steer end of
the machine.
2 Loosen the wheel lug bolts. Do not remove
them.
3 Raise the machine approximately
6 inches / 5 cm. Place blocks under the chassis
for support.
Crushing hazard. The chassis will
fall if not properly supported.
10 Repeat steps 7 through 9 for the upper yoke
pivot pin.
11 Remove the yoke and drive motor assembly
from the machine.
4 Remove the wheel lug bolts. Remove the tire
and wheel assembly.
5 Tag, disconnect and plug the hoses from the
drive motor. Cap the fittings on the drive motor.
Crushing hazard. The yoke and
drive motor assembly may
become unbalanced and fall if not
properly supported and secured to
the lifting jack when it is removed
from the machine.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to
allow the oil pressure to
dissipate gradually. Do not
allow oil to squirt or spray.
4 - 86
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 4 • Repair Procedures
REV A
STEER AXLE COMPONENTS
How to Remove a Drive Motor
Component damage hazard.
Repairs to the motor should only
be performed by an authorized
dealer.
11-2
Steer Cylinder
How to Remove the
Steer Cylinder
Component damage hazard. The
work area and surfaces where this
procedure will be performed must
be clean and free of debris that
could get into the hydraulic system
and cause severe component
damage. Dealer service is
recommended.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose must be replaced and
then torqued to specification
during installation. Refer to
Section Two, Hydraulic Hose and
Fitting Torque Specifications.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose must be replaced and
then torqued to specification
during installation. Refer to
Section Two, Hydraulic Hose and
Fitting Torque Specifications.
1 Tag, disconnect and plug the hydraulic hoses
from the steer cylinder. Cap the fittings on the
cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
1 Loosen the wheel lug bolts. Do not remove
them.
2 Block the non-steer end wheels and center a
lifting jack under the steer end of the machine.
3 Raise the machine approximately
2 inches / 5 cm. Place blocks under the chassis
for support.
Crushing hazard. The chassis will
fall if not properly supported.
2 Remove the pin retaining fasteners from the
barrel-end pivot pin. Use a soft metal drift to
remove the pivot pin.
3 Remove the pin retaining fasteners from the
rod-end pivot pin. Use a soft metal drift to
remove the pin.
4 Remove the steer cylinder from the machine.
4 Remove the wheel lug bolts. Remove the tire
and wheel assembly.
5 Tag, disconnect and plug the hoses from the
drive motor. Cap the fittings on the drive motor.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
6 Remove the drive motor mounting fasteners.
Remove the drive motor from the machine.
Part No. 52302
GS-2668 RT • GS-3268 RT
4 - 87
Section 4 • Repair Procedures
March 2005
STEER AXLE COMPONENTS
REV A
11-3
Tie Rod
4 Center a lifting jack under the steer end of the
drive chassis and raise the machine until the
steer tires are off of the ground.
How to Remove the Tie Rod
5 Place blocks under the drive chassis for
support.
1 Remove the cotter pin from each tie rod clevis
pin. Remove the clevis pins.
6 Loosen the jam nut on the adjustable end of the
tie rod.
Always use a new cotter pin when
installing a clevis pin.
7 Remove the cotter pin from the clevis pin at the
adjustable end of the tie rod.
2 Remove the tie rod.
How to
Perform the Toe-in Adjustment
(before serial number 33737)
Always use a new cotter pin when
installing a clevis pin.
8 Slide the tie rod off of the yoke and adjust it by
turning the end.
One half turn on the adjustable
end equals approximately
1/4 inch / 6.4 mm change in the
front and rear measurements.
Perform this procedure on a firm,
level surface.
Perform this procedure with the
platform in the stowed position.
1 Straighten the steer wheels.
2 Block the tires at the non-steer end of the
machine.
3 Measure the steer tires, front to front and back
to back, using a measuring fixture.
9 Slide the tie rod onto the yoke. Install the clevis
pin.
10 Lower the machine.
11 Repeat step 3. If further adjustment is needed,
repeat steps 4 through 9.
12 Install a new cotter pin in the tie rod clevis pin.
13 Tighten the jam nut against the adjustable end
of the tie rod.
4 - 88
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
REV A
Section 4 • Repair Procedures
Non-steer Axle Components
4 Remove the wheel lug bolts. Remove the tire
and wheel assembly.
12-1
Drive Motor and Brake
How to Remove a Drive Motor
and Brake
5 Tag, disconnect and plug the hydraulic hoses
from the drive motor and brake. Cap the fittings
on the drive motor and brake.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to
allow the oil pressure to
dissipate gradually. Do not
allow oil to squirt or spray.
Component damage hazard.
Repairs to the motor should only
be performed by an authorized
dealer.
Component damage hazard. The
work area and surfaces where this
procedure will be performed must
be clean and free of debris that
could get into the hydraulic system
and cause severe component
damage. Dealer service is
recommended.
6 Support and secure the drive motor and brake
assembly to a lifting jack.
7 Remove the drive motor and brake mounting
fasteners.
8 Remove the drive motor and brake assembly
from the machine.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose must be replaced and
then torqued to specification
during installation. Refer to
Section Two, Hydraulic Hose and
Fitting Torque Specifications
Crushing hazard. The drive motor
and brake assembly may become
unbalanced and fall if not properly
supported and secured to the
lifting jack when removed from the
machine.
1 Block the steer wheels and center a lifting jack
under the drive chassis at the non-steer end of
the machine.
2 Loosen the wheel lug bolts. Do not remove
them.
3 Raise the machine approximately
2 inches / 5 cm and place blocks under the
drive chassis for support.
Part No. 52302
GS-2668 RT • GS-3268 RT
4 - 89
Section 4 • Repair Procedures
March 2005
Outrigger Components
REV A
13-1
Outrigger Cylinder
6 Attach a lifting strap from an overhead crane to
the barrel end of the outrigger cylinder for
support. Do not apply any lifting pressure.
How to Remove an Outrigger
Cylinder (if equipped)
7 Remove the outrigger mounting fasteners. Slide
the outrigger cylinder away from the machine.
Perform this procedure with the
platform in the stowed position
and the outriggers fully retracted.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose must be replaced and
then torqued to specification
during installation. Refer to
Section Two, Hydraulic Hose and
Fitting Torque Specifications
Crushing hazard. The outrigger
cylinder may become unbalanced
and fall if not properly supported
when removed from the machine.
If the outrigger cylinder is being
replaced, remove the shoulder pin
from the barrel end of the
outrigger cylinder and install it onto
the new cylinder.
1 Lower the outrigger cylinder to be removed until
the foot pad is resting on the ground. Do not
apply any downward pressure.
2 Remove the outrigger limit switch. Do not
disconnect the wiring.
3 Remove the mounting fasteners from the
outrigger cover. Remove the cover.
4 Tag and disconnect the wiring from the
outrigger cylinder solenoid valve.
5 Tag, disconnect and plug the hydraulic hoses
from the outrigger cylinder. Cap the fittings on
the cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to
allow the oil pressure to
dissipate gradually. Do not
allow oil to squirt or spray.
4 - 90
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
REV B
Section 4 • Repair Procedures
Brake Release Hand Pump Components
14-1
Brake Release Hand Pump Components
Before serial number 41200: The brake release hand pump manifold is mounted underneath the battery
in the hydraulic tray.
After serial number 41199: The brake release hand pump manifold is mounted at the non-steer end of
the chassis on the ground controls side of the machine.
Index
No.
Schematic
Item
Description
Function
Torque
1
Shuttle valve ..................................... AE ............. Brake release circuit ............................ 45-50 in-lbs / 5 Nm
2
Check valve, pilot operated .............. AF ............. Manual brake release circuit ............ 65-70 in-lbs / 7-8 Nm
3
Hand pump ....................................... AG ............ Manual brake release .............................. 30 ft-lbs / 41 Nm
4
Needle valve ..................................... AH ............ Manual brake release enable .............. 45-50 in-lbs / 5 Nm
1
Before serial number GS6804-43184
AE
AH
4
2
AF
Note: 'alpha' callouts refer
to corresponding notes on
the hydraulic schematic
AG
3
3
AG
4
AH
After serial number GS6804-43183
Part No. 52302
GS-2668 RT • GS-3268 RT
4 - 91
Section 4 • Repair Procedures
March 2005
This page intentionally left blank.
4 - 92
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
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.
Observe and Obey:
Troubleshooting and repair procedures shall be
completed by a person trained and qualified on
the repair of this machine.
Be aware of the following hazards and follow
generally accepted safe workshop practices.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating the machine.
Unless otherwise specified, perform each
repair procedure with the machine in the
following configuration:
· Machine parked on a firm, level surface
· Platform in the stowed position
· Key switch in the off position with the key
removed
· The red Emergency Stop button in the off
position at both ground and platform controls
Crushing hazard. When testing
or replacing any hydraulic
component, always support
the structure and secure it
from movement.
Electrocution hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
· Wheels chocked
· All external AC power supply disconnected
from the machine
Part No. 52302
GS-2668 RT • GS-3268 RT
5-1
Section 5 • Fault Codes
March 2005
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.
General Repair Process
Identify
symptoms
Malfunction
discovered
Troubleshoot
problem
still exists
Return to
service
5-2
problem
solved
Inspect
and test
Perform
repair
The diagnostic readout displays numerical codes
that provide information about the machine
operating status and about malfunctions. The dot
to the right of the numbers remain on when a
fault code is displayed.
The codes listed in the Fault Code Chart
describe malfunctions and can aid in
troubleshooting the machine by pinpointing the
area or component affected.
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 5 • Fault Codes
Fault Code Chart
REV B
(before serial number GS6803-42382)
Fault Code
Fault
Condition
Possible Causes
––
01, 02 or 03
10
11
12
20
21
22
Part No. 52302
Solution
Normal operation.
ECM does not allow
machine to function.
ECM does not allow
machine to function.
ECM does not allow
machine to function.
Machine does not
operate.
Defective ECM or
platform controls.
Consult Genie
Industries Service
Department
Engine will not start.
Machine will not
operate.
Ground controls
engine start toggle
switch fault, or is
activated when the
keyswitch is turned
on.
Check for stuck
toggle switch OR test
or replace the toggle
switch.
Engine will not start.
Machine will not
operate.
Ground controls
engine choke or glow
plug toggle switch
fault, or is activated
when the keyswitch
is turned on.
Check for stuck
toggle switch OR test
or replace the toggle
switch.
Ground controls
platform up/down
toggle switch fault, or
is activated when the
keyswitch is turned
on.
Platform controls
engine choke or glow
plug button fault, or is
activated when the
keyswitch is turned
on.
ECM does not allow
machine to function.
Engine will not start.
Machine will not
operate.
ECM does not allow
machine to function.
Engine will not start.
Machine will not
operate from
platform.
ECM does not allow
machine to function.
Engine will not start.
Machine will not
operate from
platform.
Platform controls
engine start button
fault, or is activated
when the keyswitch
is turned on.
ECM does not allow
machine to function.
Engine will not start.
Machine will not
operate from
platform.
Platform controls
steer left rocker
switch fault, or is
activated when the
keyswitch is turned
on.
GS-2668 RT • GS-3268 RT
Check for stuck
toggle switch OR test
or replace the toggle
switch.
Check or replace
platform control panel
switch board or
replace the platform
controls main circuit
board.
Check or replace
platform control panel
switch board or
replace the platform
controls main circuit
board.
Check for stuck
steer microswitch
OR test or replace
the steer
microswitch.
5-3
Section 5 • Fault Codes
March 2005
FAULT CODE CHART
(BEFORE SERIAL NUMBER GS6803-42382)
Fault Code
Fault
Condition
23
ECM does not allow
machine to function.
Engine will not start.
Machine will not
operate from
platform.
26
ECM does not allow
machine to function.
Engine will not start.
Machine will not
operate from
platform.
Possible Causes
Platform controls
steer right rocker
switch fault, or is
activated when the
keyswitch is turned
on.
Platform controls
platform up/down
toggle switch fault, or
is activated when the
keyswitch is turned
on.
Platform controls
platform up/down fast
speed function
enable button fault, or
is activated when the
key switch is turned
on.
Platform controls
platform up/down
slow speed function
enable button fault, or
is activated when the
keyswitch is turned
on.
27
ECM does not allow
machine to function.
Engine will not start.
Machine will not
operate from
platform.
28
ECM does not allow
machine to function.
Engine will not start.
Machine will not
operate from
platform.
ECM does not allow
machine to function.
Engine will not start.
Machine will not
operate from
platform.
Platform controls
function enable
switch fault, or is
activated when the
key switch is turned
on.
ECM does not allow
machine to function.
Engine will not start.
Machine will not
operate from
platform.
Platform controls
joystick fault, or is
activated when the
keyswitch is turned
on.
29
30
5-4
REV B
GS-2668 RT • GS-3268 RT
Solution
Check for stuck
steer microswitch
OR test or replace
the steer
microswitch.
Check for stuck
toggle switch OR test
or replace the toggle
switch.
Check for stuck
function enable
button OR test or
replace the platform
up/down fast speed
function enable
button.
Check for stuck
function enable
button OR test or
replace the platform
up/down slow speed
function enable
button.
Check for stuck
function enable
switch OR check for
function enable
switch being tied
down OR test or
replace the platform
up/down slow speed
function enable
button.
Check to make sure
the joystick is in the
center or neutral
position.
Part No. 52302
March 2005
Section 5 • Fault Codes
REV B
FAULT CODE CHART
(BEFORE SERIAL NUMBER GS6803-42382)
Fault Code
Fault
Condition
40
No power output from
ECM to the steer
right valve coil OR
ECM does not sense
the steer right valve
coil.
41
No power output from
ECM to the steer left
valve coil OR ECM
does not sense the
steer left valve coil.
42
43
No power output from
ECM to the platform
up valve coil OR
ECM does not sense
the platform up valve
coil.
No power output from
ECM to the brake
valve coil OR ECM
does not sense the
brake valve coil.
44
No power output from
ECM to the right front
and left rear drive
forward valve coil OR
ECM does not sense
the right front and left
rear drive forward
valve coil.
45
No power output from
ECM to the right front
and left rear drive
reverse valve coil
OR ECM does not
sense the right front
and left rear drive
reverse valve coil.
Part No. 52302
Possible Causes
Solution
Machine will not steer
right.
No power output from
ECM to steer right
coil (schematic item
R) OR bad valve coil.
Check wiring and
terminal at the steer
right coil OR check
wiring and terminal at
ECM.
Machine will not steer
left.
No power output from
ECM to steer left coil
(schematic item R)
OR bad valve coil.
Check wiring and
terminal at the left
right coil OR check
wiring and terminal at
ECM.
Platform will not raise.
No power output from
ECM to platform up
coil (schematic item
P) OR bad valve coil.
Check wiring and
terminal at the
platform up coil OR
check wiring and
terminal at ECM.
Machine will not
drive.
No power output from
ECM to brake coil
(schematic item T)
OR bad valve coil.
Check wiring and
terminal at the brake
coil OR check wiring
and terminal at ECM.
Machine will not drive
forward.
No power output from
ECM to right front
and left rear drive
forward valve coil
(schematic item A)
OR bad valve coil.
Check wiring and
terminals to right front
and left rear drive
forward valve coil OR
check the wiring and
terminal at the ECM
OR replace the valve
coil.
Machine will not drive
in reverse.
No power output from
ECM to right front
and left rear drive
reverse valve coil
(schematic item A)
OR bad valve coil.
Check wiring and
terminals to right front
and left rear drive
reverse valve coil
OR check the wiring
and terminal at the
ECM OR replace the
valve coil.
GS-2668 RT • GS-3268 RT
5-5
Section 5 • Fault Codes
March 2005
FAULT CODE CHART
(BEFORE SERIAL NUMBER GS6803-42382)
Fault Code
Condition
46
No power output from
ECM to the left front
and right rear drive
forward valve coil OR
ECM does not sense
the left front and right
rear drive forward
valve coil.
47
No power output from
ECM to the left front
and right rear drive
reverse valve coil
OR ECM does not
sense the left front
and right rear drive
reverse valve coil.
48
No power output from
ECM to the platform
down valve coil OR
ECM does not sense
the platform down
valve coil.
49
50
5-6
Fault
REV B
No power output from
ECM to the
parallel/series valve
coil OR ECM does
not sense the
parallel/series valve
coil.
No power output from
ECM to the
parallel/series valve
coil OR ECM does
not sense the
parallel/series valve
coil.
Possible Causes
Solution
Machine will not drive
forward.
No power output from
ECM to left front and
right rear drive
forward valve coil
(schematic item B)
OR bad valve coil.
Check wiring and
terminals to left front
and right rear drive
forward valve coil OR
check the wiring and
terminal at the ECM
OR replace the valve
coil.
Machine will not drive
in reverse.
No power output from
ECM to left front and
right rear drive
reverse valve coil
(schematic item B)
OR bad valve coil.
Check wiring and
terminals to left front
and right rear drive
reverse valve coil
OR check the wiring
and terminal at the
ECM OR replace the
valve coil.
Platform will not
lower.
No power output from
ECM to platform
down coil OR bad
valve coil.
Check wiring and
terminal at the
platform down coil
OR check wiring and
terminal at ECM.
Machine will not
drive.
No power output from
ECM to
parallel/series valve
coil (schematic item
X) OR bad valve coil.
Check wiring and
terminal at the
parallel/series valve
coil (schematic item
X) OR replace valve
coil.
Machine will not
drive.
No power output from
ECM to
parallel/series valve
coil (schematic item
V) OR bad valve coil.
Check wiring and
terminal at the
parallel/series valve
coil (schematic item
V) OR replace valve
coil.
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 5 • Fault Codes
REV B
FAULT CODE CHART
(BEFORE SERIAL NUMBER GS6803-42382)
Fault Code
51
52
60
66
Part No. 52302
Fault
Condition
No power output from
ECM to the
parallel/series valve
coil OR ECM does
not sense the
parallel/series valve
coil.
No power output from
ECM to the
porportional valve coil
OR ECM does not
sense the
porportional valve
coil.
No power output from
ECM to the LPG shutoff valve coil OR
ECM does not sense
the LPG shut-off
valve coil.
ECM does not allow
machine to function.
Possible Causes
Solution
Machine will not
drive.
No power output from
ECM to
parallel/series valve
coil (schematic item
W) OR bad valve
coil.
Check wiring and
terminal at the
parallel/series valve
coil (schematic item
W) OR replace valve
coil.
Machine will not
drive.
No power output from
ECM to proportional
valve coil (schematic
item T) OR bad valve
coil.
Check wiring and
terminal at the
proportional valve coil
(schematic item T)
OR replace valve
coil.
Engine will not start
or run on LPG.
No power output from
ECM to LPG shut-off
coil OR bad coil.
Check wiring at the
LPG shut-off valve
coil OR replace LPG
valve coil.
Low engine oil
pressure OR
defective oil pressure
switch.
Check the engine oil
level OR check
wiring and terminal at
the oil pressure
switch OR check the
wiring and terminal at
the ECM OR replace
the oil pressure
switch.
Engine will not start
or run OR engine
runs then shuts off.
GS-2668 RT • GS-3268 RT
5-7
Section 5 • Fault Codes
March 2005
FAULT CODE CHART
(BEFORE SERIAL NUMBER GS6803-42382)
Fault Code
5-8
Fault
REV B
Condition
Possible Causes
67
ECM does not allow
machine to function.
Engine will not start
or run OR engine
runs then shuts off.
High engine
temperature OR
defective water
temperature switch.
68
ECM does not allow
machine to function.
All functions do not
operate.
Low supply voltage to
ECM.
69
ECM does not allow
machine to function.
70
ECM does not allow
machine to function.
Engine starts and
runs then shuts
down.
Engine starts and
runs then shuts
down.
Engine idle RPM too
low.
Engine RPM too high.
GS-2668 RT • GS-3268 RT
Solution
Check the engine
radiator coolant level
OR check wiring and
terminal at the water
temperature switch
OR check the wiring
and terminal at the
ECM OR replace the
water temperature
switch.
Check battery or
alternator condition, E
Stop relay 1 & 2
terminals.
Consult Genie
Industries Service
Department
Consult Genie
Industries Service
Department
Part No. 52302
March 2005
Section 5 • Fault Codes
Fault Code Chart
REV A
(after serial number GS6803-42381)
Fault Code
LED
SYSTEM READY
Green
01
INTERNAL ECU
FAULT
02
PLATFORM ECU
FAULT
20
CHASSIS START
SW FAULT
21
CHASSIS CHOKE
SW FAULT
22
CHASSIS UP SW
FAULT
23
CHASSIS LIFT SW
FAULT
24
25
26
RIGHT TURN SW
FAULT
27
DRIVE ENABLE
SW FLT
28
OFF NEUTRAL
DRIVE JOYSTICK
29
PLATFORM LIFT
SW FAULT
30
OFF NEUTRAL
LIFT JOYSTICK
32
PLATFORM
START SW FAULT
33
LEFT FRONT
OUTRIG SW FLT
Part No. 52302
Solution
Internal ECM error.
System shutdown.
Replace ECM.
Red
Platform/ECM communication
error.
System shutdown.
Troubleshoot control cable OR
troubleshoot platform controls.
Red
Engine start button fault at
ground controls.
Engine will not start.
Replace ECM.
Red
Starting aid button fault at
ground controls.
Starting aid disabled.
Replace ECM.
Red
Up switch fault at ground
controls.
Platform up function inoperable.
Replace ECM.
Red
Platform up/down enable
button fault at ground controls.
Platform up/down functions
disabled.
Replace ECM.
Red
Down switch fault at ground
controls.
Platform down function disabled.
Replace ECM.
Red
Left turn switch fault.
Malfunctioning steer left
microswitch.
Troubleshoot steer left microswitch.
Red
Right turn switch fault.
Malfunctioning steer right
microswitch.
Troubleshoot steer right microswitch.
Red
Function enable switch on
joystick is activated when
machine is turned on.
Machine functions disabled.
Release function enable switch on
joystick before power up OR replace
joystick.
Red
Drive joystick off neutral when
machine is turned on.
Machine functions disabled.
Release joystick before power up OR
replace joystick.
Red
Lift enable button fault at the
platform controls.
Lift function disabled.
Troubleshoot button OR replace printed
circuit board at platform controls.
Red
Up/down switch off neutral.
Up/down function disabled.
Replace up/down switch at platform
controls.
Red
Starting aid fault at the
platform controls.
Starting aid disabled.
Troubleshoot button OR replace printed
circuit board at platform controls.
Red
Engine start button fault at
platform controls.
Engine will not start.
Troubleshoot button OR replace printed
circuit board at platform controls.
Red
Left front outrigger enable
button fault at platform
controls.
Outriggers disabled.
Troubleshoot button OR replace printed
circuit board at platform controls.
31
PLATFORM
CHOKE SW
FAULT
Result
Red
DOWN SW FAULT
LEFT TURN SW
FAULT
Condition
Normal operation
GS-2668 RT • GS-3268 RT
5-9
Section 5 • Fault Codes
March 2005
FAULT CODE CHART
(AFTER SERIAL NUMBER GS6803-42381)
Fault Code
34
RIGHT FRONT
OUTRIG SW FLT
35
LEFT REAR
OUTRIG SW FLT
36
RIGHT REAR
OUTRIG SW FLT
37
AUTO LEVEL
SWITCH FAULT
49
DRIVE COIL 1
FAULT
50
DRIVE COIL 2
FAULT
51
DRIVE COIL 3
FAULT
52
FUNC PROP COIL
FAULT
54
LED
Condition
REV A
Result
Solution
Red
Right front outrigger enable
button fault at platform
controls.
Outriggers disabled.
Troubleshoot button OR replace printed
circuit board at platform controls.
Red
Left rear outrigger enable
button fault at platform
controls.
Outriggers disabled.
Troubleshoot button OR replace printed
circuit board at platform controls.
Red
Right rear outrigger enable
button fault at platform
controls.
Outriggers disabled.
Troubleshoot button OR replace printed
circuit board at platform controls.
Red
Outrigger autolevel enable
button fault at platform
controls.
Outriggers disabled.
Troubleshoot button OR replace printed
circuit board at platform controls.
Red
Drive coil 1 (Y1) fault.
High torque drive function will not
operate.
Troubleshoot coil OR wiring.
Red
Drive coil 2 (Y1A) fault.
High torque drive function will not
operate.
Troubleshoot coil OR wiring.
Red
Drive coil 3 (Y1B) fault.
High torque drive function will not
operate.
Troubleshoot coil OR wiring.
Red
Proportional coil (Y9) fault.
Lift and outrigger functions are
disabled.
Troubleshoot coil OR wiring.
Red
Up coil (Y8) fault.
Platform will not raise.
Troubleshoot coil OR wiring.
Red
Down coil (Y7) fault.
Platform will not lower.
Troubleshoot coil OR wiring.
Red
Right turn coil (Y3) fault.
Machine will not turn right.
Troubleshoot coil OR wiring.
Red
Left turn coil (Y4) fault.
Machine will not turn left.
Troubleshoot coil OR wiring.
Red
Brake release coil (Y2) fault.
Brakes will not release.
Troubleshoot coil OR wiring.
Red
Forward 1 coil (Y6) fault.
Drives slow or not at all when
elevated.
Troubleshoot coil OR wiring.
Red
Reverse 1 coil (Y5) fault.
Drives slow or not at all when
elevated.
Troubleshoot coil OR wiring.
Red
Forward 2 coil (Y6A) fault.
Drives slow or not at all when
elevated.
Troubleshoot coil OR wiring.
Red
Reverse 2 coil (Y5A) fault.
Drives slow or not at all when
elevated.
Troubleshoot coil OR wiring.
UP COIL FAULT
55
DOWN COIL
FAULT
56
RIGHT TURN COIL
FAULT
57
LEFT TURN COIL
FAULT
58
BRAKE COIL
FAULT
60
FORWARD 1 COIL
FAULT
61
REVERSE 1 COIL
FAULT
62
FORWARD 2 COIL
FAULT
63
REVERSE 2 COIL
FAULT
5 - 10
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 5 • Fault Codes
REV A
Fault Code
66
LOW OIL
PRESSURE
67
HIGH COOLANT
TEMPERATURE
68
LOW ECU
VOLTAGE
69
LOW ENGINE
RPM
70
HIGH ENGINE
RPM
80
LEFT FRONT
OTRG COIL FLT
81
LEFT REAR OTRG
COIL FLT
82
RIGHT FRONT
OTRG COIL FLT
83
RIGHT REAR
OTRG COIL FLT
84
OUTRIGGER EXT
COIL FLT
85
OUTRIGGER RET
COIL FLT
86
OUTRIGGER
SLOW COIL FLT
90
2 SPEED COIL
FAULT
92
DRIVE FWD PROP
COIL FAULT
93
DRIVE REV PROP
COIL FAULT
94
MACHINE TYPE
FAULT
Part No. 52302
FAULT CODE CHART
(AFTER SERIAL NUMBER GS6803-42381)
LED
Condition
Result
Solution
Check the engine oil level OR check
wiring from the oil pressure switch to
ECM
OR replace the oil pressure switch.
Gasoline/LPG models: Check the
engine radiator coolant level OR check
the wiring from the water temperature
switch to ECM OR replace the water
temperature switch.
Diesel models: Check the engine oil
level OR check the wiring from the oil
temperature switch to ECM OR replace
the oil temperature switch.
Red
Low oil pressure.
Engine stops.
Red
High coolant temperature.
High engine temperature OR
defective engine coolant or oil
temperature switch.
Red
Low ECM voltage.
System shutdown.
Charge battery.
Red
Low RPM.
Engine idle RPM too low.
Consult Genie Industries Service
Department.
Red
High RPM.
Engine RPM too high.
Consult Genie Industries Service
Department.
Red
Left front outrigger coil (Y35)
fault.
Left front outrigger disabled.
Troubleshoot coil OR wiring.
Red
Left rear outrigger coil (Y33)
fault.
Left rear outrigger disabled.
Troubleshoot coil OR wiring.
Red
Right front outrigger coil (Y36)
fault.
Right front outrigger disabled.
Troubleshoot coil OR wiring.
Red
Right rear outrigger coil (Y34)
fault.
Right rear outrigger disabled.
Troubleshoot coil OR wiring.
Red
Outrigger extend coil (Y40)
fault.
Outrigger extend function disabled.
Troubleshoot coil OR wiring.
Red
Outrigger retract coil (Y39)
fault.
Outrigger retract function disabled.
Troubleshoot coil OR wiring.
Red
Outrigger slowdown coil (Y44)
fault.
Outrigger slow extend function
disabled.
Troubleshoot coil OR wiring.
Red
2 speed coil (Y1) fault
High torque drive function disabled.
Troubleshoot coil OR wiring.
Red
Drive pump forward
proportional coil (Y51) fault
Drive forward function disabled.
Troubleshoot coil OR wiring.
Red
Drive pump reverse
proportional coil (Y51) fault
Drive reverse function disabled.
Troubleshoot coil OR wiring.
Red
Wrong machine type selected
Machine will not operate.
Correct selection.
GS-2668 RT • GS-3268 RT
5 - 11
Section 5 • Fault Codes
March 2005
This page intentionally left blank.
5 - 12
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
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 hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
Troubleshooting and repair procedures shall be
completed by a person trained and qualified on
the repair of this machine.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Hydraulic Schematics
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
Repair any machine damage or malfunction
before operating the machine.
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.
General Repair Process
Identify
symptoms
Malfunction
discovered
Troubleshoot
problem
still exists
Return to
service
Part No. 52302
GS-2668 RT • GS-3268 RT
problem
solved
Inspect
and test
Perform
repair
6-1
Section 6 • Schematics
March 2005
Electronic Control Module Layout
(before serial number GS6803-42382)
REV A
Engine
Platform controls
Down limit switch
Up limit switch
J4
J3
Electronic Control Module
J1
J2
Level
sensor
Horn
Function manifold
Flashing beacon
Ground controls
6-2
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 6 • Schematics
Electronic Control Module Pin-Out Legend
(before serial number GS6803-42382)
REV A
9 2^]]TRc^a
9!2^]]TRc^a
9"2^]]TRc^a
"%_X]
"%_X]
'_X]
?X]
3TbRaX_cX^]
1!
1"
1#
1$
1%
1&
1'
1(
1)
1! 1!!
1!"
2!
2"
CdUUbbYWXd°I#
CdUUb\UVd°I$
@\QdV_b]e`°I(
2bQ[UbU\UQcU°I"
4bYfUV_bgQbT°I&
4bYfUbUfUbcU°I%
4bYfUV_bgQbT°I&1
4bYfUbUfUbcU°I%1
@\QdV_b]T_g^°I'
4bYfU`QbQ\\U\°I!
4bYfU`QbQ\\U\°I!1
4bYfU`QbQ\\U\°I!2
6\QcXY^WRUQS_^°62!
<UVdVb_^d_edbYWWUb_ed`ed°
I#%
@b_`_bdY_^Q\V\_gS_^db_\°
I)
>_decUT
BYWXdVb_^d_edbYWWUb_ed`ed
°I#&
?edbYWWUbUhdU^T°I$ ?edbYWWUbbUdbQSd°I#)
?edbYWWUbUhdU^Tc\_g°
I$$
>_decUT
>_decUT
>_decUT
>_decUT
@_gUbY^`ed
@_gUbY^`ed
@_gUbY^`ed
@_gUbY^`ed
>_decUT
>_decUT
7b_e^T
7b_e^T
>_decUT
>_decUT
@_gUbY^`ed
@_gUbY^`ed
2#
2$
2%
2&
2'
2(
2)
2! 2!!
2!"
3!
3"
3#
3$
3%
3&
3'
3(
3)
3! 3!!
3!"
?X]
1!
1"
1#
1$
1%
1&
1'
1(
1)
1! 1!!
1!"
2!
2"
2#
2$
2%
2&
2'
2(
2)
2! 2!!
2!"
3!
3"
3#
3$
3%
3&
3'
3(
3)
3! 3!!
3!"
3TbRaX_cX^]
@\QdV_b]e`Y^`ed
@\QdV_b]T_g^Y^`ed
>_decUT
>_decUT
;UicgYdSX`_gUb
<UfU\cU^c_bY^`ed
@\QdV_b]_fUb\_QTY^`ed
<UVdVb_^d_edbYWWUbY^`ed
>_decUT
BYWXdVb_^d_edbYWWUbY^`ed
>_decUT
>_decUT
1ed_\UfU\cU^c_b
>_decUT
1ed_\UfU\cU^c_b
>_decUT
>_decUT
>_decUT
3__\Q^ddU]`UbQdebU<54
?Y\`bUccebU<54
>_decUT
<UfU\cU^c_b_ed`ed
8_b^bU\Qi_ed`ed
1\Qb]_ed`ed
4YQW^_cdYSTYc`\Qi1
4YQW^_cdYSTYc`\Qi2
4YQW^_cdYSTYc`\Qi3
4YQW^_cdYSTYc`\Qi4
4YQW^_cdYSTYc`\Qi5
4YQW^_cdYSTYc`\Qi6
4YQW^_cdYSTYc`\Qi7
4YQW^_cdYSTYc`\Qi8
4YQW^_cdYSTYc`\Qi:
4YQW^_cdYSTYc`\Qi;
>_decUT
>_decUT
?X]
1!
1"
1#
1$
1%
1&
2!
2"
2#
2$
2%
2&
3!
3"
3#
3$
3%
3&
3TbRaX_cX^]
<Y]YdcgYdSXY^`ed°
`\QdV_b]e`
<Y]YdcgYdSXY^`ed°
`\QdV_b]T_g^
<Y]YdcgYdSXY^`ed°
UhdU^cY_^TUS[
4QdQ\Y^[°
4QdQ\Y^[°
<UVdbUQb_edbYWWUb
Y^`ed
<UVdbUQb_edbYWWUb
_ed`ed°I##
BYWXdbUQb_edbYWWUb
_ed`ed°I#$
>_decUT
7b_e^TVb_]`\QdV_b]
BYWXdbUQb_edbYWWUb
Y^`ed
4bYfY^W\YWXdc_ed`ed
>_decUT
>_decUT
>_decUT
>_decUT
>_decUT
>_decUT
9#2^]]TRc^a
?X]
1!
1"
1#
1$
1%
1&
2!
2"
2#
2$
2%
2&
3!
3"
3#
3$
3%
3&
C 1
'_X]
3TbRaX_cX^]
<@7cU\USdY^`ed
5^WY^UcdQbdY^`ed
3X_[UW\_g`\eWY^`ed
8YWXYT\UY^`ed
DQSX_]UdUbcYW^Q\Y^`ed
>_decUT
3__\Q^ddU]`UbQdebUcgYdSX
Y^`ed
?Y\`bUccebUcgYdSXY^`ed
>_decUT
8YWXYT\U_ed`ed
5^WY^UcdQbd_ed`ed
7U^UbQd_bcU\USd_ed`ed°
I")
<@7cU\USd_ed`ed
7Qc_\Y^UcU\USd_ed`ed
3X_[UW\_g`\eW_ed`ed
9W^YdY_^VeU\_ed`ed
>_decUT
>_decUT
6
B 1
6
A 1
6
18 pin connector (J3 and J4)
6
6
6
A 1
C 1
B 1
12
12
C 1
A 1
12
6
B 1
6
6
12
12
J2
12
12
12
A 1
B 1
A 1
Part No. 52302
C 1
12
6
B 1
6
6
Electronic Control Module
J1
C 1
B 1
A 1
C 1
J3
J4
GS-2668 RT • GS-3268 RT
36 pin connector (J1 and J2)
6-3
Section 6 • Schematics
March 2005
Electronic Control Module Layout
(after serial number GS6803-42381)
REV A
Platform controls
Engine
To outriggers
Flashing beacons
Down limit
switch
Electronic Control Module
J1
J2
Level
sensor
Generator
Horn
Outriggers and manifold
Function manifold
6-4
GS-2668 RT • GS-3268 RT
Ground controls
and ECM
Part No. 52302
March 2005
Section 6 • Schematics
Electronic Control Module Pin-Out Legend
(after serial number GS6803-42381)
REV A
J1 Connector
J2 Connector
(36 pin)
(36 pin)
Pin
Description
Pin
Description
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
Right turn coil Y3 (output)
Left turn coil Y4 (output)
Up coil Y8 (output)
Brake coil Y2 (output)
Drive forward1 Y6 (output)
Drive reverse1 Y5 (output)
Drive forward2 Y6A (output)
Drive reverse2 Y5A (output)
Down coil Y7 (output)
Drive coil1 Y1 (output)
Drive coil Y1A (output)
Drive coil Y1B (output)
A1
A2
B1
B2
B3
Generator coil Y29 (output)
Plug
Proportional flow control Y9
(output)
Plug
Right front outrigger coil
Y36 (output)
Outrigger extend coil Y40
(output)
Outrigger retract coil Y39
(output)
Outrigger extend coil Y40
(output)
Left front outrigger coil Y35
(output)
Left rear outrigger coil Y33
(output)
Right rear outrigger coil Y34
(output)
LPG select OR
Diesel shut off coil (output)
Up limit switch LS5 (input)
Down limit switch LS6
(input)
Aux down power (input)
Aux down relay CR23
terminal 86 (output)
Key switch terminal 3 (input)
Level sensor S7 (white)
(input)
Plug
Plug
Plug
Platform controls (ground)
(input)
Platform controls (data +)
(input)
Platform controls (data -)
(input)
B4
B5
B6
B7
B8
B9
B10
B11
B12
C1
C2
C3
C4
C5
C6
C7
C8
C9
C10
C11
C12
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
B1
B2
B3
B4
B5
B6
B7
B8
B9
B10
Pin layout
36 pin connector
B11
Plug
Platform overload (input)
Right front outrigger limit
switch LS13 (input)
Right rear outrigger limit
switch LS15 (input)
Left front outrigger limit
switch LS12 (input)
Left rear outrigger limit
switch LS14 (input)
Alternator (input)
Engine oil pressure SW2
(input)
Engine water temp SW1 OR
oil temp SW3 (input)
Plug
Fuel coil (output)
Plug
B12
C 1
B 1
A 1
12
6
6
C1
C2
C3
C4
C5
12
6
12
C6
C7
C8
C9
C10
C11
12
12
B 1
A 1
12
GS-2668 RT • GS-3268 RT
12
12
C 1
B 1
J2
J1
Part No. 52302
A 1
Electronic Control Module
System power (input)
System power (input)
System power (input)
Engine starting aid (output)
Oscillate stowed relay CR84
terminal 86 (output)
Oscillate raised relay CR85
terminal 86 (output)
Ground (output)
Plug
Plug
Auxiliary down relay CR23
terminal 87 (output)
Flashing beacons FS1
(output)
ECM power (input)
C 1
12
C12
Level sensor S8 (blue)
(input)
Level sensor S8 (black)
(input)
Level sensor S8 (yellow)
(input)
Plug
Plug
Plug
Engine start relay CR1
terminal 86 (output)
Ignition relay CR8 terminal
86 (output)
Engine high idle (output)
Level sensor S8 (red)
(output)
Horn relay CR5 terminal 86
(output)
Alarm (output)
6-5
Section 6 • Schematics
March 2005
Wiring Diagram - Platform Control Box
(before serial number GS6803-42382)
REV A
P2
P2
EMERGENCY STOP
BUTTON
EMERGENCY STOP
BUTTON
BK
RD
2
2
NC 1
RD
NC 1
BK
RD
RD
JC4
JC4
JOYSTICK
CONTROLLER
JOYSTICK
CONTROLLER
BN
BN
WH/BL
WH/BK
WH/RD
WH/RD
WH
WH/YL
PP
BN
U3
OR
WH
WH/BL
U3
PLATFORM
CONTROLS
CIRCUIT
BOARD
PLATFORM
CONTROLS
CIRCUIT
BOARD
WH/BK
PP
OR
OR
PP
D7
SW25
D7
SW25
VOLTAGE
REGULATOR
DIP SWITCH
VOLTAGE
REGULATOR
DIP SWITCH
ON
1
2
DIP
3
4
5
6
7
ON
8
1
2
DIP
3
4
5
6
7
8
YL
BL
WH
RD
RD
WH
WH
GN
BK
BK
BL
BL
WH
BK
BK
BL
WH
BK
YL
YL
BK
RD
BK
RD
BK
H1
ALARM
BN12
BN13
FUNCTION
ENABLE/
HIGH SPEED
BUTTON
FUNCTION
ENABLE/
LOW SPEED
BUTTON
WH
RD
TS20
PLATFORM
UP/DOWN
TOGGLE
SWITCH
H1
BN12
BN13
ALARM
FUNCTION
ENABLE/
HIGH SPEED
BUTTON
FUNCTION
ENABLE/
LOW SPEED
BUTTON
TS20
PLATFORM UP/DOWN
TOGGLE SWITCH
(MODELS WITHOUT OUTRIGGERS)
- OR -
TS21
TO COIL CORD ASSEMBLY
TO COIL CORD ASSEMBLY
Gasoline/LPG models
before serial number 1241
and
Diesel models
before serial number 1055
6-6
PLATFORM UP/DOWN / OUTRIGGER UP/DOWN
TOGGLE SWITCH
(MODELS WITH OUTRIGGERS)
Gasoline/LPG models
after serial number 1240
and
Diesel models
after serial number 1054
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 6 • Schematics
Wiring Diagram - Platform Control Box
(after serial number GS6803-42381)
REV A
COIL CORD ASSEMBLY
H1
ALARM
BK
NC 1
2
RD
P2
EMERGENCY
STOP
OR
BL
JC1
WH
JOYSTICK
CONTROLLER
5
1
J5
GY
4
J3
BK
RD
U3
PLATFORM
CONTROLS
CIRCUIT
BOARD
1
BK
PP
YL
WH/BL
14
1
GY
J2
BL
OR
RD
WH
BN
6
BK
YL
BL
TS20
OR
TS21
RD
1
J1
TS20 PLATFORM UP/DOWN TOGGLE SWITCH (MODELS WITHOUT OUTRIGGERS)
TS21 PLATFORM UP/DOWN / OUTRIGGER UP/DOWN TOGGLE SWITCH (MODELS WITH OUTRIGGERS)
Part No. 52302
GS-2668 RT • GS-3268 RT
6-7
Section 6 • Schematics
March 2005
Electrical Schematics Abbreviation and Wire Color Legends
REV A
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I$-CdUUb\UVd
I%-4bYfUbUfUbcU
I%1-4bYfUbUfUbcU
I&-4bYfUV_bgQbT
I&1-4bYfUV_bgQbT
I'-@\QdV_b]T_g^
I'1-@\QdV_b]T_g^7C#"&(_^\i
I(-@\QdV_b]e`
I)-@b_`_bdY_^Q\V\_gS_^db_\
I! -1ehY\YQbi`\QdV_b]T_g^7C#"&(_^\i
RUV_bUcUbYQ\^e]RUb$ " '
I! 1-1ehY\YQbi`\QdV_b]T_g^7C#"&(_^\i
I")-7U^UbQd_b_^_`dY_^
I##-<UVdbUQb_edbYWWUb
I#$-BYWXdbUQb_edbYWWUb
I#%-<UVdVb_^d_edbYWWUb
I#&-BYWXdVb_^d_edbYWWUb
I#)-?edbYWWUbbUdbQSd
I$ -?edbYWWUbUhdU^T
I$$-?edbYWWUbUhdU^Tc\_g
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 6 • Schematics
Electrical Symbols Legend
REV A
P1
KS1
PLATFORM
M4
GROUND
Emergency Stop
button
GROUND
Key switch
30
86
87
85
Solenoid valve with
spike supression
diode
Motor or pump
Solenoid valve
no diode
Spark plugs
Flashing beacon
Wire connection
Control relay
Horn or alarm
Glow plug(s)
No connection
(circuits crossing)
Button
Solenoid valve with
redundant coils
A
A
C
C
B
B
D
D
E
E
Quick disconnect
Diode
M3
Pressure switch
Starter motor
Electro-mechanical
solenoid
CB1
20A
S32
Circuit breaker
S33
Toggle switch
S34
S35
S36
Temperature switch
S37
S38
R
D1 F
S39
DIP switch
Alternator
LED
Voltage regulator
(+)
Capacitor
G6
G6
(+)
-
( )
Hour meter
Ignition coil
-
Potentiometer
Limit switch
G
( )
12V DC
Battery
Resistor
Work lights
Part No. 52302
Level sensor
Distributor
(models without outriggers)
GS-2668 RT • GS-3268 RT
6-9
Section 6 • Schematics
March 2005
Electrical Schematic
Gasoline/LPG Models (before serial number 21161)
Part 1 of 2
REV B
P1
EMERGENCY
STOP
CB2
PLATFORM
KS1
1A
GROUND
85
86
CR43
GROUND
87
85
CR1
(+)
BN23
AUXILIARY
PLATFORM
DOWN
86
-
( )
(GS-3268RT ONLY)
87
ENGINE
START
85
86
CR25
C2
ENGINE RUN
30
33000 uf
R7 2000
30
85
B4
12V DC
POWER TO
ECM
30
87
87
86
CR8
IGNITION
30
TS56 TS54
TS52
85
STARTING
AID
86
20A
87
CR4
J4-A4
J4-A3
J4-A2
J2-A5
J4-A5
J4-B5
U5
ELECTRONIC CONTROL MODULE
J4-C2
J4-C1
J4-B6
J2-B8
J2-B7
J4-B2
J4-B1
J1-B1
J2-B12
J1-A9
J2-B11
J1-C1\C4
J1-C11,C12
J4-C4
J4-B4
R
J4-C3
HIGH IDLE
30
D1 F
G6
HIGH IDLE
85
CR15
30
CHOKE
CB1
86
START
87
L30
U19
Q7
30
CR5
L27
86
G
U26
H1
M3
Q1
Q2
85
87
Q3
SW1 SW2 L41
N.O.
H2
N.C.
L42
B1
M4
FB1
12V DC
SW1
SW2 L41 L42 L27 Y29
Q1 M4 Q2
GASOLINE SELECT
FUEL PUMP
LPG SELECT
GENERATOR (OPTION)
OIL PRESSURE LED
GENERATOR ON LED
COOLANT
TEMPERATURE LED
OIL PRESSURE SWITCH
COOLANT
TEMPERATURE SWITCH
PLATFORM DOWN
(GS-3268 ONLY)
FLASHING BEACON (OPTION)
PLATFORM DOWN
TILT ALARM
Y7A FB1 H1
AUTOMOTIVE-STYLE HORN
(OPTION)
Y7
WORK LIGHTS (OPTION)
Q3 L30 H2
HIGH IDLE SOLENOID
ALTERNATOR
Q7
CHOKE
ENGINE STARTER
G6
HOURMETER
BATTERY 12V DC
U19 U26 U20
SPARK PLUG(S)
D1
DISTRIBUTOR
M3
IGNITION COIL
B1
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
6 - 10
ES0116F
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 6 • Schematics
Electrical Schematic
Gasoline/LPG Models (before serial number 21161)
Part 2 of 2
REV B
P2
QD4
G8
EMERGENCY
STOP
QD3
C
C
C
C
A
A
A
B
B
B
D
D
E
E
BK
BK
POWER TO PLATFORM
A
RD
POWER TO GROUND
B
WH
GROUND
PIO3
D
D
BL
DATA LINK (HIGH)
PIO4
E
E
YL
DATA LINK (LOW)
PIO5
RD
PIO2
DIAGNOSTIC
DISPLAY
12V DC
FUNCTION
ENABLE
RD
LS6
LS5
LS1
PLATFORM
DOWN
PLATFORM
UP
EXTENSION
DECK
WH
N.C.
1
2
3
4
5
6
7
8
PP
R15
OR
5K
POTENTIOMETER
WH/YL
TS66
S7
DATA LINK (-) YL
WH
J1-C7,C8
Y1A Y1B
PLATFORM CONTROLS
MEMBRANE DECAL
BK
POUT2
POWER LED L19
POUT7
LPG LED L22
POUT4
FAULT LED L25
POUT5
GENERATOR LED L27
POUT6
HIGH TORQUE LED L21
POUT8
HIGH IDLE LED L23
PIN5
ENGINE STOP BN1
J1-B3
J1-A12
Y1
J1-A11
Y6A Y5A
J1-A10
J1-A8
Y5
J1-A7
Y6
J1-A6
Y2
J1-A5
J1-A4
J1-A3
J1-A2
J1-A1
Y8
WH/RD
PIN14
BN
J2-B10
J2-A6
J3-A5
J3-A4
J3-B4
J2-C1/C10
J3-A3
J3-A1
J3-A2
J2-A2
J2-A1
Y4
FUNCTION ENABLE
LEVEL
SENSOR
ELECTRONIC CONTROL MODULE
Y3
WH/BL
PIN18
PIN15
DATA LINK (+) BK
DOWN
PLATFORM
UP
U5
SW6 STEER
LEFT/ RIGHT
SW5
RIGHT
N.C.
JOYSTICK
CONTROLLER
LEFT
N.C.
GROUND FROM PLATFORM
N.C.
JC1
BN
WH/BK
LEVEL
SENSOR
CIRCUIT
BOARD
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
DIP
SWITCH
TS67
D7
U3
SW25
Y9
PIN6
ENGINE START BN2
PIN10
HIGH IDLE BN4
PIN19
HORN BN5
PIN9
HIGH TORQUE BN6
PIN24
GENERATOR BN7
PIN25
PLATFORM EXT/RET ENABLE BN16
PIN29
STARTING AID BN3
PIN13
LPG SELECT BN14
WH
PIN1
LIFT ENABLE HIGH BN12
PROPORTIONAL
FLOW CONTROL
DRIVE PARALLEL
DRIVE PARALLEL
DRIVE PARALLEL
DRIVE REVERSE (2)
DRIVE FORWARD (2)
DRIVE REVERSE (1)
DRIVE FORWARD (1)
BRAKE RELEASE
PLATFORM UP
STEER LEFT
STEER RIGHT
BL
PIN2
LIFT ENABLE LOW BN13
RD
PIN3
UP
PLATFORM UP/DOWN TS20
YL
PIN4
POUT1
PIN11
DOWN
RD
+
BK
-
H1
ALARM
PLATFORM CONTROLS
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
ES0116F
Part No. 52302
GS-2668 RT • GS-3268 RT
6 - 11
Section 6 • Schematics
March 2005
Electrical Schematic
Gasoline/LPG Models (from serial number 21161 to 21837)
Part 1 of 2
REV B
P1
EMERGENCY
STOP
CB2
PLATFORM
KS1
1A
GROUND
85
86
CR43
GROUND
87
85
CR1
(+)
BN23
AUXILIARY
PLATFORM
DOWN
86
-
( )
(GS-3268RT ONLY)
87
ENGINE
START
30
85
B4
12V DC
85
87
87
POWER TO
ECM
30
86
CR25
ENGINE RUN
30
86
CR8
IGNITION
30
TS56 TS54
TS52
85
STARTING
AID
86
20A
87
CR4
J4-A4
J4-A3
J4-A2
J2-A5
J4-A5
J4-B5
U5
ELECTRONIC CONTROL MODULE
J4-C2
J4-C1
J4-B6
J2-B8
J2-B7
J4-B2
J4-B1
J1-B1
J2-B12
J1-A9
J2-B11
J1-C1\C4
J1-C11,C12
J4-C4
J4-B4
R
J4-C3
HIGH IDLE
30
D1 F
G6
HIGH IDLE
85
CR15
30
CHOKE
CB1
86
START
87
L30
U19
Q7
30
CR5
L27
86
G
U26
H1
M3
Q1
Q2
85
87
Q3
SW1 SW2 L41
N.O.
H2
N.C.
L42
B1
M4
FB1
12V DC
SW1
SW2 L41 L42 L27 Y29
Q1 M4 Q2
GASOLINE SELECT
FUEL PUMP
LPG SELECT
GENERATOR (OPTION)
OIL PRESSURE LED
GENERATOR ON LED
COOLANT
TEMPERATURE LED
OIL PRESSURE SWITCH
COOLANT
TEMPERATURE SWITCH
PLATFORM DOWN
(GS-3268 ONLY)
FLASHING BEACON (OPTION)
PLATFORM DOWN
TILT ALARM
Y7A FB1 H1
AUTOMOTIVE-STYLE HORN
(OPTION)
Y7
WORK LIGHTS (OPTION)
Q3 L30 H2
HIGH IDLE SOLENOID
ALTERNATOR
Q7
CHOKE
ENGINE STARTER
G6
HOURMETER
BATTERY 12V DC
U19 U26 U20
SPARK PLUG(S)
D1
DISTRIBUTOR
M3
IGNITION COIL
B1
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
6 - 12
ES0116G
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 6 • Schematics
Electrical Schematic
Gasoline/LPG Models (from serial number 21161 to 21837)
Part 2 of 2
REV B
P2
QD4
G8
EMERGENCY
STOP
QD3
C
C
C
C
A
A
A
B
B
B
D
D
E
E
BK
BK
POWER TO PLATFORM
A
RD
POWER TO GROUND
B
WH
GROUND
PIO3
D
D
BL
DATA LINK (HIGH)
PIO4
E
E
YL
DATA LINK (LOW)
PIO5
RD
PIO2
DIAGNOSTIC
DISPLAY
12V DC
FUNCTION
ENABLE
RD
LS6
LS5
LS1
PLATFORM
DOWN
PLATFORM
UP
EXTENSION
DECK
WH
N.C.
1
2
3
4
5
6
7
8
PP
R15
OR
5K
POTENTIOMETER
WH/YL
TS66
S7
DATA LINK (-) YL
WH
J1-C7,C8
Y1A Y1B
PLATFORM CONTROLS
MEMBRANE DECAL
BK
POUT2
POWER LED L19
POUT7
LPG LED L22
POUT4
FAULT LED L25
POUT5
GENERATOR LED L27
POUT6
HIGH TORQUE LED L21
POUT8
HIGH IDLE LED L23
PIN5
ENGINE STOP BN1
J1-B3
J1-A12
Y1
J1-A11
Y6A Y5A
J1-A10
J1-A8
Y5
J1-A7
Y6
J1-A6
Y2
J1-A5
J1-A4
J1-A3
J1-A2
J1-A1
Y8
WH/RD
PIN14
BN
J2-B10
J2-A6
J3-A5
J3-A4
J3-B4
J2-C1/C10
J3-A3
J3-A1
J3-A2
J2-A2
J2-A1
Y4
FUNCTION ENABLE
LEVEL
SENSOR
ELECTRONIC CONTROL MODULE
Y3
WH/BL
PIN18
PIN15
DATA LINK (+) BK
DOWN
PLATFORM
UP
U5
SW6 STEER
LEFT/ RIGHT
SW5
RIGHT
N.C.
JOYSTICK
CONTROLLER
LEFT
N.C.
GROUND FROM PLATFORM
N.C.
JC1
BN
WH/BK
LEVEL
SENSOR
CIRCUIT
BOARD
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
DIP
SWITCH
TS67
D7
U3
SW25
Y9
PIN6
ENGINE START BN2
PIN10
HIGH IDLE BN4
PIN19
HORN BN5
PIN9
HIGH TORQUE BN6
PIN24
GENERATOR BN7
PIN25
PLATFORM EXT/RET ENABLE BN16
PIN29
STARTING AID BN3
PIN13
LPG SELECT BN14
WH
PIN1
LIFT ENABLE HIGH BN12
PROPORTIONAL
FLOW CONTROL
DRIVE PARALLEL
DRIVE PARALLEL
DRIVE PARALLEL
DRIVE REVERSE (2)
DRIVE FORWARD (2)
DRIVE REVERSE (1)
DRIVE FORWARD (1)
BRAKE RELEASE
PLATFORM UP
STEER LEFT
STEER RIGHT
BL
PIN2
LIFT ENABLE LOW BN13
RD
PIN3
UP
PLATFORM UP/DOWN TS20
YL
PIN4
POUT1
PIN11
DOWN
RD
+
BK
-
H1
ALARM
PLATFORM CONTROLS
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
ES0116G
Part No. 52302
GS-2668 RT • GS-3268 RT
6 - 13
Section 6 • Schematics
March 2005
Electrical Schematic
Gasoline/LPG Models (from serial number 21838 to 38464)
Part 1 of 3
REV B
CB2 CHANGED TO 7 AMP
AFTER SERIAL NUMBER 33850
P1
EMERGENCY
STOP
CB2
PLATFORM
KS1
1A
GROUND
85
86
GROUND
87
30
85
CR1
(+)
BN23
AUXILIARY
PLATFORM
DOWN
86
-
( )
(GS-3268RT ONLY)
30
12V DC
85
CR25
30
85
B4
ENGINE RUN
86
CR8
87
87
POWER TO
ECM
86
87
ENGINE
START
CR43
30
IGNITION
TS56 TS54
TS52
85
86
86
20A
CR4
87
J4-A4
J4-A3
J4-A2
J2-A5
J4-A5
J1-C11,C12
J4-B5
J4-C4
U5
ELECTRONIC CONTROL MODULE
J4-C2
J4-C1
J4-B6
J2-B8
J2-B7
J4-B1
J4-B2
J2-B12
J1-B1
J1-A9
J2-B11
J1-C1\C4
G6
J4-C3
HIGH IDLE
J4-B4
30
R
D1 F
HIGH IDLE
85
STARTING
AID
CHOKE
CB1
30
START
CR15
87
L30
U19
Q7
30
CR5
L27
86
G
U26
M3
SW1
H2
FB1
12V DC
N.O.
M4
N.C.
GASOLINE SELECT
FUEL PUMP
LPG SELECT
GENERATOR (OPTION)
OIL PRESSURE LED
GENERATOR ON LED
PLATFORM DOWN
(GS-3268 ONLY)
COOLANT
TEMPERATURE LED
PLATFORM DOWN
TILT ALARM
HIGH IDLE SOLENOID
FB1 H1 SW1 SW2 L41 L42L27 Y29 Q1 M4 Q2
OIL PRESSURE SWITCH
COOLANT
TEMPERATURE SWITCH
Y7A
FLASHING BEACON (OPTION)
Y7
AUTOMOTIVE-STYLE HORN
(OPTION)
Q3 L30 H2
WORK LIGHTS (OPTION)
Q7
CHOKE
ALTERNATOR
G6
HOURMETER
ENGINE STARTER
SPARK PLUG(S)
BATTERY 12V DC
U19 U26 U20
DISTRIBUTOR
D1
IGNITION COIL
M3
SW2
L42
B1
B1
Q2
85
87
Q3
Q1
L41
H1
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
6 - 14
ES0116N
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 6 • Schematics
Electrical Schematic
Gasoline/LPG Models (from serial number 21838 to 38464)
Part 2 of 3
REV B
QD4
NOTE: LS5, LS1
USED ON
GS-3268 ONLY
AFTER SERIAL
NUMBER 26562
C
C
A
A
B
B
D
D
E
E
G8
OUTRIGGERS
(OPTION)
DIAGNOSTIC
DISPLAY
(OPTION)
TS67
FUNCTION
ENABLE
RD
LS6
LS5
LS1
PS3
PLATFORM
DOWN
PLATFORM
UP
EXTENSION
DECK
PLATFORM
OVERLOAD
N.C.
N.C.
N.O.
N.C.
LS12
LS13
LS14
LS15
LEFT
FRONT
OUTRIGGER
RIGHT
FRONT
OUTRIGGER
LEFT
REAR
OUTRIGGER
RIGHT
REAR
OUTRIGGER
TS66
N.O.
N.O.
S7
MODELS
WITHOUT
OUTRIGGERS
DATA LINK (-) YL
LEVEL
SENSOR
BN
J1-C7,C8
J2-B10
J2-A6
J2-C1/C10
J3-A5
J3-A4
J3-B4
J3-B5
J3-A6
J2-A10
J2-A8
J2-A7
J3-A3
J3-A1
J3-A2
J2-A2
J2-A1
U5
N.O.
DATA LINK (+) BK
DOWN
PLATFORM
UP
N.O.
LEVEL
SENSOR
CIRCUIT
BOARD
GROUND FROM PLATFORM
N.C.
WH
ELECTRONIC CONTROL MODULE
J2-B3
J2-B1
J1-B8
J2-B10
J1-B7
J1-B6
J3-B2
J3-B1
J1-B5
J1-B2
J1-B3
J1-A12
J1-A11
J1-A10
J1-A8
J1-A7
J1-A6
J1-A5
J1-A4
J1-A3
J1-A2
J1-A1
YL
BL
RD
S8
2-AXIS
LEVEL
SENSOR
BK
Y40
Y39
Y44
S9
AUTO LEVELING
SENSOR
Y34
OUTRIGGER RETRACT
Y33
OUTRIGGER EXTEND
SLOW
DRIVE REVERSE
Y36
OUTRIGGER EXTEND
DRIVE FORWARD
Y35
RIGHT REAR
OUTRIGGER
BRAKE RELEASE
Y9
LEFT REAR
OUTRIGGER
PLATFORM UP
Y1A Y1B
RIGHT FRONT
OUTRIGGER
STEER LEFT
Y1
LEFT FRONT
OUTRIGGER
STEER RIGHT
Y6A Y5A
PROPORTIONAL
FLOW CONTROL
Y5
DRIVE PARALLEL
Y6
DRIVE PARALLEL
Y2
DRIVE PARALLEL
Y8
DRIVE REVERSE
Y4
DRIVE FORWARD
Y3
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
ES0116N
Part No. 52302
GS-2668 RT • GS-3268 RT
6 - 15
Section 6 • Schematics
March 2005
Electrical Schematic
Gasoline/LPG Models (from serial number 21838 to 38464)
Part 3 of 3
REV B
P2
C
P2
EMERGENCY
STOP
QD3
A
A
RD
BK
POWER TO PLATFORM
BK
C
RD
POWER TO GROUND
B
B
WH
GROUND
PIO3
D
D
BL
DATA LINK (HIGH)
PIO4
E
E
YL
DATA LINK (LOW)
PIO5
EMERGENCY
STOP
QD3
PIO2
C
C
BK
POWER TO PLATFORM
A
A
RD
POWER TO GROUND
BK
RD
B
B
WH
GROUND
PIO3
D
D
BL
DATA LINK (HIGH)
PIO4
E
E
YL
DATA LINK (LOW)
PIO5
PIO2
12V DC
OR
R15
PP
5K
POTENTIOMETER
WH/YL
WH/BL
PIN18
POWER LED L19
POUT3
JOYSTICK
CONTROLLER
WH/YL
FUNCTION ENABLE
WH/RD
PIN15
SW6 STEER
LEFT/ RIGHT
WH
PLATFORM CONTROLS
MEMBRANE DECAL
POUT2
PP
5K
POTENTIOMETER
SW5
PIN14
BK
R15
RIGHT
WH
JC1
BN
LEFT
RIGHT
WH/RD
OR
WH/BK
LEFT
PIN15
PIN14
FUNCTION ENABLE
1
2
3
4
5
6
7
8
PLATFORM CONTROLS
MEMBRANE DECAL
BK
POUT2
POWER LED L19
POUT3
LIFT ERROR INDICATOR LED L57
POUT4
FAULT LED L25
POUT4
FAULT LED L25
POUT5
GENERATOR LED L27
POUT5
GENERATOR LED L27
POUT6
HIGH TORQUE LED L21
POUT6
HIGH TORQUE LED L21
POUT7
LPG LED L22
POUT7
LPG LED L22
POUT8
HIGH IDLE LED L23
POUT8
HIGH IDLE LED L23
ENGINE STOP BN1
PIN5
ENGINE STOP BN1
PIN5
PIN6
ENGINE START BN2
PIN6
ENGINE START BN2
PIN10
HIGH IDLE BN4
PIN10
AUTO LEVEL BN20
PIN19
HORN BN5
PIN19
HIGH TORQUE/LF OUTRIGGER BN17
PIN23
HIGH TORQUE BN6
PIN23
HIGH IDLE BN4
PIN24
GENERATOR BN7
PIN24
LPG SELECT/RR OUTRIGGER BN22
PIN13
LPG SELECT BN14
PIN13
HORN/LR OUTRIGGER BN15
PIN25
PLATFORM EXT/RET ENABLE BN16
PIN25
OUTRIGGER ENABLE BN16
PIN29
STARTING AID BN3
PIN25
GENERATOR/RF OUTRIGGER BN18
PIN29
STARTING AID BN3
PIN1
PIN2
PIN3
PIN4
POUT1
PIN11
WH
LIFT ENABLE HIGH BN12
BL
LIFT ENABLE LOW BN13
RD
PLATFORM UP/DOWN TS20
YL
RD
BK
WH
PIN1
UP
DOWN
-
RD
POUT1
ALARM
PLATFORM CONTROLS
(GASOLINE/LPG MODELS WITHOUT OUTRIGGERS)
UP
YL
PIN4
H1
LIFT ENABLE LOW BN13
RD
PIN3
+
LIFT ENABLE HIGH BN12
BL
PIN2
BK
PIN11
6 - 16
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
SW6 STEER
LEFT/ RIGHT
SW5
WH/BL
JOYSTICK
CONTROLLER
D7
U3
SW25
DIP
SWITCH
JC1
BN
WH/BK
PIN18
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
DIP
SWITCH
1
2
3
4
5
6
7
8
D7
U3
SW25
12V DC
DOWN
+
-
PLATFORM & OUTRIGGER
UP/DOWN TS21
H1
ALARM
PLATFORM CONTROLS
(GASOLINE/LPG MODELS WITH OUTRIGGERS)
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 6 • Schematics
This page intentionally left blank.
Part No. 52302
GS-2668 RT • GS-3268 RT
6 - 17
Section 6 • Schematics
March 2005
Electrical Schematic
Gasoline/LPG Models (from serial number 38465 to 41199)
Part 1 of 3
REV B
P1
EMERGENCY
STOP
CB2
PLATFORM
KS1
7A
GROUND
85
86
GROUND
87
30
85
CR1
(+)
BN23
AUXILIARY
PLATFORM
DOWN
86
-
( )
(GS-3268RT ONLY)
30
12V DC
85
CR25
30
85
B4
ENGINE RUN
86
CR8
87
87
POWER TO
ECM
86
87
ENGINE
START
CR43
30
IGNITION
TS56 TS54
TS52
85
86
86
20A
CR4
87
J4-A4
J4-A3
J4-A2
J2-A5
J4-A5
J1-C11,C12
J4-B5
J4-C4
U5
ELECTRONIC CONTROL MODULE
J4-C2
J4-C1
J4-B6
J2-B8
J2-B7
J4-B1
J4-B2
J2-B12
J1-B1
J1-A9
J2-B11
J1-C1\C4
G6
J4-C3
HIGH IDLE
J4-B4
30
R
D1 F
HIGH IDLE
85
STARTING
AID
CHOKE
CB1
30
START
CR15
87
L30
U19
Q7
30
CR5
L27
86
G
U26
M3
SW1
H2
FB1
12V DC
N.O.
M4
N.C.
GASOLINE SELECT
LPG SELECT
FUEL PUMP
GENERATOR (OPTION)
OIL PRESSURE LED
GENERATOR ON LED
COOLANT
TEMPERATURE LED
TILT ALARM
OIL PRESSURE SWITCH
COOLANT
TEMPERATURE SWITCH
FLASHING BEACON (OPTION)
PLATFORM DOWN
AUXILLIARY PLATFORM DOWN
(GS-3268 ONLY)
PLATFORM DOWN
(GS-3268 ONLY)
HIGH IDLE SOLENOID
AUXILLIARY PLATFORM DOWN
Y7 Y10 Y7A Y10A FB1 H1 SW1 SW2 L41 L42 L27 Y29 Q1 M4 Q2
AUTOMOTIVE-STYLE HORN
(OPTION)
Q3 L30 H2
WORK LIGHTS (OPTION)
Q7
CHOKE
ALTERNATOR
G6
HOURMETER
ENGINE STARTER
SPARK PLUG(S)
BATTERY 12V DC
U19 U26 U20
DISTRIBUTOR
D1
IGNITION COIL
M3
SW2
L42
B1
B1
Q2
85
87
Q3
Q1
L41
H1
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
6 - 18
ES0116S
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 6 • Schematics
Electrical Schematic
Gasoline/LPG Models (from serial number 38465 to 41199)
Part 2 of 3
REV B
QD4
NOTE: LS5, LS1
USED ON
GS-3268 ONLY
AFTER SERIAL
NUMBER 26562
C
C
A
A
B
B
D
D
E
E
G8
OUTRIGGERS
(OPTION)
DIAGNOSTIC
DISPLAY
(OPTION)
TS67
FUNCTION
ENABLE
RD
LS6
LS5
LS1
PS3
PLATFORM
DOWN
PLATFORM
UP
EXTENSION
DECK
PLATFORM
OVERLOAD
N.C.
N.C.
N.O.
N.C.
LS12
LS13
LS14
LS15
LEFT
FRONT
OUTRIGGER
RIGHT
FRONT
OUTRIGGER
LEFT
REAR
OUTRIGGER
RIGHT
REAR
OUTRIGGER
TS66
N.O.
N.O.
S7
MODELS
WITHOUT
OUTRIGGERS
DATA LINK (-) YL
LEVEL
SENSOR
BN
J1-C7,C8
J2-B10
J2-A6
J2-C1/C10
J3-A5
J3-A4
J3-B4
J3-B5
J3-A6
J2-A10
J2-A8
J2-A7
J3-A3
J3-A1
J3-A2
J2-A2
J2-A1
U5
N.O.
DATA LINK (+) BK
DOWN
PLATFORM
UP
N.O.
LEVEL
SENSOR
CIRCUIT
BOARD
GROUND FROM PLATFORM
N.C.
WH
ELECTRONIC CONTROL MODULE
J2-B3
J2-B1
J1-B8
J2-B10
J1-B7
J1-B6
J3-B2
J3-B1
J1-B5
J1-B2
J1-B3
J1-A12
J1-A11
J1-A10
J1-A8
J1-A7
J1-A6
J1-A5
J1-A4
J1-A3
J1-A2
J1-A1
YL
BL
RD
S8
2-AXIS
LEVEL
SENSOR
BK
Y40
Y39
Y44
S9
AUTO LEVELING
SENSOR
Y34
OUTRIGGER RETRACT
Y33
OUTRIGGER EXTEND
SLOW
DRIVE REVERSE
Y36
OUTRIGGER EXTEND
DRIVE FORWARD
Y35
RIGHT REAR
OUTRIGGER
BRAKE RELEASE
Y9
LEFT REAR
OUTRIGGER
PLATFORM UP
Y1A Y1B
RIGHT FRONT
OUTRIGGER
STEER LEFT
Y1
LEFT FRONT
OUTRIGGER
STEER RIGHT
Y6A Y5A
PROPORTIONAL
FLOW CONTROL
Y5
DRIVE PARALLEL
Y6
DRIVE PARALLEL
Y2
DRIVE PARALLEL
Y8
DRIVE REVERSE
Y4
DRIVE FORWARD
Y3
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
ES0116S
Part No. 52302
GS-2668 RT • GS-3268 RT
6 - 19
Section 6 • Schematics
March 2005
Electrical Schematic
Gasoline/LPG Models (from serial number 38465 to 41199)
Part 3 of 3
REV B
P2
C
P2
EMERGENCY
STOP
QD3
A
A
RD
BK
POWER TO PLATFORM
BK
C
RD
POWER TO GROUND
B
B
WH
GROUND
PIO3
D
D
BL
DATA LINK (HIGH)
PIO4
E
E
YL
DATA LINK (LOW)
PIO5
EMERGENCY
STOP
QD3
PIO2
C
C
BK
POWER TO PLATFORM
A
A
RD
POWER TO GROUND
BK
RD
B
B
WH
GROUND
PIO3
D
D
BL
DATA LINK (HIGH)
PIO4
E
E
YL
DATA LINK (LOW)
PIO5
PIO2
12V DC
OR
R15
PP
5K
POTENTIOMETER
WH/YL
WH/BL
PIN18
PIN15
POWER LED L19
POUT3
JOYSTICK
CONTROLLER
WH/YL
FUNCTION ENABLE
WH/RD
SW6 STEER
LEFT/ RIGHT
WH
PLATFORM CONTROLS
MEMBRANE DECAL
POUT2
PP
5K
POTENTIOMETER
SW5
PIN14
BK
R15
RIGHT
WH
JC1
BN
LEFT
RIGHT
WH/RD
OR
WH/BK
LEFT
PIN15
PIN14
FUNCTION ENABLE
1
2
3
4
5
6
7
8
PLATFORM CONTROLS
MEMBRANE DECAL
BK
POUT2
POWER LED L19
POUT3
LIFT ERROR INDICATOR LED L57
POUT4
FAULT LED L25
POUT4
FAULT LED L25
POUT5
GENERATOR LED L27
POUT5
GENERATOR LED L27
POUT6
HIGH TORQUE LED L21
POUT6
HIGH TORQUE LED L21
POUT7
LPG LED L22
POUT7
LPG LED L22
POUT8
HIGH IDLE LED L23
POUT8
HIGH IDLE LED L23
ENGINE STOP BN1
PIN5
ENGINE STOP BN1
PIN5
PIN6
ENGINE START BN2
PIN6
ENGINE START BN2
PIN10
HIGH IDLE BN4
PIN10
AUTO LEVEL BN20
PIN19
HORN BN5
PIN19
HIGH TORQUE/LF OUTRIGGER BN17
PIN23
HIGH TORQUE BN6
PIN23
HIGH IDLE BN4
PIN24
GENERATOR BN7
PIN24
LPG SELECT/RR OUTRIGGER BN22
PIN13
LPG SELECT BN14
PIN13
HORN/LR OUTRIGGER BN15
PIN25
PLATFORM EXT/RET ENABLE BN16
PIN25
OUTRIGGER ENABLE BN16
PIN29
STARTING AID BN3
PIN25
GENERATOR/RF OUTRIGGER BN18
PIN29
STARTING AID BN3
PIN1
PIN2
PIN3
PIN4
POUT1
PIN11
WH
LIFT ENABLE HIGH BN12
BL
LIFT ENABLE LOW BN13
RD
PLATFORM UP/DOWN TS20
YL
RD
BK
WH
PIN1
UP
DOWN
-
RD
POUT1
ALARM
PLATFORM CONTROLS
(GASOLINE/LPG MODELS WITHOUT OUTRIGGERS)
UP
YL
PIN4
H1
LIFT ENABLE LOW BN13
RD
PIN3
+
LIFT ENABLE HIGH BN12
BL
PIN2
BK
PIN11
6 - 20
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
SW6 STEER
LEFT/ RIGHT
SW5
WH/BL
JOYSTICK
CONTROLLER
D7
U3
SW25
DIP
SWITCH
JC1
BN
WH/BK
PIN18
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
DIP
SWITCH
1
2
3
4
5
6
7
8
D7
U3
SW25
12V DC
DOWN
+
-
PLATFORM & OUTRIGGER
UP/DOWN TS21
H1
ALARM
PLATFORM CONTROLS
(GASOLINE/LPG MODELS WITH OUTRIGGERS)
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 6 • Schematics
This page intentionally left blank.
Part No. 52302
GS-2668 RT • GS-3268 RT
6 - 21
Section 6 • Schematics
March 2005
Electrical Schematic
Gasoline/LPG Models (from serial number 41200 to 41823)
Part 1 of 3
REV B
PLATFORM
KS1
GROUND
85
86
CR43
GROUND
87
(+)
85
CR1
-
86
CR25
87
B4
86
30
( )
85
85
86
CR8
87
87
ENGINE RUN
30
ENGINE
START
12V DC
POWER TO
ECM
30
85
BN68
IGNITION
30
START
86
CR15
87
GLOW
PLUG
30
CB1
20A
85
86
R
D1 F
J4-A2
J2-A5
J4-A5
U5
ELECTRONIC CONTROL MODULE
J4-B6
J2-B8
J2-B7
J4-B2
J4-B1
J1-B1
J1-A9
J2-B11
(OPTION)
J1-C11,C12 J2-B12
J1-C1\C4
HYDRAULIC
OIL COOLER
J4-B5
L30
2
J4-C4
G6
J4-C3
HIGH IDLE
30
J4-B4
1
CR4
87
3
F9A
B1
SW4
20A
12V DC
(+)
U19
G
M3
30
86
87
85
CR17
U26
30
CR5 86
87
85
Q7
N.O.
L27
Q3
H2
N.O.
L42
SW1
SW2 L41 L42 L27 Y29
GENERATOR (OPTION)
OIL PRESSURE LED
GENERATOR ON LED
COOLANT
TEMPERATURE LED
OIL PRESSURE SWITCH
COOLANT
TEMPERATURE SWITCH
WORK LIGHTS (OPTION)
FLASHING BEACON (OPTION)
CHOKE
TILT ALARM
HOURMETER
AUXILIARY PLATFORM
DOWN (GS-3268 ONLY)
HYDRAULIC OIL
TEMPERATURE SWITCH
Y7 Y10 Y7A Y10A H1 FB1
PLATFORM DOWN
(GS-3268 ONLY)
Q3 L30 H2
AUXILIARY PLATFORM
DOWN (GS-3268 ONLY)
Q7
PLATFORM DOWN
G6
AUTOMOTIVE-STYLE HORN
(OPTION)
SW4
HIGH IDLE SOLENOID
M1
HYDRAULIC OIL
COOLING FAN (OPTION)
( )
SPARK PLUG(S)
ENGINE STARTER
U19 U26 U20
DISTRIBUTOR
BATTERY 12V DC
D1
IGNITION COIL
M3
ALTERNATOR
B1
N.C.
FB1
M1
-
SW1 SW2 L41
H1
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
6 - 22
ES0116U
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 6 • Schematics
Electrical Schematic
Gasoline/LPG Models (from serial number 41200 to 41823)
Part 2 of 3
REV B
P1
EMERGENCY
STOP
QD4
C
C
A
A
B
B
D
D
E
E
G8
OUTRIGGERS
(OPTION)
DIAGNOSTIC
DISPLAY
(OPTION)
BN44 FUNCTION
RD
ENABLE
BN90 TS54
HIGH
IDLE
BN83
BN84
PLATFORM
UP
PLATFORM
DOWN
PS3
PLATFORM
OVERLOAD
N.O.
N.C.
N.C.
LS12
LS13
LS14
LS15
LEFT
FRONT
OUTRIGGER
RIGHT
FRONT
OUTRIGGER
LEFT
REAR
OUTRIGGER
RIGHT
REAR
OUTRIGGER
N.O.
N.O.
N.O.
N.O.
S7
MODELS
WITHOUT
OUTRIGGERS
DATA LINK (-) YL
DATA LINK (+) BK
LEVEL
SENSOR
BN
J1-C7,C8
J2-B10
J2-A6
J2-C1/C10
J3-A5
J3-A4
J3-B4
J3-B5
J3-A6
J2-A10
J2-A8
J2-A7
J3-A3
J3-A1
J3-A2
J2-A2
J2-A1
J4-A4
J4-A3
U5
LEVEL
SENSOR
CIRCUIT
BOARD
GROUND FROM PLATFORM
GLOW
PLUG
LS6
PLATFORM
DOWN
WH
ELECTRONIC CONTROL MODULE
J4-C2
J4-C1
J2-B3
J2-B1
J1-B8
J2-B10
J1-B7
J1-B6
J3-B2
J3-B1
J1-B5
J1-B2
J1-B3
J1-A12
J1-A11
J1-A10
J1-A8
J1-A7
J1-A6
J1-A5
J1-A4
J1-A3
J1-A2
J1-A1
YL
BL
RD
S8
2-AXIS
LEVEL
SENSOR
Q1
BK
M4
S9
Q1 M4 Q2
GASOLINE SELECT
Y44
LPG SELECT
Y39
FUEL PUMP
Y40
AUTO LEVELING
SENSOR
Y34
OUTRIGGER RETRACT
Y33
OUTRIGGER EXTEND
SLOW
DRIVE REVERSE
Y36
OUTRIGGER EXTEND
DRIVE FORWARD
Y35
RIGHT REAR
OUTRIGGER
BRAKE RELEASE
Y9
LEFT REAR
OUTRIGGER
PLATFORM UP
Y1A Y1B
RIGHT FRONT
OUTRIGGER
STEER LEFT
Y1
LEFT FRONT
OUTRIGGER
STEER RIGHT
Y6A Y5A
PROPORTIONAL
FLOW CONTROL
Y5
DRIVE PARALLEL
Y6
DRIVE PARALLEL
Y2
DRIVE PARALLEL
Y8
DRIVE REVERSE
Y4
DRIVE FORWARD
Y3
Q2
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
ES0116U
Part No. 52302
GS-2668 RT • GS-3268 RT
6 - 23
Section 6 • Schematics
March 2005
Electrical Schematic
Gasoline/LPG Models (from serial number 41200 to 41823)
Part 3 of 3
REV B
P2
C
P2
EMERGENCY
STOP
QD3
A
A
RD
BK
POWER TO PLATFORM
BK
C
RD
POWER TO GROUND
B
B
WH
GROUND
PIO3
D
D
BL
DATA LINK (HIGH)
PIO4
E
E
YL
DATA LINK (LOW)
PIO5
EMERGENCY
STOP
QD3
PIO2
C
C
BK
POWER TO PLATFORM
A
A
RD
POWER TO GROUND
BK
RD
B
B
WH
GROUND
PIO3
D
D
BL
DATA LINK (HIGH)
PIO4
E
E
YL
DATA LINK (LOW)
PIO5
PIO2
12V DC
OR
R15
PP
5K
POTENTIOMETER
WH/YL
WH/BL
PIN18
PIN15
POWER LED L19
POUT3
JOYSTICK
CONTROLLER
WH/YL
FUNCTION ENABLE
WH/RD
SW6 STEER
LEFT/ RIGHT
WH
PLATFORM CONTROLS
MEMBRANE DECAL
POUT2
PP
5K
POTENTIOMETER
SW5
PIN14
BK
R15
RIGHT
WH
JC1
BN
LEFT
RIGHT
WH/RD
OR
WH/BK
LEFT
PIN15
PIN14
FUNCTION ENABLE
1
2
3
4
5
6
7
8
PLATFORM CONTROLS
MEMBRANE DECAL
BK
POUT2
POWER LED L19
POUT3
LIFT ERROR INDICATOR LED L57
POUT4
FAULT LED L25
POUT4
FAULT LED L25
POUT5
GENERATOR LED L27
POUT5
GENERATOR LED L27
POUT6
HIGH TORQUE LED L21
POUT6
HIGH TORQUE LED L21
POUT7
LPG LED L22
POUT7
LPG LED L22
POUT8
HIGH IDLE LED L23
POUT8
HIGH IDLE LED L23
ENGINE STOP BN1
PIN5
ENGINE STOP BN1
PIN5
PIN6
ENGINE START BN2
PIN6
ENGINE START BN2
PIN10
HIGH IDLE BN4
PIN10
AUTO LEVEL BN20
PIN19
HORN BN5
PIN19
HIGH TORQUE/LF OUTRIGGER BN17
PIN23
HIGH TORQUE BN6
PIN23
HIGH IDLE BN4
PIN24
GENERATOR BN7
PIN24
LPG SELECT/RR OUTRIGGER BN22
PIN13
LPG SELECT BN14
PIN13
HORN/LR OUTRIGGER BN15
PIN25
PLATFORM EXT/RET ENABLE BN16
PIN25
OUTRIGGER ENABLE BN16
PIN29
STARTING AID BN3
PIN25
GENERATOR/RF OUTRIGGER BN18
PIN29
STARTING AID BN3
PIN1
PIN2
PIN3
PIN4
POUT1
PIN11
WH
LIFT ENABLE HIGH BN12
BL
LIFT ENABLE LOW BN13
RD
PLATFORM UP/DOWN TS20
YL
RD
BK
WH
PIN1
UP
DOWN
-
RD
POUT1
ALARM
PLATFORM CONTROLS
(GASOLINE/LPG MODELS WITHOUT OUTRIGGERS)
UP
YL
PIN4
H1
LIFT ENABLE LOW BN13
RD
PIN3
+
LIFT ENABLE HIGH BN12
BL
PIN2
BK
PIN11
6 - 24
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
SW6 STEER
LEFT/ RIGHT
SW5
WH/BL
JOYSTICK
CONTROLLER
D7
U3
SW25
DIP
SWITCH
JC1
BN
WH/BK
PIN18
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
DIP
SWITCH
1
2
3
4
5
6
7
8
D7
U3
SW25
12V DC
DOWN
+
-
PLATFORM & OUTRIGGER
UP/DOWN TS21
H1
ALARM
PLATFORM CONTROLS
(GASOLINE/LPG MODELS WITH OUTRIGGERS)
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 6 • Schematics
This page intentionally left blank.
Part No. 52302
GS-2668 RT • GS-3268 RT
6 - 25
Section 6 • Schematics
March 2005
Electrical Schematic
Gasoline/LPG Models (from serial number 41824 to GS6803-42381)
Part 1 of 3
PLATFORM
B
REV A
2
GROUND
B1
4
85
GROUND
86
CR43
3
87
KS1
POWER TO
ECM
30
KEY SWITCH
85
CR1
86
CR25
87
86
30
85
85
86
CR8
87
87
ENGINE RUN
30
ENGINE
START
BN68
IGNITION
30
START
87a
85
86
CR15
87
STARTING AID
30
CB1
20A
85
86
R
D1 F
CR4
87
J4-A2
J2-A5
J4-A5
U5
ELECTRONIC CONTROL MODULE
J4-B6
J2-B8
J2-B7
J4-B2
J4-B1
J1-B1
J1-A9
J2-B11
(OPTION)
J1-C11,C12 J2-B12
J1-C1\C4
HYDRAULIC
OIL COOLER
J4-B5
J4-C4
L30
J4-C3
G6
J4-B4
HIGH IDLE
30
F9A
B1
SW4
20A
12V DC
(+)
U19
G
M3
30
86
87
85
CR17
U26
30
CR5 86
87
85
Q7
N.O.
L27
Q3
H2
N.O.
L42
SW1
SW2 L41 L42 L27 Y29
GENERATOR (OPTION)
OIL PRESSURE LED
GENERATOR ON LED
COOLANT
TEMPERATURE LED
OIL PRESSURE SWITCH
COOLANT
TEMPERATURE SWITCH
WORK LIGHTS (OPTION)
FLASHING BEACON (OPTION)
CHOKE
TILT ALARM
HOURMETER
AUXILIARY PLATFORM
DOWN (GS-3268 ONLY)
HYDRAULIC OIL
TEMPERATURE SWITCH
Y7 Y10 Y7A Y10A H1 FB1
PLATFORM DOWN
(GS-3268 ONLY)
Q3 L30 H2
AUXILIARY PLATFORM
DOWN (GS-3268 ONLY)
Q7
PLATFORM DOWN
G6
AUTOMOTIVE-STYLE HORN
(OPTION)
SW4
HIGH IDLE SOLENOID
M1
HYDRAULIC OIL
COOLING FAN (OPTION)
( )
SPARK PLUG(S)
ENGINE STARTER
U19 U26 U20
DISTRIBUTOR
BATTERY 12V DC
D1
IGNITION COIL
M3
ALTERNATOR
B1
N.C.
FB1
M1
-
SW1 SW2 L41
H1
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
6 - 26
ES0116V
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 6 • Schematics
Electrical Schematic
Gasoline/LPG Models (from serial number 41824 to GS6803-42381)
Part 2 of 3
REV A
P1
EMERGENCY
STOP
QD4
C
C
A
A
B
B
D
D
E
E
G8
OUTRIGGERS
(OPTION)
DIAGNOSTIC
DISPLAY
(OPTION)
BN44 FUNCTION
RD
ENABLE
BN90 TS54
HIGH
IDLE
BN83
BN84
PLATFORM
UP
PLATFORM
DOWN
PS3
PLATFORM
OVERLOAD
N.O.
N.C.
N.C.
LS12
LS13
LS14
LS15
LEFT
FRONT
OUTRIGGER
RIGHT
FRONT
OUTRIGGER
LEFT
REAR
OUTRIGGER
RIGHT
REAR
OUTRIGGER
N.O.
N.O.
N.O.
N.O.
S7
MODELS
WITHOUT
OUTRIGGERS
DATA LINK (-) YL
DATA LINK (+) BK
LEVEL
SENSOR
BN
J1-C7,C8
J2-B10
J2-A6
J2-C1/C10
J3-A5
J3-A4
J3-B4
J3-B5
J3-A6
J2-A10
J2-A8
J2-A7
J3-A3
J3-A1
J3-A2
J2-A2
J2-A1
J4-A4
J4-A3
U5
LEVEL
SENSOR
CIRCUIT
BOARD
GROUND FROM PLATFORM
GLOW
PLUG
LS6
PLATFORM
DOWN
WH
ELECTRONIC CONTROL MODULE
J4-C2
J4-C1
J2-B3
J2-B1
J1-B8
J2-B10
J1-B7
J1-B6
J3-B2
J3-B1
J1-B5
J1-B2
J1-B3
J1-A12
J1-A11
J1-A10
J1-A8
J1-A7
J1-A6
J1-A5
J1-A4
J1-A3
J1-A2
J1-A1
YL
BL
RD
S8
2-AXIS
LEVEL
SENSOR
Q1
BK
M4
S9
Q1 M4 Q2
GASOLINE SELECT
Y44
LPG SELECT
Y39
FUEL PUMP
Y40
AUTO LEVELING
SENSOR
Y34
OUTRIGGER RETRACT
Y33
OUTRIGGER EXTEND
SLOW
DRIVE REVERSE
Y36
OUTRIGGER EXTEND
DRIVE FORWARD
Y35
RIGHT REAR
OUTRIGGER
BRAKE RELEASE
Y9
LEFT REAR
OUTRIGGER
PLATFORM UP
Y1A Y1B
RIGHT FRONT
OUTRIGGER
STEER LEFT
Y1
LEFT FRONT
OUTRIGGER
STEER RIGHT
Y6A Y5A
PROPORTIONAL
FLOW CONTROL
Y5
DRIVE PARALLEL
Y6
DRIVE PARALLEL
Y2
DRIVE PARALLEL
Y8
DRIVE REVERSE
Y4
DRIVE FORWARD
Y3
Q2
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
ES0116V
Part No. 52302
GS-2668 RT • GS-3268 RT
6 - 27
Section 6 • Schematics
March 2005
Electrical Schematic
Gasoline/LPG Models (from serial number 41824 to GS6803-42381)
Part 3 of 3
REV A
P2
C
P2
EMERGENCY
STOP
QD3
A
A
RD
BK
POWER TO PLATFORM
BK
C
RD
POWER TO GROUND
B
B
WH
GROUND
PIO3
D
D
BL
DATA LINK (HIGH)
PIO4
E
E
YL
DATA LINK (LOW)
PIO5
EMERGENCY
STOP
QD3
PIO2
C
C
BK
POWER TO PLATFORM
A
A
RD
POWER TO GROUND
BK
RD
B
B
WH
GROUND
PIO3
D
D
BL
DATA LINK (HIGH)
PIO4
E
E
YL
DATA LINK (LOW)
PIO5
PIO2
12V DC
OR
R15
PP
5K
POTENTIOMETER
WH/YL
WH/BL
PIN18
PIN15
POWER LED L19
POUT3
JOYSTICK
CONTROLLER
WH/YL
FUNCTION ENABLE
WH/RD
SW6 STEER
LEFT/ RIGHT
WH
PLATFORM CONTROLS
MEMBRANE DECAL
POUT2
PP
5K
POTENTIOMETER
SW5
PIN14
BK
R15
RIGHT
WH
JC1
BN
LEFT
RIGHT
WH/RD
OR
WH/BK
LEFT
PIN15
PIN14
FUNCTION ENABLE
1
2
3
4
5
6
7
8
PLATFORM CONTROLS
MEMBRANE DECAL
BK
POUT2
POWER LED L19
POUT3
LIFT ERROR INDICATOR LED L57
POUT4
FAULT LED L25
POUT4
FAULT LED L25
POUT5
GENERATOR LED L27
POUT5
GENERATOR LED L27
POUT6
HIGH TORQUE LED L21
POUT6
HIGH TORQUE LED L21
POUT7
LPG LED L22
POUT7
LPG LED L22
POUT8
HIGH IDLE LED L23
POUT8
HIGH IDLE LED L23
ENGINE STOP BN1
PIN5
ENGINE STOP BN1
PIN5
PIN6
ENGINE START BN2
PIN6
ENGINE START BN2
PIN10
HIGH IDLE BN4
PIN10
AUTO LEVEL BN20
PIN19
HORN BN5
PIN19
HIGH TORQUE/LF OUTRIGGER BN17
PIN23
HIGH TORQUE BN6
PIN23
HIGH IDLE BN4
PIN24
GENERATOR BN7
PIN24
LPG SELECT/RR OUTRIGGER BN22
PIN13
LPG SELECT BN14
PIN13
HORN/LR OUTRIGGER BN15
PIN25
PLATFORM EXT/RET ENABLE BN16
PIN25
OUTRIGGER ENABLE BN16
PIN29
STARTING AID BN3
PIN25
GENERATOR/RF OUTRIGGER BN18
PIN29
STARTING AID BN3
PIN1
PIN2
PIN3
PIN4
POUT1
PIN11
WH
LIFT ENABLE HIGH BN12
BL
LIFT ENABLE LOW BN13
RD
PLATFORM UP/DOWN TS20
YL
RD
BK
WH
PIN1
UP
DOWN
-
RD
POUT1
ALARM
PLATFORM CONTROLS
(GASOLINE/LPG MODELS WITHOUT OUTRIGGERS)
UP
YL
PIN4
H1
LIFT ENABLE LOW BN13
RD
PIN3
+
LIFT ENABLE HIGH BN12
BL
PIN2
BK
PIN11
6 - 28
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
SW6 STEER
LEFT/ RIGHT
SW5
WH/BL
JOYSTICK
CONTROLLER
D7
U3
SW25
DIP
SWITCH
JC1
BN
WH/BK
PIN18
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
DIP
SWITCH
1
2
3
4
5
6
7
8
D7
U3
SW25
12V DC
DOWN
+
-
PLATFORM & OUTRIGGER
UP/DOWN TS21
H1
ALARM
PLATFORM CONTROLS
(GASOLINE/LPG MODELS WITH OUTRIGGERS)
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 6 • Schematics
This page intentionally left blank.
Part No. 52302
GS-2668 RT • GS-3268 RT
6 - 29
Section 6 • Schematics
March 2005
Electrical Schematic
ANSI Models with Gasoline/LPG Power
(from serial number GS6803-42382 to GS6805-43594)
Part 1 of 3
P1
KS1 KEY SWITCH
B1
REV A
EMERGENCY STOP
2
PLATFORM
CONTROL
B
4
3
GROUND
CONTROL
AB1
CB2 20A
AB3
AB3
AB7
AB3
AB28
CR41
CONTROL
SYSTEM
CR42
CR5
CR8
POWER
HORN
IGNITION
CR1
CR23
ENGINE
START
AUXILIARY
DOWN
N.C.
G6
HOUR
METER
AB1
86
85
30
87
1
86
87A
85
2
86
87A
85
30
87
30
87
5
86
87A
85
30
87
4
86
87A
85
30
87
3
86
87A
85
87
LS6
PLAT
DOWN
LIMIT
SWITCH
6
30
87A
STA
J1-A9
U19
J1-A3
J1-C7
J2-C4
J2-B9
J2-A3
D1
J2-A5
WORK LIGHTS
EXCT
J2-C1/C3
J2-A2
J2-C12
J1-C2
J2-B11
ECM
J2-B8
L30
BAT
J2-B7
J2-A4
U5
BN23
BN91
AUXILIARY DOWN
AUXILIARY DOWN
ENABLE
(+)
B1
-
( )
STARTER
+
86
CR4
STARTING
AID
HIGH IDLE
30
7
86
87A
85
30
8
G
U26
CR15
M3
-
85
87
H2
87
87A
Q7
Q3
CHOKE
SOLENOID
HIGH IDLE
SOLENOID
C5
4700 uF
Y7A
Y8
Y7
Y10A
Y10
Y10A AUX PLATFORM DOWN
(GS-3268 ONLY)
Y7A PLATFORM DOWN
(GS-3268 ONLY)
Y10 AUX PLATFORM DOWN
Y7 PLATFORM DOWN
Y8 PLATFORM UP
G6 ENGINE HOURMETER
Q3 HIGH IDLE SOLENOID
L30 WORK LIGHTS (OPTION)
U32 GLOW PLUG (OPTION)
D1 ALTERNATOR
U20 SPARK PLUG(S)
U26 DISTRIBUTOR
U19 IGNITION COIL
K1 STARTER RELAY
M3 STARTER MOTOR
H2 AUTOMOTIVE-STYLE HORN
B1 12 VOLT BATTERY
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
6 - 30
ES7161A
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 6 • Schematics
Electrical Schematic
ANSI Models with Gasoline/LPG Power
(from serial number GS6803-42382 to GS6805-43594)
Part 2 of 3
REV A
AB2
SW4
F9A
WH
RD
CR8 TERMINAL 30
BATTERY (+)
N.O.
20A
CR17
30
86
N.C.
87
HYDRAULIC
OIL COOLER
LEVEL SENSOR
CIRCUIT BOARD
85
M1
(OPTION)
S7 LEVEL
SENSOR
MODELS WITHOUT
OUTRIGGERS
BATTERY (-)
AB23
BK
AB29
AB1
J2-B10
J2-A6
J2-B2
U5
ELECTRONIC CONTROL MODULE
J2-C7
J1-B12
J1-C11
AB11
J1-B1
J1-B3
J1-A8
J1-A7
J1-A6
J1-A5
J1-A4
J1-A12
J1-A11
J1-A10
J1-A1
J1-A2
J2-C11
J2-B12
J1-C9
J1-C8
AB22
AB13
Y4
Y1B
Y1
Y6
Y9
Y6A
Q2
Q1
M4
SW2
SW1
H5
FB1
Y3
Y1A
Y5
Y2
Y5A
S7 LEVEL SENSOR
ECM GROUND
Q1 LPG SELECT
M4 FUEL PUMP
Q2 GASOLINE SELECT
PROPORTIONAL
FLOW CONTROL
Y29 GENERATOR (OPTION)
Y9
Y5A DRIVE REVERSE (2)
Y6A DRIVE FORWARD (2)
Y5 DRIVE REVERSE (1)
Y6 DRIVE FORWARD (1)
Y2 BRAKE RELEASE
Y1B DRIVE PARALLEL
Y1A DRIVE PARALLEL
Y1 DRIVE PARALLEL
Y3 STEER RIGHT
Y4 STEER LEFT
FB1 FLASHING BEACON (OPTION)
H5 ALARM
SW1 COOLANT TEMPERATURE SWITCH
SW2OIL PRESSURE SWITCH
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
ES7161A
Part No. 52302
Y29
GS-2668 RT • GS-3268 RT
6 - 31
Section 6 • Schematics
March 2005
Electrical Schematic
ANSI Models with Gasoline/LPG Power
(from serial number GS6803-42382 to GS6805-43594)
Part 3 of 3
REV A
P2
QD3
QD4
WH/RD
4
4
4
4
BK
POWER TO PLATFORM
POWER TO GROUND
EMERGENCY
STOP
BK
RD
RD/WH
3
3
3
3
RD
BL
1
1
1
1
WH
GROUND
WH
BK
2
2
2
2
BL
DATA LINK (HIGH)
BL
OR
5
5
5
5
OR
DATA LINK (LOW)
OR
J5 PIN1
J5 PIN4
J5 PIN5
OUTRIGGERS
J5 PIN2
(OPTION)
AB3
AB3
AB2
D7
U3
AB2
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
12V DC
5V DC
S8
2 AXIS
TILT LEVEL
SENSOR
J5 PIN3
J2 PIN5
J2 PIN6
J2 PIN7
AB1
HALL EFFECT
GENERATOR
YL
WH
BN
BL
PP
GY
SW5
OR
FUNCTION ENABLE
BK
J2-A12
J2-A11
J2-A10
J2-B2
J2-B3
J2-B10
J2-B1
J1-C4
J1-C6
J1-C3
J1-C5
Y36
AB7
AB8
Y34
Y35
ELECTRONIC
CONTROL
MODULE
J1-B8
J1-B7
J1-B6
J1-B10
J1-B11
J1-B9
J1-B5
AB14
AB15
AB6
Y40
Y33
Y44
Y39
J2 PIN14
WH/BL
POUT1
HORN BN5
PIN3
STARTING AID BN3
PIN4
ENGINE START BN2
PIN5
HIGH TORQUE BN6
PIN6
GENERATOR BN7
PIN7
LPG SELECT BN14
PIN8
HIGH IDLE BN4
PIN9
LF OUTRIGGER ENABLE BN85
PIN10
RF OUTRIGGER ENABLE BN86
PIN11
LR OUTRIGGER ENABLE BN87
PIN12
RR OUTRIGGER ENABLE BN24
S8 2-AXIS LEVEL SENSOR
Y44 OUTRIGGER DOWN SLOW
Y39 OUTRIGGER RETRACT
Y40 OUTRIGGER EXTEND
Y33 LEFT REAR OUTRIGGER
Y34 RIGHT REAR OUTRIGGER
Y35 LEFT FRONT OUTRIGGER
Y36 RIGHT FRONT OUTRIGGER
PIN13
LIFT FUNCTION BN9
PIN14
ORGR AUTOLEVEL ENABLE BN20
PIN15
SYSTEM STATUS L50
J1 PIN4
J1 PIN3
J1 PIN1
J1 PIN5
J3 PIN1
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
6 - 32
STEER
LEFT/ RIGHT
RD
PIN2
AB10
SW6
J2 PIN8
U5
AB9
JC1
JOYSTICK
CONTROLLER
RIGHT
AB25
J2 PIN4
GY
LEFT
AB16
DATA LINK (-)
GND FROM PLAT
AB17
AB24
DATA LINK (+)
BK
AB26
J2 PIN13
N.O.
AB23
AB27
GROUND
YL
N.O.
BL
N.O.
J2 PIN2
J2 PIN12
J2 PIN3
RD
N.O.
ROLL
LF
RF
LR
RR
O-RIG
O-RIG
O-RIG
O-RIG
LIMIT
LIMIT
LIMIT
LIMIT
SWITCH SWITCH SWITCH SWITCH
PITCH
POWER
LS12 LS13 LS14 LS15
J2 PIN1
J3 PIN2
ES7161A
GS-2668 RT • GS-3268 RT
YL
PLATFORM UP/DOWN TS20
-ORPLATFORM & OUTRIGGER
UP/DOWN
TS21
BL
RD
BK
RD
BK
+
H1
ALARM
PLATFORM
CONTROLS
Part No. 52302
March 2005
Section 6 • Schematics
This page intentionally left blank.
Part No. 52302
GS-2668 RT • GS-3268 RT
6 - 33
Section 6 • Schematics
March 2005
Electrical Schematic
ANSI Models with Gasoline/LPG Power
(after serial number GS6805-43594)
Part 1 of 3
F9 5A FUSE
KS1 KEY SWITCH
REV A
P1EMERGENCY STOP
2
B1
PLATFORM
CONTROL
4
B
3
GROUND
CONTROL
AB1
CB2 20A
AB3
AB3
AB7
AB3
AB28
CR41
CONTROL
SYSTEM
CR42
CR5
CR8
POWER
HORN
IGNITION
CR1
CR23
ENGINE
START
AUXILIARY
DOWN
N.C.
G6
HOUR
METER
AB1
86
85
30
87
1
86
87A
85
2
86
87A
85
30
87
30
87
5
86
87A
85
30
87
4
86
87A
85
30
87
3
86
87A
85
30
87
LS6
PLAT
DOWN
LIMIT
SWITCH
6
87A
STA
J1-A9
U19
J1-A3
J1-C7
J2-C4
J2-B9
J2-A3
D1
J2-A5
WORK LIGHTS
EXCT
J2-C1/C3
J2-A2
J2-C12
J1-C2
J2-B11
ECM
J2-B8
L30
BAT
J2-B7
J2-A4
U5
BN23
BN91
AUXILIARY DOWN
AUXILIARY DOWN
ENABLE
(+)
B1
-
( )
STARTER
+
86
CR4
STARTING
AID
HIGH IDLE
30
7
86
87A
85
30
8
G
U26
CR15
M3
-
85
87
H2
87
87A
Q7
Q3
CHOKE
SOLENOID
HIGH IDLE
SOLENOID
C5
4700 uF
Y7A
Y8
Y7
Y10A
Y10
Y10A AUX PLATFORM DOWN
(GS-3268 ONLY)
Y7A PLATFORM DOWN
(GS-3268 ONLY)
Y10 AUX PLATFORM DOWN
Y7 PLATFORM DOWN
Y8 PLATFORM UP
G6 ENGINE HOURMETER
Q3 HIGH IDLE SOLENOID
L30 WORK LIGHTS (OPTION)
U32 GLOW PLUG (OPTION)
D1 ALTERNATOR
U20 SPARK PLUG(S)
U26 DISTRIBUTOR
U19 IGNITION COIL
K1 STARTER RELAY
M3 STARTER MOTOR
H2 AUTOMOTIVE-STYLE HORN
B1 12 VOLT BATTERY
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
6 - 34
ES7161D
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 6 • Schematics
Electrical Schematic
ANSI Models with Gasoline/LPG Power
(after serial number GS6805-43594)
Part 2 of 3
REV A
AB2
SW4
F9A
WH
RD
CR8 TERMINAL 30
BATTERY (+)
N.O.
20A
CR17
30
86
N.C.
87
HYDRAULIC
OIL COOLER
LEVEL SENSOR
CIRCUIT BOARD
85
M1
(OPTION)
S7 LEVEL
SENSOR
MODELS WITHOUT
OUTRIGGERS
BATTERY (-)
AB23
BK
AB29
AB1
J2-B10
J2-A6
J2-B2
U5
ELECTRONIC CONTROL MODULE
J2-C7
J1-B12
J1-C11
AB11
J1-B1
J1-B3
J1-A8
J1-A7
J1-A6
J1-A5
J1-A4
J1-A12
J1-A11
J1-A10
J1-A1
J1-A2
J2-C11
J2-B12
J1-C9
J1-C8
AB22
AB13
Y4
Y1B
Y1
Y6
Y9
Y6A
Q2
Q1
M4
SW2
SW1
H5
FB1
Y3
Y1A
Y5
Y2
Y5A
S7 LEVEL SENSOR
ECM GROUND
Q1 LPG SELECT
M4 FUEL PUMP
Q2 GASOLINE SELECT
PROPORTIONAL
FLOW CONTROL
Y29 GENERATOR (OPTION)
Y9
Y5A DRIVE REVERSE (2)
Y6A DRIVE FORWARD (2)
Y5 DRIVE REVERSE (1)
Y6 DRIVE FORWARD (1)
Y2 BRAKE RELEASE
Y1B DRIVE PARALLEL
Y1A DRIVE PARALLEL
Y1 DRIVE PARALLEL
Y3 STEER RIGHT
Y4 STEER LEFT
FB1 FLASHING BEACON (OPTION)
H5 ALARM
SW1 COOLANT TEMPERATURE SWITCH
SW2OIL PRESSURE SWITCH
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
ES7161D
Part No. 52302
Y29
GS-2668 RT • GS-3268 RT
6 - 35
Section 6 • Schematics
March 2005
Electrical Schematic
ANSI Models with Gasoline/LPG Power
(after serial number GS6805-43594)
Part 3 of 3
REV A
P2
QD3
QD4
WH/RD
4
4
4
4
BK
POWER TO PLATFORM
POWER TO GROUND
EMERGENCY
STOP
BK
RD
RD/WH
3
3
3
3
RD
BL
1
1
1
1
WH
GROUND
WH
BK
2
2
2
2
BL
DATA LINK (HIGH)
BL
OR
5
5
5
5
OR
DATA LINK (LOW)
OR
J5 PIN1
J5 PIN4
J5 PIN5
OUTRIGGERS
J5 PIN2
(OPTION)
AB3
AB3
AB2
D7
U3
AB2
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
12V DC
5V DC
S8
2 AXIS
TILT LEVEL
SENSOR
J5 PIN3
J2 PIN5
J2 PIN6
J2 PIN7
AB1
HALL EFFECT
GENERATOR
YL
WH
BN
BL
PP
GY
SW5
OR
FUNCTION ENABLE
BK
J2-A12
J2-A11
J2-A10
J2-B2
J2-B3
J2-B10
J2-B1
J1-C4
J1-C6
J1-C3
J1-C5
Y36
AB7
AB8
Y34
Y35
ELECTRONIC
CONTROL
MODULE
J1-B8
J1-B7
J1-B6
J1-B10
J1-B11
J1-B9
J1-B5
AB14
AB15
AB6
Y40
Y33
Y44
Y39
J2 PIN14
WH/BL
POUT1
HORN BN5
PIN3
STARTING AID BN3
PIN4
ENGINE START BN2
PIN5
HIGH TORQUE BN6
PIN6
GENERATOR BN7
PIN7
LPG SELECT BN14
PIN8
HIGH IDLE BN4
PIN9
LF OUTRIGGER ENABLE BN85
PIN10
RF OUTRIGGER ENABLE BN86
PIN11
LR OUTRIGGER ENABLE BN87
PIN12
RR OUTRIGGER ENABLE BN24
S8 2-AXIS LEVEL SENSOR
Y44 OUTRIGGER DOWN SLOW
Y39 OUTRIGGER RETRACT
Y40 OUTRIGGER EXTEND
Y33 LEFT REAR OUTRIGGER
Y34 RIGHT REAR OUTRIGGER
Y35 LEFT FRONT OUTRIGGER
Y36 RIGHT FRONT OUTRIGGER
PIN13
LIFT FUNCTION BN9
PIN14
ORGR AUTOLEVEL ENABLE BN20
PIN15
SYSTEM STATUS L50
J1 PIN4
J1 PIN3
J1 PIN1
J1 PIN5
J3 PIN1
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
6 - 36
STEER
LEFT/ RIGHT
RD
PIN2
AB10
SW6
J2 PIN8
U5
AB9
JC1
JOYSTICK
CONTROLLER
RIGHT
AB25
J2 PIN4
GY
LEFT
AB16
DATA LINK (-)
GND FROM PLAT
AB17
AB24
DATA LINK (+)
BK
AB26
J2 PIN13
N.O.
AB23
AB27
GROUND
YL
N.O.
BL
N.O.
J2 PIN2
J2 PIN12
J2 PIN3
RD
N.O.
ROLL
LF
RF
LR
RR
O-RIG
O-RIG
O-RIG
O-RIG
LIMIT
LIMIT
LIMIT
LIMIT
SWITCH SWITCH SWITCH SWITCH
PITCH
POWER
LS12 LS13 LS14 LS15
J2 PIN1
J3 PIN2
ES7161D
GS-2668 RT • GS-3268 RT
YL
PLATFORM UP/DOWN TS20
-ORPLATFORM & OUTRIGGER
UP/DOWN
TS21
BL
RD
BK
RD
BK
+
H1
ALARM
PLATFORM
CONTROLS
Part No. 52302
March 2005
Section 6 • Schematics
This page intentionally left blank.
Part No. 52302
GS-2668 RT • GS-3268 RT
6 - 37
Section 6 • Schematics
March 2005
Electrical Schematic
CE Models with Gasoline/LPG Power
(from serial number GS6803-42382 to GS6805-43594)
Part 1 of 3
P1
KS1 KEY SWITCH
B1
REV A
EMERGENCY STOP
2
PLATFORM
CONTROL
B
4
3
GROUND
CONTROL
AB1
CB2 20A
AB4
AB3
AB7
AB28
PS2
PLATFORM
OVERLOAD
PRESSURE
SWITCH
AB20
CR41
CONTROL
SYSTEM
CR42
CR5
CR8
POWER
HORN
IGNITION
CR1
CR23
ENGINE
START
AUXILIARY
DOWN
N.C.
G6
HOUR
METER
AB1
86
85
30
87
1
86
87A
85
2
86
87A
85
30
87
5
86
87A
85
30
87
4
86
87A
85
30
87
30
87
3
86
87A
85
87
LS6
PLAT
DOWN
LIMIT
SWITCH
6
30
87A
AB21
STA
U19
J2-B9
J1-A9
AB1
J1-A3
J1-C7
J2-C4
J2-A3
D1
J2-A5
EXCT
J2-C1/C3
BAT
J2-A2
J2-C12
J1-C2
J2-B11
J2-B8
ECM
J2-B7
J2-A4
U5
BN23
BN91
AUXILIARY DOWN
AUXILIARY DOWN
ENABLE
(+)
B1
-
( )
STARTER
+
U26
L30
CR15
CR4
STARTING
AID
HIGH IDLE
86
AB1
7
86
87A
85
30
WORK
LIGHTS
30
8
N.C.
LS24
LS25
MAXIMUM
HEIGHT
LIMIT SW
LOAD SENSE
DELAY
LIMIT SW
G
86
M3
85
87
87
H2
Q7
Q3
CHOKE
SOLENOID
HIGH IDLE
SOLENOID
9
30
CR77
87A
DOWN
ENABLE
C5
-
AB12
N.C.
85
87
Y7A
87A
Y10A
4700 uF
Y7
Y8
Y10
Y10A AUX PLATFORM DOWN
(GS-3268 ONLY)
Y7A PLATFORM DOWN
(GS-3268 ONLY)
Y10 AUX PLATFORM DOWN
Y7 PLATFORM DOWN
Y8 PLATFORM UP
G6 ENGINE HOURMETER
L30 WORK LIGHTS (OPTION)
Q3 HIGH IDLE SOLENOID
U32 GLOW PLUG (OPTION)
D1 ALTERNATOR
U20 SPARK PLUG(S)
U26 DISTRIBUTOR
U19 IGNITION COIL
K1 STARTER RELAY
M3 STARTER MOTOR
H2 AUTOMOTIVE-STYLE HORN
B1 12 VOLT BATTERY
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
6 - 38
ES7161A
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 6 • Schematics
Electrical Schematic
CE Models with Gasoline/LPG Power
(from serial number GS6803-42382 to GS6805-43594)
Part 2 of 3
REV A
AB2
SW4
F9A
WH
RD
CR8 TERMINAL 30
BATTERY (+)
N.O.
20A
CR17
30
86
N.C.
87
HYDRAULIC
OIL COOLER
LEVEL SENSOR
CIRCUIT BOARD
85
M1
(OPTION)
S7 LEVEL
SENSOR
MODELS WITHOUT
OUTRIGGERS
BATTERY (-)
AB23
BK
AB29
AB1
J2-B10
J2-A6
J2-B2
U5
ELECTRONIC CONTROL MODULE
J2-C7
J1-B12
J1-C11
AB11
J1-B1
J1-B3
J1-A8
J1-A7
J1-A6
J1-A5
J1-A4
J1-A12
J1-A11
J1-A10
J1-A1
J1-A2
J2-C11
J2-B12
J1-C9
J1-C8
AB22
AB13
Y4
Y1B
Y1
Y6
Y9
Y6A
Q2
Q1
M4
SW2
SW1
H5
FB1
Y3
Y1A
Y5
Y2
Y5A
S7 LEVEL SENSOR
ECM GROUND
Q1 LPG SELECT
M4 FUEL PUMP
Q2 GASOLINE SELECT
PROPORTIONAL
FLOW CONTROL
Y29 GENERATOR (OPTION)
Y9
Y5A DRIVE REVERSE (2)
Y6A DRIVE FORWARD (2)
Y5 DRIVE REVERSE (1)
Y6 DRIVE FORWARD (1)
Y2 BRAKE RELEASE
Y1B DRIVE PARALLEL
Y1A DRIVE PARALLEL
Y1 DRIVE PARALLEL
Y3 STEER RIGHT
Y4 STEER LEFT
FB1 FLASHING BEACON (OPTION)
H5 ALARM
SW1 COOLANT TEMPERATURE SWITCH
SW2OIL PRESSURE SWITCH
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
ES7161A
Part No. 52302
Y29
GS-2668 RT • GS-3268 RT
6 - 39
Section 6 • Schematics
March 2005
Electrical Schematic
CE Models with Gasoline/LPG Power
(from serial number GS6803-42382 to GS6805-43594)
Part 3 of 3
REV A
P2
QD3
QD4
WH/RD
4
4
4
4
BK
POWER TO PLATFORM
POWER TO GROUND
EMERGENCY
STOP
BK
RD
RD/WH
3
3
3
3
RD
BL
1
1
1
1
WH
GROUND
WH
BK
2
2
2
2
BL
DATA LINK (HIGH)
BL
OR
5
5
5
5
OR
DATA LINK (LOW)
OR
J5 PIN1
J5 PIN4
J5 PIN5
OUTRIGGERS
J5 PIN2
(OPTION)
AB3
AB3
AB2
D7
U3
AB2
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
12V DC
5V DC
S8
2 AXIS
TILT LEVEL
SENSOR
J5 PIN3
J2 PIN5
J2 PIN6
J2 PIN7
AB1
HALL EFFECT
GENERATOR
YL
WH
BN
BL
PP
GY
SW5
OR
FUNCTION ENABLE
BK
J2-A12
J2-A11
J2-A10
J2-B2
J2-B3
J2-B10
J2-B1
J1-C4
J1-C6
J1-C3
J1-C5
Y36
AB7
AB8
Y34
Y35
ELECTRONIC
CONTROL
MODULE
J1-B8
J1-B7
J1-B6
J1-B10
J1-B11
J1-B9
J1-B5
AB14
AB15
AB6
Y40
Y33
Y44
Y39
J2 PIN14
WH/BL
POUT1
HORN BN5
PIN3
STARTING AID BN3
PIN4
ENGINE START BN2
PIN5
HIGH TORQUE BN6
PIN6
GENERATOR BN7
PIN7
LPG SELECT BN14
PIN8
HIGH IDLE BN4
PIN9
LF OUTRIGGER ENABLE BN85
PIN10
RF OUTRIGGER ENABLE BN86
PIN11
LR OUTRIGGER ENABLE BN87
PIN12
RR OUTRIGGER ENABLE BN24
S8 2-AXIS LEVEL SENSOR
Y44 OUTRIGGER DOWN SLOW
Y39 OUTRIGGER RETRACT
Y40 OUTRIGGER EXTEND
Y33 LEFT REAR OUTRIGGER
Y34 RIGHT REAR OUTRIGGER
Y35 LEFT FRONT OUTRIGGER
Y36 RIGHT FRONT OUTRIGGER
PIN13
LIFT FUNCTION BN9
PIN14
ORGR AUTOLEVEL ENABLE BN20
PIN15
SYSTEM STATUS L50
J1 PIN4
J1 PIN3
J1 PIN1
J1 PIN5
J3 PIN1
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
6 - 40
STEER
LEFT/ RIGHT
RD
PIN2
AB10
SW6
J2 PIN8
U5
AB9
JC1
JOYSTICK
CONTROLLER
RIGHT
AB25
J2 PIN4
GY
LEFT
AB16
DATA LINK (-)
GND FROM PLAT
AB17
AB24
DATA LINK (+)
BK
AB26
J2 PIN13
N.O.
AB23
AB27
GROUND
YL
N.O.
BL
N.O.
J2 PIN2
J2 PIN12
J2 PIN3
RD
N.O.
ROLL
LF
RF
LR
RR
O-RIG
O-RIG
O-RIG
O-RIG
LIMIT
LIMIT
LIMIT
LIMIT
SWITCH SWITCH SWITCH SWITCH
PITCH
POWER
LS12 LS13 LS14 LS15
J2 PIN1
J3 PIN2
ES7161A
GS-2668 RT • GS-3268 RT
YL
PLATFORM UP/DOWN TS20
-ORPLATFORM & OUTRIGGER
UP/DOWN
TS21
BL
RD
BK
RD
BK
+
H1
ALARM
PLATFORM
CONTROLS
Part No. 52302
March 2005
Section 6 • Schematics
This page intentionally left blank.
Part No. 52302
GS-2668 RT • GS-3268 RT
6 - 41
Section 6 • Schematics
March 2005
Electrical Schematic
CE Models with Gasoline/LPG Power
(after serial number GS6805-43594)
Part 1 of 3
F9 5A FUSE
KS1 KEY SWITCH
REV A
P1EMERGENCY STOP
2
B1
PLATFORM
CONTROL
4
B
3
GROUND
CONTROL
AB1
CB2 20A
AB4
AB3
AB7
AB28
PS2
PLATFORM
OVERLOAD
PRESSURE
SWITCH
AB20
CR41
CONTROL
SYSTEM
CR42
CR5
CR8
POWER
HORN
IGNITION
CR1
CR23
ENGINE
START
AUXILIARY
DOWN
N.C.
G6
HOUR
METER
AB1
86
85
30
87
1
86
87A
85
2
86
87A
85
30
87
5
86
87A
85
30
87
4
86
87A
85
30
87
30
87
3
86
87A
85
87
LS6
PLAT
DOWN
LIMIT
SWITCH
6
30
87A
AB21
STA
U19
J2-B9
J1-A9
AB1
J1-A3
J1-C7
J2-C4
J2-A3
D1
J2-A5
EXCT
J2-C1/C3
BAT
J2-A2
J2-C12
J1-C2
J2-B11
J2-B8
ECM
J2-B7
J2-A4
U5
BN23
BN91
AUXILIARY DOWN
AUXILIARY DOWN
ENABLE
(+)
B1
-
( )
STARTER
+
U26
L30
CR15
CR4
STARTING
AID
HIGH IDLE
86
AB1
7
86
87A
85
30
WORK
LIGHTS
30
8
N.C.
LS24
LS25
MAXIMUM
HEIGHT
LIMIT SW
LOAD SENSE
DELAY
LIMIT SW
G
86
M3
85
87
87
H2
Q7
Q3
CHOKE
SOLENOID
HIGH IDLE
SOLENOID
9
30
CR77
87A
DOWN
ENABLE
C5
-
AB12
N.C.
85
87
Y7A
87A
Y10A
4700 uF
Y7
Y8
Y10
Y10A AUX PLATFORM DOWN
(GS-3268 ONLY)
Y7A PLATFORM DOWN
(GS-3268 ONLY)
Y10 AUX PLATFORM DOWN
Y7 PLATFORM DOWN
Y8 PLATFORM UP
G6 ENGINE HOURMETER
L30 WORK LIGHTS (OPTION)
Q3 HIGH IDLE SOLENOID
U32 GLOW PLUG (OPTION)
D1 ALTERNATOR
U20 SPARK PLUG(S)
U26 DISTRIBUTOR
U19 IGNITION COIL
K1 STARTER RELAY
M3 STARTER MOTOR
H2 AUTOMOTIVE-STYLE HORN
B1 12 VOLT BATTERY
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
6 - 42
ES7183B
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 6 • Schematics
Electrical Schematic
CE Models with Gasoline/LPG Power
(after serial number GS6805-43594)
Part 2 of 3
REV A
AB2
SW4
F9A
WH
RD
CR8 TERMINAL 30
BATTERY (+)
N.O.
20A
CR17
30
86
N.C.
87
HYDRAULIC
OIL COOLER
LEVEL SENSOR
CIRCUIT BOARD
85
M1
(OPTION)
S7 LEVEL
SENSOR
MODELS WITHOUT
OUTRIGGERS
BATTERY (-)
AB23
BK
AB29
AB1
J2-B10
J2-A6
J2-B2
U5
ELECTRONIC CONTROL MODULE
J2-C7
J1-B12
J1-C11
AB11
J1-B1
J1-B3
J1-A8
J1-A7
J1-A6
J1-A5
J1-A4
J1-A12
J1-A11
J1-A10
J1-A1
J1-A2
J2-C11
J2-B12
J1-C9
J1-C8
AB22
AB13
Y4
Y1B
Y1
Y6
Y9
Y6A
Q2
Q1
M4
SW2
SW1
H5
FB1
Y3
Y1A
Y5
Y2
Y5A
S7 LEVEL SENSOR
ECM GROUND
Q1 LPG SELECT
M4 FUEL PUMP
Q2 GASOLINE SELECT
PROPORTIONAL
FLOW CONTROL
Y29 GENERATOR (OPTION)
Y9
Y5A DRIVE REVERSE (2)
Y6A DRIVE FORWARD (2)
Y5 DRIVE REVERSE (1)
Y6 DRIVE FORWARD (1)
Y2 BRAKE RELEASE
Y1B DRIVE PARALLEL
Y1A DRIVE PARALLEL
Y1 DRIVE PARALLEL
Y3 STEER RIGHT
Y4 STEER LEFT
FB1 FLASHING BEACON (OPTION)
H5 ALARM
SW1 COOLANT TEMPERATURE SWITCH
SW2OIL PRESSURE SWITCH
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
ES7183B
Part No. 52302
Y29
GS-2668 RT • GS-3268 RT
6 - 43
Section 6 • Schematics
March 2005
Electrical Schematic
CE Models with Gasoline/LPG Power
(after serial number GS6805-43594)
Part 3 of 3
REV A
P2
QD3
QD4
WH/RD
4
4
4
4
BK
POWER TO PLATFORM
POWER TO GROUND
EMERGENCY
STOP
BK
RD
RD/WH
3
3
3
3
RD
BL
1
1
1
1
WH
GROUND
WH
BK
2
2
2
2
BL
DATA LINK (HIGH)
BL
OR
5
5
5
5
OR
DATA LINK (LOW)
OR
J5 PIN1
J5 PIN4
J5 PIN5
OUTRIGGERS
J5 PIN2
(OPTION)
AB3
AB3
AB2
D7
U3
AB2
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
12V DC
5V DC
S8
2 AXIS
TILT LEVEL
SENSOR
J5 PIN3
J2 PIN5
J2 PIN6
J2 PIN7
AB1
HALL EFFECT
GENERATOR
YL
WH
BN
BL
PP
GY
SW5
OR
FUNCTION ENABLE
BK
J2-A12
J2-A11
J2-A10
J2-B2
J2-B3
J2-B10
J2-B1
J1-C4
J1-C6
J1-C3
J1-C5
Y36
AB7
AB8
Y34
Y35
ELECTRONIC
CONTROL
MODULE
J1-B8
J1-B7
J1-B6
J1-B10
J1-B11
J1-B9
J1-B5
AB14
AB15
AB6
Y40
Y33
Y44
Y39
J2 PIN14
WH/BL
POUT1
HORN BN5
PIN3
STARTING AID BN3
PIN4
ENGINE START BN2
PIN5
HIGH TORQUE BN6
PIN6
GENERATOR BN7
PIN7
LPG SELECT BN14
PIN8
HIGH IDLE BN4
PIN9
LF OUTRIGGER ENABLE BN85
PIN10
RF OUTRIGGER ENABLE BN86
PIN11
LR OUTRIGGER ENABLE BN87
PIN12
RR OUTRIGGER ENABLE BN24
S8 2-AXIS LEVEL SENSOR
Y44 OUTRIGGER DOWN SLOW
Y39 OUTRIGGER RETRACT
Y40 OUTRIGGER EXTEND
Y33 LEFT REAR OUTRIGGER
Y34 RIGHT REAR OUTRIGGER
Y35 LEFT FRONT OUTRIGGER
Y36 RIGHT FRONT OUTRIGGER
PIN13
LIFT FUNCTION BN9
PIN14
ORGR AUTOLEVEL ENABLE BN20
PIN15
SYSTEM STATUS L50
J1 PIN4
J1 PIN3
J1 PIN1
J1 PIN5
J3 PIN1
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
6 - 44
STEER
LEFT/ RIGHT
RD
PIN2
AB10
SW6
J2 PIN8
U5
AB9
JC1
JOYSTICK
CONTROLLER
RIGHT
AB25
J2 PIN4
GY
LEFT
AB16
DATA LINK (-)
GND FROM PLAT
AB17
AB24
DATA LINK (+)
BK
AB26
J2 PIN13
N.O.
AB23
AB27
GROUND
YL
N.O.
BL
N.O.
J2 PIN2
J2 PIN12
J2 PIN3
RD
N.O.
ROLL
LF
RF
LR
RR
O-RIG
O-RIG
O-RIG
O-RIG
LIMIT
LIMIT
LIMIT
LIMIT
SWITCH SWITCH SWITCH SWITCH
PITCH
POWER
LS12 LS13 LS14 LS15
J2 PIN1
J3 PIN2
ES7183B
GS-2668 RT • GS-3268 RT
YL
PLATFORM UP/DOWN TS20
-ORPLATFORM & OUTRIGGER
UP/DOWN
TS21
BL
RD
BK
RD
BK
+
H1
ALARM
PLATFORM
CONTROLS
Part No. 52302
March 2005
Section 6 • Schematics
This page intentionally left blank.
Part No. 52302
GS-2668 RT • GS-3268 RT
6 - 45
Section 6 • Schematics
March 2005
Electrical Schematic
Diesel Models (before serial number 21161)
Part 1 of 2
REV B
P1
EMERGENCY
STOP
CB2
PLATFORM
KS1
1A
GROUND
85
86
CR43
GROUND
87
85
(GS-3268RT ONLY)
-
85
CR25
C2
ENGINE RUN
30
33000 uf
R7 2000
30
85
B4
12V DC
86
87
ENGINE
START
86
( )
AUXILIARY
PLATFORM
DOWN
CR1
(+)
BN23
POWER TO
ECM
30
86
CR8
87
87
FUEL
30
TS56 TS54
TS52
85
86
85
86
20A
HIGH IDLE
GLOW
PLUG
30
GLOW PLUG
CB1
START
CR15
87
CR4
87
J4-A4
J4-A3
J4-A2
J4-A5
J2-A5
J4-B5
J1-C11,C12
J4-C4
U5
ELECTRONIC CONTROL MODULE
J4-B6
J2-B8
J2-B7
J4-B2
J4-B1
J1-B1
J2-B12
J1-A9
J2-B11
J1-C1\C4
G6
J4-C3
D1 F
J4-B4
HIGH IDLE
30
R
B1
12V DC
(+)
30
Q3
(PULL)
(HOLD)
M3
CR5
L27
86
SW1 SW2 L41
H1
85
87
N.O.
H2
U32
N.C.
L42
FB1
-
( )
Q8
HIGH IDLE SOLENOID
AUTOMOTIVE-STYLE HORN
(OPTION)
PLATFORM DOWN
PLATFORM DOWN
(GS-3268 ONLY)
TILT ALARM
SW1
SW2 L41 L42 L27 Y29
GENERATOR (OPTION)
H1 FB1
OIL PRESSURE LED
Y7A
GENERATOR ON LED
Y7
COOLANT
TEMPERATURE LED
H2
OIL PRESSURE SWITCH
Q3
COOLANT
TEMPERATURE SWITCH
U32
FLASHING BEACON (OPTION)
G6
GLOW PLUG
ENGINE STARTER
Q8
HOURMETER
BATTERY 12V DC
D1
FUEL SHUT OFF
M3
ALTERNATOR
B1
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
6 - 46
ES7140A
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 6 • Schematics
Electrical Schematic
Diesel Models (before serial number 21161)
Part 2 of 2
REV B
P2
QD4
G8
EMERGENCY
STOP
QD3
C
C
C
C
A
A
A
B
B
B
D
D
E
E
BK
BK
POWER TO PLATFORM
A
RD
POWER TO GROUND
B
WH
GROUND
PIO3
D
D
BL
DATA LINK (HIGH)
PIO4
E
E
YL
DATA LINK (LOW)
PIO5
RD
PIO2
DIAGNOSTIC
DISPLAY
12V DC
FUNCTION
ENABLE
RD
LS6
LS5
LS1
PLATFORM
DOWN
PLATFORM
UP
EXTENSION
DECK
WH
N.C.
1
2
3
4
5
6
7
8
PP
R15
OR
5K
POTENTIOMETER
WH/YL
TS66
S7
DATA LINK (-) YL
WH
PLATFORM CONTROLS
MEMBRANE DECAL
BK
POUT2
POWER LED L19
POUT3
J1-C7,C8
Y1A Y1B
POUT4
FAULT LED L25
POUT5
GENERATOR LED L27
POUT6
HIGH TORQUE LED L21
POUT8
HIGH IDLE LED L23
PIN5
ENGINE STOP BN1
J1-B3
J1-A12
Y1
J1-A11
Y6A Y5A
J1-A10
J1-A8
Y5
J1-A7
Y6
J1-A6
Y2
J1-A5
J1-A4
J1-A3
J1-A2
J1-A1
Y8
WH/RD
PIN14
BN
J2-B10
J2-A6
J3-A5
J3-A4
J3-B4
J2-C1/C10
J3-A3
J3-A1
J3-A2
J2-A2
J2-A1
Y4
FUNCTION ENABLE
LEVEL
SENSOR
ELECTRONIC CONTROL MODULE
Y3
WH/BL
PIN18
PIN15
DATA LINK (+) BK
DOWN
PLATFORM
UP
U5
SW6 STEER
LEFT/ RIGHT
SW5
RIGHT
N.C.
JOYSTICK
CONTROLLER
LEFT
N.C.
GROUND FROM PLATFORM
N.C.
JC1
BN
WH/BK
LEVEL
SENSOR
CIRCUIT
BOARD
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
DIP
SWITCH
TS67
D7
U3
SW25
Y9
PIN6
ENGINE START BN2
PIN10
HIGH IDLE BN4
PIN19
HORN BN5
PIN9
HIGH TORQUE BN6
PIN24
GENERATOR BN7
PIN25
PLATFORM EXT/RET ENABLE BN16
PIN29
STARTING AID BN3
WH
PIN1
LIFT ENABLE HIGH BN12
PROPORTIONAL
FLOW CONTROL
DRIVE PARALLEL
DRIVE PARALLEL
DRIVE PARALLEL
DRIVE REVERSE
DRIVE FORWARD
DRIVE REVERSE
DRIVE FORWARD
BRAKE RELEASE
PLATFORM UP
STEER LEFT
STEER RIGHT
BL
PIN2
LIFT ENABLE LOW BN13
RD
PIN3
UP
PLATFORM UP/DOWN TS20
YL
PIN4
POUT1
PIN11
DOWN
RD
+
BK
-
H1
ALARM
PLATFORM CONTROLS
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
ES7140A
Part No. 52302
GS-2668 RT • GS-3268 RT
6 - 47
Section 6 • Schematics
March 2005
Electrical Schematic
Diesel Models (from serial number 21161 to 21837)
Part 1 of 2
REV B
P1
EMERGENCY
STOP
CB2
PLATFORM
KS1
1A
GROUND
85
86
CR43
GROUND
87
85
(GS-3268RT)
-
85
CR25
C2
ENGINE RUN
30
33000 uf
R7 2000
30
85
B4
12V DC
86
87
ENGINE
START
86
( )
AUXILIARY
PLATFORM
DOWN
CR1
(+)
BN23
POWER TO
ECM
30
86
CR8
87
87
FUEL
30
TS56 TS54
TS52
85
86
85
86
20A
HIGH IDLE
GLOW
PLUG
30
GLOW PLUG
CB1
START
CR15
87
CR4
87
J4-A4
J4-A3
J4-A2
J4-A5
J2-A5
J4-B5
J1-C11,C12
J4-C4
U5
ELECTRONIC CONTROL MODULE
J4-B6
J2-B8
J2-B7
J4-B2
J4-B1
J1-B1
J2-B12
J1-A9
J2-B11
J1-C1\C4
G6
J4-C3
D1 F
J4-B4
HIGH IDLE
30
R
B1
12V DC
(+)
30
Q3
(PULL)
(HOLD)
M3
CR5
L27
86
SW1 SW2 L41
H1
85
87
N.O.
H2
U32
N.C.
L42
FB1
-
( )
Q8
HIGH IDLE SOLENOID
AUTOMOTIVE-STYLE HORN
(OPTION)
PLATFORM DOWN
PLATFORM DOWN
(GS-3268 ONLY)
TILT ALARM
SW1
SW2 L41 L42 L27 Y29
GENERATOR (OPTION)
H1 FB1
OIL PRESSURE LED
Y7A
GENERATOR ON LED
Y7
COOLANT
TEMPERATURE LED
H2
OIL PRESSURE SWITCH
Q3
COOLANT
TEMPERATURE SWITCH
U32
FLASHING BEACON (OPTION)
G6
GLOW PLUG
ENGINE STARTER
Q8
HOURMETER
BATTERY 12V DC
D1
FUEL SHUT OFF
M3
ALTERNATOR
B1
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
6 - 48
ES7140B
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 6 • Schematics
Electrical Schematic
Diesel Models (from serial number 21161 to 21837)
Part 2 of 2
REV B
P2
QD4
G8
EMERGENCY
STOP
QD3
C
C
C
C
A
A
A
B
B
B
D
D
E
E
BK
BK
POWER TO PLATFORM
A
RD
POWER TO GROUND
B
WH
GROUND
PIO3
D
D
BL
DATA LINK (HIGH)
PIO4
E
E
YL
DATA LINK (LOW)
PIO5
RD
PIO2
DIAGNOSTIC
DISPLAY
12V DC
FUNCTION
ENABLE
RD
LS6
LS5
LS1
PLATFORM
DOWN
PLATFORM
UP
EXTENSION
DECK
WH
N.C.
1
2
3
4
5
6
7
8
PP
R15
OR
5K
POTENTIOMETER
WH/YL
TS66
S7
DATA LINK (-) YL
WH
PLATFORM CONTROLS
MEMBRANE DECAL
BK
POUT2
POWER LED L19
POUT3
J1-C7,C8
Y1A Y1B
POUT4
FAULT LED L25
POUT5
GENERATOR LED L27
POUT6
HIGH TORQUE LED L21
POUT8
HIGH IDLE LED L23
PIN5
ENGINE STOP BN1
J1-B3
J1-A12
Y1
J1-A11
Y6A Y5A
J1-A10
J1-A8
Y5
J1-A7
Y6
J1-A6
Y2
J1-A5
J1-A4
J1-A3
J1-A2
J1-A1
Y8
WH/RD
PIN14
BN
J2-B10
J2-A6
J3-A5
J3-A4
J3-B4
J2-C1/C10
J3-A3
J3-A1
J3-A2
J2-A2
J2-A1
Y4
FUNCTION ENABLE
LEVEL
SENSOR
ELECTRONIC CONTROL MODULE
Y3
WH/BL
PIN18
PIN15
DATA LINK (+) BK
DOWN
PLATFORM
UP
U5
SW6 STEER
LEFT/ RIGHT
SW5
RIGHT
N.C.
JOYSTICK
CONTROLLER
LEFT
N.C.
GROUND FROM PLATFORM
N.C.
JC1
BN
WH/BK
LEVEL
SENSOR
CIRCUIT
BOARD
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
DIP
SWITCH
TS67
D7
U3
SW25
Y9
PIN6
ENGINE START BN2
PIN10
HIGH IDLE BN4
PIN19
HORN BN5
PIN9
HIGH TORQUE BN6
PIN24
GENERATOR BN7
PIN25
PLATFORM EXT/RET ENABLE BN16
PIN29
STARTING AID BN3
WH
PIN1
LIFT ENABLE HIGH BN12
PROPORTIONAL
FLOW CONTROL
DRIVE PARALLEL
DRIVE PARALLEL
DRIVE PARALLEL
DRIVE REVERSE
DRIVE FORWARD
DRIVE REVERSE
DRIVE FORWARD
BRAKE RELEASE
PLATFORM UP
STEER LEFT
STEER RIGHT
BL
PIN2
LIFT ENABLE LOW BN13
RD
PIN3
UP
PLATFORM UP/DOWN TS20
YL
PIN4
POUT1
PIN11
DOWN
RD
+
BK
-
H1
ALARM
PLATFORM CONTROLS
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
ES7140B
Part No. 52302
GS-2668 RT • GS-3268 RT
6 - 49
Section 6 • Schematics
March 2005
Electrical Schematic
Diesel Models (from serial number 21838 to 38464)
Part 1 of 3
REV B
CB2 CHANGED TO 7 AMP
AFTER SERIAL NUMBER 33850
P1
EMERGENCY
STOP
CB2
PLATFORM
KS1
1A
GROUND
85
86
CR43
GROUND
87
85
(GS-3268RT)
-
85
CR25
C2
ENGINE RUN
30
33000 uf
R7 2000
30
85
B4
12V DC
86
87
ENGINE
START
86
( )
AUXILIARY
PLATFORM
DOWN
CR1
(+)
BN23
POWER TO
ECM
30
86
CR8
87
87
FUEL
30
TS56 TS54
TS52
85
86
85
86
20A
HIGH IDLE
GLOW
PLUG
30
GLOW PLUG
CB1
START
CR15
87
CR4
87
J4-A4
J4-A3
J4-A2
J2-A5
J4-A5
U5
ELECTRONIC CONTROL MODULE
J4-B6
J2-B8
J2-B7
J4-B2
J4-B1
J1-B1
J1-A9
J2-B11
G6
J1-C11,C12 J2-B12
J1-C1\C4
J4-B5
J4-C4
D1 F
J4-C3
J4-B4
HIGH IDLE
30
R
B1
12V DC
(+)
30
F9
Q3
(PULL)
(HOLD)
30A
M3
CR5
L27
86
SW1 SW2 L41
H1
85
87
N.O.
H2
U32
N.C.
L42
FB1
-
( )
Q8
PLATFORM DOWN
PLATFORM DOWN
(GS-3268 ONLY)
GENERATOR (OPTION)
AUTOMOTIVE-STYLE HORN
(OPTION)
OIL PRESSURE LED
HIGH IDLE SOLENOID
SW2 L41 L42 L27 Y29
GENERATOR ON LED
GLOW PLUG
F9 ADDED AFTER
SERIAL NUMBER 38365
SW1
COOLANT
TEMPERATURE LED
Y7A H1 FB1
OIL PRESSURE SWITCH
Y7
COOLANT
TEMPERATURE SWITCH
H2
FLASHING BEACON (OPTION)
Q3
TILT ALARM
U32
HOURMETER
ENGINE STARTER
G6
FUEL SHUT OFF
BATTERY 12V DC
D1 F9 Q8
FUSE
M3
ALTERNATOR
B1
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
6 - 50
ES7140C
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 6 • Schematics
Electrical Schematic
Diesel Models (from serial number 21838 to 38464)
Part 2 of 3
REV B
QD4
NOTE: LS5, LS1
USED ON
GS-3268 ONLY
AFTER SERIAL
NUMBER 26562
C
C
A
A
B
B
D
D
E
E
G8
OUTRIGGERS
(OPTION)
DIAGNOSTIC
DISPLAY
(OPTION)
TS67
FUNCTION
ENABLE
RD
LS6
LS5
LS1
PS3
PLATFORM
DOWN
PLATFORM
UP
EXTENSION
DECK
PLATFORM
OVERLOAD
N.C.
N.C.
N.O.
N.C.
LS12
LS13
LS14
LS15
LEFT
FRONT
OUTRIGGER
RIGHT
FRONT
OUTRIGGER
LEFT
REAR
OUTRIGGER
RIGHT
REAR
OUTRIGGER
TS66
N.O.
N.O.
S7
MODELS
WITHOUT
OUTRIGGERS
DATA LINK (-) YL
LEVEL
SENSOR
BN
J1-C7,C8
J2-B10
J2-A6
J2-C1/C10
J3-A5
J3-A4
J3-B4
J3-B5
J3-A6
J2-A10
J2-A8
J2-A7
J3-A3
J3-A1
J3-A2
J2-A2
J2-A1
U5
N.O.
DATA LINK (+) BK
DOWN
PLATFORM
UP
N.O.
LEVEL
SENSOR
CIRCUIT
BOARD
GROUND FROM PLATFORM
N.C.
WH
ELECTRONIC CONTROL MODULE
J2-B3
J2-B1
J1-B8
J2-B10
J1-B7
J1-B6
J3-B2
J3-B1
J1-B5
J1-B2
J1-B3
J1-A12
J1-A11
J1-A10
J1-A8
J1-A7
J1-A6
J1-A5
J1-A4
J1-A3
J1-A2
J1-A1
YL
BL
RD
S8
2-AXIS
LEVEL
SENSOR
BK
Y40
Y39
Y44
S9
AUTO LEVELING
SENSOR
Y34
OUTRIGGER RETRACT
Y33
OUTRIGGER EXTEND
SLOW
DRIVE REVERSE
Y36
OUTRIGGER EXTEND
DRIVE FORWARD
Y35
RIGHT REAR
OUTRIGGER
BRAKE RELEASE
Y9
LEFT REAR
OUTRIGGER
PLATFORM UP
Y1A Y1B
RIGHT FRONT
OUTRIGGER
STEER LEFT
Y1
LEFT FRONT
OUTRIGGER
STEER RIGHT
Y6A Y5A
PROPORTIONAL
FLOW CONTROL
Y5
DRIVE PARALLEL
Y6
DRIVE PARALLEL
Y2
DRIVE PARALLEL
Y8
DRIVE REVERSE
Y4
DRIVE FORWARD
Y3
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
ES7140C
Part No. 52302
GS-2668 RT • GS-3268 RT
6 - 51
Section 6 • Schematics
March 2005
Electrical Schematic
Diesel Models (from serial number 21838 to 38464)
Part 3 of 3
REV B
P2
C
P2
EMERGENCY
STOP
QD3
A
A
RD
BK
POWER TO PLATFORM
BK
C
RD
POWER TO GROUND
B
B
WH
GROUND
PIO3
D
D
BL
DATA LINK (HIGH)
PIO4
E
E
YL
DATA LINK (LOW)
PIO5
EMERGENCY
STOP
QD3
PIO2
C
C
BK
POWER TO PLATFORM
A
A
RD
POWER TO GROUND
BK
RD
B
B
WH
GROUND
PIO3
D
D
BL
DATA LINK (HIGH)
PIO4
E
E
YL
DATA LINK (LOW)
PIO5
PIO2
12V DC
D7
U3
SW25
1
2
3
4
5
6
7
8
OR
R15
PP
5K
POTENTIOMETER
WH/YL
WH/BL
PIN18
POWER LED L19
POUT3
JOYSTICK
CONTROLLER
WH/YL
FUNCTION ENABLE
WH/RD
PIN15
SW6 STEER
LEFT/ RIGHT
WH
PLATFORM CONTROLS
MEMBRANE DECAL
POUT2
PP
5K
POTENTIOMETER
SW5
PIN14
BK
R15
RIGHT
WH
JC1
BN
LEFT
RIGHT
WH/RD
PIN15
PIN14
OR
WH/BK
LEFT
FUNCTION ENABLE
1
2
3
4
5
6
7
8
PLATFORM CONTROLS
MEMBRANE DECAL
BK
POUT2
POWER LED L19
POUT3
LIFT ERROR INDICATOR LED L57
POUT4
FAULT LED L25
POUT4
FAULT LED L25
POUT5
GENERATOR LED L27
POUT5
GENERATOR LED L27
POUT6
HIGH TORQUE LED L21
POUT6
HIGH TORQUE LED L21
POUT8
HIGH IDLE LED L23
POUT8
HIGH IDLE LED L23
ENGINE STOP BN1
PIN5
ENGINE STOP BN1
PIN5
PIN6
ENGINE START BN2
PIN6
ENGINE START BN2
PIN10
HIGH IDLE BN4
PIN10
AUTO LEVEL BN20
PIN19
HORN BN5
PIN19
HIGH TORQUE/LF OUTRIGGER BN17
PIN23
HIGH TORQUE BN6
PIN23
HIGH IDLE BN4
PIN24
GENERATOR BN7
PIN24
RR OUTRIGGER BN24
PIN25
PLATFORM EXT/RET ENABLE BN16
PIN13
HORN/LR OUTRIGGER BN15
PIN29
STARTING AID BN3
PIN25
OUTRIGGER ENABLE BN16
PIN25
GENERATOR/RF OUTRIGGER BN18
PIN29
WH
PIN1
PIN1
UP
PLATFORM UP/DOWN TS20
POUT1
DOWN
PIN11
BK
+
-
ALARM
PIN11
PLATFORM CONTROLS
(DIESEL MODELS WITHOUT OUTRIGGERS)
UP
YL
POUT1
H1
LIFT ENABLE LOW BN13
RD
PIN3
PIN4
RD
LIFT ENABLE HIGH BN12
BL
PIN2
YL
PIN4
WH
LIFT ENABLE LOW BN13
RD
PIN3
STARTING AID BN3
LIFT ENABLE HIGH BN12
BL
PIN2
6 - 52
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
SW6 STEER
LEFT/ RIGHT
SW5
WH/BL
JOYSTICK
CONTROLLER
D7
U3
SW25
DIP
SWITCH
JC1
BN
WH/BK
PIN18
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
DIP
SWITCH
12V DC
DOWN
RD
+
BK
-
PLATFORM & OUTRIGGER
UP/DOWN TS21
H1
ALARM
PLATFORM CONTROLS
(DIESEL MODELS WITH OUTRIGGERS)
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 6 • Schematics
This page intentionally left blank.
Part No. 52302
GS-2668 RT • GS-3268 RT
6 - 53
Section 6 • Schematics
March 2005
Electrical Schematic
Diesel Models (from serial number 38465 to 40173)
Part 1 of 3
REV B
P1
EMERGENCY
STOP
CB2
PLATFORM
KS1
7A
GROUND
85
86
CR43
GROUND
87
85
(GS-3268RT)
86
-
( )
AUXILIARY
PLATFORM
DOWN
86
CR25
87
(+)
BN23
30
B4
12V DC
85
87
POWER TO
ECM
30
C2
ENGINE RUN
30
33000 uf
R7 2000
CR1
85
ENGINE
START
87
86
CR8
FUEL
30
TS56 TS54
TS52
85
86
85
86
20A
HIGH IDLE
GLOW
PLUG
30
GLOW PLUG
CB1
START
CR15
87
CR4
87
J4-A4
J4-A3
J4-A2
J2-A5
J4-A5
U5
ELECTRONIC CONTROL MODULE
J4-B6
J2-B8
J2-B7
J4-B2
J4-B1
J1-B1
J1-A9
J2-B11
G6
J1-C11,C12 J2-B12
J1-C1\C4
J4-B5
J4-C4
J4-C3
D1 F
J4-B4
HIGH IDLE
30
R
B1
12V DC
(+)
30
F9
Q3
(PULL)
(HOLD)
30A
M3
CR5
L27
86
SW1 SW2 L41
H1
85
87
N.O.
H2
U32
N.C.
L42
FB1
-
( )
Q8
SW1
SW2 L41 L42 L27 Y29
GENERATOR (OPTION)
OIL PRESSURE LED
GENERATOR ON LED
COOLANT
TEMPERATURE LED
OIL PRESSURE SWITCH
COOLANT
TEMPERATURE SWITCH
FLASHING BEACON (OPTION)
AUTOMOTIVE-STYLE HORN
(OPTION)
TILT ALARM
HIGH IDLE SOLENOID
AUXILIARY PLATFORM
DOWN (GS-3268 ONLY)
GLOW PLUG
Y7 Y10 Y7A Y10A H1 FB1
PLATFORM DOWN
(GS-3268 ONLY)
H2
AUXILIARY PLATFORM
DOWN (GS-3268 ONLY)
Q3
PLATFORM DOWN
U32
HOURMETER
ENGINE STARTER
G6
FUEL SHUT OFF
BATTERY 12V DC
D1 F9 Q8
FUSE
M3
ALTERNATOR
B1
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
6 - 54
ES7140H
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 6 • Schematics
Electrical Schematic
Diesel Models (from serial number 38465 to 40173)
Part 2 of 3
REV B
QD4
C
C
A
A
B
B
D
D
E
E
G8
GS-3268 ONLY
OUTRIGGERS
(OPTION)
DIAGNOSTIC
DISPLAY
(OPTION)
TS67
FUNCTION
ENABLE
RD
LS6
LS5
LS1
PS3
PLATFORM
DOWN
PLATFORM
UP
EXTENSION
DECK
PLATFORM
OVERLOAD
N.C.
N.C.
N.O.
N.C.
LS12
LS13
LS14
LS15
LEFT
FRONT
OUTRIGGER
RIGHT
FRONT
OUTRIGGER
LEFT
REAR
OUTRIGGER
RIGHT
REAR
OUTRIGGER
TS66
N.O.
N.O.
S7
MODELS
WITHOUT
OUTRIGGERS
DATA LINK (-) YL
LEVEL
SENSOR
BN
J1-C7,C8
J2-B10
J2-A6
J2-C1/C10
J3-A5
J3-A4
J3-B4
J3-B5
J3-A6
J2-A10
J2-A8
J2-A7
J3-A3
J3-A1
J3-A2
J2-A2
J2-A1
U5
N.O.
DATA LINK (+) BK
DOWN
PLATFORM
UP
N.O.
LEVEL
SENSOR
CIRCUIT
BOARD
GROUND FROM PLATFORM
N.C.
WH
ELECTRONIC CONTROL MODULE
J2-B3
J2-B1
J1-B8
J2-B10
J1-B7
J1-B6
J3-B2
J3-B1
J1-B5
J1-B2
J1-B3
J1-A12
J1-A11
J1-A10
J1-A8
J1-A7
J1-A6
J1-A5
J1-A4
J1-A3
J1-A2
J1-A1
YL
BL
RD
S8
2-AXIS
LEVEL
SENSOR
BK
Y40
Y39
Y44
S9
AUTO LEVELING
SENSOR
Y34
OUTRIGGER RETRACT
Y33
OUTRIGGER EXTEND
SLOW
DRIVE REVERSE
Y36
OUTRIGGER EXTEND
DRIVE FORWARD
Y35
RIGHT REAR
OUTRIGGER
BRAKE RELEASE
Y9
LEFT REAR
OUTRIGGER
PLATFORM UP
Y1A Y1B
RIGHT FRONT
OUTRIGGER
STEER LEFT
Y1
LEFT FRONT
OUTRIGGER
STEER RIGHT
Y6A Y5A
PROPORTIONAL
FLOW CONTROL
Y5
DRIVE PARALLEL
Y6
DRIVE PARALLEL
Y2
DRIVE PARALLEL
Y8
DRIVE REVERSE
Y4
DRIVE FORWARD
Y3
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
ES7140H
Part No. 52302
GS-2668 RT • GS-3268 RT
6 - 55
Section 6 • Schematics
March 2005
Electrical Schematic
Diesel Models (from serial number 38465 to 40173)
Part 3 of 3
REV B
P2
C
P2
EMERGENCY
STOP
QD3
A
A
RD
BK
POWER TO PLATFORM
BK
C
RD
POWER TO GROUND
B
B
WH
GROUND
PIO3
D
D
BL
DATA LINK (HIGH)
PIO4
E
E
YL
DATA LINK (LOW)
PIO5
EMERGENCY
STOP
QD3
PIO2
C
C
BK
POWER TO PLATFORM
A
A
RD
POWER TO GROUND
BK
RD
B
B
WH
GROUND
PIO3
D
D
BL
DATA LINK (HIGH)
PIO4
E
E
YL
DATA LINK (LOW)
PIO5
PIO2
12V DC
D7
U3
SW25
1
2
3
4
5
6
7
8
OR
R15
PP
5K
POTENTIOMETER
WH/YL
WH/BL
PIN18
PIN15
POWER LED L19
POUT3
JOYSTICK
CONTROLLER
WH/YL
FUNCTION ENABLE
WH/RD
SW6 STEER
LEFT/ RIGHT
WH
PLATFORM CONTROLS
MEMBRANE DECAL
POUT2
PP
5K
POTENTIOMETER
SW5
PIN14
BK
R15
RIGHT
WH
JC1
BN
LEFT
RIGHT
WH/RD
PIN15
PIN14
OR
WH/BK
LEFT
FUNCTION ENABLE
1
2
3
4
5
6
7
8
PLATFORM CONTROLS
MEMBRANE DECAL
BK
POUT2
POWER LED L19
POUT3
LIFT ERROR INDICATOR LED L57
POUT4
FAULT LED L25
POUT4
FAULT LED L25
POUT5
GENERATOR LED L27
POUT5
GENERATOR LED L27
POUT6
HIGH TORQUE LED L21
POUT6
HIGH TORQUE LED L21
POUT8
HIGH IDLE LED L23
POUT8
HIGH IDLE LED L23
ENGINE STOP BN1
PIN5
ENGINE STOP BN1
PIN5
PIN6
ENGINE START BN2
PIN6
ENGINE START BN2
PIN10
HIGH IDLE BN4
PIN10
AUTO LEVEL BN20
PIN19
HORN BN5
PIN19
HIGH TORQUE/LF OUTRIGGER BN17
PIN23
HIGH TORQUE BN6
PIN23
HIGH IDLE BN4
PIN24
GENERATOR BN7
PIN24
RR OUTRIGGER BN24
PIN25
PLATFORM EXT/RET ENABLE BN16
PIN13
HORN/LR OUTRIGGER BN15
PIN29
STARTING AID BN3
PIN25
OUTRIGGER ENABLE BN16
PIN25
GENERATOR/RF OUTRIGGER BN18
PIN29
WH
PIN1
PIN1
UP
PLATFORM UP/DOWN TS20
POUT1
DOWN
PIN11
BK
+
-
ALARM
PIN11
PLATFORM CONTROLS
(DIESEL MODELS WITHOUT OUTRIGGERS)
UP
YL
POUT1
H1
LIFT ENABLE LOW BN13
RD
PIN3
PIN4
RD
LIFT ENABLE HIGH BN12
BL
PIN2
YL
PIN4
WH
LIFT ENABLE LOW BN13
RD
PIN3
STARTING AID BN3
LIFT ENABLE HIGH BN12
BL
PIN2
6 - 56
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
SW6 STEER
LEFT/ RIGHT
SW5
WH/BL
JOYSTICK
CONTROLLER
D7
U3
SW25
DIP
SWITCH
JC1
BN
WH/BK
PIN18
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
DIP
SWITCH
12V DC
DOWN
RD
+
BK
-
PLATFORM & OUTRIGGER
UP/DOWN TS21
H1
ALARM
PLATFORM CONTROLS
(DIESEL MODELS WITH OUTRIGGERS)
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 6 • Schematics
This page intentionally left blank.
Part No. 52302
GS-2668 RT • GS-3268 RT
6 - 57
Section 6 • Schematics
March 2005
Electrical Schematic
Diesel Models (from serial number 40174 to 40939)
Part 1 of 3
REV B
P1
EMERGENCY
STOP
CB2
PLATFORM
KS1
7A
GROUND
85
86
CR43
GROUND
87
85
(GS-3268RT)
86
-
( )
AUXILIARY
PLATFORM
DOWN
86
CR25
87
(+)
BN23
30
B4
12V DC
85
87
POWER TO
ECM
30
C2
ENGINE RUN
30
33000 uf
R7 2000
CR1
85
ENGINE
START
87
86
CR8
FUEL
30
TS56 TS54
TS52
85
86
85
86
20A
HIGH IDLE
GLOW
PLUG
30
GLOW PLUG
CB1
START
CR15
87
CR4
87
J4-A4
J4-A3
J4-A2
J2-A5
J4-A5
U5
ELECTRONIC CONTROL MODULE
J4-B6
J2-B8
J2-B7
J4-B2
J4-B1
J1-B1
J1-A9
J2-B11
G6
J1-C11,C12 J2-B12
J1-C1\C4
J4-B5
J4-C4
L30
J4-C3
D1 F
J4-B4
HIGH IDLE
30
R
B1
12V DC
(+)
30
F9
(HOLD)
(PULL)
L27
86
SW1 SW2 L41
H1
Q3
30A
M3
CR5
85
87
N.O.
H2
U32
N.C.
L42
FB1
-
( )
Q8
SW1
SW2 L41 L42 L27 Y29
GENERATOR (OPTION)
OIL PRESSURE LED
GENERATOR ON LED
COOLANT
TEMPERATURE LED
OIL PRESSURE SWITCH
COOLANT
TEMPERATURE SWITCH
FLASHING BEACON (OPTION)
TILT ALARM
AUXILIARY PLATFORM
DOWN (GS-3268 ONLY)
PLATFORM DOWN
(GS-3268 ONLY)
AUXILIARY PLATFORM
DOWN (GS-3268 ONLY)
WORK LIGHTS (OPTION)
Y7 Y10 Y7A Y10A H1 FB1
PLATFORM DOWN
GLOW PLUG
AUTOMOTIVE-STYLE HORN
(OPTION)
Q3 L30 H2
HIGH IDLE SOLENOID
U32
HOURMETER
ENGINE STARTER
G6
FUEL SHUT OFF
BATTERY 12V DC
D1 F9 Q8
FUSE
M3
ALTERNATOR
B1
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
6 - 58
ES7140
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 6 • Schematics
Electrical Schematic
Diesel Models (from serial number 40174 to 40939)
Part 2 of 3
REV B
QD4
C
C
A
A
B
B
D
D
E
E
G8
GS-3268 ONLY
OUTRIGGERS
(OPTION)
DIAGNOSTIC
DISPLAY
(OPTION)
TS67
FUNCTION
ENABLE
RD
LS6
LS5
LS1
PS3
PLATFORM
DOWN
PLATFORM
UP
EXTENSION
DECK
PLATFORM
OVERLOAD
N.C.
N.C.
N.O.
N.C.
LS12
LS13
LS14
LS15
LEFT
FRONT
OUTRIGGER
RIGHT
FRONT
OUTRIGGER
LEFT
REAR
OUTRIGGER
RIGHT
REAR
OUTRIGGER
TS66
N.O.
N.O.
S7
MODELS
WITHOUT
OUTRIGGERS
DATA LINK (-) YL
LEVEL
SENSOR
BN
J1-C7,C8
J2-B10
J2-A6
J2-C1/C10
J3-A5
J3-A4
J3-B4
J3-B5
J3-A6
J2-A10
J2-A8
J2-A7
J3-A3
J3-A1
J3-A2
J2-A2
J2-A1
U5
N.O.
DATA LINK (+) BK
DOWN
PLATFORM
UP
N.O.
LEVEL
SENSOR
CIRCUIT
BOARD
GROUND FROM PLATFORM
N.C.
WH
ELECTRONIC CONTROL MODULE
J2-B3
J2-B1
J1-B8
J2-B10
J1-B7
J1-B6
J3-B2
J3-B1
J1-B5
J1-B2
J1-B3
J1-A12
J1-A11
J1-A10
J1-A8
J1-A7
J1-A6
J1-A5
J1-A4
J1-A3
J1-A2
J1-A1
YL
BL
RD
S8
2-AXIS
LEVEL
SENSOR
BK
Y40
Y39
Y44
S9
AUTO LEVELING
SENSOR
Y34
OUTRIGGER RETRACT
Y33
OUTRIGGER EXTEND
SLOW
DRIVE REVERSE
Y36
OUTRIGGER EXTEND
DRIVE FORWARD
Y35
RIGHT REAR
OUTRIGGER
BRAKE RELEASE
Y9
LEFT REAR
OUTRIGGER
PLATFORM UP
Y1A Y1B
RIGHT FRONT
OUTRIGGER
STEER LEFT
Y1
LEFT FRONT
OUTRIGGER
STEER RIGHT
Y6A Y5A
PROPORTIONAL
FLOW CONTROL
Y5
DRIVE PARALLEL
Y6
DRIVE PARALLEL
Y2
DRIVE PARALLEL
Y8
DRIVE REVERSE
Y4
DRIVE FORWARD
Y3
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
ES7140
Part No. 52302
GS-2668 RT • GS-3268 RT
6 - 59
Section 6 • Schematics
March 2005
Electrical Schematic
Diesel Models (from serial number 40174 to 40939)
Part 3 of 3
REV B
P2
C
P2
EMERGENCY
STOP
QD3
A
A
RD
BK
POWER TO PLATFORM
BK
C
RD
POWER TO GROUND
B
B
WH
GROUND
PIO3
D
D
BL
DATA LINK (HIGH)
PIO4
E
E
YL
DATA LINK (LOW)
PIO5
EMERGENCY
STOP
QD3
PIO2
C
C
BK
POWER TO PLATFORM
A
A
RD
POWER TO GROUND
BK
RD
B
B
WH
GROUND
PIO3
D
D
BL
DATA LINK (HIGH)
PIO4
E
E
YL
DATA LINK (LOW)
PIO5
PIO2
12V DC
D7
U3
SW25
1
2
3
4
5
6
7
8
OR
R15
PP
5K
POTENTIOMETER
WH/YL
WH/BL
PIN18
POWER LED L19
POUT3
JOYSTICK
CONTROLLER
WH/YL
FUNCTION ENABLE
WH/RD
PIN15
SW6 STEER
LEFT/ RIGHT
WH
PLATFORM CONTROLS
MEMBRANE DECAL
POUT2
PP
5K
POTENTIOMETER
SW5
PIN14
BK
R15
RIGHT
WH
JC1
BN
LEFT
RIGHT
WH/RD
PIN15
PIN14
OR
WH/BK
LEFT
FUNCTION ENABLE
1
2
3
4
5
6
7
8
PLATFORM CONTROLS
MEMBRANE DECAL
BK
POUT2
POWER LED L19
POUT3
LIFT ERROR INDICATOR LED L57
POUT4
FAULT LED L25
POUT4
FAULT LED L25
POUT5
GENERATOR LED L27
POUT5
GENERATOR LED L27
POUT6
HIGH TORQUE LED L21
POUT6
HIGH TORQUE LED L21
POUT8
HIGH IDLE LED L23
POUT8
HIGH IDLE LED L23
ENGINE STOP BN1
PIN5
ENGINE STOP BN1
PIN5
PIN6
ENGINE START BN2
PIN6
ENGINE START BN2
PIN10
HIGH IDLE BN4
PIN10
AUTO LEVEL BN20
PIN19
HORN BN5
PIN19
HIGH TORQUE/LF OUTRIGGER BN17
PIN23
HIGH TORQUE BN6
PIN23
HIGH IDLE BN4
PIN24
GENERATOR BN7
PIN24
RR OUTRIGGER BN24
PIN25
PLATFORM EXT/RET ENABLE BN16
PIN13
HORN/LR OUTRIGGER BN15
PIN29
STARTING AID BN3
PIN25
OUTRIGGER ENABLE BN16
PIN25
GENERATOR/RF OUTRIGGER BN18
PIN29
WH
PIN1
PIN1
UP
PLATFORM UP/DOWN TS20
POUT1
DOWN
PIN11
BK
+
-
ALARM
PIN11
PLATFORM CONTROLS
(DIESEL MODELS WITHOUT OUTRIGGERS)
UP
YL
POUT1
H1
LIFT ENABLE LOW BN13
RD
PIN3
PIN4
RD
LIFT ENABLE HIGH BN12
BL
PIN2
YL
PIN4
WH
LIFT ENABLE LOW BN13
RD
PIN3
STARTING AID BN3
LIFT ENABLE HIGH BN12
BL
PIN2
6 - 60
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
SW6 STEER
LEFT/ RIGHT
SW5
WH/BL
JOYSTICK
CONTROLLER
D7
U3
SW25
DIP
SWITCH
JC1
BN
WH/BK
PIN18
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
DIP
SWITCH
12V DC
DOWN
RD
+
BK
-
PLATFORM & OUTRIGGER
UP/DOWN TS21
H1
ALARM
PLATFORM CONTROLS
(DIESEL MODELS WITH OUTRIGGERS)
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 6 • Schematics
This page intentionally left blank.
Part No. 52302
GS-2668 RT • GS-3268 RT
6 - 61
Section 6 • Schematics
March 2005
Electrical Schematic
Diesel Models (from serial number 40940 to 41199)
Part 1 of 3
REV B
P1
EMERGENCY
STOP
CB2
PLATFORM
KS1
7A
GROUND
85
86
CR43
GROUND
87
85
(GS-3268RT)
86
-
( )
AUXILIARY
PLATFORM
DOWN
86
CR25
87
(+)
BN23
30
B4
12V DC
85
87
POWER TO
ECM
30
C2
ENGINE RUN
30
33000 uf
R7 2000
CR1
85
ENGINE
START
87
86
CR8
FUEL
30
TS56 TS54
TS52
85
86
85
86
20A
HIGH IDLE
GLOW
PLUG
30
GLOW PLUG
CB1
START
CR15
87
CR4
87
J4-A4
J4-A3
J4-A2
J2-A5
J4-A5
U5
ELECTRONIC CONTROL MODULE
J4-B6
J2-B8
J2-B7
J4-B2
J4-B1
J1-B1
J1-A9
J2-B11
G6
J1-C11,C12 J2-B12
J1-C1\C4
J4-B5
J4-C4
L30
J4-C3
D1 F
J4-B4
HIGH IDLE
30
R
B1
12V DC
(+)
30
F9
(HOLD)
(PULL)
L27
86
SW1 SW2 L41
H1
Q3
30A
M3
CR5
85
87
N.O.
H2
U32
N.C.
L42
FB1
-
( )
Q8
SW1
SW2 L41 L42 L27 Y29
GENERATOR (OPTION)
OIL PRESSURE LED
GENERATOR ON LED
COOLANT
TEMPERATURE LED
OIL PRESSURE SWITCH
COOLANT
TEMPERATURE SWITCH
FLASHING BEACON (OPTION)
TILT ALARM
AUXILIARY PLATFORM
DOWN (GS-3268 ONLY)
PLATFORM DOWN
(GS-3268 ONLY)
AUXILIARY PLATFORM
DOWN (GS-3268 ONLY)
WORK LIGHTS (OPTION)
Y7 Y10 Y7A Y10A H1 FB1
PLATFORM DOWN
GLOW PLUG
AUTOMOTIVE-STYLE HORN
(OPTION)
Q3 L30 H2
HIGH IDLE SOLENOID
U32
HOURMETER
ENGINE STARTER
G6
FUEL SHUT OFF
BATTERY 12V DC
D1 F9 Q8
FUSE
M3
ALTERNATOR
B1
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
6 - 62
ES7140N
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 6 • Schematics
Electrical Schematic
Diesel Models (from serial number 40940 to 41199)
Part 2 of 3
REV B
QD4
C
C
A
A
B
B
D
D
E
E
G8
GS-3268 ONLY
OUTRIGGERS
(OPTION)
DIAGNOSTIC
DISPLAY
(OPTION)
TS67
FUNCTION
ENABLE
RD
LS6
LS5
LS1
PS3
PLATFORM
DOWN
PLATFORM
UP
EXTENSION
DECK
PLATFORM
OVERLOAD
N.C.
N.C.
N.O.
N.C.
LS12
LS13
LS14
LS15
LEFT
FRONT
OUTRIGGER
RIGHT
FRONT
OUTRIGGER
LEFT
REAR
OUTRIGGER
RIGHT
REAR
OUTRIGGER
TS66
N.O.
N.O.
S7
MODELS
WITHOUT
OUTRIGGERS
DATA LINK (-) YL
LEVEL
SENSOR
BN
J1-C7,C8
J2-B10
J2-A6
J2-C1/C10
J3-A5
J3-A4
J3-B4
J3-B5
J3-A6
J2-A10
J2-A8
J2-A7
J3-A3
J3-A1
J3-A2
J2-A2
J2-A1
U5
N.O.
DATA LINK (+) BK
DOWN
PLATFORM
UP
N.O.
LEVEL
SENSOR
CIRCUIT
BOARD
GROUND FROM PLATFORM
N.C.
WH
ELECTRONIC CONTROL MODULE
J2-B3
J2-B1
J1-B8
J2-B10
J1-B7
J1-B6
J3-B2
J3-B1
J1-B5
J1-B2
J1-B3
J1-A12
J1-A11
J1-A10
J1-A8
J1-A7
J1-A6
J1-A5
J1-A4
J1-A3
J1-A2
J1-A1
YL
BL
RD
S8
2-AXIS
LEVEL
SENSOR
BK
Y40
Y39
Y44
S9
AUTO LEVELING
SENSOR
Y34
OUTRIGGER RETRACT
Y33
OUTRIGGER EXTEND
SLOW
DRIVE REVERSE
Y36
OUTRIGGER EXTEND
DRIVE FORWARD
Y35
RIGHT REAR
OUTRIGGER
BRAKE RELEASE
Y9
LEFT REAR
OUTRIGGER
PLATFORM UP
Y1A Y1B
RIGHT FRONT
OUTRIGGER
STEER LEFT
Y1
LEFT FRONT
OUTRIGGER
STEER RIGHT
Y6A Y5A
PROPORTIONAL
FLOW CONTROL
Y5
DRIVE PARALLEL
Y6
DRIVE PARALLEL
Y2
DRIVE PARALLEL
Y8
DRIVE REVERSE
Y4
DRIVE FORWARD
Y3
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
ES7140N
Part No. 52302
GS-2668 RT • GS-3268 RT
6 - 63
Section 6 • Schematics
March 2005
Electrical Schematic
Diesel Models (from serial number 40940 to 41199)
Part 3 of 3
REV B
P2
C
P2
EMERGENCY
STOP
QD3
A
A
RD
BK
POWER TO PLATFORM
BK
C
RD
POWER TO GROUND
B
B
WH
GROUND
PIO3
D
D
BL
DATA LINK (HIGH)
PIO4
E
E
YL
DATA LINK (LOW)
PIO5
EMERGENCY
STOP
QD3
PIO2
C
C
BK
POWER TO PLATFORM
A
A
RD
POWER TO GROUND
BK
RD
B
B
WH
GROUND
PIO3
D
D
BL
DATA LINK (HIGH)
PIO4
E
E
YL
DATA LINK (LOW)
PIO5
PIO2
12V DC
D7
U3
SW25
1
2
3
4
5
6
7
8
OR
R15
PP
5K
POTENTIOMETER
WH/YL
WH/BL
PIN18
POWER LED L19
POUT3
JOYSTICK
CONTROLLER
WH/YL
FUNCTION ENABLE
WH/RD
PIN15
SW6 STEER
LEFT/ RIGHT
WH
PLATFORM CONTROLS
MEMBRANE DECAL
POUT2
PP
5K
POTENTIOMETER
SW5
PIN14
BK
R15
RIGHT
WH
JC1
BN
LEFT
RIGHT
WH/RD
PIN15
PIN14
OR
WH/BK
LEFT
FUNCTION ENABLE
1
2
3
4
5
6
7
8
PLATFORM CONTROLS
MEMBRANE DECAL
BK
POUT2
POWER LED L19
POUT3
LIFT ERROR INDICATOR LED L57
POUT4
FAULT LED L25
POUT4
FAULT LED L25
POUT5
GENERATOR LED L27
POUT5
GENERATOR LED L27
POUT6
HIGH TORQUE LED L21
POUT6
HIGH TORQUE LED L21
POUT8
HIGH IDLE LED L23
POUT8
HIGH IDLE LED L23
ENGINE STOP BN1
PIN5
ENGINE STOP BN1
PIN5
PIN6
ENGINE START BN2
PIN6
ENGINE START BN2
PIN10
HIGH IDLE BN4
PIN10
AUTO LEVEL BN20
PIN19
HORN BN5
PIN19
HIGH TORQUE/LF OUTRIGGER BN17
PIN23
HIGH TORQUE BN6
PIN23
HIGH IDLE BN4
PIN24
GENERATOR BN7
PIN24
RR OUTRIGGER BN24
PIN25
PLATFORM EXT/RET ENABLE BN16
PIN13
HORN/LR OUTRIGGER BN15
PIN29
STARTING AID BN3
PIN25
OUTRIGGER ENABLE BN16
PIN25
GENERATOR/RF OUTRIGGER BN18
PIN29
WH
PIN1
PIN1
UP
PLATFORM UP/DOWN TS20
POUT1
DOWN
PIN11
BK
+
-
ALARM
PIN11
PLATFORM CONTROLS
(DIESEL MODELS WITHOUT OUTRIGGERS)
UP
YL
POUT1
H1
LIFT ENABLE LOW BN13
RD
PIN3
PIN4
RD
LIFT ENABLE HIGH BN12
BL
PIN2
YL
PIN4
WH
LIFT ENABLE LOW BN13
RD
PIN3
STARTING AID BN3
LIFT ENABLE HIGH BN12
BL
PIN2
6 - 64
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
SW6 STEER
LEFT/ RIGHT
SW5
WH/BL
JOYSTICK
CONTROLLER
D7
U3
SW25
DIP
SWITCH
JC1
BN
WH/BK
PIN18
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
DIP
SWITCH
12V DC
DOWN
RD
+
BK
-
PLATFORM & OUTRIGGER
UP/DOWN TS21
H1
ALARM
PLATFORM CONTROLS
(DIESEL MODELS WITH OUTRIGGERS)
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 6 • Schematics
This page intentionally left blank.
Part No. 52302
GS-2668 RT • GS-3268 RT
6 - 65
Section 6 • Schematics
March 2005
Electrical Schematic
Diesel Models (from serial number 41200 to 41823)
Part 1 of 3
REV B
PLATFORM
KS1
GROUND
85
86
CR43
GROUND
87
(+)
85
CR1
-
86
CR25
87
B4
86
33000 uf
R7 2000
30
( )
85
C2
ENGINE RUN
30
ENGINE
START
12V DC
POWER TO
ECM
30
85
86
CR8
87
87
85
BN68
FUEL
30
START
86
CR15
87
GLOW
PLUG
30
CB1
20A
85
86
R
D1 F
CR4
87
J4-A2
J2-A5
J4-A5
U5
ELECTRONIC CONTROL MODULE
J4-B6
J2-B8
J2-B7
J4-B2
J4-B1
J1-B1
J1-C11,C12 J2-B12
J1-A9
J2-B11
(OPTION)
J4-B5
J1-C1\C4
HYDRAULIC
OIL COOLER
B1
J4-C4
L30
J4-C3
G6
J4-B4
HIGH IDLE
30
F9A
12V DC
20A
SW4
30
CR5 86
87
85
(+)
N.O.
L27
30
F9
Q3
CR17
30A
M3
86
N.O.
(HOLD)
(PULL)
H2
85
87
N.C.
U32
L42
FB1
M1
-
SW1 SW2 L41
H1
( )
Q8
SW1
SW2 L41 L42 L27 Y29
GENERATOR (OPTION)
OIL PRESSURE LED
GENERATOR ON LED
COOLANT
TEMPERATURE LED
OIL PRESSURE SWITCH
FLASHING BEACON (OPTION)
TILT ALARM
AUXILIARY PLATFORM
DOWN (GS-3268 ONLY)
PLATFORM DOWN
(GS-3268 ONLY)
AUXILIARY PLATFORM
DOWN (GS-3268 ONLY)
COOLANT
TEMPERATURE SWITCH
Y7 Y10 Y7A Y10A H1 FB1
PLATFORM DOWN
AUTOMOTIVE-STYLE HORN
(OPTION)
HOURMETER
U32 Q3 L30 H2
HIGH IDLE SOLENOID
G6
WORK LIGHTS (OPTION)
SW4
GLOW PLUG
M1
HYDRAULIC OIL
TEMPERATURE SWITCH
ENGINE STARTER
Q8
HYDRAULIC OIL
COOLING FAN (OPTION)
BATTERY 12V DC
D1
FUEL SHUT OFF
M3
ALTERNATOR
B1
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
6 - 66
ES7140P
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 6 • Schematics
Electrical Schematic
Diesel Models (from serial number 41200 to 41823)
Part 2 of 3
REV B
P1
EMERGENCY
STOP
QD4
C
C
A
A
B
B
D
D
E
E
G8
OUTRIGGERS
(OPTION)
DIAGNOSTIC
DISPLAY
(OPTION)
BN44 FUNCTION
RD
ENABLE
BN90 TS54
HIGH
IDLE
BN83
BN84
PLATFORM
UP
PLATFORM
DOWN
PS3
PLATFORM
OVERLOAD
N.O.
N.C.
N.C.
LS12
LS13
LS14
LS15
LEFT
FRONT
OUTRIGGER
RIGHT
FRONT
OUTRIGGER
LEFT
REAR
OUTRIGGER
RIGHT
REAR
OUTRIGGER
N.O.
N.O.
N.O.
N.O.
S7
MODELS
WITHOUT
OUTRIGGERS
DATA LINK (-) YL
DATA LINK (+) BK
LEVEL
SENSOR
BN
J1-C7,C8
J2-B10
J2-A6
J2-C1/C10
J3-A5
J3-A4
J3-B4
J3-B5
J3-A6
J2-A10
J2-A8
J2-A7
J3-A3
J3-A1
J3-A2
J2-A2
J2-A1
J4-A4
J4-A3
U5
LEVEL
SENSOR
CIRCUIT
BOARD
GROUND FROM PLATFORM
GLOW
PLUG
LS6
PLATFORM
DOWN
WH
ELECTRONIC CONTROL MODULE
J2-B3
J2-B1
J1-B8
J2-B10
J1-B7
J1-B6
J3-B2
J3-B1
J1-B5
J1-B2
J1-B3
J1-A12
J1-A11
J1-A10
J1-A8
J1-A7
J1-A6
J1-A5
J1-A4
J1-A3
J1-A2
J1-A1
YL
BL
RD
S8
2-AXIS
LEVEL
SENSOR
BK
Y40
Y39
Y44
S9
AUTO LEVELING
SENSOR
Y34
OUTRIGGER RETRACT
Y33
OUTRIGGER EXTEND
SLOW
DRIVE REVERSE
Y36
OUTRIGGER EXTEND
DRIVE FORWARD
Y35
RIGHT REAR
OUTRIGGER
BRAKE RELEASE
Y9
LEFT REAR
OUTRIGGER
PLATFORM UP
Y1A Y1B
RIGHT FRONT
OUTRIGGER
STEER LEFT
Y1
LEFT FRONT
OUTRIGGER
STEER RIGHT
Y6A Y5A
PROPORTIONAL
FLOW CONTROL
Y5
DRIVE PARALLEL
Y6
DRIVE PARALLEL
Y2
DRIVE PARALLEL
Y8
DRIVE REVERSE
Y4
DRIVE FORWARD
Y3
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
ES7140P
Part No. 52302
GS-2668 RT • GS-3268 RT
6 - 67
Section 6 • Schematics
March 2005
Electrical Schematic
Diesel Models (from serial number 41200 to 41823)
Part 3 of 3
REV B
P2
C
P2
EMERGENCY
STOP
QD3
A
A
RD
BK
POWER TO PLATFORM
BK
C
RD
POWER TO GROUND
B
B
WH
GROUND
PIO3
D
D
BL
DATA LINK (HIGH)
PIO4
E
E
YL
DATA LINK (LOW)
PIO5
EMERGENCY
STOP
QD3
PIO2
C
C
BK
POWER TO PLATFORM
A
A
RD
POWER TO GROUND
BK
RD
B
B
WH
GROUND
PIO3
D
D
BL
DATA LINK (HIGH)
PIO4
E
E
YL
DATA LINK (LOW)
PIO5
PIO2
12V DC
D7
U3
SW25
1
2
3
4
5
6
7
8
OR
R15
PP
5K
POTENTIOMETER
WH/YL
WH/BL
PIN18
PIN15
POWER LED L19
POUT3
JOYSTICK
CONTROLLER
WH/YL
FUNCTION ENABLE
WH/RD
SW6 STEER
LEFT/ RIGHT
WH
PLATFORM CONTROLS
MEMBRANE DECAL
POUT2
PP
5K
POTENTIOMETER
SW5
PIN14
BK
R15
RIGHT
WH
JC1
BN
LEFT
RIGHT
WH/RD
PIN15
PIN14
OR
WH/BK
LEFT
FUNCTION ENABLE
1
2
3
4
5
6
7
8
PLATFORM CONTROLS
MEMBRANE DECAL
BK
POUT2
POWER LED L19
POUT3
LIFT ERROR INDICATOR LED L57
POUT4
FAULT LED L25
POUT4
FAULT LED L25
POUT5
GENERATOR LED L27
POUT5
GENERATOR LED L27
POUT6
HIGH TORQUE LED L21
POUT6
HIGH TORQUE LED L21
POUT8
HIGH IDLE LED L23
POUT8
HIGH IDLE LED L23
ENGINE STOP BN1
PIN5
ENGINE STOP BN1
PIN5
PIN6
ENGINE START BN2
PIN6
ENGINE START BN2
PIN10
HIGH IDLE BN4
PIN10
AUTO LEVEL BN20
PIN19
HORN BN5
PIN19
HIGH TORQUE/LF OUTRIGGER BN17
PIN23
HIGH TORQUE BN6
PIN23
HIGH IDLE BN4
PIN24
GENERATOR BN7
PIN24
RR OUTRIGGER BN24
PIN25
PLATFORM EXT/RET ENABLE BN16
PIN13
HORN/LR OUTRIGGER BN15
PIN29
STARTING AID BN3
PIN25
OUTRIGGER ENABLE BN16
PIN25
GENERATOR/RF OUTRIGGER BN18
PIN29
WH
PIN1
PIN1
UP
PLATFORM UP/DOWN TS20
POUT1
DOWN
PIN11
BK
+
-
ALARM
PIN11
PLATFORM CONTROLS
(DIESEL MODELS WITHOUT OUTRIGGERS)
UP
YL
POUT1
H1
LIFT ENABLE LOW BN13
RD
PIN3
PIN4
RD
LIFT ENABLE HIGH BN12
BL
PIN2
YL
PIN4
WH
LIFT ENABLE LOW BN13
RD
PIN3
STARTING AID BN3
LIFT ENABLE HIGH BN12
BL
PIN2
6 - 68
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
SW6 STEER
LEFT/ RIGHT
SW5
WH/BL
JOYSTICK
CONTROLLER
D7
U3
SW25
DIP
SWITCH
JC1
BN
WH/BK
PIN18
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
DIP
SWITCH
12V DC
DOWN
RD
+
BK
-
PLATFORM & OUTRIGGER
UP/DOWN TS21
H1
ALARM
PLATFORM CONTROLS
(DIESEL MODELS WITH OUTRIGGERS)
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 6 • Schematics
This page intentionally left blank.
Part No. 52302
GS-2668 RT • GS-3268 RT
6 - 69
Section 6 • Schematics
March 2005
Electrical Schematic
Diesel Models (from serial number 41824 to GS6803-42381)
Part 1 of 3
PLATFORM
B
REV A
2
GROUND
B1
4
GROUND
85
86
87
30
85
86
87
30
85
86
87
30
CR43
3
KS1
POWER TO
ECM
KEY SWITCH
ENGINE
START
86
33000 uf
ENGINE RUN
R7 2000
30
85
C2
CR25
CR1
87
CR8
BN68
FUEL
START
87a
CB1
85
86
87
30
85
86
87
30
CR15
GLOW
PLUG
20A
R
D1 F
CR4
J4-A2
J2-A5
J4-A5
U5
ELECTRONIC CONTROL MODULE
J4-B6
J2-B8
J2-B7
J4-B2
J4-B1
J1-B1
J1-C11,C12 J2-B12
J1-A9
J2-B11
(OPTION)
J4-B5
J1-C1\C4
HYDRAULIC
OIL COOLER
B1
J4-C4
L30
J4-C3
G6
J4-B4
HIGH IDLE
F9A
12V DC
20A
SW4
30
CR5 86
87
85
(+)
N.O.
L27
30
F9
Q3
CR17
30A
M3
86
N.O.
(HOLD)
(PULL)
H2
85
87
N.C.
U32
L42
FB1
M1
-
SW1 SW2 L41
H1
( )
Q8
SW1
SW2 L41 L42 L27 Y29
GENERATOR (OPTION)
OIL PRESSURE LED
GENERATOR ON LED
COOLANT
TEMPERATURE LED
OIL PRESSURE SWITCH
FLASHING BEACON (OPTION)
TILT ALARM
AUXILIARY PLATFORM
DOWN (GS-3268 ONLY)
PLATFORM DOWN
(GS-3268 ONLY)
AUXILIARY PLATFORM
DOWN (GS-3268 ONLY)
COOLANT
TEMPERATURE SWITCH
Y7 Y10 Y7A Y10A H1 FB1
PLATFORM DOWN
AUTOMOTIVE-STYLE HORN
(OPTION)
HOURMETER
U32 Q3 L30 H2
HIGH IDLE SOLENOID
G6
WORK LIGHTS (OPTION)
SW4
GLOW PLUG
M1
HYDRAULIC OIL
TEMPERATURE SWITCH
ENGINE STARTER
Q8
HYDRAULIC OIL
COOLING FAN (OPTION)
BATTERY 12V DC
D1
FUEL SHUT OFF
M3
ALTERNATOR
B1
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
6 - 70
ES7140R
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 6 • Schematics
Electrical Schematic
Diesel Models (from serial number 41824 to GS6803-42381)
Part 2 of 3
REV A
P1
EMERGENCY
STOP
QD4
C
C
A
A
B
B
D
D
E
E
G8
OUTRIGGERS
(OPTION)
DIAGNOSTIC
DISPLAY
(OPTION)
BN44 FUNCTION
RD
ENABLE
BN90 TS54
HIGH
IDLE
BN83
BN84
PLATFORM
UP
PLATFORM
DOWN
PS3
PLATFORM
OVERLOAD
N.O.
N.C.
N.C.
LS12
LS13
LS14
LS15
LEFT
FRONT
OUTRIGGER
RIGHT
FRONT
OUTRIGGER
LEFT
REAR
OUTRIGGER
RIGHT
REAR
OUTRIGGER
N.O.
N.O.
N.O.
N.O.
S7
MODELS
WITHOUT
OUTRIGGERS
DATA LINK (-) YL
DATA LINK (+) BK
LEVEL
SENSOR
BN
J1-C7,C8
J2-B10
J2-A6
J2-C1/C10
J3-A5
J3-A4
J3-B4
J3-B5
J3-A6
J2-A10
J2-A8
J2-A7
J3-A3
J3-A1
J3-A2
J2-A2
J2-A1
J4-A4
J4-A3
U5
LEVEL
SENSOR
CIRCUIT
BOARD
GROUND FROM PLATFORM
GLOW
PLUG
LS6
PLATFORM
DOWN
WH
ELECTRONIC CONTROL MODULE
J2-B3
J2-B1
J1-B8
J2-B10
J1-B7
J1-B6
J3-B2
J3-B1
J1-B5
J1-B2
J1-B3
J1-A12
J1-A11
J1-A10
J1-A8
J1-A7
J1-A6
J1-A5
J1-A4
J1-A3
J1-A2
J1-A1
YL
BL
RD
S8
2-AXIS
LEVEL
SENSOR
BK
Y40
Y39
Y44
S9
AUTO LEVELING
SENSOR
Y34
OUTRIGGER RETRACT
Y33
OUTRIGGER EXTEND
SLOW
DRIVE REVERSE
Y36
OUTRIGGER EXTEND
DRIVE FORWARD
Y35
RIGHT REAR
OUTRIGGER
BRAKE RELEASE
Y9
LEFT REAR
OUTRIGGER
PLATFORM UP
Y1A Y1B
RIGHT FRONT
OUTRIGGER
STEER LEFT
Y1
LEFT FRONT
OUTRIGGER
STEER RIGHT
Y6A Y5A
PROPORTIONAL
FLOW CONTROL
Y5
DRIVE PARALLEL
Y6
DRIVE PARALLEL
Y2
DRIVE PARALLEL
Y8
DRIVE REVERSE
Y4
DRIVE FORWARD
Y3
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
ES7140R
Part No. 52302
GS-2668 RT • GS-3268 RT
6 - 71
Section 6 • Schematics
March 2005
Electrical Schematic
Diesel Models (from serial number 41824 to GS6803-42381)
Part 3 of 3
REV A
P2
C
P2
EMERGENCY
STOP
QD3
A
A
RD
BK
POWER TO PLATFORM
BK
C
RD
POWER TO GROUND
B
B
WH
GROUND
PIO3
D
D
BL
DATA LINK (HIGH)
PIO4
E
E
YL
DATA LINK (LOW)
PIO5
EMERGENCY
STOP
QD3
PIO2
C
C
BK
POWER TO PLATFORM
A
A
RD
POWER TO GROUND
BK
RD
B
B
WH
GROUND
PIO3
D
D
BL
DATA LINK (HIGH)
PIO4
E
E
YL
DATA LINK (LOW)
PIO5
PIO2
12V DC
D7
U3
SW25
1
2
3
4
5
6
7
8
OR
R15
PP
5K
POTENTIOMETER
WH/YL
WH/BL
PIN18
PIN15
POWER LED L19
POUT3
JOYSTICK
CONTROLLER
WH/YL
FUNCTION ENABLE
WH/RD
SW6 STEER
LEFT/ RIGHT
WH
PLATFORM CONTROLS
MEMBRANE DECAL
POUT2
PP
5K
POTENTIOMETER
SW5
PIN14
BK
R15
RIGHT
WH
JC1
BN
LEFT
RIGHT
WH/RD
PIN15
PIN14
OR
WH/BK
LEFT
FUNCTION ENABLE
1
2
3
4
5
6
7
8
PLATFORM CONTROLS
MEMBRANE DECAL
BK
POUT2
POWER LED L19
POUT3
LIFT ERROR INDICATOR LED L57
POUT4
FAULT LED L25
POUT4
FAULT LED L25
POUT5
GENERATOR LED L27
POUT5
GENERATOR LED L27
POUT6
HIGH TORQUE LED L21
POUT6
HIGH TORQUE LED L21
POUT8
HIGH IDLE LED L23
POUT8
HIGH IDLE LED L23
ENGINE STOP BN1
PIN5
ENGINE STOP BN1
PIN5
PIN6
ENGINE START BN2
PIN6
ENGINE START BN2
PIN10
HIGH IDLE BN4
PIN10
AUTO LEVEL BN20
PIN19
HORN BN5
PIN19
HIGH TORQUE/LF OUTRIGGER BN17
PIN23
HIGH TORQUE BN6
PIN23
HIGH IDLE BN4
PIN24
GENERATOR BN7
PIN24
RR OUTRIGGER BN24
PIN25
PLATFORM EXT/RET ENABLE BN16
PIN13
HORN/LR OUTRIGGER BN15
PIN29
STARTING AID BN3
PIN25
OUTRIGGER ENABLE BN16
PIN25
GENERATOR/RF OUTRIGGER BN18
PIN29
WH
PIN1
PIN1
UP
PLATFORM UP/DOWN TS20
POUT1
DOWN
PIN11
BK
+
-
ALARM
PIN11
PLATFORM CONTROLS
(DIESEL MODELS WITHOUT OUTRIGGERS)
UP
YL
POUT1
H1
LIFT ENABLE LOW BN13
RD
PIN3
PIN4
RD
LIFT ENABLE HIGH BN12
BL
PIN2
YL
PIN4
WH
LIFT ENABLE LOW BN13
RD
PIN3
STARTING AID BN3
LIFT ENABLE HIGH BN12
BL
PIN2
6 - 72
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
SW6 STEER
LEFT/ RIGHT
SW5
WH/BL
JOYSTICK
CONTROLLER
D7
U3
SW25
DIP
SWITCH
JC1
BN
WH/BK
PIN18
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
DIP
SWITCH
12V DC
DOWN
RD
+
BK
-
PLATFORM & OUTRIGGER
UP/DOWN TS21
H1
ALARM
PLATFORM CONTROLS
(DIESEL MODELS WITH OUTRIGGERS)
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 6 • Schematics
This page intentionally left blank.
Part No. 52302
GS-2668 RT • GS-3268 RT
6 - 73
Section 6 • Schematics
March 2005
Electrical Schematic
ANSI Models with Diesel Power
(from serial number GS6803-42382 to GS6805-43594)
Part 1 of 3
P1
KS1 KEY SWITCH
B1
REV A
EMERGENCY STOP
2
PLATFORM
CONTROL
B
4
3
GROUND
CONTROL
AB1
CB2 20A
AB3
AB3
AB7
AB3
AB28
CR41
CONTROL
SYSTEM
CR42
CR5
CR8
POWER
HORN
IGNITION
CR1
CR23
ENGINE
START
AUXILIARY
DOWN
N.C.
G6
HOUR
METER
AB1
86
85
30
87
1
86
87A
85
2
86
87A
85
30
87
5
86
87A
85
30
87
4
86
87A
85
30
87
30
87
3
86
87A
85
30
87
LS6
PLAT
DOWN
LIMIT
SWITCH
6
87A
(HOLD)
(PULL)
H2
HIGH IDLE
87
86
87A
85
30
87
BN91
AUXILIARY DOWN
AUXILIARY DOWN
ENABLE
WORK
LIGHTS
8
87A
Y7A
KUBOTA DIESEL ONLY
-
85
CR4
STARTING
AID
7
BN23
L30
CR15
30
J2-A3
M3
86
J2-A5
STARTER
+
J1-A9
30A
B1
J1-A3
F9
J1-C7
J2-C4
J2-B9
J2-C1/C3
STA
J2-A2
D1
EXCT
J2-C12
BAT
J1-C2
J2-B11
J2-B8
J2-B7
ECM
J2-A4
U5
U32
Q8
4700 uF
Q3
GLOW
PLUG
(OPTION)
FUEL
SHUT
OFF
Y10A
C5
HIGH IDLE
SOLENOID
Y7
Y8
Y10
Y10A AUX PLATFORM DOWN
(GS-3268 ONLY)
Y7A PLATFORM DOWN
(GS-3268 ONLY)
Y10 AUX PLATFORM DOWN
Y7 PLATFORM DOWN
Y8 PLATFORM UP
G6 ENGINE HOURMETER
L30 WORK LIGHTS (OPTION)
Q3 HIGH IDLE SOLENOID
U32 GLOW PLUG (OPTION)
D1 ALTERNATOR
Q8 FUEL SHUT OFF
K1 STARTER RELAY
M3 STARTER MOTOR
H2 AUTOMOTIVE-STYLE HORN
B1 12 VOLT BATTERY
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
6 - 74
ES7162A
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 6 • Schematics
Electrical Schematic
ANSI Models with Diesel Power
(from serial number GS6803-42382 to GS6805-43594)
Part 2 of 3
REV A
AB2
SW4
F9A
WH
RD
CR8 TERMINAL 30
BATTERY (+)
N.O.
20A
CR17
30
86
N.C.
87
HYDRAULIC
OIL COOLER
LEVEL SENSOR
CIRCUIT BOARD
85
M1
(OPTION)
S7 LEVEL
SENSOR
MODELS WITHOUT
OUTRIGGERS
BATTERY (-)
AB23
BK
AB29
AB1
J2-B10
J2-A6
J2-B2
U5
ELECTRONIC CONTROL MODULE
J2-C7
H5
J1-B1
J1-B3
AB13
FB1
Y1B
Y1
Y3
Y1A
Y6
Y5
Y2
Y9
Y6A
Y5A
Y29
S7 LEVEL SENSOR
ECM GROUND
PROPORTIONAL
FLOW CONTROL
Y29 GENERATOR (OPTION)
Y9
Y5A DRIVE REVERSE (2)
Y6A DRIVE FORWARD (2)
Y5 DRIVE REVERSE (1)
Y6 DRIVE FORWARD (1)
Y2 BRAKE RELEASE
Y1B DRIVE PARALLEL
Y1A DRIVE PARALLEL
Y1 DRIVE PARALLEL
Y3 STEER RIGHT
Y4 STEER LEFT
FB1 FLASHING BEACON (OPTION)
H5 ALARM
SW1 COOLANT TEMPERATURE SWITCH
SW2OIL PRESSURE SWITCH
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
ES7162A
Part No. 52302
J1-A8
J1-A7
J1-A6
J1-A5
J1-A4
SW1
J1-A12
AB11
Y4
SW2
J1-A11
J1-A10
J1-A1
J1-A2
J2-C11
J2-B12
J1-C9
J1-C8
AB22
GS-2668 RT • GS-3268 RT
6 - 75
Section 6 • Schematics
March 2005
Electrical Schematic
ANSI Models with Diesel Power
(from serial number GS6803-42382 to GS6805-43594)
Part 3 of 3
REV A
P2
QD3
QD4
WH/RD
4
4
4
4
BK
POWER TO PLATFORM
POWER TO GROUND
EMERGENCY
STOP
BK
RD
RD/WH
3
3
3
3
RD
BL
1
1
1
1
WH
GROUND
WH
BK
2
2
2
2
BL
DATA LINK (HIGH)
BL
OR
5
5
5
5
OR
DATA LINK (LOW)
OR
J5 PIN1
J5 PIN4
J5 PIN5
OUTRIGGERS
J5 PIN2
(OPTION)
AB3
AB3
AB2
D7
U3
AB2
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
12V DC
5V DC
S8
2 AXIS
TILT LEVEL
SENSOR
J5 PIN3
J2 PIN5
J2 PIN6
J2 PIN7
AB1
HALL EFFECT
GENERATOR
YL
WH
BN
BL
PP
GY
SW5
OR
FUNCTION ENABLE
BK
J2-A12
J2-A11
J2-A10
J2-B2
J2-B3
J2-B10
J2-B1
J1-C4
J1-C6
J1-C3
J1-C5
Y36
AB7
AB8
Y34
Y35
ELECTRONIC
CONTROL
MODULE
J1-B8
J1-B7
J1-B6
J1-B10
J1-B11
J1-B9
J1-B5
AB14
AB15
AB6
Y40
Y33
Y44
Y39
J2 PIN14
WH/BL
POUT1
HORN BN5
PIN3
STARTING AID BN3
PIN4
ENGINE START BN2
PIN5
HIGH TORQUE BN6
PIN6
GENERATOR BN7
PIN7
LPG SELECT BN14
PIN8
HIGH IDLE BN4
PIN9
LF OUTRIGGER ENABLE BN85
PIN10
RF OUTRIGGER ENABLE BN86
PIN11
LR OUTRIGGER ENABLE BN87
PIN12
RR OUTRIGGER ENABLE BN24
S8 2-AXIS LEVEL SENSOR
Y44 OUTRIGGER DOWN SLOW
Y39 OUTRIGGER RETRACT
Y40 OUTRIGGER EXTEND
Y33 LEFT REAR OUTRIGGER
Y34 RIGHT REAR OUTRIGGER
Y35 LEFT FRONT OUTRIGGER
Y36 RIGHT FRONT OUTRIGGER
PIN13
LIFT FUNCTION BN9
PIN14
ORGR AUTOLEVEL ENABLE BN20
PIN15
SYSTEM STATUS L50
J1 PIN4
J1 PIN3
J1 PIN1
J1 PIN5
J3 PIN1
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
6 - 76
STEER
LEFT/ RIGHT
RD
PIN2
AB10
SW6
J2 PIN8
U5
AB9
JC1
JOYSTICK
CONTROLLER
RIGHT
AB25
J2 PIN4
GY
LEFT
AB16
DATA LINK (-)
GND FROM PLAT
AB17
AB24
DATA LINK (+)
BK
AB26
J2 PIN13
N.O.
AB23
AB27
GROUND
YL
N.O.
BL
N.O.
J2 PIN2
J2 PIN12
J2 PIN3
RD
N.O.
ROLL
LF
RF
LR
RR
O-RIG
O-RIG
O-RIG
O-RIG
LIMIT
LIMIT
LIMIT
LIMIT
SWITCH SWITCH SWITCH SWITCH
PITCH
POWER
LS12 LS13 LS14 LS15
J2 PIN1
J3 PIN2
ES7162A
GS-2668 RT • GS-3268 RT
YL
PLATFORM UP/DOWN TS20
-ORPLATFORM & OUTRIGGER
UP/DOWN
TS21
BL
RD
BK
RD
BK
+
H1
ALARM
PLATFORM
CONTROLS
Part No. 52302
March 2005
Section 6 • Schematics
This page intentionally left blank.
Part No. 52302
GS-2668 RT • GS-3268 RT
6 - 77
Section 6 • Schematics
March 2005
Electrical Schematic
ANSI Models with Diesel Power
(after serial number GS6805-43594)
Part 1 of 3
F9 5A FUSE
KS1 KEY SWITCH
REV A
P1EMERGENCY STOP
2
B1
PLATFORM
CONTROL
4
B
3
GROUND
CONTROL
AB1
CB2 20A
AB3
AB3
AB7
AB3
AB28
CR41
CONTROL
SYSTEM
CR42
CR5
CR8
POWER
HORN
IGNITION
CR1
CR23
ENGINE
START
AUXILIARY
DOWN
N.C.
G6
HOUR
METER
AB1
86
85
30
87
1
86
87A
85
2
86
87A
85
30
87
5
86
87A
85
30
87
4
86
87A
85
30
87
30
87
3
86
87A
85
30
87
LS6
PLAT
DOWN
LIMIT
SWITCH
6
87A
(HOLD)
(PULL)
H2
HIGH IDLE
87
86
87A
85
30
87
BN91
AUXILIARY DOWN
AUXILIARY DOWN
ENABLE
WORK
LIGHTS
8
87A
Y7A
KUBOTA DIESEL ONLY
-
85
CR4
STARTING
AID
7
BN23
L30
CR15
30
J2-A3
M3
86
J2-A5
STARTER
+
J1-A9
30A
B1
J1-A3
F9
J1-C7
J2-C4
J2-B9
J2-C1/C3
STA
J2-A2
D1
EXCT
J2-C12
BAT
J1-C2
J2-B11
J2-B8
J2-B7
ECM
J2-A4
U5
U32
Q8
4700 uF
Q3
GLOW
PLUG
(OPTION)
FUEL
SHUT
OFF
Y10A
C5
HIGH IDLE
SOLENOID
Y7
Y8
Y10
Y10A AUX PLATFORM DOWN
(GS-3268 ONLY)
Y7A PLATFORM DOWN
(GS-3268 ONLY)
Y10 AUX PLATFORM DOWN
Y7 PLATFORM DOWN
Y8 PLATFORM UP
G6 ENGINE HOURMETER
L30 WORK LIGHTS (OPTION)
Q3 HIGH IDLE SOLENOID
U32 GLOW PLUG (OPTION)
D1 ALTERNATOR
Q8 FUEL SHUT OFF
K1 STARTER RELAY
M3 STARTER MOTOR
H2 AUTOMOTIVE-STYLE HORN
B1 12 VOLT BATTERY
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
6 - 78
ES7162D
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 6 • Schematics
Electrical Schematic
ANSI Models with Diesel Power
(after serial number GS6805-43594)
Part 2 of 3
REV A
AB2
SW4
F9A
WH
RD
CR8 TERMINAL 30
BATTERY (+)
N.O.
20A
CR17
30
86
N.C.
87
HYDRAULIC
OIL COOLER
LEVEL SENSOR
CIRCUIT BOARD
85
M1
(OPTION)
S7 LEVEL
SENSOR
MODELS WITHOUT
OUTRIGGERS
BATTERY (-)
AB23
BK
AB29
AB1
J2-B10
J2-A6
J2-B2
U5
ELECTRONIC CONTROL MODULE
J2-C7
H5
J1-B1
J1-B3
AB13
FB1
Y1B
Y1
Y3
Y1A
Y6
Y5
Y2
Y9
Y6A
Y5A
Y29
S7 LEVEL SENSOR
ECM GROUND
PROPORTIONAL
FLOW CONTROL
Y29 GENERATOR (OPTION)
Y9
Y5A DRIVE REVERSE (2)
Y6A DRIVE FORWARD (2)
Y5 DRIVE REVERSE (1)
Y6 DRIVE FORWARD (1)
Y2 BRAKE RELEASE
Y1B DRIVE PARALLEL
Y1A DRIVE PARALLEL
Y1 DRIVE PARALLEL
Y3 STEER RIGHT
Y4 STEER LEFT
FB1 FLASHING BEACON (OPTION)
H5 ALARM
SW1 COOLANT TEMPERATURE SWITCH
SW2OIL PRESSURE SWITCH
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
ES7162D
Part No. 52302
J1-A8
J1-A7
J1-A6
J1-A5
J1-A4
SW1
J1-A12
AB11
Y4
SW2
J1-A11
J1-A10
J1-A1
J1-A2
J2-C11
J2-B12
J1-C9
J1-C8
AB22
GS-2668 RT • GS-3268 RT
6 - 79
Section 6 • Schematics
March 2005
Electrical Schematic
ANSI Models with Diesel Power
(after serial number GS6805-43594)
Part 3 of 3
REV A
P2
QD3
QD4
WH/RD
4
4
4
4
BK
POWER TO PLATFORM
POWER TO GROUND
EMERGENCY
STOP
BK
RD
RD/WH
3
3
3
3
RD
BL
1
1
1
1
WH
GROUND
WH
BK
2
2
2
2
BL
DATA LINK (HIGH)
BL
OR
5
5
5
5
OR
DATA LINK (LOW)
OR
J5 PIN1
J5 PIN4
J5 PIN5
OUTRIGGERS
J5 PIN2
(OPTION)
AB3
AB3
AB2
D7
U3
AB2
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
12V DC
5V DC
S8
2 AXIS
TILT LEVEL
SENSOR
J2-A12
J2-A11
Y36
AB7
AB8
Y34
Y35
ELECTRONIC
CONTROL
MODULE
J1-B8
J1-B7
J1-B6
J1-B10
J1-B11
J1-B9
J1-B5
AB14
AB15
AB6
Y40
Y33
J2 PIN6
Y44
Y39
J2 PIN14
BN
BL
PP
GY
SW5
OR
FUNCTION ENABLE
BK
SW6
STEER
LEFT/ RIGHT
RD
WH/BL
PIN2
HORN BN5
PIN3
STARTING AID BN3
PIN4
ENGINE START BN2
PIN5
HIGH TORQUE BN6
PIN6
GENERATOR BN7
PIN7
LPG SELECT BN14
PIN8
HIGH IDLE BN4
PIN9
LF OUTRIGGER ENABLE BN85
PIN10
RF OUTRIGGER ENABLE BN86
PIN11
LR OUTRIGGER ENABLE BN87
PIN12
RR OUTRIGGER ENABLE BN24
S8 2-AXIS LEVEL SENSOR
Y44 OUTRIGGER DOWN SLOW
Y39 OUTRIGGER RETRACT
Y40 OUTRIGGER EXTEND
Y33 LEFT REAR OUTRIGGER
Y34 RIGHT REAR OUTRIGGER
Y35 LEFT FRONT OUTRIGGER
Y36 RIGHT FRONT OUTRIGGER
PIN13
LIFT FUNCTION BN9
PIN14
ORGR AUTOLEVEL ENABLE BN20
PIN15
SYSTEM STATUS L50
J1 PIN4
J1 PIN3
J1 PIN1
J3 PIN1
- NOTE -
6 - 80
JC1
JOYSTICK
CONTROLLER
POUT1
J1 PIN5
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
WH
J2 PIN8
J2-A10
J2-B2
J2-B3
J2-B1
J1-C4
J2-B10
J1-C6
J1-C3
J1-C5
AB10
J2 PIN5
J2 PIN7
AB1
U5
AB9
J5 PIN3
HALL EFFECT
GENERATOR
YL
RIGHT
AB25
J2 PIN4
GY
LEFT
AB16
DATA LINK (-)
GND FROM PLAT
AB17
AB24
DATA LINK (+)
BK
AB26
J2 PIN13
N.O.
AB23
AB27
GROUND
YL
N.O.
BL
N.O.
J2 PIN2
J2 PIN12
J2 PIN3
RD
N.O.
ROLL
LF
RF
LR
RR
O-RIG
O-RIG
O-RIG
O-RIG
LIMIT
LIMIT
LIMIT
LIMIT
SWITCH SWITCH SWITCH SWITCH
PITCH
POWER
LS12 LS13 LS14 LS15
J2 PIN1
J3 PIN2
ES7162D
GS-2668 RT • GS-3268 RT
YL
PLATFORM UP/DOWN TS20
-ORPLATFORM & OUTRIGGER
UP/DOWN
TS21
BL
RD
BK
RD
BK
+
H1
ALARM
PLATFORM
CONTROLS
Part No. 52302
March 2005
Section 6 • Schematics
This page intentionally left blank.
Part No. 52302
GS-2668 RT • GS-3268 RT
6 - 81
Section 6 • Schematics
March 2005
Electrical Schematic
CE Models with Diesel Power
(from serial number GS6803-42382 to GS6805-43594)
Part 1 of 3
P1
KS1 KEY SWITCH
B1
REV A
EMERGENCY STOP
2
PLATFORM
CONTROL
B
4
3
GROUND
CONTROL
AB1
CB2 20A
AB4
AB3
AB7
PLATFORM
OVERLOAD
PRESSURE
SWITCH
AB20
CR41
CONTROL
SYSTEM
CR42
CR5
CR8
POWER
HORN
IGNITION
CR1
CR23
ENGINE
START
AUXILIARY
DOWN
N.C.
G6
HOUR
METER
AB1
86
85
30
87
1
86
87A
85
2
86
87A
85
30
87
5
86
87A
85
30
87
4
86
87A
85
30
87
30
87
3
86
87A
85
30
87
LS6
PLAT
DOWN
LIMIT
SWITCH
6
87A
B1
(PULL)
M3
86
H2
CR4
STARTING
AID
HIGH IDLE
30
7
86
87A
85
30
WORK
LIGHTS
8
87
87
LS25
MAXIMUM
HEIGHT
LIMIT SW
LOAD SENSE
DELAY
LIMIT SW
AUXILIARY DOWN
ENABLE
9
30
CR77
DOWN
ENABLE
C5
85
87
Y7A
87A
Y10A
4700 uF
Q3
GLOW
PLUG
(OPTION)
FUEL
SHUT
OFF
BN91
AUXILIARY DOWN
N.C.
LS24
87A
U32
Q8
BN23
AB12
N.C.
86
85
KUBOTA DIESEL ONLY
-
(HOLD)
STARTER
L30
CR15
J1-A9
30A
J1-A3
F9
J1-C7
J2-C4
J2-B9
J2-A3
STA
J2-A5
D1
EXCT
J2-C1/C3
BAT
J2-A2
J2-C12
J1-C2
J2-B11
J2-B8
ECM
J2-B7
J2-A4
U5
+
AB3
AB28
PS2
HIGH IDLE
SOLENOID
Y7
Y8
Y10
Y10A AUX PLATFORM DOWN
(GS-3268 ONLY)
Y7A PLATFORM DOWN
(GS-3268 ONLY)
Y10 AUX PLATFORM DOWN
Y7 PLATFORM DOWN
Y8 PLATFORM UP
G6 ENGINE HOURMETER
L30 WORK LIGHTS (OPTION)
Q3 HIGH IDLE SOLENOID
U32 GLOW PLUG (OPTION)
D1 ALTERNATOR
Q8 FUEL SHUT OFF
K1 STARTER RELAY
M3 STARTER MOTOR
H2 AUTOMOTIVE-STYLE HORN
B1 12 VOLT BATTERY
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
6 - 82
ES7162A
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 6 • Schematics
Electrical Schematic
CE Models with Diesel Power
(from serial number GS6803-42382 to GS6805-43594)
Part 2 of 3
REV A
AB2
SW4
F9A
WH
RD
CR8 TERMINAL 30
BATTERY (+)
N.O.
20A
CR17
30
86
N.C.
87
HYDRAULIC
OIL COOLER
LEVEL SENSOR
CIRCUIT BOARD
85
M1
(OPTION)
S7 LEVEL
SENSOR
MODELS WITHOUT
OUTRIGGERS
BATTERY (-)
AB23
BK
AB29
AB1
J2-B10
J2-A6
J2-B2
U5
ELECTRONIC CONTROL MODULE
J2-C7
H5
J1-B1
J1-B3
AB13
FB1
Y1B
Y1
Y3
Y1A
Y6
Y5
Y2
Y9
Y6A
Y5A
Y29
S7 LEVEL SENSOR
ECM GROUND
PROPORTIONAL
FLOW CONTROL
Y29 GENERATOR (OPTION)
Y9
Y5A DRIVE REVERSE (2)
Y6A DRIVE FORWARD (2)
Y5 DRIVE REVERSE (1)
Y6 DRIVE FORWARD (1)
Y2 BRAKE RELEASE
Y1B DRIVE PARALLEL
Y1A DRIVE PARALLEL
Y1 DRIVE PARALLEL
Y3 STEER RIGHT
Y4 STEER LEFT
FB1 FLASHING BEACON (OPTION)
H5 ALARM
SW1 COOLANT TEMPERATURE SWITCH
SW2OIL PRESSURE SWITCH
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
ES7162A
Part No. 52302
J1-A8
J1-A7
J1-A6
J1-A5
J1-A4
SW1
J1-A12
AB11
Y4
SW2
J1-A11
J1-A10
J1-A1
J1-A2
J2-C11
J2-B12
J1-C9
J1-C8
AB22
GS-2668 RT • GS-3268 RT
6 - 83
Section 6 • Schematics
March 2005
Electrical Schematic
CE Models with Diesel Power
(from serial number GS6803-42382 to GS6805-43594)
Part 3 of 3
REV A
P2
QD3
QD4
WH/RD
4
4
4
4
BK
POWER TO PLATFORM
POWER TO GROUND
EMERGENCY
STOP
BK
RD
RD/WH
3
3
3
3
RD
BL
1
1
1
1
WH
GROUND
WH
BK
2
2
2
2
BL
DATA LINK (HIGH)
BL
OR
5
5
5
5
OR
DATA LINK (LOW)
OR
J5 PIN1
J5 PIN4
J5 PIN5
OUTRIGGERS
J5 PIN2
(OPTION)
AB3
AB3
AB2
D7
U3
AB2
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
12V DC
5V DC
S8
2 AXIS
TILT LEVEL
SENSOR
J5 PIN3
J2 PIN5
J2 PIN6
J2 PIN7
AB1
HALL EFFECT
GENERATOR
YL
WH
BN
BL
PP
GY
SW5
OR
FUNCTION ENABLE
BK
J2-A12
J2-A11
J2-A10
J2-B2
J2-B3
J2-B10
J2-B1
J1-C4
J1-C6
J1-C3
J1-C5
Y36
AB7
AB8
Y34
Y35
ELECTRONIC
CONTROL
MODULE
J1-B8
J1-B7
J1-B6
J1-B10
J1-B11
J1-B9
J1-B5
AB14
AB15
AB6
Y40
Y33
Y44
Y39
J2 PIN14
WH/BL
POUT1
HORN BN5
PIN3
STARTING AID BN3
PIN4
ENGINE START BN2
PIN5
HIGH TORQUE BN6
PIN6
GENERATOR BN7
PIN7
LPG SELECT BN14
PIN8
HIGH IDLE BN4
PIN9
LF OUTRIGGER ENABLE BN85
PIN10
RF OUTRIGGER ENABLE BN86
PIN11
LR OUTRIGGER ENABLE BN87
PIN12
RR OUTRIGGER ENABLE BN24
S8 2-AXIS LEVEL SENSOR
Y44 OUTRIGGER DOWN SLOW
Y39 OUTRIGGER RETRACT
Y40 OUTRIGGER EXTEND
Y33 LEFT REAR OUTRIGGER
Y34 RIGHT REAR OUTRIGGER
Y35 LEFT FRONT OUTRIGGER
Y36 RIGHT FRONT OUTRIGGER
PIN13
LIFT FUNCTION BN9
PIN14
ORGR AUTOLEVEL ENABLE BN20
PIN15
SYSTEM STATUS L50
J1 PIN4
J1 PIN3
J1 PIN1
J1 PIN5
J3 PIN1
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
6 - 84
STEER
LEFT/ RIGHT
RD
PIN2
AB10
SW6
J2 PIN8
U5
AB9
JC1
JOYSTICK
CONTROLLER
RIGHT
AB25
J2 PIN4
GY
LEFT
AB16
DATA LINK (-)
GND FROM PLAT
AB17
AB24
DATA LINK (+)
BK
AB26
J2 PIN13
N.O.
AB23
AB27
GROUND
YL
N.O.
BL
N.O.
J2 PIN2
J2 PIN12
J2 PIN3
RD
N.O.
ROLL
LF
RF
LR
RR
O-RIG
O-RIG
O-RIG
O-RIG
LIMIT
LIMIT
LIMIT
LIMIT
SWITCH SWITCH SWITCH SWITCH
PITCH
POWER
LS12 LS13 LS14 LS15
J2 PIN1
J3 PIN2
ES7162A
GS-2668 RT • GS-3268 RT
YL
PLATFORM UP/DOWN TS20
-ORPLATFORM & OUTRIGGER
UP/DOWN
TS21
BL
RD
BK
RD
BK
+
H1
ALARM
PLATFORM
CONTROLS
Part No. 52302
March 2005
Section 6 • Schematics
This page intentionally left blank.
Part No. 52302
GS-2668 RT • GS-3268 RT
6 - 85
Section 6 • Schematics
March 2005
Electrical Schematic
CE Models with Diesel Power
(after serial number GS6805-43594)
Part 1 of 3
F9 5A FUSE
KS1 KEY SWITCH
REV A
P1EMERGENCY STOP
2
B1
PLATFORM
CONTROL
4
B
3
GROUND
CONTROL
AB1
CB2 20A
AB4
AB3
AB7
PLATFORM
OVERLOAD
PRESSURE
SWITCH
AB20
CR41
CONTROL
SYSTEM
CR42
CR5
CR8
POWER
HORN
IGNITION
CR1
CR23
ENGINE
START
AUXILIARY
DOWN
N.C.
G6
HOUR
METER
AB1
86
85
30
87
1
86
87A
85
2
86
87A
85
30
87
5
86
87A
85
30
87
4
86
87A
85
30
87
30
87
3
86
87A
85
30
87
LS6
PLAT
DOWN
LIMIT
SWITCH
6
87A
B1
(PULL)
M3
86
H2
CR4
STARTING
AID
HIGH IDLE
30
7
86
87A
85
30
WORK
LIGHTS
8
87
87
LS25
MAXIMUM
HEIGHT
LIMIT SW
LOAD SENSE
DELAY
LIMIT SW
AUXILIARY DOWN
ENABLE
9
30
CR77
DOWN
ENABLE
C5
85
87
Y7A
87A
Y10A
4700 uF
Q3
GLOW
PLUG
(OPTION)
FUEL
SHUT
OFF
BN91
AUXILIARY DOWN
N.C.
LS24
87A
U32
Q8
BN23
AB12
N.C.
86
85
KUBOTA DIESEL ONLY
-
(HOLD)
STARTER
L30
CR15
J1-A9
30A
J1-A3
F9
J1-C7
J2-C4
J2-B9
J2-A3
STA
J2-A5
D1
EXCT
J2-C1/C3
BAT
J2-A2
J2-C12
J1-C2
J2-B11
J2-B8
ECM
J2-B7
J2-A4
U5
+
AB3
AB28
PS2
HIGH IDLE
SOLENOID
Y7
Y8
Y10
Y10A AUX PLATFORM DOWN
(GS-3268 ONLY)
Y7A PLATFORM DOWN
(GS-3268 ONLY)
Y10 AUX PLATFORM DOWN
Y7 PLATFORM DOWN
Y8 PLATFORM UP
G6 ENGINE HOURMETER
L30 WORK LIGHTS (OPTION)
Q3 HIGH IDLE SOLENOID
U32 GLOW PLUG (OPTION)
D1 ALTERNATOR
Q8 FUEL SHUT OFF
K1 STARTER RELAY
M3 STARTER MOTOR
H2 AUTOMOTIVE-STYLE HORN
B1 12 VOLT BATTERY
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
6 - 86
ES7184B
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 6 • Schematics
Electrical Schematic
CE Models with Diesel Power
(after serial number GS6805-43594)
Part 2 of 3
REV A
AB2
SW4
F9A
WH
RD
CR8 TERMINAL 30
BATTERY (+)
N.O.
20A
CR17
30
86
N.C.
87
HYDRAULIC
OIL COOLER
LEVEL SENSOR
CIRCUIT BOARD
85
M1
(OPTION)
S7 LEVEL
SENSOR
MODELS WITHOUT
OUTRIGGERS
BATTERY (-)
AB23
BK
AB29
AB1
J2-B10
J2-A6
J2-B2
U5
ELECTRONIC CONTROL MODULE
J2-C7
H5
J1-B1
J1-B3
AB13
FB1
Y1B
Y1
Y3
Y1A
Y6
Y5
Y2
Y9
Y6A
Y5A
Y29
S7 LEVEL SENSOR
ECM GROUND
PROPORTIONAL
FLOW CONTROL
Y29 GENERATOR (OPTION)
Y9
Y5A DRIVE REVERSE (2)
Y6A DRIVE FORWARD (2)
Y5 DRIVE REVERSE (1)
Y6 DRIVE FORWARD (1)
Y2 BRAKE RELEASE
Y1B DRIVE PARALLEL
Y1A DRIVE PARALLEL
Y1 DRIVE PARALLEL
Y3 STEER RIGHT
Y4 STEER LEFT
FB1 FLASHING BEACON (OPTION)
H5 ALARM
SW1 COOLANT TEMPERATURE SWITCH
SW2OIL PRESSURE SWITCH
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
ES7184B
Part No. 52302
J1-A8
J1-A7
J1-A6
J1-A5
J1-A4
SW1
J1-A12
AB11
Y4
SW2
J1-A11
J1-A10
J1-A1
J1-A2
J2-C11
J2-B12
J1-C9
J1-C8
AB22
GS-2668 RT • GS-3268 RT
6 - 87
Section 6 • Schematics
March 2005
Electrical Schematic
CE Models with Diesel Power
(after serial number GS6805-43594)
Part 3 of 3
REV A
P2
QD3
QD4
WH/RD
4
4
4
4
BK
POWER TO PLATFORM
POWER TO GROUND
EMERGENCY
STOP
BK
RD
RD/WH
3
3
3
3
RD
BL
1
1
1
1
WH
GROUND
WH
BK
2
2
2
2
BL
DATA LINK (HIGH)
BL
OR
5
5
5
5
OR
DATA LINK (LOW)
OR
J5 PIN1
J5 PIN4
J5 PIN5
OUTRIGGERS
J5 PIN2
(OPTION)
AB3
AB3
AB2
D7
U3
AB2
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
12V DC
5V DC
S8
2 AXIS
TILT LEVEL
SENSOR
J5 PIN3
J2 PIN5
J2 PIN6
J2 PIN7
AB1
HALL EFFECT
GENERATOR
YL
WH
BN
BL
PP
GY
SW5
OR
FUNCTION ENABLE
BK
J2-A12
J2-A11
J2-A10
J2-B2
J2-B3
J2-B10
J2-B1
J1-C4
J1-C6
J1-C3
J1-C5
Y36
AB7
AB8
Y34
Y35
ELECTRONIC
CONTROL
MODULE
J1-B8
J1-B7
J1-B6
J1-B10
J1-B11
J1-B9
J1-B5
AB14
AB15
AB6
Y40
Y33
Y44
Y39
J2 PIN14
WH/BL
POUT1
HORN BN5
PIN3
STARTING AID BN3
PIN4
ENGINE START BN2
PIN5
HIGH TORQUE BN6
PIN6
GENERATOR BN7
PIN7
LPG SELECT BN14
PIN8
HIGH IDLE BN4
PIN9
LF OUTRIGGER ENABLE BN85
PIN10
RF OUTRIGGER ENABLE BN86
PIN11
LR OUTRIGGER ENABLE BN87
PIN12
RR OUTRIGGER ENABLE BN24
S8 2-AXIS LEVEL SENSOR
Y44 OUTRIGGER DOWN SLOW
Y39 OUTRIGGER RETRACT
Y40 OUTRIGGER EXTEND
Y33 LEFT REAR OUTRIGGER
Y34 RIGHT REAR OUTRIGGER
Y35 LEFT FRONT OUTRIGGER
Y36 RIGHT FRONT OUTRIGGER
PIN13
LIFT FUNCTION BN9
PIN14
ORGR AUTOLEVEL ENABLE BN20
PIN15
SYSTEM STATUS L50
J1 PIN4
J1 PIN3
J1 PIN1
J1 PIN5
J3 PIN1
- NOTE MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF
6 - 88
STEER
LEFT/ RIGHT
RD
PIN2
AB10
SW6
J2 PIN8
U5
AB9
JC1
JOYSTICK
CONTROLLER
RIGHT
AB_
J2 PIN4
GY
LEFT
AB16
DATA LINK (-)
GND FROM PLAT
AB17
AB_
DATA LINK (+)
BK
AB26
J2 PIN13
N.O.
AB23
AB27
GROUND
YL
N.O.
BL
N.O.
J2 PIN2
J2 PIN12
J2 PIN3
RD
N.O.
ROLL
LF
RF
LR
RR
O-RIG
O-RIG
O-RIG
O-RIG
LIMIT
LIMIT
LIMIT
LIMIT
SWITCH SWITCH SWITCH SWITCH
PITCH
POWER
LS12 LS13 LS14 LS15
J2 PIN1
J3 PIN2
ES7184B
GS-2668 RT • GS-3268 RT
YL
PLATFORM UP/DOWN TS20
-ORPLATFORM & OUTRIGGER
UP/DOWN
TS21
BL
RD
BK
RD
BK
+
H1
ALARM
PLATFORM
CONTROLS
Part No. 52302
March 2005
Section 6 • Schematics
This page intentionally left blank.
Part No. 52302
GS-2668 RT • GS-3268 RT
6 - 89
Section 6 • Schematics
March 2005
Hydraulic Schematics Component Call-out Legend
REV A
7H3A0D;822><?>=4=C
;464=3
8cT\
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
Y
Z
AA
AB
AC
AD
AE
AF
AG
AH
AI
AJ
AK
BA
BB
BC
BD
BE
CA
CB
CC
CD
6 - 90
5d]RcX^]
Drive circuit – directs oil to left front
and right rear wheels motors
Drive circuit – directs oil to right front
and left rear wheels motors
Check valve – drive speed select
circuit
Check valve – prevents engine from
running backward when on an incline
and reversing direction of travel
Check valve – steer circuit
Check valve – proportional circuit
Relief valve – pump 1
Check valve – proportional circuit
Test port 1
Test port 2
Relief valve – lift circuit
Check valve - drive circuit
Shuttle valve – brake release circuit
Check valve - drive circuit
Relief valve – pump 2
Platform up/down
Priority flow regulator
Steer left/right
Orifice – brake release circuit
Proportional valve – lift/drive circuit
Brake release
Relief valve – steer circuit
Drive speed select circuit
Drive speed select circuit
Drive speed select circuit
Check valve – prevents overflowing
the drive motors when in high speed
Check valve – prevents engine from
running backward when on an incline
and reversing direction of travel
Generator on/off
Flow regulator - generator speed
Relief valve – generator circuit
Platform down
Shuttle valve – brake release circuit
Pilot operated check valve – brake
release circuit
Hand pump – brake release circuit
Needle valve – brake release enable
Orifice – platform down circuit
Platform overload (option)
Relief valve – outrigger circuit
2 position, 2 way solenoid valve –
outrigger lowering slow
Orifice – outrigger lowering slow
3 position, 4 way directional valve –
outrigger cylinder extend/retract
Counterbalance valve – outrigger
Right front outrigger autolevel valve
Left front outrigger autolevel valve
Right rear outrigger autolevel valve
Left rear outrigger autolevel valve
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 6 • Schematics
Hydraulic Symbols Legend
REV A
Filter
Counterbalance
valve
Single direction
variable speed motor
Check valve
Brake
Y44
E
Engine
Fixed displacement
pump
Bi-directional
variable speed motor
Y1
Priority flow regulator
Solenoid operated
2 position 2 way
directional valve
Solenoid operated
2 position 3 way
directional valve
Solenoid operated
2 position 3 way
directional valve
Relief valve
Proportional
solenoid valve
Dual acting cylinder
Platform overload
pressure switch
Shuttle valve
Single acting cylinder
Solenoid operated
3 position 4 way
directional valve
Hand pump
0.063 in
1.6 mm
Solenoid operated
2 position 2 way valve,
normally closed
Part No. 52302
Orifice
with size
Pilot operated
check valve with
needle valve
GS-2668 RT • GS-3268 RT
6 - 91
Section 6 • Schematics
March 2005
Hydraulic Schematic
(before serial number 35557)
Part 1 of 2
REV B
OUTRIGGERS
GENERATOR
(OPTION)
(OPTION)
Y36
Y35
CB
CA
AB
GENERATOR
MANIFOLD
AD
Y29
C2
CD
Y33
4.5 gpm
17 L/min
COUNTERBALANCE
VALVE
MANIFOLD
R
R
OUTRIGGER
MANIFOLD
I
BC
Y44
Y40
X
RIGHT
REAR
OUTRIGGER
Y34
0.063 in
1.6 mm
J
S1
X
Y4
Y3
CC
BB
E
V
1500 psi
103.4 bar
BA
P1
2000 psi
137.8 bar
IN
S2
R
Y39
BD
RIGHT
LEFT
TEST 1 TEST 2
V1
B
STEER CYLINDER
BE
V2
B
3000 psi
206.8 bar
C1
3000 psi
207 bar
4.5:1
LEFT
REAR
OUTRIGGER
AC
RIGHT
FRONT
OUTRIGGER
LEFT
FRONT
OUTRIGGER
OUT
Q
2 gpm
7.5 L/min
P2
O
3500 psi
241.3 bar
6.5 gpm
24.6 L/min
FUNCTION
MANIFOLD
6.5 gpm
24.6 L/min
E
25 psi
1.7 bar
HYDRAULIC TANK
HS0032B
HS0027J
6 - 92
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 6 • Schematics
Hydraulic Schematic
(before serial number 35557)
Part 2 of 2
REV B
UPPER
LIFT CYLINDER
(GS-3268)
AJ
AJ
0.059 in
1.5 mm
LEFT
FRONT
RIGHT
FRONT
RIGHT
REAR
LEFT
REAR
0.059 in
1.5 mm
Y10A
AI
BRAKE RELEASE
MANIFOLD
LIFT
CYLINDER
Y10
AI
Y7A
AG
Y7
AE
AF
PLATFORM
OVERLOAD
(OPTION)
AH
N.O.
COM
HP
B1
AK
HP
LIFT
B1
M2A
M3A
M3B
M2B
M4A
M1A
M4B
M1B
L
A
B
N
Y2
P
Y5
Y6
U
AA
Y6A
5 psi
0.35 bar
Y5A
C
Z
G
S
Y8
3500 psi
241.3 bar
H
M
0.035 in
89 mm
Y1A
Y1
Y
Y1B
W
X
F
D
5 psi
0.35 bar
K
Y9
T
GS-3268:
2000 psi / 137.8 bar
GS-2668:
3500 psi / 241.3 bar
FUNCTION
MANIFOLD
HS0027J
Part No. 52302
GS-2668 RT • GS-3268 RT
6 - 93
Section 6 • Schematics
March 2005
Hydraulic Schematic
(from serial number 35557 to 40484)
Part 1 of 2
REV A
OUTRIGGERS
GENERATOR
(OPTION)
(OPTION)
Y36
Y35
CB
CA
AB
GENERATOR
MANIFOLD
AD
Y29
OUT-B
IN-B
Y33
4.5 gpm
17 L/min
STEER CYLINDER
OUT-R
BC
Y44
Y40
J
X
RIGHT
REAR
OUTRIGGER
Y34
0.063 in
1.6 mm
I
S1
X
Y4
Y3
CC
BB
E
V
1500 psi
103.4 bar
BA
P1
2000 psi
137.8 bar
IN
S2
R
Y39
BD
RIGHT
LEFT
TEST 1 TEST 2
3000 psi
207 bar
4.5:1
BE
3000 psi
206.8 bar
IN-R
OUTRIGGER
MANIFOLD
LEFT
REAR
OUTRIGGER
CD
AC
RIGHT
FRONT
OUTRIGGER
LEFT
FRONT
OUTRIGGER
OUT
Q
2 gpm
7.5 L/min
P2
O
3500 psi
241.3 bar
6.5 gpm
24.6 L/min
FUNCTION
MANIFOLD
6.5 gpm
24.6 L/min
E
25 psi
1.7 bar
HYDRAULIC TANK
HS0032C
HS0027J
6 - 94
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 6 • Schematics
Hydraulic Schematic
(from serial number 35557 to 40484)
Part 2 of 2
REV A
UPPER
LIFT CYLINDER
(GS-3268)
AJ
ITEMS Y10 AND Y10A ADDED
AFTER SERIAL NUMBER 38464
AJ
0.059 in
1.5 mm
LEFT
FRONT
RIGHT
FRONT
RIGHT
REAR
LEFT
REAR
0.059 in
1.5 mm
Y10A
AI
BRAKE RELEASE
MANIFOLD
LIFT
CYLINDER
Y10
AI
Y7A
AG
Y7
AE
AF
PLATFORM
OVERLOAD
(OPTION)
AH
N.O.
COM
HP
B1
AK
HP
LIFT
B1
M2A
M3A
M3B
M2B
M4A
M1A
M4B
M1B
L
A
B
N
Y2
P
Y5
Y6
U
AA
Y6A
5 psi
0.35 bar
Y5A
C
Z
G
S
Y8
3500 psi
241.3 bar
H
M
0.035 in
89 mm
Y1A
Y1
Y
Y1B
W
X
F
D
5 psi
0.35 bar
K
Y9
T
GS-3268:
2000 psi / 137.8 bar
GS-2668:
3500 psi / 241.3 bar
FUNCTION
MANIFOLD
HS0027J
Part No. 52302
GS-2668 RT • GS-3268 RT
6 - 95
Section 6 • Schematics
March 2005
Hydraulic Schematic
(from serial number 40485 to GS6804-43183)
Part 1 of 2
REV A
OUTRIGGERS
GENERATOR
(OPTION)
(OPTION)
Y36
Y35
CB
CA
AB
GENERATOR
MANIFOLD
AD
Y29
AC
RIGHT
FRONT
OUTRIGGER
LEFT
FRONT
OUTRIGGER
OUT-B
IN-B
3000 psi
206.8 bar
4.5 gpm
17 L/min
IN-R
STEER CYLINDER
OUTRIGGER
MANIFOLD
OUT-R
I
J
RIGHT
LEFT
TEST 1 TEST 2
CD
Y33
X
RIGHT
REAR
OUTRIGGER
LEFT
REAR
OUTRIGGER
Y34
BC
0.063 in
1.6 mm
Y44
Y40
S1
X
CC
BB
E
V
1500 psi
103.4 bar
BA
P1
2000 psi
137.8 bar
IN
Y4
Y3
R
Y39
BD
S2
OUT
Q
2 gpm
7.5 L/min
P2
O
3500 psi
241.3 bar
6.5 gpm
24.6 L/min
FUNCTION
MANIFOLD
6.5 gpm
24.6 L/min
E
25 psi
1.7 bar
HYDRAULIC TANK
HS0032D
HS0027L
6 - 96
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 6 • Schematics
Hydraulic Schematic
(from serial number 40485 to GS6804-43183)
Part 2 of 2
REV A
UPPER
LIFT CYLINDER
(GS-3268)
AJ
AJ
0.059 in
1.5 mm
LEFT
FRONT
RIGHT
FRONT
RIGHT
REAR
LEFT
REAR
0.059 in
1.5 mm
Y10A
AI
BRAKE RELEASE
MANIFOLD
LIFT
CYLINDER
Y10
AI
Y7A
AG
Y7
AE
AF
PLATFORM
OVERLOAD
(OPTION)
AH
N.O.
COM
HP
B1
AK
HP
LIFT
B1
M2A
M3A
M3B
M2B
M4A
M1A
M4B
M1B
L
A
B
N
Y2
P
Y5
Y6
U
AA
Y6A
5 psi
0.35 bar
Y5A
C
Z
G
S
Y8
3500 psi
241.3 bar
H
M
0.035 in
89 mm
Y1A
Y1
Y
Y1B
W
X
F
D
5 psi
0.35 bar
K
Y9
T
GS-3268:
2000 psi / 137.8 bar
GS-2668:
3500 psi / 241.3 bar
ITEMS D AND AA CHANGED
TO 200 PSI / 13.8 BAR
AFTER SERIAL NUMBER 40958
FUNCTION
MANIFOLD
HS0027L
Part No. 52302
GS-2668 RT • GS-3268 RT
6 - 97
Section 6 • Schematics
March 2005
Hydraulic Schematic
(after serial number GS6804-43183)
Part 1 of 2
REV A
OUTRIGGERS
GENERATOR
(OPTION)
(OPTION)
Y36
Y35
CB
CA
AB
GENERATOR
MANIFOLD
AD
Y29
AC
RIGHT
FRONT
OUTRIGGER
LEFT
FRONT
OUTRIGGER
OUT-B
IN-B
3000 psi
206.8 bar
4.5 gpm
17 L/min
IN-R
STEER CYLINDER
OUTRIGGER
MANIFOLD
OUT-R
I
J
RIGHT
LEFT
TEST 1 TEST 2
CD
Y33
X
RIGHT
REAR
OUTRIGGER
LEFT
REAR
OUTRIGGER
Y34
BC
0.063 in
1.6 mm
Y44
Y40
S1
X
CC
BB
E
V
1500 psi
103.4 bar
BA
P1
2000 psi
137.8 bar
IN
Y4
Y3
R
Y39
BD
S2
OUT
Q
2 gpm
7.5 L/min
P2
O
3500 psi
241.3 bar
6.5 gpm
24.6 L/min
FUNCTION
MANIFOLD
6.5 gpm
24.6 L/min
E
25 psi
1.7 bar
HYDRAULIC TANK
HS0032D
HS0027M
6 - 98
GS-2668 RT • GS-3268 RT
Part No. 52302
March 2005
Section 6 • Schematics
Hydraulic Schematic
(after serial number GS6804-43183)
Part 2 of 2
REV A
UPPER
LIFT CYLINDER
(GS-3268)
BRAKE
AJ
AJ
0.059 in
1.5 mm
0.059 in
1.5 mm
Y10A
AI
BRAKE RELEASE
MANIFOLD
LIFT
CYLINDER
LEFT
FRONT
RIGHT
FRONT
RIGHT
REAR
LEFT
REAR
Y10
AI
Y7A
Y7
AG
PLATFORM
OVERLOAD
(OPTION)
N.O.
COM
MANUAL
AH
RELEASE
AK
LIFT
HP
HAND
PUMP
B
B1
M2A
M3A
M3B
M2B
M4A
M1A
M4B
M1B
L
A
B
N
Y2
P
Y5
Y6
U
AA
Y6A
200 psi
13.8 bar
Y5A
C
Z
G
S
Y8
3500 psi
241.3 bar
H
M
0.035 in
89 mm
Y1A
Y1
Y
Y1B
W
X
F
D
200 psi
13.8 bar
K
Y9
T
GS-3268:
2000 psi / 137.8 bar
GS-2668:
3500 psi / 241.3 bar
FUNCTION
MANIFOLD
HS0027M
Part No. 52302
GS-2668 RT • GS-3268 RT
6 - 99
Section 6 • Schematics
March 2005
This page intentionally left blank.
6 - 100
GS-2668 RT • GS-3268 RT
Part No. 52302
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.
Phone 425.881.1800
Toll Free USA and Canada
800.536.1800
Fax 425.883.3475
Genie Australia Pty Ltd.
Phone +61 7 3375 1660
Fax +61 7 3375 1002
Genie Scandinavia
Phone +46 31 575100
Fax +46 31 579020
Genie France
Phone +33 (0)2 37 26 09 99
Fax +33 (0)2 37 26 09 98
Genie Iberica
Phone +34 93 579 5042
Fax +34 93 579 5059
Genie Germany
Phone +49 (0)4202 88520
Fax +49 (0)4202 8852-20
Genie U.K.
Phone +44 (0)1476 584333
Fax +44 (0)1476 584334
Genie Mexico City
Phone +52 55 5666 5242
Fax +52 55 5666 3241
Genie China
Phone +86 21 53852570
Fax +86 21 53852569
Genie Malaysia
Phone +65 98 480 775
Fax +65 67 533 544
Genie Japan
Phone +81 3 3453 6082
Fax +81 3 3453 6083
Genie Korea
Phone +82 25 587 267
Fax +82 25 583 910
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Phone +55 11 41 665 755
Fax +55 11 41 665 754
Genie Holland
Phone +31 183 581 102
Fax +31 183 581 566
Distributed By:
Genie North America
Service Manual GS-2668 RT & GS-3268 RT
Part No.
52302
Rev D